191MEC601T – Design of Machine Elements and Transmission Systems

Assignment- 2

1. A mild steel link, as shown in Fig by full lines, transmits a pull of 80 kN. Find the dimensions b and t if b = 3t.
Assume the permissible tensile stress as 70 MPa. If the original link is replaced by an unsymmetrical one, as
shown by dotted lines in Fig., having the same thickness t, find the depth b, using the same permissible stress
as before.

2. Fig shows a solid forged bracket to carry a vertical load of 13.5 kN applied through the centre of hole. The
square flange is secured to the flat side of a vertical stanchion through four bolts. Calculate suitable diameter D
and d for the arms of the bracket, if the permissible stresses are 110 MPa in tension and 65 MPa in shear.
Estimate also the tensile load on each top bolt and the maximum shearing force on each bolt.

3. 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.

4. Find the diameter of a solid steel shaft to transmit 20 kW at 200 r.p.m. The ultimate shear stress for the steel
may be taken as 360 MPa and a factor of safety as 8. If a hollow shaft is to be used in place of the solid shaft,
find the inside and outside diameter when the ratio of inside to outside diameters is 0.5.
5. A hollow shaft is required to transmit 600 kW at 110 r.p.m., the maximum torque being 20% greater than the
mean. The shear stress is not to exceed 63 MPa and twist in a length of 3 metres not to exceed 1.4 degrees.
Find the external diameter of the shaft, if the internal diameter to the external diameter is 3/8. Take modulus of
rigidity as 84 GPa.
6. 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 / mm 2. 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.

7. Design a helical spring for a spring loaded safety valve (Ramsbottom safety valve) for the following
conditions: Diameter of valve seat = 65 mm ; Operating pressure = 0.7 N/mm 2; Maximum pressure when the
valve blows off freely = 0.75 N/mm2; Maximum lift of the valve when the pressure rises from 0.7 to 0.75
N/mm2 = 3.5 mm ; 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.

8. A suspension system in an industrial machine requires a closely coiled helical spring to absorb vibrations and
maintain stability under load. The spring is manufactured from a 10 mm diameter steel wire and consists of 10
complete turns with a mean coil diameter of 120 mm. When subjected to an axial load of 200 N, it is crucial to
determine the spring's performance parameters to ensure reliable operation. Calculate, (i) The deflection of the
spring under the applied load (ii) The stiffness of the spring, ensuring it provides adequate resistance (iii) The
strain energy stored in the spring, which contributes to energy absorption. Take the material has a modulus of
rigidity (G) of 80 kN/mm².
9. A bracket as shown in fig. 3 is fitted a wall with 5 bolts, three at the top side and two at the bottom with a wall
the bolts are equally spaced. A load of 20000 N is acting at an eccentrically of 200 mm vertical distances of
first and second rows from the hinge point are 50 mm and 250 mm respectively. Select the suitable bolt size
for this application.

10. An eccentrically loaded lap riveted joint is to be designed for a steel bracket as shown in Fig. 4. The bracket
plate is 25 mm thick. All rivets are to be of the same size. Load on the bracket, P = 50 kN ; rivet spacing, C =
100 mm; load arm, e = 400 mm. Permissible shear stress is 65 MPa and crushing stress is 120 MPa. Determine
the size of the rivets to be used for the joint.

11. Select a flat belt to drive a mill at 250 rpm from a 10 kW, 730 rpm motor. Centre distance is to be around 2 m.
The mill shaft pulley is of 1m diameter.
12. Design a V-Belt drive to transmit 50 kW at 1440 rpm from an electric motor to a textile machine running 24
hours a day. The speed of the machine shaft is 480 rpm.

13. In a spur gear drive for a stone crusher the gears are made of C40 steel. The pinion is transmitting 30 kW at
1200 rpm. The gear ration is 3 and the gear is work 8 hours per day, six days in week for 3 years. Design a gear
drive.

14. Design a bevel gear drive to transmit 7kW at 1600 rpm for the following data: Gear ratio=3, Material for
pinion and gear=C45 steel, Life=10000 hours.

15. A nine speed gear box used as a headstock gear box of a turret lathe is to provide a speed range of 180 rpm to
1800 rpm. Using standard step ratio, draw the speed diagram, and the kinematic layout. Also find and fix the
number of teeth on all gears.

16. Design the layout of a 12 speed gearbox for a lathe. The minimum and maximum speeds are 25 and 600 rpm.
Power is 2.25 kW from 1440 rpm induction motor. Construct the speed diagram using a standard speed ratio.
Calculate the number of teeth in each gear wheel and sketch the arrangement of the gearbox.

17. Design a multi-plate clutch for an industrial machine that transmits 55 kW of power at 1800 rpm, ensuring
smooth and efficient torque transfer in high-performance applications such as automotive transmissions or
heavy-duty machinery. The friction surface has a coefficient of 0.1, and the axial pressure intensity must not
exceed 160 kN/m² to prevent excessive wear and overheating. The clutch plates have an internal radius of 80
mm, with the external radius being 1.43 times the internal radius. Determine the required number of plates to
ensure reliable power transmission while maintaining durability and operational efficiency.

18. Design a chain drive to actuate a compressor from a 10 kW electric motor at 960 rpm. The compressor speed is
to be 350 rpm. Minimum centre distance should be 500 mm. Motor is mounted on an auxiliary bed.
Compressor is to work for 8 hours/day