Design of machine elements question with key

1 What are the various phases of design process? i. Recognition of need. ii. Definition of problem iii. Synthesis iv. Analysis and optimization v. Evaluation vi. Presentation Define: Factor of safety The ratio between maximum stresses to working stress is known as factor of safety.Factor of safety = Maximum stress / Working stress The dimensions of the mating parts, according to basic hole system, are given as follows: Hole: 25.00 mm Shaft: 24.97 mm 25.02 mm 24.95 mm Find the hole tolerance, shaft tolerance and allowance

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1 A hollow shaft of 40 mm outer diameter and 25 mm inner diameter is subjected to a twisting moment of 120 N-m, simultaneously, it is subjected to an axial thrust of 10 kN and a bending moment of 80 N-m. Calculate the maximum compressive and shear stresses.

2 Give some methods of reducing stress concentration. i.Avoiding sharp corners. ii.Providing fillets. iii.Use of multiple holes instead of single hole iv.Undercutting the shoulder parts. Determine the design stress for a piston rod where the load is completely reversed. The surface of the rod is ground and the surface finish factor is 0.9. There is no stress concentration. The load is predictable and the factor of safety is2. Solution. Given: Ksur = 0.9; F.S. = 2 The piston rod is subjected to reversed axial loading. We know that for reversed axial loading, the load correction factor (Ka) is 0.8.

What are the various factors to be considered for failure and wear aspects of machine co mponents? Ans: To prevent failure of critical parts, the following factors should be considered. (i) Develop a suitable shape. This may require a kinematic analysis of the system (ii) Anticipate probable loads and environmental effect to be encountered. (iii)Established and evaluate criteria of behavior related to the expected modes of failure, such as measures of the effects of loading and /or environment of the part. (iv)Select materials on the basis of their mechanical, physics and chemical properties and their economy .The selection involves a comparison of the anticipated effects of loading andenvironment expressed in terms of the appropriate criteria of behavior, and correspon ding limiting characteristics or design criteria of the material for the particular condition of loading the choice of design criteria may be influenced by the type of material. (v) Select the final dimensions, tolerances & surface finish etc. (vi)Construct a prototype, test, evaluate the performance and if necessary, redesign the pa rt in the light of test result.

2 Define stress concentration and stress concentration factor. Stress concentration is the increase in local stresses at points of rapid change in cross section or discontinuities. Stress concentration factor is the ratio of maximum stress at critical section to the nominal stress

A machine component is subjected to a flexural stress which fluctuates between +300 10 2 2 MN/m and -150 MN/m . Determine the value of minimum ultimate strength according to 1. Gerber relation 2. Modified Goodman relation and 3.Soderberg relation. Take yield strength = 0.55 Ultimate strength; Endurance strength = 0.5 Ultimate strength; and factor of safety = 2.

Solution. Given: 1=300 MN/m2; 2=-150 MN/m2; y=0.55 u; e=0.5 u; F.S. = 2

3 A double riveted lap joint is made between 15 mm thick plate. The rivet diameter and pitch are 25 mm and 75 mm respectively. If the ultimate stresses are 400 MPa in tension, 320 MPa in shear and 640 MPa in crushing, find the minimum force per pitch which will rupture the joint. If the above joint is subjected to a load such that the factor of safety is 4, find out the actual stresses developed in the plates and the rivets.

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3 Give the application and advantages of screwed fasteners

Application a. For readily connecting & disconnecting machine parts without damage b. The parts can be rigidly connected c. Used for transmitting power Advantage a. They are highly reliable in operation b. They are convenient to assemble & disassemble c. A wide range of screws can be used for various operating conditions

d. They are relatively cheap to produce

Design a boiler joint (longitudinal & circumferential) to handle a pressure 1.8 MPa with an internal diameter of 1.3 m. Solution, Given data: Pi= 1.8 MPa D = 1.3 m = 1300 mm Selecting Plate Material: SAE 2010 Syt = 246 MPa; Sys = 154 MPa Rivet Material: SAE 1010 Syt = 218 MPa; Sys = 140 MPa Thickness of plate: t = PD/2Sdt = 14.26 mm Thickness of rivet plate: t1 = PiD/2Sd = 16.77 mm ( = 85% for triple row) d= 6t or 7t d = 6.5t = 26.61 mm P = {(/4d2 (2n2 +n1) Sds)/ tSdt} + d = 201.3 mm Circumferential Joint /4D2Pi = (/4d2Sds)N N = 90 Pitch = (D+2t)/N = 96.54mm Check the pitch: Pmin = 2.5d = 66.525 mm. As pitch is less than Pmin, arrange the rivets in two rows. Therefore, no. of rivets per row is 90/2 = 45. Pitch = 2 x 46.54 = 93.1 mm Margin m = 1.5d = 39.9 mm

