Name Of The Subject : DESIGN OF MACHINE ELEMENTS.

Branch : Diploma in Mechanical Engineering.

Subjective Questions:-
Module-1
1. a) What is the purpose of “standardization”?
b). What are the causes of stress concentration? Explain with neat sketch. Explain the methods to
reduce stress concentration
c) Describe any four factors that govern selection of material while designing a machine component.
2. a) Define the factor of safety ? What are the different factors to be considered while selecting the
factor of safety?
b) Define: Endurance limit, fatigue, creep, ductility, malleability, hardness, toughness, reliability.
3. a)Define Hooke’s Law. Draw the stress-strain curve for a ductile material and show the salient points.
b) Define stress and strain. What are the different types of stresses and strains?
c) Draw S-N curve for steels and show endurance limit on it.
4. a) Explain the importance of aesthetic considerations in machine design. What is the relationship
between the functional requirement and the appearance of a product?
b) What is Ergonomics? Discuss its scope in machine design.
c) Explain the man-machine closed-loop system.

Module-2
1. Calculate i)the diameter of the rods ,ii) the dia of knuckle pin, iii) the dia and thickness of eye end, for
a knuckle joint connecting two rods subjected to a pull of 120 kN. The rods and pin are made up of steel
.Take ft=45 N/mm2 ,fs=40 N/mm2, fb=60 N/mm2. Consider all the possible failures of the parts.
2. a) A knuckle joint required for a rod which has to withstand a total load of 100 kN. Find i) the
diameter of the rod and ii) the diameter of the knuckle pin. The rods and pin are made up of steel .Take
ft=45 N/mm2 ,fs=40 N/mm2, fb=60 N/mm2. Consider all the possible failures of the parts.
b) How do you differentiate between a knuckle and a cotter joint?
3. It is required to design a spigot and socket type cotter joint to connect two steel rods of equal
diameter. Each rod is subjected to an axial reciprocating types of force of 50 kN. Take ft=45 N/mm2 ,fs=40
N/mm2, fb=60 N/mm2. Calculate i) the dia of rod ii) mean width of cotter iii) the dia of spigot. Consider
all the possible failures of the different parts.
4. a) A hand lever is 1 meter from centre of the shaft to the point of application of 200 N. Calculate i)
Diameter of solid shaft, allowable shear stress is 25 N/mm2 ii) What is the twist of shaft per meter
length? Take modulus of rigidity as 0.84X105 N/mm2
b) Differentiate between simple and compound levers.

Module-3
1. a) A circular shaft is required to transmit 1 MW power at 240 rpm. The shaft should not twist more
than 10 on a length of one meter. The modulus of rigidity of shaft material is 80 N/mm2. Calculate: i) the
diameter of the shaft, ii) the shear stress induced in the shaft.
b) A propeller shaft is required to transmit 45 kW at 500 rpm. It is hollow having inside diameter 0.6
times of outside diameter. Design the shaft. Take fs=40 N/mm2.
2. a) Determine the length and thickness of sunk key for a shaft of 0.09 m diameter. Assuming that the
shearing resistance of the material of the key is same as that of the shaft. Width of the key is 25 mm and
fs = 0.4 X fc.
b) What is the function of a coupling?
3. Two shafts are connected by a C.I. flange coupling which transmits 40 kW at 350 rpm. Assume for
shaft , key and bolts material ft=45 N/mm2 ,fs=40 N/mm2, fc=60 N/mm2 and fs for C.I. as 15 N/mm2
Consider all the possible failures of the different parts.
i) design the shafts. ii) design the key. iii) design the bolts
4. a) How do you differentiate between a coupling and a clutch? How do you classify couplings? Explain
the function of each type. What are the advantages and disadvantages of flange coupling?
b) The bolt in the flange coupling should be made weaker than the other components of coupling, why?

