Code No: RR321401 Set No.

1
III B.Tech II Semester Supplimentary Examinations, Aug/Sep 2007
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. (a) “For the state of uniaxial stress, the strain state is triaxial.” Justify the state-
ment.
(b) What do you mean by factor of safety? What are the various factors involved
in the factor of safety. [8+8]

2. (a) Draw the sketches of various types of keys used and indicate where each one
is preferred. Give your reasons for the choice.
(b) A belt pulley is fastened to a 75mm diameter shaft running at 200rpm by
means of a key 16mm wide and 125mm long. Allowable stress for the shaft
and the key materials are 40MPa shear and 100MPa in crushing. Find the
horsepower transmitted and the depth of key required. [8+8]

3. Define the following terms as applied to rolling contact bearings:

(a) Basic static load rating

(b) Static equivalent load
(c) Basic dynamic load rating
(d) Dynamic equivalent load [4x4=16]

4. A 50mm diameter steel shaft is transmitted by means of a C.I flange rigid coupling.
A tentative selection is made with 4 bolts on a bolt circle diameter of 150 mm if the
bolts are made of the same material as the shaft with an ultimate tensile strength
of 550 MPa and allowable shear stress of 550 MPa. Determine the necessary size
of bolts to resist the shaft torque, also design the other dimensions of the coupling.
Make a sketch of the coupling. [16]

5. The machined shaft shown in figure 5is made of steel having σu =900 MPa and
σy =750 MPa. The most several loading occurs when an object is held near the
periphery of the disk at a radius of 100 mm, with sufficient force to develop a
friction torque of 10 Nm. Assume a coefficient of friction of 0.5 between the object
and the disk. Calculate the factor of safety for fatigue failure of the shaft. D=18mm,
d=16 mm, r=5 mm.

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Code No: RR321401 Set No. 1

Figure 5
6. Design a cast iron trunk type piston for a single acing four stroke engine developing
75 kW per cylinder when running at 600 rpm. The other available data is as follows:
Maximum gas pressure = 4.8 N/mm2 ;
Indicated mean effective pressure = 0.65 N/mm2 ;
Mechanical efficiency 95%;
Radius of crank = 110 mm;
Fuel consumption = 0.3 kg/BP/hr;
calorific value of fuel (higher) = 44 x 103 kJ/kg;
Differences of temperatures at the center and edges of the piston head = 2000 C;
Allowable stress of the material of the piston = 33.5 MPa;
Allowable stress of the material of the piston rings and gudgeon pin = 80 MPa;
Allowable bearing pressure on the piston barrel = 0.4 N/mm2
and allowable bearing pressure on the gudgeon pin = 17 N/mm2 . [16]

7. The following particulars refer to a belt drive using a cast iron pulley mounted on
a shaft:
Power: 25 kW
Speed of driving shaft: 300 rpm
Speed of driven shaft: 100 rpm
Allowable tension: 10 N/mm width [16]
Design suitable belt drive.

8. A pair of spur gear is to be designed to transmit 15 kW. Pinion has 24 teeth runs
at 250 rpm. Velocity ratio is 2.8:1. Assume pinion is made by alloy steel has design
compressive stress 950 N/mm2 , design bending stress 320 N/mm2 and hardness
number 280. Assume wheel is made by C 45 steel has design compressive stress
500 N/mm2 , design bending stress 140 N/mm2 and hardness number 175. [16]

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Code No: RR321401 Set No. 2
III B.Tech II Semester Supplimentary Examinations, Aug/Sep 2007
PRINCIPLES OF MACHINE DESIGN
(Mechatronics)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. Explain the following theories failure:

(a) Rankine’s Theory,

(b) Tresca’s Theory,
(c) Vonmises and Hencky’s Theory,
(d) St.venant’s Theory. [4x2=16]

2. A pulley is keyed to shaft mid-way between two antifriction bearings. The bending
moment at the pulley varies from 150N-m CW to 450N-m CCW as the torsional
moment in the shaft varies from 50 to 150MPa. The shaft is made of cold drawn
steel having an ultimate strength of 560MPa and yield strength of 400MPa. The
frequency of the variation of the required diameters of the shaft for an indefinite
life. The stress concentration factors for the keyway in the bending and torsion
may be taken as 1.7 and 1.4 respectively. Use design factor of 1.8.Design the shaft.
[16]

