Course file Rev 01

COURSE FILE
OF

M.PRASAD, ASST.PROF, and (MECHANICAL ENGINEERING)

For the Subject

MACHINE DESIGN

for B .E- V SEM, for the Academic Year 2018-2019

This File Contains:

(1) Essence of the Course File

(2) Teaching Plan & Its implementation
(3) Unit wise Lecture Notes
(Listing of subtopics, Graphs, Characteristics, Laws, Theorems, Equations, etc.)
(4) Syllabus Copy
(5) Previous Question Papers
(Minimum of 4 sets of Regular Exam and 4 sets of Supplementary Exam)

Methodist College of Engineering & Technology

Abids , Hyderabad
 Course file Rev 01

I. ESSENCE OF THE COURSE FILE

1) Name of the faculty: M.PRASAD

2) Designation & Department: MECHANICAL ENGINEERING
3) Subject and its code: MACHINE DESIGN , PC503ME
4) Subject for: B.E – V SEM for the A. Y.—2018-2019
5) Subject objective:
 To know the design of springs for various loads in stress , deflection and energy
considerations
 To understand the design of different gears from strength and wear
considerations
 To design the bearings used in different applications
 To know the application and design of various components of IC Engine
components
 To know the concepts of theory of bending for members with different cross
sections
6)Subject outcome:
 Classify the different types of springs, applications ,and to design spring for
static and fluctuating loads.
 Differentiate different types of gears ,and design spur ,helical, bevel and worm
gears.
 Understand the principle of hydro static and hydro dynamic lubrication for
bearings, Estimate the load carrying capacity of bearings for axial and thrust
loads under static and cyclic loads
 Design of IC engine components like piston, connecting rod, crank shaft
 Design of fly wheel subjected to mechanical and thermal loads
 Differentiate between curved beams and straight beams
 Apply design principles for crane hooks, C Clamps and machine frames

6) Subject schedule:

Planned Executed
Unit From -To No. of From -To No. of
periods periods
Unit-I : Mechanical Springs 02-07-2018 TO 14
21-07-2018
Unit-II: Gears 23-07-2018 TO 14
10-08-2018
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Unit-III : Bearings 13-08-2018 TO 14

01-09-2018
Unit-IV: I.C. Engine Parts 04-09- 2018TO 14
22-09-2018

Unit-V : Theory of bending 24-09-2018 TO 14

27-10-2018
No. of periods planned: 70 No. of periods executed:
Remarks, if any:

7) Target:
1) Pass percentage:
2) Percentage scoring 60% & above:
8) Outcome: On completion of this course, the student shall be able to:

9) Pedagogy: Black board/ OHP/LCD:

10) Methods of evaluation:
 Assignments:
 Periodic class room tests:
 Periodic class room quizzes:
 University quizzes:
 University Mid exams:
 Class room seminars

11) Reference Books:

1.DESIGN OF MACHINE ELEMETS BY R.S KHURMI

2. DESIGN OF MACHINE ELEMETS BY BHANDARI.V.B

12) Guidelines to the students:

 All students should be properly and neatly dressed

 The behavior of the students, both within and outside the college campus should be decent
and befitting to a professional institution.
 Students should attend classes; submit assignments, records, home work etc. in time.
Students coming late shall enter the class only with the permission of the teacher. Late
comers will not get attendance for the period. No student shall leave the class before the
class is dispersed by the teacher handling the class.
 Students shall move silently when proceeding from one class to another so as not to disturb
other classes.
 The class tests, series tests and model examinations are to be attended by all the students
with sufficient preparation. Re-tests will not be conducted normally.
 Course file Rev 01

 Students must park their vehicles only in the places specified for the same, and should not
use the vehicles inside the campus beyond the parking areas.
 All assignments must be turned in on the appointed day of class.
 Late assignments will lose 1 mark each day they are late.
 Any assignment three or more days late will be counted as a zero

Signature of faculty with Date Signature of HOD with Date.

II. TEACHING PLAN & ITS EXECUTION

The objective of the unit is:

 Able to Design Helical springs under stress deflection, Fluctuating

loads, and Energy

 Able to Design leaf springs

 To know the applications of springs

(1) Unit-I Mechanical Springs

(2)Planning of Lectures & Their Execution:

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Unit I
(Topic Name )
Sl. Topics Planned Executed
No.
No. of Date No. of Ref.Book Pedagogy
Periods Periods no.

