JSS MAHAVIDYAPEETHA
JSS ACADEMY OF TECHNICAL EDUCATION,
NOIDA DEPARTMENT OF MECHANICAL
ENGINEERING Subject: MACHINE DESIGN
(KME-602)
B. Tech. Sixth Semester
Assignment I: CO 1
C319.1 Interpret and make use of design requirements, procedures
and standards in design and analyze the mechanical components
subjected to static and fluctuating loads for finite and infinite
life
C319.2 Design of riveted and welded joints for various structures and
Application of the various aspects of shaft design subjected to static
and dynamic loading.
C319.3 Analyze the forces acting on gear tooth and design spur &
helical gear based on beam strength and wear strength as per Indian
standards
C319.4 Select Journal bearing performance characteristic and determine the
heat generated in hydrodynamic journal bearing and also select
rolling contact bearing from the manufacturers catalogue subjected
to constant and varying load
C319.5 Design of Friction Clutches and IC engine parts to meet the required
specifications.
1. What is a static load?
2. Mention the difference between ductile and brittle materials with appropriate
examples.
3. Explain in brief the three basic modes of failure of mechanical components.
4. Why is it necessary to use factor of safety?
5. State and explain the theory of failure.
6. What are the steps involved in design of a machine element?
7. It is required to standardize 11 speeds from 72 to 720 rpm for a machine
tool. Specify the Speeds.
ANSWER:
Speed 1: 72 rpm
Speed 2: 72 + 64.8 = 136.8 rpm
Speed 3: 136.8 + 64.8 = 201.6 rpm
Speed 4: 201.6 + 64.8 = 266.4 rpm
Speed 5: 266.4 + 64.8 = 331.2 rpm
Speed 6: 331.2 + 64.8 = 396 rpm
Speed 7: 396 + 64.8 = 460.8 rpm
Speed 8: 460.8 + 64.8 = 525.6 rpm
Speed 9: 525.6 + 64.8 = 590.4 rpm
Speed 10: 590.4 + 64.8 = 655.2 rpm
Speed 11: 655.2 + 64.8 = 720 rpm
8. An overhang crank with pin and shaft is shown in Fig. tangential load of
15 KN acts on the crank pin. Determine the maximum principal stress and
the maximum shear stress at the center of the crankshaft bearing.
ANSWER: (Maximum principal stress = 9.01 MPa, Maximum shear stress = 5.245 MPa)
9. The stresses induced at a critical point in a machine component made of
steel 45C8 (σyt = 380 N/mm2) are as follows: σx = 100 N/mm2 σy = 40
N/mm2 τxy = 80 N/mm. Calculate the factor of safety by (i) the maximum
normal stress theory, (ii) the maximum shear stress theory, and (iii) the
distortion energy theory.
ANSWER:
Maximum Normal Stress Theory: FOS ≈ 2.44
Maximum Shear Stress Theory: FOS ≈ 2.22
Distortion Energy Theory: FOS ≈ 2.40
10. A bolt is subjected to a tensile load of 25KN and shear load of 10KN.
Determine the diameter of the bolt according to,
(a) Maximum principal stress theory.
(b) Distortion energy theory.
(c) Maximum shear stress theory. Assume factor of safety is 2.5, yield
point stress in simple tension is 300 N/mm2 and poison’s ratio is 0.25.
ANSWER:
Maximum Principal Stress Theory: d ≈ 13.66 mm
Distortion Energy Theory: d ≈ 14.16 mm
Maximum Shear Stress Theory: d ≈ 10.5 mm
11. Explain the following terms in connection with design of machine
members subjected to variable loads: (a) Endurance limit, (c) Size
factor, (b) Surface finish factor, and (d) Notch sensitivity.
12. Explain with an S-N Curve Rotating Beam Fatigue Testing Machine.
13. A round shaft made of a brittle material and subjected to a bending moment
of 15 N-m is shown in Fig. The stress concentration factor at the fillet is
1.5 and the ultimate tensile strength of the shaft material is 200 N/mm2.
Determine the diameter d, the magnitude of stress at the fillet and the factor
of safety
ANSWER:
The diameter of the shaft, d, is approximately = 17.8 mm
The magnitude of the stress at the fillet = 200 N/mm
The factor of safety = 1.0
14. A plate, 10 mm thick, subjected to a tensile load of 20 KN is shown in Fig.
The plate is made of cast iron (σut = 350 N/mm2) and the factor of safety
is 2.5. Determine the fillet radius.
ANSWER: (Fillet Radius = 1mm)
15. What is stress concentration? Mention the methods of reducing stress
concentration.
16. A cantilever beam made of steel Fe 540 (Sut = 540 N/mm2 and Syt = 320
N/mm2) and subjected to a completely reversed load (P) of 5 KN is shown
in Fig. The beam is machined and the reliability is 50%. The factor of
safety is 2 and the notch sensitivity factor is 0.9.
Calculate (i) Endurance limit at the fillet section; and (ii) diameter d of the
beam for infinite life
ANSWER: (Endurance Limit at the fillet section = 103.35 N/mm^2, diameter of the
beam for infinite life, d = 6.26mm)
17. A solid circular shaft made of steel Fe 620 (Sut = 620 N/mm2 and Syt =
380 N/mm2) is subjected to an alternating torsional moment, which varies
from –200 N-m to + 400 N-m. The shaft is ground and the expected
reliability is 90%. Neglecting stress concentration, calculate the shaft
diameter for infinite life. The factor of safety is 2. Use the distortion energy
theory of failure.
ANSWER: (Diameter = 2.52 approx.)
18. A solid circular shaft, 15 mm in diameter, is subjected to torsional shear
stress, which varies from 0 to 35 N/mm2 and at the same time, is subjected
to an axial stress that varies from –15 to +30 N/mm2. The frequency of
variation of these stresses is equal to the shaft speed. The shaft is made of
steel Fe E400 (Sut = 540 N/mm2 and Syt = 400 N/mm2) and the
corrected endurance limit of the shaft is 200 N/mm2. Deter mine the factor
of safety.
ANSWER:
Equivalent Von Mises Stress: Approximately 31.2 N/mm²
Factor of Safety: Approximately 6.41
19. A bar of steel has an ultimate tensile strength of 700 MPa, a yield point
stress of 400 MPa and fully corrected endurance limit (Se) of 220 MPa.
The bar is subjected to a mean bending stress of 60 MPa and a stress
amplitude of 80 MPa. Superimposed on it is a mean torsional stress and
torsional stress amplitude of 70 and 35 MPa respectively. Find the factor of
safety.
ANSWER:
Equivalent Von Mises Stress: Approximately 117 MPa
Factor of Safety: Approximately 1.88
