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MACHINE DESIGN
Q. 1 A metric threads of pitch 2 mm and thread angle 60c is inspected for its pitch
diameter using 3-wire method. The diameter of the best size wire in mm is
(A) 0.866 (B) 1.000
(C) 1.154 (D) 2.000
Q. 2 Two threaded bolts A and B of same material and length are subjected to
identical tensile load. If the elastic strain stored in bolt A times of bolt B and the
mean diameter of bolt A is 12 mm, the mean diameter of bolt B in mm is
(A) 16 (B) 24
(C) 36 (D) 48
Q. 4 If the rivets are to be designed to avoid crushing failure, the maximum permissible
load P in kN is
(A) 7.50 (B) 15.00
(C) 22.50 (D) 30.00
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Q. 9 A band brake having band-width of 80 mm, drum diameter of 250 mm, coefficient
of friction of 0.25 and angle of wrap of 270 degrees is required to exert a friction
torque of 1000 Nm. The maximum tension (in kN) developed in the band is
(A) 1.88 (B) 3.56
(C) 6.12 (D) 11.56
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Q. 10 A bracket (shown in figure) is rigidly mounted on wall using four rivets. Each
rivet is 6 mm in diameter and has an effective length of 12 mm.
Direct shear stress (in MPa) in the most heavily loaded rivet is
(A) 4.4 (B) 8.8
(C) 17.6 (D) 35.2
Q. 11 A lightly loaded full journal bearing has journal diameter of 50 mm, bush bore of
50.05 mm and bush length of 20 mm. If rotational speed of journal is 1200 rpm
and average viscosity of liquid lubricant is 0.03 Pa s, the power loss (in W) will be
(A) 37 (B) 74
(C) 118 (D) 237
Q. 14 Given that the tooth geometry factor is 0.32 and the combined effect of dynamic
load and allied factors intensifying the stress is 1.5; the minimum allowable stress
(in MPa) for the gear material is
(A) 242.0 (B) 166.5
(C) 121.0 (D) 74.0
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Q. 16 A clutch has outer and inner diameters 100 mm and 40 mm respectively. Assuming
a uniform pressure of 2 MPa and coefficient of friction of liner material is 0.4, the
torque carrying capacity of the clutch is
(A) 148 N-m (B) 196 N-m
(C) 372 N-m (D) 490 N-m
Q. 17 A spur gear has a module of 3 mm, number of teeth 16, a face width of 36 mm
and a pressure angle of 20c. It is transmitting a power of 3 kW at 20 rev/s.
Taking a velocity factor of 1.5 and a form factor of 0.3, the stress in the gear
tooth is about.
(A) 32 MPa (B) 46 MPa
(C) 58 MPa (D) 70 MPa
Q. 18 One tooth of a gear having 4 module and 32 teeth is shown in the figure. Assume
that the gear tooth and the corresponding tooth space make equal intercepts on
the pitch circumference. The dimensions a and b, respectively, are closest to
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(A) P-2, Q-4, R-1, S-6 (B) P-1, Q-4, R-5, S-6
(C) P-2, Q-6, R-4, S-2 (D) P-6, Q-3, R-1, S-5
Q. 22 A ball bearing operating at a load F has 8000 hours of life. The life of the bearing,
in hours, when the load is doubled to 2F is
(A) 8000 (B) 6000
(C) 4000 (D) 1000
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Q. 25 A bolted joint is shown below. The maximum shear stress, in MPa in the bolts
at A and B , respectively are
Q. 26 A block-brake shown below has a face width of 300 mm and a mean co-efficient
of friction of 0.25. For an activating force of 400 N, the braking torque in Nm is
(A) 30
(B) 40
(C) 45
(D) 60
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Q. 31 A disc clutch is required to transmit 5 kW at 2000 rpm. The disk has a friction
lining with coefficient of friction equal to 0.25. Bore radius of friction lining is
equal to 25 mm. Assume uniform contact pressure of 1 MPa. The value of outside
radius of the friction lining is
(A) 39.4 mm
(B) 49.5 mm
(C) 97.9 mm
(D) 142.9 mm
Q. 32 Twenty degree full depth involute profiled 19 tooth pinion and 37 tooth gear are
in mesh. If the module is 5 mm, the centre distance between the gear pair will be
(A) 140 mm (B) 150 mm
(C) 280 mm (D) 300 mm
Q. 34 A 60 mm long and 6 mm thick fillet weld carries a steady load of 15 kN along the
weld. The shear strength of the weld material is equal to 200 MPa. The factor of
safety is
(A) 2.4 (B) 3.4
(C) 4.8 (D) 6.8
