KCG COLLEGE OF TECHNOLOGY

Department of Mechanical Engineering

III YEAR/VI SEMESTER –ME 2352 - DESIGN OF TRANSMISSION SYSTEMS
Question paper – UNIT – 1
Design of Transmission Systems for Flexible Elements
PART-A
1) What are the factors upon which the coefficient of friction between the belt and pulley depends?
( MAY – 2014)
Ans: i) Material of belt ii) Material of pulley iii) Slip of belt iv) Speed of belt
2) Brief the term “ Crowning of Pulley”. ( MAY – 2014)
Ans: The pulley rims are tapered slightly towards the edges. This slight convexity is known as
“crowning”. Crowning tends to keep the belt in centre on a pulley rim while in motion. Crowning
reduces the tendency of the belt to slip.
3) What is meant by the ply of belt? (NOV – 2013)
Ans: Flat belts are made of thin strips and laminated one over the other in order to get thick belt. These
thin strips are called as plies of belt. Belts are specified according to the number of layers, e.g., single
ply, double ply or triple ply.
4) Write any four wire rope applications. (NOV – 2013)
Ans: i) Elevators ii) Cranes iii) Conveyors iv) Mine hoists v)suspension bridges.
5) What are the materials used for belt-drive? ( MAY – 2013 )
Ans: i) Leather ii) Fabric and cotton iii) Rubber iv) Balata and v) Nylon
6) Why slip is less in the case of v-belts when compared with flat belts? ( MAY – 2013 )
Ans: Slip is less in case of V belts due to wedging action in the grooved pulley.
7) What are the advantages of “V-Flat” drive? (NOV – 2012)
Ans: In a V- belt drive, if the large grooved pulley is replaced by a flat – faced pulley with smaller
pulley remaining V- grooved, then the drive is known as V-flat drive. The larger pulley has a greater
contact angle than the smaller pulley, that compensates for the loss of wedging action.
8) In chain drives, the sprocket has odd number of teeth and the chain has even number of links. Why?
(NOV – 2012)
Ans: To facilitate uniform wear i.e., the wear will be evenly distributed and thus total wear will be
lower.
9) Give an expression for ratio of tensions in a flat belt drive. (NOV – 2012)
Ans: ( T1 / T2 ) = eµθ where, T1 – Tight side tension, T2 – Slack side tension,µ - coefficient of friction,
θ – angle of contact or angle of wrap.
10) How is a V – belt specified? (MAY – 2012)
Ans: V-belts are designated by its type and nominal inside length. e.g., C2845 belt means it has a cross-
section of type C and has a nominal inside length of 2845mm.
11) Give the advantages of chain drives over belt drives. (MAY – 2012)
Ans: i) Chain drives can be used for long as well as short centre distances ii) more compact iii) no slip
between chain and sprocket iv) higher efficiency v) transmits more power.vi) operated under adverse
temperature and atmospheric conditions.
12) Mention the materials used for making link plates in chain drives. (MAY – 2012)
Ans: Link plates in chain drives are made of cold-rolled steel, medium carbon steel or alloy steel such
as C45,C50 and 40Cr1.
13) Mention the disadvantages of V belts over flat belts. (MAY – 2012)
Ans: i) V-belts cannot be used for large centre distances ii) construction of V-grooved pulleys is
complicated and costlier compared with pulleys of the flat belt drive.iii) V-belts are not so durable as
flat belt iv) V-belt cannot be used for cross belt drive.
14) What is chordal action in chain drives? What is its effect?( NOV – 2011)
Ans: When chain passes over a sprocket, it moves as a series of chords instead of a continuous arc as in
the case of a belt drive. It results in varying speed of the chain drive. This phenomenon is known as
chordal action.
Chordal action results in a pulsating and jerk motion of a chain. To reduce the variation in chain
speed, the number of teeth on the sprocket should be increased.
15) Specify the five parts of roller chain. (NOV– 2011)
Ans: i) Pin link or coupling link ii) Roller link iii) pins iv) bushes and v) Roller
16) Distinguish between open and cross drive of a belt drive. Which is better? (MAY – 2011)
Ans:
OPEN BELT DRIVE CROSS BELT DRIVE
Used with shafts arranged parallel and Used with shafts arranged parallel and
rotating in same direction. rotating in opposite direction.
Open belt drive is better because Cross belt drive will be subjected to more wear as the belts rub where
the belt crosses each other.
17) Give any three applications of chain drives. What are their limitations? (MAY – 2011)
Ans: i) Chain drives are used where we require velocity ratios upto 10, chain velocities upto 25m/s and
power ratings upto 150KW ii) Transportation machineries like motorcycles, bicycles, automobiles and
conveyors iii) Machineries like machine tools, agricultural machinery etc.,
Limitations: i) Production cost is high ii) needs careful maintenance iii) Design is complicated.
18) Give the condition for maximum power transmission in terms of centrifugal tension in case of belt
drive. (MAY – 2011)
Ans: The power transmitted shall be maximum when the centrifugal tension Tc is one third of the
maximum belt tension T. T = 3 Tc
19) In what way silent chain is better than ordinary driving chain? (MAY – 2011)
Ans: Silent chains are preferred for high power high speed and smooth operation because of noiseless
operation.
