CamScanner

CamScanner
CamScanner
CamScanner
CamScanner
CamScanner
CamScanner
CamScanner
CamScanner
CamScanner
CamScanner
Scanned with CamScanner
Scanned with CamScanner
 BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Course No: ME 352 (Machine Design Sessional)
Problem Class: 03

A ductile hot-rolled steel bar has minimum yield strength in tension and compression
of 350 MPa. Using the distortion-energy and maximum-shear-stress theories
determine the factors of safety for the following plane stress states:
1.
a) σx = −50 MPa, σy = −75 MPa, τxy = −50 MPa
b) σx = 100 MPa, σy = 20 MPa, τxy = −20 MPa

For an ASTM 30 cast iron, find the factors of safety using the BCM and MM theories:
2. a) σx = −50 MPa, σy = −75 MPa, τxy = −50 MPa
b) σx = 100 MPa, , τxy = −75 MPa

A cold-drawn AISI 1015 steel tube is 300 mm OD by 200 mm ID and is to be

3. subjected to an external pressure caused by a shrink fit. Using the distortion-energy
theory, determine the maximum pressure that would cause the material of the tube to
yield.
This bar is made of AISI 1006 cold-drawn steel and is loaded by the forces F = 0.55
kN, P = 4.0 kN, and T = 25 N · m.

4.

(a)For an ASTM 30 cast iron, find the factors of safety using the BCM and MM
theories
(b)For AISI1006 Steel, find the safety factor using the distortion energy theorem.
 BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Course No: ME 352 (Machine Design Sessional)
Problem Class: 04

A plate 100 mm wide, 200 mm long, and 12 mm thick is loaded in tension in the
direction of the length. The plate contains a crack with the crack length of 16 mm at
1. the middle of the plate at an edge. The material is steel with KIc = 80 MPa √m, and Sy
= 950 MPa. Determine the maximum possible load that can be applied before the plate
(a) yields, and (b) has uncontrollable crack growth.
A cylinder subjected to internal pressure pi has an outer diameter of 350mm and a
25mm wall thickness. For the cylinder material, KIc = 80 MPa √m, Sy = 1172 MPa,
2. and Sut = 1324 MPa. If the cylinder contains a radial crack in the longitudinal
direction of depth 12.5 mm determine the pressure that will cause uncontrollable crack
growth.
A countershaft carrying two V-belt pulleys is shown in the figure. Pulley A receives
power from a motor through a belt with the belt tensions shown. The power is
transmitted through the shaft and delivered to the belt on pulley B. Assume the belt
tension on the loose side at B is 15 percent of the tension on the tight side. The shaft is
to be made of AISI 1035 CD steel. Using a conservative failure theory with a design
factor of 2, determine the minimum shaft diameter to avoid yielding [Dimension is in
mm].

3.

A 1020 CD steel shaft is to transmit 16 kW while rotating at 1750 rpm. Determine the
4. minimum diameter for the shaft to provide a minimum factor of safety of 3 based on
the maximum-shear stress theory.
 BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Course No: ME 352 (Machine Design Sessional)
Problem Class: Online Problem Class 3 (Fatigue Failure #1)

1. A thick walled cylinder in Fig. 1 is subjected to a fluctuating internal pressure of 0 to 100 MPa. The outer
and inner diameters of the cylinder are 250 mm and 150 mm, respectively. The material is Ferritic-pearlitic steel
with Sut = 800 MPa and Sy = 600 MPa. The fracture toughness of the material is 50 MPa√𝑚. A nick of 0.2 mm
is detected by the ultrasonic detector. Estimate the No. of cycle of life remaining of this cylinder.

Fig. 1 Fig. 2 Fig. 3

2. A steel bar having a cross section of 6 mm × 12 mm (in Fig. 2) of Sut = 1280 MPa, Sy = 1170 MPa, KIC = 81
MPa√𝑚, subjected to a repeated moment of 0 to 135 Nm. A crack is detected as 0.1 mm at the edge. Estimate
no. of life cycle remaining by linear elastic fracture mechanics method. [C = 114 × 10-15 (m/cycle)/(MPa√𝑚)m,
m = 3.00]

3. The steel shaft with diameter d is subjected to the completely reversed bending moment of M = -10 kNm to
+10 kNm as shown in Fig. 3. The shaft material is AISI 4140 Q&T steel and the shaft has a fully corrected
endurance strength of 250 MPa. Determine the safe diameter of the shaft if the life expectancy is (i) 105 cycles
(ii) 500 cycles.

