ME 603: Machine Design, Machine Workshop and Practice

Materials Engineering:
1. Which of the following is the structural class of steel?
a. High speed steel b. Tool and die c. Low carbon d. High carbon
2. Ability to resist deformation under stress:
a. Plasticity b. All of these c. Stiffness d. Toughness
3. The changes in shape or geometry of the body due to action of a force on it is called
deformation or _____.
a. Shear stresses b. Stresses c. Compressive stress d. Strain
4. The ratio of the moment of inertia of the cross section of the beam to the section modulus
a. Equal to the radius of gyration c. Measure of a distance
b. Equal to the area of the cross section d. Dependent on the modulus of elasticity of
beam measured
5. Stresses that are independent of loads:
a. Working stress b. Operating stress c. Residual stress d. Shear stress
6. The following pertain to joining of metals except:
a. Welding b. Soldering c. Casting d. Brazing
7. Killed steel is always associated with:
a. Silicon b. Manganese c. Phosphorous d. Sulphur
8. The usual ratio of water to soluble oil used as cutting fluid:
a. 50% water to 50% oil b. 2 water to 1 oil c. 3 water to 1 oil d. 4 to 80 water to
1 oil
9. The good deoxidizer in steel melting:
a. Manganese b. Silicon c. All of these d. Aluminum
10. Good stabilizer in stainless steel:
a. Columbium b. Titanium c. All of these d. Tantalium
11. What is/are the common cutting fluids used for cutting
metals?
a. All of these b. Water with soda or borax c. Light mineral oil d. Soluble
oil
12. Metals are conducive because:
a. The electrons are loosely bound to the nuclei and therefore mobile
b. Having a characteristics metallic cluster
c. They are on the left side of the periodic table.
d. They have extra electrons as exhibited by normally
possible balance state.
13. The yield strength of a regular yellow brass (65 to 70% Cu, 30 to 35% Zn) can be
increased/improved by:
a. Cold working b. Tempering c. Chill casting d. Heat treatment
14. Used in as cast condition steel casting with carbon content less than __________ % C.
a. 0.26 b. 0.15 to 0.18 c. 0.20 d. 0.25
15. Liners normally are made of:
a. Cast iron b. Alloyed bronze c. Alloyed steel d. Alloyed
aluminum
16. Endurance strength is nearly proportional to the ultimate
strength but not with ________.
a. Yield strength b. Design stress c. Shear stress d. All of the above

17. A furnace used in melting non-ferrous metals:

 ME 603: Machine Design, Machine Workshop and Practice

a. Cupola furnace b. Crucible furnace c. Induction furnace d. Normalizing

furnace
18. Alloy that improves strength of steel at high temperature application:
a. Tungsten b. Molybdenum c. All of these d. Chromium
19. The best instrument for measuring a thousand of an inch:
a. Micrometer b. Tachometer c. Calliper d. Pyrometer
20. All are associated with standard material specification, EXCEPT:
a. American Iron and Steel Institute c. Southeast Asia Iron and Steel Institute
b. Society of Automotive Engineers d. American Society for Testing Materials
21. Separate forces which can be so combined are called:
a. Non-concurrent forces b. Couple c. Combined forces d. Concurrent
forces*
22. That property of matter which causes it to resist any change in its motion or state of rest:
a. Brake b. Friction c. Inertia* d. Impulse
23. Negative allowance is also called:
a. Interference of metal b. Clearance c. Advance d. Allowance of positive fit*
24. If the velocity of a mass is the same all the time during which motion takes place is called:
a. Deceleration b. Uniform motion* c. Acceleration d. None of these
25. When two elastic bodies collide, which of the following laws can be used to solve for the
resulting velocity?
a. Dalton’s law c. Conservation of energy
b. Avogadro d. Conservation of momentum and conservation of energy*
26. The ability of a metal to be deformed considerably without rupture is called:
a. Plasticity* b. All of these c. Ductility d. Malleability
27. A system of forces in space is in equilibrium. If two equal and opposite collinear forces are
added, which of the following if any is true?
a. Equilibrium is destroyed c. None of these is true
b. Equilibrium is maintained* d. An unbalance of moment exit
28. Metal that assists lubrication or lubricant itself:
a. Zinc b. Antimony c. Babbitt* d. Lead
29. The smallest area at the point of rupture of a tensile specimen divided by the original area is
called:
a. Percentage elongation b. Isod test c. Charpy test d. Percentage reduction of
area*
30. The product of the resultant of all forces acting on a body and the time that the resultant
acts:
a. Angular impulse b. Angular momentum c. Linear impulse* d. Linear
momentum
Machine Design
31. An eyebolt is lifting a block weighing 350 lbs. The eyebolt is of SAE C1040 material with S U
=67 ksi and Sy = 55 ksi, what is the stress area (in inches square) of the bolt if it is under the
unified coarse series thread?
a. 0.1341 b. 0.1134 c. 0.0991 d. 0.1043
32. Compute the working strength of 1 in. bolt which is screwed up tightly in packed joint when
the allowable working stress is 13,000 psi.
a. 3,600 lbs b.3,950 lbs c. 3,900 lbs d. 3,800 lbs
33. If the pitch of a screw is 2/9, find the thread per inch.
a. 0.34 b. 4.5 c. 5.4 d. 17
 ME 603: Machine Design, Machine Workshop and Practice

