NUMERICAL QUESTION BANK

SUBJECT: Design of Machine Elements SUBJECT CODE: 3171917

Sr. No. Detail GTU Year

Chapter 1 – DESIGN CONSIDERATION
What are preferred numbers? The maximum & minimum load carrying
capacities of dumpers in a manufacturing unit are 40 KN and 630 KN
1 May-16
respectively. The company is interested in developing seven models in this
range. Specify their load carrying capacities.
It is required to standardize eleven shafts from 100 mm to 1000 mm
2 Dec-15
diameter. Specify there diameters.
Standardize six speeds between 250 to 1400 RPM and state the series of torque
3 June-15
for 0.5 kW drive.
Chapter 2 – DESIGN OF COUPLING
Design a cast iron protective type flange coupling to transmit 15 kW power at
900 r.p.m from an electric motor to a compressor. The service factor may be
assumed as 1.7. The permissible stresses are as follows.
1. Shear stress for shaft, bolt and key = 40 MPa
1 2. Crushing stress for bolt and key = 80 MPa Dec-18
3. Shear stress for cast iron flange = 8 MPa
Standard shaft diameters are:
20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40
Take number of bolts as 3.
For a muff coupling which is used to connect to shafts transmitting 40 kw at
350 r.p.m. The allowable shear and crushing stresses may be taken as 40
Mpa and 80 Mpa respectively for shaft and key. For the muff allowable
2 June-17
shear stress may be assumed as 15 Mpa.
Calculate 1) Design for shaft
2) Design for sleeve
Design a cast iron protective type flange coupling to transmit 15 kW at 900
r.p.m. from an electric motor to a compressor. The service factor may be
assumed as 1.35. The shaft, bolt and key are made from steel having yield
3 Nov-16
point stress and crushing stress of 160 N/mm2. The ultimate tensile strength
of cast iron is 32 N/mm2. Assume the shear stress is half of the normal stress
and factor of safety of 2.
Design muff coupling to connect two steel shafts transmitting 40 kW at
350rpm. The material for shafts and key is plain carbon steel for which
4 June-16
allowable shear and crushing stresses are 40 MPa and 80 MPa respectively.
The material for muff is cast iron for which allowable shear stress is 15 MPa.
CHAPTER 3 – DESIGN OF SPRINGS
Design a close coiled helical compression spring for a service load ranging
from 2250 N to 2750 N. The axial deflection of the spring for the load range is
1 Nov-17
6 mm. Assume a spring index of 5. The permissible shear stress intensity is 420
N/mm2 and modulus of rigidity, G = 84 kN/mm2.
A semi-elliptic leaf spring used for automobile suspension consists of three
extra full-length leaves and 15 graduated-length leaves, including the master
2 Nov-17
leaf. The center to center distance between two eyes of the spring is 1 m. The
maximum

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Sr. No. Detail GTU Year
force that can act on the spring is 75 kN. For each leaf, the ratio of width to
thickness is 9:1. The modulus of elasticity of the leaf material is 207000
N/mm2. The leaves are pre-stressed in such a way that when the force is
maximum, the stresses induced in all leaves are same and equal to 450 N/mm2.
Determine (i) the width and thickness of the leaves; (ii) The initial nip.
Design a leaf spring for following specification:
Total load = 14 tonnes
Numbers of springs supporting the load = 4
Maximum number of leaves = 10
3 May-17
Span of the spring = 1000 mm
Permissible deflection = 80 mm
Take Young Modulus = 0.2x106 N/mm2,
Allowable stress in spring material = 600 N/mm2.
Design a helical compression spring for a maximum load of 1000 N for a
deflection of 25 mm using the value of spring index as 5. The maximum
4 May-17
permissible stress for spring wire is 420 N/mm2, and modulus of rigidity is 84
KN/mm2.
A spring having outer diameter of coil as 72 mm, deflects for 50 mm at the
maximum load of 700 N. Calculate the wire diameter and number of turns
5 Nov-18
for the spring if the shear stress is 300 MPa and modulus of rigidity 84
KN/mm2 . Take spring index of 8
Design a helical compression spring with plain ends made out of bronze
for operating load range of 100 N to 150 N. The deflection of the spring is 6
mm and spring index = 9. The allowable shear stress for spring is 300 MPa and
6 Nov-18
modulus of rigidity is 80 KN/mm2. Determine (1) Diameter of spring wire (2)
Mean coil diameter (3) Total number
of turns (4) Stiffness of spring
CHAPTER 4 – DESIGN OF PRESSURE VESSEL
A closed vessel is to be designed to withstand an internal pressure of 5 MPa
having inside diameter of 450 mm. The properties of the vessel material are
yield strength is 300 MPa, ultimate tensile strength is 500 MPa, Poisson’s ratio
1 Nov-17
= 0.3. Determine the required wall thickness of the vessel using a factor
of safety of 1.5 based on yield strength on the basis of i) maximum principal
stress theory, ii) maximum shear stress theory.
The cover of a cylindrical pressure vessel made of cast iron. The inner diameter
of the cylinder is 500 mm and the internal pressure is limited to 2 MPa. The
cover is fixed to the cylinder by means of 16 bolts with a nominal diameter of
20 mm. Each bolt is initially tightened with a preload of 20 kN. The bolts are
2 made of steel FeE 250 having yield stress = 250 N/mm2. The Young’s module Nov-17
of elasticity for steel, cast iron and zinc is 207 kN/mm2, 100 kN/mm2 and 90
kN/mm2 respectively. Determine the factor of safety for bolts considering the
effect of the gasket. Assume thickness of cylinder cover, cylinder flange and
zinc gasket is 25 mm, 25 mm and 5 mm respectively.
A pressure vessel consists of a cylindrical shell with an inside diameter of
1650 mm, which is closed by tori spherical heads with a crown radius of
1300 mm. The operating pressure inside the vessel is 1.5 MPa. The yield
3 Nov-17
strength of the material used for the shell and head is 255 N/mm2 and the weld
joint efficiency may be assumed to be 0.8. The corrosion allowance is 2 mm.
Determine the thickness of the cylindrical shell and the tori spherical head.

