Khaire sir classes

Subject : Design of machine

element(DME)
Unit : 2nd Design of joint, lever and link
Mark: 12
Total questions ask in last MSBTE exam
2 for 12 mark
Q1. Explain design procedure of cotter joint
Let P = Load carried by the rods,
d = Diameter of the rods,
d1 = Outside diameter of socket,
d2 = Diameter of spigot or inside diameter of socket,
d3 = Outside diameter of spigot collar,
t1 = Thickness of spigot collar,
d4 = Diameter of socket collar,
c = Thickness of socket collar,
b = Mean width of cotter,
t = Thickness of cotter,
l = Length of cotter
a = Distance from the end of the slot to the end of rod,
σt = Permissible tensile stress for the rods material
τ = Permissible shear stress for the cotter material
σc = Permissible crushing stress for the cotter material
Step 1: Failure of rod in tension
Rod may be fail in tension due to force p

Stress = force/ area

σt = P/A

σt = P
(п/4)Xd2

From above equation diameter of rod can calculated

Step2: Failure of spigot in tension across slot

Stress = force/ area

FIG 05: SPIGOT BREAKING IN
TENSION ACROSS SLOT
σt = P/A

σt = P
((п/4)xd22 -txd2 )
From above equation d2 can calculated
Step3: Failure of spigot due to crushing

Stress = force/ area

σck = P
d2xt

From above equation crushing stress can check

Step4: Failure of spigot end in shear

d2

a
FIG 10: SHEARING OF SPIGOT END

Shear stress = Force/ area

τ = P

2x d2x a

From above equation a can be calculated

Step5: Failure of spigot collar in crushing

Crushing stress is given by

σck = P

(п/4) x d32 - (п/4) x d22

From above equation d3 can be calculated

Step 6: Failure of socket in tension across slot or weakest section

Stress = force/ area

σt = P/A

σt = P

(п/4) x d12 - (п/4) x d22 – t(d1 - d2)

From above equation outer diameter of socket can calculated

Step7: Failure of socket in crushing
t
………
……..
Crushing stress is given by

σck = P …
d2
d1
t(d1 - d2)
………
From above equation crushing ……..
stress
can be check
Step 8: Failure of socket collar in crushing

Crushing stress is given by

Crushing stress = force/ area

σck = P
t (d4 - d2)

From above equation d4(socket collar diameter) can calculated

Step9: failure of socket end in shear

Shear stress is given by

Shear stress = Force/ area

c
τ = P

2x (d4 –d2)x C

From above equation thickness of collar can be calculated

Step10: Failure of cotter pin in shear

Shear stress is given by

Shear stress = Force/ area

τ = P

2x b x t

From above equation width of cotter can be calculated

Q2. Why cotter in taper shape…….(W-13,S-15…2 Mark)
Cotter is in flat wedge shape having rectangular cross sectional
area
Reasons
1. Taper help easy removal of cotter pin from joint
2. Due to taper shape cotter remain in its fix position
3. Taper shape provide maximum frictional area
4. Taper provide self locking to spigot and socket
5. Taper shape are easy to manufacture
6. Taper is provide in range of 1 in 24
Numerical 1: Design and draw cotter joint to support a load
of 30KN in tension and compression. The material has
following stresses
Tensile stress = compressive stress = 50 mpa
Shear stress = 35 mpa, crushing stress = 60mpa
Given data:
P = 30kN = 30 X 103 N
σt = σc = 50Mpa = 50 N/mm2
τ = 35 Mpa = 35 N/mm2
σck = 60 Mpa = 60 N/mm2
Numerical 2. Design a cotter joint to
transmit 200KN load. Stresses for
material are 75 mpa in tension, 50mpa in
shear, and 75 mpa in crushing.
Numerical 2: Design of cotter joint to connect
two mild steel rods for pull of 30KN.
Maximum principle stress are 50 Mpa in
tension, 40Mpa in shear, 70Mpa in crushing.
Draw neat sketch of cotter joint.
Ans.(d = 22mm, d2 = 32mm, t = 14mm, d1=
44mm, b = 30mm, a = 12mm, d4 = 65mm,
d3=40mm)
Q4. Explain design procedure of Knuckle joint
Let consider
d = diameter of rod
d1 = diameter of knuckle pin
d2 = diameter of single eye or double eye
d3 = diameter of knuckle pin collar
t = thickness of single eye
t1 = thickness of double eye
t2 = thickness of knuckle pin collar
Step 1: Failure of rod in tension

