राष्ट्रीय प्रौद्योगिकी संस्थान, जमशेदपरु

National Institute of Technology, Jamshedpur

Sample Question Paper

1. The fig 1 is a schematic drawing of countershaft that supports two V-belt pulleys. The belt tension on the
loose side of pulley A is 15% of the tension on tight side. Assuming that the belt pulls are parallel, find the
shaft diameter for shear yield stress of 150 MPa for the shaft material.

Figure 1

2. A motor running at 1440 rpm drives a pump at 800 rpm through a flat drive. The centre distance between the
pulleys is 200 mm and the motor transmits a power of 15 kW. The density of the belt material is 980 kg/m3
and the maximum belt stress is 1.85 MPa. The co-efficient of friction between the belt and the pulley is 0.4.
Determine the belt width and the required belt length. Assume that the pulley diameter (in mm) follows R20
series to the nearest multiple of 10; the belt thickness follows R10 series but do not exceed 6.5 mm. The
service factor and the speed factor are 1.4 and 1.0 respectively. The other factor(s), if any, should be as per
standard norms.
3. A helical compression spring, placed between two rigid plates and operative under variable load, has a spring
index of 7 and wire diameter of 5 mm, if the average load on the spring is 300 N, compute the permissible
maximum and minimum loads on the springs for a factor of safety 1.5. When the range of operative load on
the spring is 10% less than the permissible maximum load to 10% more than the permissible minimum load,
 राष्ट्रीय प्रौद्योगिकी संस्थान, जमशेदपरु
National Institute of Technology, Jamshedpur
Jharkhand, India-831014
An Institute of National Importance under MHRD, Government of India
Department of Mechanical Engineering

the spring deflection is 8 mm. Determine the safe frequency of operation for the spring. For the spring material

the σYP = 1690 MPa, density ρ = 7800 kg/m3 and G=80 GPa.

4. Find the maximum stress induced in the following case taking stress concentration into account: A stepped
shaft shown in Fig. and carrying a tensile load of 12 kN, bending load of 25 kN-m, and torque of 20 kN-m.
Geometric data are D=50mm, d=25 mm, r=5 mm.

5. A shaft is subjected to bending moment varying from -200 N-m to +500 N-m and a varying torque from 50
N-m to 175 N-m. If material of the shaft is 30C8, stress concentration factor is 1.85, notch sensitivity is 0.95,
surface finish factor is 0.89, size factor is 0.85, reliability factor is 0.75, and factor of safety is 1.5, find the
diameter of the shaft using Soderberg and modified Goodman criterion.Endurance limit is 50% of ultimate

tensile strength. Material property : σut = 490 MPa, σyt = 270 MPa.

6. A rotating steel bar is subjected to a completely reversed bending stress of 350 MPa. The yield strength,
ultimate strength and endurance strength of the bar material may be taken as 450 MPa, 600 MPa, and 315
MPa respectively. Estimate the life of the bar. Note: consider 90% of the ultimate strength at N= 10 3 and
100% of endurance strength at N= 106 to construct the constant slope S-N diagram. Use log10 scale to
demonstrate the S-N diagram.
7. 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 350MPa and modulus of rigidity 84 GPa. Find the axial load that the spring can carry and the
deflection per active turn, by considering the effect of curvature.
8. A helical spring of wire diameter 6mm and spring index 6 is acted by an initial load of 800 N. After
compressing it further by 10mm, the stress in the wire is 500 MPa. Find the number of active coils. G= 84
GPa. (Consider Wahl factor).
9. A helical spring is made of hard drawn spring steel (G=84 GPa) wire 2 mm in diameter and has an outside
diameter of 22 mm. The ends are plain and ground, and there are 8½ total coils (Ssy=703.4 MPa)
 राष्ट्रीय प्रौद्योगिकी संस्थान, जमशेदपरु
National Institute of Technology, Jamshedpur
Jharkhand, India-831014
An Institute of National Importance under MHRD, Government of India
Department of Mechanical Engineering

a. The spring is wound to a free length which is the largest possible with a solid-safe property (Take factor
of safety 1.2), Find its free length
b. What is the pitch of this spring?
c. What force is needed to compress this spring to its solid length?
d. Estimate the spring rate.
10. A closely coiled helical spring connected to a cam-follower mechanism is subjected to the maximum and
minimum load of 350N and 100 N, respectively; and an axial displacement of 20 mm during operation. Take
permissible shear stress as 450 MPa and shear modulus 84 GPa for the spring material. Determine the size of
the spring with 21 active coils.

11. A solid circular rod is cantilevered at one end. The rod is 0.6 m long and supports a completely reversing
transverse load ±2kN. If the rod must support this load for 104 cycles with a design factor of 1.5. Determine
the diameter of the shaft.
Neglect any stress concentration at support end. (Ultimate strength Sut=770 MPa (112 kpsi), Yield strength
Sy=420 MPa, Surface factor, ka=0.49, Size modification factor, kb=0.85, Fatigue strength, Sf = bNa, where N
is the number of cycle, use graph to find ‘f’) Ans: 35 mm

12. A rotating shaft shown in Figure is machined from AISI CD steel it is subjected to a force F=6 kN. Find the
minimum factor of safety for fatigue based on infinite life. Diameter of the shaft is 35 mm. (Sut=470 MPa,
ka=0.88, kb=0.85) Ans: 1.08
 राष्ट्रीय प्रौद्योगिकी संस्थान, जमशेदपरु
National Institute of Technology, Jamshedpur
Jharkhand, India-831014
An Institute of National Importance under MHRD, Government of India
Department of Mechanical Engineering

13. The shaft shown in the figure is machined from AISI 1040 CD steel. The shaft rotates at 1600 rpm and is
supported in rolling bearings at A and B. The applied forces are F1 = 2500 lbf and F2 = 1000 lbf. Determine
the minimum fatigue factor of safety based on achieving infinite life. If infinite life is not predicted, estimate
the number of cycles to failure. Also check for yielding.