34. A 2” single thread, square screw has a TPI of 2 and coefficient of friction of 0.2. What is the
efficiency?
a. 31% b. 44% c. 35% d. 55%
35. Determine the number of ½ in. diameter set-screw needed to transmit a 4 Hp at a shaft
speed of 1000 rpm and the shaft diameter of 1 in.
a. 1 b. 2 c. 3 d. 4

36. Find the working pressure required to punch 4” diameter hole on ¼” thick steel plate.
a. 60 Tons b. 70 Tons c. 75 Tons d. 80 Tons
37. Find the horsepower required to drive a power screw lifting a load of 4000 lbs. A 2 ½”
double square thread with two threads per inch is to be used. The frictional radius of the
collar is 2 inches and the coefficient of friction are 0.1 for the threads and 0.15 for the collar.
The velocity of the nut is 10 ft/min.
a. 4.395 Hp b. 3.459 Hp c. 4.953 Hp d. 5.935 Hp
38. A three extension coil springs are hooked in series that support a single weight of 100 kgs.
The first spring is rated at 0.4 kg/mm and the other 2 lower is rated at 0.64kg/mm. Compute
the total deflection.
a. 563 mm b. 268 mm c. 156 mm d. 250 mm
39. Compute the maximum deflection of an 18 coils helical spring having a load of 100 kgs. The
modulus of elasticity in shear of springs is 98.62 GPa, OD of 9.256 cm and wire diameter of
9.525 mm. The spring is squared and ground ends.
a. 9 mm b. 90 mm c. 11 mm d. 14 mm
40. A coiled spring with 5 cm of outside diameter is required to work under the load of 190 N.
The wire diameter is 5mm, the spring is to have 6 active coils and the ends are to be closed
and ground. Determine the total number of coils. The modulus of rigidity is 80 GPa and the
mean radius is to be 23 mm, with 7 mm pitch of the spring.
a. 6 b. 7 c. 8 d. 9
41. A cantilever spring is composed of six graduated leaves each 60 mm wide and 12 mm thick.
Find the maximum induced stress if loaded with 8000N at the tip. Length of spring is 700
mm. Use E = 200 GPa.
a. 648.14 MPa b. 684.41 MPa c. 641.14 MPa d. 468.41 MPa
42. A pulley 610 mm in diameter transmits 40 kW at 500 rpm. The arc of contact between the
belt and pulley is 144 degrees, the coefficient of friction between the belt and pulley is 0.35
and the safe working stress of the belt is 2.1 MPa. Find the width of the belt used if its
thickness is 6 mm.
a. 250 mm b. 300 mm c. 340 mm d. 430 mm
43. An industrial fan running at 600 rpm is driven by a 25 kW, 960 rpm, induction motor. The
pulley mounted on the motor shaft is 270 mm. Center to center distance is 1.45 m and use
f=0.35. Determine the minimum angle of wrap and the length of the belt.
a. 3.0298 rad, 4006.7 mm c. 4.0201 rad, 5000 mm
b. 3.0289 rad, 4007.6 mm d. 4.0989 rad, 5010 mm
44. Steel pulleys, 120 mm and 530 mm in diameter are to transmit 2.5 kW at 1100 rpm of the
smaller pulley, through a single-ply oak-tanned leather belt. Use f=0.35 for oak-tanned
leather, allowable stress of 2.8 MPa, distance between shafts is 3000 mm and belt thickness
of 3.215 mm. Determine the ratio of net tension.
a. 2.85 b. 5.82 c. 8.52 d. 2.58
45. Determine the bending stress of wire rope with drum diameter of 7.8 inches and wire
diameter of 0.0987 inch.
 ME 603: Machine Design, Machine Workshop and Practice

