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IInnddeexx

Sr. No.

Particulars

Page Number

1 Scheme 3

2 Syllabus 4

3 Lecture Plan 6

4 List of Books 9

5 Tutorial Sheets -

6 Assignments 10

7 MID Question Papers 20

8 Gtu Question Paper 21

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Course of Study and Scheme of Examination for Batch starting from December 2018

B.E-6th Semester (MECHANICAL ENGINEERING )

Teaching Scheme

Credit Examination Marks Total

Marks L T P C

Theory Marks Practical Marks

ESE(E) PA(M) ESE(V)

PA(I) PA ALA ESE OEP

4 0 2 6 70 20 10 20 10 20 150

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SSYYLLLLAABBUUSS

UNIT-I

Introduction

Concepts of stresses and Strain, Combinations of Axial, Shear, Torsional and Bending loads; Theories

of Failures: Distortion energy (von Mises), Maximum-Shear stress, Maximum Principal stress,

Coulomb-Mohr Theory, Selection and Use of theories of failures; Factor of safety, Contact stresses,

Crushing and Bearing stress. Application Problems: Eccentric Loading; Cotter and Knuckle Joints;

Design and analysis of levers: Cranked, Bell crank, Foot, Rocker arm.

UNIT-II

Beams and Columns

Different types of supports / end conditions, Revision of Stresses in beams: Effect of Section,

Orientation, and type of loading; Deflection of beams for different loading conditions.

Compressive axial loading of columns and struts, Slenderness ratio, Compressive stress and Buckling

of members, Effect of end conditions; Euler’s Formula, Applications, validity and limitations;

Rankine’s Formula, Johnson’s equation; Eccentric loading of long columns.

UNIT-III

Shafts, Keys and Couplings

Design of solid and hollow circular shaft subjected to torque and combined loading; Design of shaft

for rigidity and stiffness; Design of Keys: Saddle, Sunk, Woodruff, Square, Flat, Kennedy key and

Splines. Design of Couplings: Concept of rigid and flexible couplings, Design of: Clamp, Rigid flange

and Flexible couplings.

UNIT-IV

1. Power Screws and Threaded Joints

Forms of thread, Single and Multiple threaded screw, Terminology of power screw, Torque

requirement of lifting/lowering, Self-locking, Efficiency of threads, coefficient of friction, design of

screw and nut. Basic types of screw fastening, Cap and Set screw, Bolt of Uniform strength, locking

devices, Terminology of Screw thread, Bolted Joint: Simple and Eccentric loading, Torque

requirement for bolt tightening, Design of turnbuckle, Elastic analysis of bolted joints.

.

2. Welded and Riveted Joints

Category of Course

Course Title Course Code Theory Paper L T P

Mechanical Machine Design & Industrial Drafting

2141907 4 0 2 70

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Welded joints: stress relieving of welded joints, Strength of butt and fillet joint, Eccentric load in the

plane of weld, Welded joint subjected to bending and torsion. Riveted joints: rivet materials, types of

ailure, strength and efficiency of joint, Caulking and Fullering, Longitudinal and Circumferential lap

joint, Eccentrically loaded riveted joint.

UNIT – V

Tolerances, Limits and Fits

Introduction, Basic Definitions, Maximum Metal Condition, Least Metal Condition, Grade of

tolerance, Linear and Angular Tolerances, Fundamental deviations, Types of Fits and its basis, Gauge

design. Basic terminology of GD & T, Different tolerance characteristics, symbols and tolerance

modifiers, Different aspects of datums, Parameters of surface texture and qualifications, Relation of

surface roughness and various manufacturing processes, Surface Lay Indication.

