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UNIT 1

1. Define with suitable sketches the following terminologies used in the limit systems
used in design.
(i)Nominal size (ii) Limits of sizes (iii) Tolerance Zone (iv) Clearance fit (v)
Interference fit

2. (i)Explain normal stress theory (Rankine’s Theory) (4)

(ii) A mild steel shaft of 50 mm diameter is subjected to a bending moment of


2500 N-m and a torque of ‘T’. If the yield point of the steel is 200 MPa,find the
maximum value of this torque without causing yielding of this shaft according to
Rankine’s theory.

3. The maximum load on a petrol engine push rod 300mm long is 1400N. It is
hollow having the outer diameter 1.25 times the inner diameter.spherical seated
bearings are used for the push rod . the modulus of elasticity for the materials of the
push rod is 210kn/mm^2.find a suitable size for the push rod ,taking a factor of safety
of 2.5
UNIT 2
1). The connecting rod of a petrol engine at 2000 rpm and developing a maximum
pressure of 35 bar. The diameter of the piston is 100 mm. Mass of the reciprocating
parts per cylinder is 2.3 kg.Length of the connecting rod = 150 mm. Stroke of the
engine is 110 mm. Compression ratio of the engine is 7.5.Take the factor of safety
as 4.Take the length to diameter ratio for the big end bearing as 1.3 and the small
end bearing as 2 and the corresponding bearing pressures as 10 N/mm2 and 15
N/mm2.The density of the material of the rod may be taken as 8000 kg/m3.Design
the connecting rod for the I Section alone. Mark your designed dimensions in sketch

2.) , A four stroke diesel engine has the


following specification brake power =5kw
speed =200rpm
indicated mean effective pressure
%=0.3N mechanical efficiency
=80%
determine

(i) Bore and length of the cylinder


(ii) Thickness of the cylinder head; and
(iii) Size of studs for the cylinder head

.
3.) Design a cast iron piston for a single acting four stroke engine for the following
data:
Cylinder bore = 90 mm
Cylinder stroke =90 mm
Maximum gas pressure
=70 bar Mechanical
Efficiency = 80 %
Fuel consumption 0.14 kg/brake
power per hour HCV of fuel = 42000
KJ/kg
Speed= 2500 rpm
Any other required data may be assumed or referred from Design Data book.
UNIT.3
1.)An internal combustion engine has a bore and stroke of 100 mm and 110 mm
respectively. The engine speed is 3000 rpm. Mean effective pressure is 0.15
N/mm2. The maximum combustion pressure is 5 N/mm2.The mass of the flywheel
is 70 kg. When the crank has turned 20 from TDC the pressure on the piston is 0.08
N/mm2.and the on the crank is maximum. The ratio of connecting rod length to
crank radius is 1.8.Design the crankshaft when the crank at the dead centre
for
(i) crank pin (ii) crank webs.

2.) (a) Design a single-throw, double-view crank shaft made of forged


steel for a single cylinder,vertical IC engine having cylinder diameter of
120mm and stroke length of 160mm. The engine develops 10KW at 300 mm.
The explosion pressure is 2.5 N/mm^2gauge. The maximum tirque is developed
when the crank shaft turns through 25degree from the TDC position during the
expansion stroke. The burnt gas pressure at that moment is 2.0N/mm^2.the crank
shall main bearings are 320mm apart.
(B) Design an overhang crank shaft with-two main bearings for an IC engines
with the following data: Cylinder bore =250mm
Stroke length =300mm
Flywheel weight
=27KN Max. Pressure
=2.5N/mm^2
Max.torque at crank rotation 30 degree the pressure at that instant 1.7 N/mm^2.

