22564

22223
4 Hours / 70 Marks Seat No.

Instructions – (1) All Questions are Compulsory.

(2) Answer each next main Question on a new page.
(3) Illustrate your answers with neat sketches wherever
necessary.
(4) Figures to the right indicate full marks.
(5) Assume suitable data, if necessary.
(6) Use of Non-programmable Electronic Pocket
Calculator is permissible.
(7) Mobile Phone, Pager and any other Electronic
Communication devices are not permissible in
Examination Hall.
(8) Use of steam tables, logarithmic, Mollier’s chart is
permitted.
Marks

1. Attempt any FIVE of the following: 10

a) Explain term ‘Endurance Limit’.
b) State the significance of Wahl’s correction factor in Design
of spring.
c) List any four applications of Foot lever.
d) Classify Keys.
e) Draw Acme and V thread profile.
f) List different materials used for making springs.
g) Name any two bearing manufacturers.

P.T.O.
22564 [2]
Marks
2. Attempt any THREE of the following: 12
a) Explain in brief the general design procedure.
b) Explain design procedure of muff coupling.
c) Design an offset link for a load of 1000 N. Maximum
permissible stress in tension for link material is 60 N/mm2.
Assume b = 3t for rectangular cross section of the link.
Refer Fig. No. 1.

Fig. No. 1.

d) A bracket as shown in Fig. No. 2 is fixed to a vertical steel

column by means of four standard bolts. Determine the
diameter of the fixing bolts. Assume safe working stress of
70 MPa in tension and 50 MPa in shear.

Fig. No. 2.
22564 [3]
Marks
3. Attempt any THREE of the following: 12
a) State the meaning of following colour codes used in Aesthetic
considerations while designing a product
i) Red
ii) Green
iii) Orange
iv) Blue
b) Explain the term Self locking and overhauling of Screw.
c) Explain construction of leaf spring and state its applications.
d) Explain the term ‘Stress Concentration’. State its causes and
remedies with suitable example.
e) Write strength equations for designing symmetrically loaded
parallel and transverse weld with neat sketch.

4. Attempt any TWO of the following: 12

a) State the necessity of ‘Ergonomic’ considerations while
designing product. Explain any four ergonomic consideration
in the designing of machine element.
b) Design a Knuckle joint to withstand 150 kN, the design stress
are 75 MPa, 60 MPa and 150 MPa in tension, shear and
compression respectively.
c) A hollow shaft is to be designed to transmit 600 kW at
110 rpm. The maximum torque being 20% greater than the
mean. The shear stress is not to exceed 63 MPa and angle
of twist in a length of 3 mts not to exceed 1.4 degree.
Find external diameter of the shaft if the internal diameter
to external diameter is 3/8. Take modulus of rigidity 84 GPa.

P.T.O.
22564 [4]
Marks
5. Attempt any TWO of the following: 12
a) A belt pulley is fastened to a 90 mm diameter shaft running
at 300 r.p.m. by means of a key 20 mm wide and 140 mm
long. Allowable stress for the shaft and key material are
40 N/mm2 in shear and 100 N/mm2 in crushing. Find the
power transmitted and the depth of the key required.
b) A screw jack is used to lift a load of 50 kN through a
maximum lift of 200 mm. The material used for a screw is
steel of allowable stresses in tension and compression as
100 N/mm2 and 50 N/mm2 respectively. The pitch of screw
is 8 mm. The nut is made of phosphor bronze with allowable
stresses as 50 N/mm2 and 45 N/mm2 in tension and crushing.
The allowable shear stress for nut material is 40 N/mrn2. The
allowable bearing pressure between nut and screw is not to
exceed 20 N/mm2. If the coefficient of friction between screw
and nut is 0.14, design the screw and nut.
c) Explain the selection process of deep groove ball bearing for
given application with manufacturer’s catalogue with suitable
example.

