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Model Answers for Machine Design Exam

The document outlines the examination instructions and model answers for the subject 'Elements of Machine Design' from the Maharashtra State Board of Technical Education. It includes guidelines for examiners on assessing student responses, the marking scheme for various questions, and specific topics such as the factor of safety, properties of materials, and design principles. Additionally, it covers theoretical concepts, practical applications, and design procedures relevant to machine design.

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0% found this document useful (0 votes)

280 views111 pages

Model Answers for Machine Design Exam

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
WINTER – 19EXAMINATION
Subject Name: Elements of Machine Design Model Answer Subject Code: 22564
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in themodel answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may tryto assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given moreImportance (Not applicable for
subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in thefigure. The figures
drawn by candidate and model answer may vary. The examiner may give credit for anyequivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constantvalues may vary and
there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.

Q. Sub Marking
No. Q. N Scheme

1. Attempt anyFIVE of the following 10 Marks

a) Define factor of safety for ductile and brittle material.

Ans Factor of safety for ductile material: It is defined as ratio of yield stress to the working stress or

01 M

Factor of safety for Brittle material : It is defined as ratio of ultimate stress to the working stress
/permissible /design stress or

01 M

b) List four properties desirable for spring material(Any Four)

Ans 1)High Resilience 2) High ductile 1/2 M each

3)High static strength 4) High fatigue strength 5) Non corrosive
c) 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 1/2 M each
4)Valve mechanism, 5) Fulcrum of lever, 6) Joint for rail shifting mechanism
d) Name four types of keys(Any Four)

1) Sunk keys 2) Gibb-head key 3)Feather key 4)Woodruff key 5)Saddle keys 1/2 M each
6)Tangent keys 7)Round keys 8) Splines Key
e) List any four application of power screw.

Ans 1) Machine Vice 2) power press 3) Universal testing machine 4) C clamps etc. OR 1/2 M each
1)To raise the load 2) To clamp the work-piece 3) to load specimen 4)to obtain accurate motion
f) Classify springs

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Ans 1) Helical springs: Compression helical spring, Tension helical spring 1/2 M each
2) Conical and volute springs
3) Torsion springs
4) Laminated or leaf springs
5)Disc or Belleville springs
6) Special purpose springs
g) Give four applications of gear drive. (Any Four)

Ans 1) Gear box of vehicle 2)Machine tool 3)Gear mechanism of wrist watch 1/2 M each
4) Dial Indicator 5) Cement mixing unit 4) Diff. Mechanism of automobiles
2. Attempt anyTHREE of the following 12 Marks

a) Write the meaning of following material designation.

Ans 1)40C8 : Plain carbon steel carbon 0.4% of average, manganese 0.8% 1 Mark each
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%,
b) Explain the failure of cotter in bending with suitable sketch and strength equation

Ans 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.

2 Marks fig.

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

2 Marks

c) Write Lewis equation for strength of gear tooth give meaning of each term

Ans Lewis equation for strength of gear tooth : 2 Marks for

WT = 6w.b. Pc. Y = 6w.b.πm. y equation
Where,
WT = Tangential load acting at the term , &
6w = Beam strength of the tooth ,
b = Width of the gear face 2 Marks for
Pc = Circular pitch notations
m = Module
Y = Lewis form factor or tooth form factor.
d) Draw freehand sketches of thread profiles ( any four) with full details

Ans

1 Marks for
each type

3. Attempt any THREE of the following: 12marks

a) Explain maximum principal stress theory and maximum shear stress theory with their uses.

Ans 1. Maximum Principal (Normal) Stress Theory (Rankine’s Theory):

According to this theory, the failure or yielding occurs at a point in a member when the maximum
principal (Normal) stress in a bi-axial stress system reaches the limiting strength of the material in a
simple tension test.

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Since, for ductile material the limiting strength is the stress at yield point & for brittle material the
limiting strength is the ultimate stress.

 According to the above theory, taking FOS into consideration,

The maximum principal (Normal) stress (t1) in a bi-axial stress system is given by,
2 marks

Application:
Designing of machine components of brittle material.
Examples:
Spindle of screw jack, machine bed, C-frame, Overhang crank.
2. Maximum Shear Stress Theory (Guest’s or Tresca’s Theory):
According to this theory, the failure or yielding occurs at a point in a member when the maximum
Shear Stress in a bi-axial stress system reaches a value equal to shear stress at yield point in a simple
tension test.

 According to the above theory, taking FOS into consideration,

The maximum principal (Normal) stress (t1) in a bi-axial stress system is given by,

Since, the shear stress at yield point in a simple tension test is equal to one-half the yield stress in 2 marks
tension.

Application:
Designing of machine components of ductile material.
Examples:
Spring, key, crank shaft, propeller shaft.
b) Write general design procedure of the bell crank lever. (any four steps)

Ans

Page No: ____/ N

W X lw =(P) X lp

2. Find reaction at fulcrum pin at F,

Find:

3. Design of fulcrum pin:

1 marks for
i. Fulcrum pin is designed by considering under bearing pressure, any four
steps each

where, = length of fulcrum pin.

= 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.

A brass bush of 3 mm thickness is pressed into the boss of the fulcrum as a bearing so that renewal
become simple when wear occurs.

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

Check the induced in the lever arm at the fulcrum.

5. Design of lever to find dimensions:

The lever is subjected to B.M. ,
The maximum B.M. acts near the boss,

i. Consider rectangular cross-section of the lever,

where,
b = depth of the lever.
t = thickness of the lever.

ii. For elliptical section,

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

where,

t = minor axis of ellipse.

b = major axis of ellipse.

c) State any four applications of spring.

Ans Applications of spring: (Any Four)

1 mark for
1. In automobile suspension.
one applica-
2. In railway suspension.
3. In shot blasting machine. tion any four
4. In clocks and toys to store energy. each
5. In spring balance and engine indicator to measure force.
6. In clutch, brakes, spring loaded valves, etc.
d) Define stress concentration. Explain any four methods to reduce it with neat sketch.

Ans
Fordefinition
Stress Concentration:

Whenever the machine component changes the shape of its cross section the stress distribution
2 marks for
pattern no longer holds good and the neighborhood of the discontinuity is different.
stress
The stresses induced in the neighborhood are much higher than the stress induced in the other part concen-
of the component. This abrupt change in cross section or the discontinuity form is called stress
-tration
concentration.

It is for all kinds of stresses caused due to keyways, grooves, notches, roughness or scratches.

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

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: 2 marks for
methods to
1. Providing additional holes and notches.
reduce them
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.

e) Define the following terms with respect to spring:

Ans i) Free length:

It is the length of the spring in free or unloaded condition.

It is denoted by ‘Lf’.

Free length = Solid Length + Maximum Compression + clearance between adjacent coils.

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

Free length = Lf = n’d + max + 0.15 x max

= n’d + max + (n’-1) x 1mm.

The clearance between two adjacent coils is taken as 1mm sometimes it is taken as 15% of the
maximum deflection.

ii) Solid length:

When the compression spring is compressed until the coil comes in contact or touches each
other, then the spring is said to be in solid condition. This length of spring is known as solid 1 Mark for
length. each term
It is denoted by ‘Ls’.

Solid length = Ls = n’d

where n’ = total number of coils or turns.

d = diameter of wire in mm.

iii) Spring index:

It is defined as the ratio of mean diameter of coil to the diameter of wire.

It is denoted by ‘C’.

Spring index = C =

Where, Dm = Mean diameter of coil in mm.

d = wire diameter in mm.

iv) Spring rate:

The spring rate/ spring stiffness is defined the load required per unit deflection of the wire.

It is denoted by ‘K’.

Spring rate/ Spring Stiffness = K = (N/mm)

where W = axial load in N.

= maximum deflection in mm

Q.4 Attempt any TWO of the following: 12 marks

Page No: ____/ N

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 6 marks
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.

b) The pull in the tie rod of a roof truss is 44 kN. Design a suitable adjustable screw joint. The
6 marks
permissible tensile and shear stresses are 75 MPa and 37.5 MPa respectively.

Ans Let,

dc = core diameter of tie rod.

d = do = nominal (maximum) diameter of tie rod

D = Outside diameter of coupler nut.

l = Length of coupler nut.

D1 = Inside diameter of coupler.

D2 = Outside diameter of coupler.

L = Total length of coupler = 0.6 d

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

c) A Lathe receives power from an overhung shaft situated exactly above the lathe pulley by means of
the belt drive. A pulley weighing 400 N and of diameter 270 mm is fixed on the shaft. The centre to
centre distance between the two shaft supporting bearing is 900 mm. the maximum power required 6 marks
by machine is 5 kW at 200 rpm. The belt tension ratio is 2.5. Determine the diameter of the shaft.
Allowable shear stress for shaft material is 40 N/mm2.

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

5. Attempt anyTWO of the following 12 Marks

a) A flanged protective type coupling is required to transmit 7.5 KW at 720 rpm. Assume the
following stresses for the coupling components. Permissible shear stress for shaft, bolt & key
material = 33 N/mm2. Permissible crushing stress for bolt & key material = 60 N/mm2.
Find:
(i) Diameter of shaft
(ii) Diameter of key
(iii) Diameter of bolt
Ans P = 7.5 KW
N= 720rpm
= 33 N/mm2
= 60 N/mm2
Step 1)Find Torque

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

T= 99.47N.m= 99.47 [Link]

Step 2) We also know that

99.47 [Link]=
= 15351.41d = 24.85 mm=25mm
Step 3)Design of hub
Outer diameter of hub
D= 2d = 2 25 = 50 mm

Length of hub, L= 1.5d =1.5 25= 37.5mm

Let, now check induced shear stress

99.47 103=

Since induced shear stress is less than permissible value 33N/mm2 the design is safe

Step 4)Design of key, here Rectangle key is used

from table W=10mm

t= 8mm
Length of key is taken as length of the hub = L = 37.5mm
Let us now check induced stresses

T=l×w×Ʈ×

99.47 103= 37.5× 10 × Ʈ ×

Ʈ =21.22≤ 33N/mm2

99.47 103 = l× ×σ
ck
×

99.47 103 = 37.5 × ×σ

ck
×

σ
ck = 53.05≤ 60N/mm
2

Design is safe.
Step 5) Design for flange

Page No: ____/ N

Now, check induced shear stress in flange

99.47 103 ==
= 8.10 N/mm2
Flange is safe.

Step 6) Design for bolts

Number of bolts is n = 3
D1= 3d= 3 25=75mm
Bolts are subjected to shear stress
T=

99.47 103 =

d 12=
d 12= 34.11
d1=5.84mm

Assume coarse thread nearest to standard diameter M6

step 7) Outer diameter of the flange,D2= 4d= 4×25 = 100mm

Step 8) Thickness of protective circumferential flange, tp= 0.25d = 0.25×25 = 6.25mm

b) The lead screw of lathe has ACME thread of 60 mm outside diameter & 8 mm pitch. It supplies
drive to a tool carriage which need an axial force of 2000 N. A collar bearing with inner & outer
radius as 30 mm & 60 mm respectively is provided. The coefficient of friction for the screw thread
is 0.12 & collar is 0.10. Find the torque required to drive the screw & the efficiency of the screw.
Ans d0= 60mm
W= 2000N
D2= 30mm
D1= 60mm
p = 8mm
µ =0.12
µ2 = 0.10
To Find
Page No: ____/ N
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
T=?
=?

Step 1 ) Mean diameter of screw

d = d0- = 60 - = 56mm

tanα = =

tanα =0.045
angle for ACME thread 2β=290β=14.50
µ1=tan 1=

µ1=tan 1=

µ1 = tan 1=0.1239
Step 2) Torque required to overcome friction of screw
T1 = W ×d/2

T1 = 2000 × ×56/2
T1= [Link]
Step 3) Assuming uniform wear to overcome collar friction
R= =

R= = 45mm
T2= µ×W×R = 0.10×2000×45 = [Link]
T = T1 +T2 = 9576 + 9000 = 18576 [Link]
Step 4)

Ƞ= =

Ƞ= =
Ƞ=0.1371=13.71%
c) 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.

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
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
OR

6. Attempt anyTWO of the following 12 Marks

a) A plate 75 mm wide & 12.5 mm thick is to be joined with another plate by single transverse &
parallel fillet weld. Maximum tensile & shear stresses are 70 N/mm2& 56 N/mm2 respectively. Find
the length of each parallel fillet weld if joint is subjected to 90 KN.