Stress = force/ area

σt = P/A

σt = P
(п/4)Xd2
From above equation rod diameter can calculated
Step2: Dimension of knuckle joint using formulas

d1 = d
d2 = 2d
d3 = 1.5d
t = 1.25d
t1 = 0.75d
t2 = 0.5d
Step3: Failure of single eye in tension at slot

d1 t

d2

Stress = force/ area

σt = P/A

σt = P
t(d2 -d1)
From above equation tensile stress can check
Step 4. Failure of single eye in crushing at slot

d1

Crushing stress is given by

Crushing stress = force/ area

σck = P
t xd1
From above equation crushing stress can check
Step 5. Failure of double eye in tension

d1 t1

d2

Stress = force/ area

σt = P/A

σt = P
2. t1(d2 -d1)
From above equation tensile stress can check
Step 6. Failure of double eye in crushing

t1

d1

Crushing stress is given by

Crushing stress = force/ area

σck = P
2. t1xd1

From above equation crushing stress can check

 Step7. Failure knuckle pin in shear

d1

Shear stress is given by

Shear stress = Force/ area

τ = P
2 x ∏ x d2 1
4
From above equation shear stress can check
 Numerical on knuckle Joint
Numerical1. Design knuckle joint at a load of
150KN. It is subjected to tensile , shear &
crushing stresses are 75 mpa, 60mpa & 150 mpa

Numerical2. Design knuckle joint at a load of

25KN. It is subjected to tensile , shear & crushing
stresses are 56 mpa, 70mpa & 70mpa
Numerical3: Design knuckle joint at a load of
32KN. It is subjected to ultimate tensile ,
ultimate shear & ultimate crushing strength are
344 mpa, 240mpa & 520mpa
 Q7. State function of split pin in knuckle joint
(W-13,W-15, S-16)
Function of split pin
1. Split pin avoid movement of knuckle
pin during working
2. Split pin maintain position of knuckle
pin in to joint.
3. It is made up with thin wire of semi-
circular cross section area.
Q8. State difference between cotter joint and knuckle joint
(S-13, W-14, S-17)

Cotter joint Knuckle joint

1. Cotter joint is capable for taking 1 Knuckle joint is capable for

both tensile and compressive load. taking only tensile load.
2.Cotter is not subjected to bearing 2. Knuckle joint is subjected to
load. bearing load.
3. Cotter joint does not provide 3. Knuckle joint provide angular
angular movement. movement.
4.Cotter pin has rectangular cross 4. Knuckle pin has circular cross
section area section area
5.Cotter pin is in tapper shape 5.Knuckle pin is in circular shape

6. Application. Foundation of 6.Application. In bridge, rail and

machine tractor
 Q8. Explain design procedure of C-Clamp
C-clamp is a type of clamp device typically used to hold
a wood or metal work piece

Where
F= Force on clamp
e = eccentric distance from load to y
axis
b = width of clamp
t = thickness of clamp
Step1: C-clamp get fail due to direct stress
σo = F
A

