Code No: R05312401 Set No.

1
III B.Tech I Semester Regular Examinations, November 2007
DESIGN OF MACHINE ELEMENTS
(Automobile Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
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1. (a) What is meant by hole basis system?

(b) What is meant by shaft basis system and why is it preferred?
[8+8]

2. (a) Explain the Modified Goodman’s line theory for designing the components
subjected to fatigue loads
(b) A thin wall cylindrical pressure vessel of mean diameter of 60 cm is subjected
to internal pressure varying from 0 to 40 MPa. Find the required thickness
of the pressure vessel based on yield point of 400 MPa, endurance limit of 22
Mpa, and a factor of safety of 3. Use Soderberg criterion of failure. [6+10]

3. (a) How is the allowable stress calculated for a riveted joint subjected to alternat-
ing type of load.
(b) The end of a receiver, cylindrical in shape is closed by a lap joint using rivets.
The maximum pressure in the receiver is 1 MPa. The axial length of the
receiver is limited to 2 m while its storing capacity is 2 m3 . Design the suitable
lap joint giving a neat sketch. The permissible stresses in shear and crushing
of rivets may be taken as 30 MPa and 70 MPa. The permissible tensile stress
for the plate material is 80 MPa. [6+10]

4. (a) What is Woodruff key? Give its applications.

(b) A shaft and a key are made of the same material and the key width is 41 of the
shaft diameter. Consider shear only, determine the minimum length of the
key in terms of the shaft diameter. The shearing strength of the key material
is 60% of its crushing strength. Determine the thickness of the key to make
the key equally strong in shear and crushing. [6+10]

5. (a) Under What circumstances, concentric springs are preferred?

(b) A rail carriage weighing 200kN and running at 5 km/hour is brought to rest by
four buffer springs of close coiled helical type during connection with another
carriage which is already at rest. The mean coil diameter is 5 times the wire
diameter. The deflection of each spring is 220 mm, to bring the carriage to
rest. Safe shear stress for the spring material is 400 N/mm2 . Calculate the
maximum load on the spring, diameter of wire and coil, number of turns and
free length of spring. Assume the ends of spring are squared and ground. Take
G= 0.8×104 N/mm2 . [2+14]

6. (a) Explain the various types of lubrication?

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Code No: R05312401 Set No. 1
(b) A 310 deep groove ball bearing has a work cycle with 1000r.p.m for one-third
of the time, 2000 r.p.m for the next one =third of the time, and 4000 r.p.m
for the last one-third of the time. The outer race of the bearing rotates.
Assume light shock condition. The radial load is 3.5kN and axial load is 2kN.
Determine the expected average life in hours, if the basic dynamic capacity of
the bearing is 47 kN. [4+12]

7. Design the Cross-head for double acting steam engine having cylinder bore of 30cm,
stroke 60cm, steam pressure at the port and back pressure of 0.9MPa and 0.1MPa
respectively. The engine is running at 120 rpm. Ratio of Connecting rod to crank
length is 4. Gudgeon pin is made of bronze with allowable bearing pressure of
7MPa and bolts of carbon steel with safe stress of 100MPa. Forged steel is used for
all other parts and take σt =80MPa and σs =60MPa for it. Safe bearing pressure
for the slide ranges between 0.3MPa to 0.5MPa. [16]

8. Design an aluminum alloy piston for a single acting four stroke engine for the
following data:
Cylinder bore = 400mm
Stroke = 375mm
Maximum gas pressure = 9 M Pa
Break mean effective pressure = 2MPa
Fuel consumption = 0.22kg/kW/hr
Speed =50rev/min. [16]

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Code No: R05312401 Set No. 2
III B.Tech I Semester Regular Examinations, November 2007
DESIGN OF MACHINE ELEMENTS
(Automobile Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. Enumerate the factors to be considered while selecting the materials for machine
parts. Recommend suitable materials for each of the following components :

(a) Crankshaft
(b) Body of electric motor
(c) Worm gear
(d) Piston for motor car engine
(e) Lathe bed
(f) Bearing bush [16]

2. (a) Explain the Modified Goodman’s line theory for designing the components
subjected to fatigue loads
(b) A thin wall cylindrical pressure vessel of mean diameter of 60 cm is subjected
to internal pressure varying from 0 to 40 MPa. Find the required thickness
of the pressure vessel based on yield point of 400 MPa, endurance limit of 22
Mpa, and a factor of safety of 3. Use Soderberg criterion of failure. [6+10]

3. (a) What do you mean by efficiency of riveted joint?

