DOM GTU IMP

3 MARKS
1. What are preferred numbers? How many basic series are used? How will you denote
them?
2. What is factor of safety? Explain various factors affecting the selection of factor of
safety.
3. Answer the following question. 1. What is the difference between failure due to static
load and fatigue failure? 2. What is endurance limit? 3. What is S–N curve?
4. Derive the expression to determine bending stress induced in simply supported beam
carrying uniformly distributed load.
5. What is bolt of uniform strength?
6. How will you determine the diameter of the bolts used in clamp coupling?
7. Derive the expression to determine the beam strength of spur gear.
8. Discuss the different type of rolling element bearings with their specific applications.
9. State different factors affecting the selection of materials.
10. Name the various alloying elements in ‘alloy’ steels.
11. Define stress concentration and endurance limit.
12. What is coupling? Give its classifications.
13. What are the types of keys?
14. A manufacturer is interested in starting a business with five different models of tractors
ranging from 7.5 to 75 kW capacities. Specify power capacities of the models. There is an
expansion plan to further increase the number of models from five to nine to fulfill the
requirement of farmers. Specify the power capacities of the additional models.
15. State the advantages and disadvantages of gear drive over other types of drives.
16. Describe the factors affecting the endurance limit.
17. Explain the standardisation in design of machine components with suitable applications.
18. What are the causes of stress concentration? What are the methods of reducing stress
concentration?
19. State the assumptions used in Euler’s column theory. Explain the limitation of Euler’s
theory
20. Derive the expression to determine bending stress induced in cantilever beam carrying
uniformly distributed load.
21. An electric motor weighing 10 kN is lifted by means of an eye bolt. The eye bolt is
screwed into the frame of the motor. The eye bolt has coarse threads. It is made of plain
carbon steel 30C8 (Syt = 400 N/mm2 ) and the factor of safety is 6. Determine the size of
the bolt.
22. What is bolt of uniform strength?
23. Derive the expression to determine the diameter of hollow shaft based on rigidity.
24. A single-row deep groove ball bearing is subjected to a radial force of 8 kN and a thrust
force of 3 kN. The shaft rotates at 1200 rpm. The expected life L10h of the bearing is
20000 h. The minimum acceptable diameter of the shaft is 75 mm. Determine the
equivalent dynamic load acting on the bearing.