4 Design a cotter joint to support a load varying from 30 KN in compression to 30 KN in te 12 nsion. The material used is carbon steel for which the following allowable stresses may b e used. The load applied is statically. Tensile stress = Compressive stress = 50MPa; Shear stress = 35MPa & Crushing stress = 90 MPa. Solution Given data: P = 30 KN Sdt =50 N/mm2 Sdc = 90 N/mm2 Sds = 35 N/mm2 1) Diameter of rod (d):

Considering failure of rod in tension. P = /4 d4 Sdt d=28mm 2) Diameter of spigot (d2) & thickness of cotter(t): Considering failure of spigot in tension across weakest section. P = (/4(d4)(d2t)).Sdt d2 = 34 mm. t= d2/4 = 8.5 mm 3) Outside diameter of socket(d1): Considering failure of socket in tension across the slot. P = {( /4(d12)(d22) (d1 d2) }.Sdt d1 = 50 mm 4) Width of cotter(b): Considering failure of cotter in shear. Since, cotter is in double shear P = 2.b.t .Sds b = 43mm 5) Diameter of socket collar (d4): Considering failure socket collar of in crushing. P = (d4 d2)t .Sdc d4=75mm 6) Thickness of socket collar(t1): Considering failure of socket end in shear. Since, socket end is in double shear. P = 2(d4d2)t1.Sds t1 = 12 mm 7) Diameter of spigot collar(d3): Considering failure of spigot collar in crushing. P = {( /4(d32) (d22) }Sdc d3 = 45 mm 8) Thickness of spigot collar(t2): Considering failure of spigot collar in shearing. P = d2 t2 Sds t2= 8 mm 9) Length of cotter(L): L = 4d = 112 mm 10) Distance from the end of slot to the end of rod (a): Considering rod end in shear. Since, rod end is in double shear. P = 2ad2Sds, a = 11 mm. 11) Dimension e e = 1.2 d e =34 mm.

4 A plate of 100 mm wide & 10 mm thick is welded to another plate by a single transverse fillet weld & a double parallel fillet welds as shown in figure. The maximum working ten sile & shear stresses are 75 N/mm2 & 55 N/mm2 respectively. Find the length of respective welds. Assume overall length equal to 12.5 mm.

Ans: Given data: w = 100 mm; t =10 mm; Sdt = 75 N/mm2; Sds = 55 N/mm2 l1 + l2 = 12.5 mm Load on plate P = Area x Stress =75000N Length of transverse weld = l2 = 10012.5 = 87.5 mm Load carried by joint P = 0.707.h.l2.Sdt +1.414hl1Sds l1 = 36.77 mm
State the two types of eccentric welded connections. i. Welded connections subjected to moment in a plane of the weld. ii. ii. Welded connections subjected to moment in a plane normal to the plane of the weld.

List any five advantage of welded joints over riveted joints

5 a)What are the basic assumption made in torsion equation?

b) A shaft is transmitting 97.5 kW at 180 r.p.m. If the allowable shear stress in the material is 60 MPa, find the suitable diameter for the shaft. The shaft is not to twist than 10 in a length of 3 meters. Take C = 80 GPa

c). What are the types of Flexible coupling? i. Universal, ii. Oldhams, iii. Pushed pin type coupling.

(OR) 5 A steel shaft ABCD having a total length of 3.5 m consist of three lengths different section as follows: AB is hollow having outside and inside diameter of 100 mm and 62.5 mm respectively, and BC and CD are solid. BC has a diameter of 100 mm and CD has a diameter of 87.5 mm. If the angle of twist is the same for each section, determine the length of each section. Find the value of the applied torque and the total angle of twist, if the maximum shear stress in the hollow portion is 47.5 MPa shear modulus, C = 82.5 GPa

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