1

DIRECTORATE OF TECHNICAL EDUCATION, CHENNAI

BOARD EXAMINATIONS – APRIL 2018
ANSWER KEY
COURSE : MECHANICAL ENGINEERING MAXIMUM MARKS : 75
SUBJECT : DESIGN OF MACHINE ELEMENTS QUESTION PAPER CODE : 807
[M-SCHEME].

(Each question carries 15 marks) (5 x 15 = 75)

I. (A) (i) What are the factors to be considered for the selection of materials for the
design of machine elements. [5 Marks]
Solution:
1. Availability of material
2. Cost of material
3. Physical properties (colour, size and shape)
4. Mechanical properties (strength, stiffness etc.,)
5. Manufacturing process adopted(machining, casting, rolling, forging etc.,) --- 5 Marks

************

(ii) Design a knuckle joint to take a load of 𝟏𝟒𝟎𝒌𝑵 for the following permissible
stresses: 𝟕𝟓𝑴𝑷𝒂 in tension, 𝟏𝟒𝟎 𝑴𝑷𝒂 in compression and 𝟔𝟓 𝑴𝑷𝒂 in shear.
[10 Marks]

Given Data:
 Load, 𝑃 = 140 𝑘𝑁 = 140 𝑋 103 𝑁
 [𝜎𝑡 ] Permissible Tensile Stress = 75 𝑀𝑃𝑎 = 75 𝑁/𝑚𝑚2
 [𝜎𝑐 ] Permissible Compressive Stress = 140 𝑀𝑃𝑎 = 140 𝑁/𝑚𝑚2
 [𝜏] Permissible Shear Stress = 65 𝑁/𝑚𝑚2

Procedure and Formula: --- 3 Marks

Arriving Solution: --- 7 Marks
Solution:

1. To find diameter of Rod [𝑑] --- 3 Marks

𝐿𝑜𝑎𝑑
Tensile stress on Rod, 𝜎𝑡 = 𝐴𝑟𝑒𝑎
𝑃
[𝜎𝑡 ] = 𝜋
𝑋 𝑑2
4

4𝑃 4 𝑋 140 𝑋 103
𝑑 = √𝜋[𝜎 ] = √
𝑡 𝜋 𝑋 [75]

𝑑 = 48.7516 𝑚𝑚
For standard value, take 𝑑 = 50 𝑚𝑚

2. Outer Dimensions: --- 3 Marks

 Diameter of pin, 𝑑1 = 𝑑 = 50 𝑚𝑚
 Outer eye diameter, 𝑑2 = 2𝑑 = 2 𝑋 50 = 100 𝑚𝑚
 Diameter of knuckle pin head and collar, 𝑑3 = 1.5𝑑 = 1.5 𝑋 50 = 75𝑚𝑚
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 Thickness of single eye or rod end, 𝑡 = 1.25𝑑 = 1.25 𝑋 50 = 62.5 𝑚𝑚

 Thickness of fork, 𝑡1 = 0.75𝑑 = 0.75 𝑋 50 = 37.5 𝑚𝑚
 Thickness of pin head, 𝑡2 = 0.5𝑑 = 0.5 𝑋 50 = 25 𝑚𝑚

Check for stresses:

3. Knuckle pin: --- 2 Marks

𝑃
Induced shear stress, 𝜏 = 𝜋
2𝑋 𝑋 𝑑1 2
4

140 𝑋 103
𝜏= 𝜋 = 35.65 𝑁/𝑚𝑚2
2𝑋 𝑋 502
4
𝜏 = 35.65 𝑁/𝑚𝑚2 , [𝜏] = 65 𝑁/𝑚𝑚2
𝜏 < [𝜏], Hence pin size is safe.

4. Stress on single eye (or) Rod end: --- 1 Mark

𝑃 140 𝑋 103
Induced tensile stress, 𝜎𝑡 = (𝑑 = (100−50)𝑋 62.5
2 −𝑑1 )𝑋 𝑡
𝜎𝑡 = 44.8 𝑁/𝑚𝑚2
[𝜎𝑡 ] = 75 𝑁/𝑚𝑚2
𝜎𝑡 < [𝜎𝑡 ], Rod end size is safe.

5. Shear failure of single eye (or) Rod end:

𝑃 140 𝑋 103
Induced shear stress, 𝜏 = (𝑑 )𝑋 𝑡
= (100−50)𝑋 62.5
2 −𝑑1
𝜏 = 44.8 𝑁/𝑚𝑚2
[𝜏] = 65 𝑁/𝑚𝑚2
𝜏 < [𝜏], Design is safe.

6. Crushing failure of single eye (or) Rod end:

𝑃 140 𝑋 103
Induced crushing stress, 𝜎𝑐 = =
𝑑1 𝑋𝑡 50 𝑋 62.5
𝜎𝑐 = 44.8 𝑁/𝑚𝑚2
[𝜎𝑐 ] = 140 𝑁/𝑚𝑚2
𝜎𝑐 < [𝜎𝑐 ], Design is safe.

