Syllabus

NME-501 : MACHINE DESIGN-I

UNIT I
Introduction Definition, Design requirements of machine elements, Design procedure, Standards in
design, Selection of preferred sizes, Indian Standards designation of carbon & alloy steels, Selection of
materials for static and fatigue loads. 3 Design for Static Load Modes of failure, Factor of safety,
Principal stresses, Stresses due to bending and torsion, Theory of failure.
UNIT II

Design for Fluctuating Loads Cyclic stresses, Fatigue and endurance limit, Stress concentration factor,
Stress concentration factor for various machine parts, Notch sensitivity, Design for finite and infinite life,
Soderberg, Goodman & Gerber criteria.
Riveted Joints Riveting methods, materials, Types of rivet heads, Types of riveted joints, Caulking and
Fullering, Failure of riveted joint, Efficiency of riveted joint, Design of boiler joints, Eccentric loaded
riveted joint.
UNIT III

Shafts Cause of failure in shafts, Materials for shaft, Stresses in shafts, Design of shafts subjected to
twisting moment, bending moment and combined twisting and bending moments, Shafts subjected to
fatigue loads, Design for rigidity.
Keys and Couplings Types of keys, splines, Selection of square & flat keys, Strength of sunk key,
Couplings, Design of rigid and flexible couplings.
UNIT IV

Mechanical Springs Types, Material for helical springs, End connections for compression and tension
helical springs, Stresses and deflection of helical springs of circular wire, Design of helical springs
subjected to static and fatigue loading.
Power Screws Forms of threads, multiple threads, Efficiency of square threads, Trapezoidal threads,
Stresses in screws, Design of screw jack

Note: Design data book is allowed in the examination Books and References
UNIT-I
 MEERUT INSTITUTE OF TECHNOLOGY MEERUT
B.Tech (Mechanical) (V semester)
Subject-Machine Design-1
Assignment No-1

1. What is Machine Design? What are the steps in Machine Design process?
2. What do you mean by need analysis? Write its importance in design. (U.P.T.U
2008-09)
3. Explain the brain storming. What are their rules?
4. What is standardization? Give the advantages of standardization. (U.P.T.U
2007-08)
5. What is interchangeability?
6. Explain Concurrent Engineering.
7. What is preferred number? Derive the R-10 series.
8. Explain the importance of preferred size in design process. (U.P.T.U
2004-05)
9. Find out the number of R-20/4 (10…100) derived series.
10. Discuss the effect of silicon, manganese, sulphur and phosphorus on cast iron.
11. Designate the following materials
(a) Grey cast iron with minimum tensile strength of 300 N/mm2.
(b) Designate plain carbon steel with 0.5 % carbon and 0.85 manganese
(c) Carbon= 0.35 - 0.45 %, chromium= 0.90 - 1.1 %.
(d) Carbon 0.12 - 0.20 % , Ni= 0.8 -1.2 %, Cr= 0.6 – 1.0 %
(e) C=0.15 -0.25 %, Si=0.10 – 0.50 %, Mn= 0.3 – 0.5 %, Ni=2.5 – 3.5 %, Cr= 18-
24 %
(f) 50Cr1V23 U.P.T.U 2005-06)