3.) (A)design a side crank shaft for an ic engine as per the following
specification Bore =150mm
Stroke length=190mm
Connecting rod length =
380mm
Maximum pressure =
320N/mm
Speed =600rpm
Brake mean effective pressure =70N/mm

Design stress for the crank shaft =30N/mm(Nov/Dec 2014)

(B) design a plain carbon steel centre crankshaft for a single acting, four stroke , single
cylinder engine for the following data;
Piston diameter
=250mm
Stroke length
=400mm
Maximum combustion pressure
=2.5N/mm^2
Weight of the flywheel=16kN
Total belt pull=3N
Connecting rod length=950mm

When the crank has turned through 30degree from top dead centre, the pressure on the
piston is 1 N/mm^2 and the torque on the crank is maximum (Nov/Dec 2014)
UNIT 4

1.)A single cylinder, single acting four stroke oil engine develops 20 kW
indicated power at 300 rpm. The work done by the gases during the expansion
stroke is 2.3 times the work done on the gases during the compression stroke
and work done during the suction and exhaust strokes is negligible, if the speed
is to be maintained within 1% of the mean speed, fine the flywheel effect.

2.) The turning moment diagram of a four stroke engine is represented by a four
triangles, the areas of which from the zero pressure are as follows; suction
stroke = 0.45 10-3m2; compression stroke = 1.7 10-3m2; Expansion stroke
= 6.85 10-3m2 Exhaust stroke = 0.65 10-3m2. Each m2 of area represents
3MN-m of energy. Assuming resisting torque to be uniform, find the mass of
the rim of the flywheel required to keep the speed between 200 and 19 rpm. The
mean radius of the rim is 0.4m

3.) .(A) the turing moment diagram for a multi cylinder engine has been
drawn to a scale of 1mm=1000N-m and 1mm=6degree. The areas above and
below the mean turning moment line taken in order are 530, 330, 380, 470, 180,
360, 350 qnd 280 sq.mm. For the engine find the diameter of the flywheel. Ther
mean rpm, is 150 and the total fluctuation of speed must not exceed 3.5% of the
mean. Detemine a suitable cross-sectional area of the rim of the flywheel
assuming the total energy of the flywheel to be 15/14 that of the rim. The
peripheral velocity of the flywheel is 15m/s.
(B) Design a flywheel for a single cylinder , four stroke vertical cylinder
diesel engine developing 4KW at 1500rpm. Asuume coefficient of speed
fluctuation Cs=0.01
Unit 5

1.)(a) Design a suitable spring for the exhaust valve of a petrol engine. The
spring should be capable of exerting a net force of 360N when the valve is
open and 200N when it is closed. The maximum inside diameter of the spring
is 25mm. The compression in spring is 8mm.
(b) The following data refer to a cam operating the suction valve
of a 4-stroke petrol Engine;
Least radius
=18m
m Lift
=10mm Nose radius
=3mm
Crank angle when the suction valve opens
before TDC = 4o Crank angle when the suction
valve closes after BDC =50o Cam shaft speed
=80rpm
The cam is of circular type with circular nose and flanks. It integral with the
cam shaft and operates a flat faced follower. Calculate
(i) The maximum acceleration and retardation of the valve
(ii) The maximum force to be exerted by the spring to
overcome inertia of valve parts whose mass is 250gram. Also
calculate the angles of cam rotation during the acceleration
and retardation of the follower.

2.)(a) Design a rocker arm of I section made of cast steel for operating an
exhaust valve of a gas engine. The effective lenth of the rocker arm is 250mm
and angle between the arm is 135o. The exhaust valve is 80mm in diameter
and the gas pressure when the valve begins to open is 0.4N/mm2. The greatest
suction pressure is 0.03N/mm2 below atmospheric. The initial load may be
assumed as 0.05N/mm2 of valve area and the valve inertia and friction losses
as 120N. The ultimate strength of cast steel is 750 Mpa. The allowable bearing
pressure is 8N/mm2 and the permissible stress in the material is
72Mpa.(MAY/JUNE 2014)

(b) Thefollowing data refer to a circular arc cam which operats flat faced followers
Least radius = 50mm; Total fit 25mm ; Flank radius 50mm ; Angle of lift 70
degrees; calculate the principal dimensions of the cam and draw the cam
profile.
3.)Design the various components of a valve gear mechanism for a horizontal
diesel engine for the following specifications.
Brake power =
10kW Bore =
140mm Speed =
600 rpm
Maximum gas pressure = 3.5 N/mm2: The valve opens 30º before TDC and
closes 20º after BDC. It opens and closes with constant acceleration and
deceleration for each half of the lift. The length of the rocker arm on either side
of the fulcrum is 150mm and the included angle is 135º. The mass of the valve
is 0.3kg.
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