6. Attempt any TWO of the following: 12

a) A double start square thread of power screw has nominal
diameter 100 mm pitch 12 mm is to used to raise the load
of 300 kN. The coefficient of friction at screw thread is 0.25
Neglect collar friction calculate Torque required.
b) A helical spring is made from a wire of 8 mm diameter and
has outside diameter 90 mm; if the permissible shear stress
is 350 N/mm2 and modulus of rigidity 84 kN/mm2, find the
axial load which the spring can carry and the deflection per
active turn.
i) Neglecting the effect of curvature
ii) Considering the effect of curvature
c) Design “C” clamp frame for a total clamping force of 20 kN.
The cross-section of the frame is rectangular and width to
thickness ratio is 2. The distance between the load line and
natural axis of rectangular cross section is 120 mm and the
gap between two faces is 180 mm. The frame is made of
cast steel for which maximum permissible tensile stress is
100 N/mm2.
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SUMMER – 2023 EXAMINATION
Model Answer – Only for the Use of RAC Assessors

Subject Name: Elements of Machine Design Subject Code: 22564

Important Instructions to examiners: XXXXX
1) The answers should be examined by key words and not as word-to-word as given in the model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not applicable for
subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The figures
drawn by candidate and model answer may vary. The examiner may give credit for any equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values may vary and
there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual (English +
Marathi) medium is introduced at first year of AICTE diploma Programme from academic year 2021-2022. Hence if
the students write answers in Marathi or bilingual language (English +Marathi), the Examiner shall consider the
same and assess the answer based on matching of concepts with model answer.

Q. Sub Answer Marking

No. Q. Scheme
N.

1 Attempt any FIVE of the following: (5x2=10) 10 marks

a) Explain term “Endurance Limit”. Definitio

n
Ans: Endurance Limit: It is defined as maximum value of the completely reversed bending
stress which a polished standard specimen can withstand without failure, for infinite 1 Mark
number of cycles (usually 106 cycles).It is known as endurance or fatigue limit (ϭe
• Endurance limit is not a property of material.

• Endurance limit is affected by the size and shape of component ,surface finish, temp.,&
notch sensitivity of material.

• Stress amplitude (Sf) versus number of cycles before (N) fatigue failure for ductile steels is
shown.

S-N
diagram

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1 Mark

b) State the significance of Wahl's correction factor in Design of spring. Suitable

explanati
Ans:
A stress factor that is caused by the changes and direct shear in coil curvature is called Wahl's Factor. on

2 marks
We know; Wahl’s factor K= +

Wahl’s correction factor is calculated using spring index C. Hence selection of spring index C has a
great significance in spring design. Figure shows the effect of spring index C on Wahl’s factor

Spring index : It is ratio of mean coil diameter to wire diameter.

C=

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The spring index indicates the relative sharpness of the curvature of the coil.

A low spring index means high sharpness of curvature.

• If C is low (C < 3), the actual stresses are excessive due to curvature effect and special care in
coiling is required to avoid cracking in some wires during manufacturing.

• If C is high (C > 15), it results in large variation in the coil diameter. Such a spring is prone to
buckling and also tangles easily during handling.

• C from 4 to 12 is considered best from manufacturing considerations.

• A spring index in the range of 6 to 9 is still preferred particularly for close tolerance springs

and those subjected to cyclic loading.

In this way Wahl’s factor K is significant in design of spring.

c) List any four applications of Foot lever Any four

applicati
Ans: Basically a foot lever is the first type of levers, in which the fulcrum is in between the load and
ons
effort. In this case, the effort arm is greater than load arm, therefore mechanical advantage
obtained is more than one. Applications of the foot lever can be as given below. 0.5
I. Bell cranked levers used in railway signaling arrangement, marks
each
II. Rocker arm in internal combustion engines,

III. Handle of a hand pump,

IV. Hand wheel of a punching press,

V. Beam of a balance,

VI. Foot levers to apply brakes of automobiles.

d) Classify Keys. 2 Marks

Ans: 1. Sunk keys-

• Rectangular Sunk Key

• Square sunk Key

• Parallel sunk Key

• Gib Headed Key

• Feather Key

• Woodruff Key

2. Saddle keys –

• Flat saddle Key

• Hollow Saddle Key

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3. Tangent keys

4. Round keys

5. Splines.

e) Draw Acme and V thread profile. 1 mark

each
Ans:

Acme Thread Profile V Thread Profile

f) List different materials used for making springs. Any Two

Ans: The springs are mostly made from 1 mark
each
(i) Patented and cold-drawn steel wires (unalloyed) Music wire - used for small springs.

