Design of Machine Elements

Lab Sheet
Lab-II
1. A 50 mm diameter steel rod supports a load of 9 kN and in addition is subjected to a
torsional moment of 100 N-m as shown in Fig-1. If the material is C-50 steel with Sut
= 80 kgf/mm2, Syt = 50 kgf/mm2 and factor of safety 2.5. Find the maximum stress
induced in the rod. Also check for correct design.
2. Two plates subjected to a tensile force of 50 kN are fixed together by means of three
rivets as shown in Fig-2. The plates and rivets are made up of same material (plain
carbon steel, 10C4) with tensile yield strength of 250 N/mm2. The yield strength in
shear is 50% of tensile yield strength and the factor of safety is 2.5. Determine (i) the
diameter of the rivets, (ii) the thickness of the plates.
3. A rectangular plate 15mm thick, made up of brittle material is as shown. Calculate the
stresses at each of the three holes of 3, 5, 10 mm diameter.(Figure-3)
4. A round shaft made up of brittle material and subjected to bending moment of 15 N-m
as shown in Figure-4. The stress concentration factor at the fillet is 1.5 and the ultimate
tensile strength of the material is 200 N/mm2. Determine the diameter‘d’, magnitude
of stress at the fillet and the factor of safety.
5. A shaft carrying a load of 5 kN midway between two bearings is as shown in Figure-
5. Determine the bending stress at the fillet section. Assume the shaft material to be
brittle.
6. A plate 10mm thick subjected to a tensile load of 20kN as shown in Figure-6. The plate
is made up of CI (Sut = 350 N/mm2)and the factor of safety is 2.5. Find the fillet radius.

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 Design of Machine Elements
Lab Sheet
Lab-III
1. A component machined from a plate made of steel 45C8 (S ut = 630 N/mm2) is subjected to
completely reversed axial load of 50 kN as shown in Fig.Q1. The expected reliability is 90%
and the factor of safety is 2. The size factor may be taken as 0.85 and notch sensitivity as 0.8.
Determine the plate thickness for infinite life.
2. A rotating shaft subjected to a non-rotating force of 5 kN and simply supported between two
bearings A and E as shown in Fig. Q2. The shaft is machined from plain carbon steel 30C8 (S ut
= 500 N/mm2) and the expected reliability is 90%. The equivalent notch radius at the fillet
section can be taken as 3mm. What is the life of the shaft?
3. A simply supported beam has a concentrated load at the centre which fluctuates from value of
P to 4P. The span of the beam is 500mm and its cross section is circular with diameter of 60mm.
The ultimate stress for the beam material can be taken as 700MPa, yield stress of 500MPa, and
factor of safety of 1.3. Calculate the maximum value of P. Take a size factor of 0.75 and a
surface finish factor of 0.9.
4. A steel rod is subjected to a reversed axial load of 180 kN. Find the diameter of the rod for a
factor of safety 2 considering both Goodman and Soderberg equations. The material has
ultimate tensile strength 1070 MPa and yield strength of 910 MPa.
5. A cantilever beam made of cold drawn steel 40C8 is shown in Fig. Q5. The force P acting at
the free end varies from -50N to +150N. The expected reliability is 90% and factor of safety is
2. The notch sensitivity factor at the fillet is 0.9. Determine the diameter d at the fillet cross
section.
6. A solid circular shaft made of steel Fe 620 (Sut = 620 N/mm2 and Syt = 380 N/mm2) is subjected
to an alternating torsional moment, that varies from -200 Nm to +400 Nm. The shaft is ground
and expected reliability is 90%. Neglecting stress concentration, calculate the shaft diameter
for infinite life. The factor of safety is 2. Use distortion energy theory of failure.
7. A cantilever as shown in Fig Q7 is subjected to an axial load which varies from 150 N
(compression) to 450 N (tension) and also a transverse load at its free end which varies from
80N up to 120 N down. The cantilever is of diameter 1.5d for the first 80mm and of diameter d
for the remaining length. Determine its diameter for a minimum margin of safety as 2. Shaft is
made up of 0.4% C steel and r/d = 0.15.
8. A pulley keyed to a shaft midway between two bearings. The shaft is made up of cold drawn
steel for which an ultimate tensile strength is 550 MPa and the yield strength is 400 MPa. The
bending moment at the pulley varies from (-150 Nm) to (400Nm) and the torque on the shaft
varies from (-50Nm) to (150Nm). Determine the diameter of the shaft for 90000 cycles. The
stress concentration factor for the keyway at the pulley in bending and torsion are 1.6 and 1.3
respectively. Take factor of safety as 1.5, size factor 0.85 and surface finish factor as 0.88.
 Design of Machine Elements
Lab Sheet

Lab-IV

1. Design the rectangular key for a shaft of 50mm diameter. The shearing and crushing
stresses for the key material are 42MPa and 70MPa.
2. A 45mm diameter shaft of steel with a yield strength of 400MPa.A parallel key of
size 14mm wide and 9mm thick made of yield strength of 340 MPa is to be used.
Find the required length of key, if the shaft is loaded to transmit the maximum
permissible torque. Use maximum shear stress theory and assume FOS 2.
3. How do you accommodate the effect of keyway on a shaft? A standard splined
connection 8x52x60 is used for gear and the shaft assembly of a gear box. A 20 kW
power at 300 rpm is transmitted by the splines. The normal pressure on splines is
limited to 6.5N/mm2. If µ=0.06 calculate: 1) the length of hub of the gear, 2) force
required to shift the gear.
4. An automobile engine has a capacity of 250Nm. The clutch is attached to its driven
shaft by means of six splines that is to slide when not under load. Determine the
dimensions of the shaft and spline. The material of shaft and splines is steel and the
load is applied with moderate shock. The maximum pressure on spline is
8.5N/mm2. Assume length of the spline is 1.5 times the shaft diameter.
5. A standard splined connection 8x36x40 is used for a gear and shaft assembly
rotating at 700 rpm. The length of the gear hub is 50mm. Calculate the power that
can be transmitted from the gear on the shaft.
6. Explain the design of socket and spigot type quarter joint subjected to a load of
10kN in tension and compression. (σyt = 320MPa,τyt =160MPa).
7. Design a socket spigot joint to support a load of 100kN.the material used is carbon
steel for which the following allowable stresses may be used. The load applied is
static. Tensile stress=compressive stress=50MPa, shear stress=35MPa, crushing
stress=90MPa.
8. Two steel rods are to be connected by means of a steel sleeve, and two steel cotters.
The rods are subjected to tensile load of 40kN. Design the joint by drawing a free
hand neat sketch of the joint. The permissible stress in tension=60MPa, in
shear=50MPa and crushing =90MPa may be assumed.
9. Design and draw a cotter joint to support a load from 80kN in compression to 80kN
in tension. The material used is carbon steel for which following allowable stresses
may be taken. Tensile stress=compressive stress=60MPa, shear stress=40MPa,
crushing stress=100MPa.
10. Design a knuckle joint to transmit 150kN. The design stresses are Tensile
stress=compressive stress=80MPa, shear stress=50MPa, crushing stress=140MPa.