a. 37.96 x 104 psi b. 33.96 x 104 psi c. 31.96 x 104 psi d. 30.96 x 104 psi
46. What horsepower is required to lift a load of 5000 lbs by means of a cable wrapped around
the drum hoist, the drum being 40 in. diameter and making 24 rpm?
a. 28 b. 50 c. 18 d. 38
47. A 4 inches diameter shaft is driven at 3600 rpm by a 400 Hp motor. The shaft drives a 48
inches diameter chain sprocket having an output efficiency of 85%. The output force of the
driving sprocket and the output of the driven sprocket are:
a. 200 lb and 250 hp c. 291.66 lb and 340 hp
b. 261.6 lb and 300 hp d. 207.66 lb and 350 hp
48. A certain farm equipment which requires 2200 Newton mater torque at 500 RPM has a
diesel engine to operates at 1500 RPM as its prime mover. A No. 60 roller chain with a total
length of 60 pitches and a small sprocket with 23 teeth are to be used with an operating
temperature to remain constant at 45 degree C. Determine the no. of teeth of the larger
sprocket.
a. 70 b. 69 c. 68 d. 71
49. A sleeve bearing has an outside diameter of 1.5 in and a length of 2 in, the wall thickness is
3/16 in. The bearing is subjected to a radial load of 450 lb. Find the bearing pressure.
a. 100 psi b. 150 psi c. 200 psi d. 250 psi
50. A cut gear transmits 25 Hp at a pitch line velocity of 6000 ft/min. If the service is intermittent
the dynamic load is:
A. 244 B. 264 C. 274 D. 284
51. An internal gearing requires an idler gear if the driving gear of 6 inches in diameter and the
center distance of the idler to the driver is 20 inches. What is the inside diameter of the
driven gear?
A. 62 B. 70 C. 74 D. 81
52. In a standard bevel gear, the pinion rotates at 150 rpm, its number of teeth is 14 while the
gear has 42 teeth, what is the pitch angle of the pinion?
A. 18.4 degrees B. 20 degrees C. 14.5 degrees D. 20.5 degrees
53. A 10" diameter pulley is belt driven with a net torque of 250 ft-lbs. The ratio of tensions in
the tight to stack sides of the belt is 4 to 1. What is the maximum tension in the belt?
A. 250 lbs. B. 800 lbs. C. 83 lbs. D. 500 lbs.

54. Compute how many 3/8 inch diameter set screws required to transmit 3 Hp at a shaft speed
of 1000 rpm. The shaft diameter is 1 inch
A. 1½ B. 2 C. 3 D. 1
55. A drop hammer of 1 ton dead weight capacity is propelled downward by a 12 inch diameter
cylinder. At 100 psi air pressure what is the impact velocity if the stroke is 28 inches?
A. 47.4 ft/sec B. 31.6 ft/sec C. 15.8 ft/sec D. 63.2 ft/sec
56. A link has a load factor of 0.8 the surface factor 0.8, the surface factor is 0.92 and the
endurance strength is 28000 psi. Compute the alternating stress of the link if it is subjected
to a reversing load. Assume a factor of safety of 3.
A. 8150 B. 10920 C. 9,333 D. 7260
57. A 16 mm plate is lapped over and secured by fillet weld on the inside and outside to form a
penstock 1.5 meter in diameter. Determine the safe internal pressure, assuming an
allowable stress of 140 MPa on the plate and an allowable shear stress of 90 MPa on the
throat side of the 14 mm fillet weld.
A. 2.376 MPa B. 3.590 MPa C. 2.843 MPa D. 1.695 Mpa
 ME 603: Machine Design, Machine Workshop and Practice

