SKP Engineering College Course on Design of Machine Elements

S.K.P.
Engineering College, Tiruvannamalai V SEM
SKP Engineering College

Tiruvannamalai – 606611
A Course Material
on
Design of Machine Elements
By
Mr.C.Naveen Kumar / Mr.R.Saravanan / Mr.G.Delhi Babu /

Mr.R.Bharath
Assistant Professor
Mechanical Engineering Department
1
Mechanical Engineering Department Design of machine elements
S.K.P. Engineering College, Tiruvannamalai V SEM
Quality Certificate
This is to Certify that the Electronic Study Material
Subject Code: ME 6503
Subject Name: Design of Machine Elements
YEAR / SEM: III/V
Being prepared by me and it meets the knowledge requirement of the university

curriculum.
Signature of the Author
Name: Mr.C.Naveen Kumar /

Mr.R.Saravanan / Mr.G.Delhi Babu
/R.bharath
Designation: Assistant Professor
This is to certify that the course material being prepared by Mr.C.Naveen Kumar/
Mr.R.Saravanan/ Mr.G.Delhi Babu/ Mr.R.Bharath is of the adequate quality. He has
referred more than five books and among them minimum one is from abroad author.
Signature of HD Signature of the Principal
Name: Dr.J. Kuberan Name: Dr.V.Subramania Bharathi
Seal: Seal:
2
ME6503 DESIGN OF MACHINE ELEMENTS LTPC

3 0 0 3
COURSE OBJECTIVES:
• To familiarize the various steps involved in the Design Process
• To understand the principles involved in evaluating the shape and dimensions of a component
to satisfy functional and strength requirements.
• To learn to use standard practices and standard data
• To learn to use catalogues and standard machine components
(Use of P S G Design Data Book is permitted)
UNIT I STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS10
Introduction to the design process - factors influencing machine design, selection of materials
based on mechanical properties - Preferred numbers, fits and tolerances – Direct, Bending and
torsional stress equations – Impact and shock loading – calculation of principle stresses for
various load combinations, eccentric loading – curved beams – crane hook and ‘C’ frame- Factor
of safety - theories of failure – Design based on strength and stiffness – stress concentration –
Design for variable loading.
UNIT II SHAFTS AND COUPLINGS 8
Design of solid and hollow shafts based on strength, rigidity and critical speed – Keys, keyways
and splines - Rigid and flexible couplings.
UNIT III TEMPORARY AND PERMANENT JOINTS 9
Threaded fasteners - Bolted joints including eccentric loading, Knuckle joints, Cotter joints –
Welded joints, riveted joints for structures - theory of bonded joints.
UNIT IV ENERGY STORING ELEMENTS AND ENGINE COMPONENTS 9
Various types of springs, optimization of helical springs - rubber springs - Flywheels considering
stresses in rims and arms for engines and punching machines- Connecting Rods and crank shafts.
UNIT V BEARINGS 9
Sliding contact and rolling contact bearings - Hydrodynamic journal bearings, Sommerfeld
Number, Raimondi and Boyd graphs, -- Selection of Rolling Contact bearings.
TOTAL: 45 PERIODS
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COURSE OUTCOMES:
Upon completion of this course, the students will be able to
 Aquire fundamental knowledge of the Standards used in the design of machine
elements
 Design machine elements which are subjected to various types of loading.
 Analyse the fluctuating loads that will cause failure in real parts using the
Soderberg, Gerber and Goodman techniques.
 Design shafts and couplings under various loading conditions.
 Design various temporary and permanent joints used in the assembly of a machine
component.
 Design components which are used to store energy.
 Design various engine components.
 Design the different types of bearings.
TEXT BOOKS:
1. Bhandari V, “Design of Machine Elements”, 3rd Edition, Tata McGraw-Hill Book Co, 2010.
2. Joseph Shigley, Charles Mischke, Richard Budynas and Keith Nisbett “Mechanical
Engineering Design”, 8th Edition, Tata McGraw-Hill, 2008.
REFERENCES:
1. Sundararajamoorthy T. V. Shanmugam .N, “Machine Design”, Anuradha Publications,
Chennai, 2003.
2. Robert C. Juvinall and Kurt M. Marshek, “Fundamentals of Machine Design”, 4th Edition,
Wiley, 2005
3. Alfred Hall, Halowenko, A and Laughlin, H., “Machine Design”, Tata McGraw-Hill
BookCo.(Schaum’s Outline), 2010
4. Bernard Hamrock, Steven Schmid,Bo Jacobson, “Fundamentals of Machine Elements”,2nd
Edition, Tata McGraw-Hill Book Co., 2006.
5. Orthwein W, “Machine Component Design”, Jaico Publishing Co, 2003.
6. Ansel Ugural, “Mechanical Design – An Integral Approach", 1st Edition, Tata McGraw-Hill
Book Co, 2003.
7. Merhyle F. Spotts, Terry E. Shoup and Lee E. Hornberger, “Design of Machine Elements” 8th
Edition, Printice Hall, 2003.
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TABLE OF CONTENTS
S.No. Contents Page Number
1. UNIT I (PART - A) 7
2. UNIT I (PART – B) 10
3. UNIT II (PART - A) 33
4. UNIT II (PART – B) 38
5. UNIT III (PART - A) 61
6. UNIT III (PART – B) 64
7. UNIT IV (PART - A) 82
8. UNIT IV(PART – B) 88
9. UNIT V (PART - A) 124
10. UNIT V (PART – B) 127
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UNIT I
STEADY STRESSES AND VARIABLE STRESSES IN MACHINE
MEMBERS
Introduction to the design process - factors influencing machine design, selection of materials
based on mechanical properties - Preferred numbers, fits and tolerances – Direct, Bending and
torsional stress equations – Impact and shock loading – calculation of principle stresses for
various load combinations, eccentric loading – curved beams – crane hook and ‘C’ frame- Factor
of safety - theories of failure – Design based on strength and stiffness – stress concentration –
Design for variable loading.
PART - A
1. What do you mean by Optimum design? (ODD- 2011)
It is the best design for the given objective function under the specified constraints. It
may be achieved by minimizing the undesirable effects.
2. Describe material properties hardness, stiffness and resilience. (EVEN- 2016)
Hardness is the ability of material to resist scratching and indentation.
Stiffness is the ability to resist deformation under loading.
Resilience is the ability of material to resist absorb energy and to resist shock and impact
load.
3. State the difference between straight beams and curved beams. (ODD- 2012)
In straight beams, the neutral axis of the section coincides with its centroidal axis and the stress
distribution in the beam is linear. But in case of curved beams, the neutral axis of the cross-
section is shifted towards the centre of curvature of the beam causing a non-linear (hyperbolic)
distribution of stress.
4. Define ‘Factor of Safety’. (ODD-2015)
6
The ratio between maximum stresses to working stress is known as factor of safety.
Factor of safety = Maximum stress / Working stress
5. List the important factors that influence the magnitude of factor safety. (ODD- 2011)
1. The reliability of the properties of the material and change of these properties during
service.
2. The reliability of test results and accuracy of application of these results to actual
machine parts
3. The reliability of applied load
4. The certainty as to exact mode of failure
5. The extent of simplifying assumptions
6. The extent of localised stresses
7. The extent of initial stresses set up during manufacture
8. The extent of loss of life if failure occurs and
9. The extent of loss of property if failure occurs.
6. Which are mechanical properties of the metals? List any four mechanical properties.
(EVEN- 2012)
The mechanical properties of the metals are those which are associated with the ability of
the material to resist mechanical forces and load.
These mechanical properties of the metal include strength, stiffness, elasticity, plasticity,
ductility, brittleness, malleability, toughness, resilience, creep and hardness.
7. Why normal stress theory is not suitable for ductile materials?
Ductile materials are mostly undergone by shearing. But this theory considers only
tensile or compressive stresses. So, this is not suitable for ductile materials.
8. Define stress concentration. (EVEN- 2012)(EVEN-2016)
Whenever a machine component changes the shape of its cross-section, the simple
stressdistribution no longer holds good and the neighbourhood of the discontinuity is different.
Thisirregularity in the stress distribution caused by abrupt changes of form is called stress
concentration.It occurs for all kinds of stresses in the presence of fillets, notches, holes, keyways,
splines, surfaceroughness or scratches etc.,
9. What is ‘Adaptive design’? Where is it used? Give examples. (ODD-2012)
In most cases, the designer’s work is concerned with adaptation of existingdesigns. This
type of design needs no special knowledge or skill and can be attempted by designers of ordinary
technical training. The designer only makes minor alternation or modification in the
existingdesigns of the product.
8. What are unilateral and bilateral tolerances? (EVEN- 2013)
7
It is the difference between the upper limit and lower limit of a dimension. In other
words, it is the maximum permissible variation in a dimension. The tolerance may be unilateral
or bilateral.
+ .
When all the tolerance is allowed on one side of the nominal size, e.g. − . , then it is
said to be unilateral system of tolerance.
When the tolerance is allowed on both sides of the nominal size, e.g. + .
− . , then it is
said to be bilateral system of tolerance. In this case + 0.002 is the upper limit and – 0.002 is the
lower limit.
9. What are the various theories of failure? (EVEN- 2013)
1. Maximum principal (or normal) stress theory (also known as Rankine’s theory).
2. Maximum shear stress theory (also known as Guest’s or Tresca’s theory).
3. Maximum principal (or normal) strain theory (also known as Saint Venant theory).
4. Maximum strain energy theory (also known as Haigh’s theory).
5. Maximum distortion energy theory (also known as Hencky and Von Mises theory).
10. State Rankine’s theory.
Failure occurs when the maximum normal stress is equal to the tensile yield strength.
11. State St. Venant theory of failure.
According to this theory, failure occurs when the maximum strain in the member equals
the tensile yield strain.
1– ( 2+ 3) (or) 2– ( 3+ 1) (or) 3– ( 1 + 2) = y, whichever is maximum, where =

Poisson’s ratio.
12. What is Gerber theory?
Gerber parabola joins endurance stress and ultimate stress (like Goodman line).
According to Gerber method, the relationship between m, a, u, -1 is give by
a = -1 (1-( m/ u) )
2
13. Define the term equivalent torque and equivalent moment.
Equivalent torque, M e  M b2  M t2
14.What are the methods to reduce stress concentration?
Avoiding sharp corners, Providing fillets, Use of multiple holes instead of single hole,
Undercutting the shoulder parts.
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15. Differentiate between static and variable stresses.