Ans Given data

Page No: ____/ N

Step 1) Load carried by single transverse

P1= 0.707× s × l1× σ t
2 Marks
P1= 0.707 × 12.5 × 62.5×70 ……………………………( l1 =75-12.5 =62.5)
P1= 38664.06 N
Step 2) Double parallel fillet weld
P2= 1.414 × S × l2× Ʈ
2 Marks
P2= 1.414 × 12.5 × l2× 56
P2= 989.8 × l2
Step 3) P= P1 + P2
90 × 103 = 38664.06 + 989.8 × l2
l2= 51.86mm 2 Marks

l2= 51.86+ 12.5

l2 = 64.36 mm
b)

Ans W= 1000N
= 25mm
C= = 0.6
mm
G=84 × 103 N/mm2

Step 1) Mean diameter of spring coil

K=
K= 1.31
Step 2) Maximum shear stress

420 =K = 1.31

d = 6.3mm

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
From table take d = 6.401 or same value also considered
D=C d=5 = 32.005
Outer diameter of spring
D0= D+d=32.005 + 6.401= 38.406 mm

Step 3) number of turns of the coil

= 13.44=14

Step 4) for square and ground ends

n'= n+2 = 14+2 =16
Step 5) Free length
Lf= n'd + + 0.15 = 16 + + 0.15 = 131.2 mm
Step 6) Pitch of the coil

= = = 8.76 mm

c) A hollow transmission shaft having inside diameter 0.6 times outside diameter, is made up of plain
carbon steel 40C8 & having permissible shear stress equal to 65 MPa. A belt pulley, 1000 mm in
diameter is mounted on a shaft, which overhangs the left hand bearing by 250 mm. The belt are
vertical power transmit to the machine shaft below the pulley. The tension on tight & slack side of
belt are 3 kN& 1 kN respectively, while weight of pulley is 500 N. The angle of rap of the belt on
pulley is 180°. Calculate outside & inside diameter of shaft.

Ans Given data

d = 0.6 D
T 1= 3 N
T2= 1 N
Wt =500N

1800
Diameter of the pulley, D=1000mm
K= d/D =0.6

Step 1) Find torque

Page No: ____/ N

Wt = T1 + T2 + W= 3000+1000+500= 4500 N
Step 2) Bending moment 02 Marks
M= Wt = 4500 = 1.125 106 [Link]
Step 3) Find equivalent twisting moment

Teq = = = 1.50 106 [Link]

Teq= d03 (1 - K4)

1.56 106= d 03 (1-0.64)
02 Marks
d0= 51.97 =55mm
di = 0.6 55 =33 mm

Page No: ____/ N

Subject Name: Elements of Machine Design Subject Code: 22564

Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in themodel answer
scheme.
2) The model answer and the answer written by candidate may vary but the examiner may tryto assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given moreImportance (Not
applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in thefigure. The
figures drawn by candidate and model answer may vary. The examiner may give credit for anyequivalent
figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constantvalues
may vary and there may be some difference in the candidate’s answers and model answer.
6) In case of somequestions credit may be given by judgement on part of examiner of relevant answer
based on candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual
(English + Marathi) medium is introduced at first year of AICTE diploma Programme from academic year
2021-2022. Hence if the students in first year (first and second semesters) write answers in Marathi or
bilingual language (English +Marathi), the Examiner shall consider the same and assess the answer
based on matching of concepts with model answer.

Sub
Q. Marking
Q. Answer
No. Scheme
N.
Que.1 Attempt any FIVE of the following 10 Marks

a) Give composition of 45Cr20Si2

Sol. Alloy Steel Containing 0.45% of carbon , 20% of chromium and 2% of silicon. 02 Mark

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 02 Mark
called creep.
c) State two application of Knuckle Joint

i. Tie rod of roof truss.

Sol.
ii. Link of bicycle chain. 01 Mark
iii. Link of roller chain. for one
iv. Tension link in bridge structure. application
v. Tie rod of jib crane.
vi. Air braking arrangement of locomotive and track shifting mechanism of railway. Any two
vii. It is used in coupling trolley with railway. expected
viii. It is used in structure for suspension link.

Page No: ____/ N

Sub
Q. Marking
Q. Answer
No. Scheme
N.

d) State any two examples where hollow shafts are used

i. It is used in machine tool spindle.
Sol. 01 Mark
ii. Marine applications. for each
iii. Automobile. Any two
iv. Electric motor. expected

e) Explain “bolts of uniform strength”

A method of drillling an axial hole through the head of the bolt as far as the threaded
Sol.
portion; such that the area of the shank became equal to the root area of the thread. By
achieving this the intensity of stress, that is stress in the shank portion and the threaded
portion is [Link] gives the bolt of uniform strength.

02 Mark

Let,
d1= Diameter of hole
d₀ = Outer diameter of thread
dc = Core diameter of thread
=
=√

f) State any two applications of torsion spring.

i. Clocks. 01 Mark
Sol.
ii. Automobile. for each
iii. Door Hinges. Any two
iv. Spring balance. expected

g) Define “Basic Static Load Rating” of rolling contact bearings.

The basic static load rating is defined as the static radial load which correponds to a
Sol.
permanent deformation of the ball and race at the most heavily stressed contact equal to 02 Mark
0.0001 times the ball diameter.

Page No: ____/ N

Q.2 Attempt any THREE of the following: 12 Marks

a) Explain the term stress concentration and remedies to reduce stress concentration with
neat sketch (any four)
Sol. 1. During the design of any machine component, discontinuities in any machine part
are there due keyway, threaded grooves and steps are present on the component
which is functional requirement to perform their functions.
2. Such type of discontinuity alters the stress distribution in the vicinity of the
discontinuity and elementary stress equations no longer describe the state of stress
in the component.
02 Marks
3. The stresses induced in the neighbourhood of the discontinuity are much higher
than the stresses in the other part of the component.
4. This concentration of high stresses due to the discontinuities or abrupt change of
cross-section is called stress concentration.

5. remedies to reduce stress concentration are as follows:

i. Additional notches and holes in tension member like use of use of multiple notches
and drilling additional holes.
ii. Fillet radius,undercutting and notch for member in bending.
iii. Reduction of stress concentration in Threaded members.
iv. Change in cross-section should be gradual. 01 Mark
v. By improving surface finish

01 Mark

b) Discuss the design procedure of socket and spigot cotter joint.

Page No: ____/ N

01 Mark
for Fig &
notation

Fig: Socket spigot cotter joint

Let, P = load carried by the rods
d = diameter of rod 01 Mark for figure
d1= outside diameter of socket
d2= inside diameter of socket/ diameter of spigot
d3= outside diameter of spigot collar
d4= outside diameter of socket collar
a = distance from the end of the slot to the end of the rod
b = mean width of cotter
c = thickness of socket collar
l = length of cotter
t = thickness of cotter
t1 = thickness of spigot collar
σt = permissible tensile stress for the rod material
σc = permissible crushing stress for the cotter material 1/2 Mark
τ = permissible shear stress for the cotter material
I) Design of Rod:
σt =𝑃 = P /(π÷4) find ‘d’
𝐴
II) Design of Spigot:
i. Spigot failure in tension
σt = = P / *(π÷4) - .t] always take t = 2/4 find ‘d2’ & ‘t’ 1/2 Mark

ii. Spigot failure in crushing

σcrush = = P / (d2.t) Check σcrush and finalize d2& t

iii. Spigot failure in shear

τ = = P / 2 (d2.a) find ‘a’ 1/2 Mark

iv. Spigot collar failure in shear

τ = = P / (π d2.t1) find ‘t1’

v. Spigot collar failure in crushing 1/2 Mark

σcrush = = P / *(π÷4)( )] find ‘d3’

Page No: ____/ N

i) Socket failure in tension

σt = = P / *(π÷4) ( )] – [(d1 - d2) t] find ‘d1’

ii) Socket collar failure in crushing

1/2 Mark
σcrush = = P / [(d4 - d2) t] find ‘d4’

iii) Socket collar failure in shear 1/2 Mark

τ= = P / 2 [(d4 - d2) c] find ‘c’

IV) Design of Cotter:

τ= = P / 2 (b.t) find ‘b’

Length of Cotter L = 4.d

c) Explain with neat sketch different types of sunk keys.

Different types of sunk keys are as follows:

1. Rectangular sunk key.
2. Square sunk key.
01 Mark
3. Parallel sunk key.
4. Gib headed key.
5. Feather key.
6. Woodruff key.
1. Rectangular sunk key.

1/2
i. The various proportions of this key are: Mark
ii. Width of key = w =
iii. Thickness of key = t=
iv. Where,d = diameter of the shaft
v. The key has taper 1 in 100 on the top side only.

Page No: ____/ N

Sub
Q. Marking
Q. Answer
No. Scheme
N.
Sol. 2. Square sunk key.

The only difference between a rectangular sunk key and square sunk key is that its
width and thickness are equal. 1/2 Mark
W=t=

3. Parallel sunk key.

i. The parallel key may be of rectangular or square cross-section uniform in width and 1/2 Mark
thickness throught.
ii. It may be noted that parallel key is taperless and is used where pulley, gear or other
mating piece is required to slide along the shaft.

4. Gib headed key.

1/2 Mark

i. It is a rectangular key with a head on one end known as gib head.

ii. It is usually provided to facilitate the removal of key.

5. Feather key.

i. A key attached to one member of a pair and which permits relative axial 1/2 Mark
movement is known as feather key,
ii. It is a special type of parallel key which transmits a turning moment and also
permits axial moment,
iii. It is fastened either to a shaft or hub, the key being a sliding fit in the keyway of
the moving piece.

Page No: ____/ N

Sub
Q. Marking
Q. Answer
No. Scheme
N.
6. Woodruff key.

i. The woodruff key is an easily adjustable key.

ii. It is a piece from a cylindrical disc having segmental cross-section in front view. 1/2 Mark
This key is capable of tilting in a recess milled out in the shaft by a cutter having
the same curvature as the disc from which the key is made.
iii. This key is largely used in machine tool and automobile construction.

Explain self locking and overhauling property of screw.

Sol. Self Locking Screw

The effort required at the circumference of the screw to lower the load is given by equation,
P = [Link] (ø - α)

T = [Link] (ø - α). (dm/2)

02 Mark
In the above equation, if ø > α (i.e friction angle is greater than helix angle), the torque
required to lower the screw is positive i.e. some effort is required to lower the load, such a
screw is known as self locking.

Over-hauling Screw
The effort required at the circumference of the screw to lower the load is given by equation,
P = [Link] (ø - α)
02 Mark
T = [Link] (ø - α). (dm/2)

In the above equation, if ø < α (i.e friction angle is less than helix angle), the torque
required to lower the screw is negative i.e. load will start moving downward without the
application of any torque. Such condition is known as overhauling of screw.

Page No: ____/ N

Sub
Q. Marking
Q. Answer
No. Scheme
N.
Que.3 Attempt any THREE of the following 12 Marks

a) Explain construction of leaf spring with neat sketch

Sol.

Diagram
&lable:

1 & 1/2

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. Explanation
• Thus, leaf spring carry lateral load, brake torque, driving thrust and shocks. :
• It consists of number of semi-elliptical plates called blade or leaves. 2 & 1/2
• The leaves are given initially curvature or camber so that they tend to straighten
under the load.
• The blades vary in length and are held together by a bolt passing through the center
acting as a beam of uniform strength.
• The spring is clamped to the axle housing by means of ‘U’ bolts.
• The longest leave is known as master leaves, has its end formed in the shape of an
eye through which the bolts are passed to secure the spring to its supports.
• The eyes are attached to shackle provided with bushing of anti-friction material such
as bronze or rubber. The other leaves are graduated leaves.
• To prevent digging in the adjacent leaves, the ends of graduated leaves are trimmed in
various forms.
• The master leaf has to withstand vertical bending load, side thrust and twisting
moment due to presence of stresses caused by these loads so it is usual to provide two
full length leaves and rest graduated leaves.
• Rebound clips are located at intermediate position in the length of the spring so that
graduated leaves also shear the stresses induced in the full-length leaves when the
spring rebound.
• Highly cambered spring provides a 50% suspension but they also increase tendency to
jaw (movement about vertical axis). Flat spring reduces tendency of the vehicle to dip
(pitching), when brake or accelerate suddenly.
• Generally rear spring are kept longer than the front spring. This causes them to vibrate
at different frequencies, which prevent excessive bounce.