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LECTURE PLAN

Lecture Topics to be covered Teaching

hours

1 Concepts of stresses and Strain, Combinations of Axial, Shear,

Torsional and Bending loads

1

2 Theories of Failures: Maximum Principal stress 1

3 Maximum-Shear stress, Maximum Tensile Strain Theory 1

4 Maximum Strain Energy Theory, Distortion energy (von Mises)

Theory

1

5 Selection and Use of theories of failures; Factor of safety 1

6 Contact stresses, Crushing and Bearing stress 1

7 Design of Spigot and Cotter Joint 1

8 Design of Sleeve and Cotter Joint 1

9 Design of Gib and Cotter Joint 1

10 Design of Knuckle Joint 1

11 Design of Levers, General procedure to design lever 1

12 Design of Cranked, Design of Bell Crank 1

13 Design of Rocker arm 1

14 Design of Foot and hand levers 1

15 Different types of supports / end conditions, Revision of Stresses in

beams

1

16 Effect of Section, Orientation, and type of loading 1

17 Deflection of beams for different loading conditions 1

18 Compressive axial loading of columns and struts, Slenderness ratio 1

19 Compressive stress and Buckling of members, Effect of end

conditions

1

20 Euler’s Formula, Applications, validity and limitations 1

21 Rankine’s Formula, Johnson’s equation, Eccentric loading of long

columns

1

22

Design of solid circular shaft subjected to torque and combined

loading, Design of solid circular shaft subjected to torque and

combined loading

1

23

Design of hollow circular shaft subjected to torque and combined

loading, Design of hollow circular shaft subjected to torque and

combined loading

1

23 Design of shaft for rigidity, Design of shaft for stiffness, Numericals 1

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based on Shafts as per ASME

24 • Riveted joints: rivet materials, types of failure 1

25 • strength and efficiency of joint, 1

26 • Numerical, Caulking and Fullering 1

27 • Boiler Joints - Longitudinal and Circumferential lap joint 1

28 • Numerical on Boiler Joints 1

29 • Eccentrically loaded riveted joint 1

30 • Numerical on Eccentrically loaded riveted joint 1

31 • Welded joints: stress relieving of welded joints 1

32 • Strength of Transverse fillet Welded joint and Parallel Fillet Welded

Joint

1

33 • Special Cases of Welded Joints, Strength of butt joint, 1

34 • Numerical on Fillet and Welded Joints 1

35 • Eccentric load in the plane of weld 1

36 • Numerical on Eccentric loaded welded Joint 1

37 • Forms of thread, Single and Multiple threaded screw,

Terminology of power screw 1

38 • Torque requirement of lifting/lowering, Self-locking, Efficiency

of threads 1

39 • coefficient of friction, design of screw and nut 1

40 • Basic types of screw fastening, Cap and Set screw, Bolt of

Uniform strength, locking devices

41 • Basic types of screw fastening, Cap and Set screw, Bolt of

Uniform strength, locking devices

42 • Terminology of Screw thread

43 • Bolted Joint: Simple and Eccentric loading, Torque requirement

for bolt tightening

44 • Design of turnbuckle, Elastic analysis of bolted joints 1

45

Introduction, Basic Definitions, Maximum Metal Condition, Least

Metal Condition, Grade of tolerance, Linear and Angular Tolerances,

Fundamental deviations 1

46 • Tolerance, Types of Tolerane, Fits, Types of Fits and its basis, BIS

Designation of Tolerance and Fits 1

47 • Basic terminology of GD & T, BIS Designation 1

48 • Different tolerance characteristics, symbols and tolerance modifiers 1

49 • Different aspects of datum’s, Parameters of surface texture and

qualifications 1

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50 • Relation of surface roughness and various manufacturing processes,

Surface Lay Indication 1

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REFERENCE BOOK

S. No. TITLE AUTHOR PUBLISHER / EDITION

1 Machine Design R S KHURMI S. Chand

2 Design of Machine Elements V B Bhandari McGraw Hill

3 Fundamentals of Machine

Component Design R C Juvinall Wiley

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ASSIGNMENT TOPICS

S. No. TOPIC

1 Introduction

2 Beams and Columns

3 Shafts

4 Keys and Couplings

5 Riveted Joints

6 Welded Joints

7 Power Screws and Threaded Joints

8 Tolerances, Limits and Fits

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ASSIGNMENT -1

INTRODUCTION

Sr. No.

Questions

1 What is stress concentration? Explain methods to relieve stress concentration? Explain any two stresses with simple sketches.

