EXPLAIN THE FAILURE OF COTTER IN BENDING WITH SUITABLE SKETCH AND STRENGTH EQUATION

Bending failure of cotter: Theoretically .It is assumed that the

load is uniformly distributed over the various cross-sections of the
joint. But in actual practice, this does not happen and the cotter is
subjected to bending. In order to find out the bending stress
induced, it is assumed that the load on the cotter in the rod end is
uniformly distributed while in the socket end it varies from zero at
the outer diameter (d4) and maximum at the inner diameter (d2),
as shown in Fig.

WRITE LEWIS EQUATION FOR STRENGTH OF GEAR TOOTH GIVE MEANING OF EACH TERM
ANS LEWIS EQUATION FOR STRENGTH OF GEAR TOOTH : WT = 6W.B. PC. Y = 6W.B.ΠM. Y WHERE,
WT = TANGENTIAL LOAD ACTING AT THE TERM , 6W = BEAM STRENGTH OF THE TOOTH , B = WIDTH OF
THE GEAR FACE PC = CIRCULAR PITCH M = MODULE Y = LEWIS FORM FACTOR OR TOOTH FORM FACTOR.

WRITE GENERAL DESIGN PROCEDURE OF THE BELL CRANK LEVER. (ANY FOUR STEPS)

1. Find the effort (P) required to raise the load (W), Taking moment about
the fulcrum F, we have, W X lw =(P) X lp 2. Find reaction at fulcrum pin at F,

3.Design of fulcrum pin: i. Fulcrum pin is designed by considering under

bearing pressure, where Lp, = length of fulcrum pin.dp = diameter of fulcrum
pin. Find : ,

, ii. Fulcrum pin is

subjected to double shear, Find: Check the shear stress induced in the
fulcrum pin. 4. Diameter of boss of lever: The boss of the lever is subjected
to bending stress due to bending moment of lever. Let, di = inner diameter of
the boss of the lever/ diameter of hole in lever. do = outer diameter of the
boss of the lever/ diameter of boss at fulcrum.
 APPLICATIONS OF SPRING: (ANY FOUR1. IN AUTOMOBILE SUSPENSION. 2. IN RAILWAY SUSPENSION. 3.
IN SHOT BLASTING MACHINE. 4. IN CLOCKS AND TOYS TO STORE ENERGY. 5. IN SPRING BALANCE AND
ENGINE INDICATOR TO MEASURE FORCE. 6. IN CLUTCH, BRAKES, SPRING LOADED VALVES, ETC.)

DEFINE STRESS CONCENTRATION. EXPLAIN ANY FOUR METHODS TO REDUCE IT WITH NEAT SKETCH.
ANS STRESS CONCENTRATION: WHENEVER THE MACHINE COMPONENT CHANGES THE SHAPE OF ITS
CROSS SECTION THE STRESS DISTRIBUTION PATTERN NO LONGER HOLDS GOOD AND THE
NEIGHBORHOOD OF THE DISCONTINUITY IS DIFFERENT. THE STRESSES INDUCED IN THE NEIGHBORHOOD
ARE MUCH HIGHER THAN THE STRESS INDUCED IN THE OTHER PART OF THE COMPONENT. THIS ABRUPT
CHANGE IN CROSS SECTION OR THE DISCONTINUITY FORM IS CALLED STRESS CONCENTRATION. IT IS FOR
ALL KINDS OF STRESSES CAUSED DUE TO KEYWAYS, GROOVES, NOTCHES, ROUGHNESS OR SCRATCHES.

The effect of stress concentration cannot be completely

eliminated but its effect can be reduced by altering the geometry
of the component. So the following methods are adopted to
reduce the effect of stress concentration: 1. Providing additional
holes and notches. a. Use of multiple notches. b. Drilling
additional holes. c. Removing roughness. 2. By providing fillet
radius to the corners of the members and under and notches for
the members in bending. 3. Reduction in stress concentration of
the threaded component. 4. By drilling small holes near the large
holes or providing additional holes in the shafts. 5. By providing
taper cross sections to the members having sharp corners.