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Q. 36 The maximum tension that can be generated in the band during braking is
(A) 1200 N (B) 2110 N
(C) 3224 N (D) 4420 N
Q. 38 Two mating spur gears have 40 and 120 teeth respectively. The pinion rotates at
1200 rpm and transmits a torque of 20 Nm. The torque transmitted by the gear is
(A) 6.6 Nm (B) 20 Nm
(C) 40 Nm (D) 60 Nm
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Q. 41 In a bolted joint two members are connected with an axial tightening force of
2200 N. If the bolt used has metric threads of 4 mm pitch, the torque required for
achieving the tightening force is
Q. 44 Square key of side d/4 each and length l is used to transmit torque T from
the shaft of diameter d to the hub of a pulley. Assuming the length of the key
to be equal to the thickness of pulley, the average shear stress developed in the
key is given by
(A) 4T (B) 16T
ld ld 2
(C) 8T2 (D) 16T3
ld pd
Q. 45 In a band brake the ratio of tight side band tension to the tension on the slack
side is 3. If the angle of overlap of band on the drum is 180c, the coefficient of
friction required between drum and the band is
(A) 0.20 (B) 0.25
(C) 0.30 (D) 0.35
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Q. 49 The coupling used to connect two shafts with large angular misalignment is
(A) a flange coupling (B) an Oldhams coupling
(C) a flexible bush coupling (D) a Hookes joint
Q. 51 Large speed reductions (greater than 20) in one stage of a gear train are possible
through
(A) spur gearing (B) worm gearing
(C) bevel gearing (D) helical gearing
Q. 52 If the wire diameter of a closed coil helical spring subjected to compressive load
is increased from 1 cm to 2 cm, other parameters remaining same, the deflection
will decrease by a factor of
(A) 16 (B) 8
(C) 4 (D) 2
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Q. 53 Bars AB and BC , each of negligible mass, support load P as shown in the figure.
In this arrangement,
Q. 54 Two helical tensile springs of the same material and also having identical mean
coil diameter and weight, have wire diameters d and d/2. The ratio of their
stiffness is
(A) 1 (B) 4
(C) 64 (D) 128
*********
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SOLUTION
2AA EA 2A B E B
Since bolts of same material and length and subjected to identical tensile load,
i.e.
EA = EB , LA = LB , FA = FB
So that 1 = 4
AA AB
1 = 42 A = p d2
d A2 dB 4
or d B2 = 4d A2
or dB = 2dA = 2 # 12 = 24 mm
Sol. 54 Option (C) is correct.
If the rivets are to be designed to avoid crushing failure, maximum permissible
load
P = sp # A
where for crushing failure A = ^w - 3dhole h # t
So that P = ^w - 3dhole h # t # sp
= ^200 - 3 # 11h # 5 # 200
= 167000 N = 167 kN
Sol. 54 Option (C) is correct.
For Design against tearing failure, maximum permissible load
P = n.drivet # t # sc
= 3 # 10 # 5 # 150
= 22500 N = 22.5 kN
Sol. 54 Option (C) is correct.
Given : Width of fillets s = 10 mm , l = 30 mm , t = 94 MPa
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The shear strength of the joint for single parallel fillet weld is,
P = Throat Area # Allowable stress
= t#l#t
From figure t = s sin 45c = 0.707 s
P = 0.707 # s # l # t
= 0.707 # (0.01) # (0.03) # (94 # 106)
= 19937 N or 19.93 kN
Sol. 54 Option (B) is correct.
Given : T1 = 400 N, m = 0.25, q = 180c = 180c # p = p rad.
180c
D = 0.5 m, r = D = 0.25 m
2
For the band brake, the limiting ratio of the tension is given by the relation,
T1 = emq
T2
400 = e0.25 # p = 2.19
T2
T2 = 400 = 182.68 N
2.19
For Band-drum brake, Braking Torque is
TB = (T1 - T2) # r
= (400 - 182.68) # 0.25 = 54.33 Nm , 54.4 Nm
Sol. 54 Option (B) is correct.
F.O.S = Allowable shear stress
Design shear stress
Design shear stress for solid circular shaft
3
t = 16T3 = 16 # 50 3# 10 From T = t
pd pd J r
3
Therefore F.O.S = 140 # pd
16 # 50 # 103
3
or, 2 = 140 # pd 3
16 # 50 # 10
3
d 3 = 2 # 16 # 50 # 10
140 # p
d = 15.38 mm , 16 mm
Sol. 54 Option (B) is correct.
Given : WP = 30 kN , WQ = 45 kN
L = b C l # 106 revolutions
k
Life of bearing,
W
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W
These are the identical bearings. So for the Life of P and Q.
LP WQ 3 45 3 3 3 27
c LQ m = cWP m = b 30 l = b 2 l = 8
Sol. 54 Option (D) is correct.
