Code No: R05321403 Set No.

1
III B.Tech Supplimentary Examinations, Aug/Sep 2008
PRINCIPLES OF MACHINE DESIGN
(Mechatronics)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
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1. Enumerate the most commonly used engineering materials and state at least one
important property and application of each. [16]

2. (a) What are the principal causes of stress concentration?

(b) A pulley is keyed to a shaft midway between two anti-friction bearings. The
bending moment of the pulley varies from 150Nm to 450Nm as torsional mo-
ment of the shaft varies from 50Nm to 150Nm. The frequency of variation of
the loads is the same as the shaft speed. The shaft is made of cold drawn steel
having an ultimate strength of 550 MPa and yield strength of 310 MPa. De-
termine the required diameter for an indefinite life. The stress concentration
factor for the key way in bending and torsion may be taken as 1.6 and 1.3
respectively. Use a design factor of 1.8, size factor 0.85 and surface correction
factor 0.88.
Use for torsion, size correction factor = 0.6 and The nominal design torsion
stress = 0.6 Yield point in tension. [6+10]

3. A pillar crane having a circular base of 600 mm diameter is fixed to the foundation
of concrete base by means of four bolts. The bolts are of size 30 mm and are equally
spaced on a bolt circle diameter of 500 mm. The load lifted by the pillar crane is 60
KN and is at a distance of 1.5 m from the centre of the base. Find the maximum
stress induced in the bolt material. [16]

4. (a) Differentiate between a cotter and a key.

(b) Design a gib and cotter joint to connect square rods with a side of the square
as 25mm.Consider σr =60MPa σ r = 90MPa and τ = 40MPa. The joint has
to carry a load of 35kN.(t=8mm,B=55(30+25)mm and length of the tail of
the rod is 12mm. [4+12]

5. (a) What is a spring and how they are classified?

(b) Design a spring for spring loaded safely value for the following Conditions:
Operating pressure 100N/cm2 . Diameter of valve seat 100mm. Design shear
stress for the spring is 400 N/mm2 ,G=0.86×105 N/mm2 . The spring is to be
kept in a casting of 120 mm inner diameter and 400 mm long. The spring
should be at maximum lift of 6mm when the pressure is 107.5 N/cm2 . [4+12]

6. (a) What are the factors to be considered while selecting the material for plain
Bearing?

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Code No: R05321403 Set No. 1
(b) The thrust of propeller shaft in a marine engine is taken up by number of
collars integral with the shaft which is 300mm in diameter. The thrust on the
shaft is 200kN and the speed is 75r.p.m. Taking coefficient of friction constant
and equal to 0.05 and assuming the bearing pressure as uniform and equal to
0.3N/mm2 , find:
i. Number of collars required,
ii. Power lost in friction, and
iii. Heat generated at the bearing in kJ/min. [4+12]

7. (a) What is meant by creep of a belt and what is its effect?

(b) A belt,100×10mm is transmitting power at 15m/s.The angle of contact on the
driver (smaller ) pulley is 1560 . If the permissible stress for the belt material is
2N/mm2 ; determine the power that can be transmitted at this speed take the
density of leather as 1000kg/m3 ,and coefficient of friction as 0.25. Calculate
the maximum power that can be transmitted by this belt, and the speed at
which this can be transmitted. [4+12]

8. (a) What is the herringbone gear? Where are they used.

(b) A helical cast steel gear with 30o helix angle has to transmit 35kW at 2000
r.p.m. If the gear has 25 teeth, find the necessary module, pitch diameters
and face width for 200 full-depth involute teeth. The static stress for cast
steel may be taken as 100MPa. The face width may be taken as 3 times the
normal pitch. The tooth form factor is given by expression y=0.154-0.912 /
TE , where TE represents the equivalent number of teeth. The velocity factor
is given by Cv = 6/ (6+V) where V is the peripheral speed of the gear in m/s.
[4+12]

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Code No: R05321403 Set No. 2
III B.Tech Supplimentary Examinations, Aug/Sep 2008
PRINCIPLES OF MACHINE DESIGN
(Mechatronics)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) What is meant by Yielding? How is Yield Strength defined for materials,
which do not show a clear yield point?
(b) Discuss briefly about different types of failures in machine parts.
(c) What are the advantages of Plastics over the other materials? Give some
examples. [4+6+6]

2. (a) Explain the following methods of reducing stress concentration.

i. Removal of undesired material
ii. Added grooves.
(b) A steel connecting rod is subjected to a completely reversed axial load of 120
KN. Suggest the suitable size of the rod using a factor of safety 1.8. The
ultimate strength of the material is 1000 MPa.
Load correction factor 0.7
Size factor 0.85
Surface finish factor 0.8 [4+12]

