Register Number:……………..

DEPARTMENT OF MECHANICAL ENGINEERING

(Regulation 2018)
Fifth Semester
MECHANICAL ENGINEERING
U18MET5003/Design of Machine Elements
(Use of Standard Design Data Book is permitted)
COURSE OUTCOMES
CO1: Apply the concept of steady stresses in design of machine elements subjected to steady
loads
CO2: Solve problems in machine elements subjected to varying loads

Maximum Marks: 100

Answer all the Questions: -

Simple Stresses
1 A mild steel rod of 12 mm diameter was tested for tensile strength with CO1 [K2]
the gauge length of 60 mm. Following observations were recorded :
Final length = 80 mm; Final diameter = 7 mm; Yield load = 3.4 kN and
Ultimate load = 6.1 kN. Calculate : 1. yield stress, 2. ultimate tensile
stress, 3. percentage reduction in area, and 4. percentage elongation
2 A shaft is transmitting 97.5 kW at 180 r.p.m. If the allowable shear stress CO1 [K2]
in the material is 60 MPa, find the suitable diameter for the shaft. The
shaft is not to twist more that 1° in a length of 3 metres. Take C = 80 GPa
3 A cast iron link, as shown in figure is required to transmit of steady tensile load CO1 [K2]
of 45 kN. Find the tensile stress induced in the link material at section A-A and
B-B

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4 A pull of 80 kN is transmitted from a bar X to bar Y through a pin as shown in CO1 [K3]
figure.if the permissible shear stress in the pin is 80 N/mm2 find the diameter
of the pin.

5 An electric motor weighing 500 N is mounted on a short cantilever beam of CO1 [K3]
uniform rectangular cross section. The weight of a motor act as 300 mm
distance from a support. The depth of the section is twice the width. Determine
the cross section of the beam. The available stress in the beam is 40 N/mm2.
Eccentric loading
1 A hollow circular column of external diameter 250 mm and CO1 [K2]
internal diameter 200 mm carries a projecting bracket on which a
load of 20 kN rests, as shown in Fig. The centre of the load from
the centre of the column is 500 mm. Find the stresses at the sides
of the column. All dimensions in mm.

2 A mild steel bracket as shown in Figure., is subjected to a pull of 6000 N acting CO1 [K2]
at 45° to its horizontal axis. The bracket has a rectangular section whose depth
is twice the thickness. Find the cross-sectional dimensions of the bracket, if the
permissible stress in the material of the bracket is limited to 60 MPa.

3 A horizontal pull P = 5 kN is exerted by the belting on one of the cast iron wall CO1 [K2]
brackets which carry a factory shafting. At a point 75 mm from the wall, the
bracket has a T-section as shown in Fig. Calculate the maximum stresses in the

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 flange and web of the bracket due to the pull.

4 An overhang crank with pin and shaft is shown in Fig. A tangential load of 15
kN acts on the crank pin. Determine the maximum principal stress and the
maximum shear stress at the centre of the crankshaft bearing.

Curved beam
1 The crane hook as a section, which for the purpose of the analysis is CO1 [K3]
considered as trapezoidal as shown in figure .it is made of plain carbon steel
with an yield strength of 380 MPa in tension. Determine the load capacity of
the hook, for a factor of safety of 3.

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2 A hanger is made from ASTM A36 structural steel bar with a square cross CO1 [K3]
section, 10 mm on a side, as shown in below Figure. The radius of curvature is
150 mm to the inside surface of the bar. Determine the load F that would cause
yielding of the steel.

3 A coping saw frame shown in below Figure is made from SAE 1020 CD steel. A CO1 [K3]
screw thread in the handle draws the blade of the saw into a tension of 120 N.
Determine the resulting design factor based on yield strength in the area of
the corner radii of the frame

4 Repeat Problem 3for the hacksaw frame shown in below Figure when the
tensile force in the blade is 480 N.

5 The C-clamp in Figure is made of cast zinc, ZA12. Determine the force that the
clamp can exert for a design factor of 3 based on ultimate strength in either
tension or compression.

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6 A link shaped in the form of a letter S is made up of 30 mm diameter bar, as CO1 [K3]
shown in fig. Determine the maximum tensile stress and maximum shear stress
in the link.

7 A wall crane with a pin – joint tie rod is as shown in Fig. The crane hook is to CO1 [K3]
take a maximum load 35kN, when the load is at a distance of 2 m from the wall.
The tie rod and pin are made of steel FeG 250 (Syt = 250 N/mm 2) and the
factor of safety is 5. Calculate the diameter of the tie rod and the pin.

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8 A riveting machine has s C-Frame and its subjected to a force of 25 Kn as CO1 [K3]
shown in figure.it is made of an material with an ultimate strength of 560 MPa.if
the factor of safety is 3 ,find the dimension of the rectangular cross section.