4. The notched rectangular bar in Fig. 4 is subjected to the fluctuating load from -5 to +10 kN. The material is
AISI 1030 CD steel, room temperature operation, reliability goal is 0.95. Thickness of the part is d/6. Use the
Soderberg equation to determine the diameter d.

Fig. 4 Fig. 5

5. A machine part of uniform thickness, t = b/5 is shaped as shown in Fig. 5. The part is made of steel Sy = 510
MPa, Sut = 650 MPa. The design is to be made for indefinite life with the following two load cases.
i) Fluctuating load of 0 to 10 kN
ii) Completely reversed load of -5 to +5 kN.
Determine the dimension (b) of the part considering a design factor of 1.4 based on Goodman equation. Also,
choose 95 % reliability for your design.

Fig. 6

6. A stepped shaft as shown in the Fig. 6. is made from cold drawn steel (BHN 290) is subjected to a
completely reversed torque T. Based on infinite life, 90% reliability and a factor of safety 2.1 find the maximum
allowable safe torque T that can be applied if d = 8 mm.
 BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Course No: ME 352 (Machine Design Sessional)
Problem Class: Online Problem Class 3 (Fatigue Failure #2, Statistics)

1. The steel shaft with diameter d is subjected to the completely reversed bending moment of M = -12 kNm to
+12 kNm. The shaft material is AISI 1050 HR steel and the shaft has a fully corrected endurance strength of
250 MPa. Determine the safe diameter of the shaft if the life expectancy is (i) 105 cycles (ii) 500 cycles.

Fig. 1 Fig. 2
2. The machine shaft in the Fig. 1 is machined from steel material and is subjected to a combined axial, bending
and torsional stresses. F is fluctuating load that varies between 0 to + 10 kN, whereas M is completely reversed
bending moment of 10 kN-m. The shaft is also subjected to a constant torsion of 5kN-m.
Considering d = 50 mm, D = 100 mm, Sut = 800 MPa, Syt = 500 MPa, determine the factor of safety that is
maintained in the design for infinite life based on Soderberg and Gerber Criteria.

3. A flat bar with a hole at its center (as shown in Fig. 2.) is to be used as a machine part where it will be
subjected to the combined axial (F = 0 to 5 kN) and bending (M = -2 to +2 kN-m) loads. The design is to be for
indefinite life and the material is AISI 1018 steel material. Using the Soderberg criterion, find the minimum
dimension ‘d’ of the part, consider a safety factor of 1.5. Use 95% reliability in your design.
4. The cold drawn AISI 1040 steel member shown in the Fig.3 is subjected to completely reversed axial load of
-5 kN to +5 kN and a bending load of 8 kN. If a fatigue factor of safety 1.5 is to be used on the basis of
modified Goodman approach, determine the minimum size h for this part. Consider room temperature operation
and 95 % reliability for your design.

Fig. 3 Fig. 4

5. A forged flat bar (thickness = 3.0 cm) with notches is subjected to reversed bending moment as shown in Fig.
4. The material is BS 945M38 Steel hardened and tempered to BHN 230. For an operating temperature of 390o
C and a reliability of 95 % find the life of the bar. Consider r = 2.5 cm, w = 15 cm and applied bending moment,
M = 5 kN-m.

6. From a lot of 1000 of pieces of AISI 1030 Normalized steel billets, a sample of 20 billets are tested to find
Syt. The test result is:
Syt(MPa) 400-420 421-440 441-460 461-480 481-500
No. of samples 3 4 6 4 3
If the allowable range of Syt is 430 MPa ≤ Syt ≤ 480MPa
Find: i) Most frequent Syt
ii) Natural Spread, N.S.
iii) Standard Deviation
iv) Tolerance
v) How many billets will be rejected from the lot? (Assuming Normal Distribution)

7. A shaft manufacturer has produced 500 MS pipes of nominal outside diameter 150 mm. Measurements show
the maximum diameter to be 151.1 mm while the minimum diameter to be 149.3mm. However, during
shipment pipes of diameter 150 mm ±0.5mm were accepted and the rest were rejected. Assume
Gaussian/Normal distribution.
(a) Neatly sketch the frequency/probability distribution curve and show all pertinent dimensions.
.

