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ME6503 - DESIGN OF MACHINE ELEMENTS UNIT - I NOTES

ME6503 - DESIGN OF MACHINE ELEMENTS UNIT - I NOTES
THE QUESTION NUMBER WILL MATCH TO THE QUESTION BANK ATTACHED AT THE END

ME6503 - DESIGN OF MACHINE ELEMENTS UNIT - I NOTES

  1. 1. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 3 UNIT – I – STEADY STRESSES AND VARIABLE STRESSES IN MACHINE ELEMENTS PART - A 1.1) Define CAD. 1.2) What are the advantages of CAD? 1.3) What are the factors to be considered in the selection of materials for a machine element? 1.4) What is an adaptive design? [AU, Apr / May – 2015, May / Jun – 2016] 1.5) What is adaptive design? Where it is used? Give examples. [AU, Nov / Dec – 2012] 1.6) How are materials classified? 1.7) What are the common materials used in mechanical engineering design? [AU, Nov / Dec – 2015] 1.8) What are the mechanical properties to be considered in selecting a material for engineering applications? 1.9) What are the mechanical properties of metals? List any four mechanical prosperities. [AU, May / Jun - 2012] 1.10) What is meant by interchangeability? 1.11) What are the steps in machine design process? [AU, Apr / May – 2010] 1.12) How will you account for stress concentration in design of the machine parts . [AU, Apr / May – 2010] 1.13) What do you mean by Optimum design? [AU, Nov / Dec –2011] 1.14) What are the methods to reduce stress concentration? [AU, Nov / Dec –2008] 1.15) Define nominal, basic and actual size. 1.16) What is meant by tolerance? 1.17) Define limits of size. 1.18) Define limits and fits. [AU, Apr / May – 2015, May / Jun – 2016] 1.19) Define fits, clearance and interference. 1.20) What are the types of fits? [AU, Nov / Dec– 2008] 1.21) Write short notes on clearance fit and interference fit. 1.22) Explain transition fit.
  2. 2. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 4 1.23) What are unilateral and bilateral tolerances? [AU, May / Jun - 2013] 1.24) Using the table for tolerances, find the types of fit, maximum and minimum clearance of interference for 150 G7 – e8 combination. 1.25) The fit between a hole and a shaft is defined by  70 H9F7. Find the allowance. 1.26) What is hole basis system? 1.27) What is shaft basis system? 1.28) Define preferred numbers. 1.29) What is meant by standardization? 1.30) Mention some standard codes of specification of steels. [AU, Nov / Dec– 2008] 1.31) Define load. What are the different types of loads that can act on machine components? 1.32) What are the factors that govern selection of materials while designing a machine component? [AU, Nov / Dec– 2010] 1.33) What is steady and variable load? 1.34) What is impact load? [AU, Nov / Dec – 2015] 1.35) What is an impact load? Give example. [AU, May / Jun - 2012] 1.36) What is meant by shock and impact load? 1.37) What are the methods used to improve fatigue strength? [AU, Nov / Dec –2013] 1.38) List at least two methods to improve the fatigue strength. [AU, Nov / Dec –2014] 1.39) Define stress and strain. 1.40) Define Poisson’s ratio. [AU, Apr / May – 2011] 1.41) Explain the normal stress theory and its limitations [AU, Apr / May – 2010] 1.42) Which theory of failure is suitable for the design of brittle materials? [AU, Nov / Dec – 2015] 1.43) Explain the different types of stresses. 1.44) What is meant by double shear? Give an example. 1.45) Define resilience [AU, Nov / Dec –2009] 1.46) Define proof resilience and modulus of resilience. 1.47) What in meant by modulus of rigidity? 1.48) Explain factor of safety. [AU, Apr / May – 2010] 1.49) Define factor of safety. [AU, Nov / Dec –2012, 2015]
  3. 3. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 5 1.50) List the important factors that influence the magnitude of factor of safety. [AU, Nov / Dec –2011] 1.51) Explain stress - strain diagram with an example. 1.52) What is the yield point of the material? 1.53) Define ultimate and breaking stress. 1.54) Explain working stresses. 1.55) Differentiate the stress distribution in a bar subjected to an axial force and beam subjected to bending [AU, Apr / May – 2010] 1.56) What is factor of safety for brittle materials? [AU, Apr / May – 2011] 1.57) Discuss the factors affecting the selection of factor of safety. 1.58) Define Poisson's ratio and bulk modulus. 1.59) Give the relation between bulk modulus and Young's modulus. 1.60) Give the relation between Young's modulus and modulus of rigidity. 1.61) Calculate the force required to punch a circular blank of 60 mm diameter in a plate of 5 mm thick. The ultimate shear stress of the plate is 350 N/mm2. 