Static stress does not change in magnitude and in direction. Variable stress changes in
magnitude or direction or both.
16. What are the types of variable stresses?
i. Completely reversed or cyclic stresses
ii. Fluctuating stresses
iii. Repeated stresses
iv. Alternating stresses
17. 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
18. How is factor of safety is defines for brittle and ductile materials?
For ductile material, Factor of safety = Yield stress / Working stress
For ductile material, Factor of safety = Ultimate stress / Working stress
19.Define Principal plane, principal stress.
A plane where only normal stresses act, with no shear stress acting is called principal
plane. The (normal) stress acting in this plane is called principal stress.
20. What are the various optimization methods available.
i. Optimization by evaluation
ii. Optimization by intuition
iii. Optimization by trail and error.
PART B
1. An overhang crank with pin and shaft is shown in Figure.A tangential loadof 15 kN acts
on the crank pin. Determine the maximum principal stress and the maximum shear stress
at the centre of the crankshaft bearing. (EVEN-
2010)
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10
2. A rectangular strut is 150 mm wide and 120 mm thick. It carries a load of 180kN at an
eccentricity of 10 mm in a plane bisecting the thickness as shown in Figure. Find
themaximum and minimum intensities of stress in the section.
11
3. A mild steel link, as shown in Fig. by full lines, transmits a pull of 80 kN. Find the
dimensions b and t if b = 3t. Assume the permissible tensile stress as 70 MPa. If the original
link is replaced by an unsymmetrical one, as shown by dotted lines in Fig. 5.24, having the
same thickness t, find the depth b1, using the same permissible stress as before.(ODD-2013)
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4. A mild steel bracket as shown in Fig., is subjected to a pull of 6000 N acting at 45° to its
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
of the bracket is limited to 60 MPa. (ODD- 2007)
A little consideration will show that the bending moment due to the horizontal component of the
load induces tensile stress on the upper surface of the bracket and compressive stress on the
lower surface of the bracket. ∴ Maximum bending stress on the upper surface due to horizontal
component,
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5. The frame of a punch press is shown in Fig. 5.9. Find the stresses at the inner and outer
surface at section X-X of the frame, if W = 5000 N. (EVEN -2014)
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6. The crane hook carries a load of 20 kN as shown in Fig. The section at X-X is
rectangular whose horizontal side is 100 mm. Find the stresses in the inner and outer fibers
at the given section.(ODD- 2006)
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17
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7. A cast iron pulley transmits 10 kW at 400 rpm. 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 major
axis. Determine the dimension of the arm if the allowable bending stress is 15 MPa.
(EVEN- 2011)
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8. A circular bar of 500 mm length is supported freely at its two ends. It is acted upon by a
central concentrated cyclic load having a minimum value of 20 kN and a maximum value
of 50 kN. Determine the diameter of bar by taking a factor of safety of 1.5, size effect of
0.85, surface finish factor of 0.9. The material properties of bar is given by: ultimate
strength of 650 MPa, yield strength of 500 MPa and endurance strength of 350 MPa.
(EVEN- 2011)
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9. A C-clamp is subjected to a maximum load of W, as shown in Fig. 5.13. If the maximum

tensile stress in the clamp is limited to 140 MPa, find the value of load W.( ODD-2012)
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10. A rectangular plate 60 mm × 10 mm with a hole 12 diameter as shown in Fig. 6.13 (a)
and subjected to a tensile load of 12 kN. (ODD- 2008)
Given : b = 60 mm ; t = 10 mm ; d = 12 mm ; W = 12 kN = 12 × 103 N We know that

cross-sectional area of the plate,
11. A cast iron pulley transmits 10 kW at 400 r.p.m. The diameter of the pulley is 1.2 metre
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 15 MPa.
(EVEN- 2008)
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12. A hot rolled steel shaft is subjected to a torsional moment that varies from 330 N-m
clockwise to 110 N-m counterclockwise and an applied bending moment at a critical section
varies from 440 N-m to – 220 N-m. The shaft is of uniform cross-section and no keyway is
present at the critical section. Determine the required shaft diameter. The material has an
ultimate strength of 550 MN/m2 and a yield strength of 410 MN/m2. Take the endurance
limit as half the ultimate strength, factor of safety of 2, size factor of 0.85 and a surface
finish factor of 0.62. (ODD- 2013)
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13. Determine the diameter of a circular rod made of ductile material with a fatigue
strength (complete stress reversal), σe = 265 MPa and a tensile yield strength of 350 MPa.
The member is subjected to a varying axial load from Wmin = – 300 × 103 N to Wmax =
700 × 103 N and has a stress concentration factor = 1.8. Use factor of safety as 2.0. (EVEN-
2009)
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14. Determine the thickness of a 120 mm 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 = 225 MPa, and Yield point stress = 300 MPa.
The factor of safety based on yield point may be taken as 1.5. (ODD- 2006)
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15. Define Stress concentration. Give some methods of reducing stress concentration.
(EVEN- 2011)
Stress concentration
Whenever a machine component changes the shape of its cross-section, the simple stress
distribution no longer holds good and the neighborhood of the discontinuity is different. This
irregularity in the stress distribution caused by abrupt changes of form is called stress
concentration.
It occurs for all kinds of stresses in the presence of fillets, notches, holes, keyways,
splines, surface roughness or scratches etc. In order to understand fully the idea of stress
concentration, consider a member with different cross-section under a tensile load as shown in
Fig.
A little consideration will show that the nominal stress in the right and left hand sides will
be uniform but in the region where the cross-section is changing, a re-distribution of the force
within the member must take place. The material near the edges is stressed considerably higher
than the average value. The maximum stress occurs at some point on the fillet and is directed
parallel to the boundary at that point.
The theoretical or form stress concentration factor is defined as the ratio of the maximum
stress in a member (at a notch or a fillet) to the nominal stress at the same section based upon net
area. Mathematically, theoretical or form stress concentration factor,
Kt = Maximum stress / Nominal stress
The value of Kt depends upon the material and geometry of the part.
Methods of reducing stress concentration
Whenever there is a change in cross-section, such as shoulders, holes, notches or