4 MARKS
1. What is Design for Manufacturing? What are the principles of designing cast iron
components? What are the principles for the design of machined components?
2. Discuss the various failure mode of pin of knuckle joint.
3. What do you understand by a column or strut? Explain the various end conditions of a
column or strut. State the assumptions used in Euler’s column theory.
4. Discuss the design steps for pins of bushed pin coupling.
5. Derive the expression to determine the maximum load acting on the bolt of a bracket
having circular base under eccentric loading condition.
6. What do you understand by self-locking screw? Explain the condition for self-locking.
7. What are the different type of failures taking place in gear drives?
8. Define the static and dynamic load carrying capacity of rolling contact bearing.
9. 1. What do you understand by derived series of preferred numbers? Explain with
examples.
2. Explain the importance of ergonomics in design.
10. Discuss the different failure mode of cotter pin of cotter joint.
11. Define static load carrying capacity and dynamic load carrying capacity of ball bearing.
12. Discuss the design steps for clamp coupling.
13. How the shaft is designed when it is subjected to only twisting moment, only bending
moments and both twisting moment and bending moment?
14. Explain the various mode of gear tooth failure.
15. A T-section 150 mm × 120 mm × 20 mm is used as a strut of 4 m long hinged at both
ends. Calculate the crippling load, if Young’s modulus for the material of the section is
200 kN/mm2
16. Following data is given for a steel spur gear transmitting 7.5 kW power running at 1440
rpm to a machine running at 480 rpm. Approximate center distance = 240 mm,
Allowable bending stress for pinion and gear are 200 MPa and 160MPa respectively.
Surface hardness is 450 BHN. Tooth system is 20⁰ full depths involutes. Suggest size of
the pinion and gear for this application.
17. A machine component is subjected to a flexural stress which fluctuates between +300
MN/m2 and –150 MN/m2 . Determine the value of minimum ultimate strength
 according to 1. Gerber relation; and 2. Modified Goodman relation. Take, yield strength
= 0.55*Ultimate strength; Endurance strength = 0.5*Ultimate strength; and factor of
safety = 2.
18. A column of uniform cross section is shown in Figure. If the permissible tensile stress for
the column material is 70 MPa, determine the width ‘t’ of the column.
19. The maximum load on a petrol engine push rod 300 mm long is 1400 N. It is hollow
having the outer diameter 1.25 times the inner diameter. Spherical seated bearings are
used for the push rod. The modulus of elasticity for the material of the push rod is 210
kN/mm2 . Find a suitable size for the push rod, taking a factor of safety of 2.5.
20. A foot lever is 1 m from the centre of shaft to the point of application of 800 N load.
Find: 1. Diameter of the shaft, 2. Dimensions of the key, and 3. Dimensions of
rectangular arm of the foot lever at 60 mm from the centre of shaft assuming width of
the arm as 3 times thickness. The allowable tensile stress may be taken as 73 MPa and
allowable shear stress as 70 MPa.
21. A cast iron pulley transmits 20 kW at 300 r.p.m. The diameter of pulley is 550 mm and
has four straight arms of elliptical cross-section in which the major axis is twice the
minor axis. Find the dimensions of the arm if the allowable bending stress is 15 MPa.
Mention the plane in which the major axis of the arm should lie
22. A 25 × 50 mm bar of rectangular cross-section is made of plain carbon steel 40C8 (Syt =
380 N/mm2 and E = 207 000 N/mm2 ). The length of the bar is 500 mm. The two ends of
the bar are hinged and the factor of safety is 2.5. The bar is subjected to axial
compressive force.
1. Determine the slenderness ratio.
2. Which of the two equations—Euler’s or Johnson’s—will you apply to the bar?
23. It is required to design the screw of a screw-jack by buckling consideration. One end of
the screw is fixed in the nut and the other end supports a load of 20 kN. The length of
the screw between the fixed and free ends is 500 mm, when the load is completely
raised. The screw is made of steel 40C8 (Syt = 380 N/mm2 and E = 207 000 N/mm2 ).
Assuming a factor of safety of 2.5, determine the core diameter of the screw
24. Select a suitable ball bearing for above application (Q:23)
25. A column of uniform cross section is shown in Figure. If the permissible tensile stress for
the column material is 70 MPa, determine the width ‘t’ of the column.

7 MARKS
1. What is advantage of using the theories of elastic failures? What are the important
theories of elastic failures? State and discuss any two theories of elastic failures.
2. Demonstrate the various steps to design the socket and spigot cotter joint.
3. Demonstrate the various steps to determine the dimensions of cranked lever.
4. 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 the material are 600 N/mm2
and 450 N/mm2 respectively. Find the factor of safety using 1. Gerber theory 2.
Soderberg line 3. Goodman line Also, find the factor of safety against static failure.
5. A cantilever beam made of cold drawn steel 4OC8 (Sut = 600 N/mm2 and Syt = 380
N/mm2 ) is shown in following 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 safety is 2. The notch
sensitivity factor at the fillet is 0.9. Determine the diameter ‘d’ of the beam at the fillet
crosssection. Take Ka = 0.77, Kb = 0.85, Kc = 0.897, Kt = 1.44.
6. It is required to design a screw jack for supporting the machine parts during their repair
and maintenance on the shop floor. It should be a general-purpose jack with a load
carrying capacity of ‘P’ kN and a maximum lifting height of ‘h’ m. The jack is to be
manually operated.
7. A line shaft is driven by means of a motor placed vertically below it. The pulley on the
line shaft is 1.5 metre in diameter and has belt tensions 5.4 kN and 1.8 kN on the tight
side and slack side of the belt respectively. Both these tensions may be assumed to be
vertical. If the pulley be overhang from the shaft, the distance of the centre line of the
pulley from the centre line of the bearing being 400 mm, find the diameter of the shaft.
Assuming maximum allowable shear stress of 42 MPa
8. A 60 mm diameter shaft of a machine operates continuously for 8 hrs daily. The shaft
bearing will be subjected to a varying load and speed cycle as per the following table The
shock factors for ball bearing are Steady load = 1, Light shock = 1.5. Bearing number
6412, C0 = 69500 N, C = 83000 N. Determine life of bearing.