(b) Calculate: (i) The natural spread (ii) standard deviation (iii) tolerance (iv) How many pipes were
probably rejected?
 BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Course No: ME 352 (Machine Design Sessional)
Problem Class: Spring

A helical compression spring is to be made of music wire of 4-mm diameter with a

spring index of C = 10. The spring is to operate inside a hole, so buckling is not a
problem and the ends can be left plain. The free length of the spring should be 80 mm.
A force of 50 N should deflect the spring 15 mm.
(a) Determine the spring rate.
(b) Determine the minimum hole diameter for the spring to operate in.
1.
(c) Determine the total number of coils needed.
(d) Determine the solid length.
(e) Determine a static factor of safety based on the yielding of the spring if it is
compressed to its solid length.
(f) Determine the fatigue factor of safety when repeatedly cycled from free length to
solid length.
A holding fixture for a workpiece 37.5 mm thick at the clamp locations is being
designed. The detail of one of the clamps is shown in the figure. A spring is required to
drive the clamp upward when removing the workpiece with a starting force of 45 N.
The clamp screw has an M10 × 1.25 thread. Allow a diametral clearance of 1.25 mm
between it and the uncompressed spring. It is further specified that the free length of
the spring should be L0 ≤ 48 mm, the solid height Ls ≤ 31.5 mm, and the safety factor
when closed solid should be ns ≥ 1.2. Starting with d = 2 mm, design a suitable helical
coil compression spring for this fixture. Wire diameters are available in 0.2-mm
increments between 0.2 to 3.2 mm.

2.

An automobile leaf spring supports a total vertical load of 6 kN, so that half of this
load acts on each tip (eye). The spring has 8 leaves each of width 90 mm and thickness
of 10 mm. Total span of the main leaf is 500 mm. Take, E = 200 GPa and find
(i) the maximum stress and its location,
(ii) spring constant, and
3 (iii) energy absorbed.
 BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Course No: ME 352 (Machine Design Sessional)
Rolling Contact Bearing
Class problems:
1. A certain application requires a ball bearing with the inner ring rotating, with a design
life of 25 Kh at a speed of 350 rpm. The radial load is 2.5 KN and an application factor of
1.2 is appropriate. Find the rating life, L10 and the catalog rating C10 with which to enter a
bearing table for the following cases
a) 90% reliability b) 50% reliability c) 95% reliability
Choose a 02-series deep-groove ball bearing.

2. For a bearing note the following data

Load (KN) Speed (rpm) Duration
45 10 25% of time
35 50 50% of time
20 30 25% of time
Desired/design life = 3 Khr & reliability 80%.

i) Select a 02-series deep-groove ball bearing.

ii) Find reliability of the selected bearing

3.
Assignment

.
 BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Course No: ME 352 (Machine Design Sessional)
Journal Bearing
1. A 64 × 64-mm sleeve bearing uses grade 20 lubricant. The axial-groove sump has a steady state
temperature of 430C. The shaft journal has a diameter of 63.5 mm with a unilateral tolerance of -0.025
mm. The bushing bore has a diameter of 63.6 mm with a unilateral tolerance of 0.025 mm. The journal
speed is 1120 rev/min and the radial load is 5.34 KN. Estimate
a. The magnitude and location of the minimum oil-film thickness
b. The eccentricity
c. The coefficient of friction
d. The power loss rate
e. Both the total and side oil-flow rates
f. The maximum oil-film pressure and its angular location
g. The terminating position of the oil film
h. The average temperature of the side flow
i. The oil temperature at the terminating position of the oil film.

2. A 32 mm x 32 mm sleeve bearing with 3.2 kN load rotates at 3600 rpm. SAE 10 lubricating oil is used
with an average film temperature of 70°C. Estimate the radial clearance necessary to run the bearing in
a minimum friction condition.

3. A full journal bearing with shaft diameter of 25 mm and bore diameter of 25.04 mm, has l/d ratio of
unity. The journal rotates at 1200 rev/min supporting a bushing load of 1.25 kN. The average viscosity
of the oil is 50 mPa.s. Find the power loss, and the percentage of side flow.

4. A natural-circulation pillow-block bearing has a journal diameter d of 62.5 mm with a unilateral

tolerance of −0.025 mm. The bushing bore diameter B is 62.6 mm with a unilateral tolerance of 0.1 mm.
The shaft runs at an angular speed of 1120 rev/min; the bearing uses SAE grade 20 oil and carries a
steady load of 1350 N in shaft-stirred air at 210C. The lateral area of the pillow-block housing is 38700
mm2. Perform a design assessment using minimum radial clearance for a load of 1350 N. Use Trumpler’s
criteria and assume both l/d and α are unity.