3. Design a hydrodynamic full journal bearing of 200 mm x 200 mm to support 20

kN. Calculate the operating parameters and check for necessity for cooling. Speed
of journal is 1500 rpm. [12+4]

4. Design a clamp coupling to transmit 30kW at 100rpm. The allowable shear stress
for the shaft and key is 40N/mm2 and number of bolt connecting the two halves
are six. The permissible tensile stress for the bolts is 70N/mm2 .The coefficient of
friction between the muff and shafts surface may be taken as 0.3. [16]

5. A steel connecting rod having σu =1000 M N/m2 , σy =900 MN/m2 , is subjected to

a completely reversed axial load of 50 kN. Assuming CL = 0.85, CD = 0.9, Cs = 0.82
and N= 2, determine the size of the rod. Take Kt =1.5, q=0.6 and neglect any
column action. [16]

6. The following projected data refer to a four cylinder petrol engine of a car:
Diameter of the piston = 68 mm
Stroke length = 75 mm
Maximum pressure = 2.5 MN/m2
Connecting rod length = 175 mm
Brake power = 32 kW at 5000 rpm
bsfc = 0.33 kg/kWh
Design a suitable piston. [16]

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Code No: RR321401 Set No. 2
7. A machine is driven at 1440 rpm by means of a flat belt. The pulleys on the motor
and machine shafts are of 200 mm and 800 mm diameter, respectively. Design the
belt for transmitting 25 kW power. [16]

8. A pair of spur gear is to be designed to transmit 15 kW. Pinion has 24 teeth runs
at 250 rpm. Velocity ratio is 2.8:1. Assume pinion is made by alloy steel has design
compressive stress 950 N/mm2 , design bending stress 320 N/mm2 and hardness
number 280. Assume wheel is made by C 45 steel has design compressive stress
500 N/mm2 , design bending stress 140 N/mm2 and hardness number 175. [16]

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Code No: RR321401 Set No. 3
III B.Tech II Semester Supplimentary Examinations, Aug/Sep 2007
PRINCIPLES OF MACHINE DESIGN
(Mechatronics)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Explain the chemical, physical, mechanical, dimensional and technological

properties of engineering materials.
(b) What are the various design considerations, explain? [8+8]

2. Figure2 shows a shaft for a hand-operated machine. The frictional torque in the
journal bearings at A and B is 15 N-m each. Find the diameter (d) of the shaft
(on which the pulley is mounted using maximum distortion energy criterion. The
shaft material is 40 C8 steel for which the yield stress in tension is 380 MPa and
the factor of safety is 1.5. [16]

Figure 2
3. (a) What are the rolling contact bearings? Discuss their advantages over sliding
contact bearings.
(b) Write short note on different types of antifriction bearings. [8+8]

4. Design a muff coupling to connect two shafts transmitting 40 kW at 120 rpm. The
permissible shear and crushing stress for the shaft and key material (mild steel) are
30 MPa and 80 MPa respectively. The material of muff is cast iron with permissible
shear stress of 15 MPa. Assume that the maximum torque transmitted is 25 percent
greater than the mean torque. [16]

5. A carbon steel rod of circular cross-section having σu =600MN/m2 , σy =450 MN/m2 ,

′
σe = 300 MN/m2 is subjected to a bending moment which varies between 300 to 500
Nm and axial load which varies between 5 to 10 kN. Assuming that the bending
moment and axial load are in phase determine the diameter of the rod to have a
factor of safety of 2. [16]

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Code No: RR321401 Set No. 3
6. Design and draw a trunk type of piston for a single cylinder four-stroke diesel engine
running at 1000 rpm. Other data available are:
Maximum explosion pressure = 3.5 MN/m2
Mean effective pressure = 0.65 MN/m2
Diameter of piston = 150 mm
Stroke length = 200 mm
Connecting rod length = 450 mm
bsfc = 0.27 kg/kWh [12+4=16]