Page No: ____/ N

Sub
Q. Marking
Q. Answer
No. Scheme
N.

b) Explain with neat sketch different types of radial Ball bearings.

Following are the various types of radial ball bearings:

Sol.

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 1 Mark for
then centered and the balls are symmetrically located by the use of a retainer or each type
[Link] 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 (Sketch &
related to the size and number of the balls. explanation)
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.
Following are the two types of self-aligning bearings: (a) Externally self-aligning bearing,
and (b) Internally self-aligning bearing.

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________ ___________
Q. Marking
Sub
No. Answer Scheme
Q.
N.
Design a helical compression spring for a maximum load of 1000 N for a deflection
c)
of 25 mm using the 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.

Given : W = 1000 N ; δ = 25 mm ; C = D/d = 5 ; τ = 420 MPa = 420 N/mm2 ;

Sol.
G = 84 kN/mm2 = 84 × 103 N/mm2

a) Considering Curvature effect :

1. Mean diameter of the spring coil

Let D = Mean diameter of the spring coil, and d = Diameter of the spring wire.

We know that Wahl’s stress factor,

Wahl’s factor K = = = 1.31

and maximum shear stress (τ),

Maximum shear stress, Ʈ = , 420 = 2 Mark

2
d = 16 677 / 420 = 39.7 or d = 6.3 mm
∴Mean diameter of the spring coil, D = C.d = 5 d = 5 × 6.3 = 31.5 mm Say 32 mm

2. Number of turns of the coils

Let n = Number of active turns of the coils.
We know that compression of the spring (δ),

δ= , 25 = = 1.86 n
n=25/1.86 = 13.44 ..Say 14 numbers of turns
Assuming square and grounded ends, total numbers of turns is given by, 2 Mark

n’=n+2=14+2=16 numbers of turns

Page No: ____/ N

Q. Marking
Sub
No. Answer Scheme
Q.
N.

OR
b) Without Considering Curvature effect :

1 Mean diameter of the spring coil

Let D = Mean diameter of the spring coil, and d = Diameter of the spring wire.

and maximum shear stress (τ),

2 Mark
Maximum shear stress, Ʈ = , 420 =
d 2 = 12732.39/ 420 = 30.31 or d = 5.5 mm say 6 mm
∴Mean diameter of the spring coil, D = C.d = 5 d = 5 × 6= 30 mm

2 Number of turns of the coils

Let n = Number of active turns of the coils.
We know that compression of the spring (δ),

δ= , 25 = = 1.98 n
n=25/1.86 = 12.62 ..Say 13 numbers of turns 2 Mark

d) Explain selection of ball bearing using manufacturer’s Catalogue.

Procedure for selection of bearing from manufacturer’s Catalogue.

Sol.
The following procedure is followed in selecting the bearing from the
manufacturer’scatalog.
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. Correct
5) Calculate ratios Fa/VFr and Fa/Co. Explanation
6) Calculate values of radial and thrust factors.(X & Y) from catalogue. /steps
7) For given application find value of load factor Ka from catalogue. 4 Mark
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

Page No: ____/ N

Q. Sub Marking
No. Q. Answer Scheme
N.

OR ( flow chart)

Flow Chart

4 Mark

Page No: ____/ N

Q. Sub Marking
No. Q. Answer Scheme
N.
Que.4 Attempt any TWO of the following 12 Marks

A screw jack is to lift a load of 80 kN through a height of 400 mm. The elastic strength
a)
of screw material in tension and compression is 200 MPa and in shear 120 MPa. The
material for nut is phosphor bronze for which the elastic limit may be taken as 100
MPa in tension, 90 MPa in compression and 80 MPa in shear. The bearing pressure
between the nut and the screw is not to exceed 18 N/mm2. Design and draw the
screw jack. Take FOS = 2
Solution. Given : W = 80 kN = 80 × 10 3 N ; H1 = 400 mm = 0.4 m ;
Sol. 2
σet = σec = 200 MPa = 200 N/mm ; τe = 120 MPa = 120 N/mm2 ;
σet(nut) = 100 MPa = 100 N/mm2 ; σec (nut) = 90 MPa = 90 N/mm2 ;
τe(nut) = 80 MPa = 80N/mm2 ; Pb = 18 N/mm2

1. Design of screw for spindle

Let dc = Core diameter of the screw. Since the screw is under compression,

∴Load (W)

Value dc

: 1 Mark
(dc )2 = 80 × 103 / 78.55 = 1018.5 or dc = 32 mm

For square threads of normal series, dimensions of the screw selected is

Core diameter, dc = 38 mm Ans
Nominal or outside diameter of spindle, do = 46 mm Ans.
Pitch of threads, P = 8 mm Ans.
Now let us check for principal stresses:
We know that the mean diameter of screw d = (do + dc) / 2 = ( 46+38 )/ 2 = 42 mm
And tan α = p / π d = 8 / π x 42 = 0.0606
Assuming coefficient of friction between screw and nut, μ = tan φ = 0.14
∴ Torque required to rotate the screw in the nut

Calculation:

1 Mark

Page No: ____/ N

Q. Sub Marking
No. Q. Answer Scheme
N.

Calculation
of No. of
Threads &
Height of
Nut :

1 Mark

Design of Nut :

Dia&
thickness
of nut :

2 Mark

Page No: ____/ N

Q. Sub Marking
No. Q. Answer Scheme
N.

01mark

Design a cast iron protective type flange coupling to transmit 15 KW at 900 rpm from
b)
an electric motor to compressor.
use following permissible stress
shear stress for shaft ,bolt and key = 40 Mpa
crushing stress for Bolt and key= 80 Mpa
shear stress for cast iron = 8 Mpa.
Given : P = 15 kW = 15 × 103 W ; N = 900 r.p.m. ; τs = τb = τk = 40 MPa = 40 N/mm2 ;
Sol.
σcb = σck = 80 MPa = 80 N/mm2 ; τc = 8 MPa = 8 N/mm2

The protective type flange coupling is designed as discussed below :

1) Design for shaft

First of all, let us find the diameter of the shaft (d). We know that the torque
transmitted by the shaft,
T = P x 60/2π N = (15 x 103 x 60)/ (2 π x900) =159.15 Nm = 159.15 x 103Nmm
Design of
T = π/16 x τ xd3 , 159.15 x 103 = π/16 x 40 xd3 , d3=20263,60 d=27.26 mm say 28 mm shaft :

2) Design of Hub: 2 Mark

hub Outside dia. of hub , D=2d =2x28=56mm

Length of Hub l= 1.5 d = 1.5 x 28 = 42 mm
The shear stress induced in the hub is given by

Design of
T = π/16 x τc x d3 x (1-k4 ) Where K = d/D = 0.5 Hub :
159.15 x 103 = π/16 x τc x56 3 x(1-0.54 ) τc =4.923 < 8 Mpa
2 Mark
Hence, Hub is safe against shear failure.

Page No: ____/ N

Q. Sub Marking
No. Q. Answer Scheme
N.
3)Design of Flange:

Thickness of flange tf= 0.5 d = 0.5 x 28 = 14 mm

Thickness of Protective flange
Tp= 0.25 x d = 0.25 x 28 = 7 mm

Dia of Bolt circle:

D1 = 3 d = 3 x 28 = 84 mm Design of
Dia of Outer Falnge : flange:
D2 = 4d = 4 x 28 = 112 mm
2 Mark
Dia of flange recess D3 = 1.1 D = 1.1 X 56 = 61.6 mm
Direct stress induced in the flange at a junction with hub is
Tf = ( T/D/2) / (ΠxDxtf )
= 2T / (ΠxD2xtf ) = (2X 159.15 x 103 ) / (Π x 562 x 14 )
=2.3 N/mm2 < 8 N/mm2
Flange is safe against shear failure.

c) 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.
Outside diameter of hollow shaft (do) = Diameter of solid shaft (d)
Sol.
For same material: Density of solid = density of hollow shaft

LS =LH,di = inside diameter of hollow shaft = 0.75 do , =0.5

I )Comparison of weight:

We know that weight of a hollow shaft

WH= Cross sectional area x Length x Density

………….I
and Weight of the solid shaft

WS= Cross sectional area x Length x Density Comparison

of weight:
………………..
2Mark
Since both the shafts have the same material and length, therefore by dividing
equation (i) by
equation(ii), we get

Page No: ____/ N

Q. Sub Marking
No. Q. Answer Scheme
N.

As K= di/do

=1- (0.5)2 =0.75

WH=0.75 WS ………………….Ans Comparison

of strength:
II) Comparison of Strength: 2 Mark

Strength of hollow shaft TH =

Strength of Solid shaft Ts =

= ==

TH=0.93 TS ………………….. Ans

III) Comparison of Stiffness:

Stiffness of hollow shaft SH =

Comparison
of stiffness:
2 Mark
Stiffness of Solid shaft Ss

= ==

SH=0.93 SS ……………… Ans

Que.5 Attempt any TWO of the following 12 Marks

a) Explain general considerations in Machine Design.

Page No: ____/ N

Q. Sub Marking
No. Q. Answer Scheme
N.
1. Type of load and stresses caused by the load.
Sol.
The load, on a machine component, may act in several ways due to which the internal stresses
are set up. :
a) Compression- Applying forces to both ends
b) Tension- Forces applied in the opposite direction
c) Shear- Sliding forces that are applied in the opposite direction
d) Bending- Force off-centered
e) Torsional- Twisting force
f) Combination – Combination of any loads
2. Motion of the parts or kinematics of the machine.
The successful operation of any machine depends largely upon the simplest arrangement of
the parts which will give the motion required.
The motion of the parts may be:
a) Rectilinear motion which includes unidirectional and reciprocating motions.
b) Curvilinear motion which includes rotary, oscillatory, and simple harmonic.
c) Constant velocity
d) Constant or variable acceleration.
3. Selection of materials
The following factors should be considered while selecting the material: Any 6
a) Availability b) Cost c) Mechanical properties d) Manufacturing Considerations consideratio
4. Form and size of the parts: Form and size of the parts can decide manufacturing process
ns
and cost of the product.
5. Frictional resistance and lubrication: There is always a loss of power due to frictional
resistance and it should be noted that the friction of starting is higher than that of running
friction. It is, therefore, essential that careful attention must be given to the matter of 1 Mark each
lubrication of all surfaces which move in contact with others, whether in rotating, sliding,
or rolling bearings.
6. Ergonomic Considerations: User friendly machine operations, ease of control, proper force
required to operate and safety for operating.
7. Aesthetic considerations: Considerations related to the beauty of the product to attract
the customer.
8. Standardization: Use of standard parts makes product economical for design and
maintenance with improved quality.
9. Safety of operation: Designer should always provide safety devices for the safety of the
operator.
10. Manufacturing capability: Best manufacturing processes can provide quality but adds to
the cost. Therefore appropriate manufacturing processes and available manufacturing set up
must be used to the best possible effect so that cost of manufacturing must be limited.
11. The number of components to be manufactured: Suitability of design for job production,
batch production and mass production.
12. Cost of manufacturing: The aim of the design engineer under all conditions should be to
reduce the manufacturing cost to the minimum with optimum quality.
[Link] for assembly: Designer must consider the ease of assembly and disassembly of the
product to be manufactured.

Page No: ____/ N

Q. Sub Marking
No. Q. Answer Scheme
N.
Define factor of safety and state the factors affecting on selection of factor of safety
b)
for ductile and brittle material.
Sol. Factor of Safety:
It isdefined as the ratio of failure stress to allowable or working stress. OR it is the ratio
of failure load to allowable or working load.
– Allowable stress for ductile material &

– Allowable stress for brittle material

Selection of factor of safety (fs) depends upon following factors- 1 Mark

i) Effect of failure: Time, finance, danger to human life decides the value of fs.
ii) Type of load : Static load– low fs, Dynamic load and Impact Load-high fs,
Any 5
iii) Degree of accuracy in force analysis: Accurate - low fs,
factors
iv) Material of component: Homogeneous material or ductile low fs,
v) Reliability of component: fsincreases for higher reliability of component.
vi) Cost of component: Cost of component is directly proportional to value of factor
1 Mark
of safety. each
vii) Testing of machine element: Actual testing conditions known - low fs
viii) Service conditions: Operating conditions like temp, corrosion, humidity add to
value of factor of safety.
ix) Quality of Manufacture: High Mfg. quality leads to low fs
Selection of value of factor of safety is normally low for ductile materials and high for
brittle materials. It is essentially a compromise between the associated additional cost
and weight and the benefit of increased safety or/and reliability.

c)
Sol.

