Question Bank - DME

Question Bank for End – Sem Examination
Design of Machine Elements

1 What is stress concentration? What are the causes of stress concentration? With neat sketches,
explain the methods of reduction of stress concentration.
2 What is modifying factor to account for stress concentration? Explain Endurance strength
Modifying factors?
3 Explain with neat sketch the Gerber curve, Soderberg and Godman lines?
4 Write a short note on Cumulative damage.
5 Explain modified Goodman diagram. Draw neat labeled sketches of modified Goodman
diagram for axial & Bending stresses.
6 Explain 1) Stress Concentration 2) Notch Sensitivity 3) Fatigue life 4) Endurance limit. 5)
Modified Goodman diagram
7 Explain modified Goodman diagram. Draw neat labeled sketches of modified Goodman
diagram for axial & Bending stresses.
8 Explain Fatigue Design under Combined Stresses
9 A rotating bar made of steel 45C8(Sut = 630 MPa) is subjected to a completely reversed
bending stress. The corrected endurance limit of the bar is 315 N/mm 2. Calculate the fatigue
strength of the bar for a life of 90,000 cycles.
10 A forged steel bar, 50 mm in diameter, is subjected to a reversed bending stress of 250
N/mm2. The bar is made of steel 40C8 (Sut= 600 N/mm2). Calculate the life of the bar for a
reliability of 90%. Take Ka = 0.44, Kb = 0.85, Kc = 0.897
11 A machine component is subjected to fluctuating stress that varies from 40 to 100N/mm2. The
corrected endurance limit stress for the machine component is 270 N/mm 2. The ultimate
tensile strength and yield strength of the material are 600 and 450 N/mm2 respectively. Find
the factor of safety using
(i) Gerber theory (ii) Soderberg line (iii) Goodman line
Also, find the factor of safety against static failure.
12 A cantilever beam of circular cross-section is made of alloy steel with Sut = 1500 N/mm2,is
fixed at one end and subjected to a completely force of 100 N at free end perpendicular to
axial and at distance 400 mm from fixed end. Take Ka = 0.79, Kb = 0.85, Kc = 0.868.
Temperature factor = 0.975 desired life of beam is 50000 cycles, Take factor of safety 1.5,
Theoretical stress concentration factor 1.33 and notch sensitivity factor 0.85. Find diameter of
shaft.
13 A cantilever beam of circular cross section made of steel Fe 550 (Sut= 550 N/mm2is fixed at
one end andsubjected to a completely reversed load (P)of 15 kN is at the free end. He force P
is perpendicular to the axis of beam. The distance between force to fixed end is 200 mm.
Take Kt = 1.35,q = 0.85s,Ka = 0.8,Kc = 0.897,Kb are as follows Thefactor of safety is 2
Calculate the diameter d of the beam for infinite life.
d (mm) Kb
d≤ 7.5 1.0
7.5< d ≤ 50 0.85
d> 50 0.75
14 A cantilever beam made of cold drawn steel 4OC8 (Sut = 600 N/mm2 and Syt = 380N/mm2)
is shown in Figure The force P acting at the free end varies from –50 N to +150 N. The
expected reliability is 90% and the factor of safetyis 2. The notch sensitivity factor at the fillet
is 0.9. Determine the diameter ‘d’ of the beam at the fillet cross-section.
Take Ka = 0.77,K = 0.85, Kc = 0.897K = 1.44
15 A cantilever beam made of steel material with Sut=550 N/mm 2,Syt=320 N/mm2 as shown in
figure is subjected to load which varies from –F to 3F Take Ka = 0.89,K = 0.85, Kt = 1.42
q=0.9, fos=2. Determine maximum value of F which the cantilever beam can withstand for
infinite life.
16 Derive expression for torque required to raise the loads in case of square threads
17 Derive expression for torque required to lower the loads in case of square threads
18 Explain self-locking and over-hauling property of screw. Prove the condition for screw to be
self-locking.
19 Derive and expression for maximum efficiency of square threads
20 What are the advantages of trapezoidal threads over square threads? State the meaning of
each term involved in designation Tr40×14(p7).
21 Explain with neat sketch, differential screw and Compound screw
22 Explain with neat sketch, re-circulating ball screw. State its application
23 The lead screw of a lathe has Acme threads of 50 mm outside diameter and 8 mm pitch. The
screw must exert an axial pressure of 2500 N in order to drive the tool carriage. The thrust is
carried on a collar 110 mm outside diameter and 55 mm inside diameter and the lead screw
rotates at 30 r.p.m. Determine (a) the power required to drive the screw; and (b) the efficiency
of the lead screw. Assume a coefficient of friction of 0.15 for the screw and 0.12 for the
