DESIGN OF MACHINE MEMBER-II QUESTION BANK UNIT I

BEARINGS : Types of Journal bearings Lubrication Bearing Modulus Full and partial bearings Clearance ratio Heat dissipation of bearings, bearing materials journal bearing design Ball and roller bearings Static loading of ball & roller bearings, Bearing life. _________________________________________________________________________________ 1. i. What are the desirable properties of bearing materials? ii. A hydrodynamic full journal bearing is to carry a load of 25 kN at a speed of 3000 rpm. The journal diameter is 150 mm and the length of bearing is 75 mm. SAE 30 oil is used with an average operating temperature of 55oC.If the radial clearance is 0.075 mm, calculate the power loss, the side leakage and the minimum film thickness. (Aug/Sep 07) i. What is equivalent static load. ii. The radial reaction on a bearing is 9000 N. It also carries a thrust of 5000 N. The speed of the shaft is 1000 rpm. The outer ring stationary. Expected average life of bearing is about 25,000 hours. The load on the bearing is smooth, the service is 8 hours/day. Select, i. Suitable roller bearing ii. What is the rated 90% life of selected bearing? iii. Compute the probability of the selected bearing surviving 25,000 hours (Aug/Sep 07) i. Name the various bearing materials and name the important requirements of bearing materials for efficient operation.

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ii. Design a full journal bearing of 100 mm long supports a radial load of 5 kN. The shaft rotates at 500 rpm. The diametral clearance is 0.1 mm. The room temperature is 25oC and temperature of the surface of the bearing is to be limited to 55oC. The bearing is well ventilated and no artificial cooling is to be used. Select a suitable oil to satisfy above requirements.

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A roller bearing is selected to withstand a radial load of 40 kN and life of 1200 hrs at 600 rpm. What load rating would you look for in searching from manufacturers catalogue if it specifies loud at speed 500 rpm and life 3000 hrs ii. Select a suitable rolling bearing for a 55 mm diameter shaft. The bearing should be capable of withstanding 3 kN radial and 1.5 kN axial load at 750 rpm. The bearing is to have a desired rated life of 2000 hrs at a reliability of 94% . There is a light shock load and inner ring rotates. (Aug/Sep 07) i. Explain wedge film and squeeze film journal bearings. ii. The load on a 100 mm full hydrodynamic journal bearing is 9000 N. Speed of the journal is 320 rpm. consider L/D = 1, C/D = 0.0011. The operating temperature = 65C and minimum oil film thickness = 0.022 mm. i. Select an oil that will closely accord with the stated conditions. For these selected oil, determine ii. the friction loss iii. the hydrodynamic oil flow through the bearing iv. the amount of leakage v. the temperature rise of oil passes through the bearing and vi. maximum oil pressure (Aug/Sep 07) i. What are the various types of lubrication methods for journal bearings? ii. Design a suitable journal bearing for a centrifugal pump from the following available data: Load on the bearing = 13.5 kN Diameter of the journal = 75 mm Speed = 1440 rpm Bearing characteristic number at the working temperature of 75C = 30 Permissible bearing pressure intensity = 0.7 N/mm2 to 1.4 N/mm2 Average atmospheric temperature = 30C Calculate the cooling requirements, if any (Aug/Sep 07) i. What are the dimensionless parameters used in designing hydrodynamic bearing? Explain their significance. ii. A 3 kN load is supported by a journal bearing of 75 mm diameter and 75 mm long. Diametral clearance 0.05 mm and bearing is lubricated by an oil of 0.0207 PaS viscosity at operating temperature. Determine the maximum speed of rotation of bearing when it is capable of dissipating 80 watts by heat transfer.1centipoise=103 PaS. (May 07) i. A journal bearing 80 mm in diameter and 120 mm long runs at 600 rpm. It uses oil having viscosity of 60 centipoises. Radial clearance provided is 0.15 mm. Determine the safe load, bearing can take. Assume sommer feld number =1.43 109

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ii. A 75 mm journal bearing 100 mm long is subjected to 2.5 kN at 600 rpm. If the room temperature is 24oC what viscosity of oil should be used to limit the bearing surface temperature at 55oC. D/C = 1000. (May 07) i. What is meant by square bearing? ii. Select a suitable spherical roller bearing from SKF series 222C to support a radial load of 4 kN and an axial load of 2 kN. Minimum life required is 10,000 hoursat1000 rpm. For the selected bearingfind. i. The expected life under the given loads ii. The equivalent load that can be supported with a probability of survival of 95% with 10,000 hours

