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ME 6503 — DESIGN OF MACHINE ELEMENTS

Mechanical Engineering
Fifth Semester
UNIT - 2
Part A

1. Define the term critical speed of a shaft. (N/D 16)

The speed at which the shaft runs so that the additional deflection of the shaft from the axis of
rotation becomes infinite is known as critical or whirling speed.

2. What are the types of flexible coupling and rigid couplings? (N/D 16)
1. Rigid couplings:
i) Sleeve couplings
ii) Flange couplings
iii) Clamp couplings
2. Flexible couplings:
i) Universal couplings
ii) Oldham’s couplings
iii) Pushed pin type couplings

3. What is the effect of key ways cut into the shaft? (M/J 16)
i) It reduces the strength of the shaft because of material removal
ii) It increases stress concentration
4. Differentiate between rigid coupling and flexible coupling. (M/J 16)
SI. No. Rigid coupling Flexible coupling

1. Rigid couplings produce the greatest Flexible couplings produce the greatest
reactions on equipment. flexibility while producing the lowest external
loads on equipment.

2. Mechanical element type such as gear, chain, The mechanical element type generally obtain
and grid couplings produce moderate to high their flexibility from loose-fitting parts or rolling
moments and forces on equipment that are a or sliding of mating parts or from both.
function of torque and misalignment.

3. Elastomeric element couplings produce The elastomeric element types obtain their
moderate to low moments and forces that are flexibility from stretching or compressing a
slightly dependent on torque. resilient material (rubber,plastic, etc.

4. Metallic element couplings produce relatively The metallic element types obtain their flexibility
low moments and forces which are relatively from the flexing of thin metallic disc or
independent of torque. diaphragms.

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5. What is meant by design of a shaft based on rigidity? (N/D 15)

The shaft is to be designed by considering torsional rigidity as well as lateral rigidity. Design based
on rigidity is to ensure that maximum deflection (because of bending) and maximum twist (due to
torsion) of the shaft is within the allowable limits. Rigidity consideration is also very important in
some cases for example position of a gear mounted on the shaft will change if the shaft gets
deflected and if this value is more than some allowable limit, it may lead to high dynamic loads and
noise in the gears.

6. What are the possible modes of failure of the pin (bolt) in a flexible coupling? (N/D 15)
Following are the possible modes of failure of the pin (bolt)in a flexible coupling:

i) Bearing failure
ii) Shear failure
iii) Bending failure
iv) Tensile failure due to combined bending and shear stress

7. What is meant by woodruff keys? (M/J 13)

A woodruff key is used to transmit small value of Torque in automotive and machine tool
industries. The keyway in the shaft is milled in a curves shape whereas the key way in the
hub is usually straight.

8. What is coupling? (A/M 09) (N/D 09)

Couplings are used to connect sections of long transmission shafts and to connect the shaft of a
driving machine to the shaft of a driven machine.
9. Differentiate between keys and splines. (N/D 2011)
Keys – A shaft which is having single keyway
Keys are used in couplings.
Splines – A shaft which is having multiple keyways
Splines are used in automobiles and machine tools

10. Why a hollow shaft has greater strength and stiffness than solid shaft of equal weight? (N/D 2012)

Stresses are maximum at the outer surface of a shaft. A hollow shaft has almost all the material
concentrated at the outer circumferences and so has a better strength and stiffness for equal
weight.

11. What are the purposes in machinery for which couplings are used?
1. To provide misalignment of the shafts (or) to introduce mechanical flexibility.
2. To reduce the transmission of shock from one shaft to another.
3. To introduce protection against over load.

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12. Under what circumstances flexible couplings are used? (N/D 07/08/09)
They are used to join the abutting ends of the shafts when they are not in exact alignment.
They are used to permit an axial misalignment of the shafts without under absorption of power,
which the shafts are transmitting.
13. Why is maximum shear stress theory used for shaft? (A/M 09) (N/D 09)
Since the shaft is made of ductile materials, maximum shear stress theory is used.
14. Write bending and torsion equation.

1. (Bending)

2. (Torsion)

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Part B
1. Design and make a neat dimensioned sketch of a muff coupling which is used to connect two steel
shafts transmitting 40 kW at 350 rpm. The material for the shafts and key is plain carbon steel for
which allowable shear and crushing stresses may be taken as 40 MPa and 80 MPa respectively.
The material for the muff is cast iron for which the allowable shear stress may be assumed as 15
MPa. (16) (N/D 16)

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2. A hollow shaft of 0.5 m outside diameter and 0.3 m inside diameter is used to drive a propeller of a
marine vessel. The shaft is mounted on bearings 6 metre apart and it transmits 5600 kW at 150
rpm. The maximum axial propeller thrust is 500 kN and the shaft weighs 70 kN.
Determine
(i) The maximum shear stress developed in the shaft, and
(ii) The angular twist between the bearings. (16) (N/D 16)

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3. A solid steel shaft is supported on two bearings 1.8 m apart and rotates at 250 rpm. A 20º involute
gear D, 300 mm diameter is keyed to the shaft at a distance of 150 mm to the left on the right hand
bearing. Two pulleys B and C are located on the shaft at distances of 600 mm and 1350 mm
respectively to the right of the left hand bearing. The diameters of the pulleys B and C are 750 mm
and 600 mm respectively. 30 kW is supplied to the gear, out of which 18.75 kW is taken off at the
pulley C and 11.25 kW from pulley B. The drive from B is vertically downward while from C the
drive is downward at an angle of 60º to the horizontal. In both cases the belt tension ratio is 2 and
the angle of lap is 180º. The combined fatigue and shock factors for torsion and bending may be
taken as 1.5 and 2 respectively. Design a suitable shaft taking working stress to be 42 MPa in
shear and 84 MPa in tension. (16) (M/J 16)