20) How are the ends of flat belt joined? (MAY – 2010)
Ans: i) Cemented/glued joint ii) Laced joint iii) Hinged joint iv) Crest joint
21) How is a wire rope specified? (MAY – 2009)
Ans: Wire ropes are designated by the number of strands and the number of wires in each strand. e.g.,
A 6 X 19 wire rope means a rope is made from 6 strands with 19 wires in each strand.
22) What is a silent chain? In what situations, silent chains are preferred? (NOV – 2007)
Ans: Inverted tooth chains are called silent chains because of their relatively quiet operation. A silent
chain consists of a series of toothed plates pinned together in rows across the width of the chain. Even
though the structure of silent chain is more complicated, its engagement with sprocket is very smooth
and hence we get noiseless operation.
Silent chains are preferred for high power high speed and smooth operation because of noiseless
operation.
PART-B
1) A V – belt drive is to transmit 45KW in a heavy duty saw mill which works in two shifts of 8 hours
each. The speed of motor shaft is 1400rpm with the approximate speed reduction of 3 in the machine
shaft. Design the drive and calculate the average stress induced in the belt.
(MAY – 2014)
2) Design a chain drive to actuate a compressor from 15KW electric motor running at 1000rpm, the
compressor speed being 350rpm. The minimum centre distance is 500mm. The compressor operates 15
hours per day. The chain tension may be adjusted by shifting the motor.
(MAY – 2014)
3) A centrifugal pump running at 340rpm is to be driven by a 100KW motor running at 1440rpm. The
drive is to work for atleast 20 hours every day. The centre distance between the motor shaft and the
pump shaft is 2000mm, suggest a suitable multiple V – belt drive for this application. Also calculate the
actual belt tensions and stress induced. (NOV – 2013)
4) The transporter of a heat treatment furnace is driven by a 4.5KW, 1440rpm induction motor through
a chain drive with a speed reduction ratio of 2.4 The transmission is horizontal with bath type of
lubrication. Rating is continuous with 3 shifts per day. Design the complete chain drive.
( NOV – 2013)
5) Design a V-belt drive to the following specifications: Power to be transmitted: 75 kW
Speed of driving wheel: 1400 rpm Speed of driven wheel: 400 rpm Diameter of driving wheel: 300 mm
Centre distance: 2500 mm Service: 16 hours/day. (MAY – 2013)
6) Design a chain drive to actuate a compressor from a 10 kW electric motor at 960 rpm. The
compressor speed is to be 350 rpm. Minimum centre distance should be 0.5 m. Compressor is to work
for 8 hours/day. (MAY – 2013)
7) A crusher running at a speed of 400rpm is driven by an electric motor of 10KW with a reduction in
speed of 3 times. Taking a centre distance of 600mm, design a V belt drive.
(NOV – 2012)
8) A bucket elevator is to be driven by a gear motor and a roller chain drive. Gear motor power =
7.5KW; speed of gear motor = 1400rpm; transmission ratio = 10:1 Assuming a minimum centre
distance of 550mm between sprockets, select a suitable chain. (NOV – 2012)
9) A flat belt drive is to be designed to drive a flour mill. The driving power requirement of the mill is
22.5KW at 750 rpm with a speed reduction of 3.0. The distance between the shafts is 3m. Diameter of
the mill pulley is 1.2m. Design and make a neat sketch of the drive. (MAY – 2012)
10) A workshop crane carries a load of 30KN using wire ropes and a hook. The hook weighs 15KN.
Diameter of the rope drum is 30 times the diameter of the rope. The load is lifted with an acceleration
of 1m/s2. Find the diameter of the rope. FS = 6, Er = 80KN/mm2, σu = 180KN/mm2
Cross section of the rope = 0.4 x (dia. Of rope)2. (NOV – 2011)
 KCG COLLEGE OF TECHNOLOGY
Department of Mechanical Engineering
III YEAR/VI SEMESTER –ME 2352 - DESIGN OF TRANSMISSION SYSTEMS
Question paper – UNIT – 2
Spur Gears and Parallel Axis Helical Gears
PART-A
1) What is pressure angle? What is the effect of increase in pressure angle? (MAY – 2014)
Ans: It is the angle between the common normal to two gear teeth at the point of contact and the
common tangent at the pitch point.
The increase of pressure angle results in a stronger tooth, because the tooth acting as a beam is wider
at the base.
2) What condition must be satisfied in order that a pair of spur gears may have a constant velocity
ratio? (MAY – 2014)
Ans: Law of gearing states that for obtaining a constant velocity ratio, at any instant of teeth the
common normal at each of contact should always pass through the pitch point, situated on the line
joining the centres of rotation of the pair of mating gears.
3) Differentiate between circular pitch and diametral pitch. (NOV – 2013)
Ans: Circular Pitch: It is the distance measured along the circumference of the pitch circle from a point
on one tooth to the corresponding point on the adjacent tooth. Pc = πD / Z,where D – Diameter of pitch
circle, Z – no of teeth on the gear
Diametral Pitch: It is the ratio of number of teeth to the pitch circle diameter. Pd = Z/D = π/Pc
4) Where do we use spiral gears? (NOV – 2013)
Ans: A pair of crossed – helical gears are known as spiral gears. Skew or Spiral gears are used to
connect and transmit motion between two non parallel and non intersecting shafts.