1.62) Determine the force required to punch a hole of 20mm diameter in a 5mm thick plate with ultimate shear strength of 250 MPa? [AU, Nov / Dec –2014] 1.63) A mild steel bar of 12mm diameter is subjected to an axial load of 50 KN in tension. Find the magnitude of the induced stress. 1.64) A M.S. bar of diameter 12 mm and length 1 m is subjected to an axial load of 50 KN in tension and modulus of elasticity is 2 x 105MPa. Find the elongation of the bar. 1.65) Steel flat 10 mm wide and 12 mm thick is bent into a circular arc of radius 12 m. Find the maximum intensity of stress induced in the cross section. 1.66) How is the allowable stress estimated in ductile and brittle materials? 1.67) Define the term principal planes and principal stress 1.68) State the various theories of failure. 1.69) What are the various theories of failure? [AU, May / Jun - 2013] 1.70) What is the maximum principal strain theory (Saint Vennant's theory)? [AU, Nov / Dec – 2009] 1.71) State the maximum strain energy theory (Haigh's theory)
  4. 4. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 6 1.72) State the difference between straight beams and curved beams. [AU, Nov / Dec –2012] 1.73) What is eccentric loading? 1.74) Define stress concentration. [AU, May / Jun – 2012, 2016] 1.75) What is meant by stress concentration? [AU, May / Jun - 2009, Nov / Dec –2011] 1.76) Give one method of reducing stress concentration in key slots. [AU, May / Jun - 2012] 1.77) What are the sources of stress concentration in machine elements? 1.78) Define stress concentration factor. 1.79) Define stress concentration and stress concentration factor. [AU, May / Jun – 2014] 1.80) How to avoid stress concentration? [AU, Nov / Dec –2012] 1.81) What are the methods of reducing stress concentration? [AU, May / Jun - 2009] 1.82) What are the factors to be considered while designing machine parts to avoid fatigue failure? 1.83) Define fatigue stress concentration factor. 1.84) Define (a) stiffness and (b) resilience [AU, May / Jun - 2009] 1.85) Describe the material properties of hardness, stiffness and resilience. [AU, Nov / Dec –2013, May / Jun – 2016] 1.86) Differentiate between hardness and toughness of materials. [AU, May / Jun – 2014] 1.87) What are the types and modes of fracture? 1.88) Explain soderberg and Goodman lines in details. 1.89) What is Geber theory [AU, Nov / Dec – 2009] 1.90) Write Soderberg equation for a machine component subjected to (a)Combination of mean and variable torques (b) Combination of mean and variable bending moments [AU, Nov / Dec – 2010]
  5. 5. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 7 PART –B 1.91) Discuss in detail about the factors influencing machine design. [AU, May / Jun - 2012] 1.92) What are the factors influencing machine design? Explain it. [AU, May / Jun – 2014] 1.93) Explain various phases in Design using a flow diagram and enumerate the factors influencing the machine design. [AU, May / Jun - 2013] 1.94) What is factor of safety? List the factors to be considered while deciding the factor of safety. [AU, May / Jun – 2014] 1.95) Write short notes on preferred numbers, fits and types of fits. [AU, May / Jun - 2012] 1.96) What is meant by hole basis system and shaft basis system? Which one is preferred and why? [AU, May / Jun - 2013] 1.97) Explain the maximum normal stress theory of failure (Rankine's theory) 1.98) Explain the maximum shear theory of failure (Guest's theory) 1.99) Explain distortion energy theory of failure (Hencky and Von Mises theory) 1.100) What is the difference between Gerber curve and soderberg and Goodman lines? [AU, May / Jun - 2013] 1.101) Explain notch sensitivity. What are the factors that affect notch sensitivity? 1.102) Explain in detail the maximum shear stress theory [AU, Nov / Dec – 2009] 1.103) Explain soderberg and Goodman lines in details. [AU, Nov / Dec – 2009] 1.104) Discuss in detail about CAD and optimum design. State their relevance in designing mechanical elements. [AU, Nov / Dec – 2008] 1.105) Write short notes on the following: [AU, May / Jun – 2014]  Interchangeability  Tolerance  Allowance 1.106) Define Stress concentration. Give some methods of reducing stress concentration. [AU, Nov / Dec –2011] 1.107) The dimensions of mating parts, according to basic hole system are given as follows: Hole: 25mm Shaft: 24.97mm