(May 07) 10. i. Distinguish between full and partial journal bearings. ii. Design a journal bearing for a steam turbine, whose shaft is supported on two bearings one at each side of the turbine, and is coupled with a generator for power production. The weight of turbine with shaft is measured as 40 kN and the shaft rotates at 1500 rpm. Diameter of the shaft is 100 mm. (Apr/May 06) 11 i. What is the most important advantage gained in using needle bearing? ii. A 6203 single row deep groove ball bearing has a basic static load rating of 4500 N and basic dynamic load rating of 7350 N. If it is subjected to radial load of 1350 N and axial load of 1260 N, what is the rated life with outer ring stationary? iii. What is the nominal life in working hours of a deep groove ball bearing 6308, which is carrying a constant radial load of 2.82 kN at a speed of 800 rpm? (Apr/May 06) 12. i. i. ii. iii. Define the following: (Apr/May 06) Eccentricity of journal bearing Minimum film thickness Design a journal bearing for a centrifugal pump running at 1440 rpm. Diameter of the journal is 10 cm and load on each bearing is 2000 kg. The factor ZN/P may be taken as 2800 for centrifugal pump bearings. Assume the followings. Atmospheric temperature = 30 degree C Operating temperature = 75 degrre C Energy dissipation coefficient = 0.00125 C/D ratio = 0.001 L/D ratio = 1.5

13. i. What factors should be considered when selecting bearings? ii. Design a full journal bearing for the following specifications. Radial load =30 kN Journal diameter = 120 mm Speed of the journal = 500 rpm Minimum oil film thickness = 0.025 mm 14. i. What do you understand by boundary lubrication in journal bearings? ii. The following data refer to a journal bearing Diameter of the journal = 100 mm Length of the journal = 175 mm Load = 28 kN Speed = 250 rpm C/D = 0.001 Determine the coefficient of friction and heat generated.

(Apr/May 06) (Apr/May 06)

15. i. What are the commonly used non-metallic bearing materials? (Apr/May 06) ii. The radial load on a roller bearing varies as follows. A load of 50 kN is acting 20% of time at 500 rpm and a load of 40 kN is acting 50% of time at 600 rpm. In the remaining time, the load is varying from 40 kN to 10 kN linearly at 700 rpm. Select a roller bearing from NU22 series for a life of at least 4000 hours. The operating temperature is 175 degree C. ______________________________________________________________________________________

UNIT II
ENGINE PARTS : Connecting Rod : Thrust in connecting rod stress due to whipping action on connecting rod ends Cranks and

Crank shafts, strength and proportions of over hung and center cranks Crank pins, Crank shafts. 1. What are the stresses to which an over hanging shaft is subjected to? How would you proceed to design such a crank shaft. (Aug/Sep- 07/06) (Apr/May-06)

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Design a center crankshaft for a single acting 175175 mm air compressor working at 360-rpm. The maximum pressure on the cylinder is 70N/sq.mm. Select suitable material and factor of safety. (Aug/Sep 07) Enumerate the design procedure for the connecting rod section considering it as a simple compression or tension member subjected to fluctuating load. (Aug/Sep 07) i. Give the design criteria for selection of diameter of connecting rod ends. ii. Sketch the inertial loading pattern on connecting rod and state when it will occur. i. What is the function of a crank shaft? ii. Explain the different stresses induced in crank pin.

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iii. Explain the different stresses induced in crank Web. iv. How crank shaft bearings are lubricated?

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Design a plain carbon steel crankshaft for a 0.40 m by 0.60m single acting 4-stroke diesel engine to operate at 200 rpm. The mean eective pressure is 0.49 MPa, and the maximum combustion pressure is 2.624MPa at a maximum torsional moment. When the crank angle is 36o, the gas pressure is 0.975 MPa. The ratio of connecting rod length to crank radius is 4.8. The flywheel is used as a pulley the weight of the flywheel 54.50kN and the total belt pull is 6.75kN. Assume the suitable values for the missing data. (Apr/May 06)

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Give design consideration in determining i. Diameter of crank pin ii. Web section iii. Crank shaft diameter