58. A turbine developing 15,000 Hp turns the shaft at 300 rpm. The propeller attached to this
shaft develops a thrust of 150,000 lb. A hollow steel shaft having an outside diameter of 14
in. is to be used. Determine the inside diameter of the shaft if the maximum shearing
stressed based on the torsion alone is not to exceed 7500 psi. What is the percentage
savings in weight.
A. 37.3% B. 35.3% C. 73.3% D. 77.3%
59. A short compression member with Do= 2Di is to support a dead load of 25 tons. The material
is to be 4130. A short compression member with Do= 2Di is to support a dead load of 25
tons. The material is to be 4130 steel, WQT 1100⁰F. Calculate the outside and inside
diameters on the basis of yield strength of 114 ksi and factor of safety of 2.
A. Do=1.22 in. and Di=0.61 in. C. Do=2.11 in. and Di=0.69 in.
B Do=1.55 in. and Di=0.91 in. D. Do=2.11 in. and Di=0.96 in.
60. A 15/16-in wide key has a depth of 5/8 in. It is 12 inches long and is to be used on a 200 hp,
1160 rpm, squirrel-cage induction motor. The shaft diameter is 3 7/8 inches. The maximum
running torque is 200% of the full-load torque. Determine the maximum compressive stress
of the key
A. 779 psi B. 997 psi C. 197 psi D. 279 psi
61. A storage tank for air, 36 inches in diameter, is to withstand an internal pressure of 200 psi
with a design factor of 4 based on Su. The steel has the strength equivalent to C1020
annealed and the welded joints should have a relative strength (efficiency) of 90%. If Su for
annealed C1020 steel is 57 ksi. Compute the longitudinal stress.
A. 128,000 psi B. 821,000 psi C. 800,000 psi D. 12,800 psi
62. The mass of a flywheel is 175 kg and its radius of gyration is 380 mm. Find the torque
required to attain a speed of 500 rpm from rest in 30 seconds.
A. 40.46 N B. 44.12 N C. 35.66 N D. 38.48 N
63. The cylinder head of a 10in x 18in. freon compressor is attached by 10 stud bolts made of
SAE grade 5. The cylinder pressure is 300 psi. What is the approximate tightening torque
should be used to induce a tightening stress (St) of 0.90 times the proof stress if the
diameter of the bolt is 5/8 in and coefficient of collar friction c = 0.2?
A. 2161 in-lb B. 2060 in-lb C. 3161 in-lb D 3060 in-lb
64. A broach is used to cut a key way 8mm wide, 5mmm deep in a boss 64mm long. Determine
the cutting length of broach if the rise per tooth is 0.0875mm and the number of finishing
teeth is 13.
A. 672 mm B. 627 mm C. 762 mm D. 726 mm
65. A double square thread screw is used to raise a load of 20,000 lb at a velocity of 3 fpm.
Outside diameter of thread and pitch are 2 7/8 in. and 1 in. respectively. Collar friction
coefficient is 0.12, thread friction coefficient is 0.10. Mean diameter of collar 5 in. Determine
the power required to drive the screw.
A. 3.45 hp B. 4.29 hp C. 4.65 hp D. 5.02 hp
66. Two 2 ¾ in sellers standard square thread screws are used to raise and lower a hydraulic
gate weighing 60 tons. A 570 rpm electric motor operates the screws. The coefficients of
collar and thread friction are 0.03 and 0.14 respectively. The mean diameter of the collar
4in. if the gate rises at the rate of 2fpm, determine the size of the motor required to lift the
gate if the mechanical efficiency is 85% for the speed reducing equipment.
A. 20 hp B. 30 hp C. 34 hp D. 24 hp
67. A crate weighing 4,000 lb is moving at a speed of 4ft/s. It is brought to rest by two
compression spring in stopping the crate, the springs are to be compressed 8 in. If the spring
 ME 603: Machine Design, Machine Workshop and Practice