  6. 6. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 8 25.02mm 24.95mm Find the hole tolerance, shaft tolerance and allowance. 1.108) The following results were obtained in a tensile test on a mild steel specimen of original diameter of 20 mm and guage length 40 mm. At the limit of proportionality, the load was 80000 N and extension is 0.048 mm. The specimen yielded at a load of 85000 N and the maximum load was 150000 N. When two parts are fitted together after being broken, the guage length was found to be 55.6 mm and the diameter at neck was 15.8 mm. Calculate the Young’s modulus, stress at the limit of proportionality, yield stress, ultimate stress, percentage elongation and reduction and working stress. Take factor of safety = 2 1.109) Consider two aluminum rods and one steel rod combined as one unit which supports a weight of 1000 kg. If the area of cross section of aluminum and steel rods is 2 cm2 each and strains are equal, find the stresses acting on aluminum and steel rods. 2626 /10x1.2/10x7.0 cmkgfEcmkgfE steelAl  1.110) An unknown weights falls through 10mm onto a collar which is rigidly attached to the lower end of a vertical bar 3 m long and 600 mm2 cross section. The maximum instantaneous extension is 2mm. What is the corresponding stress and the value of the weight? Take E = 200 kN/mm2 . [AU, Nov / Dec –2014, 2015] 1.111) A flat bar 32 mm wide and 12 mm thick is loaded by a steady tensile load of 85 kN. The material is mild steel with yield point stress of 315 N/mm2 . Find the factor of safety based on the yield point. [AU, Nov / Dec – 2008] 1.112) A flat plate of width 60 mm has a central hole of 10 mm diameter. If the plate is subjected to an axial tensile load of 10 kN, determine the thickness of the plate. Assume yield point stress 300 MPa and factor of safety as 2.5. [AU, Nov / Dec – 2008] 1.113) A shaft is transmitting 100 KW at 160 rpm. Find the suitable diameter of the shaft if the maximum torque transmitted exceeds the mean by 25%. Take the maximum allowable shear stress as 70 MPa. 1.114) A cast iron pulley transmits 10kW at 400rpm. The diameter of the pulley is 1.2m and it has four straight arms of elliptical cross section in which the major
  7. 7. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 9 axis is twice of the minor axis. Determine the dimension of the arm if the allowable bending stress is 15MPa. [AU, May / Jun - 2009] 1.115) A shaft is supported in bearings, the distance between their centers being 1 m. It carries a pulley in the centre and it weighs 1 KN. Find the diameter of the shaft, if the permissible bending stress for the shaft material is 40 N/mm 2 . 1.116) Determine the diameter of circular rod made of ductile material with endurance limit is 265MPa and tensile yield strength of 350MPa. The member is subjected to a varying axial load form – 300kN to 700kN and has a stress concentration factor is 1.8. The factor of safety as 2. [AU, May / Jun - 2009] 1.117) Two rods made of plain carbon steel 40C8 (Syt= 380 N/mm2 ) are connected by means of cotter joint. The diameter of each rod is 50mm and the cotter is made of steel plate of 15mm thickness. Calculate the dimension of the socket end making the following assumptions. (i) the yield strength in compression is twice of the tensile yield strength and (ii) the yield strength in shear is 50% of the tensile yield strength. Factor of safety is 6. [AU, Nov / Dec – 2009] 1.118) It is desired to bend a strip of 6 mm thick and 20 mm wide of spring steel into a loop with the end overlapping and riveted. Find the minimum radius of the loop if the stresses due to bending are limited to 100 MPa. Also determine the bending moment required to bend the strip. Take Young’s modulus .10x1.2 5 MPaE  1.119) A rod of linkage mechanism made up of steel 40Crl (Sut = 550N/mm2 ) is subjected to completely reversed axial load of 100kN. The rod is machined on the lathe and expected reliability is 95%. There is no stress concentration. Determine the diameter of the rod using a factor of safety of 2 for an infinite life condition. [AU, Nov / Dec – 2009] 1.120) A shaft transmits 20 KW power and rotates at 500 rpm. The material of shaft is 50 C4 and the factor of safety is 2.  Determine the diameter of the shaft on the basis of its shear strength Determine the diameter of shaft on the basis of its torsional rigidity, if the permissible angle of twist is 30 per meter length and the modulus of rigidity of the shaft material is 79300 N/mm2 . [AU, May / June – 2007]