1 Introduction 1 BLACK
BOARD
2 Types of springs and  1
materials used.
3 Design of helical springs on  2
stress, 
4 Design of helical springs on,  1
deflection 
5 Design of helical springs on  2
energy considerations
6 Design for fluctuating loads.  1
7  Concentric springs.  2
8 Leaf Springs: Stresses and  1
Deflection. 
9 Principles of Limit design.  1
Nipping of Leaf springs.
10 Problems from previous papers 2

Assignment questions

1)A helical compression spring is required to deflect through 25mm when the external force acting
on it varies from 500 to 1000N. The spring index is 8. The spring has square and ground ends.
There should be a gap of 2mm between adjacent coils when the spring is subjected to the
maximum force of 1000N. The spring is made of cold drawn steel wire with ultimate tensile
strength of 1000 MPa, and permissible shear strength is 500 MPa, G=81370 MPa. Design the
spring the calculate : (i) wire diameter (ii) Mean coil diameter (iii) number of active coils (iv) total
number of coils (v) solid length (vi) free length.
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2) A semi elliptic leaf spring used for automobile suspension consists of three extra full length
leaves and 15 graduated leaves including the master leaf. The centre to centre distance between
two eyes of the spring is 1.5m. The maximum force acting on spring is 100 kN. For each leaf the
ratio of width to thickness is 9:1.E=200GPa, the leaves are prestressed in such a way that when the
force is maximum, the stresses induced in all leaves are same and equal to 450MPa. Determine (i)
the width and thickness of leaves, (ii) the initial nip; and (iii) the initial preload required to close
the gap C between extra full length leaves and graduated length leaves.

3)A helical- compression spring of a cam - mechanism is subjected to an initial preload of 50N.
The maximum operationg force during the load cycle is 150N. The wire diameter is 3mm, while
the mean coil diameter is 18mm. The spring is made of oil-hardened and tempered valve spring
wire of grade VW (Sut= 1430 N/ mm2). Determine the factor of safety used in the design.

4) A truck spring has 12 number of leaves, two of which are full length leaves. The spring supports
are 1.05m apart and the central band is 85mm 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

5) Briefly discuss the importance of A.M Wahl'sfactor in the design of helical springs..

6)What is concentric spring? Enumerate the advantages.

7). What is nip of leaf spring? Explain

The objective of the unit is:

 Able to Design Spur, helical bevel and worm gears

 To know materials used for gears

 To know the applications of gears

 To know the different gear failure modes

(1) Unit-II : Gears

(2)Planning of Lectures & Their Execution:

 Course file Rev 01

Unit II
(Topic name)
Sl. Topics Planned Executed
No
. No. of Date No. of Ref. Pedagogy
Periods Periods Book
no
1 Types of gears and materials used 1 BLACK
BOARD
2 standards for gear specifications. . 1

3 Design of Spurgear. 2

4  Design of , Helicalgear,  2
5  Design of, Bevel Gears ­  2
6  Design of Worm Gears. 2

7 Strength and Wear considerations.  1
Types of failure of gear tooth and 
preventive measures
8 Types of failure of gear tooth and  1
preventive measures
9 Problems 2

Assignment questions

1)It is required to design a pair of spur gears with 20° full- depth involute teeth based on Lewis
equation. The velocity factor is to be used to account for dynamic load. The pinion shaft is
connected to a 10kW, 1440 r.p.m motor. The starting torque of the motor is 150% of the rated
torque. The speed reduction is 4: 1. The pinion as well as the gear are made of plain carbon steel
40 C 8 (Sut= 600N/mm2). The factor of safety can be taken as 1.5. Design the gears, specify their
dimensions and suggest suitable surface hardness for the gears.

2)A pair of straight bevel gears has a velocity ratio of 2: 1. The pitch circle diameter of the pinion
is 80mm at the large end of the tooth. A 5kW power is supplied to the pinion, which rotates at 800
 Course file Rev 01

t.p.m. The face width is 40mm and the pressure angle is 20°. Calculate the tangential, radial and
axial components of the resultant tooth force acting on the pinion

3)A steel pinion with 20o full depth involute teeth is transmitting 7.5 kW power at 1000 rpm from
an electric motor. The starting torque of the motor is twice the rated torque. The number of teeth on
pinion is 25, while module is 4mm. The face width is 45mm. Assuming that velocity factor
accounts for the dynamic calculate (i) the effective load on the gear tooth; and (ii) the bending
stresses in gear tooth.

4)A pair of straight bevel gears consists of a 24 teeth pinion meshing with a 48 teeth gear. The
module at the outside diameter is 6mm, while face width is 50mm. The gears are made of grey cast
from FG 220 (Sut=220 MPa), pressure angle is 20o . The teeths are generated and assume that
velocity factor accoutns for the dynamic load. The pinion rotates at 300 rpm and the service factor
is 1.5, calculate (i) the beam strength of the tooth, (ii) the static load that the gears can, transmit
with a factor of safety of 2 for bending consideration and (iii) the rated power that the gears can
transmit

5)Sketch bevel and worm gears and show the forces acting on it

6) . List the different types of gear tooth failures.