σo = F
bxt

σo = F
2t x t

σo = F ………1
2t2
Step2 : C-clamp get fail due bending stress
σb = BM
Z

σb = Fxe
1 t x b2
6
b = 2t
σb = 6xFxe
t x (2t)2

σb = 6xFxe . ……..2
4 x t3
Step3: Resultant stress

σR = σo + σb

= F + 6 x F x e ………3
2t2 4 x t3
1. Design a C- clamp for total load of 20 KN. The
cross section of c clamp s rectangular and width to
thickness ratio is 2. The distance between load and
neutral axis is 120mm and gap between two forces is
180mm. Take tensile stress is 100 N/mm2

Given data:
F= 20KN = 20 x 103
b = 2t
e = 120 mm
σR = 100N/mm2
Step1: C-clamp get fail due to direct stress
σo = F
A

σo = F
bxt

σo = 20 x 103 = 10 x103
2txt t2
Step2 : C-clamp get fail due bending stress
σb = BM
Z

σb = Fxe
1 t x b2
 σb = 6 x F x e
t x (2t)2
σb = 6 x 20 x 103 x 120
4.t3
σb = 3.6 x 106
t3
We know

σR = σo + σb

100 = 10 x103 + 3.6 x 106

t2 t3
Multiply by t3 on both side

100t3 = 10 x103 t + 3.6 x 106

100t3 -10 x103 t - 3.6 x 106 = 0
t = 34.02 mm
We know given is b = 2t
b=2xt
= 2 x 34.02
= 68.04 mm

t = 34.02 mm
b= 68.04mm
2. Design a C- clamp for total load of 35 KN. The cross
section of c clamp s rectangular and width to thickness
ratio is 2. The distance between load and neutral axis is
120mm and gap between two forces is 180mm. Take
tensile stress is 140 N/mm2

3. Design a C- clamp for total load of 22 KN. The cross

section of c clamp s rectangular and width to thickness
ratio is 2. The distance between load and neutral axis is
110 mm and gap between two forces is 180mm. Take
tensile stress is 130 N/mm2
4. Design a C- clamp for total load of 18 KN. The
cross section of c clamp s rectangular and width to
thickness ratio is 3. The distance between load and
neutral axis is 122 mm and gap between two forces is
180mm. Take tensile stress is 130 N/mm2

5. Design a C- clamp for total load of 24 KN. The

cross section of c clamp s rectangular and width to
thickness ratio is 3. The distance between load and
neutral axis is 125 mm and gap between two forces is
180mm. Take tensile stress is 140 N/mm2
6. A c- clamp is subjected to force of 15 KN as shown
in fig. It is made up with FG 300 with ultimate strength
300mpa. Factor of safety is 2.5. Determine dimension
of C- clamp.
7. Spindale of drilling machine as shown in fig is subject
maximum load of 10 kn. Determine diameter of solid cast
iron if tensile stress is 40 n/mm2. The distance between
axis and load is 350mm. Also calculate direct stress

d=? F

e = 350 mm
 Numerical on off-set link
1.Design off set link for a load of 15000 N. Maximum
permissible stress in tension is 60 N/mm2. Assume b = 4t
for rectangular cross section as shown in fig.
2.Design off set link for a load of 120 N. Maximum
permissible stress in tension is 70 N/mm2. Assume b = 4t
for rectangular cross section as shown in fig.

3.Design off set link for a load of W Newton. Maximum

permissible stress in tension is 20 N/mm2. Off set link is
in rectangular cross section as shown in fig find load W
4.Design off set link for a load of W Newton. Maximum
permissible stress in tension is 30 mpa. Off set link is in
rectangular cross section as shown in fig. Find load W