  8. 8. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 10 1.121) Design a suitable diameter for a circular shaft required to transmit 90 KW at 120 rpm. The shear stress for the shaft is not to exceed 70 N/mm2 and the maximum torque exceeds the mean by 40 %. 1.122) The shaft of an overhang crank is subjected to a force F of 2kN as shown in figure. The shaft is made of 30Mn2 steel having an allowable shear strength equal to 100N/mm2 . Determine the diameter of the shaft. [AU, Apr / May – 2015, May / Jun – 2016] 1.123) A weight W falls 10mm on a collar rigidity attached to the lower end of vertical part 6m long 400mm2 in cross section. The maximum instantaneous extension is found to be 2mm. Take Young’s modulus 2 * 105 N/mm2 . Find the value W and impact stress induced 1.124) A bolt is subjected to a direct tensile load of 25kN and shear load of 15kN. Considering various theories of failure, determine the suitable size of bolt if the yield stress in tension is 250N/mm2 . Take FOS as 2 and Poisson’s ratio as 0.3 [AU, Nov / Dec – 2008] 1.125) An I-section beam of depth 250 mm is supported at two points 4 m apart. It is loaded by a weight of 4 KN falling through a height h and striking the beam at mid span. The moment of inertia of the section is 8 x 107 mm4 ; E = 210 KN/ mm2 . Determine h if the stress is 120 N/mm2 . 1.126) A man weighing 60 kg jumps from a height of 50 cm on a diving board of rectangular cross - section having 30 cm width and 2 m long. If the maximum induced stress is limited to 400 kg/cm2 and the modulus of elasticity of the board is 1 x 105kg/cm2, find the thickness of the diving board.
  9. 9. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 11 1.127) A cantilever beam of span 800mm carries a uniformly distributed load of 12kN/m. the yield value of material of cantilever is 400MPa. Factor of safety is 2.5 find the economical section of cantilever among (i) circular cross section of diameter ‘d’ (ii)rectangular cross section of depth ‘d’ and width ‘w’ d/w= 2.5 (iii) ‘I’ section of total depth 7t width 5t where ‘t’ is thickness. Find the dimension and cross sectional area of the economic section [AU, Apr / May – 2010] 1.128) A vertical pillar of 50 mm diameter is subjected to a vertical load of 1 kN acting eccentrically at a distance of 30 mm from the axis. Calculate the maximum stress in the pillar and locate it. 1.129) A shaft of diameter 40 mm is used to transmit the power of 30 KW at 710 rpm and is supported in bearings 500 mm apart. A load of 10 KN is concentrated at the centre of shaft vertically. Calculate the maximum principle stress and shear stress. 1.130) A hollow shaft is required to transmit 600 kW at 110 rpm, the maximum torque being 20% greater than the mean. The shear stress is not to exceed 63 Mpa and twist in a length of 3 meter not to exceed 1.4 degrees. Find the external diameter of the shaft, if the internal diameter to the external diameter is 3/8. Take modulus of rigidity as 84 Gpa. [AU, Apr / May 2011] 1.131) Determine the diameter of a steel bar, which is of ductile nature subjected to an axial tensile of 60kN and torsional moment of 1600N-m. Use the factor of safety of 2.5, E= 200GPa [AU, Apr / May – 2010] 1.132) A shaft as shown in figure is subjected to a bending load of 3kN, pure torque of 1000 N-m and an axial pulling force of 15kN. Calculate the stress at A and B [AU, Apr / May – 2010, May / Jun – 2016]
  10. 10. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 12 1.133) A cantilever beam made of cold drawn carbon steel of circular cross section as shown in fig ., is subjected to a load which varies from –F to 3 F. Determine the maximum load that this member can withstand for an indefinite life using a factor of safety as 2. The theoretical stress concentration factor is 1.42 and the notch sensitivity is 0.9. Assume the following values: Ultimate stress =550 Mpa Yield stress = 470 Mpa Endurance limit = 275 Mpa Size factor = 0.85 Surface finish factor = 0.89. [AU, Apr / May – 2011] 1.134) A simply supported beam has concentrated load at the centre which fluctuates a value from P to 4P. The span of the beam is 500 mm and its cross section is circular with a diameter of 60 mm. Beam material is cold drawn 0.2% carbon steel. Calculate the maximum permissible value of P for a factor of safety of 1.3. Beam surface is ground [AU, Nov / Dec – 2010] 1.135) The C frame of 100kN capacity press is shown in fig. the material of the frame is grey cast iron an d the factor of safety is 3 determine the dimensions of the frame [AU, Apr / May – 2010]