Forked End: --- 1 Mark

7. Tension failure of forked end:

𝑃 140 𝑋 103
Induced tensile stress, 𝜎𝑡 = (𝑑 = (100−50)𝑋 37.5 𝑋 2
2 −𝑑 1 )𝑋 𝑡1 𝑋 2
2
𝜎𝑡 = 37.33 𝑁/𝑚𝑚
[𝜎𝑡 ] = 75 𝑁/𝑚𝑚2
𝜎𝑡 < [𝜎𝑡 ], Design is safe.
8. Shear failure of forked end:
𝑃 140 𝑋 103
Induced tensile stress (double shear), 𝜏 = (𝑑 = (100−50)𝑋 37.5 𝑋 2
2 −𝑑1 )𝑋 𝑡1 𝑋 2
𝜏 = 37.33 𝑁/𝑚𝑚2
[ 𝜏] = 75 𝑁/𝑚𝑚2
𝜏 < [𝜏], Design is safe.
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9. Crushing failure of forked end:

𝑃 140 𝑋 103
Induced crushing stress, 𝜎𝑐 = = 50 𝑋 37.5 𝑋 2
𝑑1 𝑋 𝑡1 𝑋2
2
𝜎𝑐 = 37.33 𝑁/𝑚𝑚
[𝜎𝑐 ] = 140 𝑁/𝑚𝑚2
𝜎𝑐 < [𝜎𝑐 ], Design is safe.

************
(B) (i) Explain preferred numbers with an example. [5 Marks]
Solution:

Explanation: --- 3 Marks

Example: --- 2 Marks
1. Preferred Numbers are useful to specify the sizes of the Engineering products.
2. They are conventionally rounded off values derived from geometric series from integral
powers of 10.
3. Five Basic series are: R5, R10, R20, R40, and R80.
4. Series Series Factor
5
R5 Series √10 = 1.58
10
R10 Series √10 = 1.26
20
R20 Series √10 = 1.12
40
R40 Series √10 = 1.06
80
R80 Series √10 = 1.03

5. The series is obtained by taking first number and multiplying with series factor to get next
value. The second number is again multiplied by the series factor to get a third value.

Example: R5 Series Series Factor

I number 1
II number 1 𝑋 1.58 = 1.58 ≅ 1.60
III number 1.60𝑋 1.58 = 2.528 ≅ 2.50
IV number 2.5 𝑋 1.58 = 3.95 ≅ 4.00
V number 4 𝑋 1.58 = 6.32 ≅ 6.30
VI number 6.3 𝑋 1.58 = 9.954 ≅ 10.00
6. Preferred numbers from R5 series are, 1.00, 1.60, 2.50, 4.00, 6.30, and 10.00.
R5, R10, R20, R40 and R80 are Basic series.
7. Preferred numbers are used to standardize the size of the products.

************
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(ii) The head of a steam engine cylinder 𝟓𝟎𝟎 𝒎𝒎 diameter is subjected to a pressure of
𝟏 𝑵/𝒎𝒎𝟐 . The head is held in position by 16 numbers of M30 bolts. A copper gasket is
used to make the joint steam tight. Determine the stress induced in the bolt. Assume
𝒌 = 𝟎. 𝟓. [10 Marks]
Given Data:
 Diameter of Engine cylinder, 𝐷 = 500 𝑚𝑚
 Steam pressure, 𝑝 = 1 𝑁/𝑚𝑚2
 Number of Bolts, 𝑛 = 16
 Bolt size, 𝑑 = 30 𝑚𝑚, 𝑘 = 0.5

Procedure and Formula: --- 3 Marks

Arriving Solution: --- 7 Marks
Solution:

1. Load due to initial tightening: --- 3 Marks

𝑃𝑖 = 2840 𝑋 𝑑 = 2840 𝑋 30 = 85,200 𝑁

2. External load on each Bolt: --- 2 Marks

𝜋 1
𝑃𝑒 = 𝑋 𝐷2 𝑋 𝑝 𝑋
4 𝑛
𝜋 2 1
𝑃𝑒 = 4 𝑋 500 𝑋 1 𝑋 16 = 12,271.85 𝑁

3. Net Load on the Bolt (P): --- 2 Marks

𝑃 = 𝑃𝑖 + 𝐾𝑃𝑒
𝑃 = 85,200 + (0.5 𝑋 12,271.85)
𝑃 = 91,335.925 𝑁

4. Stress Area Bolt [A]: --- 1 Mark

From Data Book, for Bolts
Stress Area, 𝐴 = 561 𝑚𝑚2

5. Stress induced [𝜎𝑡 ]: --- 2 Marks

𝑃 91335.925
𝜎𝑡 = = = 162.809 𝑁/𝑚𝑚2
𝐴 561
𝜎𝑡 = 162.809 𝑁/𝑚𝑚2

************

II. (A) A line shaft is driven by an electrical motor placed vertically below it. The pulley on
the line shaft is 𝟏. 𝟓 𝒎 in diameter. The belt tensions are 𝟓. 𝟒 𝒌𝑵 and 𝟏. 𝟖 𝒌𝑵 on the tight
and slack sides 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, determine the diameter of the
shaft. Assume maximum allowable shear stress as 𝟒𝟐 𝑴𝑷𝒂. [15 Marks]
Given Data:
 Pulley diameter, 𝐷𝑝 = 1.5 𝑚 = 1500 𝑚𝑚
 Belt tensions: 𝑇1 = 5.4 𝑘𝑁 = 5.4 𝑋 103 𝑁
𝑇2 = 1.8 𝑘𝑁 = 1.8 𝑋 103 𝑁
 5

 Pulley overhang distance, 𝑙 = 400 𝑚𝑚

 Allowable shear stress, [𝜏] = 42 𝑀𝑃𝑎 = 42 𝑁/𝑚𝑚2

Procedure and Formula: --- 5 Marks

Arriving Solution: --- 10 Marks
Solution:

1. Torque Transmitted [T]: --- 4 Marks

𝑇 = (𝑇1 − 𝑇2 ) 𝑋 𝑅𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑝𝑢𝑙𝑙𝑒𝑦
𝐷 𝑝
= (𝑇1 − 𝑇2 ) 𝑋 2
𝑇 = 2700 𝑁 − 𝑚, 𝑇 = 2700 𝑋 103 𝑁 − 𝑚𝑚

2. Bending Moment [M]: --- 4 Marks

Total load on Pulley, 𝑊 = 𝑇1 + 𝑇2
𝑊 = 7.2 𝑋 103 𝑁
Bending Moment, 𝑀 = 𝑊 𝑋 𝑙
𝑀 = 2880 𝑋 103 𝑁 − 𝑚𝑚

3. Equivalent Twisting Moment [𝑇𝑒 ]: --- 3 Marks

𝑇𝑒 = √𝑀2 + 𝑇 2
𝑇𝑒 = 3947.7082 𝑋 103 𝑁 − 𝑚𝑚

4. Diameter of shaft [𝑑]: --- 4 Marks

𝜋
We know, 𝑇𝑒 = 16 𝑋 𝑑 3 𝑋 [𝜏]
16 𝑋 𝑇 1/3
∴𝑑=[ ]
𝜋 𝑋 [𝜏]
𝑑 = 78.23 𝑚𝑚
∴ Take 𝒅 = 𝟖𝟎 𝒎𝒎

************

(B) A 15kW, 960 rpm motor has a mild steel shaft of 40mm diameter and the extension
being 75mm. The permissible shear and crushing stresses for key material are 𝟓𝟔𝑴𝑷𝒂
and 𝟏𝟏𝟐𝑴𝑷𝒂 respectively. Design the keyway in the motor shaft extension. Check the
shear strength of the key against the normal strength of the shaft. [15 Marks]

Given Data:
 Power transmitted = 𝑃 = 15 𝑘𝑊 = 15𝑋 103 𝑊
 Speed, 𝑁 = 960 𝑟𝑝𝑚
 Diameter of Shaft, 𝑑 = 40 𝑚𝑚
 Keyway length, 𝑙 = 75 𝑚𝑚 [𝑒𝑥𝑡𝑒𝑛𝑠𝑖𝑜𝑛 𝑜𝑓 𝑆ℎ𝑎𝑓𝑡]
 Allowable shear stress, [𝜏]𝑘 = 56 𝑀𝑃𝑎 = 56 𝑁/𝑚𝑚2
 Permissible crushing stress, [𝜎𝑐 ]𝑘 = 112 𝑀𝑃𝑎 = 112 𝑁/𝑚𝑚2

Procedure and Formula: --- 5 Marks

Arriving Solution: --- 10 Marks
 6

Solution:

1. Torque transmitted [𝑇]: --- 3 Marks

60 𝑃
𝑇=
2𝜋𝑁
𝑇 = 149.208𝑋103 𝑁 − 𝑚𝑚

2. Width and Thickness of key [𝑤, 𝑡]: --- 3 Marks

2𝑇
𝑤> = 1.78 𝑚𝑚
𝑑 𝑋 𝑙 𝑋 [𝜏]𝑘
Since, this value is very small,
𝑑
Take 𝑤 = = 10 𝑚𝑚
4
Here, [𝜎𝑐 ]𝑘 = 2 𝑋 [𝜏]𝑘
∴ Square key may be used
i.e., 𝑤 = 10 𝑚𝑚, 𝑡 = 10 𝑚𝑚 [𝑆𝑞𝑢𝑎𝑟𝑒 𝑘𝑒𝑦]