NAME ANY TWO BEARING MANUFACTURERS. A) SKF – SWEDISH SKF GROUP B) NRB C) FAG D) NSK E)
TIMKEN F) NTN G) INA H) KOYO I) MENON LIST FOUR PROPERTIES DESIRABLE FOR SPRING
MATERIAL(ANY FOUR) ANS 1)HIGH RESILIENCE 2) HIGH DUCTILE 3)HIGH STATIC STRENGTH 4) HIGH
FATIGUE STRENGTH 5) NON CORROSIVE LIST FOUR APPLICATIONS OF KNUCKLE JOINTS (ANY FOUR)
ANS 1) LINK OF BICYCLE CHAIN, 2) TIE BAR OF ROOF TRUSS, 3) LINK OF SUSPENSION BRIDGE 4)VALVE
MECHANISM, 5) FULCRUM OF LEVER, 6) JOINT FOR RAIL SHIFTING MECHANISM
EXPLAIN IMPORTANCE OF SHAPE AND SIZE IN AESTHETIC DESIGN. ANS THE AESTHETIC
CHARACTERISTICS IS A VERY IMPORTANT FOR ALL DESIGN ELEMENTS. THE AESTHETICS IS THE PROPERTY
TO HAVE GOOD PERFORMANCE ALONG WITH THE BETTER APPEARANCE FOR THE SATISFACTION OF THE
CUSTOMER. IN THE BUYER’S MARKET, HAVE A NUMBER OF PRODUCTS WITH SAME IDENTICAL
PARAMETERS, BUT THE APPEARANCE OF THE OF THE PRODUCT PLAYS A MAJOR ROLE IN ATTRACTING
THE CUSTOMERS. THE AESTHETIC HAS A PRODUCE WITH THE EXTENT WHICH CONTRIBUTES VARIES
FROM PRODUCT TO PRODUCT. THIS IS IMPORTANT FOR THE DESIGNER TO HAVE DEVELOP THE SHAPE OF
A PRODUCT SO THAT CUSTOMER GET ATTRACTED TOWARDS IT AND THE APPEARANCE SHOULD BE
PLEASING. FOR EXAMPLE THE CARS ARE DESIGNED IN THE FORM OF AERODYNAMIC SHAPE, THIS
AESTHETIC FORMS HELPS IN THE PERFORMANCE BY GETTING LESS RESISTANCE OF AIR AS WELL AS THE
APPEARANCE WHICH EXTENT IN CONTRIBUTION. THE SHAPE IS ALSO THE IMPORTANT AESTHETIC
CRITERIA THAT THE PRODUCTS DEVELOPS AND DESIGNED SHOULD NOT BE BULKY IN SIZE WHICH WILL
AFFECT THE PERFORMANCE AS WELL AS THE APPEARANCE OF THE PRODUCT. THE DESIGNER THUS HAVE
THE CHOICE TO MINIMIZE THE SHAPE AND CAN FORM SMALLER SIZE PRODUCT DESIGNS RATHER THAN
BULKY DESIGNS. THUS, AESTHETICS HELPS TO GET THE BETTER APPEARANCE AND PERFORMANCE
WHICH EXTENT ITS CONTRIBUTIONS FROM PRODUCT TO PRODUCT.

STATE THE STEPS INVOLVED IN SELECTION OF PROPER BALL

BEARING FROM MANUFACTURER’S CATALOGUE. ANS 1) Calculate radial and axial forces and
determine dia. of shaft. 2) Select proper type
of bearing. 3) Start with extra light series for
given diagram go by trial of error method 4)
Find value of basic static capacity (co) of
selected bearing from catalogue. 5) Calculate
ratios Fa/VFr and Fa/Co. 6) Calculate values
of radial and thrust factors.(X & Y) from
catalogue. 7) For given application find value
of load factor Ka from catalogue. 8) Calculate
equivalent dynamic load using relation. Pe =
(XVFr + YFA) Ka. 9) Decide expected life of
bearing considering application. Express life
in million revolutions L10 10) Calculate
required basic dynamic capacity for bearing
by relation. 11) Check whether selected
bearing has req. dynamic capacity, IF it not
select the bearing of next series and repeat
procedure from step-4
DESIGN HELICAL COMPRESSION SPRING FOR - MAXIMUM LOAD OF 1000 N FOR DEFLECTION OF 25
MM USING VALUE OF SPRING INDEX AS 5. THE MAXIMUM PERMISSIBLE SHEAR STRESS FOR SPRING
WIRE IS 420 MPA AND MODULUS OF RIGIDITY IS 84 KN/MM2