Given : b = 80 mm , d = 250 mm , m = 0.25 , q = 270c, TB = 1000 N-m
Let, T1 " Tension in the tight side of the band (Maximum Tension)
T2 " Tension in the slack side of the band (Minimum Tension)
Braking torque on the drum,
TB = (T1 - T2) r
T1 - T2 = TB = 1000 = 8000 N ...(i)
r 0.125
We know that limiting ratio of the tension is given by,
T1 = emq = ea0.25 # 180
p
# 270k
= 3.246
T2
T2 = T1
3.246
Substitute T2 in equation (i), we get
T1 - T1 = 8000 & 3.246T1 - T1 = 25968
3.246
2.246T1 = 25968 & T1 = 25968 = 11.56 kN
2.246
Sol. 54 Option (B) is correct.
Given : d = 6 mm , l = 12 mm , P = 1000 N
Each rivets have same diameter, So equal Load is carried by each rivet.
Primary or direct force on each rivet,
F = P = 1000 = 250 N
4 4
Shear area of each rivet is,
A = p ^6 # 10-3h2 = 28.26 # 10-6 mm2
4
Direct shear stress on each rivet,
t =F = 250 = 8.84 # 106 - 8.8 MPa
A 28.26 # 10-6
Sol. 54 Option (A) is correct.
Given : d = 50 mm , D = 50.05 mm , l = 20 mm , N = 1200 rpm , m = 0.03 Pa s
Tangential velocity of shaft,
-3
u = pdN = 3.14 # 50 # 10 # 1200 = 3.14 m/ sec
60 60
And Radial clearance, y = D - d = 50.05 - 50 = 0.025 mm
2 2
Shear stress from the Newtons law of viscosity,
t = m # u = 0.03 # 3.14 = 3768 N/m2
y 0.025 # 10-3
Shear force on the shaft,
F = t # A = 3768 # (p # d # l)
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= 995
36 # 10-3 # 0.3 # 3 # 10-3
sb = 995 = 30.70 # 106 Pa = 30.70 MPa
3.24 # 10-5
Permissible working stress
sW = sb # Cv = 30.70 # 1.5 = 46.06 MPa , 46 MPa
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W
L = b C l # 106 revolution
3
For ball bearing, k = 3 ,
W
For initial condition life is,
L1 = bC l # 106
3
F
8000 hr = bC l # 106
3
...(i)
F
L2 = b C l # 106 = 1 # bC l # 106
3 3
For final load,
2F 8 F
= 1 (8000 hr) = 1000 hr From equation (i)
8
Sol. 54 Option (B) is correct.
Given : d = 200 mm , t = 1 mm , su = 800 MPa , se = 400 MPa
Circumferential stress induced in spherical pressure vessel is,
p r p 100
s = # = # = 50p MPa
2t 2#1
Given that, pressure vessel is subject to an internal pressure varying from 4 to
8 MPa.
So, smin = 50 # 4 = 200 MPa
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p c = 2 # radial clearance
-3
S.N. = 20 # 10 #6 20 # b 50 2
-3 l
0.8 # 10 100 # 10
-3
= 20 # 10 #6 20 # b 1 l # 106 = 0.125
2
0.8 # 10 2
Sol. 54 Option (A) is correct.
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We know that in S-N curve the failure occurs at 106 cycles (at endurance strength)
We have to make the S-N curve from the given data, on the scale of log 10 .
Now equation of line whose end point co-ordinates are
^log 10 1000, log 10 490h and ^log 10 10 , log 10 70h
6
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p c
It is a dimensionless parameter used extensively in the design of journal bearing.
i.e. sommerfeld number is also function of b ZN , d l. Therefore option (A) is
p c
correct.
Sol. 54 Option (B) is correct.
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to 2110 N
Sol. 54 Option (B) is correct.
Maximum wheel torque or braking torque is given by,
TW = (T1 - T2) r = (2110 - 200) # 0.2 = 382 N-m
Sol. 54 Option (D) is correct.
Velocity Ratio, ZP = NG
ZG NP
Z
NG = P # NP = 40 # 1200 = 400 rpm
ZG 120
Power transmitted is same for both pinion & Gear.
P = 2pNP TP = 2pNG TG
60 60
NP TP = NG TG
TG = NP TP = 1200 # 20 = 60 N-m
NG 400
So, the torque transmitted by the Gear is 60 N-m
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We can easily see from the S-N curve that, steel becomes asymptotic nearly at
106 cycles .
Sol. 54 Option (C) is correct.
Given : Ft = 2200 N , p = 4 mm = 0.004 m
Torque required for achieving the tightening force is,
T = Ft # r = Ft # Pitch = 2200 # 0.004 = 1.4 N-m
2p 2 # 3.14
Sol. 54 Option (B) is correct.