3. Shaft Strength factor [𝑒]: --- 3 Marks

𝑤 ℎ
𝑒 = 1 − 0.2 ( ) − 1.1 ( )
𝑑 𝑑
10 𝑡 𝑡
= 1 − 0.2 ( ) − 1.1 ( ) [ℎ = ]
40 2𝑑 2
𝑒 = 0.8125
𝜋 𝑋 𝑑3
4. Strength of keyway with Shaft = 𝑋𝜏𝑋𝑒 --- 2 Marks
16
𝜋 𝑋 (40)3
[= 𝑋 56 𝑋 0.8125]
16
𝜏𝑆+𝐾 = 5,71,770 𝑁 − 𝑚𝑚

5. Shear strength of key [𝜏𝑘 ]: --- 2 Marks

𝑑 𝑑
𝜏𝑘 = 𝐹 𝑋 = 𝑙 𝑋 𝑤 𝑋 𝜏 𝑋
2 2
𝜏𝑘 = 8,40,000 𝑁 − 𝑚𝑚

6. Ratio of Strengths: --- 2 Marks

𝑆ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝐾𝑒𝑦 8,40,000
= = 1.47
𝑁𝑜𝑟𝑚𝑎𝑙 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑆ℎ𝑎𝑓𝑡 5,71,770
Shear strength of Key > Normal strength of Shaft

************

III. (A) Design a belt drive based on manufacturer’s data to transmit 𝟐𝟐. 𝟓𝒌𝑾 at 𝟕𝟒𝟎 𝒓𝒑𝒎
to an aluminium rolling machine. The speed ratio is 𝟑. The distance between the
pulleys is 𝟑𝒎. The diameter of the rolling machine pulley is 𝟏. 𝟐𝒎. [15 Marks]

Given Data:
 Power, 𝑃 = 22.5 𝑘𝑊 = 22,500 𝑊
 Speed, 𝑁 = 740 𝑟𝑝𝑚
 7

𝑁
 Speed Ratio, 𝑖 = 𝑁1 = 3
2

 Centre distance, 𝐶 = 3 𝑚 = 3000 𝑚𝑚

 Diameter of rolling machine pulley, 𝑑2 = 1.2 𝑚 = 1200 𝑚𝑚

Procedure and Formula: --- 5 Marks

Arriving Solution: --- 10 Marks
Solution:

1. Pulley Diameters [𝑑1 , 𝑑2 ]: --- 2 Marks

∅𝑑2 = 1200 𝑚𝑚, Speed Ratio, 𝑖 = 3
1200
∴ Small Pulley diameter, ∅𝑑1 = = 400 𝑚𝑚
3
𝑑2 = 1200 𝑚𝑚 𝑑1 = 400 𝑚𝑚
740
𝑁1 = 740 𝑟𝑝𝑚, 𝑁2 = = 246.67 𝑟𝑝𝑚
3
2. Arc of contact [𝜃]: --- 2 Marks
𝑑2 − 𝑑1
𝜃 = 180𝑜 − ( 𝑋 60𝑜 )
𝐶
𝜃 = 164𝑜

3. Design Power [𝑃𝑑 ]: --- 3 Marks

𝑃 𝑋 𝐾𝑠
𝑃𝑑 =
𝐾𝜃 𝑋 𝐾𝑑
From Data book:
𝐾𝑠 = 1.5 [Shock loads/Rolling machine]
𝐾𝜃 = 1.064
Small Pulley factor 𝐾𝑑 = 0.9
∴ 𝑃𝑑 = 35.245 𝑘𝑊

4. Selection of Belt: [Manufacturer’s Data] --- 1 Mark

1. 𝑆𝑒𝑙𝑒𝑐𝑡 𝐹𝑎𝑏𝑟𝑖𝑐 − ℎ𝑖𝑔ℎ 𝑠𝑝𝑒𝑒𝑑 𝑑𝑢𝑐𝑘 𝑏𝑒𝑙𝑡
2. Load rating at 10 𝑚/𝑠 = 0.023𝑘𝑊/𝑚𝑚/𝑝𝑙𝑦

5. Load Rating: --- 2 Marks

𝜋𝑑1 𝑁1
Belt speed, 𝑉 = 60 𝑋 1000

𝑉 = 15.5 𝑚/𝑠
15.5
Load Rating at 15.5 𝑚/𝑠 = 𝑋 0.023
10

L.R= 0.03565 𝑘𝑊/𝑚𝑚/ply

6. Belt Width (𝑏): Assume No. of plies= 6 --- 2 Marks

𝑃𝑑
𝑏=
𝐿. 𝑅 𝑋 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑃𝑙𝑖𝑒𝑠
𝑏 = 164.78 𝑚𝑚 ⇒ 𝑏 = 180 𝑚𝑚 [𝑆𝑡𝑑 𝑣𝑎𝑙𝑢𝑒]
 8