TAKE WAHL’S FACTOR, WHERE C = SPRING INDEX

EXPLAIN CONSTRUCTION OF LEAF SPRING WITH NEAT SKETCH

CONSTRUCTION OF LEAF SPRING : SEMI-ELLIPTICAL LEAF SPRINGS ARE WIDELY USED FOR SUSPENSION
IN LIGHT AND HEAVY COMMERCIAL VEHICLE. IN CAR THESE ARE USED FOR REAR SUSPENSION. • THE
LEAF SPRINGS ARE MADE OF FLAT SEMI-ELLIPTICAL PLATE. • THE ADVANTAGE OF LEAF SPRING OVER
HELICAL SPRING IS THAT THE ENDS OF THE SPRING MAY BE GUIDED ALONG THE DEFINITE PATH AS IT
DEFLECTS TO ACTS AS A STRUCTURAL MEMBER IN ADDITION TO ENERGY ABSORBING DEVICE. • THUS,
LEAF SPRING CARRY LATERAL LOAD, BRAKE TORQUE, DRIVING THRUST AND SHOCKS. • IT CONSISTS OF
NUMBER OF SEMI-ELLIPTICAL PLATES CALLED BLADE OR LEAVES. • THE LEAVES ARE GIVEN INITIALLY
CURVATURE OR CAMBER SO THAT THEY TEND TO STRAIGHTEN UNDER THE LOAD.
EXPLAIN WITH NEAT SKETCH DIFFERENT TYPES OF RADIAL BALL BEARINGS.:-

1. Single row deep groove bearing. : During assembly of this bearing, the races are offset and the maximum numbers
of balls are placed between the races. The races are then centered and the balls are symmetrically located by the use
of a retainer or cage.The deep groove ball bearings are used due to their high load carrying capacity and suitability for
high running speeds. The load carrying capacity of a ball bearing is related to the size and number of the balls. 2.
Filling notch bearing. : These bearings have notches in the inner and outer races which permit more balls to be
inserted than in deep groove ball bearings. The notches do not extend to the bottom of the race way and therefore
the balls inserted through the notches must be forced in position. 3. Angular contact bearing. These bearings have
one side of the outer race cut away to permit the insertion of more balls than in a deep groove bearing but without
having a notch cut into both races. This permits the bearing to carry a relatively large axial load in one direction while
also carrying a relatively large radial load. The angular contact bearings are usually used in pairs so that thrust loads
may be carried in either direction. 4. Double row bearing: These bearings may be made with radial or angular contact
between the balls and races. The double row bearing is appreciably narrower than two single row bearings. The load
capacity of such bearings is slightly less than twice that of a single row bearing 5. Self-aligning bearing: These bearings
permit shaft deflections within 2-3 degrees. It may be noted that normal clearance in a ball bearing are too small to
accommodate any appreciable misalignment of the shaft relative to the housing. If the unit is assembled with shaft
misalignment present, then the bearing will be subjected to a load that may be in excess of the design value and
premature failure may occur.
COMPARE THE WEIGHT, STRENGTH AND STIFFNESS OF A HOLLOW SHAFT OF THE SAME EXTERNAL
DIAMETER AS THAT OF SOLID SHAFT. INSIDE DIAMETER OF HOLLOW SHAFT IS HALF OF THE EXTERNAL
DIAMETER. BOTH SHAFTS HAVE THE SAME MATERIAL & LENGTH.
STATE FOUR EXAM LES OF ERGONOMICS CONSIDERATION IN DESIGN OFA LATHE MACHINE. ANY FOUR
EXAMPLES OF ERGONOMICS CONSIDERATION IN DESIGN OFA LATHE MACHINE.:- 1) THE DESIGN OF
HAND WHEEL OF SADDLE IN LATHE MACHINE. 2) THE DESIGN OF FOOT OPERATED LEVER WHICH
CONTROLS THE SPINDLE'S ROTATION AND DIRECTION. 3) DESIGN OF KNOB FOR SPEED CONTROL. 4)
DESIGN OF CHUCK KEY. 5) FORCE& POWER CAPACITY REQUIRED IN TURNING THE WHEEL AS PER
OPERATION OR HUMAN BEING CAN APPLY NORMALLY. 6) MATERIAL HANDLING OF THE JOBS.