5. A pressure-fed bearing has a journal diameter of 50.00 mm with a unilateral tolerance of −0.05 mm.
The bushing bore diameter is 50.084 mm with a unilateral tolerance of 0.10 mm. The length of the
bushing is 55 mm. Its central annular groove is 5 mm wide and is fed by SAE 30 oil is 55 0C at 200 kPa
supply gauge pressure. The journal speed is 2880 rev/min carrying a load of 10 kN. The sump can
dissipate 300 watts per bearing if necessary. For minimum radial clearances, perform a design assessment
using Trumpler’s criteria.

Assignment
A pressure-fed bearing has a journal diameter of 50.00 mm with a unilateral tolerance of -0.05 mm. The
bushing bore diameter is 50.084 mm with a unilateral tolerance of 0.10 mm. The length of the busing is
55 mm. Its central annular groove is 5 mm wide and is fed by SAE 30 oil is 55°C at 200 kPa supply
gauge pressure. The journal speed is 2880 rev/min carrying a load of 10 kN. The sump can dissipate 300
watts per bearing if necessary. For minimum radial clearances, perform a design assessment using
Trumpler's criteria.
 BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Course No: ME 352 (Machine Design Sessional)
Problem Class
Spur and Helical Gears

A steel spur pinion has a module of 1 mm and 16 teeth cut on the 20° full-depth system
1. and is to carry 0.15 kW at 400 rev/min. Determine a suitable face width based on an
allowable bending stress of 150 MPa.

A gearset has a module of 5 mm, a 20° pressure angle, and a 24-tooth cast-iron spur
pinion driving a 48-tooth cast-iron gear. The pinion is to rotate at 50 rev/min. What
2. horsepower input can be used with this gearset if the contact stress is limited to 690
MPa and F = 60 mm?

A spur gearset has 17 teeth on the pinion and 51 teeth on the gear. The pressure angle
is 20° and the overload factor Ko = 1. The diametral pitch is 6 teeth/in and the face
width is 2 in. The pinion speed is 1120 rev/min and its cycle life is to be 108
3. revolutions at a reliability R = 0.99. The quality number is 5. The material is a through-
hardened steel, grade 1, with Brinell hardness’s of 232 core and case of both gears. For
a design factor of 2, rate the gearset for these conditions using the AGMA method.

A 20° spur pinion with 20 teeth and a module of 2.5 mm transmits 120 W to a 36-tooth
gear. The pinion speed is 100 rev/min, and the gears are grade 1, 18-mm face width,
through-hardened steel at 200 Brinell, uncrowned, manufactured to a No. 6 quality
4. standard, and considered to be of open gearing quality installation. Find the AGMA
bending and contact stresses and the corresponding factors of safety for a pinion life of
108 cycles and a reliability of 0.95.

A commercial enclosed gear drive consists of a 16-tooth 20° normal pitch-angle helical
pinion with a right-hand helix angle of 30° rotates at 300 rev/min when transmitting
3.75 kW to a 48-tooth helical gear. The face width 50 mm, and the diametral pitch 6
teeth/in. The gears are grade 1 steel, through-hardened at 200 Brinell, made to No. 6
quality standards, uncrowned, and are to be accurately and rigidly mounted. Assume a
5.
pinion life of 108 cycles and a reliability of 0.90.
(a) Find the factors of safety of the gears in bending.
(b) Find the factors of safety of the gears in wear.
(c) By examining the factors of safety identify the threat to each gear and to the mesh.
 BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Course No: ME 352 (Machine Design Sessional)
Problem Class: 10

A fit or assembly of pin and hole is designated by 55mm H11/c11.