5) Define module. (MAY – 2013 )
Ans: Module is defined as the ratio of pitch circle diameter to the number of teeth. m = D/Z
where D – Diameter of pitch circle, Z – no of teeth on the gear
6) What are the main types of gear tooth failure? (MAY – 2013 )
Ans: i) Tooth breakage ii) Pitting of tooth surface iii) abrasive wear and iv) Scoring or Seizing of teeth
7) What are the advantages and disadvantages of non – metallic gears? (NOV – 2011 )
Ans: Advantages: i) silent operation ii) damping of shock and vibration iii) manufacturing economy
Disadvantages: i) Low power transmission ii) low heat conductivity
8) What is virtual number of teeth in helical gears? (NOV – 2012 )
Ans: In order to simplify the design of helical gear, an equivalent or virtual spur gear is formed whose
tooth will produce the same effect(equal strength and power transmitting capacity) as that produced by
the helical gear. The number of teeth on the virtual spur gear in the normal plane is known as virtual
number of teeth. Zeq or Zv = Z / cos3β where Z – number of teeth on a helical gear β – helix angle.
9) State the law of gearing. (NOV – 2012 )
Ans: Law of gearing states that for obtaining a constant velocity ratio, at any instant of teeth the
common normal at each of contact should always pass through the pitch point, situated on the line
joining the centres of rotation of the pair of mating gears.
10) State the advantages and disadvantages with helical gear. (NOV – 2012 )
Ans: Advantages: i) transmits more power ii) provide smooth and noiseless operation iii) used for high
speed and high velocity ratio. iv) greater load carrying capacity.
Disadvantages: i) Since the teeth are inclined to the axis of rotation, helical gears are subjected to axial
thrust loads.
11) What are the generally used gear profiles? (OR) What are the common forms of gear tooth profile?
(MAY – 2012 )
Ans: i) Involute tooth profile ii) Cycloidal tooth profile
12) Specify the significance of minimum number of teeth in pinion. (MAY – 2012 )
Ans: Minimum number of teeth in pinion is to avoid interference.
13) What does the load correction factor account for in gear design? (MAY – 2012 )
Ans: Load correction factor is considered to account for uneven distribution of tooth load along the
face width of tooth.
14) What is a stub tooth? Why is it preferred? (MAY – 2012 )
Ans: In this system, the thickness of tooth at the top surface and its root is more compared to full depth
tooth system. Also stub tooth possess shorter addendum and large pressure angle and thus interference
problem may be eliminated. Stub teeth are stronger than full depth teeth. stub teeth is preferred for i)
more compact drive ii) less interference iii) stronger and small number of teeth iv)heavy loads.
15) How does failure by pitting happen in gears? (NOV – 2011 )
Ans: Pitting happens due to over pressing of the tooth of one gear to the tooth of mating gear. During
the continuous operation, a crack may be formed which may increase in size and change in the form of
pits. To prevent pitting, the teeth are checked for surface endurance.
Pitting is the process during which small pits are formed on the active surfaces of gear tooth. It is a
surface fatigue failure which occurs when the load on the gear tooth exceeds the surface endurance
strength of the material.
16) Mention few gear materials. (MAY – 2011)
Ans: Metallic gears: steel, cast iron, alloy steel and bronze
Non-metallic gears: wood, nylon, bakelite, compressed paper and synthetic resins
17) What is working depth of a gear tooth? (MAY – 2011)
Ans: Working depth is the radial distance from the addendum circle to the clearance circle. It is equal
to the sum of the addendum of the two meshing gears.
18) What factors influence backlash in gear drives? (MAY – 2011)
Ans: i) module and ii) Pitch line velocity
19) Why is a gear tooth subjected to dynamic loading? (MAY – 2011)
Ans: In a gear tooth, dynamic loads are due to the following reasons: i) inaccuracies of tooth spacing ii)
irregularities in tooth profiles iii) misalignment between bearings iv) deflection of teeth under load v)
dynamic unbalance of rotating masses.
20) What is a herringbone gear? Where it is used? (NOV – 2009)
Ans: Herringbone gear or double helical gear consists of teeth having a right and left handed helix cut
on the same blank.
Herringbone gears are used to overcome the difficulty of end thrust in the single helical gear.
They are used in heavy machinery and gear boxes.
21) Differentiate the following terms with respect to helical gears: a) Transverse circular pitch b)
Normal circular pitch c) Axial pitch (NOV – 2007)
Ans: a) Transverse circular pitch: It is the distance between corresponding points on adjacent teeth
measured in a plane perpendicular to the shaft axis.
b) Normal circular pitch: It is the distance between corresponding points on adjacent teeth measured in
a plane perpendicular to the helix.
c) Axial pitch: It is the distance between corresponding points on adjacent teeth measured in a plane
parallel to the shaft axis.
PART-B
1) i) Explain the phenomenon of interference in involute gears.
ii) Design and draw spur gear drive transmitting 30KW at 400rpm to another shaft running
approximately at 1000 rpm. The load is steady and continuous. The material for the pinion is cast steel
and for gear is cast iron. Take module as 10mm. Also check the design for dynamic load and wear.
