I Quest ion Paper Code : 9138 4

B.E/B.Tech. DEGREE EXAMINATIONS, APRIL/MAY 2025.

Fifth Semester

Mechanical Engineering

ME 3591-DE SIGN OF MACHINE ELEMENTS

(Regulations 2021)
Time : Three hours Maximum : 100 marks
Answer ALL questions.

PART A- (10 x 2 =20 marks)

1. How does the selection of material s depend on mechanical properties in

machine design?

2. What is the factor of safety, and why is it importan t in design?

3. Why are hollow shafts preferred over solid shafts in some applications?

4. What is the role of splines in mechanical shafts?

5. What is a knuckle joint, and where is it typically used?

6. In welded joints, what is a transver se fillet weld?

7. List two common types of springs and their applications.

8. Define surge in springs and its effect on spring performance.

9. What are the primary factors to consider when selecting rolling contact
bearings for a given applicati on?

10. Differen tiate between sliding contact bearings and rolling contact bearings
with one example each.
 PART B - (5 x 13 = 65 marks)

l l. (a) A hollow shaft of 40 mm outer diamete r and 25 mm inner diamet er is

subject ed to a twisting momen t of 120 N-m, simulta neously , it is
subject ed to an axial thrust of 10 kN and a bending momen t of 80 N-m.
Calcula te the maximu m compre ssive and shear stresses .

Or
(b) The load on a bolt consists of an axial pull of 10 kN togethe r with a
transve rse shear force of 5 kN. Find the diamete r on the bolt require d
accordi ng to
(i) Maxim um princip al stress theory.
(ii) Maxim um shear stress theory;
(iii) Maxim um princip al strain theory.

12. (a) A line shaft is driven by means of a motor placed vertical ly below it. The
pulley on the line shaft is 1.5 meter in diamete r and has belt tension s
5.4 kN and 1.8 kN on the tight side and stack side of the belt
respect ively. Both these tension s may be assume d to be vertical . If the
pulley is overhan g from the shaft, the distance of the centerli ne of the
pulley from the centerli ne of the bearing being 400 mm, find the diamete r
\
of the shaft. Assumi ng maximu m allowable shear stress of 42 MPa.

Or
(b) A 45 mm diamet er shaft is made of steel with a yield strengt h of
400 MPa. A paralle l key of size 14 mm wide and 9 mm thick made of steel
with a yield strengt h of 340 MPa is to be used. Find the require d length
of key, if the shaft is loaded to transm it the maximu m permiss ible
torque. Use maximu m shear stress theory and assume a factor of safety
of 2.

13. (a) Determ ine the length of the weld run for a plate of size 120 mm wide and
15 mm thick to be welded to another plate by means of a single
transve rse weld and double parallel fillet welds when the joint is
subject ed to variabl e loads.

Or

(b) The cylinde r head of a steam engine is subjecte d to a steam pressur e of

0.7 N/mm 2. It is held in position by means of 12 bolt~. A s_oft copper
gasket is used to make the joint leak-proof. The effective d1ame_ter of
cylinde r is 300 mm. Find the size of the bolts so that the stress 1n the
bolts is not to exceed 100 MPa.

