Two Marks

UNIT I
What are the various phases in design process?
a. Recognition of need b. Definition of problem
c. Synthesis d. Analysis and Optimization
e. Evaluation f. presentation
How the machine design may be classified?
a. Adaptive design b. Developed design
c. New design d. Rational design
e. Empirical design f. Industrial design
What are the types of loads that can act on machine components?
a. Steady load b. Variable load
c. Shock load d. Impact load
What are the factors affecting selection of material for machine element?
1. Load applied 2. Purpose and operating conditions of the part.
3. Suitability for manufacture. 4. Minimum weight and optimal size
5. Availability and cost.
What is optimum design?
In iterative nature of design, we can arrive at a design which provides the best possible
technical conditions like maximum on the best performance of the product with the least cost per
unit, consistent with weight, size, strength and similar considerations. Such a design is called
Optimum design.
Define factor of safety.
Factor of safety (FOS) is defined as the ratio between the ultimate stress and working stress.
Define principal stress. (Data book-pag: no:7.2)
The direct stresses acting along the principal planes (which have no shear stress) in a
strained material is known as principal stresses.
Define Endurance limit.
Endurance limit is the maximum value of completing reversed stress that can sustain an
infinite number (106) of cycles without failure.
State different theories of failures. (Data book-pag: no:7.3)
1. Maximum principal stress theory (or) Rankines theory
2. Maximum shear stress theory (or) Guest’s theory
3. Maximum principal strain theory (or) Saint Vanant theory
4. Maximum distribution energy theory
5. Maximum strain energy theory
State St.Vanent theory of failure.
According to this theory, failure occurs when the maximum strain developed in the machine
member is equal to maximum strain at yield point in a tension test.
What are the appropriate theories of failure for ductile and brittle materials?
For ductile materials – maximum distortion energy theory
For brittle materials – maximum principle stress theory
State maximum shear stress theory.
 According to maximum shear stress theory failure occurs when the maximum shear stress
developed in a machine member is equal to the maximum shear stress at yield point in a tension
test.
Explain reasons for using different theories of failures.
The problem of predicting the failure stresses for members subjected to bi axial or tri axial
stresses is much complicated. Hence we are using different theories of failure.
Define the term fatigue.
When the material is subjected to repeated stresses, it fails at stresses below the yield point
stresses, such type of failure is known as fatigue.
Define fit and tolerance?
Fit is the relation between the two matting parts in which one is inserted in to the other
with degree of tightness or looseness.
Tolerance is the maximum permissible value within which the part can vary.
Write down the factors influencing machine design?
 Cost
 Efficiency
 Strength
 Stiffness
 Wear Resistance
 Dimension
What are the main indications of complete weld symbol?
1. Reference line 2. Arrow
3. Basic weld symbol 4. Dimensions
5. Tail 6. Supplementary symbol
7. Finish symbol 8. Specification
9. Process
What are the main types of welding?
1. Forge welding 2. Fusion welding 3. Electric resistance welding
What are various types of welded joints?
1. Lap (or) fillet joint
a. Transverse fillet b. Parallel fillet c. Circular fillet
2. Butt joint
a. Square butt b. V butt c. U butt
3. Corner joint
4. Edge jont
5. T joint
What are the advantages of welding?
1. Welded joints are higher in weight and have higher efficiency
2. Welded joints are leak proof
3. Economical from the point of coat of material and labours.
4. The design can be easily and economically modified to meet the changing product
requirements.
5. Less time for production.
State the limitation of welding.
1. It has poor vibration damping characteristics.
2. Welding results distortion of parts which induces residual stresses.
What are stresses induced in eccentrically loaded welded joint?
1. Direct shear stress
2. Bending (or) torsional shear stress
Name the bolted joint under eccentric loading.
1. Parallel to the axis of the bolts.
2. Perpendicular to the axis of the bolts
3. Both parallel perpendicular to the axis.
Why are welded joints preferred over riveted joints?
Rivetted Joints Welded Joints
1. Metal plates are to be drilled 1. Drilling work is eliminated, plates
and joined by rivets. can be directly welded.