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Sr. No. Detail GTU Year
An accumulator is required to store 175 liters of water at a pressure of 25
N/mm2. Assume the length of the stroke to be 3 meter. Determine (1) The
4 diameter of the Ram (2) The internal diameter of the cylinder (3) The thickness Nov-18
of the cylinder if the allowable stress of the cylinder made of cast iron is 60
N/mm2.
A hydraulic cylinder with closed ends is subjected to an internal pressure
of 15 MPa. The inner and outer diameters of the cylinder are 200 mm
5 and 240 mm respectively. The cylinder material is cast iron FG300. Determine May-19
the factor of safety used in design. If the cylinder pressure is further increased
by 50%, what will be the factor of safety?
A thick cylinder 120 mm inner diameter and 180 mm outer diameter carries
6 fluid under a pressure of 9 MPa. Find the tangential and radial stresses across May-19
the wall and sketch the stress distribution.
Chapter 5 – Design of Rolling contact Bearing
Find the rating life of the 50 mm bore, light series, ball bearing under 6800 N
1 radial load at 600 rpm. The load is out of balance and rotates with inner ring. Nov-19
Assume there is no shock loading.
Select a single row deep groove ball bearing for a radial load of 4000 N and an
2 axial load of 5000 N, operating at a speed of 1600 r.p.m. for an average life of May-19
5 years (300 days/year) at 10 hours per day. Assume uniform and steady load.
A bearing is subjected to the following work cycle: radial load of 4450 N,
6675 N and 2225 N at 150 rpm, 600 rpm, and 300 rpm for 30 % of time, 10
% of time, and for remaining time of the cycle respectively. The inner
3 Dec-18
ring rotates and the loads are steady. Find the expected life of this bearing in
hours, by considering the static and dynamic load carrying capacities of the
bearing as 10013 N and 14952 N respectively.
A deep groove ball bearing has a rated static and dynamic load capacity
4 of 4150 N and 4750 N respectively. The bearing has to take an axial load of Dec-18
2075 N and a radial load of 4000 N. Find the expected life of the bearing.
A single row deep groove ball bearing No. 6002 is subjected to an axial
5 thrust of 1000 N and a radial load of 2200 N. find the expected life that 50% of May-18
the bearings will complete under this condition.
A ball bearing is subjected to purely radial force. The magnitude of radial force
acting on the bearing varies in a sinusoidal manner from 0 to 1500 N in first
half revolution and 1500 N to 0 in second half revolution. The cycle then
6 Jan-21
repeats. The direction force remains fixed. The speed of rotation is 720 rpm.
Determine the dynamic load carrying capacity of the bearing for a life of 8000
hours.
Chapter 6 – Design of Sliding contact Bearing
A 360° hydrodynamic bearing operates under the following conditions:
radial load = 50 kN journal diameter = 150 mm
bearing length = 150 mm radial clearance = 0.15 mm
1 Nov-19
minimum film thickness = 0.03 mm viscosity of lubricant = 8 cP
What is the minimum speed of operation for the journal to work under
Hydrodynamic conditions?
A full journal bearing of 50 mm diameter and 100 mm long has a bearing
pressure of 1.4 N/mm2. The speed of the journal is 900 r.p.m. and the ratio of
2 May-19
journal diameter to the diametral clearance is 1000. The bearing is lubricated
with oil whose absolute viscosity at the operating temperature of 75 °C may be

