Class Exercise

➢ You are employed by a big company as a Design and Development Engineer. One of your
duties is to come up with a system to supply tons of water to the company’s facility per day.
Currently, the company is using municipal water for its processes and this is digging deep into
the company’s pocket. The nearest water source (which is a river) is about 5 km away from
the company and the company is at an altitude of 100 meters above the river.
1. Identify the problem that the company has. What type of problem is this?
2. As a Design and development engineer, use the engineering design processes to
illustrate how you would go about designing a water supply system.
3. What constraints would you have in this project
4. What are the factors that you would consider when doing the design of the water
supply system?
5. In the design of any engineering component or system, materials and material
selection play a very role in the success of your design. What factors would you
consider when selecting the materials for your water system.

➢ After you have commissioned and handed over the water system to the maintenance team,
one of the pipes and pumps decided to fail. The maintenance team was then instructed to
change the pipe and the pump, but they could not find a similar type of pipe and pump. It
then required them to select a different pump and pipe that would work similarly to what will
be replaced.
1. If you were called to assist the maintenance team in solving this problem, which
engineering problem-solving steps would you use to sort out the problem.
2. What material properties would you consider for any other design projects to come.

➢ Draw the Engineering materials’ hierarchy and mention at least 2 examples of materials
under each group.
➢ For each material mentioned above, name at least 2 applications.

Get ready for the test

1. Explain what is a problem in the engineering world
2. As a Design engineer, what factors would you consider when designing
3. what factors would you consider when selecting this material
4. What material properties would you consider for any other design projects to come
5. Draw the Engineering materials’ hierarchy and mention at least 2 examples of materials
under each group.
6. For each material mentioned above, name at least 2 applications.

a. Engineering Design is said to be the method of identifying and solving

engineering problems. What are the main types of an engineering design?
[5]
 b. The growth of production and constant increase in warehouses has forced
industries to look deep into the manhandling and stacking of goods. This is due
to the increase in challenges facing the manpower when manually lifting and
stacking goods. Unstable efficiency, injuries, high costs, and ergonomics
issues have been the biggest concern under the manhandling of goods. It is
therefore this reason industries adopted the use of lifting equipment as they
brought many advantages. The first ever designed lifting equipment was able
to reduce salary cost, injuries, and ergonomics issues and increase productivity
and efficiency. As the demand for goods constantly increases, the need for
continuous improvements in lifting equipment is still in high demand.
Companies want to save on cost and improve the efficiency of lifting and
stacking goods.

i. Identify and state the type of problem (s) in the statement above.
ii. Ergonomics is one of the concerns listed in the statement above, and it
is the main fundamental design principle. Explain why ergonomics is
important in the design of any engineering component or system.
iii. Who invented the first lifting device and what type of the device was
that?
iv. As a continuous improvement engineer, how would you carry out the
lifting equipment improvement process?
v. What factors need to be considered when improving the efficiency of
Lifting equipment?
7. Explain what is compound tolerance and give an example.
8. Graphically, illustrate the different types of fit in the shaft-based and hole-based
systems. Also, classify the tolerance in each case
9. Explain why is it necessary to specify tolerances.
10. Differentiate between the solid and blind rivets.
 Limits, Fits and Tolerances

A. The shaft has to be manufacture with the daimeter of 40 ± 0.02 mm. Find the lower and

upper limits, and the shaft tolarence

B. Consider a shaft having a dimension of 40 ± 0.05 mm and a hole having a dimension of 45 ±
0.05 mm.Find
1. The minimum and maximum limits of both shaft and hole
2. The tolarences for both shaft and hole
3. The maximum interfearance or allowance
4. What type of fit is it.
C. A 50 mm diameter shaft is made to rotate in the bush. The tolerances for both shaft and
bush are 0.050 mm. determine the dimension of the shaft and bush to give a maximum
clearance of 0.075 mm with the hole basis system.

D. In bush and pin assembly, pin of 30 mm diameter rotates in a bush. The tolerance for pin is
0.025 mm while for bush is 0.04 mm. If allowance is 0.1 mm, determine dimensions of pin
and bush considering hole-basis system.