(4+12 marks) (MAY – 2014)
2) A single stage helical gear reducer is to receive power from a 1440rpm, 25KW induction motor. The
gear tooth profile is involute full depth with 20º normal pressure angle. The helix angle is 23º, number
of teeth on pinion is 20 and the gear ratio is 3. Both the gears are made of steel with allowable beam
stress of 90MPa and hardness 250 BHN.
 i) Design the gears for 20% overload carrying capacity from the standpoint of bending strength and
wear.
ii) If the incremental dynamic load of 8KN is estimated in tangential plane, what will be the safe
power transmitted by the pair at the same speed? (10+6 marks) (MAY – 2014)
3) Design a straight spur gear drive. Transmitted power 8 kW. Pinion speed 764 rpm. Speed ratio is 2.
The gears are to be made of C45 steel. Life is to be 10,000 hours. (MAY – 2013)
4) Design a pair of helical gears to transmit 10kW at 1000 rpm of the pinion. Reduction ratio of 5 is
required. Give the details of the drive in a tabular form. (MAY – 2013)
5) Design a spur gear drive to transmit 22.5KW at 900rpm. Speed reduction is 2.5. Materials for pinion
and wheel are C15 steel and cast iron grade 30 respectively. Take pressure angle of 20º and working life
of the gears 10,000 hours. (NOV – 2013)
6) Design a helical gear to transmit 15KW at 1440 rpm to the following specifications: speed reduction
is 3; pressure angle is 20º; helix angle is 15º; the material of both the gears is C45 steel. Allowable
static stress 180GPa; surface endurance limit is 800GPa. Young’s modulus of material = 200GPa.
(NOV – 2013)
7) A motor shaft rotating at1200rpm has to transmit 12KW to a low speed shaft with a speed reduction
of 4:1. The teeth are 20º involute with 20 teeth on the pinion. Both the pinion and gear are made of steel
with a maximum safe stress of 230N/mm 2. A safe stress of 50N/mm2 may be taken for the shaft on
which the gear is mounted and for the key. Design a spur gear drive to suit the above conditions.
Assume starting torque to be 30% higher than the running torque.
(NOV – 2012)
8) Design a pair of straight spur gears to transmit 12KW at 1500rpm. Speed reduction required is 4.
Check for compressive and bending stresses. Also check for plastic deformation of teeth. Make a
schematic diagram and show the results neatly. (NOV – 2012)
9) Design a pair of full depth involute teeth helical gears to transmit 5KW at 1440rpm. Use C45 steel
for the gears. Number of teeth on pinion may be 24 and that on gear 56. Check for compressive and
bending stresses. Make a simple sketch and label the important dimensions of the drive.
(NOV – 2012)
10) Design a spur gear drive for a heavy machine tool with moderate shocks. The pinion is transmitting
18KW at 1200rpm with a gear ratio of 3.5. Design the drive and check for elastic stresses and plastic
deformation. Make a sketch and label important dimensions arrived.
(MAY-2012)
11) Design a pair of helical gears to transmit 37.5KW at 1750rpm of the pinion. The drive is subjected
to heavy shock loading. The speed reduction ratio is4 and the helix angle is15º. Select suitable material
and design the gears. Check for working stresses and sketch the drive.
(MAY-2013)
12) A general purpose enclosed gear train is based on parallel helical gears, specified life is 36,000
hours. Torque at driven shaft is 411Nm. Driving shaft speed is 475rpm. velocity ratio is 4. It is desired
to have standard center distance. Design the gear drive. (NOV – 2011)
 KCG COLLEGE OF TECHNOLOGY
Department of Mechanical Engineering
III YEAR/VI SEMESTER –ME 2352 - DESIGN OF TRANSMISSION SYSTEMS
Question paper – UNIT – 3
Bevel, Worm and Cross Helical Gears
PART-A
1) Define the following terms a) Cone distance b) Face angle. (MAY – 2014)
Ans: Cone distance (Pitch cone radius) is the length of the pitch cone element.
Cone distance R = pitch radius/sin δ
Face angle or Tip angle is the angle subtended by the face of the tooth at the cone centre.
Face angle = pitch angle + addendum angle
2) What is virtual number of teeth in bevel gears? (MAY – 2014)
Ans: In order to simplify the design calculation and analysis, bevel gears are replaced by equivalent
spur gears. An imaginary spur gear considered in a plane perpendicular to the tooth at the larger end is
known as virtual or formative or equivalent spur gear. An equivalent or virtual spur gear is formed
whose tooth will produce the same effect(equal strength and power transmitting capacity) as that
produced by the bevel gear. The number of teeth on the virtual spur gear in the normal plane is known
as virtual number of teeth. Zeq or Zv = Z / cos δ where Z – number of teeth on a bevel gear δ – pitch
angle.
3) What is the difference between an angular gear and a miter gear? (NOV – 2013)
Ans: Angular bevel gear: When the bevel gears connect two shafts whose axes intersect at an angle
other than a right angle, then they are known as angular bevel gears.