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Sr. No. Detail GTU Year
taken as 0.011 kg/m-s. The room temperature is 35 °C. Find: 1. The amount of
artificial cooling required, and 2. The mass of the lubricating oil required, if the
difference between the outlet and inlet temperature of the oil is 10°C. Take
specific heat of the oil as 1850 J / kg / °C.
A 3600 full journal bearing operates under the following
specifications:
Journal Diameter = 70 mm, bearing length = 70 mm,
Journal speed = 960 rpm, steady radial load = 12 KN,
Viscosity of lubricant = 16 cP,
Mass density of oil = 880 kg/m3,
3 Dec-18
Specific heat = 1.76 kJ/kg 0C, bearing clearance ratio (r/c) = 800,
Average heat transfer coefficient = 20 W/m2-0C.
Determine the required flow rate of oil. Also find the temperature of oil film
and the bearing surface area for the desired heat transfer, if the ambient
temperature is 300 C. Assume that all heat generated in the bearing is carried
away by the oil.
Calculate the maximum radial load that the journal can carry and operate
at hydrodynamic condition for the following data of a full journal bearing.
Journal diameter = 60 mm, bearing length = 60 mm, radial clearance = 0.06
4 Dec-18
mm, minimum film thickness = 0.006 mm, journal speed = 1440 rpm, viscosity
of lubricant = 20 cP. For the above calculated load, find the power lost in
friction.
A 3600 hydrodynamic bearing has 50 mm diameter and 50 mm length. The
journal is carrying a load of 15 KN and rotates at 1450 rpm. The eccentricity
ratio is 0.8.The radial clearance is 20 μm. Calculate
a) Probable coefficient of friction. b) Viscosity of oil.
5 Jan-21
c) Minimum film thickness. d) Quantity of oil in circulation.
e) Oil leakages through sides. If the oil is supplied at 280c, find the oil
temperature. The specific gravity of oil is0.86 and the specific heat can be taken
as 2.09 KJ/Kg 0c.
CHAPTER 7 – DESIGN OF GEAR DRIVE
A pair of bevel gears consists of a 30 tooth pinion meshing with a 48 tooth gear.
The axes of the connecting shafts are right angles to each other. Assume the
module of the gears to be 5 at the larger end.
Calculate:
1 1. The pitch circle diameters of pinion and gear. Nov-19
2. The pitch angles of pinion and gear.
3. The cone distance.
4. The mean radii of the pinion and gear.
5. Back cone radii of the pinion and gear.
Considering static strength determine a suitable module and face width for a
pair of helical gears that transmit 15 kW. The teeth are 20° stub in diametral
plane and have a helix angle of 45°. The pinion runs at 10 000 r.p.m. and has
2 80 mm pitch diameter. The gear has 320 mm pitch diameter. The gears are May-19
made of cast steel having allowable static strength of 100MPa. Assume
endurance strength of gear material = 618 MPa.
Also, check the gears for wear.
Design a pair of straight teeth spur gears to transmit 20 kW when the pinion
3 rotates at 300 r.p.m. The velocity ratio is 1:3. The allowable static stresses for May-19
the pinion and gear materials are 120 MPa and 100 MPa respectively. The

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Sr. No. Detail GTU Year
pinion has 15 teeth and its face width is 14 times the module. Assume steady
load condition and 8-10 hours of service per day.
Take, the tooth form factor, y = 0.154 − (0.912 / No. of teeth); and the velocity
factor, Cv = 3 / (3 + v).
A worm and worm wheel gear drive is designated as 2 / 41 / 10 / 8. The drive
is used to obtain a speed reduction of 20.5 from an input speed of 1450 rpm.
4 Material of the worm wheel is Sand Cast and Chilled Phosphor Bronze, while Dec-18
the worm is made of Case-hardened alloy steel. Determine the power
transmitting capacity of the drive based on beam strength.
Design a helical gear to transmit 30 kW from the following data;
Helix angle = 300, Speed of pinion = 1500 rpm, Pressure angle = 200 FDI,
Velocity ratio = 4, No of teeth on pinion = 24, Static stress for CI = 55 N/mm2,
5 Dec-18
BHN for pinion and gear material = 350, Young’s modulus of elasticity for
pinion and gear material = 2.1 *
105 N/ mm2.
Design a pair of CI spur gear to transmit 12 kW having pinion speed of 200
rpm. The speed reduction required is 2:1. Assume face width as 3 times circular
pitch. The minimum number of teeth on pinion is 24. Check your design in all
failures considering the following data;
6 Dec-18
Pressure angel 14.50 full depth involute, Factor of safety 1.5. The modulus of
elasticity for pair is 0.8 * 105 N/mm2, Error in manufacturing is not to exceed
0.05 mm, Allowable bending stress for CI as 45 N/mm2, Surface endurance
stress as 280 N/mm2.
A pair of bevel gears transmitting 7.5 kW at 300 rpm is shown in fig.1.the
pressure angle is 200. Determine of the components the resultant gear tooth
force and draw a free body diagram of forces acting on the pinion and gear.