3. The cylinder head of a 200 mm × 350 mm compressor is secured by means of 12

studs of rolled mild steel having yield point stress of 350 MPa and endurance limit
of 240 MPa. The gas pressure is 1.5 MPa. The initial tension in the bolts, assumed
to be equally loaded such that a cylinder pressure of 3 MPa is required for the joint
to be on the point of opening. The joint is made leak-proof by using copper gasket,
which renders the effect of external load to be half. Determine the size of bolts, if
factor of safety is 2 and stress concentration factor is 2.8. [16]

4. (a) What is the effect of keyway on

i. Strength of shaft
ii. Torsional rigidity of Shaft.
(b) Make a neat sketch showing two views of a cotter joint and write equations
showing the strength of the joint for the most probable methods of failure.
[6+10]

5. A truck spring has 10 leaves and is supported at a span length of 100cm, with
central band of 80mm wide. A load of 6kN is applied at the center of spring whose
permissible stress is 300N/mm2 . The spring has a ratio of total depth to width of
about 2.5. Determine the width, thickness, deflection and length of all leaves. [16]

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Code No: R05321403 Set No. 2
6. (a) A 150mm diameter shaft supporting a load of 10kN has a speed of 1500 r.p.m.
The shaft runs in a bearing whose length is 1.5 times the shaft diameter .If
the diametral clearance of the bearing is 0.15 mm and the absolute viscosity
of the oil at the operating temperature is 0.011 kg/m-s, find the power wasted
in friction.
(b) A 80mm long journal bearing supports a load of 2800N on a 50mm diameter
shaft. The bearing has a radial clearance of 0.05mm and the viscosity of the
oil is 0.021kg/m-s at the operating temperature. If the bearing is capable of
dissipating 80J/s, determine the maximum safe speed. [8+8]

7. A V belt drive is used to transmit 80kW at a motor speed of 100 rpm, the driven
pulley speed being 600 rpm. Approximate center distance is 1.110m, µ is 0.3,
angle of groove is 40degree and Vmax =25m/sec. Neglecting the centrifugal tension,
Calculate the size and number of belts. Also check the induced stress and find the
induced stress and find the life of the belt assuming allowable endurance strength
is 9MPa. [16]

8. A gear drive is required to transmit a maximum power of 22.5kW.The velocity ratio

is 1:2 and pinion speed is 200 rpm. The approximate center distance between the
shafts may be taken as 600mm.The teeth have 200 stub involute profiles. The static
stress for the gear material (CI) is 60MPa and face width as 10 times the module.
Find the module, Face width and number of teeth on each gear. Check the design
for dynamic and loads. The deformation or dynamic factor in the Buckingham
equation may be taken as 80 and combination factor for the wear as 1.4. [16]

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Code No: R05321403 Set No. 3
III B.Tech Supplimentary Examinations, Aug/Sep 2008
PRINCIPLES OF MACHINE DESIGN
(Mechatronics)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) How do you classify materials for engineering use?

(b) A bolt is subjected to a direct tensile load of 18000 N and a shear load of
12000N. The yield stress of the bolt material in simple tension is 350 Mpa.
Use a factor of safety of 3 and poison’s ratio of 0.25. Calculate the diameter
of the bolt by :
i. Maximum shear stress theory and
ii. Maximum principal strain theory. [4+12]

2. (a) Define stress concentration factor.

(b) A hot rolled shaft is subjected to torsional load that varies from 320 Nm
clockwise to 120Nm anti-clockwise and an applied bending moment at a critical
section varies from 400Nm to 200Nm. The shaft is of uniform cross section.
Determine the required shaft diameter. The material has an ultimate strength
of 560MPa and yield strength of 420 MPa. Assume factor of safety to be 2.
[6+10]

3. (a) Enumerate the different types of riveted joints.

(b) Two plates 16 mm thick are joined by a double riveted lap joint. The pitch
of each row of rivets is 90 mm. The rivets are 25 mm in diameter. The
permissible stresses are 140 MPa in tension, 80 MPa in shear and 160 MPa in
crushing. Find the efficiency of the joint. [8+8]

4. The shaft of an axial flow rotary compressor is subjected to maximum torque of

2000N-m and a maximum bending moment of 4000 N-m. The combined shock and
fatigue factor in torsion is 1.5 and that in bending is 2. Design the diameter of the
shaft ,if the shear stress in the shaft is 50MPa. Design a hollow shaft for the above
compressor taking the ratio of outer diameter to the inner diameter as 2. What is
the percentage saving in material? Also compare the stiffness. [16]

5. (a) With neat sketch Explain the difference between a close coiled and open coiled
helical spring.
(b) Design a coil spring for a spring-loaded governor to give a deflection of 1.25
mm under an axial load of 115N.The mean radius of the coil is 25mm and
the wire diameter is 6mm.Take C= 0.8×105 N/mm2 . Check the spring for
buckling. Give a neat sketch of the spring in the un-compressed state. [6+10]

6. (a) What is meant by square bearing?