Page No: ____/ N

Q. Sub Marking
No. Q. Answer Scheme
N.
P = 6000 N , Depth of cross section b= 2 t where t= thickness of cross section
Step I
Permissible stress
1 Mark
𝑃 𝑃

Step IICalculation of direct and bending stress

The stress is maximum at point A in the section XX. The point is subjected to
combined bending and direct tensile stresses. The force P is resolved into two
components – horizontal component 𝑃 and vertical component 𝑃
1 Mark
𝑃 𝑃
4242.64 N
𝑃 𝑃 = 4242.64 N

The bending moment at section XX is given by

=𝑃 𝑃 318198
+551543.2 1 Mark

= 869741.2 N-mm

=
( ) 1 Mark

The direct tensile stress due to horizontal component 𝑃 is given by

Step III Calculation of dimensions of cross section

The resultant tensile stress

1 Mark
by trial and error method thickness = 28.4 mm = 30 mm
depth b= 2t = 60 mm……………………..Ans. 1 Mark

Page No: ____/ N

a) Diameter of wire = d= 10 mm , number of turns = N= 10, D = 120 mm,

Axial Load P = 200 N, G = 80000 N/mm2 1 Mark

i) Shear stress ( ) induced in spring neglecting effect of stress

concentration

𝑃
( ) ∴ ( ) 1.5Mark

ii) Deflection ( ) in the spring

1.5Mark

= = = 34.56 mm

iii) Stiffness (k) of the spring

1Mark
= = = 5.8 N/mm

iv) Strain energy stored (U) in the spring

1Mark
= = = 3456 N-mm = 3.456 N-m

b) i) Stiffness / Spring rate 1.5

The stiffness of the spring (k) is deﬁned as the force required to produce unit Mark
deﬂection. Therefore
𝑃

where, 1.5
k = stiffness of the spring (N/mm)
Mark
P = axial spring force (N)
= axial deﬂection of the spring corresponding to the force P (mm)

Page No: ____/ N

Given: P = 90 KN, permissible shear stress τ = 60 N/mm2,

size of the weld= plate thickness h= 10 mm 1Mark

Length of the weld ( l ) ,

Maximum load (P) that double parallel fillet weld can carry, is given by

P = 1.414 h.l.τ.

90×103= 1.414 ×10×l×60

1Mark

Adding 12.5 mm of length for starting and stopping of the weld run, the length of the
weld is given by,
……………………………………………….Ans 1Mark

Page No: ____/ N

1Mark
𝑃
i) Effort applied P:

Take moments about fulcrum F, we have

W×500 = P ×150

And reaction at fulcrum pin F is given by 1Mark

√ √
ii) Design of fulcrum pin:

let d = diameter of fulcrum pin, l = length of the fulcrum pin and

let length of pin l=1.25 d
Considering bearing pressure at fulcrum pin

Checking fulcrum pin for shear failure,

2Marks
∴
Since shear stress is induced in fulcrum pin is less than given value 60 MPa, hence
fulcrum pin is safe in shear.
A brass bush of 3 mm thickness is pressed into boss of fulcrum as a bearing.

Diameter of hole in the lever = d + 2

Page No: ____/ N

Considering weakest section of failure at Y-Y

Let t = thickness of lever
b = width depth of lever at YY
and b= 3t
Maximum Bending Moment at Y-Y

∴
2 Marks

Therefore depth of cross section b= 3 t =28

Page No: ____/ N

22564
22223
4 Hours / 70 Marks Seat No.

Instructions – (1) All Questions are Compulsory.

(2) Answer each next main Question on a new page.
(3) Illustrate your answers with neat sketches wherever
necessary.
(4) Figures to the right indicate full marks.
(5) Assume suitable data, if necessary.
(6) Use of Non-programmable Electronic Pocket
Calculator is permissible.
(7) Mobile Phone, Pager and any other Electronic
Communication devices are not permissible in
Examination Hall.
(8) Use of steam tables, logarithmic, Mollier’s chart is
permitted.
Marks

1. Attempt any FIVE of the following: 10

a) Explain term ‘Endurance Limit’.
b) State the significance of Wahl’s correction factor in Design
of spring.
c) List any four applications of Foot lever.
d) Classify Keys.
e) Draw Acme and V thread profile.
f) List different materials used for making springs.
g) Name any two bearing manufacturers.

P.T.O.
22564 [2]
Marks
2. Attempt any THREE of the following: 12
a) Explain in brief the general design procedure.
b) Explain design procedure of muff coupling.
c) Design an offset link for a load of 1000 N. Maximum
permissible stress in tension for link material is 60 N/mm2.
Assume b = 3t for rectangular cross section of the link.
Refer Fig. No. 1.

Fig. No. 1.

d) A bracket as shown in Fig. No. 2 is fixed to a vertical steel

column by means of four standard bolts. Determine the
diameter of the fixing bolts. Assume safe working stress of
70 MPa in tension and 50 MPa in shear.

Fig. No. 2.
22564 [3]
Marks
3. Attempt any THREE of the following: 12
a) State the meaning of following colour codes used in Aesthetic
considerations while designing a product
i) Red
ii) Green
iii) Orange
iv) Blue
b) Explain the term Self locking and overhauling of Screw.
c) Explain construction of leaf spring and state its applications.
d) Explain the term ‘Stress Concentration’. State its causes and
remedies with suitable example.
e) Write strength equations for designing symmetrically loaded
parallel and transverse weld with neat sketch.

4. Attempt any TWO of the following: 12

a) State the necessity of ‘Ergonomic’ considerations while
designing product. Explain any four ergonomic consideration
in the designing of machine element.
b) Design a Knuckle joint to withstand 150 kN, the design stress
are 75 MPa, 60 MPa and 150 MPa in tension, shear and
compression respectively.
c) A hollow shaft is to be designed to transmit 600 kW at
110 rpm. The maximum torque being 20% greater than the
mean. The shear stress is not to exceed 63 MPa and angle
of twist in a length of 3 mts not to exceed 1.4 degree.
Find external diameter of the shaft if the internal diameter
to external diameter is 3/8. Take modulus of rigidity 84 GPa.

P.T.O.
22564 [4]
Marks
5. Attempt any TWO of the following: 12
a) A belt pulley is fastened to a 90 mm diameter shaft running
at 300 r.p.m. by means of a key 20 mm wide and 140 mm
long. Allowable stress for the shaft and key material are
40 N/mm2 in shear and 100 N/mm2 in crushing. Find the
power transmitted and the depth of the key required.
b) A screw jack is used to lift a load of 50 kN through a
maximum lift of 200 mm. The material used for a screw is
steel of allowable stresses in tension and compression as
100 N/mm2 and 50 N/mm2 respectively. The pitch of screw
is 8 mm. The nut is made of phosphor bronze with allowable
stresses as 50 N/mm2 and 45 N/mm2 in tension and crushing.
The allowable shear stress for nut material is 40 N/mrn2. The
allowable bearing pressure between nut and screw is not to
exceed 20 N/mm2. If the coefficient of friction between screw
and nut is 0.14, design the screw and nut.
c) Explain the selection process of deep groove ball bearing for
given application with manufacturer’s catalogue with suitable
example.

6. Attempt any TWO of the following: 12

a) A double start square thread of power screw has nominal
diameter 100 mm pitch 12 mm is to used to raise the load
of 300 kN. The coefficient of friction at screw thread is 0.25
Neglect collar friction calculate Torque required.
b) A helical spring is made from a wire of 8 mm diameter and
has outside diameter 90 mm; if the permissible shear stress
is 350 N/mm2 and modulus of rigidity 84 kN/mm2, find the
axial load which the spring can carry and the deflection per
active turn.
i) Neglecting the effect of curvature
ii) Considering the effect of curvature
c) Design “C” clamp frame for a total clamping force of 20 kN.
The cross-section of the frame is rectangular and width to
thickness ratio is 2. The distance between the load line and
natural axis of rectangular cross section is 120 mm and the
gap between two faces is 180 mm. The frame is made of
cast steel for which maximum permissible tensile stress is
100 N/mm2.
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SUMMER – 2023 EXAMINATION
Model Answer – Only for the Use of RAC Assessors

Subject Name: Elements of Machine Design Subject Code: 22564

Important Instructions to examiners: XXXXX
1) The answers should be examined by key words and not as word-to-word as given in the model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not applicable for
subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The figures
drawn by candidate and model answer may vary. The examiner may give credit for any equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values may vary and
there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual (English +
Marathi) medium is introduced at first year of AICTE diploma Programme from academic year 2021-2022. Hence if
the students write answers in Marathi or bilingual language (English +Marathi), the Examiner shall consider the
same and assess the answer based on matching of concepts with model answer.

Q. Sub Answer Marking

No. Q. Scheme
N.

1 Attempt any FIVE of the following: (5x2=10) 10 marks

a) Explain term “Endurance Limit”. Definitio

n
Ans: Endurance Limit: It is defined as maximum value of the completely reversed bending
stress which a polished standard specimen can withstand without failure, for infinite 1 Mark
number of cycles (usually 106 cycles).It is known as endurance or fatigue limit (ϭe
• Endurance limit is not a property of material.

• Endurance limit is affected by the size and shape of component ,surface finish, temp.,&
notch sensitivity of material.

• Stress amplitude (Sf) versus number of cycles before (N) fatigue failure for ductile steels is
shown.

S-N
diagram

Page No: ____/ N

b) State the significance of Wahl's correction factor in Design of spring. Suitable

explanati
Ans:
A stress factor that is caused by the changes and direct shear in coil curvature is called Wahl's Factor. on

2 marks
We know; Wahl’s factor K= +

Wahl’s correction factor is calculated using spring index C. Hence selection of spring index C has a
great significance in spring design. Figure shows the effect of spring index C on Wahl’s factor

Spring index : It is ratio of mean coil diameter to wire diameter.

Page No: ____/ N

A low spring index means high sharpness of curvature.

• If C is low (C < 3), the actual stresses are excessive due to curvature effect and special care in
coiling is required to avoid cracking in some wires during manufacturing.

• If C is high (C > 15), it results in large variation in the coil diameter. Such a spring is prone to
buckling and also tangles easily during handling.

• C from 4 to 12 is considered best from manufacturing considerations.

• A spring index in the range of 6 to 9 is still preferred particularly for close tolerance springs

and those subjected to cyclic loading.

In this way Wahl’s factor K is significant in design of spring.

c) List any four applications of Foot lever Any four

applicati
Ans: Basically a foot lever is the first type of levers, in which the fulcrum is in between the load and
ons
effort. In this case, the effort arm is greater than load arm, therefore mechanical advantage
obtained is more than one. Applications of the foot lever can be as given below. 0.5
I. Bell cranked levers used in railway signaling arrangement, marks
each
II. Rocker arm in internal combustion engines,

III. Handle of a hand pump,

IV. Hand wheel of a punching press,

V. Beam of a balance,

VI. Foot levers to apply brakes of automobiles.

d) Classify Keys. 2 Marks

Ans: 1. Sunk keys-

• Rectangular Sunk Key

• Square sunk Key

• Parallel sunk Key

• Gib Headed Key

• Feather Key

• Woodruff Key

2. Saddle keys –

• Flat saddle Key

• Hollow Saddle Key

Page No: ____/ N

4. Round keys

5. Splines.

e) Draw Acme and V thread profile. 1 mark

each
Ans:

Acme Thread Profile V Thread Profile

f) List different materials used for making springs. Any Two

Ans: The springs are mostly made from 1 mark
each
(i) Patented and cold-drawn steel wires (unalloyed) Music wire - used for small springs.

(ii) Oil-hardened and tempered spring steel wires and valve spring wires;

(iii) oil-hardened and tempered steel wires (alloyed); and

(iv) stainless steel spring wires

(v) Non-ferrous materials like phosphor bronze, Beryllium copper, monel metal, brass etc., may

be used in special cases to increase fatigue resistance, temperature resistance and corrosion
resistance.

g) Name any two bearing manufacturers. Any 2

names
Ans: a) SKF – Swedish SKF Group
1 mark
b) NRB
Each
c) FAG

d) NSK

e) TIMKEN

f) NTN

g) INA

h) KOYO

i) Menon

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k) IKO

SUMMER – 2023 EXAMINATION

Model Answer – Only for the Use of RAC Assessors

Subject Name: Subject Code: 22564

Q. Sub Answer XXXXXMarking

No. Q. N. Scheme

2 Attempt any THREE of the following: (3x4=12) 12 Marks

a) Explain in brief the general design procedure. Brief

explanati
Ans: Step 1: Markey Survey on of
each
Market survey is to be done in order study existing similar products and their features and step
utility before starting the design of a competitive product or innovative product.