12. Define these definitions

(a) Ductility (b) Brittleness (c) Creep (d) Fatigue (e) Elasticity (f) Plasticity (g)
Toughness (h) Resilience
13. What are the reasons for the use of alloy steel in machine parts? (U.P.T.U
2004-05)
14. What are the three basic mode of failure of mechanical component?
15. What is factor of safety? Why is it necessary to use factor of safety.
16. What are the factors to be considered for deciding the magnitude of factor of safety?
17. Explain different types of theories of failure in machine design.
18. Explain the importance of material selection decision in machine design. (U.P.T.U
2008-09)
19. Discuss the factors which are considered in the selection of a material for a machine
component.
20. Enumerate advantages and disadvantages of plastic material over metals. (U.P.T.U
2007-08)
UNIT-II
 MEERUT INSTITUTE OF TECHNOLOGY MEERUT
B.Tech (Mechanical) (V semester)
Subject-Machine Design-1
Tutorial No-1
Wmax=700×103 N and has a stress concentration
factor = 1.8. Use factor of safety as 2.0.
1. A forged steel bar 50 mm in diameter is subjected to 7.
reversed bending stress of 250 N/mm2. The bar is made 8.
of steel 40C8 (Sut=600 N/mm2). Calculate the life of the 7. A steel rod is subjected to a reversed axial load of
bar for a reliability of 90 %. Ans=23736 Cycle 180 kN. Find the diameter of the rod for a factor
2. A rotating beam made of steel 45C8 (Sut=630 N/mm2) is of safety of 2. Neglect column action. The
subjected to completely reversed bending stress. The material has an ultimate tensile strength of 1070
corrected endurance limit of the bar is 315 N/mm2. MPa and yield strength of 910 MPa. The
Calculate the fatigue strength of the bar for a life of endurance limit in reversed bending may be
90,000 cycle. assumed to be one-half of the ultimate tensile
3. A machine component is subjected to a flexural stress strength. Other correction factors may be taken as
which fluctuates between + 300 MN/m and – 1502
follows:For axial loading = 0.7; For machined
2
MN/m . Determine the value of minimum ultimate surface = 0.8 For size = 0.85 ; For stress
strength according to 1. Gerber relation; 2.Goodman concentration = 1.0.
relation; and 3. Soderberg relation. Take yield strength 8. A circular bar of 500 mm length is supported
= 0.55 Ultimate strength; Endurance strength = 0.5 freely at its two ends. It is acted upon by a central
Ultimate strength; and factor of safety = 2. concentrated cyclic load having a minimum value
4. A bar of circular cross-section is subjected to alternating of 20 kN and a maximum value of 50 kN.
tensile forces varying from a minimum of 200 kN to a Determine the diameter of bar by taking a factor
maximum of 500 kN. It is to be manufactured of a of safety of 1.5, size effect of 0.85, surface finish
material with an ultimate tensile strength of 900 MPa factor of 0.9. The material properties of bar are
and an endurance limit of 700 MPa. Determine the given by : ultimate strength of 650 MPa, yield
diameter of bar using safety factors of 3.5 related to strength of 500 MPa and endurance strength of
ultimate tensile strength and 4 related to endurance limit 350 MPa.
and a stress concentration factor of 1.65 for fatigue load. 9. A piston rod of circular cross section is subjected
Use Goodman straight line as basis for design. to a cyclic load fluctuating between 15 kN in
5. Determine the thickness of a 120 mm wide uniform compression to 25 kN in tension. The endurance
plate for safe continuous operation if the plate is to be limit for the piston rod material is 360 N/mm2.
subjected to a tensile load that has a maximum value of While yield strength is 400 N/mm2. The impact
250 kN and a minimum value of 100 kN. The properties factor is 1.25 while fos is 1.5. The surface finish
of the plate material are as follows: Endurance limit factor and stress concentration factor are 0.88 and
stress is 225 MPa, and Yield point stress is 300 MPa. 2.25 respectively. Determine the diameter of
The factor of safety based on yield point may be taken piston rod. d=20.70 mm
as 1.5. 10. A 50 mm diameter shaft is made from carbon
6. Determine the diameter of a circular rod made of steel having ultimate tensile strength of 630 MPa.
ductile material with a fatigue strength (complete It is subjected to a torque which fluctuates
stress reversal), σe = 265 MPa and a tensile yield between 2000 N-m to – 800 N-m. Using
strength of 350 MPa. The member is subjected to a Soderberg method, calculate the factor of safety.
varying axial load from Wmin = –300×103 N to Assume suitable values for any other data Needed
11. A simply supported beam has a concentrated load maximum value of P. Take a size factor of 0.85
at the centre which fluctuates from a value of P to and a surface finish factor of 0.9.
4 P. 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 of 1.3, calculate the
UNIT-III
 MEERUT INSTITUTE OF TECHNOLOGY MEERUT
B.Tech (Mechanical) (V semester)
Subject-Machine Design-1
Tutorial No-2