index is 6 and the allowable stress is 52,000 psi, determine the maximum load on each
springs.
A. 1491 lbs B. 2037 lbs C. 1675 lbs D. 2453 lbs
68. A square bar of wrought iron, 2 inches on each side, is raised to a temperature of 100 deg F
above its normal. If held so that it cannot expand, what stress will be induced in it? K = 6.8 x
10-6 per deg F.
a. 17,400 psi b. 18,400 psi c. 19,400 psi d. 20,400 psi
69. In problem no. 38, what is the force necessary to prevent expansion? Modulus of elasticity E
may be taken as 30 million psi.
a. 91,600 lbs b. 81,600 lbs c. 20,900 lbs d. 11,995 lbs
70. A solid circular shaft is used to transmit 200 hp at 1000 rpm. What shaft diameter is required
if the allowable maximum shearing stress is 20,000 psi?
a. 1.475 in. b. 1.250 in. c. 1.750 in. d. 2.000 in.
71. In problem No.40, if a hollow shaft is used having an inside diameter equal to the diameter
of the solid shaft, determine what must be the outside diameter of this shaft if the angular
twist of the hollow and solid shafts is to be equal.
a. 1.475 in. b. 1.402 in. c. 1.755 in. d. 1.250 in.
72. A solid transmission shaft is 3.5 inches in diameter. It is desired to replace it with a hollow
shaft of the same material and same torsional strength but its weight should only be half as
much as the solid shaft. Find the inside diameter of the hollow shaft in millimeters.
a. 86.97 b. 84.60 c. 65.97 d. 54.30
73. The manhole cover of an ammonia storage tank is to be held by 24 stud bolts. If the press
ure inside the tank will remain constant at 12.5 kg per sq. cm., and the manhole diameter is
508 mm., what would be the size of the bolts if the load will be
carried by the bolts? Disregard elastic limit of material.
a. 24.5 mm b. 26.1 mm. c. 25.4 mm d. 28.7 mm.

74. The smaller of two concentric helical springs is made of 22 mm-diameter steel spring and
has an outside diameter of 100 mm with 10 active coils. The outer spring is made of 32 mm-
diameter steel spring and has an outside diameter of 250 mm with 8 active coils. Before the
load is applied, the outer spring is 25 mm longer than the inner spring. If the load of 90 KN is
applied to this nest of springs, find the spring rate of each spring in KN/m.
a. 507.5, 143.6 b. 731.5, 212.5 c. 493.8, 126.5 d. 976.1, 318.8

75. A flange coupling has an outside diameter of 200 mm and connects two 40-mm shafts. There
are four 16 mm bolts on a 140- mm bolt circle. The radial flange thickness is 20 mm. if the
torsional stress in the shaft is not to exceed 26 MPa, determine the shearing stress in the
bolts if uniformly distributed/
a. 8.5 N/mm2 b. 5.8 N/mm2 c. 6.5 N/mm2 d. 7.5 N/mm2
76. Two short shafts having identical diameters of 38.1 mm and rotating at 400 rpm are
connected by a flange coupling having four bolts with a 100 mm bolt circle. The design
shearing stress of the bolt is 12 N/mm2 and design compressive stress of the flange is 15
N/mm2. How thick should the flange be in mm.?
a. 11.51 mm b. 13.60 mm c. 12.49 mm d. 15.65 mm
77. A shearing machine requires 150 kg-m of energy to shear a steel sheet, and has a normal
speed of 3 rev/sec, slowing down to 2.8 rev/sec during the shearing process. The flywheel
has a mean diameter of 75 cm and weighs 0.018 kg/cm3. The width of the rim is 30 cm. If
 ME 603: Machine Design, Machine Workshop and Practice