keyways and where there is an interference fit between a hub or bearing race and a shaft, then
stress concentration results. The presence of stress concentration cannot be totally eliminated but
it may be reduced to some extent. A device or concept that is useful in assisting a design
engineer to visualize the presence of stress concentration and how it may be mitigated is that of
stress flow lines, as shown in Fig 6.8. The mitigation of stress concentration means that the stress
flow lines shall maintain their spacing as far as possible.
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In Fig. 6.8 (a) we see that stress lines tend to bunch up and cut very close to the sharp re-
entrant corner. In order to improve the situation, fillets may be provided, as shown in Fig. 6.8 (b)
and (c) to give more equally spaced flow lines. Figs. 6.9 to 6.11 show the several ways of
reducing the stress concentration in shafts and other cylindrical members with shoulders, holes
and threads respectively. It may be noted that it is not practicable to use large radius fillets as in
case of ball and roller bearing mountings. In such cases, notches may be cut as shown in Fig. 6.8
(d) and Fig. 6.9 (b) and (c).
The stress concentration effects of a press fit may be reduced by making more gradual transition
from the rigid to the more flexible shaft. The various ways of reducing stress concentration for
such cases are shown in Fig. 6.12 (a), (b) and (c).
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16. Discuss in detail about the factor influencing machine design. (EVEN- 2012)
General Considerations in Machine Design
Following are the general considerations in designing a machine component :
1. Type of load and stresses caused by the load. The load, on a machine component,
may actin several ways due to which the internal stresses are set up.
2. Motion of the parts or kinematics of the machine. The successful operation of any
machinedepends largely upon the simplest arrangement of the parts which will give the motion
required.The motion of the parts may be :
(a) Rectilinear motion which includes unidirectional and reciprocating motions.
(b) Curvilinear motion which includes rotary, oscillatory and simple harmonic.
(c) Constant velocity.
(d) Constant or variable acceleration.
3. Selection of materials. It is essential that a designer should have a thorough
knowledge ofthe properties of the materials and their behaviour under working conditions. Some
of the importantcharacteristics of materials are : strength, durability, flexibility, weight,
resistance to heat and corrosion,ability to cast, welded or hardened, machinability, electrical
conductivity, etc. The various typesof engineering materials and their properties
4. Form and size of the parts. The form and size are based on judgement. The
smallestpracticablecross-section may be used, but it may be checked that the stresses induced in
the designedcross-section are reasonably safe. In order to design any machine part for form and
size, it is necessaryto know the forces which the part must sustain. It is also important to
anticipate any suddenlyapplied or impact load which may cause failure.
5. Frictional resistance and lubrication. There is always a loss of power due to
frictionalresistance and it should be noted that the friction of starting is higher than that of
runningfriction. Itis, therefore, essential that a careful attention must be given to the matter of
lubrication of all surfaceswhich move in contact with others, whether in rotating, sliding, or
rolling bearings.
6. Convenient and economical features. In designing, the operating features of the
machineshould be carefully studied. The starting, controlling and stopping levers should be
located on thebasis of convenient handling. The adjustment for wear must be provided
employing the varioustakeupdevices and arranging them so that the alignment of parts is
preserved. If parts are to be changedfor different products or replaced on account of wear or
breakage, easy access should be providedand the necessity of removing other parts to accomplish
this should be avoided if possible.The economical operation of a machine which is to be used for
30
production, or for the processingof material should be studied, in order to learn whether it has the
maximum capacity consistent withthe production of good work.
7. Use of standard parts. Theuse of standard parts is closely relatedto cost, because the
cost of standardor stock parts is only a fraction of thecost of similar parts made to order.The
standard or stock partsshould be used whenever possible ;parts for which patterns are alreadyin
existence such as gears, pulleys andbearings and parts which may beselected from regular shop
stock suchas screws, nuts and pins. Bolts andstuds should be as few as possible toavoid the delay
caused by changingdrills, reamers and taps and also todecrease the number of wrenches required.
8. Safety of operation. Some machines are dangerous to operate, especially those which
arespeeded up to insure production at a maximum rate. Therefore, any moving part of a
machinewhichis within the zone of a worker is considered an accident hazard and may be the
cause of an injury. Itis, therefore, necessary that a designer should always provide safety devices
for the safety of theoperator. The safety appliances should in no way interfere with operation of
the machine.
9. Workshop facilities. A design engineer should be familiar with the limitations of
hisemployer’s workshop, in order to avoid the necessity of having work done in some
otherworkshop.It is sometimes necessary to plan and supervise the workshop operations and to
draft methods forcasting, handling and machining special parts.
10. Number of machines to be manufactured. The number of articles or machines to
bemanufacturedaffects the design in a number of ways. The engineering and shop costs which
are calledfixed charges or overhead expenses are distributed over the number of articles to be
manufactured. Ifonly a few articles are to be made, extra expenses are not justified unless the
machine is large or ofsome special design. An order calling for small number of the product will
not permit any undueexpense in the workshop processes, so that the designer should restrict
hisspecification to standardparts as much as possible.
11. Cost of construction. The cost of construction of an article is the most
importantconsiderationinvolved in design. In some cases, it is quite possible that the high cost of
an article may immediatelybar it from further considerations. If an article has been invented and
tests of hand made samples haveshown that it has commercial value, it is then possible to justify
the expenditure of a considerable sumof money in the design and development of automatic
machines to produce the article, especially if itcan be sold in large numbers. The aimof design
engineer under allconditions, should be to reduce themanufacturing cost to the minimum.
12. Assembling. Everymachine or structure must beassembled as a unit before it
canfunction. Large units must often beassembled in the shop, tested andthen taken to be
transported to theirplace of service. The final locationof any machine is important and thedesign
engineer mustanticipate theexact location and the local facilitiesfor erection.
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17. Explain various phases in Design using flow diagram and enumerate the factors
influencing the machine design. (EVEN 2013)
18. What is meant by hole basis system and shaft basis system? Which one is preferred and
why? (EVEN- 2013)
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19. Write short notes in preferred numbers fits and types of fits. (EVEN 2012)
PREFERRED NUMBERS
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FITS
TYPES OF FITS
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UNIT II
SHAFTS AND COUPLINGS
Design of solid and hollow shafts based on strength, rigidity and critical speed – Keys, keyways
and splines - Rigid and flexible couplings.
PART A
1. Various stress induced in the shaft? (EVEN-2014)
Since the shaft is made of ductile materials, maximum shear stress theory is used.
2. What is coupling?
Couplings are used to connect sections of long transmission shafts and to connect the
shaft of a driving machine to the shaft of a driven machine.
3. What is key? (ODD- 2014)
A key is a device, which is used for connecting two machine parts for preventing relative
motion of rotation with respect to each other.
4. What are the purposes in machinery for which couplings are used? (ODD- 2015)
1. To provide misalignment of the shafts (or) to introduce mechanical flexibility.
2. To reduce the transmission of shock from one shaft to another.
3. To introduce protection against over load.
5. What is the main use of woodruff keys? (EVEN- 2016)(ODD-2013)
Woodruff key is used to transmit small value in automotive and machine tool industries.
The key is the shaft is in a curved shape where as keyway in the hub is usually straight.
6. Differentiate between keys and splines. (ODD- 2011)
Keys – A shaft which is having single keyway
Keys are used in couplings.
Splines – A shaft which is having multiple keyways
Splines are used in automobiles and machine tools
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7. At what angle of the crank the twisting moment is maximum in the crankshaft? (ODD-
2011)
The angle of the crank the twisting moment is maximum in the crankshaft is between 25o
to 35o from the TDC.
8. What is meant by woodruff keys? (EVEN- 2013)
A woodruff key is used to transmit small value of Torque in automotive and machine tool
industries. The keyway in the shaft is milled in a curves shape whereas the key way in the
hub is usually straight.
9. Name any two of the rigid and flexible couplings. (EVEN-2013)(EVEN-2016)
Rigid coupling
Sleeve and Flange coupling
Flexible Coupling
Universal and Oldham’s coupling
10. Why a hallow shaft has greater strength and stiffness than solid shaft of equal weight?
(ODD- 2012)
Stresses are maximum at the outer surface of a shaft. A hollow shaft has almost all the
material concentrated at the outer circumferences and so has a better strength and stiffness
for equal weight.
11. Under what circumstances flexible couplings are used. (ODD- 2012)
(i) They are used to join the abrutting ends of shafts when they are not in exact alignment.
(ii) They are used to permit an axial misalignment of the shaft without under absorption
of the power, which the shafts are transmitting.
12What is key?
A key is a device, which is used for connecting two machine parts for preventing relative
motion of rotation with respect to each other.
13What are the purposes in machinery for which couplings are used?
4. To provide misalignment of the shafts (or) to introduce mechanical flexibility.
5. To reduce the transmission of shock from one shaft to another.
6. To introduce protection against over load.
14Under what circumstances flexible couplings are used?
They are used to join the abutting ends of the shafts when they are not in exact alignment.
37
They are used to permit an axial misalignment of the shafts without under absorption of
power, which the shafts are transmitting.
15.What are the factors to be considered to design a shaft?
Strength and Stiffness
16. What is the main use of woodruff keys?
Woodruff key is used to transmit small value in automotive and machine tool industries.
The key is the shaft is in a curved shape where as keyway in the hub is usually straight.
17.What is simple torsion?
When a shaft is subjected to pure torsional moment M, the shaft diameter can be found
from torsional shear strength equation. Shear strength = 16*M/3.14.
18.What is simple bending?
When a shaft is subjected to a pure bending load, the principal stresses induced in the
shaft are tension and compression. The maximum stress induced in the shaft can be
determined by the theory of simple bending moment relation.
19.What are the types of Rigid Coupling?
(i)Sleeve, (ii) Flange, (iii) Clamp Coupling.
20.What material used for flange coupling?
Cast iron
21.What are the types of Flexible Coupling?
Universal, Oldham’s and Push pin type coupling
22.List the various failures occurred in sunk keys?
Shear failure and Crushing failure.
23.Write bending and torsion equation.
τs
1. = = (Bending)
R
T θ s
2. = l
= r
(Torsion)
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PART B
1.
39
2. A rigid type of coupling is used to connect two shafts transmitting 15 kW at 200 rpm.
The shaft, keys and bolts are made of C45 steel and the coupling is of cast iron. Design the
coupling. (ODD- 2013)
3. Design a cast iron protective type flange coupling to transmit 15 kW at 900 rpm from
an electric motor to a compressor. The service factor may be assumed as 1.35. The
following permissible stress may be used: Shear stress for the shaft, bolt and key
material = 40 MPa, Crushing stress for bolt and key = 80 MPa, Shear stress for cast
iron = 8 MPa. (ODD -2014)(EVEN-2016)
40
41
42
4.
43
5. Design a bushed –pin type of flexible coupling to connect a pump shaft to a motor shaft
transmitting 32 KW at 960 rpm the overall torque is 20 percent more than mean torque.
The material properties are as follows:
(i)The allowable shear and crushing stress for shaft and key material is 40 Mpa and 80
Mpa respectively.
(ii) The allowable shear stress for cast iron is 15 Mpa.
(iii) The allowable bearing pressure for rubber bush is 0.8 N/mm2.
44
(iv) The material of the pin is same as that of shaft and key. (ODD- 2015)(ODD-2012)
45
46
47
6. Two 35 mm shafts are connected by a flanged coupling. The flanges are fitted with 6
bolts on 25 mm bolt circle. The shafts transmit a torque of 800 N-m at 350 rpm. For the
safe stresses mentions below, calculate (i) diameter of bolts, (ii) thickness of flanges, (iii) key
dimensions, (iv) hub length and (v) power transmitted. Safe stress for shaft material 63
MPa. Safe stress for bolt material 56 MPa. Safe stress for cast iron coupling 10 MPa and
Safe stress for key material 46 MPa. (ODD 2011)
48
7. A Horizontal nickel steel shaft rests on two bearings, A at the left and B at the right end
and carries two gears C and D located at distances of 250 mm and 400 mm respectively
from the centre line of the left and right bearings. The pitch diameter of the gear C is 600
mm and that of gear D is 200 mm. The pitch diameter of the gear C is 600 mm and that of
gear D is 200 mm. The distance between the centre line of the bearings is 2400mm. The
shaft transmits 20 KW at 120 rpm. The power is delivered to the shaft at gear C and is
taken out at gear D in such a manner that the tooth pressure FtC of the gear C and FtD of
the gear D act vertically downwards.
Find the diameter of the shaft, if the working stress is 100 Mpa in tension and 56 Mpa in
shear. The gear C and D weighs 950 N and 350 N respectively. The combined shock and
fatigue factors for bending and torsion may be taken as 1.5 and 1.2 respectively. (ODD-
2012)
𝑷× × ×
𝑻= = = −𝒎
𝝅 𝝅×
𝑻 ×
𝑭𝒕 = 𝑹 = = 6250N
16250
= 𝑭𝒕 + 𝑾 = + = A C
D B
𝑻 ×
𝑭𝒕 = 𝑹 = = 250 1750
400
49
= 𝑭𝒕 + 𝑾 = + = 2400
𝑹 = . × / =
𝑹 = − =
= 𝑹 × = × = . × − 𝒎𝒎
= 𝑹 × = × = × − 𝒎𝒎
𝑻 = √ 𝑲𝒎 × + 𝑲𝒕 × 𝑻 2
=8725 × − 𝒎𝒎
𝝅 𝝅
8725 × = ×𝝉× = × × =
d = 92.5 mm
= [𝑲𝒎 × ] + √ 𝑲𝒎 × + 𝑲𝒕 × 𝑻 2 ]
= 𝑲𝒎 × +𝑻
d = 95.7mm
Taking the larger of the two values, we have d=95.7 mm Say 100 mm.
8. Design a shaft to transmit power from an electric motor to a lathe head stock through a
pulley by means of a belt drive. The pulley weights 200 N and is located at 300 mm from
the center of the bearing. The diameter of the pulley is 200 mm and the maximum power
transmitted is 1 kW at 120 rpm. The angle of lap of the belt is 180 o and coefficient of
friction between the belt and the pulley is 0.3. the shock arid fatigue factors for bending
and twisting are 1.5 and 2 respectively. The allowable shear stress in the shaft may be taken
as 35 MPa. (ODD- 2011)
50
51
9. A steel solid shaft transmitting 15 kW at 200 rpm is supported on two bearings 750 mm
apart and has two gears keyed to it. The pinion having 30 teeth of 5 mm module is located
100 min to the left of the right hand bearing and delivers power horizontally to the right.
The gear having 100 teeth of 5 mm module is located 150 mm to the right of the left hand
52
bearing and receives power in a vertical direction from below. Using an allowable stress of
54 MPa in shear. Determine the diameter of the shaft. (EVEN- 2013)(EVEN-2014)
53
54
55
10.
11.
56
57
58
59
12.
(EVEN-2016)
60
61
62
63
UNIT III
TEMPORARY AND PERMANENT JOINTS
Threaded fasteners - Bolted joints including eccentric loading, Knuckle joints, Cotter joints –
Welded joints, riveted joints for structures - theory of bonded joints.
PART A
1. What is known as proof strength of the boltsbolt of uniform strength? (EVEN-2015)