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4. Design and draw a protective type of cast iron flange coupling for a steel shaft transmitting 15 kW
at 200 rpm and having an allowable shear stress of 40 MPa. The working stress in the bolts should
not exceed 30 MPa. Assume that the same material is used for shaft and key and that the crushing
stress is twice the value of its shear stress. The maximum torque is 25% greater than the full load
torque. The shear stress for cast iron is 14 MPa. (16) (M/J 16)

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5. The shaft of length 1 m carrying two pulleys 1 and 2 at its left and right ends respectively and it is
supported on two bearings A and B which are located 0.25 m from the left end and the same 0.25
m from the righ end respectively. The shaft transmits 7.5 kW power at 360 rpm from pulley 1 to
pulley 2. The diameters of pulley 1 and 2 are 10 kg and 30 kg respectively. The belt tension act
vertically downward and ratio of belt tensions on tight side to slack side for each pulley is 2.5:1.
The yield strength of the shaft material σ y = 380 MPa and factor of safety is 3. Estimate the suitable
diameter of the shaft. (16) (N/D 15)

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6. Design a bushed pin type of flexible coupling for connecting a motor and a pump shaft. The
following data are provided:
Power transmitted = 20 kW; speed = 1000 rpm; Diameter of the motor and pump shafts = 50 mm.
Allowable bearing pressure in the rubber bush = 0.3 MPa. (16) (N/D 15)

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7. Design a shaft to transmit power from an electric motor to a lathe head stock through a pulley by
means of a belt drive. The pulley weights 200 N and is located at 300 mm from the center of the
bearing. The diameter of the pulley is 200 mm and the maximum power transmitted is 1 kW at 120
rpm. The angle of lap of the belt is 180o and coefficient of friction between the belt and the pulley is
0.3. the shock arid fatigue factors for bending and twisting are 1.5 and 2 respectively. The
allowable shear stress in the shaft may be taken as 35 MPa. (N/D 2011)

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8. A steel solid shaft transmitting 15 kW at 200 rpm is supported on two bearings 750 mm apart and
has two gears keyed to it. The pinion having 30 teeth of 5 mm module is located 100 min to the left
of the right hand bearing and delivers power horizontally to the right. The gear having 100 teeth of
5 mm module is located 150 mm to the right of the left hand bearing and receives power in a
vertical direction from below. Using an allowable stress of 54 MPa in shear. Determine the diameter
of the shaft. (M/J 2013)

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9. A shaft is supported by two bearings placed 1 m apart. A 600 mm diameter pulley is mounted at a
distance of 300 mm to the right of left hand bearing and this drives a pulley directly below it with the
help of belt having maxium tension of 2.25 kN. Another pulley 400 mm diameter is placed 200 mm
to the left of right hand bearing and is driven with the help of electric motor and belt, which is
placed horizontally to the right. The angle of contact for both the pulleys is 180º and µ = 0.24.
Determine the suitable diameter for a solid shaft, allowing working stress of 63 MPa in tension and
42 MPa in shear for the material of shaft. Assume that the torque on one pulley is equal to that on
the other pulley.

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10. A shaft is supported on bearings A and B, 800 mm between centres. A 20º straight tooth spur gear
having 600 mm pitch diameter, is located 200 mm to the right of the left hand bearing A, and a 700
mm diameter pulley is mounted 250 mm towards the left of bearing B. The gear is driven by a
pinion with a downward tangential force while the pulley drives a horizontal belt having 180º angle
of wrap. The pulley also serves as a flywheel and weighs 2000 N. The maximum belt tension is
3000 N and the tension ratio is 3:1. Determine the maximum bending moment and the necessary
shaft diameter if the allowable shear stress of the material is 40 MPa.

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11. A rigid type of coupling is used to connect two shafts transmitting 15 kW at 200 rpm. The shaft,
keys and bolts are made of C45 steel and the coupling is of cast iron. Design the coupling.
(M/J 2013)

12. Design a cast iron protective type flange coupling to transmit 15 kW at 900 rpm from an electric
motor to a compressor. The service factor may be assumed as 1.35. The following permissible
stress may be used: Shear stress for the shaft, bolt and key material = 40 MPa, Crushing stress for
bolt and key = 80 MPa, Shear stress for cast iron = 8 MPa. (N/D 2012)

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13. Design a bushed –pin type of flexible coupling to connect a pump shaft to a motor shaft
transmitting 32 KW at 960 rpm the overall torque is 20 percent more than mean torque.
The material properties are as follows:

(i) The allowable shear and crushing stress for shaft and key material is 40
Mpa and 80 Mpa respectively.
(ii) The allowable shear stress for cast iron is 15 Mpa.
(iii) The allowable bearing pressure for rubber bush is 0.8 N/mm2.
(iii) The material of the pin is same as that of shaft and key. Draw neat sketch of the coupling.
(N/D 2012)

