The C frame of 100kN capacity press is shown in fig.

the material of the frame is grey cast iron

FG 200 and the factor of safety is 3. Compute the dimensions of the frame.

A shaft as shown in figure is subjected to a bending load of 3kN, pure torque of 1000 N-m and
an axial pulling force of 15kN. Calculate the stress at A and B

1. A C-clamp is subjected to a maximum load of W, as shown in Fig.

If the maximum tensile stress in the clamp is limited to 140 MPa,
find the value of load W.

A mild steel bracket is shown in figure. It is subjected to a pull of 6000 N acting at 45º to the
horizontal axis. The bracket has a rectangular section whose depth is twice the thickness.
Compute the cross-sectional dimensions of the bracket if the permissible stress in the material is
60 MPa

An overhang crank with pin and shaft is shown in Fig. A tangential load of 15 kN acts on the
crank pin. Determine the maximum principal stress and
the maximum shear stress at the centre of the crankshaft
bearing.

A solid circular shaft of diameter 45 mm is loaded by bending moment 650 Nm, torque 900
Nm and an axial tensile force of 30 kN. The shaft material is ductile with yield strength of 280
MPa. Compute the factor of safety according to Maximum principle stress, Tresca and Von
misses theories of failure.
A bolt is subjected to a direct load of 25 KN and a shear load of 15 KN. Considering the various
theories of failure, Compute the suitable size of the bolt, if the material of the bolt is C15 having
200 N/mm2 yield strength.
A cylindrical shaft made of steel of yield strength 700 MPa is subjected to static loads consisting
of bending moment 10 kN-m and a torsional moment 30 kN-m. Determine the diameter of the
shaft using two different theories of failure, and assuming a factor of safety of 2. Take E = 210
GPa and poisson's ratio = 0.25.

A pulley is keyed to a shaft midway between two bearings. The shaft is made of cold drawn steel
for which the ultimate strength is 550 MPa and the yield strength is 400 MPa. The bending
moment at the pulley varies from – 150 N-m to + 400 N-m as the torque on the shaft varies from
– 50 N-m to + 150 N-m. Compute the diameter of the shaft for an indefinite life. The stress
concentration factors for the keyway at the pulley in bending and in torsion are 1.6 and 1.3
respectively. Take the following values:
Factor of safety = 1.5
Load correction factors = 1.0 in bending, and 0.6 in torsion
Size effect factor = 0.85
Surface effect factor = 0.88
Notch sensitivity = 0.9
A steel cantilever is 200 mm long. It 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 80
N up to120 N down. The cantilever is of circular cross section. It is of diameter 2d for the first
50 mm and of diameter d for the remaining length. Compute its diameter taking a factor of safety
2 Assume the following values:
Yield stress = 330 MPa
Endurance limit in reversed loading = 300 MPa
Correction factors = 0.7 in reversed axial loading
= 1.0 in reversed bending
Stress concentration factor = 1.44 for bending
= 1.64 for axial loading
Size effect factor = 0.85
Surface effect factor = 0.90
Notch sensitivity index = 0.90

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 the left-hand bearing and this drives a pulley directly below it with the help of
a belt having a maximum tension of 2.25 KN. Another pulley of 400 mm diameter is placed 200 mm to
the left of the right-hand bearing and is driven with the help of an electric motor and belt, which is placed
horizontally to the right. The angle of contact for both pulley is 180º and µ= 0.24. Compute the suitable
diameter for solid shaft; assume the working stress of 63 MPa in tension and 42 MPain shear. Assume
that the torque on one pulley is equal to the other pulley.

A steel solid shaft transmitting 15 KW at 200 rpm is supported on two bearings 750 mm apart. The pinion
having 30 teeth of 5 mm module is located 100 mm 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 the vertical direction. Take τ = 54 MPa. Design the
diameter of the shaft.

A transmission shaft is supported on two bearings 450mm apart. Two pulley C and D are located on the
shaft at distance of 100mm and 300mm respectively to the right of the left hand bearing. Power is
transmitted from pulley C to D. The diameter and weight of pulley C are 200mm and 600N and those of
pulley D are 300mm and 750N respectively. Ratio of belt tension is 2 for both pulleys. Power to be
transmitted by the shaft is 25Kw at 300rpm. The drive from C is vertically downward while from D the
drive is to the horizontal. The shaft is made of C45 steel. Using Kb=1.5 and Kt=1.2, Design the shaft. (
Practice Problem)

Compute the design parameters of a shaft to transmit power from an electric motor to a lathe headstock
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°, μ = 0.3. Kt = 1.5 and Kb = 2. The allowable shear stress
in the shaft may be taken as 35 MPa. The pulley is mounted over hung on the shaft.