A bolt of uniform strength has equal strength at the thread and shank portion.
1. External load 2. Material used 3. Bolt diameter
2. What stresses act on screw fastenings due to static loading? (EVEN- 2016)
1.Initial stresses due to screwing up 2.Stresses due to external forces 3.Combined stresses
3. Define term of self-locking of power screws. (EVEN- 2013) (ODD- 2014)
If the friction angle ( φ) is greater than helix angle (α) of the power screw, the torque applied to
lower the load will be positive, indicating that an effort is applied to lower the load. This type of
screw is known as self-locking screw.
4. What are the types of welded joints? (ODD-2013)
1. Butt joint 2. Lap joint 3. T joint 4. Corner joint 5. Edge joint
5. What are the two types of fillet weld? (EVEN-2016)
1. Longitudinal or parallel fillet weld. 2. Transverse fillet weld.
6. State the two types of eccentric welded connections. (ODD-2013)
1. Welded connection subjected to moment in a plane of the weld.
2. Welded connection subjected to moment in a plane normal to the plane of the weld.
7. Name the possible modes of failure of riveted joint.(ODD-2012)(EVEN- 2012)
1. Crushing of rivets 2.Shearing of rivet 3.Tearing of the plate at the edge 4.Tearing of
the plate between rivets.
8. Differentiate with a neat sketch the fillet welds subjected to parallel loading and
transverse loading. (EVEN- 2014)
64
9. What do you understand by the single start and double start threads? (ODD- 2011)
A screw made by cutting a single helical groove on the cylinder is known as single
threaded (or single-start) screw and if a second thread is cut in the space between the grooves of
the first, a double threaded (or double-start) screw is formed.
10. Classify the rivet heads according to IS specifications. (ODD- 2011)
1. Rivet heads for general purposes (below 12 mm diameter) according toIS : 2155 –
1982 (Reaffirmed 1996).
2. Rivet heads for general purposes (From 12 mm to 48 mm diameter) according to IS :
1929 – 1982 (Reaffirmed 1996).
3. Rivet heads for boiler work (from 12 mm to 48 mm diameter, according toIS : 1928 –
1961 (Reaffirmed 1996).
11. Determine the safe tensile load for a bolt of M20, assuming a safe tensile stress of 40
MPa? (EVEN- 2012)
For M 20 bolt the nominal diameter d p= 18.376mm & the effective diameter is 16.933
mm.
Safe tensile load = Permissible stress × Cross-sectional area at bottom of the thread
𝑑𝑝 +𝑑𝑐 . + .
= 40 x = 40 x = 9786.759 N
12. Write any two advantages and disadvantages of welded joints over riveted joints.
(EVEN- 2013)
Material is saved in welded joints and hence the machine element will be light if welded joints
are used instead of riveted joints. Leak proof joints can easily obtained by welded joints
compared riveted joints.
13. What are the ways to produce bolts of uniform strength?

1. Reducing shank diameter equal to root diameter 2.Drilling axial hole
14. What stresses act on screw fastenings?
65
1.Initial stresses due to screwing up 2.Stresses due to external forces 3.Combined

stresses
15. What are the different applications of screwed fasteners?
The different applications of screwed fasteners are
a. For readily connecting & disconnecting machine parts with out damage
b. The parts can be rigidly connected.
c. Used for transmitting power.
16. What are the advantages of screwed fasteners?
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.
17. Define Pitch.
Pitch is defined as the distance from appoint on one thread to the corresponding on the
adjacent thread in the same axis plane.
18. Define lead.
Lead is defined as the distance, which a screw thread advances axially in one rotation of
the nut.
19. What are the different types of metric thread?
1. BSW (British standard whit worth)
20. What is stud?
A stud is a bolt in which the head is replaced by a threaded end. It passes through one of
the parts to be connected and is screwed into the other part.
21. What is meaning of bolt M24 X 2?
d = 24 – Nonimal diameter, P = 2 – Pitch of the bolt
22. State the advantages of threaded joints.
a. High clamping b. Small tightening force requirement.
23. Define welding.
Welding can be defined as a process of joining two similar or dissimilar metals with or
without application of pressure along with or without addition of filler material.
24. What are the types of welded joints?
1. Butt joint 2. Lap joint 3. T joint 4. Corner joint 5. Edge joint
25. What are the two types of stresses are induced in eccentric loading of loaded jont?
1. Direct shear stress 2. Bending or torsional shear stress
66
26. Define Butt and Lap joint.

The joint is made by welding the ends or edges of two plates.
The two plates are overlapping each other for a certain distance. Then welded, such
welding is called fillet weld.
27. When will the edge preparation need?
If the two plates to be welded have more than 6 mm thickness, the edge preparation
should be carried out.
28.Why are welded joints preferred over riveted joints?
Material is saved in welding and hence the machine element will be light if welded joints
are used instead of riveted joints. Leak proof joints can be easily obtained by welded joints
compared riveted joints.
29. What is the minimum size for fillet weld? If the required weld size from strength
consideration is too small how will you fulfill the condition of minimum weld size?
It is defined as the minimum size of the weld for a given thickness of the thinner part
joined or plate to avoid cold cracking by escaping the rapid cooling.
Size of fillet weld h = √ 𝑋 𝑇ℎ 𝑎 ℎ𝑖
= 1.4142t
67
PART B
1.A plate 75 mm wide and 12.5 mm thick is joined with another plate by a single transverse
weld and a double parallel fillet weld as shown in Fig. the maximum tensile and shear
stresses are 70 MPa and 56 MPa respectively. Find the length of each parallel fillet weld, if
the joint is subjected to both static and fatigue loading(EVEN-2016)
68
2. A 200 × 150 × 10 mm angle is to be welded to a steel plate by fillet welds as shown in Fig.
10.21. If the angle is subjected to a static load of 200 kN, find the length of weld at the top
and bottom. The allowable shear stress for static loading may be taken as 75 MPa. (ODD-
2013)
69
3. A welded joint as shown in Fig. 10.24, is subjected to an eccentric load of 2 kN.Find the
size of weld, if the maximum shear stress in the weldis 25 MPa. (ODD- 2011)
4. A 50 mm diameter solid shaft is welded to a flat plate as shown in Fig.If the size of the
weld is 15 mm, find the maximum normal and shear stress in the weld. (EVEN-2014)
70
71
5. A rectangular cross-section bar is welded to a support by means of fillet welds as shown

in Fig. 10.26. Determine the size of the welds, if the permissible shear stress in the weld is
limited to 75 MPa. (ODD- 2011).
72
6. A rectangular steel plate is welded as a cantilever to a vertical column andsupports a

single concentrated load P, as shown in Fig. Determine the weld size if shear stress in the
same is not to exceed 140 MPa. (ODD -2012)( EVEN- 2013)(EVEN-2016)
73
7. Design a knuckle joint to transmit 150 kN. The design stresses may be taken as75 MPa in
tension, 60 MPa in shear and 150 MPa in compression.(ODD- 2011, ODD- 2012,ODD-2015)
74
75
8. Design and draw a cotter joint to support a load varying from 30 kN incompression to 30
kN in tension. The material used is carbon steel for which the followingallowable stresses
may be used. The load is applied statically.Tensile stress = compressive stress = 50 MPa;
shear stress = 35 MPa and crushing stress= 90 MPa. (EVEN- 2013)
76
77
78
9. A steam engine of effective diameter 300 mm is subjected to a steam pressure of1.5