7. Belt Length (𝑙): --- 2 Marks

𝜋(𝑑2 + 𝑑1 ) (𝑑2 − 𝑑1 )2
𝑙 = 2𝐶 + +
2 4𝑋𝐶
𝑙 = 8567 𝑚𝑚
Considering initial tension, 𝑙 = 0.99 𝑋 8567
𝑙 = 8482 𝑚𝑚
Pulley Width, 𝑊𝑝 = 𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝐵𝑒𝑙𝑡 + 25 --- 1 Mark
= 180 + 25
𝑊𝑝 = 205 𝑚𝑚

************

(B) Design a V-belt drive based on manufacturer’s data to the following specifications:
Dia. of driven pulley = 𝟔𝟎𝟎 𝒎𝒎
Dia. of driving pulley = 𝟐𝟎𝟎 𝒎𝒎
Centre distance between pulleys = 𝟏𝟎𝟎𝟎 𝒎𝒎 (𝒂𝒑𝒑𝒓𝒐𝒙. )
Speed of driven pulley = 𝟒𝟎𝟎 𝒓𝒑𝒎
Speed of driving pulley = 𝟏𝟐𝟎𝟎 𝒓𝒑𝒎
Power transmitted = 𝟏𝟎 𝒌𝑾
Service – heavy duty = 𝟏𝟔 𝒉𝒐𝒖𝒓𝒔/𝒅𝒂𝒚 [15 Marks]

Given Data:
 𝑑1 = 200 𝑚𝑚, 𝑑2 = 600 𝑚𝑚
 𝐶 = 1000 𝑚𝑚 (𝑎𝑝𝑝. )
 𝑁1 = 1200 𝑟𝑝𝑚, 𝑁2 = 400 𝑟𝑝𝑚
 Power, 𝑃 = 10𝑘𝑊 = 10 𝑋 103 𝑊
 Service=heavy-duty, 16 ℎ𝑜𝑢𝑟𝑠/𝑑𝑎𝑦

Procedure and Formula: --- 5 Marks

Arriving Solution: --- 10 Marks
Solution:

1. Belt Velocity [𝑉]: --- 1 Mark

𝜋𝑑1 𝑁1
𝑉=
60 𝑋 1000
𝑉 = 12.57 𝑚/𝑠

2. Angle of lap (𝜃): --- 1 Mark

𝑑2 − 𝑑1
𝜃 = 1800 − [ ] 𝑋 600
𝐶
𝜃 = 1560

3. Selection of Belt type: --- 2 Marks

For power, 𝑃 = 10 𝑘𝑊 [Refer Data Book]
 9

Preference I Preference II
Select ‘C’ type Belt Select ‘B’ type Belt
Minimum diameter of pulley= 200 𝑚𝑚 Minimum pulley diameter = 125 𝑚𝑚
Top Belt width, 𝑤 = 22 𝑚𝑚 Top Belt width, 𝑤 = 17 𝑚𝑚
Thickness, 𝑇 = 14 𝑚𝑚 Thickness, 𝑇 = 11 𝑚𝑚

4. Length of Belt [𝑙𝑝 ]: --- 2 Marks

From Data book,
𝜋(𝑑2 + 𝑑1 ) (𝑑2 − 𝑑1 )2
𝑙𝑝 = 2𝐶 + +
𝐶 4𝐶
𝑙𝑝 = 3297 𝑚𝑚
Std size (C) type Belt: Std size (B) type Belt:
𝑙𝑝 = 3205 𝑚𝑚 𝑙𝑝 = 3294 𝑚𝑚
𝑙𝑖 = 3150 𝑚𝑚 𝑙𝑖 = 3251 𝑚𝑚

5. New Centre distance [𝐶] --- 2 Marks

𝐶 = 𝐴 + √𝐴2 − 𝐵
𝑙𝑝 𝜋(𝑑2 + 𝑑1 ) (𝑑2 − 𝑑1 )2
𝐴= − , 𝐵=
4 8 8
‘C’ type Belt: ‘B’ type Belt:
𝐴 = 487 𝑚𝑚 𝐴 = 509.34
𝐵 = 20,000 𝐵 = 20,000
∴ 𝐶 = 953 𝑚𝑚 ∴ 𝐶 = 998.66 𝑚𝑚

6. Equivalent Diameter [𝑑𝑒 ] of small pulley:

𝑑𝑒 = 𝑑1 𝑋 𝐾𝑑
𝑁1
𝐾𝑑 = 1.14 [From Data book, For speed Ratio = 3]
𝑁2
∴ 𝑑𝑒 = 200 𝑋 1.14 = 228 𝑚𝑚

7. Power Rating per Belt (𝑃𝑏 ): --- 2 Marks

‘B’ type Belt:
50.8
𝑃𝑏 = (0.79 𝑋 𝑉 −0.09 − − 1.32 𝑋 10−4 𝑋 𝑉 2 ) 𝑋 𝑉
𝑑𝑒
𝑃𝑏 = 4.845 𝑘𝑊
‘C’ type Belt:
142.7
𝑃𝑏 = (1.47 𝑋 𝑉 −0.09 − − 2.34 𝑋 10−4 𝑋 𝑉 2 ) 𝑋 𝑉
𝑑𝑒
𝑃𝑏 = 6.28 𝑘𝑊