1. A solid shaft is transmitting 1 MW at 240 r.p.m. plain carbon steel and the permissible shear stress is
Determine the diameter of the shaft if the maximum 84 N/mm2. Calculate the inside and outside diameter
torque transmitted exceeds the mean torque by 20%. of the shaft. Ans: di=23.47 mm do=39.12 mm
Take the maximum allowable shear stress as 60 MPa. 8. Derived the diameter of a hollow shaft with a ratio of
. Ans: d=160 mm of 0.8, capable of transmitting 300 KW at 225
2. A cylindrical shaft made of steel of yield strength rev/min. when subjected to a maximum bending
700 MPa is subjected to static loads consisting of a moment of 5500 Nm, the load is suddenly applied with
bending moment of 10 kN-m and a torsional moment minor shock for torsional moment the bending moment
of 30 kN-m. Determine the diameter of the shaft is steady and the allowable shearing stress is 56 MPa.
using two different theories of failure and assuming a Ans: di=120 mm do=150 mm
factor of safety of 2. Ans. 100 mm 9. A shaft made of mild steel is required to transmit 100
3. Find the diameter of a solid steel shaft to transmit 20 kW at 300 r.p.m. The supported length of the shaft is 3
kW at 200 r.p.m. The ultimate shear stress for the meters. It carries two pulleys each weighing 1500 N
steel may be taken as 360 MPa and a factor of safety supported at a distance of 1 metre from the ends
as 8.If a hollow shaft is to be used in place of the respectively. Assuming the safe value of stress,
solid shaft, find the inside and outside diameter when determine the diameter of the shaft. Ans: d=70 mm
the ratio of inside to outside diameters is 0.5. 10. A hollow circular shaft of outer and inner diameter of
Ans: d=50 mm do = 50mm di=25 mm
do and di respectively is subjected to a torsional
4. A line shaft rotating at 200 r.p.m. is to transmit 20 moment of M over a length l. The permissible angle of
kW. The shaft may be assumed to be made of mild twist is θ degree. Proved that the shaft diameter is
steel with an allowable shear stress of 42 MPa. given by.
Determine the diameter of the shaft, neglecting the
bending moment on the shaft . Ans: d=50 mm d0 =
5. A solid circular shaft is subjected to a bending 11. A rotating shaft 40 mm in diameter, is made of steel
moment of 3000 N-m and a torque of 10 000 N-m. FeE 580 (Syt=580 N/mm2). It is subjected to a steady
The shaft is made of 45 C 8 steel having ultimate torsional moment of 250 N-m and bending moment of
tensile stress of 700 MPa and a ultimate shear stress 1250 N-m. Calculate the factor of safety available
of 500 MPa. Assuming a factor of safety as 6, based on Ans. (i) 2.89, (ii) 2.86
determine the diameter of the shaft. Ans: d=90 mm (i) Maximum principal stress theory
6. A line shaft rotating at 200 r.p.m. is to transmit 20 (ii) Maximum shear stress theory
kW. The allowable shear stress for the material of the 12. A Propeller shaft is required to transmit 50 kW power
shaft is 42 MPa. If the shaft carries a central load of at 600 rpm. It is hollow shaft. Having inside diameter
900 N and is simply supported between bearing 3 0.8 times of the outer diameter. It is made of steel (S yt
metre apart, determine the diameter of the shaft. The = 380 N/mm2) and the factor of safety is 4. Calculate
maximum tensile or compressive stress is not to the inside and outside diameter of the shaft.
exceed 56 MPa. Ans. d=50 mm 13. Two 400 mm diameter pulleys are keyed to a simply
7. A propeller shaft is required to transmitted 45 KW supported shaft 500 mm apart. Each pulley is 100 mm
power at 500 r.p.m. its hollow shaft having an inside from its support and has horizontal belts, tension ratio
diameter 0.6 times of outside diameter. It’s made of
 being 2.5. If the shear stress is to be limited to 80 MPa and the maximum tensile or compressive stress is not
while transmitting 45 kW at 900 r.p.m., find the shaft to exceed 56 MPa. What size of the shaft will be
diameter if it is to be used for the input-output belts required, if it is subjected to gradually applied loads?
being on the same or opposite sides. Ans. 40 mm Ans: d=53.4 mm, d=57.7 mm
14. A line shaft is driven by means of a motor placed 18. Design a shaft to transmit power from an electric motor
vertically below it. The pulley on the line shaft is 1.5 to a lathe head stock through a pulley by means of a
metre in diameter and has belt tensions 5.4 kN and 1.8 belt drive. The pulley weighs 200 N and is located at
kN on the tight side and slack side of the belt 300 mm from the centre of the bearing. The diameter
respectively. Both these tensions may be assumed to be of the pulley is 200 mm and the maximum power
vertical. If the pulley be overhang from the shaft, the transmitted is 1 kW at 120 r.p.m. The angle of lap of
distance of the centre line of the pulley from the centre the belt is 180° and coefficient of friction between the
line of the bearing being 400 mm, find the diameter of belt and the pulley is 0.3. The shock and fatigue factors
the shaft. Assuming maximum allowable shear stress for bending and twisting are 1.5 and 2.0 respectively.
of 42 MPa Ans: d=78mm The allowable shear stress in the shaft may be taken as
15. A shaft is supported by two bearings placed 1 m apart. 35 MPa. Ans: d=51.1 mm
A 600 mm diameter pulley is mounted at a distance of 19. The layout is a transmission shaft carrying two pulleys
300 mm to the right of left hand bearing and this drives B and C and supported on bearing A and D as shown in
a pulley directly below it with the help of belt having fig. Power is supplied to the shaft by means of a
maximum tension of 2.25 kN. Another pulley 400 mm vertical belt on the pulley B. when id then transmitted
diameter is placed 200 mm to the left of right hand to the pulley C carrying a horizontal belt. The
bearing and is driven with the help of electric motor maximum tension in the belt on the pulley is 2.5 KN.
and belt, which is placed horizontally to the right. The The angle of wrap for the both pulley is 1800 and the
angle of contact for both the pulleys is 180° and µ = coefficient of friction is 0.24. The shaft is made of
0.24. Determine the suitable diameter for a solid shaft, plain carbon steel 30C8 (S yt=400 N/mm2) and the factor
allowing working stress of 63 MPa in tension and 42 of safety is 3. Determine the shaft diameter on strength
MPa in shear for the material of shaft. Assume that the basis. Ans: d=45.47 mm
torque on one pulley is equal to that on the other
pulley. Ans: d=51.7mm