E. A spindle slides freely in a bush. The basic size of the fit is 50 x10– 3 mm. If the tolerances
quoted are 0 +62 for the holes and -80 +180 for the shaft, find the upper limit and lower
limit of the shaft and the minimum clearance.

F. The deviation of the hole and shaft is;

Hole : Ø500+0.025
Shaft : Ø50-0.0050-0.025
Give a graphical representation of the whole and shaft
G. A journal of nominal diameter 79 mm rotates in a bearing. The upper and lower deviations in
hole diameter are respectively +0.05 mm and 0.00 mm, while those for shaft are respectively
-0.03 mm and -0.07 mm. Calculate: (i) Extreme diameters for hole and shaft, (ii) Tolerances
for hole and shaft and (iii) maximum and minimum clearance.
H. Find the tolerances, maximum interference and type of fit for the data for the following given
data: Hole ϕ50+0.25-0.10 and Shaft ϕ50+0.20-0.20
I. A dowel pin is required to be inserted in a base.. The tolerance quoted is 0 +25 for the hole
and 26 +42 for the shaft. Find the upper and lower limits of the hole and also dowel pin, and
the maximum interference between dowel pin and the hole. The basic size of the fit is 50mm.
J. Calculate all the dimensions of 40H7/n7 fit. The fundamental deviation for the shaft
can be obtained from the Formulae for fundamental deviation table.
K. Use the tables provided to evaluate limits, type of fit, minimum clearance, and
maximum interference for a pair of diameter 30T7/h6.
 L.

M.

N.
Allowance
EXAMPLEs

1. A dowel pin is required to be inserted in a base. For this application H 7 fit for hole and a p 6 fit for the shaft
are chosen. Find the upper and lower limits of the hole and also dowel pin, and the maximum interference
between dowel pin and the hole. The basic size of the fit is 50 mm
2. Calculate the limits and allowance for a 25 mm shaft and hole pair designated by H8d9. Take the fundamental
deviation for ‘d’ shaft is -16D0.44
3. Determine the tolerances on the hole and the shaft for a precision running fit designated by 50 H7g6, given;
50 mm lies between 30-50 mm
i (in microns)=0.45(D)1/3+0.001D
Fundamental deviation for ‘H’ hole=0
Fundamental deviation for g shaft =-2.5D0.34
IT7=16i and IT6=10i
State the actual maximum and minimum sizes of the hole and shaft and maximum and minimum
clearances.
4. Calculate all the relevant dimensions of 35H7/f8 fit, dimension 35 mm falls in the step of 30-50 mm. The
fundamental deviation for f shaft is – 5.5D0.41. i (in microns) =0.45(D)1/3+0.001D, IT7=16i and IT8=25i.
5. The deviation of the hole and shaft is;
Hole : Ø500+0.025
Shaft : Ø50-0.0050-0.025
Express this in terms of tolarence grades and symbols.

6. A 50 mm diameter shaft is made to rotate in the bush. The tolerances for both shaft and bush are 0.050 mm.
determine the dimension of the shaft and bush to give a maximum clearance of 0.075 mm with the shaft basis
system. Express your final answer using symbols and tolarence grades
7. Evaluate limits and fits for a pair of – Diameter 6 H7/g6. Graphigally express the nature of the fit.
8. Calculate the limits of sizes for f 20 P7/h6 and identify the fit. Graphigally express the nature of the fit.
9. A 6 mm diameter shaft is made to rotate in the bush. The tolerances for shaft and bush are 8 µm and 12 µm
respectively. determine the dimension of the shaft and bush to give a maximum clearance of 24 µm with the
hole basis system. Express your final answer using symbols and tolarence grades
10. A 20 mm diameter shaft is made to rotate in the bush. The tolerances for shaft and bush are 18 µm and 21 µm
respectively. determine the dimension of the shaft and bush to give a maximum interference of 39 µm with
the shaft basis system. Express your final answer using symbols and tolarence grades and graphically illustrate
the fit.
 Keys and Keyways