  11. 11. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 13 1.136) The frame of a punch press is shown in fig. Find the stresses at the Inner and outer surface at section X-X of the frame, if W = 5000 N. [AU, May / Jun – 2014] 1.137) A bracket as shown in figure is bolted to the frame - work of a machine which carries a load P. The cross - section of the bracket is rectangle with 30 mm wide and 60 mm deep. If the maximum stress is limited to 30 N/mm2, find the value of P. [AU, Apr / May – 2011]
  12. 12. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 14 1.138) A mild steel bracket is shown in figure. It is subjected to a pull of 6000 N 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 60MPa [AU, Nov / Dec – 2012] 1.139) A cast-iron link, as shown in figure, is to carry a load of 20 kN. If the tensile and compressive stresses in the link are not to exceed 25 MPa and 80 MPa respectively, obtain the dimensions of the cross- section of the Link at the middle of its length. [AU, Nov / Dec –2013] 1.140) A mild steel bracket is shown in figure. It is subjected to a pull of 5000 N 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 50 N/mm2 [AU, Nov / Dec – 2005, 2007] 1.141) The crank hook carries a load of 20KN as shown in figure. 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
  13. 13. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 15 1.142) A C-clamp is subjected to a maximum load of W, as shown in figure. If the maximum tensile stress in the clamp is limited to 140 MPa., find the value of the load W. [AU, Nov / Dec –2012] 1.143) Determine the maximum shear stress induced in the member loaded as shown in figure.
  14. 14. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 16 1.144) A cylindrical bar of 50 mm diameter and 250 mm long is fixed at one end. At the free end it is loaded as shown in figure with axial load of 15 KN, a downward transverse load of 5KN and a torque of 2 KNm. Calculate the maximum stress at point A of the bar. 1.145) A bolt is subjected to a direct load of 25 KN and a shear load of 15 KN. Considering the various theories of failure, determine a suitable size of the bolt, if the material of the bolt is C15 having 200 N/mm2 yield strength. [AU, May / June – 2007] 1.146) A shaft of diameter 50 mm is subjected to a bending moment of 20 Nm and torque 15 Nm and the yield stress is 200 N/mm2 . Find the factor of safety according to all theories of failure. 1.147) A steel member is subjected to a 3 dimensional stress system and the resulting principal stresses are 120 N/mm2 tension, 80 N/mm2 and 40 N/mm2 compression. If the proportional limit of the material in simple tension is 280 N/mm2 and its Poisson’s ratio is 0.3, determine the factor of safety according to (a) Maximum principal stress theory (b) Maximum principal strain theory (c) Maximum shear stress theory. 1.148) A machine part is statically loaded and has a yield point strength of 350 N/mm2 . If the principal stresses are 70 N/mm2 and 35 N/mm2 , both tensile, find the factor of safety for the following cases. [AU, Nov / Dec – 2015]
  15. 15. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 17 (i) Maximum normal stress theory (ii) Maximum shear stress theory and (iii) Distortion energy theory. 1.149) A bolt is subjected to an axial pull of10 kN and a transverse shear force of 5 kN. The yield strength of the bolt material is 300 MPa. Considering a factor of safety of 2.5. Determine the diameter of the bolt, using (i) maximum normal stress theory, (ii) maximum shear stress theory, and (iii) maximum principal strain theory. Take Poisson's ratio as 0.2. [AU, Nov / Dec – 2015] 1.150) A compound bar of 3m length made up of copper having E = 105GN/m2 and the other of steel having = 210GN/m2 . Each bar is 25mm broad and 12.5mm thick. This component bar is stretched by a load of 50kN. Find the increase in length of the compound bar and the stress produced in the steel and copper. The length of copper as well as of steel bar is 3m each. [AU, Nov / Dec - 2011] 1.151) A tie - bar has to carry a load of 100 KN. What must be the thickness of bar of 110 mm width, if there is a rivet hole of 22 mm diameter on its, centre line? Working stress for the tie bar is 75MPa 1.152) A stepped shaft of diameters D and d is subjected to a variable axial load P which cyclically varies between 0 and 10 KN. The shaft is made of C20 steel, mirror polished with Su= 500 N/mm2 and Sy = 260 N/mm2. Determine the diameters D and d with D/d = 1.5, factor of safety = 2, notch sensitivity factor = 0.8 and r/d = 0.2 where r is the shoulder radius.