A section of commercial shafting 2 m long between bearings carries a 1000 N pulley at its
mid-point, as shown in fig. The pulley is keyed to the shaft and receives 30 kW at 150 rev/min
which is transmitted to a flexible coupling just outside the right bearing. The belt drive is
horizontal and some of the belt tensions is 8000 N. Assume Kt = Kb = 1.5. Compute the
necessary shaft diameter and compute the angle of twist between bearings G = 80 GN/m2.

Find the design parameters of a muff coupling to connect two shafts transmitting 30 kW at 100
rpm. The permissible shear and crushing stress for the shaft and key material are 40 MPa and 90
MPa respectively. The material of the muff is cast iron with permissible shear stress of 5 MPa.
Assume that the maximum torque transmitted is 20 % greater than the mean torque. Take width
and depth of the parallel key is 20 mm and 10 mm respectively.
Compute the design parameters of a muff coupling to connect two shafts transmitting 40 kW at
150 rpm. The permissible shear and crushing stress for the shaft and key material are 37 MPa
and 96.25 MPa respectively. The material of the muff is cast iron with permissible shear stress
of 1.75 MPa. Assume that the maximum torque transmitted is 20 % greater than the mean torque.
Take width and depth of the parallel key is 22 mm and 14 mm respectively.
Compute the design parameters of 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.
Compute the design parameters of a cast iron protective 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: (i) Shear stress for the bolt and key material
= 40MPa (ii) Crushing stress for the bolt and key = 80 MPa; (iii) Shear stress for cast
iron = 8 MPa.
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.
Design a journal bearing for a centrifugal pump from the following data : Load on the journal =
20 000 N; Speed of the journal = 900 r.p.m.; Type of oil is SAE 10, for which the absolute
viscosity at 55°C = 0.017 kg / m-s; Ambient temperature of oil = 15.5°C ; Maximum bearing
pressure for the pump = 1.5 N / mm2. Calculate also mass of the lubricating oil required for
artificial cooling, if rise of temperature of oil be limited to 10°C. Heat dissipation coefficient =
1232 W/m2/°C.

The load on the journal bearing is 150 kN due to turbine shaft of 300 mm diameter running at
1800 r.p.m. Determine the following :
1. Length of the bearing if the allowable bearing pressure is 1.6 N/mm2, and
2. Amount of heat to be removed by the lubricant per minute if the bearing temperature is 60°C
and viscosity of the oil at 60°C is 0.02 kg/m-s and the bearing clearance is 0.25 mm.

A full journal bearing of 50 mm diameter and 100 mm long has a bearing pressure of 1.4 N/mm2.
The speed of the journal is 900 r.p.m. and the ratio of journal diameter to the diametral clearance
is 1000. The bearing is lubricated with oil whose absolute viscosity at the operating temperature
of 75°C may be taken as 0.011 kg/m-s. The room temperature is 35°C. Find : 1. The amount of
artificial cooling required, and 2. The mass of the lubricating oil required, if the difference
between the outlet and inlet temperature of the oil is 10°C. Take specific heat of the oil as 1850
J / kg / °C.

The load on a 100 mm full hydrodynamic journal bearing is 9000 N. Speed of the journal is 320
rpm. Let l/d = 1, C/d = .0011. The operating temp. is 65 °C and minimum oil film thickness is
0.022 m. Find (i) Select an oil (ii) Frictional loss (iii) Oil flow (iv) Amount of leakage (v)
Temperature rise of oil (vi) Max. oil pressure.
Compute the design parameters of 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.
Select a suitable deep groove ball bearing for supporting a radial load of 10 KN and an axial
load of 3KN for a life of 4000hurs at 800rpm. Select from series 63. Compute the expected life
of the selected bearing.
A ball bearing is subjected to a radial load of 10KN and a thrust load of 5KN. The inner ring
rotates at 1000rpm. The average life is to be 5000hours. Compute the design parameters and the
basic load rating to select a bearing for this purpose. Take Fa/ Co= 0.5 and assume service factor
1.5.
The Radial load on a roller bearing varies as follows. A load of 50KN is acting 20% of time at
500rpm and a load of 40KN is acting 50% of time at 600rpm. In the remaining time, the load is
varying from 40KN to 10KN linearly at 700rpm. Compute the design parameters of a roller
bearing from N22 series for a life of at least 4000hrs. The operating temperature is 175C.
For 6307 ball bearing, the load varies as follows:

RADIAL AXIAL CYCLETIME SPEED

S.NO LOAD (N) LOAD (N) RATIO (Rpm)
1 6300 3000 0.5 400
2 7500 - 0.3 650
3 4000 1000 0.2 900
The inner ring rotates, loads are steady, what is the expected average life of the bearing
A ball bearing is to be used for a shaft whose speed is 400 rpm. The radial load on the bearing
is 4000 N and the axial load is also 4000N. The bearing is to have a life 10000 hours at a
reliability of 95%. Compute the dynamic capacity of the bearing. Take b = 1.34. Also assume
Fa / Co = 0.5.
Compute the design parameters of a helical tension spring for a spring-loaded safety valve for
the following conditions. (i) Diameter of valve seat = 65 mm. (ii) Operating pressure = 0.7
N/mm2; (iii) Maximum pressure = 0.75 N/mm2. (iv) Maximum lift of the valve when the pressure
ranges from 0.7 to 0.75 N/mm2 is 3.5 mm.  = 550 MPa, G = 84 KN/mm2, C = 6.
Compute the design parameters of a valve spring of a petrol engine for the following operating
conditions: Spring load when the valve is open = 400 N; Spring load when the valve is closed =
250 N; Maximum inside diameter of the spring = 25 mm; Length of the spring when the valve
is open = 40 mm; Length of the spring when the valve is closed = 50 mm; Maximum permissible
shear stress = 400 MPa.
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/mm2.
Draw a fully dimensioned sketch of the spring, showing details of the finish of the end coils.
A rail wagon of mass 20 tonnes is moving with a velocity of 2 m/s. It is brought to rest by two
buffers with springs of 300 mm diameter. The maximum deflection of springs is 250 mm. The
allowable shear stress in the spring material is 600 MPa. Design the spring for the buffers.
Design and draw a valve spring of a petrol engine for the following operating conditions:
Spring load when the valve is open = 400 N
Spring load when the valve is closed = 250 N
Maximum inside diameter of spring = 25 mm
Length of the spring when the valve is open = 40 mm
Length of the spring when the valve is closed = 50 mm
Maximum permissible shear stress = 400 MPa
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.

The areas of the turning moment diagram for one revolution of a multi-cylinder engine with
reference to the mean turning moment, below and above the line, are – 32, + 408, – 267, + 333,
– 310, + 226, – 374, + 260 and – 244 mm2. The scale for abscissa and ordinate are: 1 mm =
2.4° and 1 mm = 650 N-m respectively. The mean speed is 300 r.p.m. with a percentage speed
fluctuation of ± 1.5%. If the hoop stress in the material of the rim is not to exceed 5.6 MPa,
determine the suitable diameter and cross-section for the flywheel, assuming that the width is
equal to 4 times the thickness. The density of the material may be taken as 7200 kg / m3.
Neglect the effect of the boss and arms.
The areas of the turning moment diagram for one revolution of a multi-cylinder engine with
reference to the mean turning moment, below and above the line, are 120, + 400, – 220, + 300,
– 300, + 200, – 300, + 200 and – 200 mm2. The scale for abscissa and ordinate are: 1 mm =
2.4° and 1 mm = 650 N-m respectively. The mean speed is 300 r.p.m. with a percentage speed
fluctuation of ± 1.2%. If the hoop stress in the material of the rim is not to exceed 6 MPa,
determine the suitable diameter and cross-section for the flywheel, assuming that the width is
equal to 4 times the thickness. The density of the material may be taken as 7000 kg / m3.
Neglect the effect of the boss and arms.

Compute design parameters of a cast iron flywheel used for a four stroke I.C engine
developing 180kW at 240rpm. The hoop or centrifugal stress developed in the flywheel is
5.2MPa, 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 the cast iron is
7220kg/m3
The turning moment diagram for a petrol engine is drawn to the following scales: Turning
moment, 1 mm = 5 N-m; Crank angle, 1 mm = 1º. The turning moment diagram repeats itself at
every half revolution of the engine and the areas above and below the mean turning moment
line, taken in order are 295, 685, 40, 340, 960, 270 mm2. Determine the mass of 300 mm
diameter flywheel rim when the coefficient of fluctuation of speed is 0.3% and the engine runs
at 1800 r.p.m. Also determine the cross-section of the rim when the width of the rim is twice of
thickness. Assume density of rim material as 7250 kg / m3.

Compute the design parameters of a Sleeve and Cotter joint to support a load varying from 30
kN in compression to 30 kN in tension. The material used in carbon steel for which the following
allowable stresses may be used. The load is applied statically
Tensile stress = 50 MPa
Compressive stress = 80 MPa,
Shear stress = 50 MPa
Crushing stress = 90 MPa
Compute the design parameters of a knuckle joint for a tie rod of circular section for a maximum
pull of 70 kN. The ultimate strength of material against tearing is 420 N/mm 2. The shearing
strength of material is 396 N/mm2. Take F.O.S = 6.
Compute the design parameters of a Socket and Spigot Cotter joint to support a load varying
from 20 kN in compression to 50 kN in tension. The material used in carbon steel for which the
following allowable stresses may be used. The load is applied statically.
Shear Stress = 35 MPa
Tensile stress = 45 MPa
Compressive stress = 50 MPa
Compute the design parameters of a Sleeve and Cotter joint to support a load varying from 50
kN in compression to 50 kN in tension. The material used in carbon steel for which the following
allowable stresses may be used. The load is applied statically
Shear Stress = 35 MPa
Tensile stress = 50 MPa
Compressive stress = 75 MPa