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The critical section of a connecting rod for a diesel engine is at a 2/5 th distance from the gudgeon pin. It is the I-section having the following proportions: Width of the flange = 40 mm, Thickness of the flange = 20 mm, depth of the Section = 50 mm, the thickness of the web = 10mm, the diameter and stroke of the piston are 120 mm and 220 mm respectively and the length of the connecting rod is 450 mm, the maximum gas pressure in the cylinder is 4.7 Mpa, The speed of the engine is 1200 rpm. Check the factor of safety is sufficient or not. (Aug/Sep 06) The maximum connecting rod force on a steam engine running at 90 rpm is 70 kN. Determine the necessary size of the over hanging crank pin. Determine the diameter of the crankshaft journal if the stroke is 0.90 m and distance between centerline of bearing and pin is 0.36 m. (Aug/Sep 06) Find the diameter of steel connecting rod for an engine in which the maximum load on the piston is 700 kN, crank of the engine is 0.60m, radius of connected rod length 3m, factor of safety is 8. (May 05)/(May04) Check the suitability of I-section 15mm x 12mm x 3mm for designing the connecting rod in the case of single cylinder motor cycle engine of 40 mm bore and 50 mm stroke wherein the maximum pressure produced is 3.6 Mpa and in which the connecting rod is 4 times crank. (May 05) Design a plain carbon steel crank shaft for a 0.40 m by 0.60 m single acting 4-stroke diesel engine to operate at 200 rpm. The mean effective pressure is 0.49 Mpa, and the maximum combustion pressure is 2.624 Mpa at a maximum torsional moment. When the crank angle is 36o, the gas pressure is 0.975 Mpa and the ratio of connecting rod length to crank radius is 4.8. The flywheel is used as a pulley. The weight of the flywheel is 54.50 kN and the total belt pull is 6.75 kN. Assume the suitable values for the missing data. (May 04) Design and make sketches for a forged connecting rod for a 0.60 x 0.75 steam engine the connecting rod must be 1.875 mts long H-section and is to transmit a maximum thrust of 0.84 Mpa of piston area at 100 rpm. The crank pin is 0.1 25 mt in diameter and wrist pin 0.088 mt. The crank end is to be made open with standard type of bearing cap. The wrist pin and crank should have wedge adjustment for wear. Calculate the size of the bolts, thickness of cap and check the H-section at the mid point of the rod. (May 04) Design an over hung crank for the following data Maximum load on the crank pin when the crank and the connecting rod are at right angle is 44000 N. The crank radius is 16 mm and the distance between centers of crank pin and main bearing is 24 cm. The crank pin is hydraulically pressed in the position and web is keyed to the crankshaft. Design the crank pin and the web makes a tension of 5000 N/sq.mm in shear, bearing pressure of the crank pin 700 N/sq.mm. (May 04)

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UNIT III
Pistons, Forces acting on piston Construction Design and proportions of piston., Cylinder, Cylinder liners 1. A four stroke diesel engine has the following specifications:Brake power = 5kW; Speed= 1200 rpm; Indicated mean effective pressure=0.35M/mm2; Mean efficiency=80%. Determine:1. Bore and length of the cylinder; 2. Thickness of the cylinder head; and 3. Size of studs for the cylinder head. A four stroke diesel engine has the following specifications:Brake power = 7.5kW; Speed= 1000 rpm; Indicated mean effective pressure=0.35M/mm2; Maximum gas pressure =3.5 N/mm2; Mechanical efficiency=80%. Determine: 1. The

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dimensions of the cylinder if the length of stroke is 1.4 times the bore of the cylinder; 2. Wall thickness of the cylinder, if the hoop stress is 35 MPa; 3. Thickness of the cylinder head and the size of studs when the permissible stresses for the cylinder head and stud material are 45 MPa and 65 Mpa respectively. 3. Design a cast iron piston for a single acting four stroke engine for the following data: Cylinder bore=100mm; stroke=125 mm; Maximum gas pressure=5 N/mm2; Indicated mean effective pressure=0.75 N/mm2; Mechanical efficiency =80%; Fuel consumption=0.15 kgper brake power per hour; Higher calorific value of fuel=42X103 kJ/kg; speed=2000 rpm. Any other data required for the design may be assumed. Design a cast iron trunk type piston for a single acting four stroke engine developing 75 kW per cylinder when running at 600 rpm. The other available data is as follows: Maximum gas pressure =4.8 N/mm2; Indicated mean effective pressure=0.65 N/mm2; Mechanical efficiency =95% ; Radius of crank=110 mm; Fuel consumption=0.3 kg/BP/hr; Calorific value of fuel (higher) =44X103 kJ/kg; Difference of temperatures at the centre and the edges of the piston head = 2000C; Allowable stress for the material of the piston=33.5 MPa; Allowable stress for the material of the