  16. 16. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 18 1.153) A steel rod of yield strength 350N/mm2 and endurance limit of 265 N/mm2 is subjected to axial load of which varies from -300kN to 700kN and has a stress concentration factor 1.8. Assume FOS as 2. Calculate the diameter of steel rod [AU, Apr / May – 2011] 1.154) 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 maximum value of 250kN and a minimum values 100kN. The properties of the plate as follows. Endurance limit stress = 225MPa and yield pint stress 300MPa. The factor of safety based on yield point may be taken as 1.5. [AU, Nov / Dec - 2011] 1.155) A hot rolled steel shaft of 40mm diameter is subjected to a torsional moment that varies from 330 Nm to – 110 Nm and an applied bending moment which rises from 440 Nm to –220 Nm. The material of the shaft has an ultimate strength of 550 MN/m2 and yield strength of 410 MN/m2 . Find the approximate factor of safety using soderberg equation allowing endurance limit to be half the ultimate strength and size factor and surface finish factor to be 0.85 and 0.62 respectively. [AU, Nov / Dec – 2008] 1.156) A hot rolled steel shaft is subjected to a torsional moment that varies from 330 Nm clockwise to 110 Nm counter clockwise and an applied bending moment at a critical section varies from 440 Nm to -220 Nm 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 MPa and yield strength of410 MPa. 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. [AU, Nov / Dec –2013] 1.157) A plate of 12 mm thick, with two holes as indicated in figure below is subjected to a tensile load of 20 KN. Calculate the stresses at both the holes. [AU, Nov/Dec – 2004]
  17. 17. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 19 1.158) A medium force fit on a 50 mm shaft requires a hole tolerance of 0.025 mm and a shaft tolerance of 0.016 mm. The maximum interference is to be 0.042 mm. How will you dimension the hole and the shaft, if hole deviation is H? [AU, Nov / Dec – 2010] 1.159) A plate of uniform thickness t has two width 45 mm and 30 mm with a fillet radius of 5 mm. The smaller width portion has a transverse hole of 15 mm diameter for plate material. The ultimate strength is 200 N/mm2 . Consider stress concentration factor and assume F.S = 2.5. Find the thickness of the plate for maximum tensile load of 5 KN. [AU, Nov / Dec – 2006] 1.160) Determine the maximum stress involved in the following cases taking stress concentration into account. Case i) A rectangular plate with a hole under an axial load of 10 KN. ii) A circular shaft with a step under an axial load of 10 KN. iii) A shaft under a bending moment of 50 Nm. iv) A shaft under a twisting moment of 50 Nm. 1.161) A machine component is subjected to a flexural stress which fluctuates between +300 MN/m2and -150 MN/mm2. Determine the value of minimum ultimate strength according to i) Gerber relation ii) Modified Goodman relation iii) Soderberg relation Take yield strength = 0.55 ultimate strength; endurance strength = 0.5 ultimate strength; factor of safety = 2. 1.162) A machine component is subjected to fluctuating stress that varies from 40 to 100 N/mm2 . The corrected endurance limit stress for the machine component is 270 N/mm2 . The ultimate tensile strength and yield strength of material are 600 and 450 N/mm2 respectively. Find the factor of safety using: (1) Gerber theory (2) Soderberg line