WRITE STRENGTH EQUATION FOR DESIGNING SYMMETRICAL LOADED PARALLEL AND TRANSVERSE
WELD WITH NEAT

NAME FOUR TYPES OF KEYS(ANY FOUR) 1) SUNK KEYS 2) GIBB-HEAD KEY 3)FEATHER KEY 4)WOODRUFF
KEY 5)SADDLE KEYS 6)TANGENT KEYS 7)ROUND KEYS 8) SPLINES KEY LIST ANY FOUR APPLICATION OF
POWER SCREW. ANS 1) MACHINE VICE 2) POWER PRESS 3) UNIVERSAL TESTING MACHINE 4) C CLAMPS
ETC GIVE FOUR APPLICATIONS OF GEAR DRIVE. (ANY FOUR) ANS 1) GEAR BOX OF VEHICLE 2)MACHINE
TOOL 3)GEAR MECHANISM OF WRIST WATCH 4) DIAL INDICATOR 5) CEMENT MIXING UNIT 4) DIFF.
MECHANISM OF AUTOMOBILES CLASSIFY SPRINGS :- 1) HELICAL SPRINGS: COMPRESSION HELICAL
SPRING, TENSION HELICAL SPRING 2) CONICAL AND VOLUTE SPRINGS 3) TORSION SPRINGS 4)
LAMINATED OR LEAF SPRINGS 5)DISC OR BELLEVILLE SPRINGS 6) SPECIAL PURPOSE SPRINGS
EXPLAIN THE FOLLOWING(I) EFFECT OF KEYWAY IN STRENGTH OF SHAFT (II) PROVE THAT SQUARE KEY
IS EQUALLY STRONG IN SHEARING AND CRUSHING'.
I) EFFECT OF KEYWAY IN STRENGTH OF SHAFT THE KEYWAY CUT INTO THE SHAFT REDUCES THE LOAD
CARRYING CAPACITY OF THE SHAFT. THIS IS DUE TO THE STRESS CONCENTRATION NEAR THE CORNERS
OF THE KEYWAY AND REDUCTION IN THE CROSS-SECTIONAL AREA OF THE SHAFT. IN OTHER WORDS, THE
TORSIONAL STRENGTH OF THE SHAFT IS REDUCED. THE FOLLOWING RELATION FOR THE WEAKENING
EFFECT OF THE KEYWAY IS BASED ON THE EXPERIMENTAL RESULTS BY H.F. MOORE

E = I- 0.2(W/D) -1.1 (H/D)

E = SHAFT STRENGTH FACTOR. IT IS THE RATIO OF THE STRENGTH OF THE SHAFT WITH KEYWAY TO THE
STRENGTHOF THE SAME SHAFT WITHOUT KEYWAY, W = WIDTH OF KEYWAY, D = DIAMETER OF SHAFT,
AND H = DEPTH OF KEYWAY = THICKNESS OF KEY (T)/2 IT IS USUALLY ASSUMED THAT THE STRENGTH OF
THE KEYED SHAFT IS 75% OF THE SOLID SHAFT, WHICH IS SOMEWHAT HIGHER THAN THE VALUE
OBTAINED BY THE ABOVE RELATION. IN CASE THE KEYWAY IS TOO LONG AND THE KEY IS OF SLIDING
TYPE, THEN THE ANGLE OF TWIST IS INCREASED IN THE RATIO KE AS GIVEN BY THE FOLLOWING
RELATION:K= 1+0.4 (W/D)+O.7 (H/D)