Type of Gears Arrangement of shafts
P. Bevel gears 2. Non-parallel intersecting shafts
Q. Worm gears 3. Non-parallel, non-intersecting shafts
R. Herringbone gears 4. Parallel shafts
S. Hypoid gears 1. Non-parallel off-set shafts
So, correct pairs are P-2, Q-3, R-4, S-1.
Sol. 54 Option (C) is correct.
The wire ropes are designated by the number of strands multiplied by the number
of wires in each strand. Therefore,
6 # 19 = Number of strands # Number of wires in each strand.
Sol. 54 Option (C) is correct.
Given : Diameter of shaft = d
Torque transmitted = T
Length of the key = l
We know that, width and thickness of a square key are equal.
i.e. w =t=d
4
Force acting on circumference of shaft
F = T = 2T (r = d/2)
r d
Shearing Area, A = width # length = d # l = dl
4 4
Force 2T/d
Average shear stress, t = = = 8T2
shearing Area dl/4 ld
Sol. 54 Option (D) is correct.
Let, T1 " Tension in the tight side of the band,
T2 " Tension in the slack side of the band
q "Angle of lap of the band on the drum
Given : T1
= 3 , q = 180c = p # 180 = p radian
T2 180
For band brake, the limiting ratio of the tension is given by the relation,
T1 = emq or 2.3 log T1 = mq
T2 bT2 l
2.3 # log (3) = m # p
2.3 # 0.4771 = m # 3.14
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Let N1 , N2 , N 3 and N 4 are the speeds of pinion 1, gear 2, pinion 3 and gear 4
respectively.
Given : Z1 = 16 teeth , Z 3 = 15 teeth and Z 4 = ? , Z2 = ?
Velocity ratio N1 = Z2 /Z1 N \ 1/Z
N4 Z 3 /Z 4
= Z2 # Z 4 = 12 ...(i)
Z1 Z3
But for stage 1, N1 = Z 2 = 4 ...(ii)
N2 Z1
So, 4 # Z 4 = 12 from eq. (i)
Z3
Z4 = 3, & Z 4 = 3 # 15 = 45 teeth
Z3
From equation (ii), Z2 = 4 # Z1 = 4 # 16 = 64 teeth
Sol. 54 Option (B) is correct.
Let centre distance in the second stage is D .
D = R4 + R3 = D4 + D3
2
But, D4 = D3 = 4 m = D/Z module
Z4 Z3
D 4 = 4 # Z 4 = 4 # 45 = 180
Or, D 3 = 4 # Z 3 = 4 # 15 = 60
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When shaft is subjected to repeated stress, then it will be designed for fatigue
loading.
Sol. 54 Option (B) is correct.
For a worm gear the velocity ratio ranges between 10 : 1 to 100 : 1. So, Large
speed reductions (greater than 20) in one stage of a gear train are possible through
worm gearing.
Sol. 54 Option (A) is correct.
For Helical spring, deflection is given by,
3 3
d = 64PR4 n = 8PD4 n
Gd Gd
where, P = Compressive load
d = Wire diameter
R = Coil diameter
G = Modulus of rigidity
From the given conditions d \ 14
d
Given d1 = 1 cm and d2 = 2 cm
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d2 = d1 4
d1 b d2 l
d2 = 1 4 = 1
d1 b 2 l 16
d2 = d1
16
So, deflection will decrease by a factor of 16.
Sol. 54 Option (C) is correct.
Bars AB and BC have negligible mass. The support load P acting at the free
end of bars AB and BC . Due to this load P , In bar AB compressive stress and
in bar BC tensile stress are induced.
However, none of these bars will be subjected to bending because there is no
couple acting on the bars.
Sol. 54 Option (C) is correct.
Let L1 & L2 are lengths of the springs and n1 & n2 are the number of coils in both
the springs.
Given : W1 = W2
m1 g = m 2 g
rn1 g = rn2 g m = rn
A 1 # L 1 # rg = A 2 # L 2 # rg
p d 2 p D n = p d 2 pD n L = pDn
4 1# 1 1
4 2# 2 2
d 12 # n1 = d 22 # n2 D1 = D 2
Given : d1 = d & d 2 = d
2
2
d 2 # n1 = d # n 2
4
or, n1 = n 2
4
The deflection of helical spring is given by,
3
d = 8PD4 n
Gd
4
Spring stiffness, k = P = Gd3
d 8D n
From the given conditions, we get
4
k\d
n
k 1 = d1 4 n2
k 2 b d 2 l # a n1 k
So,
k1 = d 4 n2
k2 c d/2 m # n2 /4
k1 = 16 4 = 64
k2 #
***********
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