collar.
24 A power screw having double start square threads of 25 mm nominal diameter and 5 mm
pitch is acted upon by an axial load of 10 kN. The outer and inner diameters of screw collar
are 50 mm and 20 mm respectively. The coefficient of thread friction and collar friction may
be assumed as 0.2 and 0.15 respectively. The screw rotates at 12 r.p.m. Assuming uniform
wear condition at the collar and allowable thread bearing pressure of 5.8 N/mm2, find: 1. the
torque required to rotate the screw; 2. the stress in the screw; and 3. the number of threads of
nut in engagement with screw. Also state the condition of screw
25 A C-clamp, as shown in Figure, has trapezoidal threads of 12 mm outside diameter and 2 mm
pitch. The coefficient of friction for screw threads is 0.12 and for the collar is 0.25. The mean
radius of the collar is 6 mm. If the force exerted by the operator at the end of the handle is 80
N, find: 1) The length of handle; 2) The maximum shear stress in the body of the screw and
where does this exist; and 3) The bearing pressure on the threads.
(08)
26 A vertical two start square threaded screw of 100 mm mean diameter and 20 mm pitch
supports a vertical load of 18 kN. The nut of the screw is fitted in the hub of a gear wheel
having 80 teeth which meshes with a pinion of 20 teeth. The mechanical efficiency of the
pinion and gear wheel drive is 90 percent. The axial thru
thrust
st on the screw is taken by a collar
bearing 250 mm outside diameter and 100 mm inside diameter. Assuming uniform pressure
conditions, find, minimum diameter of pinion shaft and height of nut, when coefficient of
friction for the vertical screw and nut is 0.15 and that for the collar bearing is 0.20. The
permissible shear stress in the shaft material is 56 MPa and allowable bearing pressure is 1.4
N/mm2.
27 Write a note on: Bolts of uniform strength
28 Discuss the advantages and disadvantages of welded joints
29 Explain the procedure for the design of bolts for eccentrically loaded bolted joints in shear.
30 Discuss in brief strength of parallel fillet welds
31 Derive equations for strength of 1) Single transverse fillet weld 2) Double parallel fillet weld
32 Discuss the procedure for designing Axially Loaded Unsymmetrical Welded Sections
33 What are the assumptions made in the design of welded joint?
34 Prove that stress on the throat is equal to the ratio of force on weld to 0.707×s×l
35 The structural connection shown in Figure is subjected to an eccentric force P of 10 kN with
an eccentricity of 500 mm from the CG of the bolts. The centre distance between bolts 1 and
2 is 200 mm,, and the centre distance between bolts 1 and 3 is 150 mm.. All the bolts are
identical. The bolts are made from plain carbon steel 30C8 (Syt = 400 N/mm2) and the factor
of safety is 2.5.. Determine nominal diameter of the bolts.
36 A bracket, subjected to a force of 5 kN inclined at an angle of 600 with the vertical, is shown
in Figure. The bracket is fastened by means of four identical bolts to the structure. The bolts
are made of plain carbon steel 30C8 (Syt = 400 N/mm2) and the factor of safety is 5 based on
maximum shear stress. Assume maximum sshear hear stress theory and determine the size of the
bolts.
37 A bracket shown in figure is fixed to steel column by means of four bolts of size M14. A load
of W acts on the bracket. Take σ = 84 MPa. If ratio B/t for cross section of the arm bracket
is 45. Determine 1) Maximum load on bracket, 2) Cross section of bolts.
38 A steel plate subjected to a force of 5 kN and fixed to a channel by means of three identical
Syt = 380 N/mm2)
bolts is shown in Figure. The bolts are made from plain carbon steel 45C8 (S
and the factor of safety is 3.. Specify the size of bolts.
39 An ISA 200 × 100 × 10 angle is welded to a steel plate by means of fillet welds as shown in
Figure. The angle is subjected to a static force of 150 kN and the permissible shear stress for
the weld is 70 N/mm2. Determine the lengths of weld at the top and bottom.
(08)
40 Figure shows a welded joint subjected to a load of 20 kN. Find size of weld if permissible
shear stress 80 MPa. (10)
41 A rectangular steel plate is welded as a cantilever to a vertical column and supports a single
concentrated load 40 kN,, as shown in Figure. Determine the Maximum shear stress if size of
weld is 11.62 mm.
42 Explain the following terms for helical spring