(ii) Oil-hardened and tempered spring steel wires and valve spring wires;

(iii) oil-hardened and tempered steel wires (alloyed); and

(iv) stainless steel spring wires

(v) Non-ferrous materials like phosphor bronze, Beryllium copper, monel metal, brass etc., may

be used in special cases to increase fatigue resistance, temperature resistance and corrosion
resistance.

g) Name any two bearing manufacturers. Any 2

names
Ans: a) SKF – Swedish SKF Group
1 mark
b) NRB
Each
c) FAG

d) NSK

e) TIMKEN

f) NTN

g) INA

h) KOYO

i) Menon

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j) Schaeffler

k) IKO

SUMMER – 2023 EXAMINATION

Model Answer – Only for the Use of RAC Assessors

Subject Name: Subject Code: 22564

Q. Sub Answer XXXXXMarking

No. Q. N. Scheme

2 Attempt any THREE of the following: (3x4=12) 12 Marks

a) Explain in brief the general design procedure. Brief

explanati
Ans: Step 1: Markey Survey on of
each
Market survey is to be done in order study existing similar products and their features and step
utility before starting the design of a competitive product or innovative product.

Step 2: Product Specifications

4 Marks
The first step consists of preparing a complete list of the requirements of the product. The
requirements include the output capacity of the machine, and its service life, cost and
reliability. In some cases, the overall dimensions and weight of the product are specified. For
example, while designing a scooter, the list of specifications will be as follows: (i) Fuel
consumption = 60 km/l (ii) Maximum speed = 100 km/hr (iii) Carrying capacity = two
persons with 10 kg luggage (iv) Overall dimensions Width = 700 mm, Length = 1750 mm,
Height = 1000 mm (v) Weight = 95 kg (vi) Cost = Rs. 50000 to Rs. 55000

In consumer products, external appearance, noiseless performance and simplicity in operation

of controls are important requirements. Depending upon the type of product, various
requirements are given weightages and a priority list of specifications is prepared.

Step 3: Selection of Mechanism

After careful study of the requirements, the designer prepares rough sketches of different
possible mechanisms for the product. The alternative mechanisms are compared with each
other and also with the mechanism of the products that are available in the market. An
approximate estimation of the cost of each alternative configuration is made and compared
with the cost of existing products. This will reveal the competitiveness of the product.
Depending upon the cost-competitiveness, availability of raw materials and manufacturing
facility, the best possible mechanism is selected for the product.

Step 4: Layout of Configuration

The next step in a design procedure is to prepare a block diagram showing the general layout
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of the selected configuration. For example, the layout of an Electrically-operated Overhead
Travelling (EOT) crane will consist of the following components: (i) electric motor for power
supply; (ii) flexible coupling to connect the motor shaft to the clutch shaft; (iii) clutch to
connect or disconnect the electric motor at the will of the operator; (iv) gear box to reduce the
speed from 1440 rpm to about 15 rpm; (v) rope drum to convert the rotary motion of the shaft
to the linear motion of the wire rope; (vi) wire rope and pulley with the crane hook to attach
the load; and (vii) brake to stop the motion. In this step, the designer specifies the joining
methods, such as riveting, bolting or welding to connect the individual components. Rough
sketches of shapes of the individual parts are prepared.

Step 5: Design of Individual Components

The design of individual components or machine elements is an important step in a design

process. It consists of the following stages: (i) Determine the forces acting on the component.
(ii) Select proper material for the component depending upon the functional requirements
such as strength, rigidity, hardness and wear resistance. (iii) Determine the likely mode of
failure for the component and depending upon it, select the criterion of failure, such as yield
strength, ultimate tensile strength, endurance limit or permissible deflection. (iv) Determine
the geometric dimensions of the component using a suitable factor of safety and modify the
dimensions from assembly and manufacturing considerations. This stage involves detailed
stress and deflection analysis. The subjects ‘Machine Design’ or ‘Elements of Machine
Design’ cover mainly the design of machine elements or individual components of the
machine.

Step 6: Preparation of Drawings

The last stage in a design process is to prepare drawings of the assembly and the individual
components. On these drawings, the material of the component, its dimensions, tolerances,
surface finish grades and machining symbols are specified. The designer prepares two
separate lists of components—standard components to be purchased directly from the market
and special components to be machined in the factory. In many cases, a prototype model is
prepared for the product and thoroughly tested before finalising the assembly drawings. It is
seen that the process of machine design involves systematic approach from known
specifications to unknown solutions. Quite often, problems arise on the shop floor during the
production stage and design may require modifications. In such circumstances, the designer
has to consult the manufacturing engineer and find out the suitable modification.

b) Explain design procedure of muff coupling.