8. Design Power (𝑃𝑑 ): --- 2 Marks

𝑃 𝑋 𝐾𝑠
𝑃𝑑 =
𝐾𝑙 𝑋 𝐾𝜃
From Data book,
𝐾𝑠 = 1.3 [𝐾𝑠 = 1.4 (𝑜𝑟)1.5 𝑚𝑎𝑦 𝑎𝑙𝑠𝑜 𝑏𝑒 𝑐𝑜𝑛𝑠𝑖𝑑𝑒𝑟𝑒𝑑]
𝐾𝑙 = 1.08 (𝐵 𝑇𝑦𝑝𝑒), 𝐾𝑙 = 0.97 (𝐶 𝑇𝑦𝑝𝑒)
𝐾𝜃 = 0.94 𝑓𝑜𝑟 𝜃 = 1560
 10

B Type: C Type:
𝑃𝑑 = 12.805 𝑘𝑊 𝑃𝑑 = 14.258 𝑘𝑊

9. Number of Belts (𝑛):

B Type: C Type:
𝑃𝑑 𝑃𝑑
𝑛= 𝑛=
𝑃𝑏 𝑃𝑏
𝑛 = 2.643 𝑛 = 2.27
Take 𝑛 = 3 Take 𝑛 = 3

10. Pulley Details:

B Type: C Type:
𝑤𝑝 = (𝑛 − 1) 𝑋 𝑒 + 2𝑓 𝑤𝑝 = (𝑛 − 1) 𝑋 𝑒 + 2𝑓
= 63 𝑚𝑚 = 85 𝑚𝑚
𝑒 = 19, 𝑓 = 12.5, 𝛼 = 380 𝑒 = 25.5, 𝑓 = 17, 𝛼 = 360

************

IV. (A) (i) How bearings are classified? [5 Marks]

Solution:
Bearings:
 Sliding Bearing
 Rolling Bearing

Sliding Bearing: --- 2 Marks

 Full Journal
 Partial Journal
 Thrust Bearing
 Hydrostatic

Rolling Bearing: --- 3 Marks

 Ball Bearing
 Roller Bearing
Ball Bearing:
 Radial Ball Bearing:
 Single Row
 Double Row
 Filling Notch
 Self aligning
 Thrust Bearing
Roller Bearing
 Cylindrical Roller
 Spherical Roller
 Needle Roller
 Tapered Roller

************
 11

(ii) A journal bearing 𝟑𝟎𝟎𝒎𝒎 long 𝟏𝟓𝟎𝒎𝒎 diameter carries a radial load of
𝟗𝒌𝑵 𝒂𝒕 𝟏𝟐𝟎𝟎 𝒓𝒑𝒎, the power lost in friction is 𝟔𝒌𝑾, viscosity of oil at room
temperature is 𝟎. 𝟎𝟏𝟖𝑷𝒂𝒔. Find the diametral clearance. [10 Marks]

Given Data: Journal Bearing

 𝐿 = 300 𝑚𝑚, 𝐷 = 150 𝑚𝑚
 Load, 𝑃 = 9 𝐾𝑁 = 9 𝑋 103 𝑁
 Speed, 𝑁 = 1200 𝑟𝑝𝑚
 Friction Power lost, 𝑄𝑔 = 6 𝑋 103 𝑊
 Oil Viscosity, 𝑍 = 0.018 𝑝𝑎 − 𝑠

Procedure and Formula: --- 4 Marks

Arriving Solution: --- 6 Marks
Solution:

1. Bearing Pressure (𝑃): --- 2 Marks

𝑃
𝑝= = 0.2 𝑁/𝑚𝑚2
𝐿. 𝐷
𝑝 = 0.2 𝑋 106 𝑁/𝑚2

2. Rubbing Velocity (𝑉): --- 2 Marks

𝜋𝑋𝐷𝑋𝑁
𝑉= = 9.425 𝑚/𝑠
60 𝑋 1000
3. Co-efficient of friction [𝜇]: --- 2 Marks
𝑍𝑁 𝐷
𝜇 = 0.326 𝑋 𝑋 +𝑘
𝑝 𝐶
Taking, 𝑘 = 0.002
5281.2
𝜇 = 𝐶 𝑋 106 + 0.002 --------> 1

4. Heat generated (𝑄𝑔 ) and 𝜇: --- 2 Marks

We know, 𝑃𝑜𝑤𝑒𝑟 𝑙𝑜𝑠𝑡 𝑖𝑛 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 = 𝐻𝑒𝑎𝑡 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑
i.e., 𝑄𝑔 = 𝜇𝑃𝑉 = 6000 𝑊
𝑄𝑔
𝜇=
𝑃𝑉
∴ 𝜇 = 0.070734