(b) A locomotive boiler of 1.8 m internal diameter is required to generate steam
at 1.4 MPa gauge. Calculate the thickness of the shell plate and design the
triple riveted longitudinal double butt strap joint with unequal straps. Use
the following data:
σt = 77 MPa, τ = 60 MPa and σc = 135 MPa. Efficiency of triple-riveted lon-
gitudinal butt joint is 84%. [4+12]

4. (a) What is the function of transmission shaft?

(b) A machinery shaft is subjected to torsion only. The bearings are 2.40 metre
apart. The shaft transmits 187.5 kW at 200 rev/min. Allow a shear stress of
42 MPa after an allowance for keyways.
i. Determine the shaft diameter for steady loading
ii. Determine the shaft diameter if the load is suddenly applied with minor
shocks. [2+14]

5. (a) Under What circumstances, concentric springs are preferred?

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Code No: R05312401 Set No. 2
(b) A rail carriage weighing 200kN and running at 5 km/hour is brought to rest by
four buffer springs of close coiled helical type during connection with another
carriage which is already at rest. The mean coil diameter is 5 times the wire
diameter. The deflection of each spring is 220 mm, to bring the carriage to
rest. Safe shear stress for the spring material is 400 N/mm2 . Calculate the
maximum load on the spring, diameter of wire and coil, number of turns and
free length of spring. Assume the ends of spring are squared and ground. Take
G= 0.8×104 N/mm2 . [2+14]

6. (a) What are the commonly used materials for sliding contact bearings?
(b) A ball bearing subjected to a radial load of 5kN is expected to have a life
of 8000 hours at 1450 r.p.m with a reliability of 99%. Calculate the dynamic
load capacity of the bearing so that it can be selected from the manufacturer?s
catalogue based on a reliability of 90%. [2+14]

7. Design a connecting rod of I cross section for an automobile diesel engine of the
following specifications.
Diameter of cylinder=100mm
Stroke length =125mm
Maximum combustion pressure =2.8MPa
Maximum engine speed=2000rpm
Weight of the reciprocating parts =1.1kg
Length of connecting rod between centers=31.5cm
Assume an allowable crushing stress =3000kg/cm2 . [16]

8. Design a Cast iron piston for a single acting four stroke engine for the following
specifications.
Cylinder bore = 100mm, Stroke = 120mm, Maximum gas pressure = 5N/mm2 ,
Break mean effective pressure = 0.65N/mm2 , Fuel consumption = 0.227kg/kW/hr,
Speed =2200 rev/min, Assume suitable data. [16]

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Code No: R05312401 Set No. 3
III B.Tech I Semester Regular Examinations, November 2007
DESIGN OF MACHINE ELEMENTS
(Automobile Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) What are the various factors influencing the factor of safety? Explain.
(b) The piston of a reciprocating compressor has a diameter of 60 mm. The maxi-
mum pressure on the piston face is 1.25 MN/ m2 . Assuming that the gudgeon
pin passing through the small end of the connecting rod can be safely loaded
in shear upto 10 MN/m2 , calculate the minimum diameter of the gudgeon pin.
[6+10]

2. (a) How will you reduce stress concentration in shaft with keyway?
(b) A torsion bar spring has a solid round 20 mm diameter section which blends
smoothly at each end with a larger splined section. It is subjected to a com-
pletely reversed nominal torsional stress of 210 MN/m2 . Stress concentration
is negligible, and the surfaces are machined. Estimate the fatigue life corre-
sponding to each of the following materials:
i. steel= 250 HB,
ii. Cast iron Su = 350 MN/m2 . [4+12]

3. (a) What forms of rivet heads are used in boiler construction?

(b) A triple riveted lap joint is to be made between 6 mm plates. If the safe
working stresses are ft = 84 MPa, fs = 60 MPa and fc = 120 MPa, calculate
the rivet diameter, rivet pitch and distance between rows of rivets for the joint.
Zig-zag riveting is to be used. State how the joint will fail. [4+12]

4. (a) What is a line shaft? Give examples.

(b) A centrifugal circulating pump for a stream turbine condenser is to be directly
connected to a motor through a short shaft and a pair of flexible couplings.
The pump delivers 20 m3 per minute at 865 rev/min against a dynamic head
of 7.5 metres. The pump efficiency is 80 percent.
i. Determine the power of the motor required
ii. Assuming hot rolled C-40 steel, determine diameter of Shaft. [4+12]

5. A diesel engine weighs 800kN and is mounted on 16 springs in order to protect the
building from vibrations. The section of the spring wire is rectangular with side
ratio 1.8. One spring has four effective coils and the spring index is 6. Determine:

(a) section of the spring so that long side is parallel to the axis of the spring
(b) Deflection under load when engine is stationary.