Example 1. Design the rectangular key for a shaft of 50 mm diameter. The shearing
and crushing stresses for the key material are 42 MP and 70 MPa.
2 2
Data : Given d = 50 mm; = 42 MPa = 42 N/mm ; = 70 MPa = 70 N/mm . The
rectangular key is designed for a shaft of 50 mm diameter,

Example 2. A 45 mm diameter shaft is made of steel with a yield strength of 400

MPa. A parallel key of size 14 mm width and 9 mm thickness made of steel with a
yield strength of 340 MPa is to be used. Find the required length of key, if the shaft
is loaded to transmit the maximum permissible torque. Use maximum shear stress
theory and assume a factor of safety of 2.
2
Data : Given d = 45 mm; for shaft = 400 MPa = 400 N/mm ; w = 14 mm; t = 9 mm;

Example 3. A 15 kW, 960 rpm motor has a mild steel shaft of 40 mm diameter and
the extension being 75 mm. The permissible shear and crushing stresses for the
mild steel key are 56 MPa and 112 MPa respectively. Design the keyway in the
motor shaft extension. Check the shear strength of the key against the normal
strength of the shaft.
3
Data : Given P = 15 kW = 15 ´ 10 W; N = 960 rpm; d = 40 mm; l = 75 mm;
2 2
= 56 MPa = 56 N/mm ; c = 112 MPa = 112 N/mm .
 various elements, make a neat sketch of the assembly
Couplings indicating the important dimensions. The stresses
developed in the various members may be checked if
thumb rules are used for fixing the dimensions.
Example 1 Design and make a neat dimensioned sketch
Example 5 Two 35 mm shafts are connected by a
of a muff coupling which is used to connect two steel
flanged coupling. The flanges are fitted with 6 bolts on
shafts transmitting 40 kW at 350 r.p.m. The material for 125 mm bolt circle. The shafts transmit a torque of 800
the shafts and key is plain carbon steel for which N-m at 350 r.p.m. For the safe stresses mentioned
allowable shear and crushing stresses may be taken as below, calculate the diameter of bolts ; thickness of
40 MPa and 80 MPa respectively. The material for the flanges ; key dimensions ; hub length; and power
muff is cast iron for which the allowable shear stress transmitted. Safe shear stress for shaft material = 63
may be assumed as 15 MPa. MPa, Safe stress for bolt material = 56 MPa, Safe stress
for cast iron coupling = 10 MPa, Safe stress for key
Example 2 Design and make a neat dimensioned sketch material = 46 MPa
of a muff coupling which is used to connect two steel
shafts transmitting 40 kW at 350 r.p.m. The material for Example 8 Design a bushed-pin type of flexible
the shafts and key is plain carbon steel for which coupling to connect a pump shaft to a motor shaft
allowable shear and crushing stresses may be taken as transmitting 32 kW at 960 r.p.m. The overall torque is
40 MPa and 80 MPa respectively. The material for the 20 percent more than mean torque. The material
muff is cast iron for which the allowable shear stress properties are as follows :
may be assumed as 15 MPa.
(a) The allowable shear and crushing stress for shaft
Example 3 Design a cast iron protective type flange and key material is 40 MPa and 80 MPa respectively.
coupling to transmit 15 kW at 900 r.p.m. from an (b) The allowable shear stress for cast iron is 15 MPa.
electric motor to a compressor. The service factor may (c) The allowable bearing pressure for rubber bush is
be assumed as 1.35. The following permissible stresses 0.8 N/mm2.
may be used: Shear stress for shaft, bolt and key (d) The material of the pin is same as that of shaft and
material = 40 MPa, Crushing stress for bolt and key = key.
80 MPa, Shear stress for cast iron = 8 MPa. Draw a neat Draw neat sketch of the coupling.
sketch of the coupling.
Example 9 An universal coupling is used to connect two
Example 4 Design and draw a protective type of cast mild steel shafts transmitting a torque of 5000 N-m.
iron flange coupling for a steel shaft transmitting 15 Assuming that the shafts are subjected to torsion only,
kW at 200 r.p.m. and having an allowable shear stress find the diameter of the shafts and pins. The allowable
of 40 MPa. The working stress in the bolts should not shear stresses for the shaft and pin may be taken as 60
exceed 30 MPa. Assume that the same material is used MPa and 28 MPa respectively
for shaft and key and that the crushing stress is twice
the value of its shear stress. The maximum torque is 4. Design a muff coupling to connect two shafts
25% greater than the full load torque. The shear stress transmitting 40 kW at 120 r.p.m. The permissible shear
for cast iron is 14 MPa. and crushing stress for the shaft and key material (mild
steel) are 30 MPa and 80 MPa respectively. The
Example 5 Design and draw a cast iron flange coupling
for a mild steel shaft transmitting 90 kW at 250 r.p.m. material of muff is cast iron with permissible shear
The allowable shear stress in the shaft is 40 MPa and stress of 15 MPa. Assume that the maximum torque
the angle of twist is not to exceed 1° in a length of 20 transmitted is 25 per cent greater than the mean
diameters. The allowable shear stress in the coupling torque.
bolts is 30 MPa.
5. Design a compression coupling for a shaft to transmit