N/mm2. The cylinder head is connected by 8 bolts having yield point 330 MPa
andendurancelimit at 240 MPa. The bolts are tightened with an initial preload of 1.5 times
the steam load. A soft copper gasket is used to make the joint leak-proof. Assuming a factor
of safety 2, find the size of boltrequired. The stiffness factor for copper gasket may be taken
as 0.5. (ODD-2011)(EVEN-2016)
79
10. Determine the size of the bolts and the thickness of the arm for the bracket asshown in
Fig. if it carries a load of 40 kN at an angle of 60° to the vertical.The material of the
bracket and the bolts is same for which the safe stresses can be assumed as70, 50 and 105
MPa in tension, shear and compression respectively. (ODD- 2013)
80
81
82
83
84
85
11. A steam engine of effective diameter 300 mm is subjected to a steam pressure of1.5
N/mm2. The cylinder head is connected by 8 bolts having yield point 330 MPa and
endurancelimit at 240 MPa. The bolts are tightened with an initial preload of 1.5 times the
steam load. A softcopper gasket is used to make the joint leak-proof. Assuming a factor of
safety 2, find the size of boltrequired. The stiffness factor for copper gasket may be taken
as 0.5. (EVEN- 2016)
86
87
UNIT IV
ENERGY STORING ELEMENTS AND ENGINE COMPONENTS
Various types of springs, optimization of helical springs - rubber springs - Flywheels considering
stresses in rims and arms for engines and punching machines- Connecting Rods and crank shafts.
PART A
1. What is a spring?
A spring is an elastic member, which deflects, or distorts under the action of load and regains its
original shape after the load is removed.
2. State any two functions of springs.
i. To measure forces in spring balance, meters and engine indicators.
ii. To store energy.
3. What are the various types of springs? (EVEN- 2012)
i. Helical springs
ii. Spiral springs
iii. Leaf springs
iv. Disc spring or Belleville springs
4. Classify the helical springs.
a. Close – coiled or tension helical spring.
b. Open –coiled or compression helical spring.
5. Define: Leaf springs
A leaf spring consists of flat bars of varying lengths clamped together and Supported at both
ends, thus acting as a simply supported beam.
88
6. Define: Belleville Springs
They are made in the form of a cone disc to carry a high compressive force. In order to
improve their load carrying capacity, they may be stacked up together. The major stresses are
tensile and compressive.
7. What is spring index (C)?
The ratio of mean or pitch diameter to the diameter of wire for the spring is called the spring
index.
8. What is pitch?
The axial distance between adjacent coils in uncompressed state.
9. What is solid length?
The length of a spring under the maximum compression is called its solid length. It is the
product of total number of coils and the diameter of wire.
Ls = nt x d
Where, nt = total number of coils.
10. What are the requirements of spring while designing?
a. Spring must carry the service load without the stress exceeding the safe value.
b. The spring rate must be satisfactory for the given application.
11 What are the end conditions of spring?
(a) Plain end. (b) Plain and ground end (c). Squared end (d) Squared and ground end.
12. What is buckling of springs?
The helical compression spring behaves like a column and buckles at a comparative small
load when the length of the spring is more than 4 times the mean coil diameter.
13. What is surge in springs?
The material is subjected to higher stresses, which may cause early fatigue failure. This effect is
called as spring surge.
14. What is a laminated leaf spring?
In order to increase, the load carrying capacity, number of flat plates are placed and below the
other.
89
15. What semi – elliptical leaf springs?
The spring consists of number of leaves, which are held together by U-clips. The long
leaf fastened to the supported is called master leaf. Remaining leaves are called as graduated
leaves.
16. What is nipping of laminated leaf spring?
Prestressing of leaf springs is obtained by a difference of radii of curvature known as nipping.
17. What are the various applications of springs?
The springs are used in various applications, they are
a. Used to absorb energy or shocks (e.g. shock absorbers, buffers, e.t.c.)
b. To apply forces as in brakes clutches, spring-loaded valves, e.t.c.
c. To measure forces as in spring balances and engine indicators
d. To store energy as in watches
18. Define free length.
Free length of the spring is the length of the spring when it is free or unloaded condition. It is
equal to the solid length plus the maximum deflection or compression plus clash allowance.
Lf = solid length + Ymax + 0.15 Ymax
19. Define spring index. (ODD- 2011)
Spring index (C) is defined as the ratio of the mean diameter of the coil to the diameter of the
wire.
C =D/d
20. Define spring rate (stiffness). (ODD- 2011)(EVEN-2016)
The spring stiffness or spring constant is defined as the load required per unit deflection of the
spring.
K= W/y
Where W-load
Y-deflection
90
21. Define pitch.
Pitch of the spring is defined as the axial distance between the adjacent coils in
uncompressed state. Mathematically
22. What are the points to be taken into consideration while selecting the pitch of the
spring?
The points taken into consideration of selecting the pitch of the springs are (a)The
pitch of the coil should be such that if the spring is accidentally compressed the stress
does not increase the yield point stress in torsion.(b)The spring should not be close up before
the maximum service load is reached.
23. Define active turns.
Active turns of the spring are defined as the number of turns, which impart spring action while
loaded. As load increases the no of active coils decreases.
24. Define inactive turns.
An inactive turn of the spring is defined as the number of turns which does not
contribute to the spring action while loaded. As load increases number of inactive coils increases
from 0.5 to 1 turn.
25. What are the different kinds of end connections for compression helical springs?
The different kinds of end connection for compression helical springs are
a. Plain ends
b. Ground ends
c. Squared ends
d. Ground & square ends
26. Write about the eccentric loading of springs?
If the load acting on the spring does not coincide with the axis of the spring, then spring is said to
be have eccentric load. In eccentric loading the safe load of the spring decreases and the stiffness
of the spring is also affected.
27. Explain about surge in springs? (EVEN- 2013)
91
When one end of the spring is resting on a rigid support and the other end is loaded suddenly, all
the coils of spring does not deflect equally, because some time is required for the propagation of
stress along the wire. Thus a wave of compression propagates to the fixed end from where it
is reflected back to the deflected end this wave passes through the spring indefinitely. If the
time interval between the load application and that of the wave to propagate are equal,
then resonance will occur. This will result in very high stresses and cause failure. This
phenomenon is called surge.
28. What are the methods used for eliminating surge in springs?
The methods used for eliminating surge are
a. By using dampers on the center coil so that the wave propagation dies out
b. By using springs having high natural frequency.
29. What are the disadvantages of using helical spring of non-circular wires?
a. The quality of the spring is not good
b. The shape of the wire does not remain constant while forming the helix. It reduces the
energy absorbing capacity of the spring.
c. The stress distribution is not favorable as in circular wires. But this effect is negligible
where loading is of static nature.
30. Why concentric springs are used?
a. To get greater spring force with in a given space
b. To insure the operation of a mechanism in the event of failure of one of the spring
31. What is the advantage of leaf spring over helical spring?
The advantage of leaf spring over helical spring is that the end of the spring may be
guided along a definite path as it deflects to act a structural member in addition to energy
absorbing device.
32. Write notes on the master leaf & graduated leaf?
The longest leaf of the spring is known as main leaf or master leaf has its ends in the form of an
eye through which bolts are passed to secure the spring. The leaf of the spring other than master
leaf is called the graduated leaves.
33. What is meant by nip in leaf springs?
92
By giving greater radius of curvature to the full length leaves than the graduated leaves,
before the leaves are assembled to form a spring thus a gap or clearance will be left between
the leaves. This initial gap is called nip.
34. What is the application of leaf spring?
The leaf springs are used in automobiles as shock absorbers for giving suspension to the
automobile and it gives support to the structure.
35. Define flat spiral spring.
A flat spiral spring is a long thin strip of elastic material wound like a spiral. These
springs are frequently used in watch springs, gramophones, e.t.c
36.What are the differences between helical torsion spring and tension helical
Springs?
Helical torsion springs are wound similar to that of tension springs but the ends are shaped to
transmit torque. The primary stress in helical torsion spring is bending stress whereas in tension
springs the stresses are torsional shear stresses.
37. Define helical springs.
The helical springs are made up of a wire coiled in the form of a helix and are primarily intended
for compressive or tensile load.
38. What are the different types of helical springs?
The different types of helical springs are
a. Open coil helical spring
b. Closed coil helical spring
39. What are the differences between closed coil & open coil helical springs?(ODD-2014)
40. What is the use of flywheel? (EVEN 2012)(ODD-2015)
93
Flywheel is used in machine serves as a reservoir which store energy during the period
when the supply of energy is more than the requirement and release it during the period when the
requirement of the energy is more than the supply.
41. Write the formula for natural frequency of spring. (ODD- 2012)
𝑑 𝐺𝑔
= 𝑛𝐷 2
√ Where - density of material.
42. How does the function of flywheel differ from that of governor?(ODD- 2012) (ODD-
2011)
A governor regulates the mean speed of an engine when there are variations in the mean
loads. It automatically controls the supply of working fluid to engine with the varying load
condition and keeps the mean speed within the limits. It does not control the speed variation
caused by the varying load. A flywheel does not maintain constant speed.
43. Define Co-efficient of fluctuation of speed in flywheel. (MAY/JUNE 2013)
It is the ratio of the maximum change of speed to mean speed of the flywheel.
𝐚 − 𝐢
𝐊𝐒 =
𝐞𝐚
PART B
94
1.
(ODD- 2011)
95
2. Design a helical spring for as spring loaded spring loaded safety value of the
following conditions: Diameter of valve seat = 65 mm, Operating pressure = 0.7 N/mm2,
Maximum pressure when the valve blows freely = 0.75 N/mm2, Maximum lift of the
valve when the pressure = 3.5 mm rises from 0.7 to 0.75 N/mm2, Maximum allowable
stress = 550 MPa, Modulus of rigidity = 84 kN/mm2, Spring index = 6, Draw a neat
sketch of the free spring showing the main dimensions.(EVEN-
2012) (ODD- 2012)
96
97
(EVEN- 2013)
98
99
4.
100
(ODD-2014)
5.
(ODD-
101
102
6.
103
7.
104
105
8.
106
9.
107
108
109
10.
(ODD-2011
110
111
112
11. An engine runs at a constant load at a speed of 480 rpm. The crank effort diagram is
drawn to a scale 1 mm = 200 N-m torque and 1 mm = 3.6o crank angle. The areas of the
diagram above and below the mean torque line in sq. mm are in the following order: +110,
-132, +153, _166, +197,-162. Design the flywheel if the total fluctuation of speed is not to
exceed 10 rpm and the centrifugal stress in the rim is not to exceed 5 MPa. Assume that the
rim breadth is approximately 2.5 times the rim thickness and 90% of the moment of
inertial is due to rim. The density of the material of the flywheel is 7250 kg/m3. Make a
sketch of the flywheel giving the dimensions of the rim, the mean diameter of the rim and
other estimated dimensions of spoke, hub etc., (EVEN- 2012)
113
114
12. A machine punching 35 mm holes in 32 mm thick plate requires a7 N m of energy per