the hub and arms of the flywheel account for 15% of the total weight, find the thickness of
the rim.
a. 1 cm b. 5 cm c. 4 cm d. 3 cm
78. Find the weight of the flywheel needed by a machine to punch 20.5 mm holes in 15.87 mm
thick steel plate. The machine is to make 30 strokes per minute and a hole must be punched
every stroke. The hole is to be formed during 30° rotation of the puncher’s crankshaft. A
gear train with a ratio of 12:1 is to connect the flywheel shaft to the crankshaft. Let the
mean diameter of the flywheel rim be 91.44 cm. The minimum flywheel speed is to be 90%
of the maximum and assume mechanical efficiency of the machine to be 80%.
a. 68 kg. b. 96 kg. c. 90 kg. d. 82 kg.
79. The main bearings of a one-cylinder steam engine are 152 mm in diameter and 280 mm
long, and support a load of 4400 kg. The bearings are well-ventilated and are heavy in
construction. The coefficient of friction in bearing is 0.017 and crankshaft rotates at 450 rpm.
Bearing diametral clearance is 0.152 mm. Determine the friction loss in kW per bearing.
a. 1432 KW b. 1311 KW c. 1314 KW d. 1329 KW
80. A lineshaft carrying 20 in. pulley runs at 420 rpm. The pulley is belt-connected to a 12-in.
pulley on the countershaft. The countershaft has an 18-in. pulley transmitting power to a
final pulley rotating at 900 rpm. Compute the required diameter of the final pulley.
a. 10 in b. 12 in c. 14 in d. 28 in
Machine Workshop and Practice
81. Which of the following is not used to resemble the shape of tool bit?
a. Round nose b. Center cut* c. Square nose d. Thread cutting
82. A lathe with multiple cutting stations:
a. Turret lathe * b. Lathe machine c. Milling machine d. Grinding machine
83. A mechanism which is usually do the indexing in a machine tool:
a. Universal chuck b. Slotter c. Dividing head * d. Indexing
84. Non-ferrous filler metal is melted into grooves or as fillet on the mother metal; the base
metal is not melted. This commonly used for joining iron based machine parts or in repair
works of some materials. It is called:
a. Spot welding b. Braze welding* c. Brazing d. Gas Welding
85. How long will it take to saw a rectangular piece of aluminum alloy plate 6 in. wide and 2 in.
thick if the length of cut is 6 in.? The power hacksaw makes 120 strokes/min, and the
average feed per stroke is 0.0040 in.
a. 12.5 min. * b. 13.3 min. c. 15 min. d. 16.5 min.
86. The rpm of a milling cutter is 200; feed is 0.02 mm per tooth. If the feed per minute is 200 mm,
calculate the number of teeth in the cutter.
a. 45 b. 60 c. 80 d. 50*
87. Balancing o grinding wheel is done to
A. Make the outside diameter concentric with the bore
B. Make the sides of wheel parallel
C. Equalize the weight in every portion of the wheel*
D. None of the above
88. Quick return motion is used in a
A. drilling machine B. grinder C. lathe D. shaper*
89. Sheet metal of # 18 gage is heavier than:
A. 12 gage B. 14 gage C. 22 gage* D. 16 gage
90. Feeler gage are used for measuring the
A. clearance between mating parts C. radius of curvature
B. pitch of screw threads D. thickness of plates
 ME 603: Machine Design, Machine Workshop and Practice

91. In up cut milling the work piece is fed

A. against the rotating cutter* C. at right angle to the cutter
B. at an angle of 60* to the cutter D. in the direction of the cutter
92. A tool with hardened steel point used for scribing or laying of distances.
A. Divider* B. Hermaphrodite C. Plain scriber D. Trammel
93. A machine too used principally to machine flat or plane surfaces with a single pointed tool.
A. Drill B. Planer* C. Power Saw D. Shaper
94. The name of the taper shank used on drills is:
A. Miller B. Morse* C. Starret D. Stanley
95. A machine tool in which an abrasive wheel is used as a cutting tool to obtain a very smooth
finish.
A. Broaching machine B. Milling Machine C. Planer D. Tool
Grinder*
96. The kind of center, which is being attached and meshed to the tailstock spindle, which is also
static while the work, is rotating is know as:
A. dead center* B. focal center C. live center D. work center
97. Which of the following safety precaution should be followed when renewing a flange
gasket?
A. drain the line thoroughly C. tie down isolation valves
B. isolate the section to be worked on D. all of the above*
98. A machining operation whereby the tool reciprocates and the feed is stationary.
A. Planing B. Reaming C. Shaping* D. Turning
99. Which of the following is not part of the headstock?
A. Anvil * B. Back pressure C. Motor D. Spindle
100. A machine tool used to out metal parts a lift, medium and large section using a
reciprocating hacksaw blade.
A. planer B.power saw* C. shaper D. tool grinder