9 A punch frame has shape and loading as shown in figure. Determine the stresses CO1 [K3]
developed.

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 Theories of Failure
1 The load on a bolt consists of an axial pull of 10 kN together with a transverse CO1 [K3]
shear force of 5 kN. Find the diameter of bolt required according to
1. Maximum principal stress theory; 2. Maximum shear stress theory; 3.
Maximum principal strain theory; 4. Maximum strain energy theory; and 5.
Maximum distortion energy theory.
Take permissible tensile stress at elastic limit = 100 MPa and poisson’s ratio =
0.3
2 A solid circular shaft of diameter 45 mm is loaded by bending moment 650 CO1 [K3]
Nm, torque 900 Nm and axial tensile force of 30 kN. The shaft material is
ductile with yield strength of 280 MPa. Determine the factor of safety
according to Maximum principle stress, Tresca and Von misses theories of
failure
3 Determine the safety factors for the bracket rod shown in below Figure .based CO1 [K2]
on both the distortion-energy theory and the maximum shear theory and
compare them.
The material is 2024-T4 aluminum with a yield strength of 47 000 psi. The rod
length l = 6 in and arm a = 8 in. The rod outside diameter d = 1.5 in. Load
F = 1000 lb. the load is static and the assembly is at room
temperature.Consider shear due to transverse loading as well as other
stresses.

4 A cylindrical shaft made of steel of yield strength 700 MPa is subjected to static CO1 [K3]
loads consisting of bending moment 10 kN-m and a torsional moment 30 kN-
m. Determine the diameter of the shaft using two different theories of failure,
and assuming a factor of safety of 2. Take E = 210GPa and poisson's ratio =
0.25.
5 mild steel shaft of 50 mm diameter is subjected to a bending moment of CO1 [K3]
2000N-m and a torque T. If the yield point of the steel in tension is 200 MPa,
find the maximum value of this torque without causing yielding of the shaft
according to 1. the maximum principal stress; 2. the maximum shear stress;
and 3. the maximum distortion strain energy theory of yielding.

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 Machine elements subjected to varying
loads
1 A machine component is subjected to a flexural stress which fluctuates CO2 [K2]
between + 300 MN/m2 and – 150 MN/m2 . Determine the value of minimum
ultimate strength according to i) Gerber relation ii) Modified Goodman
relation and iii) Soderberg relation. Take yield strength = 0.55 Ultimate
strength; Endurance strength = 0.5 Ultimate strength; and factor of safety = 2.

2 A spherical pressure vessel with 40 mm inner diameter is welded from steel CO2 [K2]
plates. The vessel is subjected to inner pressure varying from 0 to 50 bar.
Assuming the ultimate tensile strength as 440 MPa.yield strength is 240 MPa.
Factor of safety 3, calculate the plate thickness.

3 A simply supported beam has a concentrated load at the centre which CO2 [K2]
fluctuates of P to 4 P. The span of the beam is 500 mm and its cross of 60 mm.
Taking for the beam material an ultimate stress of 700 MPa, a yield stress of
500 MPa, endurance limit of 330 MPa for reversed bending, and a factor of
safety of 1.3,calculate the maximum value of P. Take a size factor of 0.85 and a
surface finish factor of 0.9.

4 A transmission shaft made of C45 steel is subjected to a fluctuating torque CO2 [K2]
varying from - 100 Nm to 500 Nm. Also a fluctuating bending moment acts on
the shaft, which varies from 500 Nm to -500 Nm. Let the stress concentration
factor be 2. The shaft is machined for a factor of safety is 1.5.

5 A pulley is keyed to a shaft midway between two anti-friction bearings. The CO2 [K3]
bending moment at the pulley varies from – 170 N-m to 510 N-m and the
torsional moment in the shaft varies from 55 N-m to 165 N-m. The frequency of
the variation of the loads is the same as the shaft speed. The shaft is made of
cold drawn steel having an ultimate strength of 540 MPa and a yield strength
of 400 MPa. Determine the required diameter for an indefinite life. The stress
concentration factor for the keyway in bending and torsion may be taken as
1.6 and 1.3 respectively. The factor of safety is 1.5. Take size factor = 0.85 and
surface finish factor = 0.88.

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6 A cantilever rod of length 120 mm with circular section is subjected to a cyclic CO2 [K3]
transverse load; varying from -100 N and 300 N at its free end. Determine the
diameter ‘d’ of the rod,
by (i) Goodman method and
(ii) Soderberg method
using the following data. Factor of safety = 2; Theoretical stress concentration
factor = 1.4; Notch sensitivity factor = 0.9; Ultimate strength = 550 MPa; Yield
strength = 320 MPa; Endurance limit = 275 MPa; Size correction factor = 0.85;
Surface correction factor = 0.9

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7 A steel Cantilever is 200 mm long .it is subjected to an axial load and a CO2 [K3]
transverse load as shown in figure. Determine its diameter taking a factor of
safety of 2. Assume the following values.
Yield stress = 330 MPa
Endurance limits = 300 MPa
Correction factors =0.7 in revered axial loading
= 0.1 for axial loading
Stress concentration factor =1.44 for bending
= 1.64 for axial loading
Size effect factor = 0.85
Surface effect factor =0.90

8 A pulley is keyed to a shaft midway between two anti-friction bearings. The CO2 [K3]
shaft is made of cold drawn steel for which the ultimate strength is 550 MPa
and the yield strength is 400 MPa.The bending moment at the pulley varies
from – 150 N-m to 400 N-m and the torsional moment in the shaft varies
from 55 N-m to 165 N-m. The frequency of the variation of the loads is the
same as the shaft speed. The shaft is made of cold drawn steel having an
ultimate strength of 540 MPa and a yield strength of 400 MPa. Determine the
required diameter for an indefinite life. The stress concentration factor for
the keyway in bending and torsion may be taken as 1.6 and 1.3 respectively.
The factor of safety is 1.5. Take size factor = 0.85 and surface finish factor =
0.88

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