Miter gears: When equal bevel gears ( having equal teeth and equal pitch angles) connect two shafts
whose axes intersect at right angle, then they are known as miter gears.
4) Why phosphor bronze is widely used for worm gears? (NOV – 2013)
Ans: Phosphor bronze have high antifriction properties to resist seizure. Because in worm gear drive,
the failure due to seizure is more.
5) What are the forces acting on bevel gear? (MAY – 2013 )
Ans: i) Tangential force ii) Axial force and iii) Radial force.
6) Where do we use worm gear? (MAY – 2013 )
Ans: Worm gears are used as a speed reducer in material handling equipment, machine tools and
automobiles.
7) Mention the main types of failure in worm gear drives.(NOV – 2012 )
Ans: i) Seizure ii) Pitting and rupture.
8) When is bevel gear preferred?(OR) Under what situations, bevel gears are used?(NOV– 2012)
Ans: Bevel gears are used to transmit power between two intersecting shafts.
9) Calculate angle between the shafts of a crossed helical gears made of two left handed helical gears of
10º helix angle each. (NOV – 2012 )
Ans: Shaft angle θ = β1 + β2 = 2β = 2x10º = 20º
10) Give the speed ratio range of worm wheel drive. (MAY – 2012)
Ans: Velocity ratio ranges from 10 : 1 to 300 : 1
11) Specify the features of skew bevel gears. (MAY – 2012)
Ans: When the teeth of a bevel gear are inclined at an angle to the face of the bevel, they are known as
spiral or skew bevel gear.i) smoother in action ii) quieter in operation iii) gradual load application iv)
low impact stresses.
12) What is the effect of increasing the pressure angle in gears? (NOV – 2011)
Ans: The increase of pressure angle results in a stronger tooth, because the tooth acting as a beam is
wider at the base.
13) Why is dynamic loading rarely considered in worm gear drives? (NOV – 2011)
Ans: In worm gear drive, dynamic load is not so severe due to the sliding action between the worm and
worm gear.
14) In worm gear drive, only the wheel is designed. Why? (MAY – 2011)
Ans: Since always the strength of the worm is greater than the worm wheel, therefore only the worm
wheel is designed.
15) What is a crown gear? (MAY – 2011)
Ans: A bevel gear having a pitch angle of 90º and a plane for its pitch surface is known as crown gear.
16) Write some applications of worm gear drive. ( MAY – 2011)
Ans: Worm gears are used as a speed reducer in material handling equipment, machine tools and
automobiles.
17) What are the applications of skew helical gears? (MAY-2011)
Ans: Skew helical gears are used to connect and transmit motion between two non parallel and non
intersecting shafts.
18) When do we employ crossed helical gear? (MAY – 2010)
Ans: A pair of crossed helical gears, also known as spiral gears are used to connect and transmit
motion between two non parallel and non intersecting shafts. As the contact between the mating teeth is
always a point, these gears are suitable only for transmitting a small amount of power.
19) Mention two characteristics of hypoid gear. (MAY – 2010)
Ans: i) Axis of pinion is offset from the axis of the gear ii) Pitch surfaces are hyperboloids rather than
cones. iii) most desirable for those applications involving large speed reduction ratios iv) operates more
smoothly and quietly.
20) Usually worm is made of hard material and worm gear is made of softer material – Justify.
(NOV-2009)
Ans: Worm is made of hard material than worm gear, because amount of wear of the worm becomes
larger than that of the worm wheel.

PART-B
1) A 2KW power is applied to a worm shaft at 720rpm. The worm is of quadruple start with 50mm as
pitch circle diameter. The worm gear has 40 teeth with 5mm module. The pressure angle in the
diametral plane is 20º. Determine i) the lead angle of the worm ii) velocity ratio and iii) centre distance.
Also calculate efficiency of the worm gear drive and power lost in friction.
(MAY-2014)
2) Design a bevel gear drive to transmit 10KW power at 1440 rpm. Gear ratio is 3, and life of gears
10,000hours. Pinion and gear are made of C45 steel and minimum no. of teeth is 20.
(MAY – 2014)
3) Design a bevel gear drive to transmit 7 kW at 1600 rpm for the following data. Gear ratio : 3
Material for pinion and gear : C45 steel Life : 10,000 hrs. (MAY – 2013)
4) Design a worm gear drive to transmit 22.5 kW at a worm speed of 1440 rpm. Velocity ratio is 24:1.
An efficiency of atleast 85% is desired. The temperature rise should be restricted to 40 0C. Determine
the required cooling area. (MAY – 2013)
5) Design a straight bevel gear drive between two shafts at right angles to each other. Speed of the
pinion shaft is 360rpm and the speed of the gear wheel shaft is 120rpm. Pinion is of steel and wheel of
cast iron. Each gear is expected to work 2 hours/day for 10 years. The drive transmits 9.37KW.
(NOV – 2013)
6) The input to worm gear shaft is 18KW and 600rpm. Speed ratio is20. The worm is to be of hardened
steel and the wheel is made of chilled phosphor bronze. Considering wear and strength, design worm
and worm wheel. (NOV – 2013)
7) Design a worm gear drive to transmit 10KW at 1440rpm with a gear ratio of 12. Use steel worm and
cast steel wheel. (NOV – 2012)
8) Design a bevel gear drive to transmit 7.5KW. Speed ratio is 4. Driving shaft speed 400rpm.