20. The layout of a shaft carrying two pulleys 1 & 2 and

supported on two bearing A & B as shown in fig. The
16. A transmission shaft with keyway is subjected to a shaft transmits 7.5 KW power at 360 r.p.m from the
maximum torsional moment of 750 M-m and pulley 1 to the pulley 2. The diameter of pulleys 1 & 2
maximum bending moment of 1200 N-m.the loads are are 250mm and 500 mm respectively. The masses of
suddenly applied minor shocks are encountered, and pulley 1 & 2 are 10 kg and 30 kg respectively. The belt
the allowable shear stress is 42 MPa. Find the shaft tension act vertically downward and the ratio of belt
diameter Ans: d=68.3 mm tension on the tight side to slack side for each pulley is
17. A mild steel shaft transmits 20 kW at 200 r.p.m. It 2.5:1. The shaft is made of plain carbon steel (S yt =380
carries a central load of 900 N and is simply supported N/mm2) and fos is 3. Estimate suitable diameter of
between the bearings 2.5 meters apart. Determine the shaft. If permissible angle of twist is 0.50 per meter
size of the shaft, if the allowable shear stress is 42 MPa
 length. Calculate the shaft diameter on the basis of respectively. The material of the shaft is steel FeE 580
torsional rigidity. Assume G=79300 N/mm2. (Sut=770 N/mm2) and (Syt=580 N/mm2). The factor
Ans: d=41.37 mm Kb and Kt of ASMEAns:41.37
code are 1.5
mmand 2.0 respectively
Determine the shaft diameter. Assume that the gears
are connected to the shaft by means of keys .
. Ans: d=68.59 mm

21. A line shaft supporting two pulleys A and B as shown.

Power is supplied to the shaft by means of a vertical
belt on the pulley A. Which is then transmitted to the
25. The armature shaft of 40 kW, 720 rpm electric motor.
pulley B carrying a horizontal belt. The ratio of the belt
Mounted on two bearing A and B as shown. The total
tension on tight and loose sides is 3:1. The limiting
magnetic pull on the armature is 7 kN and it can be
value of tension in the belt is 2.7 kN. The shaft is made
assumed to be uniformly distributed over a length of
of plain carbon steel 40C8 (Sut=650 N/mm2) and
700 mm midway between the bearing. The shaft is
(Syt=380 N/mm2). The pulleys are keyed to the shaft.
made of steel with ultimate tensile strength of 770
Determine the diameter of the shaft according to the
N/mm2 and yield strength of 580 N/mm2Determine the
ASME code if Kb=1.5and kt=1.0 Ans: d=42.53mm
shaft diameter using ASME code if kb=1.5and kt=1.0
Ans: d=45.13 mm