Step 2: Product Speciﬁcations

4 Marks
The first step consists of preparing a complete list of the requirements of the product. The
requirements include the output capacity of the machine, and its service life, cost and
reliability. In some cases, the overall dimensions and weight of the product are specified. For
example, while designing a scooter, the list of specifications will be as follows: (i) Fuel
consumption = 60 km/l (ii) Maximum speed = 100 km/hr (iii) Carrying capacity = two
persons with 10 kg luggage (iv) Overall dimensions Width = 700 mm, Length = 1750 mm,
Height = 1000 mm (v) Weight = 95 kg (vi) Cost = Rs. 50000 to Rs. 55000

In consumer products, external appearance, noiseless performance and simplicity in operation

of controls are important requirements. Depending upon the type of product, various
requirements are given weightages and a priority list of speciﬁcations is prepared.

Step 3: Selection of Mechanism

After careful study of the requirements, the designer prepares rough sketches of different
possible mechanisms for the product. The alternative mechanisms are compared with each
other and also with the mechanism of the products that are available in the market. An
approximate estimation of the cost of each alternative conﬁguration is made and compared
with the cost of existing products. This will reveal the competitiveness of the product.
Depending upon the cost-competitiveness, availability of raw materials and manufacturing
facility, the best possible mechanism is selected for the product.

Step 4: Layout of Conﬁguration

The next step in a design procedure is to prepare a block diagram showing the general layout
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of the selected configuration. For example, the layout of an Electrically-operated Overhead
Travelling (EOT) crane will consist of the following components: (i) electric motor for power
supply; (ii) flexible coupling to connect the motor shaft to the clutch shaft; (iii) clutch to
connect or disconnect the electric motor at the will of the operator; (iv) gear box to reduce the
speed from 1440 rpm to about 15 rpm; (v) rope drum to convert the rotary motion of the shaft
to the linear motion of the wire rope; (vi) wire rope and pulley with the crane hook to attach
the load; and (vii) brake to stop the motion. In this step, the designer specifies the joining
methods, such as riveting, bolting or welding to connect the individual components. Rough
sketches of shapes of the individual parts are prepared.

Step 5: Design of Individual Components

The design of individual components or machine elements is an important step in a design

process. It consists of the following stages: (i) Determine the forces acting on the component.
(ii) Select proper material for the component depending upon the functional requirements
such as strength, rigidity, hardness and wear resistance. (iii) Determine the likely mode of
failure for the component and depending upon it, select the criterion of failure, such as yield
strength, ultimate tensile strength, endurance limit or permissible deﬂection. (iv) Determine
the geometric dimensions of the component using a suitable factor of safety and modify the
dimensions from assembly and manufacturing considerations. This stage involves detailed
stress and deﬂection analysis. The subjects ‘Machine Design’ or ‘Elements of Machine
Design’ cover mainly the design of machine elements or individual components of the
machine.

Step 6: Preparation of Drawings

The last stage in a design process is to prepare drawings of the assembly and the individual
components. On these drawings, the material of the component, its dimensions, tolerances,
surface finish grades and machining symbols are specified. The designer prepares two
separate lists of components—standard components to be purchased directly from the market
and special components to be machined in the factory. In many cases, a prototype model is
prepared for the product and thoroughly tested before finalising the assembly drawings. It is
seen that the process of machine design involves systematic approach from known
specifications to unknown solutions. Quite often, problems arise on the shop floor during the
production stage and design may require modifications. In such circumstances, the designer
has to consult the manufacturing engineer and find out the suitable modification.

b) Explain design procedure of muff coupling.

Ans:

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1

Mark

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c) A bracket as shown in Fig. No. 2 is fixed to a vertical steel column by means of four standard bolts.
Determine the diameter of the fixing bolts, Assume safe working stress of 70 MPa in tension and
50 MPa in shear.
Ans

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Mark

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Mark

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Mark

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Mark

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d) Design an offset link for a load of 1000 N. Maximum permissible stress in tension for link material
is 60 N/mm2. Assume b= 3t for rectangular cross section of the link. Refer Fig. No. 1.

Ans:

1 Mark

Mark

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3 Attempt any THREE of the following: (3x4=12) 12 M

3 a) 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

1 M each
1. Red : Danger-Hazard-Zone
2. Green: Safety Code
3. Orange: Possible Danger
4. Blue : Caution cold Meaning

3 b) Explain the term Self locking & Overhauling of screw

i) Self locking of a screw : Torque required to lower the load, T= W tan(φ - α) x d/2

Where W – Load to be lifted, φ is the friction angle and α is the helix angle 2M
• When φ > α, positive torque is required to lower the load.

• Under this condition, the load will not turn the screw and will not descend on its own

unless an effort P is applied. In this case, the screw is said to be ‘self-locking’.

• A self-locking screw will hold the load in place without a brake.

• Can be achieved by optimum lubrication and less lead of screw thread.

Condition for self locking is  < 50%

• Application: Screw-jack

ii) Overhauling of a power screw

• Using the same equation of torque required to lower the load, it can be seen that when;
2M
if φ< α the torque required to lower the load is negative.

• It indicates a condition that no force is required to lower the load.

• The load itself will begin to turn the screw and descend down, unless a restraining

torque is applied. This condition is called overhauling of the screw.

• Caused due to excessive lubrication (Minimum friction) or high lead of power screw thread.

Condition for Overhauling is  > 50%

• Applications- Yankee screwdriver , Power steering (Recirculating Ball type Screw)

3 C Explain construction of leaf spring and state its application 4M

Construction of leaf spring :

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Fig :
Semi-elliptical leaf springs are widely used for suspension in light and heavy commercial vehicle. 1&½
In car these are used for rear suspension.

•The leaf springs are made of flat semi-elliptical plate.

• 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.

• The blades vary in length and are held together by a bolt passing through the center acting as a
beam of uniform strength.

• The spring is clamped to the axle housing by means of ‘U’ bolts.

• The longest leaf is known as master leaf, has its end formed in the shape of an eye through
which the bolts are passed to secure the spring to its supports.

• The eyes are attached to shackle provided with bushing of anti-friction material such as bronze
or rubber. The other leaves are graduated leaves.

• To prevent digging in the adjacent leaves, the ends of graduated leaves are trimmed in various
Explain
forms.

• The master leaf has to withstand vertical bending load, side thrust and twisting moment due to 1&½
presence of stresses caused by these loads so it is usual to provide two full length leaves and rest
graduated leaves.

• Rebound clips are located at intermediate position in the length of the spring so that graduated
leaves also shear the stresses induced in the full-length leaves when the spring rebound.

• Highly cambered spring provides a 50% suspension but they also increase tendency to jaw
App:
(movement about vertical axis). Flat spring reduces tendency of the vehicle to dip (pitching), when
brake or accelerate suddenly. 1M

Application of Leaf spring 1) Bus/truck/Car suspension springs, diving board.

3 d Explain the term ‘stress concentration’ ? State its causes and remedies with suitable examples . 4M
i. Stress Concentration:

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Whenever a machine component changes the shape of its Explain:
cross-section, the simple stress distribution no longer holds
good and the neighbourhood of the discontinuity is 1M
different. This irregularity in the stress distribution
caused by abrupt changes of form is called stress
concentration.
It occurs for all kinds of stresses in the presence of fillets,
notches, holes, keyways, splines, surface roughness or
scratches etc.
Causes
Causes of stress concentration:
1M
i) Abrupt changes in cross-section like in keyway, steps, grooves, threaded holes results in stress
concentration.

ii) Poor surface finish – The surface irregularities is also one of the reason for stress concentration.

iii) Localized loading – Due to heavy load on small area the stress concentration occurs in the vicinity
of loaded area.
Remedie
iv)Variation in material properties – Particularly defects like internal flaws, voids, cracks, air holes,
cavities also results in stress concentration. s with
example
Remedies to Avoid stress concentration:
2M
The presence of stresses concentration cannot be totally eliminated but it can be reduced, so
following are the remedial measures to control the effects of stress concentration.

1. Provide additional notches and holes in tension members as shown in fig (a)

a)Use of multiple notches. b)Drilling additional holes as shown in fig(b)

2. Fillet radius, undercutting and notch for member in bending.

3. Reduction of stress concentration in threaded members as shown in fig(c)

4. Provide taper cross-section to the sharp corner of member as shown in fig(d)

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3 e Write strength equation for designing symmetrical loaded parallel and transverse weld with neat 4m
sketch.
2M(
Each for
correct
Strength of parallel weld
equation
P= 1.414 x Sw x l x Ϭt &
Sketch)

Strength of Transverse weld Or

P= 0.707 x Sw x l x Ϭt 4 M (for
correct
Combine
d
equation
OR & Sketch
Strength equation for designing symmetrical
loaded parallel and transverse weld

P= 1.414 x Sw x l1 x Ϭt + 0.707 x Sw x l2 x Ϭt

4 Attempt any TWO of the following ;(2x6=12) 12 M

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a) State the necessity of ‘Ergonomic ‘considerations while designing product. Explain any four 6M
ergonomic considerations in the designing of machine element.

Necessity of ‘Ergonomic ‘considerations:

2M
Ergonomics is the science of designing workstations and equipment to fit the human body
(Any 4
Ergonomics is necessary 1) To increases comfort, 2) To increases productivity, 3) To decreases
stress 4) To prevent work-related mental and muscle fatigue 5) To reduce costs, 6)To improve the Points )
quality of work 7) To increase the accuracy. 8) to Keep work environment comfortable 9) To Reduce
excessive repetition 10) to keep safety environment etc.

Ergonomic considerations in the designing of machine element. ( Any Four )

A)Ergonomics consideration in control design:

i) The control should be accessible and logically positioned.

ii) The shape of control component which come in contact with hands should be comfortable with
anatomy of hand.

iii) Control should be painted in red color with grey background of machine tool for attention.

iv) The control operation should involve Minimum motions.

B) Ergonomics consideration in Display design:

i) The scale on the dial indicator should be divided in suitable linear progression such as 0-10-20-30.
ii) Number of subdivisions between divisions should be minimum.

iii) Vertical figures should be used for stationary dials and radially oriented figures should be used for
rotating dials. 4M

iv) The height of letters or numbers on display should be greater or equal to reading distance /200.

v) The pointer should have knife edge with a mirror to minimize parallax error. (1 m
each,
vi) The numbering should increase in clockwise direction on circular scale, rightward on a horizontal any 4
scale and upwards on vertical scale. consider
C) Lighting: The surrounding area including walls, ceiling, floor and other object should be bright and ation )
more colored than workplace. The light should be match the needs of the task as far as illumination
is concerned.

D) Noise: vibration isolating material, plug in ears and providing sound insulating walls.

E) Temperature: i)In order to get efficiency to perform the task, the operator should feel neither too
hot nor too cold but comfortable. Ii) When the heavy work is done, the temperature should be
lowered and when the office work is done, it should be little higher.

F) Humidity and Air circulation:

i) Low humidity may cause discomfort through drying of the nose and throat.

ii) Air humidity and air velocity become important at high temp. because they influence the amount
of sweat, which can be evaporated from body surface to produce cooling effect .

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4 b Design a Knuckle joint to withstand 150 kN, the design stress is 75 MPa, 60 MPa and 150 MPa in 6M
tension, shear and compression respectively.