7 May-18

A pair of spur gears consists of a 20 teeth pinion meshing with a 120 teeth gear.
The module is 4 mm. calculate (i) the center distance, (ii) the pitch circle
8 May-18
diameter of the pinion and gear, (iii) the addendum and dedendum, (iv) the
tooth thickness, (v) the bottom clearance, and (vi) the gear ratio.
A pair of helical gears with pinions 26 teeth and gear 100 teeth supplies power
5KW at 2000 rpm of pinion. Normal pressure angle is 20o and helix angle of
teeth is 150.Both the gears are made of hardened steel with Sut = 660 N/mm2.
9 Gears are finished to accuracy of grade 8. Assume service factor =1.5, factor Jan-21
of safety = 1.8 and pitch line velocity of gears as 10 m/s, determine normal
module of gear teeth as per beam strength. Specify the hardness of the surface
of gears if Sw = Sb. b =12mn.Where b is face width.

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Sr. No. Detail GTU Year
Chapter 8 – Design of Gear Box for Machine Tools
Draw the structure and speed diagram for a gearbox having operating speed
range from 31.5 rpm to 560 rpm. Use R4 series, with standard spindle speeds,
1. Nov-19
the gearbox is connected to a motor driven by a pair of pulleys. Assume the
motor speeds to be 1440 rpm. Draw the gearbox layout diagram.
Find the range ratio, geometric progression ratio and spindle speeds for the
2. following data: Nmin = 100 r.p.m., Nmax = 1800 r.p.m. and number of speed Nov-19
steps = 8. Also, draw all possible structure diagrams.
Draw layout diagram of gear box, ray diagram and speed chart for a multi-
speed gear box of a radial drilling machine required to give eight steps.
Dec-18
3. The power from motor to the input shaft of gear box is transmitted by a V-belt
drive with a speed reduction of 1:6. The minimum and maximum spindle
speeds are 70 rpm and 1800 rpm respectively.
A 2x2 drive is required to be designed for transmitting speeds starting from 400
rpm with a geometric progression of 1.4. Draw a suitable structure and speed
4. May-17
diagram. Also draw the layout of the gearbox and determine the number of
teeth on each gear.
Chapter 9 – Design Mechanism
Design the crane hook of a hoisting block for a maximum load lifting capacity
1 of 10 ton. The material for hook is forged for which permissible tensile stress Nov-17
may be taken as 120 N/mm2. Use the modified triangular section for hook.
A crane is lifting a load of 25 kN through a wire rope and a hook. The weight
of hook, etc. is 15 kN. The rope drum diameter may be taken as 3 times the
diameter of the rope. The load is to be lifted with an acceleration of
2 m/s2.Calculate the diameter of the wire rope. Take f.o.s. of 6 and Young’s May-19
modulus for the wire rope 80 kN/mm2. The ultimate stress may be taken as
1800 Mpa. The cross-sectional area of the wire rope may be taken as 0.38 times
the square of the wire rope diameter.
A crane hook having an approximate trapezoidal section is shown in Figure 1.
The hook is made of plain carbon steel 45C8 (yield strength = 380 MPa) and
the f.o.s. is 3.5. Determine the load carrying capacity of the hook.

3 May-19

At the construction site, 1 tonne of steel is to be lifted up to a height of 20 m

with the help of 2 wire ropes of 6 x 19 size, nominal diameter 12 mm and tensile
4 Jan-21
strength designation 1770. Determine the factor of safety if the sheave diameter
is 56d and if the wire rope is suddenly stopped in 1 second when travelling at

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Sr. No. Detail GTU Year
a speed of 1.2 m/s. What is the factor of safety if bending load is neglected?
Assume mass per m is 0.498 kg, breaking load =78 KN for given tensile
strength designation and metal cross section area is 0.39d2
Design the crane hook of a hoisting block for a maximum load lifting capacity
5 of 10 ton. The material for hook is forged for which permissible tensile stress Jan-21
may be taken as 120 N/mm2. The modified triangular section is used for hook.

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