(NOV – 2012)
9) Design a worm gear drive to transmit 12KW at 1440rpm with a speed ratio of 20. Use steel worm
and cast iron wheel. (NOV – 2012)
10) Design a worm gear drive and determine the power loss by heat generation. The hardened steel
worm rotates at 1500 rpm and transmits 10KW to a phosphor bronze gear with gear ratio of 16.
(MAY – 2012)
11) Two straight bevel gears are used in a speed reducer with a transmission ratio of 2. The wheel is
supported on both sides and the pinion is overhanging. The input is from a 20KW electric motor
running at 950rpm. Design the bevel gears. (MAY – 2012)
 KCG COLLEGE OF TECHNOLOGY
Department of Mechanical Engineering
III YEAR/VI SEMESTER –ME 2352 - DESIGN OF TRANSMISSION SYSTEMS
Question paper – UNIT – 4
Design of Gear Boxes
PART-A
1) What is step ratio? Name the series in which speeds of multispeed gear box are arranged.
(MAY – 2014)
Ans: When the spindle speeds are arranged in geometric progression, then the ratio between the two
adjacent speeds is known as step ratio or progression ratio.
Speeds of multispeed gear box are arranged in Geometric series.
2) What are the methods for changing speed in Gear boxes?
Ans: The two important methods widely used are
1. Sliding mesh gearbox
2. Constant mesh gear box
3) What are preferred numbers? (MAY – 2013)
Ans: Preferred numbers are the conventionally rounded off values derived from geometric series. There
are five basic series denoted as R5, R10, R20, R40 and R80 series.
4) What are the possible arrangements to achieve 12 speeds from a gear box? (MAY – 2013)
Ans: Possible arrangements are i) 3 x 2 x 2 scheme ii) 2 x 3 x 2 scheme and iii) 2 x 2 x 3 scheme
5) State any three basic rules to be followed while deigning a gear box. (NOV – 2013)
Ans: i) The transmission ratio (i) in a gear box is limited by ¼ < i < 2
ii) For stable operation, the speed ratio of any stage should not be greater than 8 Nmax / Nmin < 8
iii) In all stages except in the first stage, Nmax > Ninput > Nmin
6) What purpose does the housing of gear-box serve?
Gear-box -housing or casing is used as container inside which, the gears, shafts, bearings and other
components are "mounted.' Also it prevents the entry of dust inside the housing and reduces noise of
operation. That is, the housing Safe-guard the inner components
7) For what purpose we are using gear-box?
Since the gear-box is provided with number of gears of different size arranged is different forms, we
can get number of output speeds by operated motor at single speed.
8) What is meant by ray diagram? (MAY – 2012)
Ans: The Ray diagram or speed diagram is a graphical representation of the drive arrangement in
general form. It serves to determine the specific values of all the transmission ratios and speeds of all
the shafts in the drive.
9) Distinguish between structural diagram and speed diagram. (NOV – 2011)
Ans: Ray diagram or Speed diagram is a graphical representation of the structural formula.
Structural diagram is a kinematic layout that shows the arrangement of gears in a gear box.
10) What are the methods of lubrication in speed reducers? (NOV – 2011)
Ans: i) Splash or spray lubricating method ii) Pressure lubrication method
11) Classify speed reducers. (NOV – 2012)
Ans: i) Single reduction speed reducers ii) Multi reduction speed reducers.
12) What is the function of spacers in a gear box? (MAY – 2011)
Ans: Spacers are sleeve like components which are mounted on shafts in between gears and bearings
or one gear and another gear in order to maintain the distance between them so as to avoid interruption
between them. The function of spacers is to provide the necessary distance between the gears and the
bearings.
13) List the ways by which the number of intermediate steps may be arranged in a gear box.
(MAY – 2010)
Ans:
S.No. Number of Speeds Preferred Structural Formula
1. 6 speeds i) 3(1) 2(3)
ii) 2(1) 3(2)
2. 8 speeds i) 2(1) 2(2) 2(4)
ii) 4(1) 2(4)
3. 9 speeds i) 3(1) 3(3)
4. 12 speeds i) 3(1) 2(3) 2(6)
ii) 2(1) 3(2) 2(6)
iii) 2(1) 2(2) 3(4)
14) Which type of gear is used in constant mesh gear box? Justify. (MAY – 2009)
Ans: Helical gears are used in constant mesh type gear boxes to provide quieter and smooth operation.
15) Where are multi-speed gear boxes employed? (MAY – 2009)
Ans: Multi – speed gear boxes are employed wherever the variable spindle speeds are necessary.
16) List six standard speeds starting from 18rpm with a step ratio 1.4 (MAY – 2008)
Ans: For the step ratio Ø = 1.4, R20 series is used. From R20 series, the standard spindle speeds are
18,20,22.4, 25, 28 and 31.5 rpm.
17) Give some applications of constant mesh gear box. (MAY – 2007)
Ans: Constant mesh Gear boxes are employed in various machine tools such as Lathe, Milling
machines etc., to provide a wide range of spindle speeds.