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14. Two 35 mm shafts are connected by a flanged coupling. The flanges are fitted with 6 bolts on 25
mm bolt circle. The shafts transmit a torque of 800 N-m at 350 rpm. For the safe stresses mentions
below, calculate (i) diameter of bolts, (ii) thickness of flanges, (iii) key dimensions, (iv) hub length
and (v) power transmitted. Safe stress for shaft material 63 MPa. Safe stress for bolt material 56
MPa. Safe stress for cast iron coupling 10 MPa and Safe stress for key material 46 MPa.
(N/D 2011)

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ME 6503 — DESIGN OF MACHINE ELEMENTS

Mechanical Engineering
Fifth Semester
UNIT - 3
Part A
1. What are the different applications of screwed fasteners? (N/D 16)
There are three basic applications for screwed fasteners:
i. To hold parts together
ii. To provide for adjustment between parts
iii. To transmit power

2. State the two types of eccentric welded connections. (N/D 16)

i. Loading in a plane different from the plane of the bolts
ii. Plane of loading is same as the plane of the bolts

3. What are the stresses act on screw fastenings due to static loading? (M/J 16)
i. Initial stresses due to screwing up
ii. Stresses due to external forces
iii. Combined stresses

4. What are the two types of fillet weld? (M/J 16)

i. Longitudinal or parallel fillet weld
ii. Transverse fillet weld

5. What is the total shear in a double strap butt joint with equal length of straps? (N/D 15)
Total shear in a double strap butt joint with equal length of strap = 2 times of single shear.

6. What is the bending stress induced in the weld when a circular rod of diameter d, welded to a rigid
plate by a circular fillet weld of size t, which is subjected to a bending moment M? (N/D 15)
Bending stress due to bending moment (M) may be calculated by bending stress equation

σb = P×e/ Zw

7. Define term of self-locking of power screws. (A/M 04) (N/D 12) (M/J 13)
If the friction angle ( φ) is greater than helix angle (α) of the power screw, the torque applied
to lower the load will be positive, indicating that an effort is applied to lower the load. This type
of screw is known as self-locking screw.
8. Write any two advantages and disadvantages of welded joints over riveted joints. (M/J 2013)
Material is saved in welded joints and hence the machine element will be light if welded joints are
used instead of riveted joints. Leak proof joints can easily obtained by welded joints compared
riveted joints

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9. What do you understand by the single start and double start threads? (N/D 2011)

A screw made by cutting a single helical groove on the cylinder is known as single threaded (or
single-start) screw and if a second thread is cut in the space between the grooves of the first, a
double threaded (or double-start) screw is formed.

10. Differentiate with a neat sketch the fillet welds subjected to parallel loading and transverse loading.
(A/M 2004)

11. Name the possible modes of failure of riveted joint. (A/M 08) (N/D 12) (M/J 12)
i. Crushing of rivets
ii. Shearing of rivet
iii. Tearing of the plate at the edge
iv. Tearing of the plate between rivets.
12. What is the minimum size for fillet weld? If the required weld size from strength consideration is too
small how will you fulfill the condition of minimum weld size? (A/M 08)
It is defined as the minimum size of the weld for a given thickness of the thinner part joined or plate
to avoid cold cracking by escaping the rapid cooling.
Size of fillet weld h =

= 1.4142t
13. Why are welded joints preferred over riveted joints? (A/M 09/08/03)
Material is saved in welding and hence the machine element will be light if welded joints are used
instead of riveted joints. Leak proof joints can be easily obtained by welded joints compared riveted
joints.
14. How is bolt designated? Give example. (A/M 09) (N/D 07)

M30 × 2.5
Md × P
M – Major diameter of bolt
d – Nonimal diameter in mm
P – Pitch in mm

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7. A 50 mm diameter solid shaft is welded to a flat plate as shown in Fig. If the size of the weld is 15 mm,
find the maximum normal and shear stress in the weld. (16) (N/D 06/07)

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8. A rectangular cross-section bar is welded to a support by means of fillet welds as shown in Fig.
Determine the size of the welds, if the permissible shear stress in the weld is limited to 75 MPa.
(16) (N/D 11)
9. A rectangular steel plate is welded as a cantilever to a vertical column and supports a single
concentrated load P, as shown in Fig. Determine the weld size if shear stress in the same is not to exceed
140 MPa. (16) (N/D 12) (M/J 13)
10. A plate 75 mm wide and 12.5 mm thick is joined with another plate by a single transverse weld and a
double parallel fillet weld as shown in Fig. the maximum tensile and shear stresses are 70 MPa and 56
MPa respectively. Find the length of each parallel fillet weld, if the joint is subjected to both static and
fatigue loading. (16) (A/M 08)
11. Design and draw a cotter joint to support a load varying from 30 kN in compression to 30 kN in tension.
The material used is carbon steel for which the following allowable stresses may be used. The load is
applied statically. Tensile stress = compressive stress = 50 MPa; shear stress = 35 MPa and crushing
stress = 90 MPa. (16) (M/J 13)
12. A 200 × 150 × 10 mm angle is to be welded to a steel plate by fillet welds as shown in Fig. If the angle
is subjected to a static load of 200 kN, find the length of weld at the top and bottom. The allowable shear
stress for static loading may be taken as 75 MPa. (16) (N/D 04)
13. A welded joint as shown in Fig. 10.24, is subjected to an eccentric load of 2 kN. Find the size of weld, if
the maximum shear stress in the weld is 25 MPa. (16) (N/D 11)
14. Determine the size of the bolts and the thickness of the arm for the bracket as shown in Fig. if it carries
a load of 40 kN at an angle of 60° to the vertical. The material of the bracket and the bolts is same for
which the safe stresses can be assumed as 70, 50 and 105 MPa in tension, shear and compression
respectively. (16) (N/D 08)
 ME 6503 — DESIGN OF MACHINE ELEMENTS
Mechanical Engineering
Fifth Semester
UNIT - 4
Part A