Example 6 Design a rigid flange coupling to transmit a 1300 N-m. The allowable shear stress for the shaft and
torque of 250 N-m between two coaxial shafts. The key is 40 MPa and the number of bolts connecting the
shaft is made of alloy steel, flanges out of cast iron and two halves are 4. The permissible tensile stress for the
bolts out of steel. Four bolts are used to couple the bolts material is 70 MPa. The coefficient of friction
flanges. The shafts are keyed to the flange hub. The between the muff and the shaft surface may be taken
permissible stresses are given, Shear stress on shaft
as 0.3.
=100 MPa, Bearing or crushing stress on shaft =250
MPa Shear stress on keys =100 MPa, Bearing stress on 6. Design a cast iron protective flange coupling to
keys =250 MPa, Shearing stress on cast iron =200 MPa connect two shafts in order to transmit 7.5 kW at 720
Shear stress on bolts =100 MPa, After designing the r.p.m. The following permissible stresses may be used
:Permissible shear stress for shaft, bolt and key shaft and bolts may be taken as 50 MPa. Determine the
material = 33 MPa shaft diameter and the diameter of the bolts.
Permissible crushing stress for bolt and key material =
10. A flanged protective type coupling is required to
60 MPa
transmit 50 kW at 2000 r.p.m.. Find :
Permissible shear stress for the cast iron = 15 MPa
7. Two shafts made of plain carbon steel are (a) Shaft diameters if the driving shaft is hollow with di
connected by a rigid protective type flange coupling. / d0 = 0.6 and driven shaft is a solid shaft. Take τ = 100
Theshafts are running at 500 r.p.m. and transmit 25 kW MPa.
power. Design the coupling completely for overload
capacity 25 per cent in excess of mean transmitted (b) Diameter of bolts, if the coupling uses four bolts.
torque capacity. Assume the following permissible Take σc = σt = 70 MPa and τ = 25 MPa. Assume pitch
stresses for the coupling components : Shaft — circle diameter as about 3 times the outside diameter
Permissible tensile stress = 60 MPa; Permissible shear of the hollow shaft.
stress = 35 MPa, Keys — Rectangular formed end sunk (c) Thickness of the flange and diameter of the hub.
key having permissible compressive strength = 60 MPa, Assume σc = 100 MPa and τ = 125 MPa.
Bolts — Six numbers made of steel having permissible
shear stress = 28 MPa, Flanges — Cast iron having (d) Make a neat free hand sketch of the assembled
permissible shear stress = 12 MPa. Draw two views of coupling showing a longitudinal sectional elevation
the coupling you have designed. with the main dimensions. The other dimensions may
be assumed suitably.
8. Design a shaft and flange for a Diesel engine in which
protected type of flange coupling is to be adopted for 11. Design a bushed-pin type flexible coupling for
power transmission. The following data is available for connecting a motor shaft to a pump shaft for the
design : Power of engine = 75 kW; speed of engine = following service conditions : Power to be transmitted
200 r.p.m.; maximum permissible stress in shaft = 40 = 40 kW ; speed of the motor shaft = 1000 r.p.m. ;
MPa; maximum permissible twist in shaft = 1° in length diameter of the motor shaft = 50 mm ; diameter of the
of shaft equal to 30 times the diameter of shaft; pump shaft = 45 mm. The bearing pressure in the
maximum torque = 1.25 × mean torque; pitch circle rubber bush and allowable stress in the pins are to be
diameter of bolts = 3 × diameter of shaft; maximum limited to 0.45 N/mm2 and 25 MPa respectively.
permissible stress in bolts = 20 MPa. Find out : 1. 12. An universal coupling is used to connect two mild
Diameter of shaft, 2. number of bolts, and 3. diameter steel shafts transmitting a torque of 6000 N-m.
of bolts. Assuming that the shafts are subjected to torsion only,
9. A marine type flange coupling is used to transmit find the diameter of the shaft and the pin. The
3.75 MW at 150 r.p.m. The allowable shear stress in the allowable shear stresses for the shaft and pin may be
taken as 55 MPa and 30 MPa respectively.
 Welding 4.2. Explain what is meant by “Stress
concentration” which is one of the factors that affect
Problem: A plate 100 mm wide and 10 mm thick is to the strength of the weld joint.
be welded to another plate by means of double
parallel fillets. The plates are subjected to a static load 4.3. Figure 1 below shows a component welded to
of 80 kN. Find the length of weld if the permissible a still pate by fillet welds (with all dimensions in mm).
shear stress in the weld does not exceed 55 MPa. The component is subjected to a static load of 240 kN.
Find the length of the weld at the top and bottom. The
Problem: A plate 100 mm wide and 12.5 mm thick is to allowable shear stress for the fatigue load can be taken
be welded to another plate by means of parallel fillet as 44.44 MPa. Neatly draw and label the right-hand
welds. The plates are subj cted to a load of 50 kN. Find side view to illustrate the direction of the applied force
the length of the weld so that the maximum stress and center of gravity.
does not exceed 56 MPa. Consider the joint first under
static loading and then under fatigue loading.