PART-B

1) Sketch the arrangements of a six speed gear box. The minimum and maximum speeds required are
around 460 and 1400rpm. Drive speed is 1440rpm. Construct speed diagram of the gear box and obtain
various reduction ratios. Use standard output speeds and standard step ratio. Calculate number of teeth
in each gear and verify whether the actual output speeds are within +2% of standard speeds.
(MAY – 2014)
2) Draw the ray diagram and kinematic layout of a gear box for an all geared headstock of a lathe. The
maximum and minimum speeds are to be 600 and 23 rpm respectively. Number of steps is 12 and drive
is from a 3000W electric motor running at 1440rpm. (MAY – 2014)
3) Determine a 9 speed gear box to give output speeds between 280 and 1800 rpm. The input power is
5.5 kW at 1400 rpm. Draw the kinematic layout diagram and the speed diagram. Determine the number
of teeth on all gears. (MAY – 2013)
4) Design the layout of a speed gear box for a lathe. The minimum and maximum speeds are 100 and
1200 rpm. Power is 5 kW from 1400 rpm. Draw the speed and kinematic diagram. Also calculate the
number of teeth on all gears. (MAY – 2013)
5) An 18 speed gear box is required to give output speeds ranging from 35 rpm to 650 rpm. The input
power is 3.75KW at 1440 rpm. Draw the structural diagram and the kinematic arrangement of gears.
(NOV – 2013)
6) A nine speed gear box, used as a headstock gear box of a turret lathe, is to provide a speed range of
180 rpm to 1800 rpm. Using standard step ratio, draw the speed diagram and the kinematic layout. Also
find and fix the number of teeth on all gears. (NOV – 2013)
7) The spindle of a machine tool is to run at 12 different speeds in the range of 70 rpm to 325 rpm.
Design a three stage gear box with a standard step ratio. The gear box receives 4KW from an electric
motor running at 330 rpm. i) Draw the layout of the gear box. ii) Sketch the speed diagram iii) Indicate
the number of teeth on each gear. (4+5+7marks) (NOV – 2012)
8) Design a nine speed gear box with a minimum speed of 200 rpm and step ratio 1.5. The input is from
a motor of 2KW at 1400 rpm. (NOV – 2012)
9) For a load lifting arrangement transmitting 10KW with electric motor running at 1400 rpm, constant
mesh type speed reducer is required with reduction ratio 12. Design a suitable arrangement and make a
neat sketch. (NOV – 2012)
10) Select speeds for a 12 speed gear box for a minimum speed of 16 rpm and maximum speed of 900
rpm. Drive speed is 900 rpm. Draw speed diagram and draw kinematic arrangement of the gear box
showing the number of teeth in all the gears. (NOV – 2012)
11) Design a sliding mesh nine speed gear box for a machine tool with speed ranging from 36 rpm to
550 rpm. Draw the speed diagram and kinematic arrangement showing number of teeth in all gears.
(MAY – 2012)
12) An all geared headstock of a lathe requires a 12 speed gear box with minimum and maximum
speeds of 110 rpm and 1440 rpm respectively. Draw speed diagram and show the details of number of
teeth in all the gears in a kinematic layout. (MAY – 2012)
 KCG COLLEGE OF TECHNOLOGY
Department of Mechanical Engineering
III YEAR/VI SEMESTER –ME 2352 - DESIGN OF TRANSMISSION SYSTEMS
Question paper – UNIT – 5
Design of Cam, clutches and Brakes
PART-A
1. State the profile of cam that gives no jerk and mention how it is eliminated? (May- 2012)
Ans: 4-5-6-7 polynomial cam profile gives no jerk. Profile smoothening techniques can remove the
excessive jerks in a cam profile.
2. What is self-locking brake? (Nov-2011)
Ans: When the frictional force is sufficient enough to apply the brake with no external force, then
the brake is said to be self-locking brake.
3. What is meant by self- energizing brake? (May-2014)
Ans: When the moment of applied force (F · l) and the moment of the frictional force (µ · R n · c)
are in the same direction, then frictional force helps in applying the brake. This type of brake is
known as self-energizing brake.
4. What are the desirable properties of friction material to be used for clutches? (Nov-2005)
Ans: A good friction material should have the following properties:
 A high and uniform coefficient of friction.
 Good resiliency.
 The ability to withstand high temperatures, together with good heat conductivity.
 High resistance to wear, scoring, and galling.
5. What is the significance of pressure angle in cam design? (Nov-2007)
Ans: The pressure angle is very important in cam design as it represents steepness of the cam
profile. If the pressure angle is too large, a reciprocating follower will jam in its bearings.
6. State the advantage of cam over other reciprocating mechanisms. (Apr-2008)
Ans: Cams are used for transmitting desired motion to a follower by direct contact. Cam
mechanisms are used in the operations of IC engine valves.
7. What are the motions of the follower? (May- 2009)
Ans: The follower can have any of the following four types of motions
(i) Uniform velocity
(ii) Simple harmonic motion
(iii) uniform acceleration and retardation
(iv) cycloidal motion.