1. State any two functions of springs. (N/D 16)

i) To provide cushioning effect or reduce the effect of shock or impact loading.
Example: automobile springs, aircraft landing gears, railway buffers and shock absorbers.
ii)To measure forces in spring balance, meters and engine indicators
iii) To store energy such as in clocks, toys, circuit breakers and starters.
iv)To apply forces and to control the motions as in brakes and clutches.

2. How does the function of flywheel differ from that of governer? (N/D 16)
Governor:
A governor regulates the mean speed of an engine or machine when there are variations in the mean
loads. It automatically controls the speed of the engine with the engine with the varying load conditions
and keeps the mean speed within the limits.
Flywheel:
A flywheel does not control the speed variation caused by the varying load. It acts as an “energy
accumulator”. It will absorb energy when the demand is less than the supply of energy and it will release
it when the demand is more than the energy being supplied.

3. Define spring rate. (M/J 16)

Spring rate is defined as the amount of weight needed to compress a spring for one inch.

4. Define the term ‘fluctuation of speed’ and ‘fluctuation of energy’. (M/J 16)
Fluctuation of speed:
The difference between the maximum and minimum speeds during a cycle is called fluctuation of speed.
Fluctuation of energy:
The difference between maximum and minimum energy during the cycle is called fluctuation of energy.

5. What is the purpose of the flywheel? (N/D 15)

A flywheel used in machine serves as a reservoir which stores energy during the period when the
supply of energy is more than the requirement and releases it dulling the period when the requirement
of energy is more than the supply.

6. What type of spring is used to maintain an effective contact between a cam and a reciprocating roller or
flat faced follower? (N/D 15)
An open coil helical compression spring is used to maintain an effective contact between a cam and a
reciprocating roller or flat faced follower.
 7. Define spring index. (N/D 11)
Spring index (C) is defined as the ratio of the mean diameter of the coil to the diameter of the wire.
C =D/d

8. What are the various types of springs?

i. Helical springs
ii.Spiral springs
iii. Leaf springs
iv. Disc spring or Belleville springs

9. What semi – elliptical leaf springs?

The spring consists of number of leaves, which are held together by U-clips. The long leaf
fastened to the supported is called master leaf. Remaining leaves are called as graduated leaves.

10. Explain
about surge in springs? (M/J 13)
When one end of the spring is resting on a rigid support and the other end is loaded suddenly, all
the coils of spring does not deflect equally, because some time is required for the propagation of
stress along the wire. Thus a wave of compression propagates to the fixed end from where it
is reflected back to the deflected end this wave passes through the spring indefinitely. If the time
interval between the load application and that of the wave to propagate are equal, then
resonance will occur. This will result in very high stresses and cause failure. This phenomenon is
called surge.

11. What are the various applications of springs?

The springs are used in various applications, they are

i. Used to absorb energy or shocks (e.g. shock absorbers, buffers, e.t.c.)
ii. To apply forces as in brakes clutches, spring-loaded valves, e.t.c.
iii. To measure forces as in spring balances and engine indicators
iv. To store energy as in watches

12. Define

Co-efficient of fluctuation of speed in flywheel. (M/J 13)

It is the ratio of the maximum change of speed to mean speed of the flywheel.

13. Define pitch.

Pitch of the spring is defined as the axial distance between the adjacent coils in
uncompressed state. Mathematically, Pitch=free length
14. What are the differences between closed coil & open coil helical springs?
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7. Design a helical spring for as spring loaded spring loaded safety value of the following conditions:
Diameter of valve seat = 65 mm, Operating pressure = 0.7 N/mm 2, Maximum pressure when the valve
blows freely = 0.75 N/mm 2, Maximum lift of the valve when the pressure = 3.5 mm rises from 0.7 to 0.75
N/mm2, Maximum allowable stress = 550 MPa, Modulus of rigidity = 84 kN/mm 2, Spring index = 6, Draw a
neat sketch of the free spring showing the main dimensions. (16) (M/J 12) (N/D 12)

