Design of Machine Elements II

10ME62

V T U - QUESTION BANK
UNIT 1
CURVED BEAMS CYLINDERS
Q.1) Give the difference between a straight beam and curved beam.

(Dec 2011/June2012)

Q.2) The cross section of a steel crane hook is a trapezium with an inner side of 50 mm and outer
side of 25 mm. The depth of the section is 64 mm. The centre of curvature of the section is at a
distance of 64 mm from the inner edge of the section and the line of action of load is 50 mm
from the same edge. Determine the maximum load the hook can carry if the allowable strength is
limited to 600 MPa.

(Dec 2012)

Q.3) Derive Lame's equation for thick cylinder.

(Dec 2012)

Q.4) A circular plate made of steel and of diameter 200 mm with thickness 10mm subjected to a

load including a pressure of 4 MPa. Taking E =201 KN, Poissions ratio = 0.3 determine:
i) The maximum stress, its location and maximum deflection when the edges of plates are
supported
ii) The maximum stress, its location and maximum deflection.

(July 2013)

Q.5) Clearly state five assumptions used in determining the stress distribution in a curved
flexural member.

(June/July 2013)

Q.6) Fig.Ql(b) shows a frame of a punching machine and its various dimensions. Determine the
combined stress at the inner and outer fibres. Also fwd the maximum shear stress and its
location. Take the force as 85 kN.
Inner radius of curved beam ri = 250 rom
Outer radius of curved beam ro= 550mm.

Department of Mechanical Engineering, SJBIT, Bengaluru.

(June/July 2013)

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Design of Machine Elements II

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Q.7) A domestic gas cylinder made of CI has an allowable tensile stress of 45 MPa. If the
internal pressure is 1.5 MPa, find the wall thickness of the cylinder. Take cylinder diameter as
300mm.

(June/July 2013)

Q.8) A CI cylinder of ID 300 mm and wall thickness 40 mm carries a fluid under pressure of 6
MPa. Find the tangential and radial stresses across the wall of the cylinder at every10 mm. Also
plot the stress distribution.

(June/July 2013)

Q.9) A curved link mechanism made from a round steel bar 1 KN is shown in Fig. Q1 (a). The
material for link is plain carbon steel 30CS with an allowable yield strength of 400 MPa.
Determine the factor of safety.

(Dec/Jan 2014)

Q.10) High pressure steel tube with inner and outer diameter I 20 mm and 40 mm respectively. It
is jacketed by an outer steel tube with an out. Diameter of 60 mm. The tubes are assembled by
shrinking process in such a way~ maximum principle stress induced in any tube is limited to
100:MFa. Calcu1ate shrinkage pressure ad original dimensions of the tubes. Take the Young's
modulus 207GPa.
Department of Mechanical Engineering, SJBIT, Bengaluru.

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Design of Machine Elements II

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Q.11) The parallel sides of a trapezoidal cross section of a crane hook of capacity 50 kN are
100mm and 60 mm. the depth of the section being 120 mm. The radius of ' curvature of the inner
fibre is 150 mm as shown is the Fig.QI(b). Determine the stresses at the extreme fibres of the
cross section of the crane hook.

(June 2012)

Q.12) Determine the dimensions of I section, shown in Fig. Q1 (a) in which maximum fibre
stress s are numerically equal in pure bending, given b, +b, = 120mm .

(Jan 2015)

Q.13) A solid shaft of 125 mm diameter is to be press into a steel flange which has an outside
diameter of 150 mm and length of 100 mm. Take E=210GPa, v = 0.3. Determine,
i) Pressure between hub and shaft.
ii) Proper size of bore, if maximum stress does not exceed 160MPa.
iii) Force require t press the parts together. Assume ~ = 0 F press fit.
iv) Torque capacity of press fit.

(Jan 2015)

UNIT 2
BELTS ROPES CHAINS
Q.1) Select a V belt drive to transmit a power of 6 kW from a shaft rotating at 1500rpm to a
parallel shaft to be running at 375 rpm. The distance between the shaft centers is 500 mm. The
pitch diameter of the smaller grooved pulley can be taken to be 150 mm. The factor of
application is to be taken as 1.2.

(Dec 2011)

Q.2) Select a standard v-belt to transmit 30 kW from an AC induction motor rotating at 1500
rpm to a centrifugal pump rotating at 150 rpm. The drive operates continuously for 8 hr/ day.
Calculate the number of belts.