sq. mm of sheared area and punches one hole in every 10 seconds. Calculate the power on
the motor required. The mean speed of the flywheel is 25 m/sec. the punch has a stroke of
100 mm. find the mass of the flywheel required if the total fluctuation of speed is not to
exceed 3% of the mean speed. Assume that the motor supplies the energy to the machine at
uniform rate. (EVEN- 2013)
115
116
13.
(ODD- 2012)(ODD-2014)
117
118
119
120
121
14.
Connecting Rod
1. Design a suitable connecting rod for a petrol engine for the following details, diameter of
the piston = 100 mm, weight of reciprocating parts per cylinder = 20 N, connecting rod
length = 300 mm, compression ratio = 7:1, maximum explosion pressure = 3 N/mm2, stroke
= 140 mm, speed of the engine = 2000 rpm (ODD- 2011(EVEN- 2012)
Given:
d = 100 mm, r = 20 N, l = 300 mm, compression ratio = 7:1, p = 3 N/mm 2, storke = 140
mm, N = 2000 rpm.
122
Solution:
i. From PSG DDB Pg. No. 7.122,
t 5t
t
4t
a = 11t2
419 4
Ixx = t
12
k xx2 = 3.18 t2.
ii. Load due to burning of gas (FG): From PSG DDB Pg. No. 7.122
d2  1002
FG = p  3  23561.94 N
4 4
iii. Crippling load (Fcr):
Fcr = FOS x FG (Assume FOS = 6)
= 6 x 23561.94 = 141371.67 N
iv. Crippling load by Rankine’s formula:
123
c  a
Fcr  2
 l 
1 c  
 k xx 
330 11t 2
141371.67  2
1  300 
1
7500  3.18t 2 
330 11t 2 3630t 2
141371.67   2
3.77
1 2 t  3.77
t t2
3630t 4
141371.67  2
t  3.77
141371.67(t  3.77)  3630t 4
2
3630t 4  141371.67t 2  532971.196  0

3630  t 4  38.95t 2  146.824  0
(38.95)  (38.95) 2  4  1 (146.824)
t2 
2
38.95  45.874
t2   42.412
2
t  6.15mm  7 mm
v. Dimensions of Cross section:
Height of ‘I’ section = 5t = 5 x 7 = 35 mm

Width of ‘I’ section = 4t = 4 x 7 = 28 mm
vi. Design of small end pin:
L1
 1.75 (Assume Pb = 13 N/mm2)
d1
FG = L1 x d1 x Pb
23561.94 = 1.75d1 x d1 x 13
d1= 32.18 mm = 33 mm
L1 = 1.75(33) = 57.75 = 58 mm
vii. Design of Big end pin:
L2
 1.375 (Assume Pb = 8 N/mm2)
d2
FG = L2 x d2 x Pb
124
23561.94 = 1.375d2 x d2 x 13
d2= 46.28 mm = 47 mm
L2 = 1.375(47) = 64.63= 65 mm
viii. Diameter of bolt:
From PSG DDB Pg. No. 7.122,
L1
 1.75
d1
p 2  cos 2 
Fi   r cos   
g  l 
 r 
2 N 2  2000
   209.44rad / sec
60 60
l = 300 mm = 0.3 m
140
r = radius of crank = stroke length / 2 = = 70 mm = 0.07 m
2
20  1 
 Fi   (209.44) 2  0.07  1 
9.81  0.3 
 0.07 
Fi  7720.736 N
W.K.T
 d c2
Fi  n  
4
 d c2
7720.736  4  100
4
d c  4.95mm  5mm
d 5
Diameter of bolt d  c   5.95  6mm
0.84 0.84
ix. Thickness of big end cap (tc):
Fi  x
Bending moment mc = (x=1.5d2)
6
7220.736  1.5  47

6
 90718.65Nmm
125
btc2
Modulus, Z = (b=L2)
6
65  tc2
 10.83tc2
6
mc
W.K.T.,  b  (Assume b=120N/mm
2
)
Z
90718.65
120 
10.83t 2
tc = 8.35 mm
tc = 8.5 mm
2. Design a connecting rod for an I.C. engine running at 1800 r.p.m. and developinga
maximum pressure of 3.15 N/mm2. The diameter of the piston is 100 mm ; mass of the
reciprocating parts per cylinder 2.25 kg; length of connecting rod 380 mm; stroke of piston
190 mm and compression ratio 6 : 1. Take a factor of safety of 6 for the design. Take length
to diameter ratio for big end bearing as 1.3 and small end bearing as 2 and the
corresponding bearing pressures as 10 N/mm2 and 15 N/mm2. The density of material of
the rod may be taken as 8000 kg/m3 and the allowable stress in the bolts as 60 N/mm2 and
in cap as 80 N/mm2. The rod is to be of I-section for which you can choose your own
proportions. Draw a neat dimensioned sketch showing provision for lubrication. Use
Rankine formula for which the numerator constant may be taken as 320 N/mm2 and the
denominator constant 1 / 7500.
126
127
128
129
130
131
132
UNIT V
BEARINGS
Sliding contact and rolling contact bearings - Hydrodynamic journal bearings, Sommerfeld
Number, Raimondi and Boyd graphs, -- Selection of Rolling Contact bearings.
PART A
1. What is bearing?
Bearing is a stationery machine element which supports a rotating shafts or axles and confines its
motion.
2. Classify the types of bearings.(EVEN-2015)
i. Depending upon the type of load coming upon the shaft:
a. Radial bearing
b. Thrust bearings.
ii. Depending upon the nature of contact:
a. Sliding contact
b. Rolling contact bearings or Antifriction bearings.
3. What are the required properties of bearing materials?
Bearing material should have the following properties.
i. High compressive strength
ii. Low coefficient of friction
iii. High thermal conductivity
iv. High resistance to corrosion
v. Sufficient fatigue strength
vi. It should be soft with a low modulus of elasticity
vii. Bearing materials should not get weld easily to the journal material.
4. What is a journal bearing?(ODD-2015)(EVEN-2015)

A journal bearing is a sliding contact bearing which gives lateral support to the rotating shaft.
5. What are the types of journal bearings depending upon the nature of contact?
1. Full journal bearing
2. Partial bearing
3. Fitted bearing.
133
6. What are the types of journal bearing depending upon the nature of lubrication?
1. Thick film type
2. Thin film type
3. Hydrostatic bearings
4. Hydrodynamic bearing.
7. What is known as self – acting bearing?

The pressure is created within the system due to rotation of the shaft, this type of bearing is
known as self – acting bearing.
8. What is a quill bearing?

Quill bearing are characterized by cylindrical rollers of very small diameter and relatively long.
They are also called needle bearings.
9. State the disadvantages of thrust ball bearing.
They are not suitable for high speeds; thrust loads try to shift the plane of rotation of balls.
10. List any four advantages of rolling contact bearings over sliding contact
bearings.(EVEN-2016)
Low starting torque can carry combined radial and axial torque. Required less axial space,
maintain accurate alignment of shaft.
11. Define anti friction bearing.(ODD-2015)(ODD-2013)
The contact between the bearing elements is rolling; this type has very small friction.
12. What is meant by life of anti-friction bearings?

It defined as the life that 90 % of group of identical bearing will complete or exceed before
fatigue failure.
13. What is the advantage of Teflon which is used for bearings?
It has low coefficient of friction; it can be used at higher temperature, and chemically inert.
14. What is a Journal bearing? List any two applications. (EVEN-2013)
A journal bearing is a sliding contact bearing which gives lateral support to the rotating
shaft.
15. Explain the term Dynamic load carrying capacities of rolling contact bearing.(ODD-
2012)
Dynamic load rating is defined as the radial load in radial bearings that can be carried for a
minimum life of one million revolutions.
16. What are the types of thrust ball bearings? One
directional flat race, One directional grooved race, two directional grooved race
17. Classify the roller bearings.
134
Depending upon the type of rolling element:-ball bearing, roller bearingDepending upon the load
to be carried, radial, angular, and thrust bearings.
18. What is load rating?
The load carrying capacity of a rolling element bearing is called load rating.
19. State any points to be considered for selection of bearings.(or) List any six types of
bearing materials.
Lead based babbit, tin based babbit, leaded bronze, copper lead alloy, gun metal, phosphor
bronze.
20. What is connecting rod?
It is a machine member, used to transmit power from a reciprocating member to rotary one.
21. Why I section used for connecting rod? It is
used due to its lightness and to keep the inertia forces as low as possible. it can also withstand
high gas pressure.
22. What are the materials used for C-r
Mild steel and alloy of aluminum —for light duty.
Alloy steels of molybdenum and chromium ----for heavy duty.
23. What are the stresses set up in an IC engine C-rod?
Tensile stress, compressive stress, bending stress due to inertia force.
24. Discuss the forces acting on the connecting rod. Or Under what force the big end bolts
and caps are designed. (ODD- 2011) (ODD- 2012)
The combined effect of (i)load on the piston due to the gas pressure and due to inertia of the
reciprocating parts, and(ii)the friction of the piston rings, piston, piston rod and cross
head.1.inertia of the connecting rod.2.the friction force in the gudgeon and crank pin bearing.
25. State the components of rolling contact bearing.