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8. A helical spring is made from a wire of 6 mm diameter and has outside diameter of 75 mm. If the
permissible shear stress is 350 MPa and modulus of rigidity 84 kN/mm 2, find the axial load which the
spring can carry and the deflection per active turn. (16)
9. Design a close coiled helical compression spring for a service load ranging from 2250 N to 2750 N.
The axial deflection of the spring for the load range is 6 mm. Assume a spring index of 5. The
permissible shear stress intensity is 420 MPa and modulus of rigidity, G = 84 kN/mm 2. Neglect the
effect of stress concentration. Draw a fully dimensioned sketch of the spring, showing details of the
finish of the end coils. (16)
10. A helical compression spring made of oil tempered carbon steel, is subjected to a load which varies
from 400 N to 1000 N. The spring index is 6 and the design factor of safety is 1.25. If the yield stress in
shear is 770 MPa and endurance stess in shear is 350 MPa, find: 1. Size of the spring wire, 2.
Diameter of the spring, 3. Number of turns of the spring, and 4. Free length of the spring. The
compression of the spring at the maximum load is 30 mm. The modulus of rigidity for the spring
material may be taken as 80 kN/mm2. (16)
11. An engine runs at a constant load at a speed of 480 rpm. The crank effort diagram is drawn to a scale 1
mm = 200 N-m torque and 1 mm = 3.6 o crank angle. The areas of the diagram above and below the mean
torque line in sq. mm are in the following order: +110, -132, +153, _166, +197,-162. Design the flywheel if
the total fluctuation of speed is not to exceed 10 rpm and the centrifugal stress in the rim is not to exceed 5
MPa. Assume that the rim breadth is approximately 2.5 times the rim thickness and 90% of the moment of
inertial is due to rim. The density of the material of the flywheel is 7250 kg/m 3. Make a sketch of the
flywheel giving the dimensions of the rim, the mean diameter of the rim and other estimated dimensions of
spoke, hub etc., (16) (M/J 12)
12. Design and draw a cast iron flywheel used for a four stroke I.C engine developing 180 kW at 240 rpm.
The hoop or centrifugal stress developed in the flywheel is 5.2 MPa, the total fluctuation of speed is to be
limited to 3% of the mean speed. The work done during the power stroke is 1/3 more than the average
work done during the whole cycle. The maximum torque on the shaft is twice the mean torque. The density
of cast iron is 7220 kg/m3. (16) (N/D 12)
13. A machine punching 35 mm holes in 32 mm thick plate requires a7 N m of energy per sq. mm of
sheared area and punches one hole in every 10 seconds. Calculate the power on the motor required. The
mean speed of the flywheel is 25 m/sec. the punch has a stroke of 100 mm. find the mass of the flywheel
required if the total fluctuation of speed is not to exceed 3% of the mean speed. Assume that the motor
supplies the energy to the machine at uniform rate. (16) (M/J 13)
14. A semi-elliptical laminated vehicle spring to carry a load of 6000 N is to consist of seven
leaves 65 mm wide, two of the leaves extending the full length of the spring. The spring is to be 1.1
m in length and attached to the axle by two U-bolts 80 mm apart. The bolts hold the central portion
of the spring so rigidly that they may be considered equivalent to a band having a width equal to
the distance between the bolts. Assume a design stress for spring material as 350 MPa.

Determine: 1. Thickness of leaves, 2. Deflection of spring, 3. Diameter of eye, 4. Length of leaves,

and 5. Radius to which leaves should be initially bent. Sketch the semi-elliptical leaf-spring
arrangement. The standard thickness of leaves are: 5,6,6.5,7,7.5,8,9,10,11 etc. in mm. (16)
 ME 6503 — DESIGN OF MACHINE ELEMENTS
Mechanical Engineering
Fifth Semester
UNIT - 5
Part A
1. Classify the types of bearings. [N/D 16]
i. Based on the type of load acting on the shaft:
a. Radial bearing
b. Thrust bearings
ii.Based on the nature of contact:
a. Sliding contact
b. Rolling contact (or) antifriction bearings

2. Define the term Reliability of a Bearing. [N/D 16]

Reliability is defined as the probability that a system or product will successfully operate for a:
i. given range of operating conditions
ii.specific environmental condition
iii. prescribed economic survival time

3. What is meant by hydrodynamic lubrication? [M/J 16]

In hydrodynamic lubrication, a thin film of lubrication is created between shaft and bearing or between
two sliding surfaces to separate them.

4. What are the advantages of Rolling Contact Bearings over Sliding Contact Bearings? [M/J 16]
i. They produce low starting and running friction except at very high speeds
ii.It can withstand momentary shock loads
iii. Accuracy of shaft alignment is high
iv. Low cost of maintenance is sufficient as no lubrication is required while in service
v.The bearings have small overall dimensions
vi. They provide good reliability of service
vii. They are easy to mount and erect
viii. They provide more cleanliness

5. What is meant by square journal bearing? [N/D 15]

When the length of journal (l) is equal to the diameter of the journal (d), then the bearing is called square
bearing.

6. Give an example for anti-friction bearing. [N/D 15]

i. Ball bearings
ii.Roller bearings
7. Discuss the forces acting on the connecting rod. Or Under what force the big end bolts and caps are
designed. (N/D 11) (N/D 12)
The combined effect of (i)load on the piston due to the gas pressure and due to inertia of the reciprocating
parts, and(ii)the friction of the piston rings, piston, piston rod and cross head.1.inertia of the connecting
rod.2.the friction force in the gudgeon and crank pin bearing.

8. State the components of rolling contact bearing.

Outer race, inner race, rolling element, retaining cage.

9. List the basic assumption used in the theory of hydrodynamic lubrication? (N/D 11)
I. The lubricant obeys newton’s law of viscous flow.
II. The pressure is assumed to be constant throughout the film thickness.
III. The lubricant is assumed to be incompressible.
IV. The viscosity is assumed to be constant throughout the film thickness.
V. The flow is one dimensional.

10. Classify
the sliding contact bearings according to the thickness of layer of the lubricant between the bearing and
journal. (M/ J 12)
I. Thick film bearing
II. Thin film bearing
III. Zero film bearing
IV. Hydrostatic bearing

11. What do you

meant by life of an individual bearing? (M/ J 13)

The life of individual bearing may be defined as the number of revolution which the bearing runs before
the first evidence of fatigue develops in the material of one of the rings or any of the rolling elements.