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UNIT IV
Design of curved beams: introduction, stresses in curved beams, Expression for radius of neutral axis for rectangular, circular, trapezoidal and T-Section. Design of crane hooks, C clamps. 1. A crane hook carries a load of 6kN, the line of the load being at a horizontal distance of 3-25 cm from the inside edge of a horizontal section through the centre of curvature, the centre of curvature being 4cm from the same edge. The horizontal section is a trapezium whose parallel sides are 1-5 cm and 3 cm and perpendicular distance apart by 3-25cm. Find the greatest tensile and compressive stresses in the hook. (Aug/Sep 07)

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The section of a crane hook is a rectangle 6cmx4cm. The centre of curvature of the section is at a distance of 8 cm from the centroid of the section. A load of 15 kN is acting through the centre of curvature. Determine the maximum and minimum bending stresses induced in the hook. (Aug/Sep 07) The section of a crane hook is a circle of 6cm diameter. The initial radius of curvature of the hook is 8cm. Locate the position of the neutral axis and the maximum and minimum stresses in the hook to lift a load of 10 kN. (Aug/Sep 07)

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A ring made of 2.5 cm diameter steel bar carries a pull of 10 kN. Calculate the maximum tensile and compressive stresses in the material of the ring. The mean radius of the ring in 15 cm. (Aug/Sep 07) A proving ring is 25 cm mean diameter, 4 cm wide and 6 mm thick. The maximum stress permitted is 550 MPa. Find the permissible load. (Apr/May 06) A chain link is subjected to a pull of 15 kN. It is composed of steel rod 2cm diameter and has a mean radius of 2.5 cm. It semi-circular ends are connected by straight pieces 2.5 cm long. Estimate the maximum compressive stress in the link and the tensile stress at the same section. (Apr/May 06) A crane hook is of trapezoidal cross-section having inner side 80 mm, outer side 30mm and depth 120mm. The raidus of curvature of the inner side is 80 mmm. If a load of 100 kN is applied to the hook passing throguh the centre of curvature, determine the maximum tensile and compressive stresses at the critical cross-section. (Aug/Sep 06) Determine the load carrying capacity of a hook of rectangular cross-section. The thickness of the hok is 75 mm; the radius of the inner fibres is 150 mm, while that of the outer fibres is 250 mm. The line of action of the force passes at a distance of 75 mm from the inner fibres. The allowable stress is 70 MN/m square. (Aug/Sep 06) A curved bar of circular cross-section 100 mm in diameter has a radius of curvature of 25 mm at the iner fibres. The bending moment acting on the bar causes a tensile stress of 20 MN/msquare in the inner fibtes. What wil be the stress in the outer fibres.? (Aug/Sep 06)

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A proving ring is 250 mm mean diameter, 40mm wide and 6 mm thick. The maximum stress permitted is 550 MN/m square. Fin dthe load to cause this stress and the load to give 6 mm deflection along the laod line, E = 200 GN/m square. (May 07) A streel bar 60 mm diameter is bent to the shape shown in Fig. 16.35 and the lower end is firmly fixed in the groudn in a vertical position. A load of 800 N is applied at the free end. Calculate the vertical deflection of the free end, E= 200 GN/Msquare. (May 07)

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A curved beam shown in Fig. 16-37 has a 30 mm square cross-section, and aradius of curvature R = 65mm. The beam is made of steel for which E = 200 GPa and v=0.30. If P=6 kN, determine the component of deflection of the free end of there curved beam in the direction of P. (May 07)

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A ring of mean diameter 100 mm is made of roudn steel 25 mm diameter. It is subjected to four dqual pulls in two directions at right angles and passing through the centre. Determine the maximum value of the pulls if the maximum tensile stress is not to exceed 80 N/mm square. (May 07)