3 Define factor of safety and state the important factors affecting the factor of

safety

4 Define following:(1) Proof Resilience (2)Preferred number (3)Principle stress

5

Explain the following principle theories of elastic failure:

[1] Max. Principle stress theory (Rankine theory)

[2] Max. shear stress theory (Coulomb theory or Tresca and Guest theory)

[3] Distortion energy theory (Von Mises and Hencky theory)

[4] Selection and use of failure theories

6 Distinguish clearly between bending and bearing stress.

7 Differentiate between (with neat sketch): (1) crushing and compressive stresses (2) Torsional and transverse shear stress.

9

Explain the following terms with neat sketches: (1)Tensile stress (2) Compressive stress (3)Principle Stress (4) Bearing pressure

10 Classify the different types of load & explain each In brief.

11 Determine the minimum size of a circular hole that can be punched in a M.S. plate, 5 mm thick and having ultimate shear strength of 300 MPa. Take compressive strength of punch as 360 MPa

12

The load on a bolt consists of an axial pull of 10 KN together with a transverse shear force of 5 KN. Find the diameter of bolt required according to (i) maximum principal stress theory, (ii) maximum principal shear stress theory, (iii)maximum distortion energy theory. Take permissible tensile stress at elastic limit as 100 MPa and poison’s ratio as 0.3

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ASSIGNMENT -2

BEAMS AND COLUMNS

Sr. No.

Questions

1 Distinguish between beams, columns and strut giving suitable examples. Explain types of beams with neat sketch.

2 Explain types of supports (or end conditions) of beam and types of loads on

beam with neat sketch

3 Define following with reference to beam with neat sketch: (i) Deflection, (ii)

Slope and (iii) Flexural rigidity.

4

List the equations for slope and deflection for following types of beams with

different loading conditions:

(i) Cantilever beam with point load at free end

(ii) (ii) Cantilever beam with UDL on the entire span

(iii) (iii) Cantilever beam with point load at free end and UDL on the

entire span

(iv) (iv) Simply supported beam with central load

(v) (v) Simply supported beam with UDL on the entire span

(vi) (vi) Simply supported beam with central load and UDL on the entire

span

5 A 2 meters long cantilever beam is having 100 mm width and 200 mm depth, carrying point load at free end. If deflection at free end is 6 mm, calculate point load at free end. Take E = 2 x 105 N/mm2.

6 A cantilever beam of span 1.5 metres carries a point load of 20 kN at its free end. Find maximum slope of beam. Flexural rigidity (EI) = 2 x 104 kN.m2.

7

A hollow rectangular section 200 mm x 450 mm external and 15 mm thickness is used for 2.7 metres cantilever beam, subjected to UDL of 64 kN/m and point load of 60 kN at free end, both downward. Find maximum slope and deflection. Take E = 200 GPa.

8 A simply supported beam 3 metres in span is subjected to UDL of 10 kN/m over entire span with central point load 5 kN. The cross section of beam is 150 mm wide x 300 mm depth. Calculate the maximum slope & deflection for the beam.

9 A cantilever beam 120 mm x 200 mm is 2.5 metres long. What UDL should the beam carry to produce a deflection of 5 mm at free end? Take E = 2 x 105 N/mm2.

10 Cross section of wooden beam is 100 mm x 240 mm. It is simply supported with 4 metres span. Find out UDL that can be placed on its full span so that deflection at centre is 6 mm. Take E = 0.11 x 105 N/mm2.

11 A steel tube of external diameter 60 mm and 8 mm thickness is used as simply supported beam of span 4 metres. If it deflects 10 mm due to a central load, find magnitude of the point load. Take E = 2 x 105 N/mm2.

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ASSIGNMENT -3

SHAFTS

Sr. No.

Questions

1 Define – Shaft, Axle and Spindle. Also state the difference between shaft, axle

and spindle with examples. Explain functions and classification of shaft

2

Explain shaft design subjected

1. To twisting moment only

2. To bending moment only.

3. To combined twisting moment and bending moment

3 Explain shaft design based on torsional rigidity and lateral rigidity

4 Explain the ASME code for shaft design.

5 Explain critical speed of shaft in details.

6 Compare the weight, strength and rigidity of a hollow shaft of same external diameter as that of solid shafts, both the shafts are made of same material. Assume that diameter ratio for the hollow shaft is di/do = 0.6.