Design of knuckle joint:

Dia of
Step 1) Diameter of Rod: d : =? Rod
Consider tensile failure of Rod 1M
1. P =σt x A , 150 x 103 = 75 x π/4 xd2 , d = 50.4 mm 52 mm ( say)

(Note: dia . may vary designer to designer and other dimensions accordingly) Knuckle
Pin
Using Imperial relations
dimensio
Diameter of Knuckle pin Outside d₁ = d = 52mm ns with
safe
Outer diameter of eye, d₂ =2d=2x52=104 mm design :
Diameter of knuckle pin head and collar, d3=1.5d-1.5x52=78mm 1M
Thickness of single eye or rod end, t=1.25 d= 1.25x52= 65 mm

Thickness of fork, t1=0.75 d= 0.75x52= 39 say 40 mm Single

Thickness of pin head, t2=0.5d=0.5×52=26 mm eye
dimensio
2. Failure of the knuckle pin in shear : ns with
safe
Since the knuckle pin is in double shear, therefore load (P),
design :
150 x 10³ =2x (π/4)x(d1)²=2x=2x (π/4)x(52)²=²=4248 τ
2M
τ =150 x103/4248 , τ =35.31 MPa

(τ allowable > τ induced ) Design is safe

3. Failure of the single eye or rod end in tension

The single eye or rod end may fail in tension due to the load. We know that load (P),
Fork
150 × 103 = (d2 – d1) t × Ϭt= (104 – 52) 65 × Ϭt= 3380 Ϭt dimensio
∴ Ϭt= 150 × 103 / 3380 = 44.4 N / mm2 , Ϭt =44.4 MPa
ns with
safe
(σt allowable > σt induced ) Design is safe design :
4. Failure of the single eye or rod end in shearing 2M
The single eye or rod end may fail in shearing due to the load. We know that load (P),

150 × 103 = (d2 – d1) t × τ = (104 – 52) 65 × τ = 3380 τ

∴ τ = 150 × 103 / 3380 = 44.4 N/mm2 , τ = 44.4 MPa

(τ allowable > τ induced ) Design is safe

Page No: ____/ N

The single eye or rod end may fail in crushing due to the load. We know that load (P),

150 × 103 = d1 × t × Ϭc = 52 × 65 × Ϭc = 3380 Ϭc

∴ Ϭc = 150 × 103 / 3380 = 44.4 N/mm2 , Ϭc =44.4 MPa

(Ϭc allowable > Ϭc induced ) Design is safe

6. Failure of the forked end in tension

The forked end may fail in tension due to the load. We know that load (P),

150 × 103 = (d2 – d1) 2 t1 × Ϭt= (104 – 52) 2 × 40 × Ϭt= 4160 Ϭt

∴ Ϭt= 150 × 103 / 4160 = 36 N/mm2, Ϭt = 36 MPa

(Ϭt allowable > Ϭt induced ) Design is safe

7. Failure of the forked end in shear

The forked end may fail in shearing due to the load. We know that load (P),

150 × 103= (d2 – d1) 2 t1 × τ = (104 – 52) 2 × 40 × τ = 4160 τ

∴ τ = 150 × 103 / 4160 = 36 N/mm2 τ = 36 MPa

(τ allowable > τ induced ) Design is safe

8. Failure of the forked end in crushing

The forked end may fail in crushing due to the load. We know that load (P),

150 × 103 = d1 × 2 t1 × Ϭc = 52 × 2 × 40 × Ϭc = 4160 Ϭc

∴ Ϭc = 150 × 103 / 4180 = 36 N/mm2 , Ϭc = 36 MPa

(Ϭc allowable > Ϭc induced ) Design is safe

From above, we see that the induced stresses are less than the given design stresses, therefore the
joint is safe.

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4 C) A hollow shaft is to be designed to transmit 600 kW at 110 rpm. The maximum torque being 20%
greater than the mean. The shear stress is not to exceed 63 MPa and angle of twist in a length of 3
mts not to exceed 1.4 degree. Find external diameter of the shaft if the internal diameter to 6M
external diameter is 3/8. Take modulus of rigidity 84 GPa,

Given that:

Let D = external diameter of shaft

Torque
d = internal diameter of the shaft = 3/8 × D = 0.375D, value:
Power (P) = 600 Kw, Speed (N) = 110 rpm, 1M
Shear stress (τ) = 63 MPa = 63 N/mm2, Angle of twist (θ) = 1.4⁰,

length (l) = 3 m, G = 80 GPa = 80 × 10⁹ Pa

Tmax :
The torque (T) is given by the equation:
1 &1/2
T= 60 P/2π N , T=( 60 x 600 x103) / (2πx 110) , T=52087 Nm M
The maximum torque ( ) = 1.2T = 1.2 × 52087 , T max =62504 Nm θ in rad
Using Torsion equation: ½M

= 0.0244 rad. Torsion

equation
From the torsion equation:
For
T G TL hollow
= J=
J L , G
1M
 D 4 )] = TL
D 4 [(1 −
32 d4 G

 62508.48 x10 3 x3000 Cal &

34
D 4 [(1 − )] =
32 84 84 x10 3 x0.0244 [Link] :
D4=950711.39 x103 , D= 175.59 mm say 180 mm 2M

Q. Sub Answer Marking

No. Q. N. Scheme

5 Attempt any TWO of the following: (2x6=12) 12 Marks

a) A belt pulley is fastened to a 90 mm diameter shaft running at 300 rpm by means of a 06 Marks
key 20 mm wide and 140 mm long. Allowable stress for the shaft and key material are
40 N/mm2 in shear 100 N/mm2 in crushing. Find the power transmitted and the depth
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of the key required.

Sol:

01 Mark

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Q. Sub Answer Marking

No Q. N. Scheme

5 b) A screw jack is used to lift a load of 50 KN through a maximum lift of 200 mm. The
material used for a screw is steel of allowable stresses in tension and compression as
100 N/mm2 and 50 N/mm2 respectively. The pitch of the screw is 8 mm. The nut is made
of phosphor bronze with allowable stresses as 50 N/mm2 and 45 N/mm2 in tension and
crushing. The allowable shear stress for nut material is 40 N/mm2. The allowable
bearing pressure between nut and screw is not to exceed 20 N/mm2. If coefficient of
friction between screw and nut is 0.14, design the Screw and Nut.

Sol:

01 Mark

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Q. Sub Answer Marking

No Q. N. Scheme

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01 Mark

Q. Sub Answer Marking

No Q. N. Scheme

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__________________________________________________________________________________________________
5 c) Explain the selection process of deep groove ball bearing for given application with
manufacturer’s catalogue with suitable example.

Sol: Procedure for selection of bearing from manufacturer’s Catalogue.

The following procedure is followed in selecting the bearing from the
manufacturer’s catalog.
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. 06 Mark
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
OR ( flowchart)

Q. Sub Answer Marking

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6 Attempt any TWO of the following: (2x6=12) 12

a) A double start square thread of power screw has nominal diameter 100 mm pitch 12 mm
is to used to raise the load of 300 KN. The coefficient of friction at screw thread is 0.25.
Neglect collar friction. Calculate Torque required.

Sol:

01 Mark

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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

Q. Sub Answer Marking

No Q. N. Scheme

6 b) A helical spring is made from a wire of 8 mm diameter and has outside diameter 90 mm;
if the permissible shear stress is 350 N/mm2 and modulus of rigidity 84 N/mm2, find the
axial load which the spring can carry and the deflection per active turn.
i) Neglecting the effect of curvature
ii) Considering the effect of curvature
Sol:

01 Mark

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__________________________________________________________________________________________________

Q. Sub Answer Marking

No Q. N. Scheme

01 Mark

6 c) Design ‘C’ clamp frame for a total clamping force of 20 KN. The cross section of the
frame is rectangular and width to thickness ratio is 2. The distance between the load
line and natural axis of rectangular cross section is 120 mm and the gap between two
faces is 180 mm. The frame is made of cast steel for which maximum permissible
tensile stress is 100 N/mm2.

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01 Mark

-----------------------------------------------------xxx END XXX------------------------------------------

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22564
23124
4 Hours / 70 Marks Seat No.

Instructions – (1) All Questions are Compulsory.

(2) Illustrate your answers with neat sketches wherever
necessary.
(3) Figures to the right indicate full marks.
(4) Assume suitable data, if necessary.
(5) Use of Non-programmable Electronic Pocket
Calculator is permissible.
(6) Mobile Phone, Pager and any other Electronic
Communication devices are not permissible in
Examination Hall.

Marks

1. Attempt any FIVE of the following: 10

a) Identify the material and it's composition.
i) X10 Cr18 Ni9 Mo4 Si2
ii) XT 72 W18 Cr4 V 1
b) Define the following terms of spring
i) Solid length
ii) Spring stiffness
c) List any four desirable properties of the shaft material.
d) Give the applications of turn buckle (any four).
e) Draw the symbolic representation of following types of weld.
i) Weld all around
ii) Single U-butt weld.
f) State the significance of "Wahl's factor."
g) State any four application of the rolling contact bearing.
P.T.O.
22564 [2]
Marks
2. Attempt any THREE of the following. 12
a) Define Endurance limit and draw typical S.-N. curve for steel.
b) Design knuckle joint to transmit 150 KN. The design stresses
may be taken as 75 MPa in tension 60 MPa in shear and
150 MPa in compression
c) Compare Rigid and Flexible coupling on following points:
i) Alignment
ii) Shock and vibration
iii) Deflection
iv) Suitability
d) Find the length of the weld run for a plate of size 120 mm wide
and 15 mm thick to be welded by means of single transverse weld
and double parallel fillet weld when subjected to dynamic loading.
Take σ+ = 75 N/mm2 and τ = 60 N/mm2

3. Attempt any THREE of the following. 12

a) Write down the steps involved in a general design procedure in
any machine design.
b) A vertical two-start sq. threaded screw at 120 mm mean diameter
and 24 mm pitch supports a vertical load of 20 KN. The axial
thrust on the screw is taken by a collar bearing of 300 mm
outside dia. and 150 mm inside dia. Find the force required at the
end of the lever which is 400 mm long in order to lift and lower
the load. Co-efficient of friction for screw and nut is 0.18 and for
collar bearing is 0.25.
c) Note on following component with their application.
i) Leaf spring
ii) Helical compression spring
d) State four examples of ergonomics consideration in design of a
lathe machine.
e) Explain self locking and overhauling of screws.
22564 [3]
Marks
4. Attempt any TWO of the following. 12
a) What is stress concentration? Illustrate method of reducing stress
concentration with neat sketches.
b) Explain with the help of neat sketches three basic types of lever.
State one application of each type.
c) Determine the diameter of hollow shaft having inside diameter is
0.6 of outside diameter. The shaft is driven by 900 mm overhang
pulley. The weight of the pulley is 600 N. The overhung is 250
mm and tension in tight and slack side are 2900 N and 1000 N
respectively. Assume τs = 80 N/mm2

5. Attempt any TWO of the following. 12

a) Design a cast iron protective flang coupling to connect the
shaft in order to transmit 7.3 KW at 500 rpm.
i) Allowable shear stress for shaft, bolt and key = 42 N/mm2
ii) Allowable crushing stress for bolt and key = 82 N/mm2
iii) Allowable shear stress for C.I. flange = 8 N/mm2
b) A screw jack carries a load of 25 KN. If the co-efficient of
friction between screw and nut is 0.15. Design the screw
and nut. Neglect collar friction and column action.
Take σc = 42 N/mm2 and τ = 30 N/mm2 for screw and nut
and take τnut = 20 N/mm2. The permissible bearing pressure on the
nut is 14 N/mm2. (Use single start thread)
c) Discuss the procedure for selection of bearing from manufacturer's
catalogue with suitable example.

P.T.O.
22564 [4]
Marks
6. Attempt any TWO of the following. 12
a) A bracket as shown in fig. (1) supports a load of 30 KN.
Determine the size of the bolt, if the maxm allowable tensile
stress in the bolt material is 60 MPa. The distances are
L1 = 80 mm, L2 = 250 mm and L3 = 500 mm.

Fig. No. 1

b) A helical valve spring is to be designed for an operating load

range of approximately 135 N. The deflection of the spring
for the load range is 7.5 mm. Assume the spring index is 10.
The permissible shear stress for the material of the
spring = 480 MPa and its modulus of rigidity = 80 KN/mm2.
Design the spring
Take
4C - 1 + 0.615
Wahl's correction factor = 4C -4 C
Where C = Spring index.
22564 [5]
Marks
c) Explain following:
i) Effect of keyway on the strength of shaft.
ii) "Square key is equally strong in shearing and crushing" -
prove.
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
- WINTER – 2023 EXAMINATION

Subject Name: Elements of Machine Design Subject Code: 22564

m
drawn by candidate and model answer may vary. The examiner may give credit for any equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values may vary and
there may be some difference in the candidate’s answers and model answer.

o
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on

.c
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual (English +

ar
Marathi) medium is introduced at first year of AICTE diploma Programme from academic year 2021-2022. Hence if
the students write answers in Marathi or bilingual language (English +Marathi), the Examiner shall consider the
same and assess the answer based on matching of concepts with model answer.