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UNIT V POWER TRANSMISSIONS SYSTEMS, PULLEYS : Transmission of power by Belt and Rope drives, Transmission
efficiencies, Belts Flat and V types Ropes - pulleys for belt and rope drives, Materials,Chain drives 1. A 8mm thick leather open belt connects two flat pulleys. The smaller pulley is 300 mm diameter and runs at 200 r.p.m. The angle of lap of this pulley is 1600 and the coefficient of friction between the belt and the pulley is 0.25. The belt is on the point of slipping when 3kW is transmitted. The safe working stress in the belt material is 1.6 N/mm2. Design the drive for 20% overload capacity. (Aug/Sep 07) i. Prove that the centrifugal tension must be 1/3rd of the maximum tension for maximum power transmission. ii. Design a cross belt drive having 1.5 m center distance between the two pulleys The diameter of bigger and smaller pulleys are 'D' and 'd' respectively. The smaller pulley rotates at 1000 r.p.m. and the bigger pulley at 500 r.p.m. The flat belt is 6 mm thick and transmits 7.5 kW power at belt speed of 13 m/s approximately. The coefficient of belt friction is 0.3 and the density of belt material is 950 kg/m3. The permissible tensile stress for the bet material is 1.75 MPa. (Aug/Sep07) An open belt connects two flat pulleys. The pulley diameters are 300 mm and 450 mm and the corresponding angles of lap are 160 and 210. The smaller pulley runs at 200 r.p.m. The coefficient of friction between the belt and pulley is 0.25. It is found that the belt is on the point of slipping when 3 kW is transmitted. To increase the power transmitted two alternatives are suggested, namely i. increasing the initial tension by 10%, and ii. increasing the coefficient of friction by 10% by the application of a suitable dressing to the belt. Which of these two methods would be more effective? Find the percentage increase in power possible in each case and also design the system. (Aug/Sep 07) i. Write the procedure for designing a wire rope. ii. Select a wire rope for a vertical mine hoist to lift a load of 55kN from a depth 300 meters. A rope speed of 500 meters/min is to be attained in 10 seconds. (May 07) An open belt connects two flat pulleys. The pulley diameters are 300 mm and 450 mm and the corresponding angles of lap are 160o and 210o. The smaller pulley runs at 200 r.p.m. The coefficient of friction between the belt and pulley is 0.25. It is found that the belt is on the point of slipping when 3 kW is transmitted. To increase the power transmitted two alternatives are suggested, namely i. increasing the initial tension by 10%, and ii. increasing the coefficient of friction by 10% by the application of a suitable dressing to the belt. Which of these two methods would be more effective? Find the percentage increase in power possible in each case and also design the system. (May 07) Design a flat belt drive to transmit 110kW at a belt speed of 25m / s between two pulleys of diameters 250mm and 400mm having a pulley center distance of 1 metre. The allowable belt stress is 8.5 kg/m2. Given that the coefficient of friction between the belt and pulleys is 0.3, determine the minimum required belt width. What would be the necessary installation force between the pulley bearings and what will be the force between the pulley bearings when the full power is transmitted? (May 07) Design a cast iron pulley of 630mm diameter to transmit 10kW at a speed of 500 r.p.m. The center plane of the pulley overhangs the nearer bearing by 300mm. The belt ends are parallel and horizontal and the belt tension ratio is 2:1. ii. Design a belt pulley to transmit 10kW at 180 r.p.m. The velocity of the belt is not to exceed 500 meter / minute and the maximum tension is not to exceed 15 N/mm width. The tension on the slack side is one half that on the tight side. Calculate i.

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all the dimensions of the pulley. Sketch neatly the sectional elevation and end view showing all leading dimensions (May 07) 8. i. List out the advantages and disadvantages of V - belts (Apr/May 06) ii. A workshop crane is lifting a load of 25 kN through a wire rope and a hook. The rope drum diameter may be taken as 30 times the diameter of the rope. The load is to be lifted with an acceleration of 1 m/s2. Calculate the diameter of the wire rope. Take a factor of safety of 6 and youngs modulus for the wire rope 80 kN/mm2. The ultimate stress may be taken as 1800 MPa. The cross sectional area of the wire rope may be taken as 0.38 times the square of the wire rope diameter.
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Prove that the centrifugal tension must be 1/3rd of the maximum tension for maximum power transmission. ii. Design a cross belt drive having 1.5 m center distance between the two pulleys The diameter of bigger and smaller are D and d respectively. The smaller pulley rotates at 1000 r.p.m. and the bigger pulley at 500 r.p.m. The flat belt is 6 mm thick and transmits 7.5 kW power at belt speed of 13 m/s
approximately. The coefficient of belt friction is 0.3 and the density of belt material is 950 kg/m3. The permissible tensile stress for the bet material is1.75 MPa. (Apr/May 06)