7

A steel spindle transmits 4 KW at 800 r.p.m. The angular deflection should not exceed 0.25⁰ per metre of the spindle. If the modulus of rigidity for the material of the spindle is 84 x 103 N/mm2, find the diameter of the spindle and the shear stress induced in the spindle.

8

Determine the diameter below which the angle of twist of a shaft is the controlling factor in design of solid shaft in torsion. The allowable shear stress is 56 MPa and the maximum allowable twist is ¼ degree per meter. Take G = 84 GPa.

9 Find the diameter of a solid shaft to transmit 30 kW at 230 rpm. The shear stress is 50 MPa. If a hollow shaft is to be used in place of solid shaft, find the inside and outside diameters when the ratio of inside to outside diameter is 6:8.

10

A line shaft is driven by means of a motor placed vertically below it. The pulley on the line shaft is 1.5 meter in diameter and has belt tensions 5.4 kN and 1.8 kN on the tight side and slack side of the belt respectively. Both these tensions may be assumed to be vertical. If the pulley be overhang from the shaft, the distance of the centre line of the pulley from the centre line of the bearing being 400 mm, find the diameter of the shaft. Assume maximum allowable shear stress of 42 MPa.

11

A 600 mm diameter pulley transmits 16 kW power at a speed of 400 rpm. Pulley is cantilever at a distance of 200 mm from the nearest bearing. The weight of the pulley is 1500 N. It is driven by a horizontal belt drive. The co-efficient of friction between belt and pulley is 0.3 and the angle of lap 180⁰. Take the fatigue and shock factors as Kb = 2.0 and Ks = 1.5. Determine the shaft diameter. The allowable shear stress in the shaft may be taken as 50 MPa.

12

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 weighs 200 N and is located at 300 mm from the centre 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 180 degree and coefficient of friction between the belt and the

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pulley is 0.3. The shock and fatigue factors for bending and twisting are 1.5 and 2.0 respectively. The allowable shear stress in the shaft may be taken as 35 MPa.

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ASSIGNMENT - 4

Keys and Couplings

Sr.

No. Name of Question

1 What are the basic functions of the key? Explain different types of keys with its

applications. Explain the purpose, requirements and types of shaft couplings.

2 Derive strength equations of sunk key based on shear and crushing (or compression)

failures.

3 Show that square key is equally strong in shearing and crushing compare to

rectangular key

4 What is splined shaft? State the applications of splined shaft. Explain the design of

splined shaft.

5 Differentiate between flexible coupling and rigid coupling.

6

Design a muff coupling which is used to connect two steel shafts transmitting 40 kW at

350 r.p.m. 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.

7

Design a clamp coupling to transmit 30 kW at 100 r.p.m. The allowable shear stress, for

the shaft and key, is 40 MPa and the number of bolts connecting the two halves are six.

The permissible tensile stress for the bolts is 70 MPa. The coefficient of friction

between the muff and the shaft surface may be taken as 0.3. Take width of key = Shaft

diameter/4 and thickness of key = Shaft diameter/6. Assume number of bolts = 4.

8

Design a cast iron split muff coupling to transmit a power of 10 kW at 250 rpm.

Consider an overload of 25%. The allowable shear stress in the shaft and key is 36 MPa

and for the muff 16 MPa. Take the co-efficient of friction 0.3 and the tensile strength of

the high tensile bolts 150 MPa.

9

Design a cast iron protective type flange coupling to transmit 15 kW at 900 r.p.m. from

an electric motor to a compressor. The service factor may be assumed as 1.35. The

following permissible stresses may be used :

Shear stress for shaft,

bolt and key material = 40 MPa

Crushing stress for bolt and key = 80 MPa

Shear stress of cast iron = 8 MPa

Standard shaft diameter: 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40 mm.

Take number of bolts are 3.

10

Design and draw a cast iron flange coupling for a mild steel shaft transmitting 90 kW at

250 r.p.m. The allowable shear stress in the shaft is 40 MPa and the angle of twist is not

to exceed 1° in a length of 20 diameters. The allowable shear stress in the coupling

bolts is 30 MPa. Take width of key = shaft diameter/4 and thickness of key = shaft

diameter/6. Assume no. of bolts = 4

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ASSIGNMENT - 5

Riveted Joints

Sr.