Outer race, inner race, rolling element, retaining cage.
26. List the basic assumption used in the theory of hydrodynamic lubrication? (ODD-2011)
 The lubricant obeys newton’s law of viscous flow.
 The pressure is assumed to be constant throughout the film thickness.
 The lubricant is assumed to be incompressible.
 The viscosity is assumed to be constant throughout the film thickness.
 The flow is one dimensional.
135
27. Classify the sliding contact bearings according to the thickness of layer of the lubricant
between the bearing and journal. (EVEN- 2012)
1. Thick film bearing 2. Thin film bearing 3. Zero film bearing 4.Hydrostatic bearing
28. What are various types of radial ball bearing? (EVEN- 2012)
1. single row deep groove ball bearing 2.Filling notch bearing 3. Angular contact bearing 4.
Double row bearing 5. Self-aligning bearing
29. What do you meant by life of an individual bearing? (EVEN- 2013)
The life of individual bearing may be defined as the number of revolution which the bearing runs
before the first evidence of fatigue develops in the material of one of the rings or any of the
rolling elements.
PART B
1. Design a journal bearing for a centrifugal pump with the following data:
Diameter of the journal = 150 mm
Load on bearing = 40 kN
Speed of journal = 900 rpm (EVEN-2012)(ODD-2013)(EVEN-2016)
Given:
D = 150 mm, W = 40 kN, n = 900 rpm, Application = Centrifugal pump
Solution:
i.Diameter of journal is already given in the problem, D = 150 mm

L
ii. From PSG DDB Pg. No. 7.81, D = 1.0 – 2.0
Bearing pressure allowable = 71014 kgf/cm2,
 
Zn
p min = 2844.5
L
Take D = 1.5,  L = 1.5 D = 1.5 x 150 = 225 mm
iii. Bearing Pressure
136
W 40103
P = L D = 225150 = 1.185 N/mm2 = 1.185 x 10 kgf/cm2 = 11.85 kgf/cm2.
which is less than allowable, so L/D value is acceptable.
iv. From PSG DDB Pg. No. 7.32, Diameter clearance C= 150 microns
= 150 x 10-3 mm
C 15010 3
Clearance ratio, D = 150 = 1 x 10-3
v.Selection of lubricating oil.
From PSG DDB Pg. No. 7.31,

Zn
P = 2844.5
2844.511.85
Z= 900 = 37.45 = 40 centipoise.
From PSG DDB Pg. No. 7.41, for Z = 40 and temperature = 60o (assume). The suitable
lubricating oil is SAE40.
vi.Bearing Characteristics number.
Zn 40900
P = 11.85 = 3037.97
It is higher than the minimum value given in PSG DDB Pg. No. 7.31.
vii.Calculation of μ.
From PSG DDB Pg. No. 7.34, μ = 1010

33.25
P  Zn  D 
C K
Zn D 1
P = 3037.97, C = 1103 ,
K = 0.0025 (for L/D = 1.5, from PSG DDB Pg. No. 7.34)
  33.25
10 10 3037.97  1101  0.0025
3
  0.0126
Hg and Hd
Hg = μ .w .v Watts
w in Newton,
137
 Dn
v = 60 in m/min,
D in meters,
n in rpm
 0.15900
Hg = 0.0126 x 4000 x 60 = 3562.56 W
 t 182 L D
Hd = k
L in meters
D in meters
K – constant, assume = 0.484 heat dissipation
∆t = temperature of bearing surface
Form ambient temperature

∆t = 2 (to  ta )
1
to = oil temperature, ta = ambient temperature

∆t =  60o  28o   16o C
1
2
16182 0.2250.15
Hd  0.484
Hd = 80.61 W
Here Hg > Hd so artificial cooling is required to carry away the excess heat.
Diameter of the bearing Db = D+C = 150 + 150 x 10-3 = 150.15 mm

Material of Bearing
From PSG DDB Pg. No. 7.30, for pump application material is rubber or moulded
plastic laminate.
Summary of Design
Material = Rubber or Moulded plastic laminate

Cooling = Artificial cooling required
Diameter of journal = 150 mm
Length of journal L = 225 mm
Diameter of bearing Db = 150.15 mm
Diameter of clearance C = 150 microns
Lubricating oil suitable = SAE40
Operating temperature = 60oC
Atmospheric temperature = 28oC
2. Following data is given for a 360o hydro dynamic bearing:
138
Journal diameter = 100 mm, Radial clearance = 0.12 mm, Radial load =50 kN,
Bearing length = 100 mm, Journal speed = 1440 rpm, Viscosity of lubricant = 16 centipoise.
Calculate: 1. Minimum film thickness, 2. Co-efficient of friction, 3. Power cost in friction.
(EVEN- 2009)
Given: D= 100 mm, Radial clearance = 0.12 mm, W = 50kN, L=100 mm, n = 1440 rpm, Z=16
centipoise = 16 x 10-3 Ns/m2.
Solution:
i. Minimum film thickness
W.K.T. Radial clearance = Diameteral clearance /2 = C/2

0.12 = C/2,
C = 0.24 mm
 CD 
Z 'n' 2
From PSG DDB Pg. No., Sommerfield number s = p
Z’ = viscosity in Ns/m2,
n’ = speed of jouranal in rps
p = bearing pressure in N/m2.
n’ = 1440/60 rps
  0.1
5010 3
W
Bearing pressure p = L D  0.1
p = 5 x 106 N/mm2.
16103  1440
60 
  0.24 
100 2
s= 5106
s = 0.013
From PSG DDB Pg. No. 7.40, for = 360o, s = 0.013 and corresponding to L/D =1,
2 ho
the minimum film thickness variable = C = 0.071
0.071C
ho= 2 = 8.52 x 10-3 mm = 0.00852 mm
ii. Co-efficient of Friction (μ):

From PSG DDB Pg. No. 7.40, for = 360o, L/D = 1, s = 0.013
  CD = 1,   1 CD = 0.24
100 = 2.4 x 10
-3
139
iii. Power cost due to friction:
Hg = μ w v
 1001440
= 2.4 x 10-3 x 50,000 x 60
Hg = 904.8 W
3. Select a bearing for a 40 mm diameter shaft rotates at 400 rpm. Due to a bevel gear
mounted in the shaft. The bearing will have to withstand a 5000 N radial load of the
bearing thrust load. The life of the bearing expected to be at least 1000 hrs.
Given: d= 40mm, n=400 rpm, Fr = 5000N, Fa = 3000N, Lh = 1000 hrs
Solution:
Select Series 62 and for d = 40 mm, From PSG DDB Pg. No. 4.13, bearing basic design
no. SKF 6208. The values of Co, C are
Co = 1600 kgf = 1600 x 10 = 16000 N

C = 2280 kgf = 2280 x 10 = 22800 N
i. Equivalent diameter load (P):
P = (X.Fr + Y.Fa) x s
For X and Y values, from PSG DDB Pg. No. 4.4, Fa and e are given
Fa/Co e
0.13 0.31
0.12   0.06
0.25 0.37 
0.12 0.06
 0.012, and  0.006
10 10
Fa 3000 F
For   0.1875  0.19 , For value of a  0.19   0.13  5(0.012)
Co 16000 Co
Similarly, For ‘e’ value = (5  0.006  0.31)  0.03  0.31 = 0.34

F
 a  0.19
Co
e  0.34
Fa 3000
  0.6 > e,
Fr 5000
140
So, X value = 0.56, ‘s’ value from PSG DDB Pg. No. 4.2
Y value = 1.2
Therefore, P = [(0.56 x 5000) + (1.2 x 3000)] x 1.2
P = 7680 N
ii. Dynamic Load capacity(C):
From PSG DDB Pg. No. 4.6 (Ball bearing), For 400 rpm and 1000 hrs life
C/P = 2.88
C
 2.88
7680
C = 2.88 x 7680 = 22118.4 N
This dynamic load is less than the tabulated (allowable) value i.e. 22800 N. So the
suitable bearing designation is SKF 6208.
4. Select a suitable ball bearing to support the overhung countershaft. The shaft is 60 mm
diameter and rotating at 1250 rpm. The bearing are to have 99% reliability corresponding
to a life of 4000 hrs. the bearing is subjected to an equivalent radial load of 6000N.
Given:
d = 60 mm, n = 1250 rpm, Reliability = 99% = 0.99 = probability = p, L = 4000 hrs, F r =
6000N.
Solution:
1/ b
L  ln(1/ p) 
From PSG DDB Pg. No. 4.2  
L '10  ln(1/ p10 ) 
Here, ln(1/ p10 ) = 0.1053, L = 4000 hrs, b = 1.34, p = 0.99
Substitute all value,
4000
 (0.09544)0.7463
L '10
L’10 = 23.093 hrs
From PSG DDB Pg. No. 4.6, For life 23.093 hrs and 1250 rpm,
C
The value is 12.40
P 12.40 =C/P
2500 hrs
141
1250 rpm
C
= 12.4
P
C = 12.4 x Fr
C = 12.4 x 6000
C = 74400N
Select the bearing for C = 74400 N or C = 7440 kgf, and the diameter of the shaft is 60
mm. (From PSG DDB Pg. No. 4.15, series 64)
Result:
SKF 6412 is suitable bearing,
Co = 7100 kgf,
C = 8450 kgf.
5. A 70mm machine shaft is to supported at ends. If operates continuously for 8 hrs per day
,320 days per year for 8 years the load of speed cycle for one of the hearing are given below,
S.No Fraction of Radial load Thrust Speed rpm Factors

cycle in N
X y Z
1. 0.25 3500 1000 600 0.56 1.2 1.5
2. 0.25 3000 1000 800 0.56 1.2 1.5
3. 0.5 4000 2000 900 0.56 1.4 1.5
Select suitable bearing.
Solution:
i. Equivalent load (p)

P1=(XFr+YFa)Z
=(0.56×3500+1.2×1000)1.5
=4740w
P2=(0.56×3000+1.2×1000)1.5
=4320w
P3=(0.56×4000+1.4×2000)1.5
=7560w
1/3
rom pg 4.2:
Cubic mean load Fm = p13n1t1+p23n2t2+p33n3t3
n1+n2+n3
142
= (4740)3x600x0.25+(4320)3x800x0.25+(7560)3x900x0.5
600+800+900
Fm = 4618.16 N
W.k.t: equivalent load = cubic mean load (p=fm)
!!) Equivalent speed (N)
N = n1t1+n2t2+n3t3
= 600x0.25+800x0.25+900x0.5
N = 800 rpm
!!!) Total life hrs = 8hrs/day , 320day s/yr For F yea