5. Diametral Clearance [𝐶]: --- 2 Marks

5281.2
∴𝜇= + 0.002 = 0.070734
𝐶 𝑋 106
𝑪 = 𝟎. 𝟎𝟕𝟔𝟖 𝒎𝒎

************
 12

(B) A journal bearing 𝟕𝟓𝒎𝒎 long supports a load of 𝟕. 𝟓𝒌𝑵 on a 𝟓𝟎𝒎𝒎 diameter journal
running at 𝟕𝟓𝟎 𝒓𝒑𝒎. The diametral clearance is 𝟎. 𝟎𝟔𝟗𝟑𝒎𝒎. Determine the viscosity of
oil, if the operating temperature of the bearing surface is limited to 𝟕𝟕𝟎 𝑪. The ambient
temperature is 𝟐𝟏𝟎 𝑪. Heat dissipating coefficient is 𝟐𝟏𝟎 𝑾/𝒎𝟐 /𝟎 𝑪. [15 Marks]

Given Data:
 𝐿 = 75 𝑚𝑚, 𝑃 = 7.5 𝑋 103 𝑁, 𝐷 = 50𝑚𝑚
 𝑁 = 750 𝑟𝑝𝑚, 𝐶 = 0.0693 𝑚𝑚
 𝑡𝑏 = 770 𝐶, 𝑡𝑎 = 210 𝐶, 𝐶𝑑 = 210 𝑊/𝑚2 /0 𝐶

Procedure and Formula: --- 5 Marks

Arriving Solution: --- 10 Marks
Solution:

1. Find heat dissipated 𝑄𝑑 : --- 3 Marks

𝐶𝑑 . 𝐴. (𝑡𝑏 − 𝑡𝑎 )
𝑄𝑑 =
106
𝑄𝑑 = 44.10 𝑊

2. Rubbing Velocity, 𝑉: --- 2 Marks

𝜋𝑋𝐷𝑋𝑁
𝑉=
60 𝑋 1000
𝑉 = 1.9635 𝑚/𝑠

3. Bearing Pressure (𝑃): --- 2 Marks

𝑃
𝑝= = 2 𝑁/𝑚𝑚2
𝐿. 𝐷
𝑝 = 2 𝑋 106 𝑁/𝑚2

4. Co-efficient of friction 𝜇: --- 3 Marks

𝑍𝑁 𝐷
𝜇 = 0.326 𝑋 𝑋 +𝑘
𝑝 𝐶
𝜇 = 0.0882𝑍 + 0.002 --------> 1

5. Find 𝜇: --- 2 Marks

Taking 𝑄𝑑 = 𝑄𝑔 [Heat Generated]
𝑄𝑔 = 𝜇𝑃𝑉 = 𝑄𝑑 = 44.10
𝜇 = 0.002995

6. Viscosity of Oil [𝑍]: --- 3 Marks

𝜇 = 0.0882𝑍 + 0.002
Sub 𝜇 value, 𝒁 = 𝟎. 𝟎𝟏𝟏𝟐𝟖 𝑵 − 𝒔/𝒎𝟐

************
 13

V. (A) Design a hand lever of rectangular section subjected to a maximum load of 𝟐𝟓𝟎𝑵 at the
end of moment arms of 𝟏. 𝟐𝒎. The thickness of the lever is constant and is equal to
𝟎. 𝟑𝟕𝟓 times the width of lever near the boss. Permissible shear stress for the shaft
material is 𝟒𝟎 𝑵/𝒎𝒎𝟐 and permissible bending stress for the lever material is
𝟖𝟎𝑵/𝒎𝒎𝟐 . [15 Marks]

Given Data:
 Load, 𝑃 = 250 𝑁
 Length of Lever, 𝐿 = 1.20𝑚 = 1200𝑚𝑚
 Permissible Shear Stress for Shaft, [𝑍] = 40 𝑁/𝑚𝑚2
 Permissible Bending Stress for lever, [𝜎𝑏 ] = 80 𝑁/𝑚𝑚2
 Cross section, 𝑡 = 0.375 𝑋 𝑏

Procedure and Formula: --- 5 Marks

Arriving Solution: --- 10 Marks
Solution:

1. Shaft diameter (𝑑): --- 4 Marks

Torque on shaft, 𝑇 = 𝑃 𝑥 𝐿
= 250 𝑥 1200
𝑇 = 300 𝑥 103 𝑁 − 𝑚𝑚
𝜋
Also, 𝑇 = 16 𝑋 [𝜏] 𝑋 𝑑 3
1⁄
16 𝑋 𝑇 3
∴𝑑=[ ] = 33.67
𝜋 𝑋 [𝜏]
Take 𝑑 = 35 𝑚𝑚