No. Name of Question Remarks

1

Define riveted joints. Classify and explain the different types of riveted joints with neat sketches.

2 Explain the following terms related to riveted joints: a) Pitch, b) Margin, c) Diagonal pitch and d) Transverse pitch.

3 Explain caulking & fullering in terms of riveted joint.

4 Discuss the different types of failures in riveted joint (or the various ways in which a riveted joint may fail).

5

Find the efficiency of the double riveted lap joints with zig-zag riveting is to be designed for 13 mm thick plates. Assume 80 MPa, 60 MPa and 120 MPa in tension, Shear and crushing respectively. Also calculate pitch of rivets.

6

A double riveted double cover butt joint in plates 20 mm thick is made with 25 mm diameter. Rivets at 100 mm pitch. The permissible stress are σt =120 N/mm2, Shear stress= 100 N/mm2, σc= 150 N/mm2. Find the Efficiency of joint, taking the strength of the rivets in double shear as twice than that of single shear.

7

A bracket is subjected to a load of 32 KN which is joined to a structure by means of 8 numbers of rivets as shown in Fig.4 Find the size of the rivets if the permissible shear stress is 80 MPa.

8

Find the value of P for joint shown in Fig.5, based on a working shear stress of 100MPa for rivets. Each of four rivets is of 20 mm diameter.

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ASSIGNMENT - 6

Welded Joints

Sr.

No. Name of Question Remarks

1 What do you understand by the term welded joint? Explain advantages and disadvantages of welded joints over riveted joints.

2 Classify and explain the types of welded joints with neat sketches and weld symbols.

3 Discuss the standard location of elements of a welding symbol.

4 Derive equations of strength for transverse and parallel fillet welded joints with neat sketches.

5 Deduce the design equation for circular fillet weld subjected to torsion.

6 What do you mean by eccentric loaded welded joint? Write the detail design procedure for designing such a joint.

7

A plate 60 mm wide and 80 mm thick. It is welded with another plate by means of single transverse and double parallel fillet welds. Find the length of each parallel fillet if allowable tensile and shear stresses in the weld material are 80 and 60 MPa respectively.

8

Two steel plates, 120 mm wide and 12.5 mm thick, are joined together by means of double transverse fillet welds. The maximum tensile stress for plates and welding materials should not exceed 110 N/mm2. Find required length of weld, if strength of weld is equal to strength of plates

9

A welded joint as shown in Fig.1, is subjected to an eccentric load of 2 KN. Find the size of weld, if the maximum shear stress in the weld is 25 N/mm².

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ASSIGNMENT - 7

Threaded Joints and Power Screws

Sr.

No. Name of Question Remarks

1 Explain the different types of screw threads used in power screw stating their applications.

2 Differentiate between power screw and threaded joint.

3 What do you understand by the single start and double start threads? Define following terms: (a) Major diameter, (b) Minor diameter, (c) Pitch and (d) Lead.

4 Derive an equation for torque required to raise (lift) load by square threaded screw.

5 Derive an equation for torque required to lower load by square threaded screw.

6

Derive an equation for efficiency of square threaded screw and maximum efficiency of a square threaded screw.

7

What is self-locking and over-hauling of power screw? What is significance of these properties? Show that the efficiency of self-locking screws is less than 50%.

8 Discuss on bolts of uniform strength giving examples of practical applications of such bolts.

9

Explain the purpose of a turn buckle (or Coupler) with neat sketch and describe its design procedure.

10

The mean diameter of the square threaded screw having pitch of 10 mm is 50 mm. A load of 20 KN is lifted through a distance of 170 mm. The external and internal diameters of the bearing surface of the loose head are 60 mm and 10 mm respectively. The coefficient of friction for the screw and the bearing surface may be taken as 0.08. Find the work done in lifting the load and the efficiency of the screw, when a) The load rotates with the screw, and b) The load rests on the loose head which does not rotate with the screw.

11

The lead screw of a lathe machine has single start trapezoidal threads of 52 mm nominal diameter and 8 mm pitch. The screw is required to exert an axial force of 2 kN in order to drive the tool carriage, during turning operation. The thrust is carried on a collar of 100 mm outer diameter and 60 mm inner diameter. The values of coefficient of friction at the screw threads and the collar are 0.15 and 0.12 respectively. The lead screw rotates at 30 rpm. Calculate: a) The power required to drive the lead screw, b) The efficiency of the screw.