22. A steel spindle transmits 4 kW at 800 r.p.m. The

angular deflection should not exceed 0.250 per meter of
the spindle. If the modulus of rigidity for the material
of the spindle is 84 GPa. Find the diameter of the 26. Figure shows a shaft carrying a pulley A and a gear B
spindle and the shear stress induced in the spindle. and supported in two bearings C and D. The shaft
. Ans: d=35 mm, τ=5.67 N/mm2 transmits 20 kW at 150 r.p.m. The tangential force F
23. A line shaft rotating at 200 r.p.m is required to transmit on the gear B acts vertically upwards as shown. The
25 kW. It carries a central load of 900 N and is simply pulley delivers the power through a belt to another
supported between bearing 3 meter apart. The pulley of equal diameter vertically below the pulley A.
allowable tensile and shear stress for the shaft are 56 The ratio of tensions T 1 /T2 is equal to 2.5. The gear
N/mm2 and 42 N/mm2 respectively. Determine the and the pulley weigh 900 N and 2700 N respectively.
diameter of the shaft. If Kt=1.25 and Km= 1.5 The permissible shear stress
Ans: for mm
d=63.5 the material of the
shaft may be taken as 63 MPa. Assuming the weight of
24. The layout of intermediate shaft of a gear box
supporting two spur gears B and C as shown. The shaft the shaft to be negligible in comparison with the other
is mounted on two bearing A and D. The pitch circle loads, determine its diameter. Take shock and fatigue
diameters of gears B and C are 900 and 600 mm
 factors for bending and torsion as 2 and 1.5
respectively. Ans: 69.6 mm