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 n spr ing
nis m use d in pri nti ng ma chi ner y con sis ts of a ten sio
14 • (a) A me cha spr ing is 2 mm
30 N. Th e wi re dia me ter of
ass em ble d wi th a par elo ad of wir ~ is
ing ind ex of 6. Th e spr ing ha s 18 act ive coils. Th e spr ing
wi th a spr s;
d oil tem per ed hav ing fol low ing ma ter ial pro per tie2
ha rd dra wn an
lus of rig idi ty = 80 kN /m
m •
De sig n she ar str ess = 680 MP a Mo du
De ter mi ne:
ess in the wir e;
(i) the ini tia l tor sio nal she ar str
(ii) spr ing rat e; an d
en gth .
y of the spr ing to its yie ld str
(iii) the force to cau se the bod
Or
at a me an
ste am eng ine dev elo ps 15 0 kW
A sin gle cyl ind er dou ble act ing is 0.1 an d the
(b)
of 80 r.p .m. Th e coe ffic ien t of flu ctu ati on of ene rgy
spe ed ter of the
on of spe ed is + 2% of me an spe ed. If the me an dia me
flu ctu ati e 5 pe rce nt of the
d the hu b an d spo kes pro vid
, flywheel rim is 2 me tre s an eel an d cro ss-
al ine rtia of the wh eel . fin d the ma ss of the fly wh
rot ati on ma ter ial
are a of the rim . As sum e the den sit y of the fly wh eel
sec tio nal
m3 .
(w hic h is cas t iro n) as 720 0 kg/
le:
jec ted to the fol low ing wo rk cyc
15. (a) A rol lin g con tac t bea rin g is sub
r.p .m . for 25% of the tim e; -
(i) Ra dia l loa d of 600 0 Na t 150
e; an d
t 600 r.p .m . for 20% of the tim
(ii) Ra dia l loa d of 7500 Na
300 r.p .m. for 55% of the tim e.
(iii) Ra dia l loa d of 200 0 N at
for an
er rin g rot ate s an d loa ds are ste ady . Se lec t a be ari ng
Th e inn
hou rs.
exp ect ed ave rag e life of 250 0
Or
fol low ing da ta:
a cen trif uga l pu mp fro m the
De sig n a jou rna l bea rin g for
Sp eed of the jou rna l = 90 0 r.p
(b) .m ; Ty pe of
on the jou rna l -:- 200 00 N; s;
Lo ad
for wh ich the abs olu te vis cos ity at 55°C = 0.0 17 kg / m-
oil is SA E 10, bea rin g pre ssu re for the
Am bie nt tem per atu re of oil = 15.5°C; Ma xim um
oil req uir ed for
2
e the ma ss of the lub ric ati ng
pu mp = 1.5 N/ mm • Ca lcu lat to 10°C. He at
ific ial coo ling , if the ris e of tem per atu re of oil is lim ite d
art
dis sip ati on coe ffic ien t = 123 2
W/m2 °C.

PA RT C - (lx 15 = 15 Ma rks
)
tor to a lat he
pow er fro m an ele ctr ic mo
(a) De sig n a sha ft to tra nsm it e pu lle y we igh s
16. by me ans of a bel t dri ve. Th
hea dst ock thr ou gh a pul ley bea rin g. Th e
an d is loc ate d at 300 mm from the cen tre of the
200 N itte d is
of the pul ley is 200 mm and the ma xim um po we r tra nsm
dia me ter coe ffic ien t of
of lap of the bel t is 180° an d
1 kW at 120 r.p ,m. Th e ang le ck an d fat igu e
t~e pul ley is 0.3. Th e sho
friction bet we en _the bel t an~ pec tiv ely . Th e
tor s for ben din g and tw ist ing are 1.5 an d 2.0 res
fac a
sha ft ma y be tak en as 35 MP
all ow abl e she ar str ess in the
Or

3 91 38 4
- - - - - - - - - - - - - - - ~ ~ - - - ~ - - r 1 1 1 1 B i 3 1 1 1 1 F•~---u-111a:11_ _ _ _ _,.....,._....-.mm

(b) Design a helical spring for a spring loaded safety valve (Ramsbottom
safety valve) for the following conditions:
Diameter of valve seat= 65 mm;
2
Operating pressure = 0. 7 N/mm ;

2
Maximum pressure when the valve blows off freely = 0. 75 N/mm ;
Maximum lift of the valve when the pressure rises from 0.7 to
0.75 NI mm 2 = 3.5 mm;
Maximum allowable stress = 550 MPa;
Modulus of rigidity =84 kN/mm
2
; Spring index =6
Draw a neat sketch of the free spring showing the main dimensions.

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