9. Design gear pair for above application (imp)

10. A rotating shaft of 16 mm diameter is made of plain carbon steel (fyt = 400 N/mm2 ). It
is subjected an axil tensile load of 5000 N, a steady torque of 50 Nm and maximum
bending moment of 75 Nm. Calculate the factor of safety available based on: (i)
Maximum normal stress theory; and (ii) Maximum shear stress theory If the factor of
safety is 1.686, find the required yield strength of the material using distortion energy
theory of failure. Assume remaining data same.
11. Explain the procedure for the design of a socket and spigot cotter joint with sketch.
12. The layout of a transmission shaft carrying two pulleys B and C and supported on
bearings A and D is shown in Figure. Power is supplied to the shaft by means of a vertical
belt on the pulley B, which is then transmitted to the pulley C carrying a horizontal belt.
The maximum tension in the belt on the pulley B is 2.5 kN. The angle of wrap for both
the pulleys is 180° and the coefficient of friction is 0.24. The shaft is made of plain 07 2
carbon steel 30C8 (Syt = 400 N/mm2) and the factor of safety is 3. Determine the shaft
diameter on strength basis.

13. A bell crank lever is to be designed to raise a load of 5 kN at the short arm end. The arm
lengths are 150 mm and 500 mm. The permissible stresses for lever and pin materials in
shear and tension are 60 N/mm2 and 90 N/mm2 respectively. The bearing pressure on
the pin is to be limited to 12 N/mm2 . Assume the lever cross section as t*4t.
14. The C-frame of a 100 kN capacity press is shown in Figure. The material of the frame is
grey cast iron FG200 and the factor ofsafety is 3. Determine the dimensions of the
frame.

15. For supporting the travelling crane in a workshop, the brackets are fixed on steel
columns as shown in Figure. The maximum load that comes on the bracket is 12 kN
acting vertically at a distance of 400 mm from the face of the column. The vertical face
of the bracket is secured to a column by four bolts, in two rows (two in each row) at a
 distance of 50 mm from the lower edge of the bracket. Determine the size of the bolts if
the permissible value of the tensile stress for the bolt material is 84 MPa. Also find the
crosssection of the arm of the bracket which is rectangular

16. In a machine tool application, the tool holder is pulled by means of an operating nut mounted on
a screw. The tool holder travels at a speed of 5 m/min. The screw has singlestartsquare threads
of 48 mm nominal diameter and 8 mm pitch. The operating nut exerts a force of 500 N to drive
the tool holder. The mean radius of the friction collar is 40 mm. The coefficient of friction at
thread and collar surfaces is 0.15. Calculate (i) power required to drive the screw; and (ii) the
efficiency of the mechanism.
17. A single row deep grove ball bearing is subjected to following work cycle:

If the dynamic capacity of bearing is 108 KN. Calculate i. The rotating life of bearing in hours ii.
The average speed of operation iii. The life of bearing in hours if reliability required is 95 %
18. Following data is given for a steel spur gear transmitting 7.5 kW power running at 1440 rpm to a
machine running at 480 rpm. Approximate centre distance = 240 mm, Allowable bending stress
for pinion and gear are 200MPa and 160 MPa respectively. Surface hardness is 450 BHN. Tooth
system is 20⁰ full depths involutes. Design a spur gear drive for above application. Take, C =
11860 *e and e = 0.064
19. What is advantage of using the theories of elastic failures? What are the important theories of
elastic failures? State and discuss theories of elastic failures used for design of machine
components made of ductile material 07 ductile material.
20. Demonstrate the various steps to design the knuckle joint.
21. Demonstrate the various steps to determine the dimensions of hand lever.
22. A cantilever beam made of cold drawn carbon steel of circular cross-section as shown in
following figure, 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
23. Explain design procedure for a machine component subjected to complete reversed loading and
subjected to fluctuate loading.
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.
25. Discuss the design of the bolts when 1. Eccentric load acting parallel to the axis of bolts 2.
Eccentric load acting perpendicular to the axis of bolts
26. Explain the procedure of bearing selection from manufacturer catalogue.