27. A solid circular shaft of diameter d is subjected to

bending moment of M and torsional moment of T.
Prove that according to maximum shear stress theory. 31. It is required to design a square key for fixing a gear
on a shaft of 25 mm diameter. The shaft is
= transmitting 15 kW power at 720 rpm to the gear.
The key is made of steel 50C4 (S yt=460 N/mm2) and
28. A solid circular shaft of diameter d is subjected to the factor of safety is 3. For key material, the yield
bending moment of M and torsional moment of T. strength in compression can be assumed to be equal
Prove that according to maximum principal r stress to the yield strength in tension. Determine the
theory. dimension of the key. Ans: l=35 mm
32. The standard cross section for a flat key which is
= fitted on a 50 mm diameter shaft is 16x10 mm. The
key is transmitting 475 N-m torque from the shaft to
29. The shaft of an axial flow rotary compressor is the hub. The key is made of commercial steel
subjected to a maximum torque of 2000 N-m and a (Syt=S yc=230 N/mm2). Determine the length of the
maximum bending moment of 4000 N-m. The key, if the factor of safety is 3. Ans: l=50 mm
combined shock and fatigue factor in torsion is 1.5 and 33. A shaft, 40 mm in diameter is transmitting 35 kW
that in bending is 2. Design the diameter of the shaft, if power at 300 rpm by means of Kennedy keys of
the shear stress in the shaft is 50 MPa. Design a hollow 10x10 mm cross section. The keys are made of steel
shaft for the above compressor taking the ratio of outer 45C8 (Syt=Syc=380 N/mm2) and the factor of safety is
diameter to the inner diameter as 2 3. Determine the required length of the key.
Ans. 96 mm 98 mm, 49 mm
34. Design the rectangular key for a shaft of 75 mm
30. A shaft made of steel receives 7.5 kW power at 1500
diameter. The shearing and crushing stresses for key
r.p.m. A pulley mounted on the shaft as shown in Fig.
material are 50MPa and 75MPa respectively.
14.19 has ratio of belt tensions 4. The gear forces are
. (UPTU-2002)
as follows : Ft= 1590 N, Fr = 580 N. Design the shaft
35. Design the rectangular key for a shaft of 50 mm
diameter by maximum shear stress theory. The shaft
diameter. The shearing and crushing stresses for key
material has the following properties: Ultimate tensile
material are 42MPa and 72MPa respectively
strength = 720 MPa; Yield strength = 380 MPa; Factor
(UPTU-2004)
of safety = 1.5. Ans. d=20 mm
36. A square key is to be used to fix a gear to a 35 mm
diameter shaft. The hub length of the gear is 60 mm.
Both the shaft and key are to be made of the same
material, having an allowable shear stress of 55
N/mm2. If the torque to be transmitted is 395 N-m.
 Determine the minimum dimension of key cross The factor of safety for the shaft and key is 4. For
section. Ans: b=6.84 mm, h=6.84 mm sleeve the fos is 6 based on ultimate strength.
37. Design a square key for fixing a gear on the shaft 43. Design a muff coupling to connect two mild steel
having 25mm diameter. The gear rotates at 550 rpm shafts to transmit 35 kW at 1440 r.p.m. The C.I
and transmits 12 kW power to the meshing gear. The sleeve connects the shaft through two mild steel sunk
key is made of steel having yield stress in tension as keys. The maximum torque transmitted is 25 %
400 N/mm2. The yield stress in compression and greater than the average torque.Allowable shear
tension may be taken equal to each other. Assume stress for C.I and mild steel are 15 N/mm2 and 65
factor of safety is 2.5. (UPTU-2005) Ans:l=34mm N/mm2.and the allowable crushing stress for mild
38. A standard splined connection 8x52x60 mm is used steel= 160 N/mm2.
for the gear and the shaft assembly of a gearbox. The Ans: d=29 mm , D= 58 mm, L=102 mm, l=51 mm
splines transmit 20 kW power at 300 rpm. The 44. Design a muff coupling to connect two shafts
dimension of the splines are as follow transmitting 40 kW at 120 r.p.m. The permissible
Major diameter= 60 mm, Minor diameter = 52 mm shear and crushing stress for the shaft and key
Number of splines = 8, Permissible normal pressure material (mild steel) are 30 MPa and 80 MPa
on splines is 6.5 N/mm2. The coefficient of friction is respectively. The material of muff is cast iron with
0.06. Calculate (i) Length of the hub (ii) The forced permissible shear stress of 15 MPa. Assume that the
require for shifting the gear. maximum torque transmitted is 25 per cent greater
Ans: l=110 mm, F= 1364.19 N than the mean torque.
39. A steel shaft has a diameter of 25 mm. The shaft 45. It is required to design a split muff coupling to
rotates at a speed of 600 r.p.m. and transmits 30 kW transmit 50 kW power at 120 rpm. The shaft, key and
through a gear. The tensile and yield strength of the clamping bolts are made of plain carbon steel 30C8
material of shaft are 650 MPa and 353 MPa (Syt =400n/mm2). The yield strength in compression
respectively. Taking a factor of safety 3, select a is 150% of tensile yield strength. The factor of safety
suitable key for the gear. Assume that the key and for the shaft, key and bolts is 5. The number of