Ans:

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1

Mark

Mark

Mark

Mark

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c) A bracket as shown in Fig. No. 2 is fixed to a vertical steel column by means of four standard bolts.
Determine the diameter of the fixing bolts, Assume safe working stress of 70 MPa in tension and
50 MPa in shear.
Ans

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Mark

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Mark

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Mark

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Mark

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d) Design an offset link for a load of 1000 N. Maximum permissible stress in tension for link material
is 60 N/mm2. Assume b= 3t for rectangular cross section of the link. Refer Fig. No. 1.

Ans:

1 Mark

Mark

Mark

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Q. Sub Answer Marking
No. Q.N. Scheme

3 Attempt any THREE of the following: (3x4=12) 12 M

3 a) State the meaning of the following colour codes used in Aesthetic considerations while designing a
product 1) Red 2) Green 3)Orange 4) Blue

Meaning of the following colour codes used in Aesthetic considerations

1 M each
1. Red : Danger-Hazard-Zone
2. Green: Safety Code
3. Orange: Possible Danger
4. Blue : Caution cold Meaning

3 b) Explain the term Self locking & Overhauling of screw

i) Self locking of a screw : Torque required to lower the load, T= W tan(φ - α) x d/2

Where W – Load to be lifted, φ is the friction angle and α is the helix angle 2M
• When φ > α, positive torque is required to lower the load.

• Under this condition, the load will not turn the screw and will not descend on its own

unless an effort P is applied. In this case, the screw is said to be ‘self-locking’.

• A self-locking screw will hold the load in place without a brake.

• Can be achieved by optimum lubrication and less lead of screw thread.

Condition for self locking is  < 50%

• Application: Screw-jack

ii) Overhauling of a power screw

• Using the same equation of torque required to lower the load, it can be seen that when;
2M
if φ< α the torque required to lower the load is negative.

• It indicates a condition that no force is required to lower the load.

• The load itself will begin to turn the screw and descend down, unless a restraining

torque is applied. This condition is called overhauling of the screw.

• Caused due to excessive lubrication (Minimum friction) or high lead of power screw thread.

Condition for Overhauling is  > 50%

• Applications- Yankee screwdriver , Power steering (Recirculating Ball type Screw)

3 C Explain construction of leaf spring and state its application 4M

Construction of leaf spring :

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Fig :
Semi-elliptical leaf springs are widely used for suspension in light and heavy commercial vehicle. 1&½
In car these are used for rear suspension.

•The leaf springs are made of flat semi-elliptical plate.

• It consists of number of semi-elliptical plates called blade or leaves.

• The leaves are given initially curvature or camber so that they tend to straighten under the load.

• The blades vary in length and are held together by a bolt passing through the center acting as a
beam of uniform strength.

• The spring is clamped to the axle housing by means of ‘U’ bolts.

• The longest leaf is known as master leaf, has its end formed in the shape of an eye through
which the bolts are passed to secure the spring to its supports.

• The eyes are attached to shackle provided with bushing of anti-friction material such as bronze
or rubber. The other leaves are graduated leaves.

• To prevent digging in the adjacent leaves, the ends of graduated leaves are trimmed in various
Explain
forms.

• The master leaf has to withstand vertical bending load, side thrust and twisting moment due to 1&½
presence of stresses caused by these loads so it is usual to provide two full length leaves and rest
graduated leaves.

• Rebound clips are located at intermediate position in the length of the spring so that graduated
leaves also shear the stresses induced in the full-length leaves when the spring rebound.

• Highly cambered spring provides a 50% suspension but they also increase tendency to jaw
App:
(movement about vertical axis). Flat spring reduces tendency of the vehicle to dip (pitching), when
brake or accelerate suddenly. 1M

Application of Leaf spring 1) Bus/truck/Car suspension springs, diving board.

3 d Explain the term ‘stress concentration’ ? State its causes and remedies with suitable examples . 4M
i. Stress Concentration:

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Whenever a machine component changes the shape of its Explain:
cross-section, the simple stress distribution no longer holds
good and the neighbourhood of the discontinuity is 1M
different. This irregularity in the stress distribution
caused by abrupt changes of form is called stress
concentration.
It occurs for all kinds of stresses in the presence of fillets,
notches, holes, keyways, splines, surface roughness or
scratches etc.
Causes
Causes of stress concentration:
1M
i) Abrupt changes in cross-section like in keyway, steps, grooves, threaded holes results in stress
concentration.

ii) Poor surface finish – The surface irregularities is also one of the reason for stress concentration.

iii) Localized loading – Due to heavy load on small area the stress concentration occurs in the vicinity
of loaded area.
Remedie
iv)Variation in material properties – Particularly defects like internal flaws, voids, cracks, air holes,
cavities also results in stress concentration. s with
example
Remedies to Avoid stress concentration:
2M
The presence of stresses concentration cannot be totally eliminated but it can be reduced, so
following are the remedial measures to control the effects of stress concentration.