(June 2012)

Q.3) Explain the advantages and applications of chain drives.

(June 2012)

Q.4) The layout of the leather belt drive transmitting 15 kW power is shown in Fig. Q8(b). The
centre distance between the pulleys is twice the diameter of the big pulley. The belt should
operate at a velocity of 20 m/s and the stresses in the belt should not exceed 2.25 MPa. The
density of the leather belt is 0.95 g/cc and the coefficient of friction is 0.35. The thickness of the
belt is 5 mm. Calculate:

(June 2012)

i) Diameter of the pulleys.

ii) The length and width belts. iii) Belt tensions.
Department of Mechanical Engineering, SJBIT, Bengaluru.

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Q.6) A nylon core flat belt 200 mm wide weighing 20 N/m, connected a 300 mm diameter pulley
to a 900 mm diameter driven pulley at a shaft spacing of 6 m, transmits 55.2kW at a belt speed of
25 m/s : i) Calculate the belt length and the angles of wrap ii) Compute the belt tensions based on
a coefficient of friction 0.38.

(July2013)

Q.7) A compressor is driven by a motor of 2.5 kW running at 1200 rpm to a 400 rpm
Compressor. Select a suitable V-belt.

(July2013)

Q.8) Write a note on construction of flat and V belt.

(Jan2014)

Q.9) It is required to design a 'V' belt drive to connect a 7.5 kW, 1440 r/min induction motor to a
fan, running at approximately 480 r/min for a service of 24 hr/day. Space is available for a centre
distance of about 1 m. Determine the pitch length of the belt and number of belts required.
(Jan2014)

UNIT 3
DESIGN OF SPRINGS
Q.1) Design a helical compression spring to sustain an axial load that fluctuates between 1.5 kN
and 2 KN with an associated deflection of 15mm during the fluctuation of load.

(Dec 2012)

Q.2) An automotive leaf spring is to designed to consist of 10 graduated leaves and 2 full length
leaves. The spring is to support a central load of 5kN over a span of 1100 mm with the actual
band width of 100 mm. The width and thickness of leaves limiting the maximum equalized stress
induced in the leaves to 350MPa. Also determine the initial gap to be provided between the
fu1llength and graduated leaves before the, assembly.

(Dec 2012)

Q.3) Derive an expression for the stress induced in a helica1 spring, with usual notations.
Consider a helical spring made of circular wire &subjected to on axial load F as shown in fig.
(June 2012)
Q.4) A carriage weighing 25000 N is moving on track with a linear velocity of 3.6kmI hour. If it
is brought to rest by two helical compression springs in the form of a bumper by undergoing a
compression of 180 mm. The springs may be assumed to have a spring index of 6 and
permissible shear strength of 450 MPa. Design the spring and determine the diameter of the wire,
Department of Mechanical Engineering, SJBIT, Bengaluru.

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mean coil diameter and the length of the spring. Assume the modulus of rigidity of the spring
material as 81.4 GPa.

(June 2012)

Q.5) Derive an expression for strain energy stored in a body when the load is applied gradually.
Q.6) A railway wagon weighing 40 kN and moving with a speed of 10km/hour has to stopped by
4 buffer springs in which the maximum compression allowed is 200 mm. Find the number of
turns in each spring of mean diameter 150 mm. The diameter of spring wire is 25 mm. Take G =
82.7 GPa.

(Jan 2014)

Q.7) A truck spring has 12 leaves of which 2 are full length leaves. The spring supports ~e 1.05
m apart and the central band is 85 mm wide. The central load is to be 5400 N with a permissible
stress of 0.28 GPa. The ratio of total depth to width of spring is 4. Assume E = 210 GPa.
Determine the maximum deflection in the spring.

(Jan 2014)

Q.8) Enumerate the application of springs. Also derive an expression for the deflection of a close
coiled helical spring.

(Jan 2014)

Q.9) A spring is subjected to a load varying from 500 N and 1200 N. It is to be made of oil
tempered cold drawn wire. Design factor based on Whal's line is 1.2.5. The spring index is to be
6. The compression in the spring for the maximum load is 30 mm. Determine the wire diameter,
mean coil diameter and free length of the spring. Take the yield stress in shear as 700MPa and
endurance stress in shear as 350 MPa for the material of the wire.

