DME-I

Mock Test Question Bank

Unit 1
Design of Simple Machine Elements

1. Explain the following

I) Factors considered for selection of Factor of safety
II) Standards & Codes
2. The frame of a hydraulic press consisting of two identical steel plates is shown in
fig. The maximum force P acting on the frame is 20KN. The plates are made of steel
45C8 with tensile yield strength of 380N/mm2. The factor of safety is 2.5. Determine
the plate thickness.

3. A bell crank lever is to be designed to raise a load of 7.5KN at the short arm end.
The arm lengths are 150mm and 500mm. The lever and pins are made up of steel
FeE300 (Syt=300N/mm2) and factor of safety is 6. The permissible bearing pressure at
the pin in lever is 10N/mm2. The lever has rectangular c/s, & ratio of width to
thickness is 4:1. The l/d is 1.5:1.
Calculate 1. Diameter and length of fulcrum pin 2.Shear stresses in the pin

4. Derive an expression for bending stress in the cotter of a cotter joint?

5. Explain briefly the various phases involved in the process of design of machine
elements.
6. A bell crank lever is to be designed to raise a load of 5KN at the short arm end. The
arm lengths are 150mm and 500mm. The permissible stresses for lever and pin
materials in shear and tension are 60N/mm2 and 90N/mm2 respectively. The bearing
pressure on the pin is to be limited to 12N/mm2. Assume lever cross section as b=4t
and the fulcrum pin length as 1.25 times pin diameter.
7. Two rods made of plain carbon steel 40C8 (Syt=380N/mm2), are to be connected by
means of cotter joint. The diameter of each rod is 50mm & cotter is made from a steel
plate of 15mm thickness. Calculate the dimensions of the socket & making the
following assumptions.
i) Yield strength in compression is twice of tensile yield strength
ii) Yield strength in shear is 50% of tensile yield strength
Factor of safety is 6

Unit 2
Design of Shafts, Keys and Couplings
1. Classify Keys. Prove that Square key is equally strong in Shearing and
crushing.
2. Two 40 mm shaft are connected by protected type flange coupling. The no.
of bolts used are 6 on 125 mm bolt PCD. The shaft transmits 30 kW at 350 rpm.
for following safe stresses

• Shear stress for shaft — 63 N/mm2

• Shear stress for bolt material — 56 N/mm2

• Shear stress for flange material — 10 N/mm2

• Shear stress of Key material - 46 N/mm2

• Crushing stress for key material - 23 N/mm2

Calculate

1) Key Dimensions

2) Flange Dimensions
3) Diameter of Bolt
3. Figure shows shaft layout, supporting two spur gears B and C as shown in
figure. The shaft is supporting by two bearings A and D. The pitch circle diameter
of gear A and B are 900 mm and 600 mm respectively. The material for shaft is
steel with Sut - 770 N/mm2 and Syt — 580 N/mm2. The factors Kb and Kt of
ASME code are 1.5 and 2.0 respectively, Determine the diameter of shaft
according to ASME code. Consider the effect of Key way. Total length of shaft is
2700mm as shown in. figure.

4. A transmission shaft supporting a spur gear B and pulley D is shown in

figure. The shaft is mounted on two bearings A and C. The diameter of pulley and
pitch circle diameter of gear are 450 and 300mm. Pulley transmit 20KW power at
500 rpm to gears. P1 and P2 are belt tensions in tight and loose sides while P t and
Pr are the tangential and radial components of gear tooth force. Assume P 1=3P2
and Pr = Pt tan(20°). Gears and pulley are keyed to the shaft. Material of shaft is
50C4 (Sut=700 and Syt= 460 N/mm2). The factors Kb and Kt of ASME code are 1.5
each. Determine shaft diameter using ASME Code.
5. A solid circular shaft of diameter ‘d’ is subjected to a torsional
moment of over a length of ‘L’. The permissible angle of twist is ‘Ѳ’ prove

that the shaft diameter is given by

6. Design a cast iron flange coupling for a mild steel shaft transmitting 90KW
at 250 rpm. Allowable shear stress for shaft material is 40MPa. The allowable
shear stress and crushing stress for key and bolt material are 45MPa and 85MPa.
The permissible shear stress for Cast Iron is 14MPa. Key is having square cross
section with width = thickness = ( diameter of shaft /4). Number of bolts are 6.
Bolts are fitted in reamed and ground holes and are finger tight.

7. Write short note on ASME Code for Shaft Design.

8. Explain in detail design procedure for rigid coupling.

Unit 3
Design for Fluctuating Load

1. Explain the following

a. Goodman diagram
b. Soderberg diagram
c. Soderberg Line

2. A transmission shaft of cold drawn steel 27Mn2, S ut = 500N/mm2 and Syt =

300N/mm2 is subjected to a fluctuating torque varies from -100 N-m to 400 N-m.
The factor of safety is 2 and reliability is 90%. Neglect the effect of stress
concentration, calculate diameter of shaft, assume distortion energy theory of
failure, if Ka, Kb, Kc are 0.79, 0.85, 0.897
3. Explain any two methods to reduce stress concentration
4. A mechanical component subjected to completely reversed bending stresses
consists following three elements:
350 N/mm2 for 85% of time,
400 N/mm2 for 12% of time,
500 N/mm2 for 3% of time
The material for the component is 50C4 Sut = 660 N/mm2 and corrected endurance
limit of the component is 280N/mm2. Determine the life of the component.
5.

6.

8. Explain low cycle and high cycle fatigue failure

9. Explain fatigue design of components under combined stresses