1. Provide additional notches and holes in tension members as shown in fig (a)

a)Use of multiple notches. b)Drilling additional holes as shown in fig(b)

2. Fillet radius, undercutting and notch for member in bending.

3. Reduction of stress concentration in threaded members as shown in fig(c)

4. Provide taper cross-section to the sharp corner of member as shown in fig(d)

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3 e Write strength equation for designing symmetrical loaded parallel and transverse weld with neat 4m
sketch.
2M(
Each for
correct
Strength of parallel weld
equation
P= 1.414 x Sw x l x Ϭt &
Sketch)

Strength of Transverse weld Or

P= 0.707 x Sw x l x Ϭt 4 M (for
correct
Combine
d
equation
OR & Sketch
Strength equation for designing symmetrical
loaded parallel and transverse weld

P= 1.414 x Sw x l1 x Ϭt + 0.707 x Sw x l2 x Ϭt

4 Attempt any TWO of the following ;(2x6=12) 12 M

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a) State the necessity of ‘Ergonomic ‘considerations while designing product. Explain any four 6M
ergonomic considerations in the designing of machine element.

Necessity of ‘Ergonomic ‘considerations:

2M
Ergonomics is the science of designing workstations and equipment to fit the human body
(Any 4
Ergonomics is necessary 1) To increases comfort, 2) To increases productivity, 3) To decreases
stress 4) To prevent work-related mental and muscle fatigue 5) To reduce costs, 6)To improve the Points )
quality of work 7) To increase the accuracy. 8) to Keep work environment comfortable 9) To Reduce
excessive repetition 10) to keep safety environment etc.

Ergonomic considerations in the designing of machine element. ( Any Four )

A)Ergonomics consideration in control design:

i) The control should be accessible and logically positioned.

ii) The shape of control component which come in contact with hands should be comfortable with
anatomy of hand.

iii) Control should be painted in red color with grey background of machine tool for attention.

iv) The control operation should involve Minimum motions.

B) Ergonomics consideration in Display design:

i) The scale on the dial indicator should be divided in suitable linear progression such as 0-10-20-30.
ii) Number of subdivisions between divisions should be minimum.

iii) Vertical figures should be used for stationary dials and radially oriented figures should be used for
rotating dials. 4M

iv) The height of letters or numbers on display should be greater or equal to reading distance /200.

v) The pointer should have knife edge with a mirror to minimize parallax error. (1 m
each,
vi) The numbering should increase in clockwise direction on circular scale, rightward on a horizontal any 4
scale and upwards on vertical scale. consider
C) Lighting: The surrounding area including walls, ceiling, floor and other object should be bright and ation )
more colored than workplace. The light should be match the needs of the task as far as illumination
is concerned.

D) Noise: vibration isolating material, plug in ears and providing sound insulating walls.

E) Temperature: i)In order to get efficiency to perform the task, the operator should feel neither too
hot nor too cold but comfortable. Ii) When the heavy work is done, the temperature should be
lowered and when the office work is done, it should be little higher.

F) Humidity and Air circulation:

i) Low humidity may cause discomfort through drying of the nose and throat.

ii) Air humidity and air velocity become important at high temp. because they influence the amount
of sweat, which can be evaporated from body surface to produce cooling effect .

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4 b Design a Knuckle joint to withstand 150 kN, the design stress is 75 MPa, 60 MPa and 150 MPa in 6M
tension, shear and compression respectively.