14. Design a cantilever bracket to support a fluctuating bending load of 100 to 1100 N amplitude for 10 9 cycles
with no failure. Operating temperature is 250 oC.
 राष्ट्रीय प्रौद्योगिकी संस्थान, जमशेदपरु
National Institute of Technology, Jamshedpur
Jharkhand, India-831014
An Institute of National Importance under MHRD, Government of India
Department of Mechanical Engineering

b=
(f Sut )
2
1 f Sut
a = − log
Se 3 Se

15. Derive the expression for length of belt in open belt drive.
16. Design a typical rigid flange coupling for connecting a motor and a centrifugal pump shafts. The coupling
needs to transmit 15 KW at 1000 rpm. The allowable shear stresses of the shaft, key and bolt materials are 60
MPa, 50 MPa and 25 MPa respectively. The shear modulus of the shaft material may be taken as 84GPa.
17. Two mild steel rods are connected by a knuckle joint to transmit an axial force of 100 kN as shown in figure-
2. Design the joint completely assuming the working stresses for both the pin and rod materials to be 100 MPa
in tension, 65 MPa in shear and 150 MPa in crushing.
18. Design a typical cotter joint to transmit a load of 50 kN in tension or compression. Consider that the rod,
socket and cotter are all made of a material with the following allowable stresses: Allowable tensile stress
(σy)= 150 MPa, Allowable crushing stress (σc) = 110 MPa, Allowable shear stress (τy) = 110 MPa.
19. Design a typical rigid flange coupling for connecting a motor and a centrifugal pump shafts. The coupling
needs to transmit 15 KW at 1000 rpm. The allowable shear stresses of the shaft, key and bolt materials are 60
 राष्ट्रीय प्रौद्योगिकी संस्थान, जमशेदपरु
National Institute of Technology, Jamshedpur
Jharkhand, India-831014
An Institute of National Importance under MHRD, Government of India
Department of Mechanical Engineering

MPa, 50 MPa and 25 MPa respectively. The shear modulus of the shaft material may be taken as 84GPa. The
angle of twist of the shaft should be limited to 1 degree in 20 times the shaft diameter.
20. A steel helical compression spring is made from wire 4 mm in diameter and is to carry a load of 450 N at a
deflection of 25 mm. Maximum shearing stress is to be 550 MPa and the number of inactive end coils equals
to 2. Find the required values for the mean radius, the number of active coil and the volume of spring material.
21. Suppose a steel alloy spring with G= 77,000 MPa must be capable of exerting a force (P1) of 135 N in its most
extended condition. After being compressed an additional amount of 9.4 mm, the torsional shearing stress
must not exceed the value of 500 MPa. Space limitation indicates that the mean helix radius should be about
10 mm. (a) Find the wire diameter, number of active of coils, and the volume of the material for the optimum
spring. (b) Suppose the designer arbitrarily decides to make the spring of NO. 9 wire (wire diameter=3.767
mm). Find the volume of material contained in the active coils and compare it with the volume of part (a).
Retain the value of R of 10 mm.
22. A spring is known to be made from music wire, ASTM A228 steel, but no other data are known. You are able
to measure the following features using simple measurement tools: Free length = Lj = 1.75 in, Outside
diameter = OD = 0.561 in, Wire diameter = D,, = 0.055 in, The ends are squared and ground. The total number
of coils is 10.0. This spring will be used in an application where the normal operating load is to be 14.0 lb.
Approximately 300 000 cycles of loading are expected. For this spring, compute and/or do the following:
i. The music wire gage number, mean diameter, inside diameter, spring index, andWahl factor.
ii. The expected stress at the operating load of 14.0 lb.
iii. The deflection ofthe spring under the 14.0-lb load.
iv. The operating length, solid length, and spring rate.
v. The force on the spring when it is at its solid length and the corresponding stress at solid length.
vi. The design stress for the material; then compare it with the actual operating stress.
vii. The maximum permissible stress; then compare it with the stress at solid length.
viii. Check the spring for buckling and coil clearance.
ix. Specify a suitable diameter for a hole in which to install the spring.
23. Design a V-bclt drive that has the input sheave on the shaft of an electric motor (normal torque) rated at 50.0
hp at 1160-rpm, full-load speed. The drive is to a bucket elevator in a potash plant that is to be used 12 hours
(h) daily at approximately 675 rpm.
 राष्ट्रीय प्रौद्योगिकी संस्थान, जमशेदपरु
National Institute of Technology, Jamshedpur
Jharkhand, India-831014
An Institute of National Importance under MHRD, Government of India
Department of Mechanical Engineering

24. Design the shaft shown in Figures. It is to be machined from AISI 1144 OQT 1000 steel. The shaft is part of
the drive for a large blower system supplying air to a furnace. Gear A receives 200 hp from gear P. Gear C
delivers the power to gear Q. The shaft rotates at 600 rpm.