7. A 50 kW, 1200 rpm, high torque squirrel-cage motor is used to drive a punch press.
The speed of the punch press flywheel is 300 rpm. If the center distance is 2.5 m,
select a suitable leather belt. [16]

8. Calculate the power that can be transmitted safely by a pair of spur gears with the
data given below. Calculate also the bending stresses induced in the two wheels
when the pair transmits this power. [8+7+4=16]
No. of teeth in the pinion = 20
No. of teeth in the gear = 80
Module = 4 mm
Width of teeth =60 mm
Tooth profile = 200 in volute
Allowable bending strength of the material
= 200 MPa, for pinion
=160 MPa, for gear
Speed of the pinion = 400 rpm
Service factor = 0.8
Lewis from factor = 0.154 − 0.912
T

3
Velocity factor = 3+v

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Code No: RR321401 Set No. 4
III B.Tech II Semester Supplimentary Examinations, Aug/Sep 2007
PRINCIPLES OF MACHINE DESIGN
(Mechatronics)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. Explain the following theories failure:

(a) Rankine’s Theory,

(b) Tresca’s Theory,
(c) Vonmises and Hencky’s Theory,
(d) St.venant’s Theory. [4x2=16]

2. Design a cotter joint to connect piston rod to the crosshead of a double acting
steam engine. The diameter of the cylinder is 300 mm and the steam pressure is
1N/mm2 . The allowable stresses for the material of cotter and piston rod are as
fallows σt = 50N/mm2 ,σc = 84N/mm2 ,τ = 40N/mm2
use standard proportions of the joint. [16]

3. (a) Discuss in detail about materials and their applications. [8]

(b) A 75 mm long full journal bearing of diameter 75mm supports a load of 12KN
on a journal turning at 1800 rpm. Assuming D/C ratio as 1000, and an oil
having viscosity 0.01 Kg/ms at the operating temperature. Determine the
coefficient of friction, minimum film thickness and oil flow using Raimondi-
Boyd curves. The data from Raimondi-Boyd curves is given in the following
table: [3+3+2]
Sommer field Coeffcient of Minimum film Flow
Number Friction variable Thickness variable variable
0.100 2.8 0.36 4.4
0.140 3.7 0.42 4.3
0.150 3.8 0.45 4.2

4. (a) Give the complete design procedure of flexible coupling with a neat sketch.
(b) What are the advantages of flexible coupling ? [8+8]

5. A pulley is keyed to a shaft midway between two bearings. The 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 as the torque on the shaft varies from - 50 N-m to + 150 N-m. Obtain the
diameter of the shaft for an indefinite life. The stress concentration factors for the
keyway at the pulley in bending and in torsion are 1.6 and 1.3 respectively. Take
the following values.
Factor of safety = 1.5

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Code No: RR321401 Set No. 4
Load correction factors = 1.0 in bending, and 0.6 in torsion
Size effect factor = 0.85
Surface effect factor = 0.88 [16]

6. Determine the dimensions of an I-Section connecting rod for a petrol engine from
the following data:
Diameter of the piston = 110 mm;
Mass of the reciprocating parts = 2 kg;
Length of the connecting rod from center to center = 325 mm;
Stroke length = 150 mm;
R.P.M = 1500 with possible over speed of 2500;
Compression ratio = 4:1;
Maximum explosion pressure = 2.5 N/mm2 . [16]

7. The drive from a motor to a machine consists of three V-belt of size B. The motor
pulleys has a pitch diameter 200 mm and the machine pulley diameter is 500 mm.
If the center distance is 1.3 m, give the full specification details of the belt. [16]

8. A pair of 200 full depth spur gears are required to transmit 22.5 kW. The speed of
the pinion is 3000 rpm and the gear ratio of the drive is 10. The pinion is made of
steel with a Brinell number of 250 and the gear is made of ordinary cast iron. The
number of teeth of the pinion should be between 15 and 24. The diameter of the
pinion should be approximately 75 mm. Design the spur gear drive. [16]

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