Problem: A plate 75 mm wide and 12.5 mm thick is

joined with another plate by a single transverse weld
and a double parallel fillet weld as shown in Fig. The
maximum tensile and shear stresses are 70 MPa and
56 MPa respectively. Find the length of each parallel
fillet weld, if the joint is subjected to both static and
fatigue loading.

Problem: Determine the length of the weld run for a

plate of size 120 mm wide and 15 mm thick to be
welded to another plate by means of

1. A single transverse weld; and

2. Double parallel fillet welds when the joint is

subjected to variable loads.
Figure 1: Permanent Joint (all dimensions in mm)
Example 1. A 50 mm diameter solid shaft is welded to
a flat plate by 10 mm fillet weld. Find the maximum
torque that the welded joint can sustain if the QUESTION 4 [20 MARKS]
maximum shear stress intensity in the weld material is
not to exceed 80 MPa. 4.1. Defects affect the strength of the weld joints.
Mention various kinds of weld defects that may
Example 2. A plate 1 m long, 60 mm thick is welded to contribute to this.
another plate at right angles to each other by 15 mm
fillet weld. Find the maximum torque that the welded 4.2. A channel, shown in figure 1 below, is welded
joint can sustain if the permissible shear stress to a steel plate and carries a tensile load of 140 kN
intensity in the weld material is not to exceed 80 MPa. along the axis of the channel. Redraw the channel and
show how the force is applied and find suitable lengths
Problem: A bracket carrying a load of 15 kN is to be (top and bottom) of the welds taking allowable tensile
welded as shown in Fig. Find the size of weld required stress in the weld as 110 MPa.
if the allowable shear stress is not to exceed 80 MPa.

Problem: A welded joint as shown in Fig. 10.24, is

subjected to an eccentric load of 2 kN. Find the size of
weld, if the maximum shear stress in the weld is 25
MPa.

QUESTION 4 [23 MARKS]

4.1. What is the difference between fillet and butt

joints?
 Figure 1: Eccentrically loaded weld joint.

A rectangular cross-section bar is welded to a support

by means of fillet welds as shown in Fig. Determine the
size of the welds, if the permissible shear stress in the
weld is limited to 70 MPa.