(Jan 2014)

Q.10) Enumerate the application of springs. Also derive an expression for the deflection of a
close coiled helical spring.

(Jan 2014)

Q.11) A spring is subjected to a load varying from 500 N and 1200 N. It is to be made of oil
tempered cold drawn wire. Design factor based on Wahls line is 1.2.5 . The spring index is to be
6. The compression in the spring for the maximum load is 30 mm. Determine the wire diameter,
mean coil diameter and free length of the spring. Take the yield stress in shear as 700 MPa and
endurance stress in shear as 350 MPa for the material of the wire.

Department of Mechanical Engineering, SJBIT, Bengaluru.

(Jan 2014)

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UNIT 4
SPUR AND HELICAL GEARS
Q.1) Design a pair of spur gears to transmit 20 kW of power at a pinion speed of 1000rpm. The
required velocity ratio 3.5: 1200 stub involutes tooth profile to be The static design stress for the
pinion is 1000 MPa and for the gear is 70 MPa pinion has 16 teeth. Determine the module, face
width, and pitch circle diameter of the gears based on a service factor is 1.25.

(Dec 2012)

Q.2) Derive the Lewis equation for the beam strength of a gear tooth. Also list the assumptions.
(Dec 2012)
Q.3) Sketch and explain the different forms of involute gear tooth.

(June 2012)

Q.4) A cast steel pinion with an allowable stress of 103 MPa rotating at 900 r/min is to drive a
cast iron gear at 1440 r/min. The teeth are 20 stub involute and the maximum power to be
transmitted is 25 kW. The allowable stress for cast iron gear is 56 MPa. Determine the module,
number of teeth on the gears and face-width from the stand point of strength, dynamic load and
wear.

(June 2012)

Q.5) Two spur gears are to be used for a rock crusher drive and are to be of minimum size. The
gears are to be designed for the following requirements. Power to be transmitted is 20 kW; speed
of pinion is 1200 rpm, velocity ratio is 3.5 : 1; tooth profile 20 stub involute. Determine module
and face width for strength requirements only.

(Dec 2012)

Q.6) Pair of mating helical gears have 200 pressure angle in the normal plane. The normal
module is 5 mm and the module in the diametral plane is 5.7735 mm. The pitch diameter. of the
smaller gear is 115.47 mm. H the transmission ratio is 4:1, calculate i) Helix angle ii) Normal
pitch iii) Transverse pitch iv) Number of teeth for each gear v) Addendum vi) Dedandum vii)
Whole depth viii) Clearance ix) Tooth thickness x) Working depth xi) Outside diameters xii)
Centre distance xiii) Root circle diameters xiv) Base circle diameters.

(Dec 2012)

Q.7) A pair of mitre gears have pitch diameter 280 mm and face width of 36 mm run at 250 rpm.
The teeth are of 1410 involutes and accurately cut and transmit 6 kW. Neglecting friction angle,
find the following: i) Outside diameter of gears ~ Resultant tooth load tangent to pitch cone, iii)
Radial load on the pinion iv) Thrust on the pinion. Assume low carbon cast steel 0.2%C heat
treated as the material for both the gears.
Department of Mechanical Engineering, SJBIT, Bengaluru.

(Dec 2012/Jan2015)
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Q.8) Write a note on design of gears based on dynamic loading and wear.

(Jan 2014)

Q.9) A cast steel 24 teeth spur pinion operating at 1150 r/min transmits 3 kW to a cast steel156
teeth spur gear. The gears have the following specifications:

(Jan 2014)

UNIT 5
BEVEL GEARS AND WORM GEARS
Q.1) Explain with a sketch the formulative number to teeth based on bevel gears.
(Dec 2012, Jan 2014)
Q.2) A pump is driven by a 30 kW motor through a pair of right angled bevd speed of the motor
is 200 rpm. The pinion on the motor has a pitch circle of 150mm and carries 30 teeth and the
gear on the pump shaft carries40 pinion made of C45 steel untreated where as the gear is made of
0.2% untreated. The teeth are generated to have 200 full depth involute. The gear pair is safe
from the stand point of bending strength.

(Dec 2012)

Q.3) A pair of bevel gears transmits 7.5 kW at 300rpm of the pinion. The pitch diameters of the
pinion and gear at their larger ends are 150mm and 200 mm respectively, and the pressure angle
is 20. Determine the components of the resultant gear tooth force and draw a free body diagram
of the forces acting on the pinion and the gear, assuming face width of 40 mm.