  18. 18. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 20 (3) Goodman line and (4) Also, find factor of safety against static failure. [AU, May / Jun - 2013] 1.163) A cantilever rod of circular section is subjected to a cyclic transverse load varying from -100N to +300 N as shown in figure. Determine the diameter d of the rod by i) Goodman method ii) Soderberg method. Using the following data : Factor of safety = 2; theoretical stress concentration factor = 1.4; notch sensitivity factor = 0.9; ultimate strength = 550 MPa ; endurance strength = 275 MPa; size correction factor = 0.85 surface correction factor = 0.9 ; yield strength = 320 MPa 1.164) A cantilever rod of length 120 mm with circular section is subjected to a cyclic transverse load; varying from -100 N to 300 N at its free end. Determine the diameter ‘d’ of the rod, by (i) Goodman method and (ii) Soderberg method using the following data. Factor of safety = 2; Theoretical stress concentration factor = 1.4; Notch sensitivity factor = 0.9; Ultimate strength= 550 MPa; Yield strength = 320 MPa; Endurance limit = 275 MPa; Size correction factor = 0.85; Surface correction factor= 0.9. [AU, Nov / Dec – 2015] 1.165) Determine the cross - section of C frame shown in figure to withstand a maximum load of 25KN. Permissible stress in tension is 100 N/mm2. Find also the stresses at X - X. Assume h = 2b
  19. 19. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 21 1.166) A cylindrical shaft made of steel of yield strength 700 MPa is subjected to static loads consisting of bending moment 10 KN-m and a torsional moment 30 KN-m. Determine the diameter of the shaft using two different theories of failure and assuming a factor of safety of 2. Take E = 210 GPa and Poisson's ratio = 0.25. [AU, Nov / Dec – 2012] 1.167) A shaft is subjected to a bending moment varying from - 200 Nm to 500 Nm and a twisting moment varying from 50 Nm to 175 Nm. The material used has SU = 600 MPa ; Se = 300 MPa; Ka = 0.76; Kb = 0.85; Kc = 0.897; Kt = 1.85 and q = 0.95. Find the diameter of the shaft by Von Misses Hencky theory. Factor of safety is 1.5 [AU, Nov / Dec – 2003] 1.168) In an elastic material, principal stresses are tensile and compressive and the ratio being 4 : 1. Determine the limiting stress according to different theories of failure if the tension test gives the elastic limit of the material as 400 N/mm2. Assume Poisson's ratio as 0.3. 1.169) A hot rolled steel shaft is subjected to a torsional load varying from 300 Nm clockwise to 150 Nm counter clockwise and to a bending moment at a critical section varying from 400 Nm positive to 200 Nm negative. The shaft has uniform cross - section and no keyway is present at the critical section. Determine the required shaft diameter assuming σu = 500 N/mm2, σy = 400 N/mm2 and n = 2
  20. 20. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 22 1.170) A rod of a linkage mechanism made of steel 40Crl(σut = 550 N/mm2 ) is subjected to a completely reversed axial load of 100 kN. The rod is machined on lathe and the expected reliability is 95%. There is no stress concentration. Determine the diameter of the rod using a factor of safety of 2 for an infinite life condition. [AU, Nov / Dec – 2009] 1.171) Determine the diameter of a circular rod made of ductile material with a endurance limit is 265 MPa and a tensile yield strength of 350 MPa. The member is subjected to a varying axial load from – 300 kN to 700 kN and has a stress concentration factor is 1.8. Take factor of safety as 2. [AU, May / June - 2009] 1.172) A shaft of diameter 'd' is subjected to a torque varying between 900 Nm to 1800 Nm. Assuming a factor of safety 2 and a stress concentration factor of 1.2, find the diameter of the shaft.Take σu = 650 N/mm2 σy = 480 N/mm2 , Size factor B = 0.85 and surface finish factor C = 0.5. [AU, Nov / Dec –2014] 1.173) A cast iron pulley transmits 10 kW at 400 rpm. 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. [AU, May / June - 2009] 1.174) 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 minor axis. Determine the dimensions of the arm if the allowable bending stress is 15 MPa. [AU, Nov / Dec –2011] 1.175) A circular bar of length 600mm is supported at its ends. It is acted upon by a concentrated cyclic load at its centre which varies from 20 KN to 50 KN. If the factor of safety is 1.5, surface finish factor is 0.9 and the size effect is 0.85. Find the diameter of the bar. The ultimate strength of the bar is 650 N/mm2, yield strength is 500 N/mm2 and endurance strength is 350 N/mm2.