Design of knuckle joint:

Dia of
Step 1) Diameter of Rod: d : =? Rod
Consider tensile failure of Rod 1M
1. P =σt x A , 150 x 103 = 75 x π/4 xd2 , d = 50.4 mm 52 mm ( say)

(Note: dia . may vary designer to designer and other dimensions accordingly) Knuckle
Pin
Using Imperial relations
dimensio
Diameter of Knuckle pin Outside d₁ = d = 52mm ns with
safe
Outer diameter of eye, d₂ =2d=2x52=104 mm design :
Diameter of knuckle pin head and collar, d3=1.5d-1.5x52=78mm 1M
Thickness of single eye or rod end, t=1.25 d= 1.25x52= 65 mm

Thickness of fork, t1=0.75 d= 0.75x52= 39 say 40 mm Single

Thickness of pin head, t2=0.5d=0.5×52=26 mm eye
dimensio
2. Failure of the knuckle pin in shear : ns with
safe
Since the knuckle pin is in double shear, therefore load (P),
design :
150 x 10³ =2x (π/4)x(d1)²=2x=2x (π/4)x(52)²=²=4248 τ
2M
τ =150 x103/4248 , τ =35.31 MPa

(τ allowable > τ induced ) Design is safe

3. Failure of the single eye or rod end in tension

The single eye or rod end may fail in tension due to the load. We know that load (P),
Fork
150 × 103 = (d2 – d1) t × Ϭt= (104 – 52) 65 × Ϭt= 3380 Ϭt dimensio
∴ Ϭt= 150 × 103 / 3380 = 44.4 N / mm2 , Ϭt =44.4 MPa
ns with
safe
(σt allowable > σt induced ) Design is safe design :
4. Failure of the single eye or rod end in shearing 2M
The single eye or rod end may fail in shearing due to the load. We know that load (P),

150 × 103 = (d2 – d1) t × τ = (104 – 52) 65 × τ = 3380 τ

∴ τ = 150 × 103 / 3380 = 44.4 N/mm2 , τ = 44.4 MPa

(τ allowable > τ induced ) Design is safe

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5. Failure of the single eye or rod end in crushing

The single eye or rod end may fail in crushing due to the load. We know that load (P),

150 × 103 = d1 × t × Ϭc = 52 × 65 × Ϭc = 3380 Ϭc

∴ Ϭc = 150 × 103 / 3380 = 44.4 N/mm2 , Ϭc =44.4 MPa

(Ϭc allowable > Ϭc induced ) Design is safe

6. Failure of the forked end in tension

The forked end may fail in tension due to the load. We know that load (P),

150 × 103 = (d2 – d1) 2 t1 × Ϭt= (104 – 52) 2 × 40 × Ϭt= 4160 Ϭt

∴ Ϭt= 150 × 103 / 4160 = 36 N/mm2, Ϭt = 36 MPa

(Ϭt allowable > Ϭt induced ) Design is safe

7. Failure of the forked end in shear

The forked end may fail in shearing due to the load. We know that load (P),

150 × 103= (d2 – d1) 2 t1 × τ = (104 – 52) 2 × 40 × τ = 4160 τ

∴ τ = 150 × 103 / 4160 = 36 N/mm2 τ = 36 MPa

(τ allowable > τ induced ) Design is safe

8. Failure of the forked end in crushing

The forked end may fail in crushing due to the load. We know that load (P),

150 × 103 = d1 × 2 t1 × Ϭc = 52 × 2 × 40 × Ϭc = 4160 Ϭc

∴ Ϭc = 150 × 103 / 4180 = 36 N/mm2 , Ϭc = 36 MPa

(Ϭc allowable > Ϭc induced ) Design is safe

From above, we see that the induced stresses are less than the given design stresses, therefore the
joint is safe.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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4 C) A hollow shaft is to be designed to transmit 600 kW at 110 rpm. The maximum torque being 20%
greater than the mean. The shear stress is not to exceed 63 MPa and angle of twist in a length of 3
mts not to exceed 1.4 degree. Find external diameter of the shaft if the internal diameter to 6M
external diameter is 3/8. Take modulus of rigidity 84 GPa,

Given that:

Let D = external diameter of shaft

Torque
d = internal diameter of the shaft = 3/8 × D = 0.375D, value:
Power (P) = 600 Kw, Speed (N) = 110 rpm, 1M
Shear stress (τ) = 63 MPa = 63 N/mm2, Angle of twist (θ) = 1.4⁰,

length (l) = 3 m, G = 80 GPa = 80 × 10⁹ Pa

Tmax :
The torque (T) is given by the equation:
1 &1/2
T= 60 P/2π N , T=( 60 x 600 x103) / (2πx 110) , T=52087 Nm M
The maximum torque ( ) = 1.2T = 1.2 × 52087 , T max =62504 Nm θ in rad
Using Torsion equation: ½M