(June 2013)

Q.4) The following data refer to a worm and worm gear drive that has to transmit 15 kW at 1750
rpm of the worm:
Centre distance = 200 mm, Pitch circle diameter of worm = 80 nun No. of starts = 4 Axial
module = 8 mm, Transmission ratio = 20, Tooth form = 20 FDI.
The work gear has an allowable bending stress of 55 MPa. The worm is made of hardened and
ground steel. Determine (i) the number of teeth on the worm gear, (ii) The lead angle (iii) face
width of the worm gear based on the beam strength of the worm gear.

(June 2013)

Q.5) Hardened steel worm rotates at 1250 r/min and transmits power to a phosphor bronze gear
with a transmission ratio of 15:1. The centre distance is to be 225 mm. Design the gear drive and

Department of Mechanical Engineering, SJBIT, Bengaluru.

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give estimated power input ratings from the stand point of strength, endurance and heat
dissipation. The teeth are of 141/2 full depth involute.

(Jan 2014)

UNIT 6
CLUTCHES AND BRAKES
Q.1) A multiple clutches steel on bronze is to transmit 8 KWatt 1440 rpm. The' diameter of the contact is
80 mm and the outer diameter of contact is 140mm.The operates in oil with expected co efficient of
friction of 0.1, the average pressure is 0.35 MPa. Assume uniform, wear theory and determine the
following,
i) No. of steel and bronze plates
ii) Axial force

(Dec 2012)

ill) Actual maximum pressure.

Q.2) A friction cone duth has to to transmit to torque of 200 N / mat 1440 rpm. The large
diameter of the cone is 350 mm; the cone pitch angle is 6.250. The face width is 65 mm. The
co-efficient of friction is 0.2 Determine:
i) The axial force required to transmit the torque
ii) The average normal pressure on the contact surface with the maximum torque is
Transmitted

(Dec 2012)

Q.3) A multiplate clutch consists of five steel plates and four bronze plates. The inner and outer
diameter of friction disks are 75 mm and 150 mm respectively. The coefficient of friction is 0.1
and the intensity of pressure is limited to 0.3 N Im2 Assuming uniform wear theory. Calculate:
i)

The

required

operating

force

ii)

Power

transmitting

capacity

at

750

r/min.

(June 2012)
Q.4) A differential band brake is shown is Fig. Q6(b). The width and thickness of the steel band
are 100 mm and 3 mm respectively. The permissible tensile stress is the band is limited to 50
MPa. The coefficient of friction between the friction lining and the drum is 0.25. Calculate:
i) Tensions is the band ii) The actuating force ill) Torque capacity of the brake.

(June 2012)

Q.5) In a multiple disc clutch, the radial width of the friction material is to be 0.2 of the
Maximum radius. The coefficient of friction is 0.250. The clutch is to transmit 60 kWat 3000
Department of Mechanical Engineering, SJBIT, Bengaluru.

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rpm. Its maximum diameter is 250 mm and the axial force is limited to 600 N. Determine i)
Number of driving and driven discs ii) Mean unit pressure on each contact surface. Assume
uniform wear.

(Dec 2012)

Q.6) In a band and block brake 0 = 15 and effective diameter is 800 mm. P = 0.4, a = 100 mm,
b = 25 mm. The power absorbed at 600 rpm is 450 kW when the force applied at the end of
levels at a distance of 1.20 m from the fulcrum is 200 N. Find the number of blocks
(June 2013)
Q.7) Design a cone clutch to transmit 40 kW at 750 rpm. Also determine the (i) force required to
transmit the torque (ii) axial force required to engage the Assume j.l. = 0.4 and p = 0.2 N/mm2
for the friction material (a 112.5).Take=6.

(June 2013)

Q.8) The band brake shown in Figure Q6(b), uses a V-belt. The pitch diameter of the V=grooved
pulley is 400 mm, the groove angle is 45 and the coefficient of friction is 0.3. Determine the
power rating of the brake.

(Jan 2014)

Q. 9) A cone clutch has a semi cone angle of 12. It is to transmit 10 kW power at 750 min, the
width of the face is one fourth of the mean diameter of friction lining. the normal intensity of
pressure between contacting surfaces is not to exceed O. N/mm2 and the coefficient of friction is
0.2, assuming uniform wear condition, calculate the dimensions of the clutch.