12

A triple threaded power screw, used in a screw jack, has a nominal diameter of 50 mm and a pitch of 8 mm. The threads are square and the length of nut is 48 mm. The screw jack is used to lift a load of 7.5 KN. The coefficient of friction at the threads is 0.12 and collar friction is negligible. Calculate: (i) the principal shear stress in the screw body, (ii) the transverse shear stresses in the screw and the nut, (iii) the unit bearing pressure. State whether the screw is self-locking or not.

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ASSIGNMENT – 8

Limits, Tolerances and Fits

Sr.

No. Name of Question

1

Define and explain following terminology used in relation with the tolerances

with the help of neat sketch: (a) Limit (b) Basic size (c) Tolerance (d) Allowance

(e) Deviation (f) Clearance (g) Fit

2 Explain types of tolerances, types of deviations and types of clearances with neat

sketch and explain applications for it.

3 Explain types of fits with neat sketch and explain applications for it.

4 What is surface roughness? Explain the parameters (or characteristics) used for

surface roughness measurement with sketch.

5 Explain hole-based and shaft based limit system with neat sketch. Give

appropriate examples also

6

Give symbols for following various geometrical tolerances and explain meaning

of it: Straightness, Flatness, Circularity, Parallelism, Perpendicularity,

Cylindricity, Symmetry, Angularity and Concentricity

7 Explain maximum metal condition (MMC) and least metal condition (LMC)

8

In bush and pin assembly, pin of 30 mm diameter rotates in a bush. The

tolerance for pin is 0.025 mm while for bush is 0.04 mm. If allowance is 0.1 mm,

determine dimensions of pin and bush considering hole-basis system.

9

A journal of nominal diameter 79 mm rotates in a bearing. The upper and lower

deviations in hole diameter are respectively +0.05 mm and 0.00 mm, while

those for shaft are respectively -0.03 mm and -0.07 mm. Calculate: (i) Extreme

diameters for hole and shaft, (ii) Tolerances for hole and shaft and (iii)

maximum and minimum clearance.

10 Find the tolerances, maximum interference and type of fit for the data for the

following given data: Hole ϕ50+0.25 -0.10 and Shaft ϕ50+0.20 -0.20.

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MID QUESTION PAPER

Laxmi Institute of Technology , Sarigam Approved by AICTE, New Delhi; Affiliated to Gujarat Technological

University, Ahmedabad Academic Year 2018-19

Centre Code: 086 Examination : Mid - I

Branch: Mechanical Semester: IV Sub Code: 2141907

Sub: MDID Date:29-1-2019 Time: 09:00-10:00 A.M. Marks: 20

Q1

Attempt any Three

A. Define Toughness and Hardness? B. Define Torsion? C. Define Back Pitch and Diagonal Pitch. D. Draw mushroom head and counter shank head for general purpose

3

Q2 Explain the failures of Socket in Design of Spigot and Socket Cotter Joint with sketch of

Resisting Area? 3

Q3 Explain the failures of Cotter in Bending with neat sketch 3

Q4

Find the efficiency of Triple riveted Double strap Butt joint of 6 mm plates with 20 mm

diameter rivets having a pitch of 65 mm. Assume Permissible Tensile Stress in plate is

120 MPa, Permissible Shearing Stress is 90 MPa and Permissible Crushing Stress in

rivets is 180 MPa.

5

OR

Q4

A Double riveted Lap joint of 12 mm plates with 25 mm diameter rivets having a pitch of

50 mm. Assume Permissible Tensile Stress in plate is 120 MPa, Permissible Shearing

Stress is 100 MPa and Permissible Crushing Stress in rivets is 150 MPa. State how the

joint will fail and Find the efficiency of the joint

5

Q5 Which Theory is better, Tresca’s Theroy or St. Venant’s Theory? Why? Derive the

necessary equation and plot the equation for it. 6

OR

Q5 Explain and Derive the equation for Haigh’s Theory? Also derive and plot the equation in

I, II, III and IV Quadrant. 6

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