2. Diameter of Shaft at Bearing Centre [𝑑1 ]: --- 4 Marks

At 𝑙 = 100 𝑚𝑚 (𝐴𝑠𝑠𝑢𝑚𝑒)
Bending Moment 𝑀 = 𝑃 𝑋 𝑙
= 250 𝑋 100
𝑀 = 25 𝑋 103 𝑁 − 𝑚𝑚
Equivalent twisting moment, 𝑇𝑒 = √𝑀2 + 𝑇 2
𝑇𝑒 = 301.03 𝑋 103 𝑁 − 𝑚𝑚
𝜋
Also, 𝑇𝑒 = 16 𝑋 [𝜏] 𝑋 𝑑1 3
1
16 𝑋 𝑇𝑒 ⁄3
∴ 𝑑1 = [ ]
𝜋 𝑋 [𝜏]
𝑑1 = 35 𝑚𝑚, since 𝑑 = 35 𝑚𝑚, 𝑡𝑎𝑘𝑒 𝑑1 = 40 𝑚𝑚
Since, 𝑑1 > 𝑑

3. Arm Cross section: --- 4 Marks

Maximum Bending Moment on arm, 𝑀 = 𝑃 𝑋 𝐿
i.e., 𝑀 = 250 𝑋 1200 = 300 𝑋 103 𝑁 − 𝑚𝑚
Also, 𝑀 = 𝑍 𝑋 [𝜎𝑏 ]
𝑀 300 𝑋 103
Section modulus, 𝑍 = 𝜎 = = 3750 𝑚𝑚3
𝑏 80
 14

𝑡𝑏 2
i.e., = 3750, 𝑡 = 0.375 𝑋 𝑏
6
0.375𝑏 𝑋 𝑏 2
∴ = 3750
6
Width, 𝑏 = 39.14 ⇒ 𝑏 = 40𝑚𝑚
Thickness, 𝑡 = 0.375 𝑋 𝑏 = 15 𝑚𝑚

4. Key Size: --- 2 Marks

𝑑 35
𝑊𝑖𝑑𝑡ℎ, 𝑤 = = = 8.75 ⇒ 𝑤 = 9𝑚𝑚
4 4
𝑑 35
𝑡= = ⇒ 𝑡 = 6𝑚𝑚
6 6
𝑙 = 1.57 𝑋 𝑑 = 1.57 𝑋 35 = 55 𝑚𝑚

5. Dimensions of Boss: --- 1 Mark

Outer diameter, 𝑑2 = 1.6𝑑 = 56 𝑚𝑚
Length of boss, 𝑙2 = 1.25𝑑 = 44 𝑚𝑚
Thickness of boss, 𝑡2 = 0.3𝑑 = 11 𝑚𝑚

************

(B) A pinion runs at 𝟔𝟎𝟎 𝒓𝒑𝒎 drives a gear at a speed ratio of 𝟒: 𝟏. Allowable static stress of
pinion and gear material is 𝟖𝟓 𝑵/𝒎𝒎𝟐 . Pinion has 16 teeth of module 8mm. Teeth are
𝟐𝟎𝟎 FD system. Face width 𝟗𝟎𝒎𝒎. Find the power transmitted. [15 Marks]

Given Data:
 𝑁1 = 600 𝑟𝑝𝑚 (𝑝𝑖𝑛𝑖𝑜𝑛), 𝑆𝑝𝑒𝑒𝑑 𝑅𝑎𝑡𝑖𝑜 4: 1
 [𝜎𝑏 ] = 85 𝑁/𝑚𝑚2 −> 𝑃𝑖𝑛𝑖𝑜𝑛 & 𝐺𝑒𝑎𝑟 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙
 𝑍1 = 16, 𝑚 = 8𝑚𝑚, 200 /𝐹. 𝐷
 𝑏 = 90 𝑚𝑚, 𝑃𝑜𝑤𝑒𝑟 = ?

Procedure and Formula: --- 5 Marks

Arriving Solution: --- 10 Marks
Solution:

1. Speed 𝑁2 (𝑓𝑜𝑟 𝐺𝑒𝑎𝑟): --- 2 Marks

Pinion, 𝑁1 = 600 𝑟𝑝𝑚 Speed Ratio 4: 1
𝑁1
𝑁2 = Speed of Gear, = 150 𝑟𝑝𝑚
4

2. Number of teeth on Gear: (𝑍2 ) --- 1 Mark

𝑍1 = 16 (𝑝𝑖𝑛𝑖𝑜𝑛) ⇒ 𝑍2 = 16 𝑋 4 = 64 𝑡𝑒𝑒𝑡ℎ

3. Pitch Diameter of pinion & Gear: --- 2 Marks

𝐷1
𝑚= ⇒ 𝐷1 = 𝑚 𝑋 𝑍1 = 8 𝑋 16 = 128 𝑚𝑚
𝑍1
Pinion Diameter, 𝐷1 = 128 𝑚𝑚
Gear Diameter, 𝐷2 = 128 𝑋 4 = 512 𝑚𝑚