shaft are made of the same material. Ans. l = 102 mm clamping bolts is 8. The coefficient of friction
40. A kennedy keys are used to transmit 30 kW power at between halves and the shaft is 0.3.
500 rpm from 40 mm diameter shaft to the hub. The 46. Design a cast iron protective flange coupling to
keys are made of steel 55C8 with yield strength of connect two shafts in order to transmit 7.5 kW at 720
400MPa and ultimate tensile strength of 700 MPa. r.p.m. The following permissible stresses may be
Ifnthe factor of safety required is 3 and over load used:
factor is 1.5, design the key. . Permissible shear stress for shaft, bolt and key
Ans: b=10 mm, h=10 mm l= 23 mm material = 33 MPa, Permissible crushing stress for
41. Design a muff coupling which is used to connect two bolt and key material = 60 MPa, Permissible shear
steel shafts transmitting 40 kW at 350 rpm. The stress for the cast iron = 15 MPa
material for the shaft and the key is plain carbon steel 47. The shaft and flange of a marine engine are to be
for which allowable shear and crushing stresses may designed for flange coupling in which the flange is
be taken as 40 MPa and 80 MPa respectively. The forged on the end of the shaft. The following
material for the muff is cast iron for which the particulars are to considered in the design
allowable shear stress may be assumed as 15 MPa. Power of engine= 3MW
42. Design of a muff coupling, which is used to connect Speed of engine= 100 rpm
two steel shafts transmitting 25 kW power at 360 Permissible shear stress in bolt and shaft = 60 Mpa,
rpm. The shaft and key are made of plain carbon No of bolts used=8
steel 30C8 (Syt = Syc=400 N/mm2). The sleeve is Pitch circle diameter of bolts = 1.6 x diameter of
made of grey cast iron FG 200 (Sut=200 N/mm2). shaft. Find Diameter of shaft, diameter of bolts
Thickness of flange, diameter of flange.
48. Design a clamp coupling to connect two plain carbon = 40 kW; speed of the motor shaft = 1000 r.p.m. ;
steel shafts to transmit 60 kW power at 500 r.p.m. diameter of the motor shaft, = 50 mm; diameter of
The C.I muff halves are clamped by four alloy steel the pump shaft = 45 mm. The bearing pressure in the
bolts. The key used has same material as that of the rubber bush and allowable stress in the pins are to be
shaft. The maximum torque transmitted is 20 % limited to 0.45 N/mm2 and 25 MPa respectively
greater than the average torque. Allowable shear 54. Design a Cast Iron protective type flange coupling to
stress for shaft and key material are 55MPa and connect two shaft of 36 mm diameter, transmitting at
allowable crushing stress for shaft and key material 720 r.p.m. The over load capacity 1.25 times the
=155 MPa. average torque. The bolt and key are made of C20
Allowable crushing stress for C.I muff = 150 MPa, steel and the flanges are made of Cast Iron. Assume
Allowable Tensile stress for alloy steel bolts =130 missing data suitable, if any U.P.T.U 2007-08)
MPa 55. Design a cast iron protective flange coupling to
49. Design a Cast Iron protective type flange coupling to connect two shafts in order to transmit 7.5 kW at 720
transmit 15 kW at 900 r.p.m from an electric motor r.p.m. The following permissible stresses may be
to a compressor. The service factor may be assumed used
as 1.35. The following permissible stresses may be Permissible shear stress for shaft, bolt and key
used. material = 33 MPa, Permissible crushing stress for
Shear stress for shaft, bolt and key = 40 MPa bolt and key material = 60 MPa, Permissible shear
Crushing stress for bolt and key = 80MPa stress for the cast iron = 15 MPa.
Shear stress for Cast Iron = 8 MPa
50. Two 35 mm shaft are connected by a flange
coupling. The flanges are fitted with 6 bolts on 125
mm bolt circle. The shaft transmits a torque of 800
N-m at 350 RPM. For the safe stresses mentioned
below, Calculate (i) diameter of bolts (ii0 thickness
of flanges (iii) Key dimension (iv) hub length and (v)
Power transmitted.
Safe shear stress for shaft material = 63 MPa
Safe stress for bolt material = 56 MPa
Safe stress for cast iron coupling = 10 MPa
Safe stress for key material = 46 MPa
51. Design a cast iron flange coupling for a mild steel
shaft transmitting 90 kW at 250 rpm. The allowable
shear stress in the shaft is 40 MPa and the angle of
twist is not to exceed 10 in a length of 20 diameters.
The allowable shear stress in the coupling bolts is 30
MPa.
52. A flexible coupling is used to transmit 15 kW power
at 100 rpm. There are six pins and their pitch circle
diameter is 200 mm. The effective length of the bush
(lb). The permissible shear and bending stress are 35
and 152 N/mm2 respectively Calculate the pin
diameter by shear consideration.
53. Design a bushed-pin type flexible coupling for
connecting a motor shaft to a pump shaft for the
following service conditions, Power to be transmitted
UNIT-IV
 MEERUT INSTITUTE OF TECHNOLOGY MEERUT
B.Tech (Mechanical) (V semester)
Subject-Machine Design-1
Tutorial No-3

