Key

03M603 Design of Transmission System

UNIT - I
1.a. Toothed belts No slippage more transmission efficiency power transmission at
constant angular velocity ratio no need for initial tension and belt tensioning devices.
- 2 marks
1.b. Determination of Nominal pitch length - 4 marks
C
d D d D
C L
4
) (
2
) (
2
2

+
+
+

= 2903 mm
Selection of various modification factors. - 3 marks
Correction factor for length =F
c
= 1.05
Service factor = F
a
=1.3
Arc of contact =
0 0
60 180
,
_

C
d D
= 157.3
0
or 2.74 radians
Calculation of maximum power capacity - 3 marks
KW =
S S
d
S
e
) 10 32 . 1
8 . 50
79 . 0 (
2 4 09 . 0

= 2.759.
Determination of number belts - 4 marks
d c
a
b
F F KW
F P
n

= 4 belts.
Calculation of actual centre distance - 4 marks
875 . 466
8 4

,
_

+

d D L
A
5 . 15312 8 / ) (
2
d D B
05 . 917
2
+ B A A C
Actual centre distance = 917.05 mm.
OR
2.a. Regular lay rope In this type, wires are twisted in one direction to form strands and
the strands are twisted in the other direction to form the rope. They are untwisting and
they are accepted as standard. - 2 marks
Long lay rope In this type, wires and strands are twisted in the same direction. They
have greater resistance to abrasive wear and failure due to fatigue. - 2 marks
2.b. Determination of the transmission ratio
i= 970/330 = 2.94 - 1 mark
Selection of teeth on the driver sprocket
Z
1
= 25 (for i= 2 to 3) &
Number of teeth on the driven sprocket
Z
2
= iZ
1
= 74 - 1 mark
Determination of optimum centre distance & pitch - 1 mark
a = 500 mm ; p
max
= a/30 = 16.6 mm
p
min
= a/50 = 10 mm; p = 15.875 mm is chosen.
Selection of chain & chain number - 1 mark
Duplex 10A-2/DR50
Determination of total load on the driving side of the chain - 1 mark
P
T
= P
t
+ P
c
+ P
s
= 1876.4 N
1
Determination of Design Load =
T s
P k
- 2
marks
k
s
= k
1
. k
2
. k
3
. k
4
. k
5
. k
6
= 1.6
Design load = 1.6*1876.4 = 3002 N
Determination of Factor of safety - 1 mark
Breaking load / Design load = 14.79
Check for induced Bearing stress on Rollers - 2 marks
Induced stress = 97 . 19

A
k P
s t
N/mm
2
<
4 . 22 ] [
N/mm
2
Determination of Corrected Chain Length - 2 marks
p p p
a
z z z z
a I /
2 2
2
2
1 2 2 1

,
_

+
,
_

+
+

= 116 links.
=
p 116
= 1.842 m.
Determination of Exact Centre Distance - 2 marks
p
M e e
a
+

4
8
2
= 512.91 mm
Determination of Sprocket diameters - 2 marks
Pitch circle diameter of smaller sprocket,
) / 180 sin(
1
1
z
p
d
= 126.66 mm
Outside diameter of smaller sprocket, d
01
= d
1
+ 0.8
dr
= 134.788 mm
Pitch circle diameter of larger sprocket,
) / 180 sin(
2
2
z
p
d
= 374.034 mm
Outside diameter of larger sprocket d
02
= d
2
+ 0.8 d
r
= 382.162 mm
UNIT - II
3.a. To account for uneven distribution of tooth load along the face width of the tooth.
- 2 marks
3.b. 1) Selection of material: - 1 mark
C45 steel
Core hardness < 350 BHN

2
720
mm
N
u

2
360
mm
N
y

2) Calculation of design stresses - 2 marks
[ ]
1
4 . 1

nK
K
bl
b
Where
50 ) ( 25 . 0
1
+ +
y u

= 119.5
2
mm
N
[ ]
2
740 .
mm
N
K HRC C
cl R c

3) Centre distance calculation - 4 marks
[ ]
[ ]
3
2
2
.
74 . 0
) 1 (

,
_

1
]
1

+
i
M E
i a
t
c

mm a 108
2
4) Calculation of module - 4 marks
mm
z z
a
m 6 . 3
2
2 1

+

Adopt m = 4, Revise a
( )
2
2 1
z z m
a
+
=120 mm
5) Calculation of Gear geometries - 2 marks
Pinion Diameter, d = 80 mm
Wheel diameter, D = 160 mm
Number of teeth in pinion, Z
1
= 20
Number of teeth in Wheel, Z
2
= 40
6) Revise Design Torque
[ ]
t
M
- 2
marks
[ ] Nm M k k k M
t d o t
130 . . .
6) Check for induced stresses - 3 marks
( )[ ]
[ ]
b
t
b
amby
M i
<
+

1

2 2
5 . 119 58
mm
N
mm
N
<
[ ] [ ]
c t c
M E
ib
i
a
i
<
,
_

+ +
.
1 1
74 . 0

2 2
740 3 . 631
mm
N
mm
N
<
Hence the design is safe.
OR
4.a. In order to avoid undercutting and interference.
- 2 marks
4.b. Determination of pitch line velocity v = 0.236m m/sec. - 2 marks
Determination of velocity factor
v
C
v
+