  21. 21. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 23 1.176) A 50 mm diameter shaft is made from carbon steel having an ultimate tensile strength of 630 MPa. It is subjected to a torque, which fluctuates between 2000 Nm to – 800 Nm. Using Soderberg methods, calculate the factor of safety. 1.177) A simply supported beam has a concentrated load at the center which fluctuates from a value of P to 4P. The span of the beam is 500 mm and its cross section is circular with a diameter of 60 mm. Taking for the beam material an ultimate stress of 700 MPa, a yield stress of 500 MPa, endurance limit of 330 MPa for reversed bending, and a factor of safety 1.3, calculate the maximum value of P. Take a size factor of 0.85 and a surface finish factor of 0.9. [AU, Nov / Dec – 2007] 1.178) A steel cantilever is 200 mm long. It is subjected to an axial load, which varies from 150 N (compression) to 450 N (tension) and also a transverse load at its free end, which varies from 80 N up to120 N down. The cantilever is of circular cross section. It is of diameter 2d for the first 50 mm and of diameter d for the remaining length. Determine its diameter taking a factor of safety 2 Assume the following values: [AU, May / Jun – 2016] Yield stress = 330 MPa Endurance limit in reversed loading = 300 MPa Correction factors = 0.7 in reversed axial loading = 1.0 in reversed bending Stress concentration factor = 1.44 for bending = 1.64 for axial loading Size effect factor = 0.85 Surface effect factor = 0.90 Notch sensitivity index = 0.90 1.179) A pulley is keyed to a shaft midway between two antifriction bearings. The bending moment at the pulley varies from – 170 Nm to 510 Nm as the torsional moment in the shaft varies from 55 Nm to 165 Nm. The frequency of the variation of the load is the same as the shaft speed. The shaft is made of cold drawn steel having an ultimate strength of 538 MPa and yield strength of 400 MPa.
  22. 22. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 24 Determine the required diameter for an indefinite life. The stress concentration factor 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 a design factor N = 1.5[AU, April / May – 2004, May / Jun - 2012] 1.180) A pulley is keyed to a shaft midway between two antifriction bearings. The bending moment at the pulley varies from – 160 Nm to 500 Nm as the torsional moment in the shaft varies from 60 Nm to 160 Nm. The frequency of the variation of the load is the same as the shaft speed. The shaft is made of cold drawn steel having an ultimate strength of 540 MPa and yield strength of 400 MPa. Determine the required diameter for an indefinite life. The stress concentration factor for the keyway in bending and torsion may be taken as 1.6 and 1.3 respectively. The factor of safety is 1.5, size factor = 0.80 and surface finish factor = 0.85 [AU, May / Jun - 2012] 1.181) A pulley is keyed to a shaft midway between two bearings. The shaft is made of cold drawn steel for which the ultimate strength is 550MPa and the yield strength is 400MPa. The bending moment at the pulley varies from -150 N-m to 400 N-m as the torque on the shaft varies from -50N-m to 150N-m. Obtain the diameter of the shaft for an indefinite life. The stress concentration factors for the keyway at the pulley in bending and in torsion are 1.6 and 1.3 respectively. Take the following values: Factor of safety = 1.5; load correction factors = 1.0 in bending and 0.6 in torsion; Size factor = 0.85; Surface effect factor = 0.88. [AU, Nov / Dec –2012] 1.182) A transmission shaft made of C 45 steel is subjected to a fluctuating torque varying from –100 Nm to + 500 Nm. Also, a fluctuating BM acts on the shaft, which varies from +500 Nm to – 500 Nm. Kt = 2. FS = 1.5. Determine the required diameter of the shaft. [AU, Nov / Dec – 2005] 1.183) 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 -500N-m. Let the stress concentration factor be 2. The shaft is machined for a FOS 1.5. Determine the required diameter of the shaft. [AU, April / May – 2010]
  23. 23. R.M.K COLLEGE OF ENGG AND TECH / AQ / R2013/ ME6503 / V / MECH / JUNE 2016 – NOV 2016 ME6503 – DESIGN OF MACHINE ELEMENTS QUESTION BANK by ASHOK KUMAR.R (AP / Mech) 25 1.184) A steel bar is subjected to a reverse axial load of 180kN. Find the diameter of the bar for a design factor of 2. Ultimate tensile strength 1070N/mm2 , yield strength 910N/mm2 . Endurance limit in bending is half of ultimate strength. Use the following data. Load factor = 0.7, surface finish factor = 0.85 and stress concentration factor 1 [AU, May / Jun - 2012] 1.185) A bar of circular cross section is subjected to alternating tensile forces varying from a minimum of 200 KN to a maximum of 500 KN. It is to be manufactured of a material with an ultimate tensile strength of 900 MPa and an endurance limit of 700 MPa. Determine the diameter of the bar using safety factors of 3.5 related to ultimate tensile strength and 4 related to endurance limit and a stress concentration factor of 1.65 for fatigue load. Use Goodman straight line as basis for design. 1.186) 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 are given by, ultimate strength of 650 MPa, Yield strength of 500 MPa and Endurance strength of 350 MPa. [AU, Nov / Dec –2011]
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ME6503 - DESIGN OF MACHINE ELEMENTS UNIT - I NOTES THE QUESTION NUMBER WILL MATCH TO THE QUESTION BANK ATTACHED AT THE END

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