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Code No: R05321403 Set No. 3
(b) Specify a suitable deep groove ball bearing for a radial load of 2.5kN and a
thrust load of 0.9kN.The operating speed is 3000 r.p.m. Assume steady load,
and life of 15000 hours at 95% reliability. Recommend the bearing with the
maximum possible bore size. [2+14]

7. (a) How are the chain drives classified?

(b) Design a chain drive to actuate a compressor from 15kW electric motor running
at 1000 rpm. The compressor speed being 350 rpm. The minimum center
distance is 500mm. The compressor operates 16 hrs/day. The chain tension
is adjusted by shifting the motor on slides. [4+12]

8. (a) What is the herringbone gear? Where are they used.

(b) A helical cast steel gear with 30o helix angle has to transmit 35kW at 2000
r.p.m. If the gear has 25 teeth, find the necessary module, pitch diameters
and face width for 200 full-depth involute teeth. The static stress for cast
steel may be taken as 100MPa. The face width may be taken as 3 times the
normal pitch. The tooth form factor is given by expression y=0.154-0.912 /
TE , where TE represents the equivalent number of teeth. The velocity factor
is given by Cv = 6/ (6+V) where V is the peripheral speed of the gear in m/s.
[4+12]

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Code No: R05321403 Set No. 4
III B.Tech Supplimentary Examinations, Aug/Sep 2008
PRINCIPLES OF MACHINE DESIGN
(Mechatronics)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Explain how cast iron is obtained.

(b) Classify and explain different types of cast irons. [8+8]

2. (a) Explain the effect of the following factors on the type of fatigue failure
i. Stress distribution
ii. Manner of loading
iii. Strain rate
iv. Type of material
(b) Determine the diameter of a circular rod made of ductile material with fatigue
strength (complete stress reversal) Endurance limit = 280 MPa and a tensile
yield strength of 350 MPa. The member is subjected to a varying axial load
from 700 kN to 300 kN. Assume Fatigue stress concentration factor = 1.8 and
Factor of Safety = 2. [8+8]

3. (a) What is the difference between caulking and fullering? Explain with the help
of neat sketches.
(b) A double riveted double cover butt joint in plates 20-mm thick is made with
25 mm diameter rivets at 100 mm pitch. The permissible stresses are 120 MPa
in tension, 100 MPa in shear and 150 MPa in crushing. Find the efficiency
of joint, taking the strength of the rivet in double shear as twice than that of
single shear. [8+8]

4. (a) What are the uses of knuckle joint?

(b) Design a sleeve and double cotter joint to be designed for connecting two steel
rods. An axial tensile load of 30000N acts on the rods. Permissible stresses.
σ t = 55 MPa , σ c = 70MPa and τ = 40MPa. [4+12]

5. (a) Define the following terms

i. Spring index
ii. Solid length
iii. Spring stiffness
iv. Free length
v. pitch.
(b) A close coiled helical compression spring of 16 active coils has a spring stiffness
of 10 N/mm. It is cut in to two springs having 7 and 9 turns .Determine the
spring stiffness of resulting springs. [8+8]

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Code No: R05321403 Set No. 4
6. (a) Define the following terms:
i. journal
ii. Eccentricity ratio.
(b) A bearing, supporting a power transmitting shaft, is subjected to 3000N radial
load and 45000N axial thrust. The shaft rotates at 400r.p.m and the expected
life of the bearing is 10,000hours. Select a suitable bearing, if the diameter of
the shaft is 40mm. [2+14]

7. (a) What are the advantages and disadvantages of V- belt drive?

(b) A fly wheel having four arms is brought to rest from an angular velocity of 36
rad/s in three revolutions, by the application of a brake. The mass of the rim
is 250kg and the radius of gyration of the rim is 0.75m. Determine the size of
the cross section of the rims; assuming it to be elliptic with minor axis equal
to 0.6 times the major axis, and permissible bending stress for the flywheel
material as 30MPa. [4+12]

8. (a) Write the expression for static strength, limiting wear load and dynamic load
for helical gears and explain the various terms used.
(b) Two precision cut forged helical gears have 200 full depth involute teeth. The
angle of helix is 230 . Permissible static bending stress 100MPa,module 3mm,
face width 500mm. The speed of rotation of pinion 900rpm gear ratio 5:1,
surface endurance strength 630MPa. Find the transmitted and wear load and
state whether the design is safe. [8+8]

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