2. It may require covering plates 2. No covering plate is required.
What are the assumptions made in design of welded joint?
1. It is assumed that the tensile stress is distributed uniformly across the section of the butt
weld.
2. It is assumed that the shear stress in a parallel fillet weld is uniformly distributed along
the entire length of the weld.
3. Stress situation in a fillet weld is complicated because of bending action of the force.
Unit II
How screw threads are formed?
A screw thread is formed by cutting a continuous helical groove on a cylindrical surface.
List the advantages of screwed joints.
1. Highly reliable
2. convenient to assemble and disassemble
3. Relatively cheap to produce due to standardization and highly efficient manufacturing
processes.
Disadvantages of screw joints.
1. Stress concentration is available in threaded portions and hence lowering of their life.
2. Self-loosening properties and hence air tight joints cannot be maintained unless providing
some locking devices.
Define self-locking in power screws.
If the friction angle is greater that the helix angle of the power screw, the torque required
lowering the load will be positive, indicating that an effort is applied to lower the load. This
type of screw is known as self-locking screw. This efficiency of the self-locking screw is less
than 50%.
Define pitch diameter of a screw thread.
It is the diameter of an imaginary cylinder on which screw thread surface would pass
through the thread at such points make equal width of thread and equal width of spaces between
threads.
Define pitch and lead of a thread.
Axial distance from a point on one thread to corresponding point of next thread is called
pitch. Lead is the distance the screw moves in one turn.
What are the stresses acts on screw fastening?
1. Initial stresses due to screwing up
2. Stresses due to external forces
3. Combined stresses
Give some examples for temporary joints and permanent joints.
Permanent joints – Riveted joints, welded joints, bonded joints
Temporary joints – Threaded joints, cotter joints, knuckle joints
What are the various forms of screw threads?
1. British standard whitowrth (BSW) thread 2. British Association thread
3. Unified standard thread 4. American national standard thread
5. Square thread 6. ACME thread 7. Metric thread
A bolt of M24 x 2 mean that.
Nominal diameter of bolt is 24mm with pitch of 2mm.
What is the difference between a stud and a bolt?
Stud is a round bar threaded at both ends.
Bolt is a cylindrical bar with threads for nut at one end and heat at the other end.
Explain why soft material is used for nut in power screws.
Soft bearing material used for nut wears fast and only a nut of small size needs replacement.
It reduces the cost of replacement.
What do you mean by single start threads?
When a nut is turned on a bolt by one full turn which is having a single continuous thread
cut on it, it advances axially through a distance equal to pitch. Hence in a single continuous
thread (single start thread) the lead is equal to pitch.
List some locking devices
1. Lock nut 2. Castle nut 3. Sawn nut 4. Grooved nut
What are the initial stresses induced due to screwing up forces?
1. Tensile stress due to stretching of bolt.
2. Torsional shear stress caused by frictional resistance of threads during its tightening
3. Shear stress across threads
4. Compression or crushing stress on threads
By what materials threaded fasteners are made of?
Steel is the material of which most of the fasteners are made. For improving their properties
alloy steels like nickel steel, Ni-Cr steel, Cr-V steel are preferred.
State the relation between pitch and lead for a single start and double start threads.
L =np
Where L – Lead
n – Number of starts
p – Pitch
For single start thread, lead = Pitch
For double start thread, lead = 2  Pitch
Unit III
What is key?
Key is an element which is used to connect two machine parts for preventing relative
motion of rotation with respect to each other.
Name the types of keys.
1. Saddle key 2. Tangent key
3. Sunk key 4. Round key and taper pin
How sunk keys are provided?
 Sunk keys are provided half in the key way of the shaft and half in the key way of the hub or
boss of the pulley.
List various types of sunk keys.
1. Rectangular sunk key 2. Square sunk key
3. Parallel head key 4. Gib head key
5. Feather key 6. woodruff key
What is a keyway?
Keyway is a slot or recess in a shaft and hob of the pulley to accommodate a key.
What is gib head key? What is the advantages?