pulleys

10. i. Write the procedure for designing a wire rope. (Apr/May 06) ii. Select a wire rope for a vertical mine hoist to lift a load of 55kN from a depth 300 meters. A rope speed of 500 meters/min is to be attained in 10 seconds. 11. An open belt connects two flat pulleys. The pulley diameters are 300 mm and 450 mm and the corresponding angles of lap are 160o and 210o. The smaller pulley runs at 200 r.p.m. The coefficient of friction between the belt and pulley is 0.25. It is found that the belt is on the point of slipping when 3 kW is transmitted. To increase the power transmitted two alternatives are suggested, namely i. increasing the initial tension by 10%, and ii. increasing the coefficient of friction by 10% by the application of a suitable dressing to the belt. Which of these two methods would be more eective? Find the percentage increase in power possible in each case and also design the system. (Aug/Sep 06)

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Design a cast iron pulley of 630mm diameter to transmit 10kW at a speed of 500 r.p.m. The center plane of the pulley overhangs the nearer bearing by 300mm. The belt ends are parallel and horizontal and the belt tension ratio is 2:1. ii. Design a belt pulley to transmit 10kW at 180 r.p.m. The velocity of the belt is not to exceed 500 meter / minute and the maximum tension is not to exceed 15 N/mm width. The tension on the slack side is one half that on the tight side. Calculate all the dimensions of the pulley. Sketch neatly the sectional elevation and end view showing all leading dimensions. (Aug/Sep 06)

13. i. State the advantages and disadvantages of flat belts. ii. A 18 kW, 900 r.p.m. motor drives a centrifugal pump at 290 r.p.m. by means of a leather belt. The pulleys are of cast iron and are 1.2 meter center distance. The pulleys of diameter less than 150 mm should not be used. The coefficient of friction between the leather belt and the cast iron pulley is 0.35, and the mass of the belt is 9 kg/m width/m length. The maximum permissible tension. (Aug/Sep 06) __________________________________________________________________________________

UNIT VI SPUR & HELICAL GEAR DRIVES : Spur gears- Helical gears Load concentration factor Dynamicload factor. Surface
compressive strength Bending strength Design analysis of spur gears Estimation of centre distance, module and face width, check for plastic deformation. Check for dynamic and wear considerations. 1. Design a cast iron spur gear drive for a crane hoist to transmit 3.75 kW at 1440 rpm. Maximum gear ratio in the gear box is 4. Each gear is expected to work 2 hours/day for 10 years. Determine the minimum centre distance, required face width and module of the gear. (Aug/Sep 07) A pair of gears is to be designed to transmit 30kW for a pinion speed of 1000 rpm and a speed ratio of l:5. Design the gear pair. (Aug/Sep 07) What should be the module, face width and number of teeth on each gear of a pair of spur gears, a C45 steel pinion driving a cast iron gear, if they are to transmit 18.75 kW at 700 rev/min of the 0.18m pinion in continuous service? The velocity ratio is 3, the teeth are 200 full depth and the load is smooth. Determine the outside and root diameters.(Aug/Sep 07) Design the teeth for a pair of cast iron spur gears with cast teeth to transmit 26kW. The pinion runs at 50 rev/min and the velocity ratio is to be 2.5. Decide upon a suitable grade of cast iron and find the module, face, and diameters, and centre distance for the gears. Check for dynamic load. (Aug/Sep 07) i. State and derive Lewis Beam Strength equation.