Figure 1: Channel welded to a steel plate (all dimensions in mm) Figure 1: Eccentrically loaded weld joint.

A 220 mm long hollow shaft of 30 mm inside diameter

and 75 mm outside diameter is welded to a flat plate
as shown in Figure 1 below. The shaft carries a load of
15 kN at the free end, which is induced by the weight
of the pulley and the tension in the pulley belt. If the
size of the weld is 22 mm, find the maximum normal
and shear stress in the weld.

Figure 1: Permanent welded Joint (all dimensions in millimetres)

Explain what is meant by residual stresses in the weld

joint.

Figure 1 below shows an eccentrically loaded welded

joint. The external force P of 36 kN acts eccentrically on
the weld joint whose leg size and length are 15 mm and
105 mm respectively. if the force is at a distance of 140
mm from the weld, determine the maximum normal
and shear stresses acting on the weld joints
 Stresses in Machine Elements
Q.1: What stresses are developed in the pin A for the bell crank mechanism shown in the figure-2.1.7.1? Find the safe diameter of the pin if the allowable tensile
and shear stresses for the pin material are 350 MPa and 170 MPa respectively.

Q.2: Two cast iron machine parts of cross-sections shown in figure-2.1.7.2 are subjected to bending moments. Which of the two sections can carry a higher
moment and determine the magnitude of the applied moments?

Q.3: What are the basic assumptions in deriving the bending equation?

Q.4: Under what condition transverse shear stresses are developed in a beam subjected to a bending moment?

Q.5: A 3m long cantilever beam of solid rectangular cross-section of 100mm width and 150mm depth is subjected to an end loading P as shown in the figure-
2.1.7.5. If the allowable shear stress in the beam is 150 MPa, find the safe value of P based on shear alone.

Q.6: Show how the transverse shear stress is distributed in a beam of solid rectangular cross-section transmitting a vertical shear force.

Q.7: In a design problem it is necessary to replace a 2m long aluminium shaft of 100mm diameter by a tubular steel shaft of the same outside diameter transmitting
the same torque and having the same angle of twist. Find the inner radius of the steel bar if GAl = 28GPa and GSt = 84GPa.

Q.8: An axially loaded brass strut hinged at both ends is 1m long and is of a square cross-section of sides 20mm. What should be the dimension of a steel strut of
the same length and subjected to the same axial loads?

Q.10: Show the stresses on the element at A in figure-2.1.7.6.

Q, 1 ;Consider an element with the following stress system (figure-2.2.6.1) sx=-10 MPa, sy = +20 MPa, τ = -20 MPa. We need to find the principal stresses and show
their senses on a properly oriented element.

Q.2: A 5mm thick steel bar is fastened to a ground plate by two 6 mm diameter pins as shown in figure-2.2.7.1. If the load P at the free end of the steel bar is 5
KN, find

(a) The shear stress in each pin and The direct bearing stress in each pin.

Q 3: A 100 mm diameter off-set link is transmitting an axial pull of 30 KN as shown in the figure- 2.2.7.3. Find the stresses at points A and B.

An off-set link of 85 mm uniform diameter is transmitting an axial push of 40 KN and a torsion of 8 kN.m, as shown in figure 2. Find the principal stresses at
points A.

Figure 1: An off-set link.

Q 4: A vertical load Py = 20 KN is applied at the free end of a cylindrical bar of radius 50 mm as shown in figure-2.2.7.5. Determine the principal and maximum
shear stresses at the points A, B and C.

Q 5: A propeller shaft for a launch transmits 75 KW at 150 rpm and is subjected to a maximum bending moment of 1KN-m and an axial thrust of 70 KN. Find the
shaft diameter based on maximum principal stress if the shear strength of the shaft material is limited to 100 MPa.

The part shown in Figure 2 below is loaded at point C with 300 N force in the positive x-direction and at point E with 200 N force in the positive y-direction. The
diameter of the bar ABD is 12 mm. Evaluate the following
6.1. Determine and sketch the stress element at point A. Evaluate the principal stresses and maximum shear at point A .