In a rectangular sunk key with a head at one end is known as gib head key.It is usually
provided to facilitate the removal of key.
What is woodruff key? State its application.
It is piece from a cylindrical disc having segmental cross section. A woodruff key is
capable of tilting in a recess milled out in the shaft by a cutter having the same curvature as the
disc from which the key is made. They are largely used in machine tool and automobile
construction.
What are advantages and disadvantages of a woodruff key?
1. It accommodates itself to any taper in the hub or boss of the mating piece.
2. It is useful on tapering shaft end. Its extra depth in the shaft prevents any tendency to
turn over in its keyway.
What are the two types of saddle keys?
1. Flat saddle key 2. hollow saddle key
List the various purposes of shaft couplings?
1. To provide for the connection of shafts of units that is manufactured separately and to
provide for disconnection for repairs or alternations.
2. To provide misalignment of the shafts or to introduce mechanical flexibility.
3. To introduce protection against overloads.
4. To reduce the transmission of shock loads from one shaft to another.
List out the requirements of a shaft coupling?
1. It should be easy to connect or disconnect.
2. It should transmit the full power of the shaft
3. It should hold the shafts in perfect alignment.
What is rigid coupling? What are its types?
It is used to connect two shafts which are perfectly aligned. The types are
1. Sleeve or muff coupling
2. Clamp or split muff or compression coupling
3. Flange coupling.
What is flexible coupling? What are its types?
Flexible coupling is a type of coupling used to connect two shafts having both lateral and
angular misalignment.
Types: a) Bushed pin type coupling
b) Universal coupling
c) Oldham’s coupling
What is a flange coupling?
It is a coupling having two separate cast iron flanges. Each flange is mounted on the shaft
end and keyed to it. The faces are turned up at right angle to the axis of the shaft. One of the
 flange has a projected portion and the other flange has a corresponding recess. This helps to
bring the shafts into line and maintain alignment.
What are various types of flange coupling?
1. Unprotected type flange coupling
2. Protected type flange coupling
3. Marine type flange coupling
What is the difference between rigid and flexible coupling?
Rigid coupling is used to connect two shafts which are perfectly aligned.
Flexible coupling is used to connect two shafts having both lateral and angular
misalignment.
List any two methods used for manufacturing of shafts.
1. Cold rolling
2. Hot rolling
3. Turning or grinding from rough bars.
What is the effect of keyway cut into the shaft?
The keyway cut into the shaft reduces the load carrying capacity of the shaft. This is due to
the stress concentration near the corners of the keyway and reduction in the cross sectional area
of the shaft.
What is the difference between coupling and a clutch?
A coupling is a device used to make permanent or semi permanent connection where as a
clutch permits rapid connection or disconnection at will of the operator.
What is the mode of failure of the bolts in a flange coupling?
Direct shear stress failure due to torque transmission.
How couplings are specified?
a) Diameter of shaft
b) Diameter of sleeve or muff
c) Length of sleeve or muff
d) Outer diameter of hub
e) Nominal diameter or bolt
f) PCD of bold circle.
What is clutch?
A clutch is a machine member used to connect a driving shaft to a driven shaft so that the
driven shaft may be started or stopped at will, without stopping the driving shaft.
What are the types of clutch?
Two types of clutches
 Positive clutches
o Jaw or claw clutch.
 Friction clutches
o Disc or plate clutch
o Cone clutch
o Centrifugal clutch.
What is brake?
A brake is a device by means of which artificial frictional resistance is applied to a moving
machine member, in order to retard or stop the motion of a machine.
What are the types of brake?
The brakes, according to the means used for transforming the energy by the braking element, are
classified as :
 Hydraulic brakes e.g. pumps or hydrodynamic brake and fluid agitator,
 Electric brakes e.g. generators and eddy current brakes, and
 Mechanical brakes.
What are self energizing brakes and self-locking brake?
The frictional force helps to apply the brake. Such type of brakes are said to be self energizing
brakes. When the frictional force is great enough to apply the brake with no external force, then the
brake is said to be self-locking brake

Unit IV
What is spring and where it is employed?