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Code No: R05312401 Set No. 3
(c) Maximum coil diameter.
(d) Shear stress induced if shorter side is parallel to the spring axis. Permissible
shear stress in spring wire material is 300 N/mm2 and modulus of rigidity is
0.8×105 N/mm2 . [16]

6. (a) Differentiate between rated and average life of anti-friction bearings.

(b) A 6203 single row deep groove ball bearing has a basic static load rating of
4500N, and basic dynamic load rating of 7350N. A radial load of 1600 N, and
an axial load of 1400N are acting on the bearing. Calculate the rated life of
the bearing. [4+12]

7. Design a connecting rod for an I.C engine from the following data:
Piston diameter = 125mm
Stroke=150mm
Length of connecting rod=300mm
Maximum gas pressure at 5% of stroke =5N/mm2
Speed of engine =1200rpm
Mass of reciprocating parts =2kg
Factor of safety=5
Material steel =35 Ni Cr 60. [16]

8. Design a Cast iron piston for a single acting four stroke engine for the following
specifications.
Cylinder bore = 100mm, Stroke = 120mm, Maximum gas pressure = 5N/mm2 ,
Break mean effective pressure = 0.65N/mm2 , Fuel consumption = 0.227kg/kW/hr,
Speed =2200 rev/min, Assume suitable data. [16]

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Code No: R05312401 Set No. 4
III B.Tech I Semester Regular Examinations, November 2007
DESIGN OF MACHINE ELEMENTS
(Automobile Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) What is meant by bilateral tolerance?

(b) Define the terms:
i. clearance fit,
ii. transition fit, and
iii. interference fit. [4+12]

2. (a) Differentiate between theoretical stress concentration factor and fatigue stress
concentration factor.
(b) A simply supported shaft of 50 mm diameter and 0.5 long is subjected at its
mid-section, a load that varies cyclically from 2P to 4P. Determine the value
of P from the following:
Yield strength = 450MPa
Endurance limit = 350MPa
Factor of safety = 2
Size correction factor = 0.85
Surface correction factor = 0.90 [4+12]

3. (a) Develop the expression for the induced maximum shear stress in parallel fillet
weld.
(b) A circular cantilever beam of 50 mm diameter and 250 mm length is to be
welded to a side member. The maximum load of 8 kN is applied repeatedly.
Determine the size of the weld required for 3,00,0000 cycles. Assume that the
shear load is distributed over the entire weld. [6+10]

4. (a) What is spindle? Give examples.

(b) A machinery shaft supported on a bearing 2.4 metre apart is to transmit
187.5 kW at 200 rev/min. It is subjected to a bending load of 5000 N located
at a distance of 0.66 metre from one bearing. Safe stress in shear is 42 MPa
and in bending 84 MPa.
i. Determine the shaft diameter for steady loading
ii. Determine the shaft diameter if the transverse load is steady and the
torsional load is suddenly applied. [4+12]

5. (a) Give in detail; the design procedure for the design of a leaf spring of an
automobile. Indicate, how the unequalised stresses produced in full length
and graduated leaves at maximum load are counted in design?

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Code No: R05312401 Set No. 4
(b) A close coiled helical compression springs of 12 active coils has a spring stiffness
of P0 . It is cut in to two springs having 5 and 7 turns. Determine spring
stiff nesses of resulting springs. [10+6]

6. (a) Explain the principle of hydrodynamic lubrication.

(b) Select a single row deep groove ball bearing for a radial load of 4000N and an
axial load of 5000 N, operating at a speed of 1600r.p.m for an average life of
5 years at 10 hours per day. Assume uniform and steady load. [6+10]

7. A crank shaft of the center- crank type is to be designed for a diesel engine de-
veloping 7.5kW on brake at 1200r.p.m. The crank shaft is of the forged type and
has to carry two fly wheels of 500N each on either side of the main bearing. The
plane of rotation of each fly wheel is 100mm from the center line of adjacent main
bearing.
The maximum load on connecting rod is 35kN. The length of stroke of piston
is 160mm and the length of connecting rod 320mm. Maximum torque will be
experienced in the crank shaft when the crank turns 300 from the inner dead center
position. The maximum permissible stress in crank pin, web and shaft should not
exceed 60N/mm2 , the safe limit for the bearing stress for the crank pin and the
main bearings is 800N/mm2 . Design the crank shaft. [16]

8. The following particulars relate to a slow speed oil engine working on 4-Stroke cycle
:
Indicated power = 15kW
RPM =300
Maximum explosion pressure = 2.1MN/m2
Mean effective Pressure = 0.56MN/m2

Design

(a) The suitable trunk piston and piston rings

(b) The Piston and give a neat dimensioned sketch of the piston assembly, incor-
porating all necessary details, clearly indicating the materials used for each
part. [16]

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