Compute the design parameters of a knuckle joint for a tie rod of circular section for a
maximum pull of 50 kN. The ultimate strength of material against tearing is 480 N/mm2. The
shearing strength of material is 350N/mm2. Take F.O.S = 4.
The Figure below shows a cylindrical rod of 50mm diameter, welded to a flat plate. The
cylindrical fillet weld is loaded eccentrically by a force of 10 kN acting at 200 mm from the
welded end. If the size of the weld is 20 mm, Compute the maximum normal stress in the weld.
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.

A bracket carrying a load of 15 kN is to be welded as shown in Fig. Find the size of weld
required if the allowable shear stress is not to exceed 80 MPa.

A welded connection, as shown in figure is subjected to eccentric force of 60kN in the plane of
welds. Compute the size of the welds, if the permissible shear stress for the weld is 100
N/mm2. Assume static conditions.

A welded joint as shown in Fig. 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.
Two lengths of mild steel tie rod having width 200 mm and thickness 12.5 mm are to be
connected by means of a butt joint with double cover plates. Design the joint if the permissible
stresses are 80 MPa in tension, 65 MPa in shear and 160 MPa in crushing. Make a sketch of the
joint.
Design a lap joint for a mild steel flat tie-bar 200 mm × 10 mm thick, using 24 mm diameter
rivets. Assume allowable stresses in tension and compression of the plate material as 112 MPa
and 200 MPa respectively and shear stress of the rivets as 84 MPa. Show the disposition of the
rivets for maximum joint efficiency and determine the joint efficiency. Take diameter of rivet
hole as 25.5 mm for a 24 mm diameter rivet.

A rectangular steel plate is welded as a cantilever to a vertical column and supports a single
concentrated load P, as shown in figure. Compute the weld size if shear stress in the same is not
to exceed 140 MPa.

A rectangular beam is to be welded to a plate. The maximum load of 14 kN is applied

repetitiously. Determine the size of weld required for 10,000,000 cycle. Assume the shear load
is distributed uniformly over the entire weld as shown in figure below.

A connecting rod is required to design for a high speed, four stroke I.C engine. The following
data are available.
Diameter of the piston = 88 mm
Mass of the reciprocating parts = 1.6 kg
Length of the connecting rod center – center = 300 mm
Stroke = 125 mm
Rpm (when developing 50kW) = 2200
Possible over speed = 3000 rpm
Compression ratio = 6.8:1
 Probable maximum explosion pressure (assumed shortly after centre, at about 3˚) = 3.5 N/mm2.
Draw fully dimensional drawings on the connecting rod showing the provision for the
lubrications.
Design a C I flywheel for a four stroke engine developing 150 KW at 200 rpm. Calculate the
mean diameter of the flywheel if the hoop stress is not to exceed 4 MPa. The total fluctuation of
speed is to be 4% of mean speed. The work done during the power stroke is 1.5 times the average
work done during the cycle. The density of CI is 7200 kg/m3
A single cylinder double acting steam engine delivers 185 KW at 100 rpm. The maximum
fluctuation of energy per revolution is 15% of energy developed per revolution. The speed
variation is limited to 1% either way from the mean. The mean diameter of the rim is 2.4 m.
Design a cast iron flywheel for the engine.
A multi cylinder engine is to run at a constant load with a speed of 600 rpm. On drawing the
crank effort diagram to a scale of 1 cm = 2500 N-m and 1cm = 300, the area above and below
the mean torque line in sq. cm are as follows.
+1.6, -1.72, +1.68, -1.91, +1.97, - 1.62.
The speed is to be kept within 1 % of the mean speed of the engine. Compute the suitable
dimensions of a cast-iron flywheel rim assuming suitable proportions.
A semi - elliptic spring has an overall length of 1.1m and sustains a load of 70 KN at its center.
The spring has 3 extra full-length leaves and 13 graduated leaves with a central band of 100mm
wide. All the leaves are to be stressed equally without exceeding 420 N/mm2 when fully loaded.
The total depth of spring is twice the width. If the Young’s modulus is 2.1 x 105N/mm2, determine
the
(i) Thickness and width of leaves
(ii) Nip to be provided for prestressing.
(iii) Load exerted on the clipping bolts after the spring is assembled.
A truck spring has 12 numbers of leaves, two of which are full lengthy leaves. The spring
supports are 1.05 m apart and the central band is 85 mm wide. The central load is to be 5.4 kN
with a permissible stress of 280 MPa. Determine the thickness and width of the steel spring
leaves. The ratio of the total depth to the width of the spring is 3. Also determine the deflection
of the spring.