5.Design off set link for a load of 1200 Newton. Maximum

permissible stress in tension is 50 mpa. Off set link is in
rectangular cross section as shown in fig assume b= 3t
6. Fig show Hack- saw blade with 320 N load is applied on it. The
frame of hack-saw is made up with steel having tensile stress
360N/mm2. Design rectangular cross section of frame at A-A and
B-B. Assume B=2.5t and factor of safety 4
6. Fig show Hack- saw blade with 400 N load is applied on it. The
frame of hack-saw is made up with steel having tensile stress
380N/mm2. Design rectangular cross section of frame at A-A and
B-B. Assume B=3t and factor of safety 2.5
 Q10. Explain design procedure of turn buckle
Two round tie rod subjected to tensile loading are connected by a
coupling device which is known as turnbuckle

d = dia. Of coupler nut

d1 = inner dia. of coupler
d2 = Outer dia. of coupler
Ɩ = Length of coupler nut
dc = core dia. of rod
do = outer diameter of rod
F = force
 Step 1: Failure of rod in tension

Stress = force/ area

dc

σt = F/A

σt = F
(п/4)Xdc2

From above equation core diameter can be calculated. And from core
diameter outer diameter and pitch can be calculated
Step 2: Failure of rod in shear

Shear stress = Force/ area

τ = F
п. dc . l

From above equation length of couple nut can be calculated

Step3: Failure of rod in crushing

dc

Crushing stress is given by

σck = F

(п/4) (do2 - dc 2) n Ɩ

From above equation number of thread can be calculated

Step4: Failure of coupler nut in tension

Stress = force/ area

σt = F/A do

σt = F
(п/4)X(d 2 - do 2 )
d

From above question diameter of coupler nut can be calculated

Step5: Failure of coupler in tension

Stress = force/ area

d2
σt = F/A
d1

σt = F
(п/4)X(d2 2 – d1 2 )

In above question d2 = 1.5d

From above question diameter of coupler can be calculated

Thickness of coupler
t = 0.75 d0
Ɩ = 1.25 d0
 Numerical on Turn buckle
1. Maximum pull of 100 KN act on round tie rod bar. If
safe tensile and shear stress in the rod are 80 N/mm2 &
30 N/mm2 respectively. Design turn buckle and draw
its sketch. (W-14, W-19…….For 4 mark)

2. Maximum pull of 50 KN act on round tie rod bar. If

safe tensile , shear & Crushing stress in the rod are 75
N/mm2, 37.5 N/mm2 & 90N/ mm2 respectively. Design
turn buckle and draw its sketch.
3. Design a turn buckle to carry a load of 5 KN. The
rod & coupler nut are made up with FeE 380. The
factor of safety is 5. (S-15)

4.. Design a turn buckle to carry a load of 7 KN. The

rod & coupler nut are made up with FeE 400. The
factor of safety is 4.6

5. Design a turn buckle to carry a load of 10 KN. The

rod & coupler nut are made up with FeE 430. The
factor of safety is 5.2
Q11. Explain with neat sketch 3 basic types of lever.
Also state its applications
There are three types of lever
1. One arm lever
2. Two arm lever
3. Angular lever

1. One arm lever: This lever has only arm.

2. Two arm lever: This lever has two arm one is load arm
and other is effort arm.
There are three types of this lever
I. First type of lever.
II. Second type of lever.
III. Third type of lever.
Q13.Define mechanical advantages
It is define as the ratio of load lifted to effort applied.

M.A. = Load lifted / effort arm = W / P

Q14. Define leverage.

It is define as ratio of effort arm to load arm.

Leverage = effort arm / Load arm

Q12. Define lever with respective
1) M.A. = 1
2) M.A. < 1
3) M.A. > 1
M.A. = 1 → In this lever load and effort are same. So this
lever is define as a lever having load arm and effort arm
are same.

