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Degree: M.E. / Branch: Mechatronics Semester: II / Year: I

Course Code: 15HB06 & Course Title: Machine Component Design
PART-B (16Marks)
UNIT: 1 INTRODUCTION
1. A Shaft is subjected to a bending moment varying from -200Nm to 500Nm and a twisting
moment varying from -200Nm to 500Nm and a twisting moment varying from 50Nm to
175Nm. The material used has Su = 600Mpa, Se = 300Mpa, Ka = 0.76, Kb = 0.85, Kc =
0.897, Kt = 1.85 and q = 0.95.
i) Find the diameter of the shaft by Von Misses Hencky theory. Factor of safety is 1.5. (10)
ii) What are the various phase of design process? (3)
iii) Define stress concentration. Give some methods of reducing stress concentration (3)

2. (i) Explain the following with mathematical expressions (10)

a) Rankine Theory or maximum principle stress theory or max normal stress.
b) Guests theory or Coloumb theory or Tresca Theory or maximum shear theory.
c) Venants theory or Maximum Strain Theory.
d) Maximum Strain Energy Theory.
e) Von-Mises-Henky stress theory.
(ii) What do you mean by bearing pressure and crushing stress? (3)
(iii) Write a short notes on selection of engineering materials (3)

3. (i)Determine the safety factor for the bracket rod based on both the distortion energy
theory and maximum shear theory and compare them. The material is 2024-T4 aluminum
with yield strength of 324Mpa. The rod length, l = 150mm and arm, a = 200mm. The rod
outside diameter, d = 37.5mm load, F = 4545N. The load is static and the assembly is at
room temperature. Consider shear due to transverse loading as well as other stresses. (10)

(ii) A hydraulic press exerts a total load of 3.5 MN. This load is carried by two steel rods,
Supporting the upper head of the press. If the safe stress is 85 Mpa and E =210
kN/mm2, find diameter of the rods (3)

(iii) Extension in each rod in a length of 2.5m. (3)

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4. (i) A pulley keyed to a shaft midway between two antifriction bearings. The bearing
moment at the pulley varies from -170Nm to 510Nm as the torsion moment in the shaft
varies from 55Nm to 165Nm. The frequency of the variation of the loads is the same as
the shaft speed. The shaft is made of cold drawn steel having an ultimate strength of
538MPa and a yield strength of 400MPa. Determine the required diameter for an
indefinite life. The stress concentration for the keyway in bending and torsion may be
taken as 1.6 and 1.3 respectively. Correction factor A = 1(for bending), A = 0.6(for
torsion), B = 0.85, C = 0.88. Use the design factor, N = 1.5. (10)

(ii) The piston rod of steam engine is 50mm in diameter and 600mm long. The diameter of
the piston is 400mm and the maximum steam pressure is 0.9N/mm 2. Find the compression of
the piston rod if the youngs modulus for the material of the piston rod is 210kN/mm2. (3)

(iii) Calculate the force required to punch a circular blank of 60mm diameter in a plate of
5mm thick. The ultimate shear stress of the plate is 350 N/mm2. (3)

5. (i) A plate of 12mm thick, with two holes as indicated in fig. is subjected to a tensile load
of 20kN. Calculate the stresses at both the holes. (9)
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(ii) A cast iron link, as shown in fig. is required to transmit a steady tensile load of
45kN.Find the tensile stress induced in the link material at sections A-A and B-B. (3)

(iii) A journal 25mm in diameter supported in sliding bearings has a maximum end reaction of
2500 N. Assuming an allowable bearing pressure of 5 N/mm 2, find the length of the sliding
bearing. (3)

6.(i)A cast iron pulley transmits 10kW at 400rpm.The diameter of the pulley is 1.2 m and it has
four straight arms of elliptical cross section in which the major axis is twice the minor axis
Determine the dimensions of the arm if the allowable bending stress is 15MPa. (10)

(ii) Write a short notes on shear stress theory (3)

(iii) Discuss the principle stresses for various load conditions. (3)

7. A cantilever rod of circular section is subjected to a cyclic transverse load; varying from
-100N to +300N.determine the diameter d of the rod by

(i) Goodman Method (6)

(ii) Soderberg Method using the following data. (6)

Factor of safety = 2

Theoretical stress concentration factor = 1.4

Notch sensitivity factor = 0.9

Yield Strength = 320MPa

Endurance Strength = 275Mpa

Size correction factor = 0.85

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Surface correction factor = 0,9

(iii) Write a short notes on mechanical properties of the material. (4)

8. (i) A transmission shaft made of C45 steel is subjected to a fluctuating torque varying from
-100N-m to +500N-m. Also, a fluctuating bending moment acts on the shaft, which varies
from +500N-m to -100N-m. Let the stress concentration factor be 2. The shaft is machined
for a factor of safety of 1.5. Determine the required diameter of the shaft. (10)

(ii) A mild steel rod of 12mm diameter was tested for tensile strength with the gauge length
of 60mm.Following observations were recorded: Final length = 80mm; Final diameter =
7mm ; yield load =3.4 kN and ultimate load = 6.1kN. Calculate 1.yield stress and ultimate
stress (3)

(iii) Calculate percentage reduction in area, and percentage elongation. (3)

9. (i) A mild steel bracket is subjected to a pull of 5000N acting at 450 to the horizontal axis. The
bracket has a rectangular section whose depth is twice the thickness. Find the cross sectional
dimensions of the bracket if the permissible stress in the material is 50N/mm2. (6)

(ii) Determine the thickness of a 120mm wide uniform plate for safe continuous operation if the
plate is to be subjected to a tensile load that has a maximum value of 250 kN and a minimum
value of 100 kN. The properties of the plate material are as follows; Endurance limit stress =
225Mpa, and yield point stress =300Mpa .The factor of safety based on yield point may be taken
as 1.5. (7)

(iii) A rectangular plate 50mm X 10mm with a hole 10mm diameter is subjected to an axial load
of 10 kN Taking stress concentration into account, find the maximum stress induced. (3)

10. (i) A bar of circular cross section is subjected to an alternating tensile forces varying from
200kN to 500kN. Materials ultimate tensile strength is 900MPa, endurance limit is 700MPa.
Determine the diameter of the bar using safety factors of 3.5 related to ultimate strength and 4
related to endurance limit, stress concentration factor is 1.65 use Goodman criteria. (10)

(ii) A stepped shaft has maximum diameter 45mm and minimum diameter 30mm. The fillet
radius is 6mm. if the shaft is subjected to an axial load of 10 kN (3)

(iii) What is meant by endurance strength of a material? How do the size and surface
condition of a component and type of load affect such strength? (3)
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11. (i) A steel bar is subjected to reverse axial load of 180 kN. Find the diameter of the bar for
the design factor of 2. Ultimate tensile strength 1070N/mm 2 and yield strength 910N/mm2.
Endurance limit in bending is half of ultimate tensile strength. Use the following data. Load
factor 0.7, Surface finish factor 0.8, Size factor 0.85 and stress concentration factor 1. (10)

(ii) Illustrate how the stress concentration in a component can be reduced (3)

(iii) Write a short note on the influence of various factors of the endurance limit of a ductile
material. (3)

Faculty In-charge
M.Rajesh AP / Mech Dean / Mech