12. What are

various types of radial ball bearing? (M/ J 12)
I. single row deep groove ball bearing
II. Filling notch bearing
III. Angular contact bearing
IV. Double row bearing
V. Self-aligning bearing

13. What is
a Journal bearing? List any two applications. (M/J 13)
A journal bearing is a sliding contact bearing which gives lateral support to the rotating shaft.
14. Explain the
term Dynamic load carrying capacities of rolling contact bearing. (N/D 12)
Dynamic load rating is defined as the radial load in radial bearings that can be carried for a minimum
life of one million revolutions.
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7. Design a suitable connecting rod for a petrol engine for the following details, diameter of the
piston = 100 mm, weight of reciprocating parts per cylinder = 20 N, connecting rod length = 300
mm, compression ratio = 7:1, maximum explosion pressure = 3 N/mm 2, stroke = 140 mm, speed
of the engine = 2000 rpm. (16) (A/M 02) (N/D 11) (M/J 12)
Given:
d = 100 mm, r = 20 N, l = 300 mm, compression ratio = 7:1, p = 3 N/mm2, stroke = 140
mm, N = 2000 rpm.

Solution:

i. From PSG DDB Pg. No. 7.122,

t 5t

4t

a = 11t2

Ixx = 419 4
t
12
2
k x = 3.18 t2.
x

ii.Load due to burning of gas (FG): From PSG DDB Pg. No. 7.122

 100
2

FG = 2  p   3  23561.94N
d
4 4

iii. Crippling load (Fcr):

Fcr = FOS x FG (Assume FOS = 6)

= 6 x 23561.94 = 141371.67 N
iv. Crippling load by Rankine’s formula:

c  a
Fcr  2
1 c  l  
 k xx  33011t
2

2
141371.67
 1
1  300 

7500   3.18t  
2

2
141371.67 33011t 3630t
2
3.77  t 2  3.77

1 2 2
t t
4
3630t
141371.67  2
t  3.77 2 4
141371.67(t  3.77)  3630t
4 2
3630t 141371.67t  532971.196  0
4 2
3630  t  38.95t 146.824  0

2 (38.95)
 (38.95)
 2  4 1(146.824)

t 
2
238.95  45.874
t   42.412
2
t  6.15mm  7mm
v.Dimensions of Cross section:

Height of ‘I’ section = 5t = 5 x 7 = 35 mm

Width of ‘I’ section = 4t = 4 x 7 = 28 mm

vi. Design of small end

pin:
(Assume Pb = 13 N/mm2)
L1
 1.75
d1
FG = L1 x d1 x Pb

23561.94 = 1.75d1 x d1 x 13
d1= 32.18 mm = 33 mm

L1 = 1.75(33) = 57.75 = 58 mm
vii. Design of Big end pin: L2
 1.375
d2
 FG = L2 x d2 x Pb

23561.94 = 1.375d2 x d2 x 13 (Assume Pb = 8 N/mm2)

d2= 46.28 mm = 47 mm

L2 = 1.375(47) = 64.63= 65 mm

viii. Diameter of bolt:

From PSG DDB Pg. No. 7.122,

L1
 1.75
d1

p
F  
r  cos cos 2
2
  l 
i
 r 
g

2 N 2  2000
  sec 60  60  209.44rad /
l = 300 mm = 0.3 m
140
r = radius of crank = stroke length / 2 = = 70 mm = 0.07 m
2

 
20 1
(209.44)  0.07   1 
2
F 
i
9.81  0.3 
0.07 

W.K.T
Fi  7720.736N

2
d
Fi  n   c
4 d
2
c
7720.736  4  100
4
dc  4.95mm  5mm
d 5
Diameter of bolt d  c   5.95  6mm
0.84 0.84

ix. Thickness of big end cap (tc):

Fi  x
(x=1.5d2)
Bending moment mc =
6
 7220.7361.5 47

6
 90718.65Nmm

2
b= c (b=L2)
Modulus, Z
6
2
65 t 2

6
c
 10.83tc
(Assume σb=120N/mm2)
mc
W.K.T.,  
b
Z
90718.65
120  2
10.83t

tc = 8.35 mm
tc = 8.5 mm
8. Design a journal bearing for a centrifugal pump with the following
data: Diameter of the journal = 150 mm
Load on bearing = 40 kN
Speed of journal = 900 rpm (16) (N/D 07) (M/J 12)

Given:
D = 150 mm, W = 40 kN, n = 900 rpm, Application = Centrifugal pump
Solution:

i. Diameter of journal is already given in the problem, D = 150 mm

L
ii. From PSG DDB Pg. No. 7.81, D = 1.0 – 2.0
Bearing pressure allowable = 71014 kgf/cm2,
= 2844.5

  Zn
p min

Take D = 1.5, L = 1.5 D = 1.5 x 150 = 225 mm

iii. Bearing 40103

Pressure
W

P = LD = 225150 = 1.185 N/mm2 = 1.185 x 10 kgf/cm2 = 11.85 kgf/cm2.

which is less than allowable, so L/D value is acceptable.

iv. From PSG DDB Pg. No. 7.32, Diameter clearance C = 150 microns
= 150 x 10-3 mm
C -3

Clearance ratio, D = 150103 = 1 x 10

150
v. Selection of lubricating oil.