= 0.0244 rad. Torsion

equation
From the torsion equation:
For
T G TL hollow
= J=
J L , G
1M
 D 4 )] = TL
D 4 [(1 −
32 d4 G

 62508.48 x10 3 x3000 Cal &

34
D 4 [(1 − )] =
32 84 84 x10 3 x0.0244 Ext.dia :
D4=950711.39 x103 , D= 175.59 mm say 180 mm 2M

Q. Sub Answer Marking

No. Q. N. Scheme

5 Attempt any TWO of the following: (2x6=12) 12 Marks

a) A belt pulley is fastened to a 90 mm diameter shaft running at 300 rpm by means of a 06 Marks
key 20 mm wide and 140 mm long. Allowable stress for the shaft and key material are
40 N/mm2 in shear 100 N/mm2 in crushing. Find the power transmitted and the depth
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__________________________________________________________________________________________________
of the key required.

Sol:

01 Mark

01 Mark

01 Mark

01 Mark

01 Mark

01 Mark

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__________________________________________________________________________________________________

Q. Sub Answer Marking

No Q. N. Scheme

5 b) A screw jack is used to lift a load of 50 KN through a maximum lift of 200 mm. The
material used for a screw is steel of allowable stresses in tension and compression as
100 N/mm2 and 50 N/mm2 respectively. The pitch of the screw is 8 mm. The nut is made
of phosphor bronze with allowable stresses as 50 N/mm2 and 45 N/mm2 in tension and
crushing. The allowable shear stress for nut material is 40 N/mm2. The allowable
bearing pressure between nut and screw is not to exceed 20 N/mm2. If coefficient of
friction between screw and nut is 0.14, design the Screw and Nut.

Sol:

01 Mark

01 Mark

01 Mark

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Q. Sub Answer Marking

No Q. N. Scheme

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__________________________________________________________________________________________________

01 Mark

01 Mark

01 Mark

Q. Sub Answer Marking

No Q. N. Scheme

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
5 c) Explain the selection process of deep groove ball bearing for given application with
manufacturer’s catalogue with suitable example.

Sol: Procedure for selection of bearing from manufacturer’s Catalogue.

The following procedure is followed in selecting the bearing from the
manufacturer’s catalog.
1) Calculate radial and axial forces and determine dia. of shaft.
2) Select proper type of bearing.
3) Start with extra light series for given diagram go by trial of error method.
4) Find value of basic static capacity (co) of selected bearing from catalogue. 06 Mark
5) Calculate ratios Fa/VFr and Fa/Co.
6) Calculate values of radial and thrust factors.(X & Y) from catalogue.
7) For given application find value of load factor Ka from catalogue.
8) Calculate equivalent dynamic load using relation. Pe = (XVFr + YFA) Ka.
9) Decide expected life of bearing considering application. Express life in
million revolutions L10.
10) Calculate required basic dynamic capacity for bearing by relation.
11) Check whether selected bearing has req. dynamic capacity, IF it not select the bearing of
next series and repeat
OR ( flowchart)

Q. Sub Answer Marking

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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No Q. N. Scheme

6 Attempt any TWO of the following: (2x6=12) 12

a) A double start square thread of power screw has nominal diameter 100 mm pitch 12 mm
is to used to raise the load of 300 KN. The coefficient of friction at screw thread is 0.25.
Neglect collar friction. Calculate Torque required.

Sol:

01 Mark

01 Mark

01 Mark

01 Mark

01 Mark

01 Mark

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

Q. Sub Answer Marking

No Q. N. Scheme

6 b) A helical spring is made from a wire of 8 mm diameter and has outside diameter 90 mm;
if the permissible shear stress is 350 N/mm2 and modulus of rigidity 84 N/mm2, find the
axial load which the spring can carry and the deflection per active turn.
i) Neglecting the effect of curvature
ii) Considering the effect of curvature
Sol:

01 Mark

01 Mark

01 Mark

01 Mark

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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________

Q. Sub Answer Marking

No Q. N. Scheme

01 Mark

01 Mark

6 c) Design ‘C’ clamp frame for a total clamping force of 20 KN. The cross section of the
frame is rectangular and width to thickness ratio is 2. The distance between the load
line and natural axis of rectangular cross section is 120 mm and the gap between two
faces is 180 mm. The frame is made of cast steel for which maximum permissible
tensile stress is 100 N/mm2.

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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(ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________
Sol:
01 Mark

01 Mark

01 Mark

01 Mark

01 Mark

01 Mark

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