Figure 2: Cantilever beam (all dimensions in millimeters)

 Pipes and Pipe joint design
1. A cast iron pipe of internal diameter 200 mm and thickness 50 mm carries water under a pressure of 5 N/mm2. Calculate
the tangential and radial stresses at radius (r) = 100 mm ; 110 mm ; 120 mm ; 130 mm ; 140 mm and 150 mm. Sketch the
stress distribution curves.
2. A seamless pipe carries 2400 m3 of steam per hour at a pressure of 1.4 N/mm2. The velocity of flow is 30 m/s. Assuming
the tensile stress as 40 MPa, find the inside diameter of the pipe and its wall thickness.
3. Find out the dimensions of a flanged joint for a cast iron pipe 250 mm diameter to carry a pressure of 0.7 N/mm2.
4. A flanged pipe with internal diameter as 200 mm is subjected to a fluid pressure of 0.35 N/mm2. The elevation of the
flange is shown in Fig. 8.12. The flange is connected by means of eight M 16 bolts. The pitch circle diameter of the bolts
is 290 mm. If the thickness of the flange is 20 mm, find the working stress in the flange.
5. Design and draw an oval flanged pipe joint for a pipe having 50 mm bore. It is subjected to an internal fluid pressure of 7
N/mm2. The maximum tensile stress in the pipe material is not to exceed 20 MPa and in the bolts 60 MPa.
6. Design a square flanged pipe joint for pipes of internal diameter 50 mm subjected to an internal fluid pressure of 7
N/mm2. The maximum tensile stress in the pipe material is not to exceed 21 MPa and in the bolts 28 MPa.
7. A cast iron pipe of internal diameter 200 mm and thickness 50 mm carries water under a pressure of 5 N/mm2. Calculate
the tangential and radial stresses at the inner, middle (radius = 125 mm) and outer surfaces.
8. A cast iron pipe is to carry 60 m3 of compressed air per minute at a pressure of 1 N/mm2. The velocity of air in the pipe
is limited to 10 m/s and the permissible tensile stress for the material of the pipe is 14 MPa. Find the diameter of the pipe
and its wall thickness.
9. A seamless steel pipe carries 2000 m3 of steam per hour at a pressure of 1.2 N/mm2. The velocity of flow is 28 m/s.
Assuming the tensile stress as 40 MPa, find the inside diameter of the pipe and its wall thickness.
10. Compute the dimensions of a flanged cast iron pipe 200 mm in diameter to carry a pressure of 0.7 N/mm2.
11. Design an oval flanged pipe joint for pipes of internal diameter 50 mm subjected to a fluid pressure of 7 N/mm2. The
maximum tensile stress in the pipe material is not to exceed 21 MPa and in the bolts 28 MPa.

Riveted Joints
1. A double riveted lap joint is made between 15 mm thick plates. The rivet diameter and pitch are 25 mm and 75 mm
respectively. If the ultimate stresses are 400 MPa in tension, 320 MPa in shear and 640 MPa in crushing, find the
minimum force per pitch which will rupture the joint. If the above joint is subjected to a load such that the factor of
safety is 4, find out the actual stresses developed in the plates and the rivets.
2. Find the efficiency of the following riveted joints :
1. Single riveted lap joint of 6 mm plates with 20 mm diameter rivets having a pitch of 50 mm.
2. Double riveted lap joint of 6 mm plates with 20 mm diameter rivets having a pitch of 65 mm.
Assume, Permissible tensile stress in plate = 120 MPa, Permissible shearing stress in rivets = 90 MPa, Permissible
crushing stress in rivets = 180 MPa
3. A double riveted double cover butt joint in plates 20 mm thick is made with 25 mm diameter rivets at 100 mm pitch.
The permissible stresses are : σt = 120 MPa; τ = 100 MPa; σc = 150 MPa. Find the efficiency of joint, taking the
strength of the rivet in double shear as twice than that of single shear.
4. Design a double riveted butt joint with two cover plates for the longitudinal seam of a boiler shell 1.5 m in diameter
subjected to a steam pressure of 0.95 N/mm2. Assume joint efficiency as 75%, allowable tensile stress in the plate
90 MPa ; compressive stress 140 MPa ; and shear stress in the rivet 56 MPa.
 5. 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.