From PSG DDB Pg. No. 7.31,

Zn
P = 2844.5
2844.511.85
Z= 900 = 37.45 = 40 centipoise.

From PSG DDB Pg. No. 7.41, for Z = 40 and temperature = 60o (assume). The suitable
lubricating oil is SAE40.

vi. Bearing Characteristics number.

Zn
P=
4090 = 3037.97
0
11.85
It is higher than the minimum value given in PSG DDB Pg. No. 7.31.

vii. Calculation of µ.
From
= PSG DDB Pg. No. 7.34, µ

33.25
 Zn  D   K
Zn P C
1010
P = 3037.97, D 1
C = 1103 ,
K = 0.0025 (for L/D = 1.5, from PSG DDB Pg. No. 7.34)

  33.25 3037.97 1
 0.0025
10 10 1103

0.0126

Hg and Hd

Hg = µ .w .v Watts

w in Newton,
 Dn
v = 60 in m/min,
D in meters,  LD
n in rpm

Hg = 0.0126 x 4000 x
 0.15900 60
= 3562.56 W
Hd = k
 L in meters
D in meters
K – constant, assume = 0.484 heat dissipation

∆t = temperature of bearing surface

Form ambient temperature

∆t = 2(to  ta )
1

to = oil temperature, ta = ambient temperature

∆t = 1
 60
o
 28
o
  16 o

C
2
Hd 2
1618 0.2250.15
 0.484

Hd = 80.61 W
Here Hg > Hd so artificial cooling is required to carry away the excess heat.

Diameter of the bearing Db = D+C = 150 + 150 x 10-3 = 150.15 mm

Material of Bearing
From PSG DDB Pg. No. 7.30, for pump application material is rubber or moulded
plastic laminate.

Summary of Design

Material = Rubber or Moulded plastic laminate

Cooling = Artificial cooling required
Diameter of journal = 150 mm
Length of journal L = 225 mm
Diameter of bearing Db = 150.15 mm
Diameter of clearance C = 150 microns
Lubricating oil suitable = SAE40
Operating temperature = 60oC
Atmospheric temperature = 28oC

9. Following data is given for a 360o hydro dynamic bearing:

Journal diameter = 100 mm, Radial clearance = 0.12 mm, Radial load =50 kN,
Bearing length = 100 mm, Journal speed = 1440 rpm, Viscosity of lubricant = 16 centipoise.
Calculate: 1. Minimum film thickness
2. Co-efficient of friction
3. Power cost in friction. (16) (M/J 09)

Given: D= 100 mm, Radial clearance = 0.12 mm, W = 50kN, L=100 mm, n = 1440 rpm, Z=16
centipoise = 16 x 10-3 Ns/m2.
Solution:

i. Minimum film thickness

W.K.T. Radial clearance = Diameteral clearance /2 = C/2

0.12 = C/2,
C = 0.24 mm


2
Z 'n ' D
From PSG DDB Pg. No., Sommerfield number s = p C
Z’ = viscosity in Ns/m2,
n’ = speed of jouranal in rps
p = bearing pressure in N/m2.
n’ = 1440/60 rps
W  50103
Bearing pressure p LD 0.10.1
=
p = 5 x 106 N/mm2.

60
100
s = 1610 
3 61440
510  0.24 2
 
s = 0.013

From PSG DDB Pg. No. 7.40, for β = 360o, s = 0.013 and corresponding to L/D =1,
2ho
the minimum film thickness variable C = 0.071
= 0.071C
ho = 2 = 8.52 x 10-3 mm = 0.00852 mm

ii. Co-efficient of Friction (µ):

From PSG DDB Pg. No. 7.40, for β = 360o, L/D = 1, s = 0.013

-3
= 1, 0.24 = 2.4 x 10
 C   1 = 100
D C

D
iii. Power cost due to friction:

Hg = µ w v 
1001
-3 440 60
= 2.4 x 10 x 50,000 x
Hg = 904.8 W
 10. Select a bearing for a 40 mm diameter shaft rotates at 400 rpm. Due to a bevel gear mounted
in the shaft. The bearing will have to withstand a 5000 N radial load of the bearing thrust load.
The life of the bearing expected to be at least 1000 hrs. (16)

Given: d= 40mm, n=400 rpm, Fr = 5000N, Fa = 3000N, Lh = 1000 hrs

Solution:

Select Series 62 and for d = 40 mm, From PSG DDB Pg. No. 4.13, bearing basic design
no. SKF 6208. The values of Co, C are

Co = 1600 kgf = 1600 x 10 = 16000 N

C = 2280 kgf = 2280 x 10 = 22800 N

i. Equivalent diameter load (P):

P = (X.Fr + Y.Fa) x s

For X and Y values, from PSG DDB Pg. No. 4.4, Fa and e are given

Fa/Co e
 0.13 0.31
0.12   0.06
 0.25 0.37 

0.12 0.06
 0.012, and  0.006
10 10 Fa

3000 0.19  0.13  5(0.012)
16000 Co
Fa
For  0.1875  0.19 , For value
Co
of

Similarly, For ‘e’ value = (5 0.006  0.31)  0.03  0.31= 0.34
Fa
  0.19
Co
e  0.34

Fa 3000
  0.6 > e,
Fr 5000

So, X value = 0.56, ‘s’ value from PSG DDB Pg. No. 4.2
Y value = 1.2

Therefore, P = [(0.56 x 5000) + (1.2 x 3000)] x 1.2

P = 7680 N
 ii.Dynamic Load capacity(C):

From PSG DDB Pg. No. 4.6 (Ball bearing), For 400 rpm and 1000 hrs life

C/P = 2.88
C
 2.88
7680

C = 2.88 x 7680 = 22118.4 N

This dynamic load is less than the tabulated (allowable) value i.e. 22800 N. So the
suitable bearing designation is SKF 6208.