a) Describe what kind of fit it is.
b) Find: i) tolerances for pin & hole,
ii) Deviations (U.D., L.D., F.D.) for hole,
iii) Deviations (U.D., L.D., F.D.) for pin,
iv) The maximum, minimum, mean clearance.
1.
c) Neatly sketch the fit/assembly and show all pertinent dimensions.
d) Given Natural Spread (N.S.) and tolerance (T) both are symmetric about mean for pin
and hole. And
N.S = 2.5 times T for hole
N.S = 3 times for pin
If, 20% of the assembly was rejected, what is the maximum clearance that was accepted?
A single-threaded 25-mm power screw is 25 mm in diameter with a pitch of 5 mm. A vertical
load on the screw reaches a maximum of 5 kN. The coefficients of friction are 0.06 for the collar
and 0.09 for the threads. The frictional diameter of the collar is 45 mm. Find
2.
(i) the overall efficiency
(ii) the torque to “raise” and “lower” the load and
(iii) determine whether the screw is self-locking or not.
A single square-thread power screw has an input power of 3 kW at a speed of 1 rev/s.
The screw has a diameter of 40 mm and a pitch of 8 mm. The frictional coefficients are
3
0.14 for the threads and 0.09 for the collar, with a collar friction radius of 50 mm. Find
the axial resisting load F and the combined efficiency of the screw and collar.
A shaft manufacturer has produced 500 MS pipes of nominal outside diameter 150 mm.
Measurements show the maximum diameter to be 151.1 mm while the minimum diameter to be
149.3 mm. However, during shipment pipes of diameter 150 mm ± 0.5mm were accepted and
the rest were rejected. Assume Gaussian/Normal distribution.
4
(a) Neatly sketch the frequency/probability distribution curve in a graph paper and show all
pertinent dimensions.
(b) Calculate: (i) The natural spread (ii) standard deviation (iii) tolerance (iv) How many pipes
were probably rejected?
Perform an adequacy assessment of the statically loaded welded cantilever carrying
2.2 KN depicted in Fig. 5. The cantilever is made of AISI 1018 HR steel and welded
with a 10 mm fillet weld as shown in the figure. An E6010 electrode was used, and the
design factor was 3.0.
(a) Use the conventional method for the weld metal.
(b) Use the conventional method for the attachment (cantilever) metal.
(c) Use a welding code for the weld metal.
5
 BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
Course No: ME 352 (Machine Design Sessional)
Worm and Bevel Gear
A worm receives power from an electric motor (that has a nominal power of 1.5 hp at
1450 rpm) and then drives an 80 teeth bronze gear that is chilled cast. Given: worm
1
speed = 1450 rpm, gear speed = 36.25 rpm, mt = 12 inch, Fe = 1", dw = 2", gear case area
is equal to twice the recommended lateral area by AGMA, frictional power loss =
1. 0.51 hp, gear box is naturally cooled, service factor = 1.22 and design factor = 1.15.
1 hp = 33000 ft-lb/min.
Calculate (i) worm's thread number, (ii) resultant force (W) and gear's driving force
(WGt), (iii) normal pressure angle, (iv) strength safety factor by using AGMA equation,
(v) temperature rise of the lubricating oil.

An electric motor (nominal power 2.5 hp at 1450 rpm) is directly coupled to a double
threaded worm (High-test CI). The worm drives a 40 teeth bronze gear that is
centrifugally cast. Given: 1 hp = 33000 ft-Ib/min, ∅𝑛 = 25°, mt = 1/6 inch, dw = 2 inch,
Fe = 1 in, lateral area of the gear case is TWICE the minimum lateral area recommended
by AGMA. To take care of unfavorable working conditions, load application factor is
1.12 and design factor is 1.25. Based on the fact that the driver worm receives input
2.
power from the motor, Find:
(a) Lead angle, gear rpm, sliding velocity and co-efficient of friction, (b)Transmitted/
Driving force of gear, Transmitted/Driving force of worm and efficiency of the drive,
(c) Safety factors by AGMA equation and Buckingham wear load equation, (d)
Temperature rise if i) no fan is used; ii) fan is used.

A pair of outboard mounted straight bevel gears have the following design data:
Material: Steel (Grade 1, through hardened to HB = 200), driver pinion (N p = 40, 250
rpm) transmits 10 kW to the gear (Ng = 80), m = 12 mm at larger end, b = 75 mm,
3. ∅𝑛 = 25°, Qv = 5, R = 95%, nL (pinion) = 8000 cycles, temperature = 70°C, crowned
teeth, both gears experience light shock. Find safety factor using suitable AGMA
equation.

A pair of outboard mounted straight bevel gears have the following design data:
Material: ASTM Grey Cast Iron, driver pinion (Np = 30, 900 rpm) transmits 10 kW to
the gear (Ng = 60), diametral pitch of 6, face width = 1.25 in, ∅𝑛 = 20°, Qv = 6,
4. temperature = 70°C, crowned teeth, both gears experience mild shock. Find the safety
factor based on AGMA equation if the life goal is 109 revolutions of the pinion at 0.999
reliability.

A pair of straight bevel gears have following particulars: the gears are of equal size,
the driver gear (50 teeth) runs at 480 rpm and transmits 1 kW which increases by 10%
5. due to mild shock. ∅= 20° and average pitch radius = 75 mm. Calculate the radial and
axial forces on the driven bevel gear
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner
Scanned by CamScanner