II)¯PROVE THAT SQUARE KEY IS EQUALLY STRONG IN SHEARING AND CRUSHING' A KEY CONNECTING
THE SHAFT AND HUB IS SHOWN IN ABOVE FIG. LET T = TORQUE TRANSMITTED BY THE SHAFT,
F = TANGENTIAL FORCE ACTING AT THE CIRCUMFERENCE OF THE SHAFT, D = DIAMETER OF SHAFT,
I = LENGTH OF KEY, W = WIDTH OF KEY. T = THICKNESS OF KEY AND OC = SHEAR AND CRUSHING
STRESSES FOR THE MATERIAL OF KEY. IN ABOVE ARRANGEMENT, DUE TO THE POWER TRANSMITTED BY
THE SHAFT, THE KEY MAY FAIL DUE TO SHEARING OR CRUSHING. CONSIDERING SHEARING OF THE KEY,
THE TANGENTIAL SHEARING FORCE ACTING AT THE CIRCUMFERENCE OF THE SHAFT F = AREA
RESISTING SHEARING X SHEAR STRESS = I X W X T , T=FXD/2 = L W R X D/2 ...(I) CONSIDERING
CRUSHING OF THE KEY, THE TANGENTIAL CRUSHING FORCE ACTING AT THE CIRCUMFERENCE OF THE
SHAFT, F = AREA RESISTING CRUSHING X CRUSHING STRESS = I .T/2. OC THE KEY IS EQUALLY STRONG IN
SHEARING AND CRUSHING, IF I.W. T .D/2.=L.T/2. OC.D/2....[EQUATING EQUATIONS (I) AND (II)]
OR W/ T = OC/2 T ...(III) THE PERMISSIBLE CRUSHING STRESS FOR THE USUAL KEY MATERIAL IS AT LEAST
TWICE THE PERMISSIBLE SHEARING STRESS. THEREFORE FROM EQUATION (III), WE HAVE W = T. IN
OTHER WORDS, WE CAN SAY THAT A SQUARE KEY IS EQUALLY STRONG IN SHEARING AND CRUSHING.

WRITE THE MEANING OF FOLLOWING MATERIAL DESIGNATION. ANS 1)40C8 : PLAIN CARBON STEEL
CARBON 0.4% OF AVERAGE, MANGANESE 0.8% 2)SG 700/2 : SPHEROIDAL GRAPHITE CAST IRON WITH
MIN UTS 700N/MM2 AND ELONGATION 0.2 % 3)FE E200 : STEEL WITH YIELD STRENGTH OF 200N/MM2
4)X10CR18NI9 : HIGH ALLOY STEEL CARBON 0.10% OF AVERAGE, CHROMIUM 18%, NICKEL 9%,
EXPLAIN DESIGN PROCEDURE OF MUFF COUPLING.

STATE THE MEANING OF THE FOLLOWING COLOUR CODES USED IN AESTHETIC

CONSIDERATIONS WHILE DESIGNING A PRODUCT 1) RED 2) GREEN 3)ORANGE 4) BLUE
MEANING OF THE FOLLOWING COLOUR CODES USED IN AESTHETIC CONSIDERATIONS
RED : DANGER-HAZARD-ZONE GREEN: SAFETY ORANGE: POSSIBLE DANGER
BLUE : CAUTION COLD
GIVE COMPOSITION OF 45CR20SI2 SOL. ALLOY STEEL CONTAINING 0.45% OF CARBON , 20% OF
CHROMIUM AND 2% OF SILICON. B) DEFINE CREEP SOL. WHEN A MACHINE COMPONENT IS
SUBJECTED TO CONSTANT STRESS (LOAD) AT HIGH TEMPERATURE FOR A LONG PERIOD OF
TIME,IT WILL UNDERGO A SLOW AND PROGRESSIVE PERMANENT DEFORMATION CALLED
CREEP. C) STATE TWO APPLICATION OF KNUCKLE JOINT SOL. I. TIE ROD OF ROOF TRUSS. II. LINK
OF BICYCLE CHAIN. III. LINK OF ROLLER CHAIN. IV. TENSION LINK IN BRIDGE STRUCTURE. V. TIE
ROD OF JIB CRANE
DESIGN A KNUCKLE JOINT TO WITHSTAND 150 KN, THE DESIGN STRESS IS 75 MPA, 60 MPA
AND 150 MPA IN TENSION, SHEAR AND COMPRESSION RESPECTIVELY.