11. Sele
ct a suitable ball bearing to support the overhung countershaft. The shaft is 60 mm diameter and
rotating at 1250 rpm. The bearing is to have 99% reliability corresponding to a life of 4000 hrs.
The bearing is subjected to an equivalent radial load of 6000N. (16)

Given: d = 60 mm, n = 1250 rpm, Reliability = 99% = 0.99 = probability = p, L = 4000 hrs, Fr =

6000N.

Solution: L  ln(1 / p)
1/b

 
From PSG DDB Pg. No. 4.2 L '10 ln(1/ p )
 10 

Here, ln(1/ p10 ) = 0.1053, L = 4000 hrs, b = 1.34, p = 0.99

Substitute all value,

4000 0.7463
 (0.09544)
L '10
L’10 = 23.093 hrs

From PSG DDB Pg. No. 4.6, For life 23.093 hrs and 1250 rpm,

C value is 12.40
The
12.40 =C/P
P
C 2500 hrs
= 12.4
P
C = 12.4 x Fr
C = 12.4 x 6000
C = 74400N
1250 rpm
 Select the bearing for C = 74400 N or C = 7440 kgf, and the diameter of the shaft is 60
mm. (From PSG DDB Pg. No. 4.15, series 64)

Result:
SKF 6412 is suitable bearing,
Co = 7100 kgf,
C = 8450 kgf.

12. A single row deep groove ball bearing no: 6002 is subjected to an axial thrust load of 1000N and
a radial load of 2200N. find the expected life that 50% of the bearing will complete under this
condition. (16)

Given:

Deep groove ball bearing no: 6002

Fa= 1000N

Fa = 2200N

Solution:

From DDB:4.12 :- For bearing no. 6002

Co = 255kgf = 255*10N

C = 440kgf = 4400N

Fa/co=1000/2550 = 0.392

From DDB 4.4 for =0.392 the value of

e=0.412 Since, fa/co= 1000/2550 = 0.454>e

The radial load factor X= 0.56

Thrust load factor Y= 1.83

Service factor from DDB 4.2, S=1.1to 1.5 , say S=1.3

.. . Equivalent load

(from DDB: 4.2) P= (XFr+YFa)S

= (0.56*2200+1.83*1000)1.3

= 3980.6N
WKT,
L= (c/p)b = (4400/3980.6)3 =1.35 million revolution
 Expected life at 50% reliability(L50) is obtained from

L50/L90= ln(1/R50) 1/b

Ln(1/R90)

1/b
L50/1.35 = ln(1/0.5) = (0.693/0.105)0,85 = 4.058
Ln(1/0.9)

L50= 4.958*1.35

L50= 6.69 million rev

13. The load on the journal bearing is 150KN due to turbine of 300mm diameter running
at 1800rpm determine the following
(1) Length of the bearing if the allowable bearing pressure is 1.6N/mm2
(2) Amount of heat to be removed by the lubricant per minute if the bearing
temperature is 600c and viscosity of the oil at 600c is 0.02kg/m-s and the
bearing clearance is 0.25. (16) (N/D 11)
3
Given: W=150KN = 150X10 N

D= 300mm=0.3m

N= 1800rpm

P= 1.6N/mm2

Z=0.02kg/m-s

C= 0.25mm

Solution:

1) Length of the bearing:

Let, l = length of bearing(mm)

WKT, projected bearing area

 A=l×d=lx300=300lmm2

And alloeable bearing pressure (P),

1.6=

l= 500/1.6 = 312.5mm

2) Amount of heat to be removed by the lubricant:

Wkt, co efficient of friction for the bearing

= 33/108

= 33/108

= 0.009+0.002= 0.011

Rubbing velacity,

V=

∴ Amount of heat to removed by the

lubricant. Q8 = 0.11x150x103x28.3

= 46.695 J/s or W

= 46.695kw

14. Design a connecting rod for an I.C. engine running at 1800 r.p.m. and developing a
maximum pressure of 3.15 N/mm2. The diameter of the piston is 100 mm; mass of the
reciprocating parts per cylinder 2.25 kg; length of connecting rod 380 mm; stroke of piston 190
mm and compression ratio 6:1. Take a factor of safety of 6 for the design. Take length to
diameter ratio for big end bearing as 1.3 and small end bearing as 2 and the corresponding
bearing pressures as 10 N/mm2 and 15 N/mm2. The density of material of the rod may be taken
as 8000 kg/m3 and the allowable stress in the bolts as 60 N/mm2 and in cap as 80 N/mm2. The rod
is to be of I-section for which you can choose your own proportions. Draw a neat dimensioned
sketch showing provision for lubrication. Use Rankine formula for which the numerator constant
may be taken as 320 N/mm2 and the denominator constant 1 / 7500. (16)
1. ]