6. The bracket as shown in Fig. 9.27, is to carry a load of 45 kN.

Determine the size of the rivet if the shear stress is not to exceed 40
MPa. Assume all rivets of the same size.

A bracket is riveted to a column by 6 rivets of equal size as shown in Fig. 9.31. It

carries a load of 60 kN at a distance of 200 mm from the centre of the column. If
the maximum shear stress in the rivet is limited to 150 MPa, determine the
diameter of the rivet.

A certain part of the lifting maching is permanently joint to its body using rivets, as show in the figure
aside. In most cases, the operator uses this part to hang heavy loads. If this machine part is permanently joined
to the body using four equal rivets, ech of 20 mm diameter with the working shear stress of 100 MPa, find the
maximum weight (in kg) that the component can carry.

1. An eccentrically loaded riveted joint is to be designed for a steel bracket, as shown aside. The
yield strength in the rivets is 300 MPa, the crushing stress is 20% greater than the tensile stress
and the shear stress is 46 % less than the crushing stress. The factor of safety may be assumed
to be 3. Assuming all rivets are the same, find the diameter of the rivet.

2. Design and make a neat sketch of a circular flanged pipe with internal diameter as 200 mm. The fluid in the pipe must not exceed an pressure of 0.4
N/mm2. The flange is to be connected by means of six M22 bolts. The pitch circle diameter of the bolts is 290 mm and the thickness of the flange is 25
mm. Also find the working stress in the flange.
3. Design and draw an oval flanged pipe joint for a pipe having 60 mm bore. It is subjected to an internal fluid pressure of 8 N/mm2. The maximum tensile
stress in the pipe material is not to exceed 30 MPa and in the bolts 60 MPa.
4. Design a cast iron protective type flange coupling to transmit 15 kW at 900 RPM. from an electric motor to a compressor. The service factor may be
assumed as 1.35. The following permissible stresses may be used:
Shear stress for shaft, bolt and key material = 40 MPa
Crushing stress for bolt and key = 80 MPa
Shear stress for cast iron = 8 MPa
Draw a neat sketch of the coupling.
5. It is required to design a split muff coupling to transmit 50 kW power at 120 rpm The shafts, key and coupling bolts are made of plain carbon steel 30C8
Syt 400 N/mm2. The yield strength in compression is 150 % of the tensile strength. The factor of safety for the shafts, key and bolts is 5. The number
of clamping bolts is 8 The co-efficient of friction between sleeve halves and shaft is 0.3.
6. Design a muff coupling to connect 2 steel shafts transmitting 25kW power at 360rpm. The shafts and keys are made of plain carbon steel 30C8
(Syt=Syc=400N/mm2). The sleeve is made of grey cast iron FG200 (Sut=200N/mm2). The factor of safety for the shafts and key is 4. For the sleeve, the
factor of safety is 6 based on ultimate strength.
7. It is required to design a bushed pin-type flexible coupling to connect the output shaft of an electric motor to the shaft of a compressor. The motor
delivers 20 kW power at 720 rpm. The starting torque is assumed to be 150% of the rated torque. Design the coupling and specify its dimensions. Take
the yield strengths for shaft, key, flange, and pin as 380 MPa, 400 MPa, 200 MPa, and 400 MPa respectively, and the factor of safety for shaft, key, and
the pin is 2 while for the flanges is 6. Assume that the key crushing yield strength is 150% of tensile yield strength, the number of pins to be 3, and the
bearing pressure to be 0.5 MPa.

11. An eccentrically loaded lap riveted joint is to be designed for a steel bracket as shown in the figure below. The bracket plate is 10 mm thick.
All rivets are to be of the same diameter of 24 mm. The eccentric load on the bracket is 18 kN. The permissible crushing stresses 120 MPa.
Determine the permissible shear stress on the rivets and the working crushing stress.
P
300

c c
All dimentions in mm. Take C as 65 mm and h as 85 mm
Figure 3: Eccentrically loaded riveted joint.