Q. Sub Answer
le Marking
No. Q. N.
lc Scheme

1 Attempt any FIVE of the following: 10

al
a) Identify the material and its composition. 2 Marks
te

Ans: i) X10 Cr18 Ni9 Mo4 Si2

Material: X means- High Alloy Steel

Composition: Avg. Carbon content is 0.10 %,
Avg. Chromium content is 18 % and
.m

Avg. Nickel content is 9 %

Avg. Molybdenum content is 4 % 1 mark
Avg. Silicon content is 2 %
w

ii) XT 72 W18 Cr4 V1

Material: High-speed tool steel

Composition: Avg. carbon content 0.72 %,
Avg. tungsten content is18 %,
w

1 mark
Avg. chromium content is 4 % and
Avg. vanadium content is 1 %.
b) Define the following terms of the spring. 2 Marks
i) Solid Length: It is defined as the axial length of the spring which is so compressed
Ans: that the adjacent coils touch each other. 1 mark for
each
ii) Spring Stiffness: It is ratio of mean coil diameter to wire diameter. C= D/d correct def

Page No: ____/ N

Ans: i) It should have high strength (Strong).

ii) It should have good machinability (easily machined).

iii) It should have low notch sensitivity factor (stress concentration is less i.e. ductile material
is used).
½ Mark
iv) It should have good heat treatment properties.
each
v) It should have high wear resistant properties. property

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vi) Material should have minimum deflection

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d) Give the applications of turn buckle (Any Four) 2 Marks

.c
i) To provide tension in wires of the fence, roofs, ropes, cables, tie rods etc

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ii) Construction of suspension bridge.

iii) Turnbuckles are used for tensioning a ship's rigging and lashings. ½ Mark

le
each
iv) Turnbuckles have been used in aircraft construction.
lc application
v) Turnbuckles are used in nearly all rigging performed in the entertainment industry.
vi) Turnbuckles find use to tension the ropes in professional wrestling rings and boxing
al
rings

2 Marks
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e) Draw the symbolic representation of the following types of weld.

i) Weld all round

sb
.m

1Mark
w

each
w

ii) Single U-Butt weld

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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

o m
f) State the significance of “ Wahl’s factor” 02 Marks

.c
A stress factor that is caused by the changes and direct shear in coil curvature is called Wahl's
Ans Factor.

ar
We know; Wahl’s factor K = +

le
Wahl’s correction factor is calculated using spring index C. Hence selection of spring index C has a
lc
great significance in spring design. Figure shows the effect of spring index C on Wahl’s factor
al
te
sb

Figure

1 mark
.m
w
w
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Spring index: It is ratio of mean coil diameter to wire diameter. Suitable

explanation
C=
1 marks
The spring index indicates the relative sharpness of the curvature of the coil.

Page No: ____/ N

• If C is low (C < 3), the actual stresses are excessive due to curvature effect and special
care in coiling is required to avoid cracking in some wires during manufacturing.

• If C is high (C > 15), it results in large variation in the coil diameter. Such a spring is prone
to buckling and also tangles easily during handling.

• C from 4 to 12 is considered best from manufacturing considerations.

• A spring index in the range of 6 to 9 is still preferred particularly for close tolerance

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springs and those subjected to cyclic loading.

In this way Wahl’s factor ‘K’ is significant in design of spring.

o
g) State any four applications of the rolling contact bearing. 02 marks

.c
Given i) Aviation cargo systems.

ar
ii) Heavy-duty rotating equipment and machinery.
1/2 Mark
iii) Automobile sector.

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iv) Medical equipment. For each
v) Power generation in hydroelectric power-plant turbines.
lc application
vi) Solar panels.
vii) Agricultural industry.
al
viii) Pulp and paper manufacturing.
2 Attempt any THREE of the following 12
te

a) Define endurance limit and draw typical S-N curve for steel. 04 Mark
sb

Ans: Endurance limit is defined as the maximum amplitude of completely revered stress that standard
specimen can sustain for an unlimited number of cycles without fatigue failure. 2 Marks
.m
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2 Marks

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__________________________________________________________________________________________________
b) Design a knuckle joint to transmit 150 kN. The design stresses may be taken as 75 MPa 04 Mark
in tension 60 MPa in shear and 150 MPa in compression.
Ans: Given: P = 150 kN, t = 75 N/mm and
2 2
= 60 N/mm , c = 150 N/mm 2

m
o
.c
ar
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lc
al
te
sb

(*Note-sketch is not mandatory)

the following notations are used

D = diameter of each rod (mm)
D1 = enlarged diameter of each rod (mm)
w

d = diameter of knuckle pin (mm)

d0 = outside diameter of eye or fork (mm)
w

a = thickness of each eye of fork (mm)

b = thickness of eye end of rod-B (mm)
w

d1 = diameter of pin head (mm)

x = distance of the Centre of fork radius R from the
eye (mm)

1. Diameter of rod (D) Considering

Tensile failure of rod

Page No: ____/ N

2. Using Empirical Relations

m
Enlarged diameter of rod D1 = 1.1* D = 1.1 *(52) = 57.2 = 60 mm

o
Thickness of each eye of fork a = 0.75 *D = 0.75 *(52) = 39 = 40 mm

.c
Thickness of eye end of rod b = 1.25 *D = 1.25* (52) = 65 = 66 mm

ar
3. Diameter of pin (d)

Considering Double shear failure of pin

le
lc
al
te
sb

Considering bending failure of pin

.m
w

1 mark
w
w

Selecting higher diameter of pin d= 70 mm

4. Using empirical relations

Outside diameter of eye or fork = d0 = 2d = 2(70) = 140 mm

Diameter of pin head d1 = 1.5 * d = 1.5 * (70) = 105 mm

Page No: ____/ N

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=32.46 MPa, which is less than 75 MPa …hence safe in tension.

Considering crushing failure of single eye

o
.c
ar
le
=32.46 MPa, which is less than 150 MPa …Hence safe in crushing
lc
Considering shear failure of single eye
al
te

1 Mark
sb

= 32.46 MPa ...which is less than 60MPa ...hence safe in shear.

6. Check dimensions of fork for stresses

Considering tensile failure of fork

w
w
w

=26.78 MPa …which is less than 75 MPa ...hence safe in tension

Considering crushing failure of fork

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__________________________________________________________________________________________________

MPa …which is less than 150 MPa ...hence safe in crushing.

Considering shear failure of fork

o m
.c
1 Mark
which is less than 60MPa ...hence safe in shear.

ar
c) Compare rigid and flexible coupling on following points 04 Mark

Ans: Rigid Coupling

le Flexible Coupling
lc
Alignment No misalignment is permissible. Slight misalignment is permissible.
al
Shock and It cannot absorb any shock and 1 mark for
Absorbs shock and vibration. each point
Vibration vibration.
te

Deflection No Deflection. Deflection is more

Suitability 1. Used to transmit power when 1. To connect parallel shafts.

there is no misalignment (Oldham’s Coupling)
between shafts.
.m

2. To Connect shafts at an angles

2. Used to transit less power where to each other. (Universal
no shacks and vibrations. Coupling)
w
w
w

d) Find the length of the weld run for a plate of size 120mm wide and 15 mm thick to be 04 Mark
welded to be welded by means of single transverse weld and double parallel fillet weld
when subjected to dynamic loading. Take t = 75 N/mm2 and = 60 N/mm2.

Ans:

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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__________________________________________________________________________________________________

m
2 2
Given: Plate width w = 120 mm, t = 15 mm, = 75 N/mm and = 60 N/mm

o
t
1. Length of the weld run for a single transverse weld

.c
The effective length of the weld run l1 for a single transverse weld may be obtained by subtracting 12.5 mm from the width of the plate.
l1= 120-12.5 = 107.5 mm 1 Mark
2. Length of the weld run for a double parallel fillet weld subjected to variable loads.
Let l2 = Length of weld run for each parallel fillet, and

ar
s = Size of weld = Thickness of plate = 15 mm
Assuming the tensile stress as 75 MPa and and shear stress = 60 N/mm 2

We know that the maximum load which the plate can carry is P = Area × Stress = 120 × 15 × 75 =
135000 N

le
Assuming Stress concentration factor for transverse weld is 1.5 and for parallel fillet welds is 2.7

Permissible tensile stress, t = 75/1.5 = 50 N/mm2 and Permissible shear stress, = 60/2.7 = 22.22
N/mm2 Load carried by single transverse weld,
lc
P1 = 0.707 s × l1 × t = 0.707×15 ×107.5 × 50 = 57001.88 N And load carried by double parallel fillet weld,
al
P2 = 1.414 s × l2 × = 1.414×15 × l2× 22.22 = 471.29 l2 N Load carried by the joint
(P),
135000 = P1 + P2 = 57001.88 + 471.29 l2
l2 = 165.5 mm
te
sb
.m

1 Mark
w
w

1 Mark
w

1 Mark

Page No: ____/ N

Q.3 Attempt any THREE of the following 12 Mark

a) Write down the steps involved in a general design procedure in any machine design. 04 Mark

Sol:

mo
.c
ar
le
lc
al
Steps in machine design ½ for each
te

1. Need: It is the First step of Machine Design in which make a complete statement of the step
problem, indicating the need, aim or purpose for which the machine is to be designed.
sb

2. Synthesis (Mechanisms): Select the possible mechanism or group of mechanisms which will
give the desired motion.
.m

3. Analysis of forces: Find the forces acting on each member of the machine and the energy
transmitted by each member.
4. Material selection: Select the material best suited for each member of the machine.
w

5. Design of elements (Size and Stresses): Find the size of each member of the machine by
considering the force acting on the member and the permissible stresses for the material used. It
w

should be kept in mind that each member should not deflect or deform than the permissible limit.
6. Modification: Modify the size of the member to agree with the past experience and judgment
w

to facilitate manufacture. The modification may also be necessary by consideration of

manufacturing to reduce overall cost.
7. Detailed drawing: Draw the detailed drawing of each component and the assembly of the
machine with complete specification for the manufacturing processes suggested. Prepare assembly
drawing giving part numbers, overall dimensions and part list. The component drawing is supplied
to the shop flow for manufacturing purpose, while assembly drawing is supplied to the assembly
shop.
8. Production: The component as per the drawing is manufactured in the workshop.

Page No: ____/ N

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__________________________________________________________________________________________________

b) Vertical to start square threaded screw at 120 mm mean diameter and 24 mm pitch 04 Mark
supports a vertical load of 20 KN. The axial thrust on screw is taken by collar diameter of
300 mm outside diameter and 150 mm inside diameter. Find the force required at the end of
lever which is 400 mm long in order to lift and lower the load. Coefficient of friction for
screw and nut is 0.18 and for collar diameter is 0.25.

Sol:

o m
.c
ar
le
lc
al
te
sb
.m
w

01 Mark
w
w

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__________________________________________________________________________________________________

o m
.c
ar
le
lc
01 Mark
al
te
sb
.m
w

01 Mark
w
w

01 Mark

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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Note on following component with their application.
c) 04 Mark
i) Leaf Spring ii) Helical compression spring

Sol:
i) 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

m
along the definite path as it deflects to acts as a structural member in addition to energy
absorbing device.

o
• Thus, leaf spring carry lateral load, brake torque, driving thrust and shocks.
• It consists of number of semi-elliptical plates called blade or leaves.

.c
• The leaves are given initially curvature or camber so that they tend to straighten under the
load.

ar
• The blades vary in length and are held together by a bolt passing through the center acting as a
beam of uniform strength.

le
• The spring is clamped to the axle housing by means of ‘U’ bolts.
• The longest leave is known as master leaves, has its end formed in the shape of an eye through
lc
which the bolts are passed to secure the spring to its supports.
01 Mark
• The eyes are attached to shackle provided with bushing of anti-friction material such as bronze
al
or rubber. The other leaves are graduated leaves.
• To prevent digging in the adjacent leaves, the ends of graduated leaves are trimmed in various
te

forms.
sb
.m
w

01 Mark
w

ii) Helical compression spring

• A compression helical spring has coil separate from each other and compressive force is
applied at the end and coil comes closer due to compressive force or load.
• This type of springs are used in telescope shock absorber, Inlet and Exhaust valves mechanism
of I.C. engine, in automobile clutches,etc.
01 Mark

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__________________________________________________________________________________________________

01 Mark

o m
d – wire dimeter

.c
D – Mean dimeter
Di – inside diameter

ar
Do – outside diameter
P – pitch

le
lc
al
d) State four examples of ergonomics consideration in design of a lathe machine. 04 Mark
te

Sol: Any four examples of ergonomics consideration in design of a lathe machine.