3
3
=
m 236 . 0 3
3
+
- 1
mark
Determination of tangential tooth load,
m
C
v
P
W
s T
84746

N - 2
marks
Determination of form factor for the pinion
p
Z
y
912 . 0
154 . 0
= 0.0932 - 2
marks
Determination of form factor for the gear
G
Z
y
912 . 0
154 . 0
= 0.1337 - 2
marks
Based on the product of operating stress and form factor,
Decision about weaker section Pinion - 2 marks
Using the Lewis equation, formulation of 0.0174m
3
-0.236m 3 = 0 - 2 marks
Solving the above, Determination of standard module m = 8 mm. - 2 marks
Determination of face width b = 112 mm - 1 mark
Determination of pitch circle diameter of the pinion, D
p
= 120 mm - 1 mark
3
Determination of pitch circle diameter of the gear, D
G
= 360 mm - 1 mark
UNIT III
5.a. Advantages: Less noisy, Stronger than spur gear, can run at greater speeds
Disadvantages: End thrust.
- 2 marks
5.b. 1. Selection of material - 2 marks
Pinion: C45, surface hardened to 45HRC and core hardness < 350 BHN
2 2
360 , 700
mm
N
mm
N
y u

Wheel: CI grade 30,
2
300
mm
N
u

2. Calculation of design stresses: - 2 marks
[ ]
2
5 . 605 . .
mm
N
K HRC C
cl R p c

[ ]
1
.
4 . 1

K n
K
bl
p b
Where
50 ) ( 25 . 0
1
+ +
y u

2
6 . 117
mm
N

[ ]
2
3 . 361 . .
mm
N
K HB C
cl B w c

[ ]
1
.
4 . 1

K n
K
bl
p b 2
3 . 50
mm
N

3. Determination of Cone radius R - 4 marks

( )[ ]
[ ]
mm
i
M E
i R
t
c y
y
13 . 158
5 . 0
72 . 0
1
2
2

,
_

,
_

4. Determination of
t
m
- 2
marks
) ( 5 26 . 4 . 1 5 . 0
1
2
std mm mm m z i m R
t t
+
5. Revise R and find b. - 2 marks
R=185.54 mm
mm
R
b 8 . 61
3

6. Calculate
av av
d m
1
,
and pitch line velocity - 2
marks
mm
R
b R
m m
t av
17 . 4
5 . 0

,
_

mm m z d
av av
75
1 1

Pitch line velocity,
s
m
n d
V
av
8 . 0
100 * 60
1 1


7. Revise k,
d
k
and
[ ]
t
M
- 2
marks
K=1.1
1
d
k
, for class 6 gears, V= 1 m/s,
[ ] Nm M
t
8 . 183
8. Check for induced stresses - 2 marks
4
( )
[ ]
2
2
2
1
3
2
5 . 605 4 . 438 .
1
5 . 0
72 . 0
mm N
mm
N
M E
ib
i
b R
t c
<
1
1
]
1

,
_

[ ]
( )
2 2
1
2
2
6 . 117 7 . 49
. 5 . 0
1
mm
N
mm
N
y m b b R
M i R
v
t
b
<

+

Hence the design is safe.
OR
6.a Spiral bevel gears with zero spiral angle is called as zero bevel gears
- 2 marks
6.b For Non parallel and non intersecting shafts, worm gear drives are used.
Major failure is Seizure.
- 2 marks
6.c. 1. Selection of materials - 1 mark
a) Worm - steel
b) Wheel bronze (sand cast)

[ ]
2
2
/ 50
/ 390
mm N
mm N
b
u

<

2. Calculation of center distance - 3 marks

( ) [ ]
( )[ ]
[ ]
3
2
10 /
540
1 /
t
c
M
q z
q z a
1
]
1

= 346 mm
3. Calculation of axial module - 2 marks
( ) z q a m
x
+ / 2
= 10mm
4. Revise a and obtain d
1
- 2 marks
( )
x
x
qm d
mm z q m a

+
1
415 5 . 0
= 110mm
5. Revise k, k
d
and
[ ]
t
M
for actual pitch line velocity of the wheel. - 2
marks

1000 60
1440
2

a
zp
V
=2.2 m/s
6. Determination of induced stresses - 2 marks
( ) [ ]
10
1 /
/
540
3
t
c
M
a
q z
q z
1
]
1

+

= 127 N/mm
2
[ ]
v x
t
b
qzy m
M
3
9 . 1

= 50 N/mm
2
7. Efficiency - 2 marks
( )

tan
tan
95 . 0
= 0.847
5
8. Determination of Housing area - 2 marks
( ) 1 Input power = K
t
(t
o
-t
a
) A
A= 8.6 m
2
UNIT IV
7. Solution:
Calculation of speed ratio, N
max
/ N
min
=
355/100 =
1 12
,