1) Active and inactive coils
2) Spring index
3) Spring rate
43 Explain with the neat sketch, nipping of leaf spring
44 What is mean by spring surge and what is its effect
45 Explain shot peening
46 Derive the expression for the shear stress induced in a helical compression springs.
47 Explain A.M. Wahl’s factor and state its importance in the design of helical springs.
48 A helical spring is made from a wire of 6 mm diameter and has outside diameter of 75 mm. If
the permissible shear stress is 350 MPa and modulus of rigidity 84 kN/mm2,
kN/mm find the axial
load which the spring can carry and the deflection per active turn.
49 Design a close coiled helical compression spring for a service load ranging from 2250 N to
2750 N.. The axial deflection of the spring for the load range is 6 mm. Assume
me a spring index
of 5.. The permissible shear stress intensity is 420 MPa and modulus of rigidity, G = 84
kN/mm2. Neglect the effect of stress concentration. Draw a fully dimensioned sketch of the
spring, showing details of the finish of the end coils.
50 Design a helical compression spring for a pressure relief valve using following data;
Operating pressure = 14.5 Bar; Valve lift at 18% pressure rise = 7 mm; Diameter of valve =
37 mm; Limiting mean coil diameter = 36 mm; Maximum shear stress = 465 MPa; G = 85
GPa, Clash clearance = 15 % of Maximum deflection of spring, End style of spring is square
and ground std. Take spring wire diameter 6, 6.5, 7, 7.5, 8, 8.5 (mm)
51 Design a helical compression spring with following data; Maximum load = 4460 N; Mean
coil
oil diameter = 85 mm; Maximum shear stress 265 N/mm2; Spring stiffnes = 67 kN/m; G=
81.5 kN/mm2; std wire diameter: - 14.5, 15, 15.5, 16, 16.5, 17 (mm).
52 A safety valve of 60 mm diameter is to blow off at a pressure of 1.2 N/mm2. It is held on its
seat by a close coiled helical spring. The maximum lift of the valve is 10 mm. Design a
suitable compression spring of spring index 5 and providing an initial compression of 35 mm.
The maximum shear stress in the material of the wire is limited to 500 MPa. The modulus of
rigidity for the spring material is 80 kN/mm2. Calculate: 1) Diameter of the spring wire, 2)
Mean coil diameter, 3) Number of active turns, and 4) Pitch of the coil.
53 A mechanism used in printing machinery consists of a tension spring assembled with a
preload of 30 N. The wire diameter of spring is 2 mm with a spring index of 6. The spring has
18 active coils. The spring wire is hard drawn and oil tempered having following material
properties: Design shear stress = 680 MPa; Modulus of rigidity = 80 kN/mm2 Determine: 1)
the initial torsional shear stress in the wire; 2) Spring rate; and 3) The force to cause the body
of the spring to its yield strength.

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Question Bank for End – Sem Examination

Design of Machine Elements

42 Explain the following terms for helical spring

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