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A shaft running at 1440 rpm drives another shaft rotating at 500 rpm approx imately. If the power to be transmitted is 10kW, and running 8 hr/day, design the spur gear. (May 07)

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i. Explain the assumptions made in deriving Lewis beam strength equation. ii. A compressor running at 250rpm is driven by a 15kW, 870 rpm motor through a pair of 141/2o full depth spur gears. Use C30 Steel for pinion and C45 for gear. Design the gear drive and check for dynamic load. (May 07) i. Does the accuracy of gear profile influence the spur gear design? Explain. ii. A pair of mating carefully cut spur gears have 20 full depth teeth of 4 mm module. The number of teeth on pinion and gear are 38 and 115 respectively. The face width is 40mm. If the pinion and gear are made of Steel with core hardness of 200 and surface hardness of 300, Calculate the safe power that can be transmitted when the pinion is to run at 1200 rpm. (May 07) (Aug\Sep-06)

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Design a cast iron spur gear drive for a crane hoist to transmit 3.75 kW at 1440 rpm. Maximum gear ratio n the gear box is 4. Each gear is expected to work 2 hours/day for 10 years. Determine the minimum centre distance, required face width and module of the gear. (Apr/May 06) It is desired to determine the proportions of a spur gear drive to transmit 8kW from a shaft rotating at 1200rpm to a low speed shaft, with a reduction of 3:1. Assume that the teeth are 20o full depth involute, with 24 teeth on pinion. The pinion is to be of 40C8 Steel and gear of 30C8 steel. Assume that the starting torque is 130 percent of rated torque. (Apr/May 06)

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10. i. Explain how the effect of dynamic load is considered in gear design. ii. A shaft running at 250 rpm is driven by a 15kW motor running at 876 rpm through a pairs of 20o full depth spur gears. If the central distance is to be approximately 400 mm ( 3mm alloweiv., design the spur gear drive. Use C30 and C45 Steels for pinion and gear respectively. (Apr/May 06) 11. Design a cast iron spur gear drive for a crane hoist to transmit 3.75 kW at 1440 rpm. Maximum gear ratio in the gear box is 4. Each gear is expected to work 2 hours/day for 10 years. Determine the minimum centre distance, required face width and module of the gear. (Apr/May 06) Design the teeth for a pair of cast iron spur gears with cast teeth to transmit 26kW. The pinion runs at 50 rev/min and the velocity ratio is to be 2.5. Decide upon a suitable grade of cast iron and find the module, face, and diameters, and centre distance for the gears. Check for dynamic load. (Aug\Sep-06) Design a cast iron spur gear drive for a crane hoist to transmit 3.75 kW at 1440 rpm. Maximum gear ratio in the gear box is 4. Each gear is expected to work 2 hours/day for 10 years. Determine the minimum centre distance, required face width and module of the gear. (Aug\Sep-06) The following data pertains to a spur gear drive: No. of gears used = 2 Power transmitted = 3.85 KW Speed of smaller gear = 1800 rpm The drive is used for intermittent service Material used is good grade CI No. of teeth on smaller gear = 18 Velocity ratio = 2.5 20o full depth gear are used. Estimate module, face width and no. of teeth on the bigger gear Check the design for wear. (Aug\Sep-06)

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What should be the module, face width and number of teeth on each gear of a pair of spur gears, a C45 steel pinion driving a cast iron gear, if they are to transmit 18.75 kW at 700 rev/min of the 0.18m pinion in continuous service? The velocity ratio is 3, the teeth are 20o full depth and the load is smooth. Determine the outside and root diameters.(May 05) 7.5kW is to be transmitted from a motor shaft rotating at 1440rpm to another shaft with a speed reduction of 3:1. The starting torque may be taken as 50% higher than the mean torque. The gears should be made of heat treated steel and the shaft of mild steel. The pinion should have a minimum of 20 teeth. Design the gear drive. (May 05) Determine the module, face, and number of teeth for a pair of gears if they are to transmit 3.75 kW at 1800 rev/min. of the pinion, for intermittent service. The material is to be good grade cast iron and the pinion is to have 18 teeth 20o full depth, VR = 2.5. (May 05)

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A pair of gears connecting parallel shafts is to transmit 415 Nm torsional moment at 2800 rev/min of the pinion. The teeth are to be 20o stub of heat treated alloy steel. The width of the face is limited to 38 mm. The driven gear rotates at 1800 rev/min. Select the necessary module and check for wear. (May 04) ____________________________________________________________________________________

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UNIT VII

Design of power screws : Design of screw, Square ACME , Buttress screws, design of nut, compound screw, differential screw,
ball screw- possible failures.

UNIT VIII Machine Tool Elements : Design of beds, slide ways, spindles- material selection, design of strength and rigidity of parts.