= 1.12 - 2
marks
The speeds are
100, 112, 125, 141, 160, 180, 200, 224, 250, 280, 315, 355 rpm - 2 marks
Construction of Ray diagram - 6 marks
Construction of kinematic arrangement - 6 marks
Calculation of number of teeth - 4 marks
Assume Z
13
= 20
;
160
100
13
14
14
13

N
N
z
z

;
160
100 20
14

z
z
14
= 32
Using Z
11
+ Z
12
= Z
13
+ Z
14
= 20+32 = 52 &
160
200
11
12
12
11

N
N
z
z
, Z
12
=23 & Z
11
=29
Between gears 9 and 10.
;
200
160
9
10
10
9

N
N
z
z
Z
9
=20(driver) & Z
10
=25
Using Z
7
+ Z
8
= Z
9
+ Z
10
= 20+25 &
6
;
200
224
7
8
8
7

N
N
z
z
Z
7
= 24; Z
8
= 21
Between gears 5 & 6
;
355
200
5
6
6
5

N
N
z
z
Z
5
= 20, Z
6
= 36
Using Z
1
+ Z
2
= Z
5
+ Z
6
= 56 &
;
355
224
1
2
2
1

N
N
z
z
Z
1
= 22, Z
2
= 34
Using Z
3
+ Z
4
= Z
5
+ Z
6
= 56 &
355
250
3
4
4
3

N
N
z
z
Z
3
= 23, Z
4
= 33
OR
8.
Calculation of speed ratio, N
max
/ N
min
=
55 . 1 ,
5 . 31
1050
1 9



- 2
marks
The speeds are 31.5, 48.8, 75.7, 117.3, 181.8, 281.8, 436.8, 677, 1049.5 rpm. 2 marks
Construction of Ray diagram - 5 marks
Construction of kinematic arrangement - 5 marks
Calculation of number of teeth & % of error - 6 marks
Z
7
= 25 (given)
3 . 117
5 . 31
8
7

z
z
, Z
8
= 93
7
Using Z
9
+Z
10
= Z
7
+Z
8
= 118 &
3 . 117
5 . 31
8
7

z
z
, Z
9
= Z
10
= 59
Using Z
11
+ z
12
= 118
72 . 3
3 . 117
8 . 436
12
11

z
z
, Z
12
=25, Z
11
= 93
Z
1
= 25;
8 . 281
3 . 117
2
1

z
z
, Z
2
= 60
Using Z
1
+Z
2
= Z
3
+Z
4
= 85 &
8 . 281
8 . 181
4
3

z
z
, Z
3
= 33, Z
4
= 52
Using Z
5
+Z
6
= 85 & Z
5
/Z
6
= 1, Z
5
= 42, Z
6
= 43
Output speed & % of error calculation
Speed
Number
Output speed Standard
speed
% error
1 31.6 31.5 0.317
2 48.1 48.8 -1.43
3 74 75.7 -2.24
4 117.4 117.3 0.08
5 178.8 181.8 -1.65
6 275.2 281.8 -2.34
7 436.8 436.8 0
8 665.3 677 -1.72
9 1023.9 1049.5 -2.43
The permissible deviation =
( ) % 5 . 5 % 1 10 t
The deviations are well within the permissible limits.
UNIT V
9.a. Factors to be considered while designing a friction clutch: - 6 marks
1. Suitable material for friction surface should be selected
2. Moving parts should have less weight in order to minimize inertia effects.
3. Clutch should not require any external force to maintain contact
4. Provision to take up wear must be provided
5. Provision for facilitating repairs
6. Provision to carry away heat generated from the contact surfaces
7. Projecting parts of the clutch should be covered by guard.
9.b. Calculation of Nominal torque - 2 marks

n
power
T

2
60
= 105.09 Nm
Calculation of design torque - 2 marks

[ ] T K T
w

8
= 262.5 Nm
Determination of R
o
and R
i
- 4 marks

sin
i o
R R
b

R
o
=128mm
R
i
= 140mm
Calculation of clamping force - 3 marks

( )
i i o
R R R P F
max
2
= 3377.8 N
Calculation of force required to engage the clutch - 3 marks

cot F F F
e
+
= 5268.7N
OR
10.a. Desirable characteristics of brake lining material: - 6 marks
1. Should have high coefficient of friction with minimum fading
2. Should have low wear rate
3. Should have high heat resistance
4. Should have high heat dissipation capacity
5. Should have low coefficient of thermal expansion
6. Should have adequate mechanical strength
7. Should not be affected by moisture and oil.
10.b. Calculation of Braking torque = load x barrel radius
= 11250Nm - 2 marks
Using, T
1
-T
2
= 37,500 &

e
T
T

2
1
, T
1
=51.38 kN & T
2
=13.88 kN - 3 marks
Calculation of band width - 4 marks

Bt
T
t
1

B=350mm
Calculation of band thickness t = 0.01D = 6mm - 1 mark
Check for bearing pressure - 2 marks

Br
T
P
1
max

= 0.489 N/mm
2
Calculation of the force to be applied at the end of the lever - 2 marks
Taking moment about fulcrum, P=480.2N
9