Module-4
1. A steel pulley transmits 10 kW power at 720 rpm with peripheral velocity 170 m/s. Angle of lap=1700
and μ=0.25, Maximum belt tension is 20 N/mm width of belt. Design i) The shaft ii) the hub iii) arms of
the pulley. considering all failures and assumptions. fs=40 N/mm2, fc=60 N/mm2.
2. a) What are the different types of gears? Specify the advantages and disadvantages of each types.
b) What are the different factors to be considered while designing a gear? State and explain Lewis
equation for spur gear design.
3. a) Derive an expression for power transmission capacity for spur gear in bending.
b) what assumptions are made in Lewis equation?
c) What assumptions are made while designing the arms of a pulley?
4. A steel pulley transmits 10 kW power at 720 rpm with peripheral velocity 170 m/s. Tension in the
tight side of belt is twice that of the slack side. Maximum belt tension is 20 N/mm width of belt. Design
i) The shaft ii) the hub iii) Dia of pulley and rim thickness. considering all failures and assumptions. fs=40
N/mm2,

Module-5
1.a) Discuss the bolt of uniform strength in detail. Which are the different stresses set up in a bolt due to
initial tightening? Discuss the advantages offered by the threaded joints.
b) Discuss the factors to be considered while selecting a thread profile.
2. a) Two machine parts are fastened together by means of a M24 c tap bolt(i.e., coarse pitch 3 mm). If
the load tending to separate these bolts are neglected, compute the stress that is set up in this bolt by
initial tightening.
b) In a steam engine the maximum steam pressure is 1.0 N/mm2 absolute and the back pressure is 0.014
N/mm2 absolute. The cylinder diameter is 0.3 m. Determine the diameter of the screwed end of the
piston rod when the allowable stress of mild steel is 45.0 N/mm2 in tension.
c) In which case fine threads are preferred over coarse threads?
3. a)Two plates are joined by means of single transverse and double parallel fillet welds. The size of the
fillet weld is 5 mm and allowable shear load per mm of weld is 330 N. Find the length of each parallel
fillet weld.
b) A 200X100X10 angle is welded to a steel plate by means of fillet welds. The angle is subjected to a
static load 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.
4.a) What are the advantages and disadvantages of welding joint over riveted joint?
b) What are the merits and demerits of screwed and welded joints?
c) Determine the requisite length of welds joining a steel strip to a plate, by a compound fillet lap joint.
The strip dimensions are: width X thickness: 150 mm X 10 mm, load = 240 kN.

Module-6
1. a) What are the functions of bearing?
b) How will you classify bearings?
c) On what factors the selection of a bearing for a particular application depends?
d) What is the importance of oil grooves in bearings?
2. a) Write down the factors upon which selection of the bearing materials depends. Name some
bearing materials stating their characteristics, limits and applications.
b) Define bearing characteristic number.
3. a) Define static and dynamic load rating of bearing.
b) Discuss the factors on which the speed limits for any bearing can be determined.

Module-7
1. What Ergonomics? . Discuss its scope in machine design. Explain the man-machine closed-loop
system.
2. What are the different factors to be considered in Ergonomics and Aesthetic consideration in Design?
What is the relationship between the functional requirement and the appearance of a product?

Module-8
1. Define costing. What are the objectives of costing? Differentiate between estimating and costing. List
various items which include the overhead expense .
2. a) What is Prime cost? What is overhead? How overhead cost may be allocated?
b) How costing of a product may be calculated?
3. What is depreciation? What are the different ways of calculation of depreciation of an equipment?
4. a) Find out the length and mass of a m.s rod of 1.8 cm dia necessary to make a hexagonal bolt of 1.5
cm dia and 2.5 cm long with a nut assuming a scale of 10% on total volume. Density of m.s=7.8 gm/cc.
b) Find out the no. of m.s rivets as shown in figure. Spherical head with radius 20 mm,Shank dia.=10mm,
Tail is truncated cone with major dia 40 mm and minor dia 20mm,length of tail 20mm.
that can be manufactured from 20 kg of m.s.

Assuming scale loss of 10% on volume. Density of m.s is 8gm/cc

Module-9
1. Find the weight of the eye end and knuckle pin of the M.S. knuckle joint as shown. Assume thickness
of eye end as 20 mm, thickness of fork end as 15mm, Dia of knuckle pin as 30 mm,length of knuckle pin
as 70 mm, thickness of knuckle pin head as 45 mm, thickness of collar 10 mm. Density of M.S. is 8 gm/cc

2. Find the volume and weight of the C.I. flange coupling (Excluding bolts and keys) as shown in the
figure. Take D=40mm, PCD of bolt =60mm, Four numbers of bolts are used. Density of C.I. is 8.5 gm/cc