The bjective of the unit is:

 Able to Design Journal bearings and roller contact bearings

 To know materials used for bearings

 To know the applications of Bearings

 To know the Static and dynamic load carrying capacity of bearings

(1) Unit-III Bearings
 Course file Rev 01

(2)Planning of Lectures & Their Execution:Unit III

(Name)
Sl.No. Topics Plann Executed
ed

No. of Date No. Ref. Pedogogy

Perio of Book
ds Peri no
ods
1  Materials used for Bearings.  1 BLACK
BOARD
2  Classification of Bearings.  1

3  Viscosity of Lubricants. Theory of  1
Hydrostatic and Hydrodynamic 
lubrication
4   Design of sliding contact bearings  1
for axial and thrust loads.
5 Different types of rolling element  2
bearings and their constructional 
details. 

6 Static and Dynamic load carrying  2
capacity,.

7  Load­life relationship. Design for  1
cyclic loads.

8 Problems 4

Assignment questions

1)A ball bearing with a dynamic load capacity of 22.8KN is subjected to a radial loads of 10KN.
Calculate (i) the expected life in million revolutions that 90% of the bearings will reach (ii) the
corresponding life in hours, if the shaft is rotating at 1500 rpm; and (iii) the life that 50% of the
bearings will complete or exceed before fatigue failure.
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2)A ball bearing subjected to a radial load of 3000N is expected to have a satisfactory life of 10000
hrs at 720 r.p.m with a reliability of 95%. Calculate the dynamic load carrying capacity of the
bearing, so that it can be selected from a manufacturer's catalogue based on 90% reliability: If
there are four such bearings each

3) Describe the assumptions in differential equation derived by Osborne Reynold for theory of
hydrodynamics lubrication.

4) What is L10 and L10h life of the bearing?

5) What is meant by "self contained bearings"?

6)Give the applications and limitations of rolling contact bearings.

The objective of the unit is:

 Able to Design Various IC Engine components

 To know materials used for IC engine components

 Course file Rev 01

 To know the Design of fly wheel

(1) Unit-IV : I C Engines

(2)Planning of Lectures &Ttheir Execution:

Unit IV
(Name)
Sl.No. Topics Plann Executed
ed

No. of Date No. of Ref. Pedogogy

Period Periods Book
s no

1 Design of piston 2 BLACK
BOARD
2 Design connecting rod  2
3 Design of crank shafts (single 2

throw and overhang).  .
4 Design of Flywheels for I.C. 3
Engines and presses.
5 problems 5

Assignment questions

1)Design a connecting rod for a single cylinder four stroke diesel engine with following
specifications: Power = 7.5kW, Mechanical Efficiency= 80%, weight of reciprocating parts= 20N,
 Course file Rev 01

Length of connecting rod= 0.30m, Speed= 1500 rev /min with a possible over speed of 2500
rev/min. Assume suitable missing data.

2)The following data is given for the cap and bolts of big end of connecting rod; engine speed =
1500 rpm, Length of connecting rod = 320mm, Length of stroke=140mm, Mass of reciprocating
parts = 1.75 kg, Length of crane pin=54mm, Diameter of cranks pin = 38mm, Permissible tensile
stress for bolts = 120 MPa, permissible bending stress for cap=120MPa, calculating the nominal
diameter of bolts and thickness of cap of the big end.
3) What is the function of a valve spring in an I.C. engine?
4) What are the methods and materials used in the manufacture of crank shafts?
5) Describe the materials used and their properties for piston and connecting rod.
6) What are design considerations for the fly wheel used in IC Engines?
7) Describe the materials used and their properties for piston and connecting rod.

The objective of the unit is:

 Able to Design Crane hooks,C camps and Machine frames

 Course file Rev 01

 To know the theory of bending of members with initial curvature

like rectangular, circular, trapezoidal sections

 To know the Materials used for hooks and c clamps

(1) Unit-V : Theory of bending

(2)Planning of Lectures & Their Execution:
Unit V
(Name)
Sl.No. Topics Plann Executed
ed

No. of Date No. Ref. Pedogogy

Perio of Book
ds Perio no
ds
1 Theory   of   bending   of   members 2
with   initial   curvature ­
rectangular,.

2 Theory   of   bending   of   members 2

with initial curvature ­ circular ­

3 Theory   of   bending   of   members 2

with   initial   curvature ,
Trapezoidal sections.  

4  . Design of crane Hooks 1
5 Design of, Machine flames  1
6 Design of C­clamps. 1

7 Problems 5

Assighnment questions
 Course file Rev 01

1)Design a crane hook with the load lifting capacity of the crane as 250 kW. The weight of the hook is
50kN.

2)Design a crane hook with the useful load lifting capacity of the crane as 100kW. The weight of the hook is
20kN.

3)Briefly discuss the effect of initial curvature on the analysis of theory of bending of beams.

4) Mention the factors to be considered while designing C- clamps.

5) Mention the criteria for the design of machine frames