(Jan 2014)

Q. 10) A single band brake shown in Fig. Q6 (b) is to be designed to stop the rotation of a shaft
transmitting a power of 45 KW at a rated speed\of 500 rpm. Selecting suitable materials
determine,
i) Dimensions of rectangular cross section of band.
ii) Dimensions of rectangular cross section of brake lever. (Assume h, = 2 b.),
iii) Diameter of fulcrum pin.
Assume Ip = 1.5 dp, bearing stress = 10M

Department of Mechanical Engineering, SJBIT, Bengaluru.

(Jan 2015)

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UNIT 7
LUBRICATION AND BEARINGS
Q.1) Discuss the mechanism of fluid film lubrication.

(Dec 2012)

Q.2) Design a journal bearing to withstand a load of 5886 N. Speed. of the journal is 11 rpm. The
journal is made of hardened steel and bearing is made of babbit. Op... Temperature is 700C and
ambient temperature is 300C. Check the design forth equilibrium and also determine the power
loss at the bearing. The lubricant used of grade. SAE 40 lid = 1.5

(Dec 2012)

Q.3) Explain the properties a good bearing material should posses. List the different types of
bearing materials.

(June 2012)

Q.4) The following data are given for a full joumal bearing: Radial load: 25 kN, L/d ratio: 1:1
Unit bearing pressure: 2.5 MPa. Viscosity of the lubricant: 20 Cp. Class of fit: H7 e7.
Calculate:
i) Dimensions of the bearing
ii) Minimum oil film thickness.
iii) Requirement of oil flow.
Assume that the process to clearance is centered.

(June 2012)

Q.5) Explain the meaning of, i) Oiliness ii) Flash point ill) Fire point iv) Pour point v) Cloud
point

(Dec 2012)

Q.6) Write a note bearing modulus

(Dec 2012)

Q.7) A 75 mm journal bearing of diameters 75 mm supports a load of 15 kN. The ratio of 1000
and the viscosity of the oil is 25 x 10-3 PaS. The heat generated in the c' bearing is 442 watts.
Determine the maximum speed of the journal using McKees equation.

(Dec 2012)

Q.8) SAE 20 oil is used to lubricate 'a hydrodynamic journal bearing of diameter 75nun and
length 75 mm. The journal rotates at 1,200 rpm, the diametric clearance is 0.075 mm, the
operating

temperature

of

the

oil

is

53C,

and

the

oil

enters

at

40C.

(June 2013)
Department of Mechanical Engineering, SJBIT, Bengaluru.

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Q.9) Explain the following types of lubrication:

i) Hydrodynamic lubrication. ii) Hydrostatic lubrication
ill) Boundary lubrication iv) Elasto hydro dynamic lubrication

(Jan 2014)

Q.10) The following data are given for a 3600 hydro - dynamic bearing:
Bearing diameter: 50.02 mm Journal diameter: 49.93 mm
Bearing length: 50 mm Journal speed: 1440 r/min
Radial load = 8kN Viscosity of lubricant: 12 cp.
The bearing is machined on a lathe from bronze casting, while the steel journal is hardened and
ground. The surface roughness values for turning and grinding are 0.8 and 0.4 microns
respectively. For thick film lubrication the minimum film
Thickness should be five times the sum of surface roughness values for the journal and the
bearing. Calculate.
i) The permissible minimum film thickness.
ii) The actual film thickness under the operating conditions.
iii) Power loss in friction.
iv) Flow requirement.

(Dec 2013/Jan 2014)

UNIT 8
IC ENGINE PARTS
Q.1) Explain the considerations given in the design of pistons for IC engines.

(Jan 2014)

Q.2) Design a trunk piston for an IC engine. The piston is made of cast iron with an allowable
stress of 38.5 MPa. The bore of the cylinder is 200 mm and the maximum explosion pressure is
0.4 MPa. The permissible bending stress of the gudgeon pin is100 MPa. The bearing pressure in
the gudgeon pin bearing of the connection rod.
The bearing pressure in the gudgeon pin bearing of the connection rod is to be taken as 200 MPa
(Dec. 2013/Jan. 2014)
Q. 3) List and explain the functions of parts of internal combustion engine.

Department of Mechanical Engineering, SJBIT, Bengaluru.

(Jan 2015)

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