A spring is an elastic body, which absorb the greatest amount of energy for the given stress
without getting permanently distorted is known as best spring. It finds applications in many places
such as automobiles, railway wagons, brakes, clutches, watches and so on.
By what materials springs can made?
Springs are made of oil tempered carbon steel containing 0.6% to 0.7% carbon and 0.6% to
1% manganese. Phosper bronze, monel metal, beryllium, copper are used for special purpose.
What are functions of the spring?
 To measure forces in spring balance, meters and engine indicators.
 To store energy.
Name various types of springs.
Helical springs, Spiral springs, leaf springs and disc (or) Belleville spring.
What is Spring Index? (Data book Pag: No: 7.103)
It is the ratio of mean pitch diameter to the diameter of the wire. (C=D/d)
What are Active and Inactive coils?
The coils which are free to defect under load is called active coils and the coils which do not
take part in deflection of a spring is called inactive coils.
Define the term “Spring Rate” or stiffness (q)? (Data book Pag: No:7.100)
It is defined as the load required per unit deflection. It is also called as stiffness of the spring.
Define surging of springs
The spring material is subjected to higher stresses, which may cause early fatigue failure of
springs. This effect is called as surging of springs.
How will you find whether the given helical spring is a compression spring or tension spring?
The ends of compression springs are flat whereas for tension springs, hooks will be
provided at the ends.
What material is used for leaf spring?
Plain carbon steel having 0.9% to 1% carbon is annealed condition is normally used for leaf
springs chrome vanadium and silica manganese steels are used for the better grade springs.
What is nipping of laminated leaf spring?
Pre stressing of leaf springs is obtained by a difference of radii of curvature known as
nipping.
The initial gap can be adjusted so that under maximum load conditions the stress in all the
leaves will be same or, if desired the stress is the full length leaves may be less.
What are the end conditions of springs?
a. Plain en. b. Plain and ground end.
 c. Squared end. d. Squared and ground end.
What is buckling of springs?
The helical compression springs behaves like a column and buckler at a comparative small
load when the length of the spring is more than four times the mean coil diameter.
Why Wahl’s factor is to be considered in the design of helical compression spring?
When wire wound in the form of helix, compressive stress is induced in the inner side of
spring and tensile stress is induced in outer side of spring. Due to this stress concentration is
produced in outer side of spring. So Wahl’s factor is to be considered in the design of helical
compression spring. (Data book Pag: No: 7.100)
Define solid length of helical spring.
When compressions spring is compressed until the coils come in contact with each other,
then the spring is said to be solid and resulting length is called solid length.
Define free length of a helical spring?
It is the length of the spring in free or unloaded condition.
Define pitch of the spring coil.
Pitch of the coil is defined as the axial distance between adjacent coils uncompressed state.
What is torsion springs?
Torsion springs may be of helical or spiral type. The helical type may be used only in
applications where the load tends to wind up the spring and are used in various electrical
mechanisms. The spring type is also used where the load tends to increase the number of coils and
when made of flat strip are used in watches and clocks.
How the stiffness of a spring can be increased?
The stiffness of a spring can be increased by decreasing the number of turns.
Write the advantage of leaf spring over helical springs?
Leaf springs are made out of flat plates. The advantage of leaf spring over helical spring is
that the end of the spring may be guided along a definite path as it deflects to act as a structural
member in addition to energy absorbing device.
What is Cotter Joint? Application
 A cotter is a flat wedge shaped piece of rectangular cross-section and its width is tapered
from one end to another for an easy adjustment.
 A cotter joint is a temporary fastening and is used to connect rigidly two co-axial rods or
bars which are subjected to axial tensile or compressive forces.
 It is usually used in connecting a piston rod to the crosshead of a reciprocating steam
engine, a piston rod and its extension as a tail or pump rod, strap end of connecting rod etc.
What are the types of Cotter Joints?
Following are the three commonly used cotter joints to connect two rods by a cotter:
 Socket and spigot cotter joint,
 Sleeve and cotter joint, and
 Gib and cotter joint.
