A A70XX Pages: 3

Reg. No. : Name:

APJ ABDUL KALAM TECHNOLOGICAL UNIVERSITY

SEVENTH SEMESTER B.TECH DEGREE EXAMINATION, DECEMBER 2018
Course Code: ME 401
Course Name: DESIGN OF MACHINE ELEMENTS – I (ME, MP)
Instructions: i) Assume missing data if any. ii) Use of standard data hand book is permitted
Max. Marks: 100 Duration: 3 Hours
PART – A
Answer any two full questions, each carries 15marks Marks
1 a) Write short notes on preferred numbers, codes and standards used in design. (4)
b) Explain the ductile behaviour of materials with the help of stress – strain diagram. (5)
c) A non – rotating shaft supporting a load of 2.5kN is shown in figure below. The shaft (6)
is made of brittle material, with an ultimate tensile strength of 300N/mm 2. The factor
of safety is 3. Determine the dimensions of the shaft.

(All dimensions are in mm)

2 a) Explain the use of stress concentration factor in the conservative design procedure. (2)

b) State any one theory of failure applicable to the brittle materials. (3)
c) A bolt is subjected to a direct tensile load of 25kN and a shear load of 15kN. Find the (10)
suitable size of the bolt using various theories of failure. Take yield strength in tension
as 25N/mm2, Poisson’s ratio as 0.3 and factor of safety as 2.
3 a) What is endurance limit? Explain the various factors affecting endurance limit of a (3)
material.
b) Define notch sensitivity index. (2)
c) A shaft of circular cross-section is subjected to a turning moment that fluctuates (10)
between 800kN-m and 600kN-m, and also a bending moment that fluctuates between
+500kN-m and -300kN-m. The material selected for the shaft has a shear value of
100MPa at endurance limit and shear value of 120MPa at the yield point. Determine
the diameter of the shaft taking a value of 2.5 for the factor of safety. Surface factor,
size factor and load factor can be taken as 0.9, 0.85 and 1 respectively. Shear stress
concentration factor is 1.8 and the notch sensitivity is 0.95.
PART – B
Answer any two full questions, each carries 15marks
4 a) What you mean by pre-loading of bolts? (3)
b) Design a lead screw for a lathe machine. The maximum axial force on the screw is (12)
2000N. The thrust collar outer diameter is 60mm and inner diameter is 30mm. The
stroke length required is 1500mm. Take bearing pressure for steel lead screw and
bronze nut as 1.5N/mm2. Allowable stresses in tension and shear for the screw are
Page 1 of 3

P.T.O.
 A Pages: 2

respectively 100N/mm2 and 50N/mm2. The allowable shear stress for the nut is
40N/mm2. The friction between screw and nut is 0.14 and collar friction is 0.08. Check
for the buckling and induced stresses.
5 a) What you mean by Caulking and fullering? (3)
b) Design a double riveted butt joint with two cover plates for the longitudinal seam of a (12)
boiler shell 1.5m in diameter subjected to a steam pressure of 0.95N/mm2. Assume
joint efficiency as 75%, allowable tensile stress in the plate 90MPa, compressive stress
140MPa and shear stress in the rivet 56MPa.
6 a) Design a socket and spigot type cotter joint to sustain an axial load of 100kN. The (5)
material selected for the joint has the following stresses: 100MPa in tension, 60MPa in
shear and 150MPa in crushing.
b) A rectangular steel plate is welded as a cantilever to a vertical column and supports a (10)
single concentrated load P, as shown in figure. Determine the weld size if the shear
stress in the same is not to exceed 140MPa.

(All dimensions are in mm)

PART – C
Answer any two full questions, each carries 20marks
7 a) Design a helical tension spring is used in the spring balance to measure the weights. (12)
One end of the spring is attached to the rigid support while the other end, which is free,
carries the weights to be measured. The maximum weight attached to the spring
balance is 1500N and the length of the scale should be approximately 100mm. The
spring index is taken as 6. The spring is made of oil-hardened and tempered steel wire
with ultimate tensile strength of 1360N/mm2 and modulus of rigidity of 81370N/mm2.
The permissible shear stress in the spring wire should be taken as 50% of the ultimate
tensile strength. Design the spring.
b) A semi-elliptical leaf spring consists of two extra full length leaves and eight graduated (8)
length leaves including the master leaf. The centre to centre distance between the two
eyes of the spring is 1m. The maximum force on the spring is 10kN and width of each
leaf is 50mm. The spring is initially pre-loaded in such a way that when the load is
maximum, the stress induced in all the leaves are equal to 350 N/mm2. The modulus of
elasticity of leaf material is 207GPa. Determine, the thickness of leaves and deflection.
8 a) How the shaft is designed when it is subjected to axial load and a combined torsion (5)
and bending load?
b) A shaft is supported on bearings A and B, 800mm between the centres. A 200 straight (15)
tooth spur gear having 600mm pitch diameter is located 200mm to the right of the left
hand bearing A and a 700mm diameter pulley is mounted 250mm towards the left of
the bearing B. The gear is driven by a pinion with a downward tangential force while
the pulley drives a horizontal pulley having 1800 angle of wrap. The pulley also serves

Page 2 of 3
 A Pages: 2

as a flywheel and weighs 2000N. The maximum belt tension is 3000N and the tension
ratio is 3:1. Determine the maximum bending moment and necessary shaft diameter if
the allowable shear stress of the material is 40MPa.
9 a) Distinguish between rigid and flexible couplings. (4)
b) Design a protective type of flange coupling of a steel shaft transmitting 25kW at (16)
300rpm. Assume the following stresses: shear stress for shaft, key and bolt are
40N/mm2, crushing stress for key and bolt are 85N/mm2, shear stress for cast iron =
14N/mm2. Draw a neat sketch of the coupling showing important dimensions.
*****

Page 3 of 3