20480 h
= 8x320x8
= 20,480 hrs 800rpm
From pg no 4.6 , For lie 20.480 hrs &800 rpm
C/P= 9.83
C= 9.83x4618.16 = 45396 N
For, C= 45,396 N & d= 70mm
The suitable size of bearing in skf= 6214
6. A single row deep groove ball bearing no: 6002 is subjected to an axial thrust load of
1000N and a radial load of 2200N. find the expected life that 50% of the bearing will
complete under this condition.(EVEN-2016)
GIVEN;-
Deep groove ball bearing no: 6002
Fa= 1000N
Fa = 2200N
143
SOLUTION:-
From DDB:4.12 :- For bearing no 6002
Co = 255kgf = 255*10N
C = 440kgf = 4400N
Fa/co=1000/2550 = 0.392
From DDB 4.4 for 𝐹𝑎/ =0.392 the value of e=0.412
Since, fa/co= 1000/2550 = 0.454>e
The radial load factor X=0.56
Thrust load factor Y= 1.83
Service factor from DDB 4.2 , S=1.1to 1.5 , say S=1.3
.. . equivalent load
(fromDDO: 4.2) P=(XFr+YFa)S
= (0.56*2200+1.83*1000)1.3
= 3980.6N
WKT,
L= (c/p)b = (4400/3980.6)3 =1.35 million revolution
Expected life at 50% reliability(L50) is obtained from
1/b
L50/L90= ln(1/R50)
Ln(1/R90)
1/b
L50/1.35 = ln(1/0.5) = (0.693/0.105)0,85 = 4.058
Ln(1/0.9)
L50= 4.958*1.35
L50= 6.69 million rev
144
145
7. The load on the journal bearing is 150KN due to turbine of 300mm diameter running
at 1800rpm determine the following
(1) Lengthof the bearing if the allowable bearing pressure is 1.6N/mm2
(2) Amount of heat to be removed by the lubricant per minute if the bearing temperature
is600c and viscosity of the oil at 600c is 0.02kg/m-s and the bearing clearance is 0.25. (ODD-
2011)
GIVEN:-
W=150KN = 150X103N
D= 300mm=0.3m
N= 1800rpm
P= 1.6N/mm2
Z=0.02kg/m-s
C= 0.25mm
SOLUTION:-
!) Length of the bearing:-
Let, l = length of bearing(mm)
WKT, projected bearing area
A=lxd=lx300=300lmm2
And alloeable bearing pressure (P),
1.6= A = l
= l
l= 500/1.6 = 312.5mm ans
!!) amount of heat to be removed by the lubricant:-
Wkt, co efficient of friction for the bearing

Z
= 33/108 +k
P
. X
= 33/108 . .
+ .
= 0.009+0.002= 0.011
146
Rubbing velacity,
π × . ×
V= = = . /
∴ Amount of heat to removed by the lubricant.
Q8 = 0.11x150x103x28.3
= 46.695 J/s or W
= 46.695kw
8. Design a journal bearing for a centrifugal pump from the following data:
Load on the journal =20000N
Speed of the journal=900rpm
Type of oil is=SAE10
For which absolute viscosity at 55oC=0.017 kg/ms
Ambient temperature of oil=15.5oC
Maximum bearing pressure for the pump=1.5N/mm2
Given:
W=20000N (ODD-2013)
N=900rpm
To= 55oC,ta=15.5oC
Z=0.017 kg/ms, p=1.5 N/mm2
Solution:
i. To find length of the journal,(l):

Assume,dia and journal d=100mm
Take / =1.6
L =1.6d=1.6x100=160mm
ii. Checking of bearing pressure:

WKT,
p=w/ld = 20000/160x100 = 1.25<1.5N/mm2 (given)
The value of l&d is safe
iii. Bearing characteristic number (ZN/P):
ZN/P = 0.017x900/1.25 = 12.24

WKT,
The minimum value of bearing modules 3K = ZN/P
Bearing module at the minimum point of friction:
147
K = 1/3(ZN/P) = 1/3x28 = 9.33 [ZN/P = 28 from table]
Since the calculated value13.24 is more than 9.33,

Therefore the bearing is operate under hydrodynamic condition.
iv. Clearance ratio: (c/d)

From the table c/d = 0.0013 (for centrifugal pump)
v. Co-efficient of friction(µ):
Z
µ=
P
+k
= x 12.24 x .
+ 0.002
= 0.0051 Ans
vi. Heat generated (Qg):
Qg = µwv
π
= µw ( )W
π .
= 0.0051x20000 ( )
= 480.7 W
vii. Heat dissipated (Qd):
Qd = CA (tb-ta)
= cld (tb-ta)W
(tb-ta) = (tb-ta) = (55o-15.5o) = 19.75oC
Qd = 1232 x 0.16 x 0.1 x 19.75
= 389.3 W (l,d – in meters)
∴ amount of artificial cooling required
= Qg-Qd
= 4807.7 – 389.3
= 91.4 W
148
9. A single row deep groove ball bearing is subjected to a radial force of 8kN and a thrust
force of 3kN. the rotates at 1200rpm the expected life L10th of the bearing is 20000hr the
minimum acceptable diameter of having for this application. (EVEN- 2012)(EVEN-2016)
GIVEN:-
Fn = 8kn
Fa = 3kn
N = 1200rpm
L10h = 20,000
d = 75mm
SOLUTION :-
STEP1 - X and Y factor
X = 0.56 , Y= 1.5 , Fr = 8000N
Fa = 3000N
WKT,
C = p(L10)1/3 = (8980)(1440)1/3
= 101406.04N
The shaft of 75mm diameter, bearing no.6315 (c= 112000) is suitable for the above data for this
bearing,
Co = 72000N
a
∴, r
= = .
a
And = = .
o
a
e = 0.24 (approximately ) and r
)>e
the value of Y is obtained by liner interpolation .
. − .
Y = 1.8 – . − .
x . − . = .
And X = 0.56
STEP 2 - Dynamic load capacity
P =XFr+YF = 0.56(8000)+ 1.79 (3000)
= 9850N
C = p (L10) = 9850(1440)1/3 = 111230.46N
1/3
STEP 3 - Selection of bearing

Bearing No.6315( c= 112000) is suitable for the above application.
RESULT:-
The suitable bearing is 6315
149
150

SKP Engineering College Course on Design of Machine Elements

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S.K.P.

Engineering College, Tiruvannamalai V SEM

SKP Engineering College

Mr.C.Naveen Kumar / Mr.R.Saravanan / Mr.G.Delhi Babu /

This is to Certify that the Electronic Study Material

Subject Code: ME 6503

Subject Name: Design of Machine Elements

YEAR / SEM: III/V

Being prepared by me and it meets the knowledge requirement of the university

Signature of the Author

Name: Mr.C.Naveen Kumar /

Designation: Assistant Professor

Signature of HD Signature of the Principal

Name: Dr.J. Kuberan Name: Dr.V.Subramania Bharathi

ME6503 DESIGN OF MACHINE ELEMENTS LTPC

S.No. Contents Page Number

5. UNIT III (PART - A) 61

6. UNIT III (PART – B) 64

9. UNIT V (PART - A) 124

10. UNIT V (PART – B) 127

STEADY STRESSES AND VARIABLE STRESSES IN MACHINE

1. What do you mean by Optimum design? (ODD- 2011)

2. Describe material properties hardness, stiffness and resilience. (EVEN- 2016)

Hardness is the ability of material to resist scratching and indentation.

Stiffness is the ability to resist deformation under loading.

4. Define ‘Factor of Safety’. (ODD-2015)

Factor of safety = Maximum stress / Working stress

7. Why normal stress theory is not suitable for ductile materials?

8. Define stress concentration. (EVEN- 2012)(EVEN-2016)

8. What are unilateral and bilateral tolerances? (EVEN- 2013)

9. What are the various theories of failure? (EVEN- 2013)

10. State Rankine’s theory.

11. State St. Venant theory of failure.

1– ( 2+ 3) (or) 2– ( 3+ 1) (or) 3– ( 1 + 2) = y, whichever is maximum, where =

12. What is Gerber theory?

13. Define the term equivalent torque and equivalent moment.

14.What are the methods to reduce stress concentration?

15. Differentiate between static and variable stresses.

9. A C-clamp is subjected to a maximum load of W, as shown in Fig. 5.13. If the maximum

Given : b = 60 mm ; t = 10 mm ; d = 12 mm ; W = 12 kN = 12 × 103 N We know that

Methods of reducing stress concentration

Whenever there is a change in cross-section, such as shoulders, holes, notches or

General Considerations in Machine Design

Following are the general considerations in designing a machine component :

TEMPORARY AND PERMANENT JOINTS

1. What is known as proof strength of the boltsbolt of uniform strength? (EVEN-2015)

10. Classify the rivet heads according to IS specifications. (ODD- 2011)

13. What are the ways to produce bolts of uniform strength?

1.Initial stresses due to screwing up 2.Stresses due to external forces 3.Combined

26. Define Butt and Lap joint.

5. A rectangular cross-section bar is welded to a support by means of fillet welds as shown

6. A rectangular steel plate is welded as a cantilever to a vertical column andsupports a

9. A steam engine of effective diameter 300 mm is subjected to a steam pressure of1.5

ENERGY STORING ELEMENTS AND ENGINE COMPONENTS

2. State any two functions of springs.

i. To measure forces in spring balance, meters and engine indicators.

ii. To store energy.

3. What are the various types of springs? (EVEN- 2012)

ii. Spiral springs

iii. Leaf springs

iv. Disc spring or Belleville springs

4. Classify the helical springs.

a. Close – coiled or tension helical spring.