What is Knuckle Joint? Application.
 A knuckle joint is used to connect two rods which are under the action of tensile loads.
 A knuckle joint may be readily disconnected for adjustments or repairs.
 Its use may be found in the link of a cycle chain, tie rod joint for roof truss, valve rod joint
with eccentric rod, pump rod joint, tension link in bridge structure and lever and rod
connections of various types.
 UNIT-V (SHAFT)
Define shaft.
A shaft is a rotating machine element which is used to transmit power from one place to another.
Shaft is used for the transmission of torque and bending moment.
Differentiate between shaft and axle.
An axle, through similar in shape to the shaft, is a stationary machine element and is used for
transmission of bending moment only. It simply acts as a support for some rotating body.
What are the materials used for shafts.
For ordinary shafts – mild steel
For high strength shafts – alloy steel such as Nickel, Ni-Cr steels (or) Cr – V steels.
What are the types of shafts and their importance?
 Transmission shafts – These shafts transmit power between the source and the machines
absorbing power. These shafts carry machine parts such as pulleys, gears etc
 Machine shafts – these shafts form an integrated part of the machine itself. The crankshaft is an
example of machine shaft.
What are various types of stresses induced in the shafts?
 Shear stresses due to transmission of torque.
 Bending stresses.
 Stresses due to combined torsional and bending loads.
What are standard sizes of transmission shafts?
 25mm to 60mm with 5mm steps.
 60mm to 110mm with 10mm steps.
 110mm to 140mm with 15mm steps.
 140mm to 500mm with 20mm steps.
 Standard length – 5m, 6m and 7m.
On what basis the shafts are designed.
 Based on rigidity and stiffness
 Based on strength
 Based on critical speed.
Differentiate the hollow shaft and solid shaft.
The hollow shafts are used in marine work. These shafts are stronger per kg of material and they
may be forged on a mandrel, thus making the material more homogenous than a solid shaft.
What are the desirable properties for the materials for shafts and axles?
 Sufficient high strength
 A low sensitivity to stress concentration
 Ability to withstand heat and case hardening treatment.
 Good machinability
How the shafts are designed when it is subjected to twisting moment only?
When the shaft is subjected to torque only, then it is designed based on torsion equation.
Why rotating shaft are generally made with circular cross section?
Stress distribution pattern will be uniform throughout the circular cross section.
Define Torsional stiffness of shaft.
It is defined as the resisting strength of a shaft to torsional load. Mathematically it can be calculated
by the formula.
Define critical speed of a shaft.
 Rotating shaft tends to vibrate violently in transverse direction at certain speeds known as critical
(or) whirling speed.
State any two reasons for preferring hollow shaft over solid shaft.
 For some weight of shaft, hollow shaft can transmit 1.5 times the torque transmitted by solid
shaft.
 For a particular power transmission hollow shaft requires minimum weight.
State any two methods of solving problems involving combined steady or variable stresses.
a) Gerber method b) Goodman method c) Soderberg method
Define Goodman line. (Data book-pag: no: 7.4)
It is a straight line connecting the endurance limit and ultimate strength in variable stress diagram
and Goodman line is applicable for designing of brittle materials.
What are Gerber curve and Soderberg line? (Data book-pag: no: 7.4)
 Gerber curve is a parabola drawn between endurance limit and ultimate tensile strength.
 Soderberg line is a straight line connecting endurance limit and the yield strength in variable
stress diagram. Soderberg line applicable for designing of ductile materials.
What is stress concentration and stress concentration factor?
 The irregularity in stress distribution caused by abrupt changes of form is called stress
concentration.
 Stress concentration factor = maximum stress at the change of cross section / nominal stress.
What are different methods to reduce stress concentration?
 Providing Fillets
 Drilling Additional Holes
 Providing Additional Grooves.
 Drilling Additional Counter Sunk
What is notch sensitivity factor? (Data book-pag: no: 7.8)
 It may be defined as the degree to which the theoretical effect of stress concentration is actually
reached.