M.A. < 1 → In this lever effort is more than load lifted. So

this lever is define as a lever having load arm is more than
effort arm.
M.A. > 1 → In this lever load lifted is more than effort
applied. So this lever is define as a lever having effort arm
is more than load arm.
Q14. Explain design procedure of hand lever
(W-13,S-15,W-17)
1) Shaft 2) Boss 3) Centre shaft
d = diameter of shaft
d1= diameter of Centre shaft
d2 = diameter of boss
L = Length of lever
L1 = Effective distance from Centre to bearing of Centre
L2 =length of boss
t2 = thickness of boss
t = thickness of lever
B = width of lever
F = Force
Step1: Consider shaft under pure torsion

T= п . τ . d3 ………………………………….1
16

But torsion on shaft is due to force applied

T = F x L …………………………………………..2

Equate equation 1 & 2

п . τ . d3 = FxL
16

From above equation diameter of shaft can be calculated

Step 2: Design of boss using fix relation

d2 = 1.6 d

L2 = 1.25d

t2 = 0.3d
Step 3: Design of Centre shaft
Centre shaft fail due to combination of Twisting and bending
moment
Twisting moment is given by
T = F x L ………………3
Bending moment is given by
M = F x L1 ………..4
Combine twisting moment is given by
Te = п . τ . d13
16

From above equation diameter of centre shaft can be

calculated
Step4: Design of level
Lever is fail in bending only. So bending moment is given by

σb= BM/Z
Bending moment is given by
BM = F x (L – d2/2)

Z = 1 x t x B2
6

σb = F x (L – d2/2)
1 x t x B2
6
 Numerical on hand lever
1. The hand lever is 800 mm long from Centre of gravity of
spindle to point of application of 300N force. The
effective overhang from nearest bearing is 100 mm. If
stresses in tension, shear, crushing not exceed to 66
N/mm2 each. Design spindle, boss, lever and Centre
shaft. Assume arm of lever is rectangular having width is
twice thickness.

2. The hand lever is 900 mm long from Centre of gravity of

spindle to point of application of 800N force. The
effective overhang from nearest bearing is 100 mm. If
stresses in tension, shear, crushing not exceed to 70
N/mm2 each. Design spindle, boss, lever and Centre
shaft. Assume arm of lever is rectangular having width is
twice thickness.
3.Design hand lever from following data.
1) Length of lever from centre of gravity to load application is 1 M
2) Maximum load = 830 N
3) Overhang distance from bearing = 120 mm
4) Take all stresses = 72 mpa
Take B = 2t

4.Design hand lever from following data.

1) Length of lever from centre of gravity to load application is 1.2
Meter
2) Maximum load = 750 N
3) Overhang distance from bearing = 110 mm
4) Take all stresses = 75 mpa
Take B = 2t
5.Design hand lever from following data.
1) Length of lever from centre of gravity to load application is
1100 mm
2) Maximum load = 800 N
3) Overhang distance from bearing = 150 mm
4) Tensile stresses = 73 mpa
5) Shear stress = 60 mpa
Take t/B = 0.5

6.Design foot lever from following data.

1) Length of lever from centre of gravity to load application is
1100 mm
2) Maximum load = 800 N
3) Overhang distance from bearing = 150 mm
4) Tensile stresses = 73 mpa
5) Shear stress = 60 mpa
Take t/B = 0.5
Q15. Explain design procedure of bell crank
Where
F = Effort applied
W = Load lift
Lw = Load arm length
Le = Effort arm length
B = Width of lever
t = Thickness of lever
df = diameter of fulcrum pin
Step 1: Design of fulcrum pin

Failure of fulcrum pin in bearing

Pb = F/A

= F
Lf x df

Lf = 1.25 x df

Pb = F
1.25 x df x df
From above equation diameter of fulcrum pin can be
calculated
Step 2: Design of load pin

Failure of load pin in bearing

Pb = F/A

= F
Lw x dw

Lw = 1.25 x dw

Pb = F
1.25 x dw x dw
From above equation diameter of load pin can be calculated
Step 3: Design of effort pin

Failure of effort pin in bearing

Pb = F/A

= F
Le x de

Le = 1.25 x de

Pb = F
1.25 x de x de
From above equation diameter of effort pin can be calculated
Step 4: Design of load arm

Failure of load arm in bending

σb = BM/Z

= W X L2
1/6 X t x B2

From above equation width and thickness can be calculated