1. A compression coil spring made of an alloy steel is permissible shear stress intensity is 420 MPa and
having the following specifications : modulus of rigidity, G = 84 kN/mm2.
Mean diameter of coil = 50 mm; Wire diameter = 5 Neglect the effect of stress concentration.
mm; Number of active coils = 20. If this spring is 7. Design a valve spring of a petrol engine for the
subjected to an axial load of 500 N; calculate the following operating conditions
maximum shear stress (neglect the curvature effect) to Spring load when the valve is open = 400 N
which the spring material is subjected. Spring load when the valve is closed = 250 N
2. A helical spring is made from a wire of 6 mm Maximum inside diameter of spring = 25 mm
diameter and has outside diameter of 75 mm. If the Length of the spring when the valve is open = 40
permissible shear stress is 350 MPa and modulus of mm
rigidity 84 kN/mm2, find the axial load which the Length of the spring when the valve is closed = 50
spring can carry and the deflection per active turn. mm
3. Design a spring for a balance to measure 0 to 1000 N Maximum permissible shear stress = 400 MPa
over a scale of length 80 mm. The spring is to be 8. Design a helical spring for a spring loaded safety
enclosed in a casing of 25 mm diameter. The valve (Ramsbottom safety valve) for the
approximate number of turns is 30. The modulus of following conditions :
rigidity is 85 kN/mm2. Also calculate the maximum Diameter of valve seat = 65 mm ; Operating
shear stress induced. pressure = 0.7 N/mm2; Maximum pressure when
4. A mechanism used in printing machinery consists of a the valve blows off freely = 0.75 N/mm2;
tension spring assembled with a preload of 30 N. The Maximum lift of the valve when the pressure rises
wire diameter of spring is 2 mm with a spring index of from 0.7 to 0.75 N/mm2 = 3.5 mm ; Maximum
6. The spring has 18 active coils. The spring wire is allowable stress = 550 MPa
hard drawn and oil tempered having following Modulus of rigidity = 84 kN/mm2; Spring index =
material properties:Design shear stress = 680 MPa, 6.
Modulus of rigidity = 80 kN/mm2 9. A safety valve of 60 mm diameter is to blow off at
Determine: 1. the initial torsional shear stress in the a pressure of 1.2 N/mm2. It is held on its seat by a
wire; 2. spring rate; and 3. the force to cause the body close coiled helical spring. The maximum lift of
of the spring to its yield strength. the valve is 10 mm. Design a suitable
5. Design a helical compression spring for a maximum compression spring of spring index 5 and
load of 1000 N for a deflection of 25 mm using the providing an initial compression of 35 mm. The
value of spring index as 5. The maximum permissible maximum shear stress in the material of the wire
shear stress for spring wire is 420 MPa and modulus is limited to 500 MPa. The modulus of rigidity for
of rigidity is 84 kN/mm2. the spring material is 80 kN/mm2.
6. Design a close coiled helical compression spring for a Calculate: 1. Diameter of the spring wire, 2. Mean
service load ranging from 2250 N to 2750 N. The coil diameter, 3. Number of active turns, and 4.
axial deflection of the spring for the load range is 6 Pitch of the coil.
mm. Assume a spring index of 5. The 10. Its required to design a helical compression spring
subjected to a maximum force of 1250 N. The
deflection of the spring corresponding to the
maximum force should be approximately 30 mm.
 The spring index can be taken as 6. The spring is modulus of rigidity of 81370 N/mm2. The
made of patented and cold drawn steel. The permissible shear stress in the spring wire should
ultimate tensile strength and modulus of rigidity be taken as 50 % of the ultimate tensile strength
of the spring material are 1090 and 81370 N/mm2 Calculate : Wire diameter, mean coil diameter, no
respectively. The permissible shear stress for the of active coil, spring rate, actual spring rate
spring wire should be taken as 50 % of the 12. A helical compression spring made of oil
ultimate strength. Design the spring and calculate. tempered carbon steel is subjected to a load which
Wire diameter, mean coil diameter, Number of varies from 400 N to 1000 N. The spring index is
active coil, free length of the spring, pitch of the 6 and the design factor of safety is 1.25. If the
coil yield stress in shear is 770 MPa and endurance
11. It’s required to design a helical compression stress in shear is 350 MPa, find: 1. Size of the
spring for the mechanism. The axial force acting spring wire, 2. Diameters of the spring, 3. Number
on the spring is 300 N when the valve is open and of turns of the spring, and 4. free length of the
150 when the valve is closed. The length of the spring.
spring is 30 mm when the valve is open and 35 The compression of the spring at the maximum
mm when the valve is closed. The spring is made load is 30 mm. The modulus of rigidity for the
of oil-hardened and tempered valve spring wire spring material may be taken as 80 kN/mm2.
and the ultimate tensile strength is 1370 N/mm2. 13. A helical compression spring of a cam-
The permissible shear stress for spring wire mechanism is subjected to an initial preload of 50
should be taken as 30% of the ultimate tensile N. The maximum operating force during the load
strength. The modulus of rigidity is 813770 cycle is 150 N. The wire diameter is 3 mm, while
N/mm2.Tyhe spring is fitted over a valve rod the the mean coil diameter is 18 mm. The spring is
minimum inside diameter of the spring should be made of oil-hardened and tempered valve spring
20 mm Calculate: wire of Grade-VW (Sut=1430 N/mm2). Determine
Wire diameter, mean coil diameter, No of active the FOS used in the diagram on the basis of
coil, total no of coil, free length of the spring, fluctuating stresses.
pitch of the coil 14. A closely coiled helical spring is made of 10 mm
(a) A helical tension spring is used in the spring diameter steel wire, the coil consisting of 10
balance to measure the weights. One end of the complete turns with a mean diameter of 120 mm.
spring is attached to the rigid support while the The spring carries an axial pull of
outer end, which is free, carries the weights to be 200 N. Determine the shear stress induced in the
measured. The maximum weight attached to the spring neglecting the effect of stress
spring balance is 1500 N and the length of the concentration. Determine also the deflection in the
scale should be approximately 100 mm. The spring, its stiffness and strain energy stored by it
spring index can be taken as 6. The spring is made if the modulus of rigidity of the material is 80
of oil hardened and tempered steel wire with kN/mm2.
ultimate tensile strength opf 1360 N/mm2 and