1) The design of hand wheel of saddle in lathe machine.
sb

2) The design of foot operated lever which controls the spindle's rotation and direction.
3) Design of knob for speed control. 01 Mark for
each
4) Design of chuck key.
.m

5) Force& power capacity required in turning the wheel as per operation or human
being can apply normally.
6) Material Handling of the jobs.
w

e) Explain Self Locking and Overhauling of screws. 04 Mark

Sol: Self-locking:
w

• The torque required to lower the load can be given by the equation,
T=W dm / 2 * tan(ϕ−α)
• When ϕ is greater than or equal to α, a positive torque is required to lower the load.
Under this condition, the load will not turn the screw and will not descend on its own unless an
effort P is applied.
• A screw will be self-locking
1)if the friction angle is greater than helix angle or coefficient of friction is greater
than tangent of helix angle i.e. µ or tan Ø ˃ tan ά
02 Mark
2) its efficiency is less than 50 % i.e. η < 50%
Page No: ____/ N
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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__________________________________________________________________________________________________
Over hauling:
• The torque required to lower the load can be given by the equation,
T=W dm / 2 * tan(ϕ−α)
• When ϕ < α torque required to lower the load is negative.
• It indicates a condition that no force is required to lower the load. The load itself will begin to
turn the screw and descend down.
• A screw will be Overhauling: if the friction angle is less helix angle or coefficient of friction is
less than tangent of helix angle.

m
• i.e. µ or tan Ø ˂ tan ά
02 Mark
its efficiency will be Greater than 50 % i.e. η ˃ 50%

o
Que
Attempt any TWO of the following 12 Mark
.4

.c
What is stress concentration? Illustrate method of reducing stress concentration with neat
(a) 06 Mark

ar
sketches.

Sol: 1. During the design of any machine component, discontinuities in any machine part are

le
there due keyway, threaded grooves and steps are present on the component which is
functional requirement to perform their functions.
2.
lc
Such type of discontinuity alters the stress distribution in the vicinity of the discontinuity
and elementary stress equations no longer describe the state of stress in the component.
al
3. The stresses induced in the neighbourhood of the discontinuity are much higher than the
stresses in the other part of the component. 03 Mark
te

4. This concentration of high stresses due to the discontinuities or abrupt change of cross-
section is called stress concentration.
sb
.m
w

Methods to reduce stress concentration are as follows:

i. Additional notches and holes in tension member like use of use of multiple notches and
drilling additional holes.
w

ii. Fillet radius, undercutting and notch for member in bending.

iii. Reduction of stress concentration in h
iv. Threaded members.
v. Change in cross-section should be gradual.
vi. By improving surface finish

Page No: ____/ N

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__________________________________________________________________________________________________

m
03 Mark

o
.c
ar
le
lc
al
Explain with the help of neat sketch three basic types os lever. State one applications of each
b) 06 Mark
type.
te

Sol:
1) One arm lever
sb

It is a one end which is pivoted at other end an effort is applied so it has only onearm and that
is effoet arm.
This type of lever has two forces applied on end of the lever.
.m

• Applications: Hand lever, Foot lever and Cranking Lever. (Any One)
w

02 Mark
w
w

2)Two arm lever

It depends on position of fulcrum pin,load and effort..
The effort and load are on either side of fulcrum pin.
The length of the load and effort arm changes with change in applications.
• Applications:Bell crank lever, governors,Rocker arm of I.C. Engine, Boiler Safety Valves,etc
(Any One)
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__________________________________________________________________________________________________

m
02 Mark

o
.c
ar
le
lc
al
te

3) Angular Lever:
sb

In this type of lever the angle between effort arm and load arm have inclined angles of range 180°
to 90°.
.m

This levers are designed for appliaction of effort in the desired direction.

• Applications:Angular effort transmission,brake lever,etc (Any One)

w
w
w

02 Mark

c) Determine the diameter of hollow shaft having inside diameter 0.6 of outside diameter. The 06 Mark
shaft is driven by 900 mm overhung pulley. The weight of the pulley is 600 N. The overhung

Page No: ____/ N

Sol:

m
01 Mark

o
.c
ar
01 Mark

le
lc
01 Mark
al
te

01 Mark
sb
.m

01 Mark
w
w

do = 46.929 mm say 48 mm and

01 Mark
di = 28.15 mm say 30 mm

Q5 12 Marks
Attempt any TWO of the following:

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Design a cast Iron protective flange coupling to connect a shaft in order to transmit 7.3 KW at 6 marks
500 rpm.
a) (i) Allowable shear stress for a shaft, bolt and key -42 N/mm 2
(ii) Allowable crushing stress for a bolt and key-82 N/mm 2
(iii) Allowable shear stress for C.I. flange -8 N/mm2

o m
.c
ar
le
lc
al
Given data :
te

3; ;
P= 7.3 KW = 7.3 X 10 N=500 rpm; τ =42 N/mm2 ; σc = 82 N/mm2 τf
2
=8N/mm
sb

3
P= 2πNT/60 ; T= 139.42 N-m= 139.42 X 10 N-mm 1 mark
*(Note-sketch is not mandatory)
.m

Design of shaft :
3
T= π/16 . τ. d
3 3
w

139.42 X 10 = π/16 X 42 X d ; d=25.66 =26 mm

Design of key :
Let us select square key,
w

∴ w=t= d/4 =26/4 =6.5 mm ; l = 1.5 d =1.5 X 26 =39 mm

Considering crushing failure of key, T = l k × t/2 ×d/2 × σc

3
139.42 X 10 = lk 6.5/2 ×26/2 × 82 lk =40.23 mm or 41 mm.

Considering shearing of key,

τ = [T/(d/2)] / w. lk ; lk= 39.28 =40 mm or 40 mm Selecting largest of three values, lk =41 mm

Design of Hub :
Length of hub = l = 41 mm 1 mark

Page No: ____/ N

Shear stress induced in hub is given by,

3 4
τh =16 T/ π D [1-k ] Where k= 26/52 =0.5
2 2
= 5.38 N/mm < 8 N/mm
Hence hub is safe against shear failure. 1 mark

Design of Flange :
Thickness of flange , tf = 0.5d = 0.5 × 26 = 13 mm
Thickness of protective flange = 0.25d = 6.5 mm
Diameter of bolt circle , D1 = 3d = 78 mm

m
Outer Diameter of flange D2 = 4d =104 mm
Diameter of flange recess , D3 = 1.1D= 57.2 mm
Let us find out shear stress induced in a flange (tf)at a junction with

o
hub T = πD tf × τf × D/2
3
139.42 X 10 = π×52× 13× τf × 52/2 ; τf = 2.52 N/mm2 < 8 N/mm2 Hence flange is safe against shear failure.

.c
2 mark
Design of Bolts:

ar
Assume number of bolts as 3 , hence n=3 Considering
shearing of bolt, Let db = Diameter of bolt. τb
2
=[T/(D1/2)]/ n.(π/4) db

le
db = 6 mm or M6
Check induced crushing stress in the bolts,
σcb = 2T/ n.D1. db tf ;
lc
σcb = 15.27 N/mm2 < 82 N/mm2 Hence bolts and flange are safe against crushing failure.
al
te

1 mark
sb
.m

A screw jack carries a load of 25 KN. If coefficient of friction between screw and nut is
b) 0.15 ,Design screw and nut. Neglect collar friction and column action. Take σ c = 42 N/mm2 ,τ = 6 marks
w

30 N/mm2 for screw, τ nut =20 N/mm2 , Pb = 14 N/mm2,( use single start thread.)
w

Ans
w

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

o m
1 mark

.c
ar
le
lc
al
te
sb

1 mark
.m
w
w
w

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

1 mark

o m
.c
ar
le 1 mark
lc
al
te

1 mark
sb
.m
w

1 mark
w
w

Page No: ____/ N

Ans Following is the selection process of bearing from manufacturer's catalogue:

:
a) Calculation of radial load (FR)and axial loads (FA)acting on bearings.
b) Calculation of shaft diameter on which bearing is mounted.
according to application select the type of bearing.
c) For known shaft diameter first start with extra light series.
d) Find the value of basic static capacity ‘ C0 ‘ of the selected bearing from the catalogue.
Calculation of FA/C0 and FA/FR
1 marks
e) Find the values of radial and thrust factors i.e. X and Y from the catalogue.

m
The values depend upon two ratios FA/C0 and FA/FR
f) The values of X and Y for a single row deep groove ball bearings are given in
standard Table .

o
g) For the required application find the value of load factor or application factor k a from

.c
the catalogue. The values of load factors are given in standard Table . 1 marks
h) Calculate the equivalent dynamic load by using relation:
F = (XVFR + YFA) ka where Y is rotation factor which is between 1 to 1.2

ar
i) According to required application choose the expected life of the bearing and
express the life in million revolutions.
j) Calculate the required basic dynamic capacity for the bearing.

le
1 marks
k) Check whether the selected bearing has the required basic dynamic capacity. If not
select the bearing of next series and resume from step 5 again.
lc
l) Calculate the equivalent static load by using relation
m) Ps = XsFr+ YsFa (where Xs and Ys are radial and thrust are load factors)
n) Calculate required basic dynamic capacity for the bearing using the relation
al
o) L10 = (C/P)a 1 marks
p) If Dynamic load rating C is greater than required dynamic capacity, then stop, otherwise
te

go for bearing of next series.

1 marks
.m
w
w
w

1 marks

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

6 Attempt any TWO of the following: 12 Marks

a) A bracket shown in fig supports a load of 30 KN. Determine size of bolts, if maximum allowable 6 marks
tensile stress in bolt material is 60 MPa.L1= 80, L2= 250, L3= 500 mm.

Ans:

o m
1 mark

.c
ar
le
1 mark
lc
al
1 mark
te
sb

1 mark
.m
w

1 mark
w
w

1 mark

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
b) A helical valve spring is to be designed for an operating load range of approximately 135 N. 6 marks
Deflection of spring is 7.5 mm for this load range. Assume spring index as 10. Permissible shear
stress for spring material = 480 MPa and modulus of rigidity is 80 KN/mm2
Design the spring. Take Wahl’s factor = [(4C-1)/(4C-4)] +0.615/C; C= spring index

Ans
:

o m
1 mark

.c
ar
le 1 mark
lc
al
te
sb

1 mark
.m

1 mark
w
w

1 mark
w

1 mark

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
c) Explain the following 6 marks
(i) Effect of keyway in strength of shaft
(ii) Prove that Square key is equally strong in shearing and crushing’.

Ans 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 1 mark

m
relation for the weakening effect of the keyway is based on the experimental results by H.F.
Moore
e = 1- 0.2(w/d) -1.1 (h/d)

o
e = Shaft strength factor. It is the ratio of the strength of the shaft with keyway to the strength

.c
of the same shaft without keyway, 1 mark
w = Width of keyway, d = Diameter of shaft, and

ar
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.

le
In case the keyway is too long and the key is of sliding type, then the angle of twist is
increased in the ratio kθ as given by the following relation:
kθ = 1 +0.4 (w/d)+0.7 (h/d) 1 mark
lc
where kθ = Reduction factor for angular twist
al
ii) Prove that Square key is equally strong in shearing and crushing’
te
sb
.m

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,
w

d = Diameter of shaft,
l = Length of key,
w

w = Width of key.
t = Thickness of key
w

τ and σc = 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 × Shear stress = l × w × τ
1 mark
∴ Torque transmitted by the shaft,

T = F X d/2 = l w τ X d/2 ...(i)

Considering crushing of the key, the tangential crushing force acting at the circumference of the shaft,
F = Area resisting crushing × Crushing stress = I .t/2. σ c
∴ Torque transmitted by the shaft, T = F.d/2 = l.t/2. σ c.d/2…..(ii)

1 mark

Page No: ____/ N

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
The key is equally strong in shearing and crushing, if
l.w. τ .d/2.=l.t/2. σc.d/2….[Equating equations (i) and (ii)]
or w/ t = σc/2 τ ...(iii) 1 mark
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.

------------------------------END------------------------------

m
o
.c
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lc
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.m
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w

Page No: ____/ N

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