8. How the ‘uniform rate of wear ‘assumption is valid for clutches? (Apr-2008)
Ans: In clutches, the value of normal pressure, axial load for the given clutch is limited by the rate
of wear that can be tolerated in the brake linings. Moreover, the assumption of uniform wear rate
gives a lower calculated clutch capacity than the assumption of the uniform pressure. Hence
clutches are usually designed on the basis of uniform wear.
9. Differentiate between self-energizing and self locking brakes (Nov-2009)
Ans: Self-Locking Brakes: When the frictional force is sufficient enough to apply the brake with
no external force, then the brake is called a Self-Locking Brakes.
Self-energizing Brakes: When the frictional force helps in applying the brake, then the brake is
said to be Self-Energizing Brakes.
10. What are the effects of temperature rise in clutches? (MAY-2007)
Ans:
 Excessive surface temperatures results in premature clutch failure.
 In case of metallic clutch plates, high temperature existing at the rubbing interface may cause
the individual plates to be welded together.
 In non-metallic clutch plates, the high temperature can cause excessive wear.
11. Why is it necessary to dissipate the heat generated during clutch operation? (Nov-2009)
 Ans: When clutch engages, most of the work done (against friction forces opposing the motion)
will be liberated as heat at the interface. Consequently the temperature of the rubbing surfaces will
increase. This increased temperature may destroy the clutch. So heat dissipation is necessary in
clutches.
12. Under what condition of a clutch,uniform rate of wear assumption is more valid? (May -2011)
Ans: If the clutch is old,then the uniform rate of wear assumption is more valid.
13. When do we use multiple disk clutches? (Apr-2010)
Ans: A multiple clutch is used when large amount of torque is to be transmitted. In a multi-plate
clutch, the number of frictional linings and the metal plates are increased which increases the
capacity of the clutch to transmit torque.
14. What is the disadvantage of block brake with one short shoe? What is the remedy? (Apr-2010)
Ans: If only one block is used for braking, then there will be a side thrust on the bearing of wheel
shaft. This drawback can be removed by providing two blocks on the two sides of the drum. This
also doubles the braking torque.
15. Name few commonly used friction materials. (Apr-2011)
Ans: Wood, Cork, Leather, Asbestos based friction materials, and Powered metal friction materials.
16. What are the factors upon which the torque capacity of a clutch depends? (Nov-2011)
Ans: Torque capacity of a clutch depends on Number of pair of Contact Surfaces, Coefficient of
Friction, Axial thrust exerted by the spring, and Mean radius of friction surface.
17. Name different types of clutch. (NOV-2012)
Ans:
I. Based on the Engagement or actuation method used:-
 Mechanical,
 Pneumatic,
 Hydraulic,
 Electrical, and
 Automatic.
II. Based on the basic operating principle used:-
 Positive Contact Clutches: Square jaw, Spiral jaw, and Toothed.
 Frictional Clutches: Axial, Radial, and Cone.
 Over-running Clutches: Roller, Sprag, and Wrap-Spring.
 Magnetic Clutches: Magnetic particles, Hysteresis, and Eddy current.
 Fluid Coupling: Dry Fluid, Hydraulic.
18. How does the function of a brake differ from that of a clutch? (NOV-2012)
Ans: The functional difference between a clutch and a brake is that a clutch connects two moving
members of a machine, whereas a brake connects a moving member to a stationary member. That is, if
any one of the moving member of a clutch is fixed, then the device becomes a brake.
19. How will you reduce the pressure angle in cam design? (MAY-2012)
Ans: The pressure angle (α) can be reduced by Speed of operation, and Weight of the
connected parts.
20. Clutches are usually designed on the basis of uniform wear. Why? (MAY-2008)
Ans: In Clutches, the value of normal pressure, axial load for the given clutch is limited by the rate of
wear that can be tolerated in the brake linings. Moreover, the assumption of uniform wear rate gives a
lower calculated clutch capacity than the assumption of uniform pressure. Hence clutches are usually
designed on the basis of uniform wear.

PART-B

1. Find the torque that a two surface, dry disk clutch can transmit if the outside and inside lining
diameters are 120 mm and 250 mm, respectively, and the applied axial force is 10 KW. Assume
 uniform wear and /t = 0.4 .Is the pressure on the lining acceptable? What lining material would be
suitable? (MAY-2007)
2. In a single block brake, the diameter of the drum is 250 mm and the angle of contact is 90 0. The
operating force of 700 N is applied at the end of lever which is at 250 mm from the center of the brake
block. The Coefficient of friction between the drum and the lining is 0.35. Determine the torque that
may be transmitted. Fulcrum is at 200 mm from the centre of brake block with an offset of 50 mm from
the surface of contact? (MAY-2007)
3. A single plate clutch transmits 25 kW at 900 rpm. The maximum Pressure intensity between the plates
is 85 kN/m2. The ratio of radii is 1.25. Both the sides of the plate are effective and the coefficient of
friction is .25. Determine (i) the diameter of the plate (ii) the axial force to engage the clutch. Assuming
the uniform wear theory. (NOV-2008)
4. A single plate clutch, effective on both sides, is required to transmit 25 kW at 3000 rpm. Determine the
outer and inner diameter of frictional surface if the coefficient of friction is 0.255, ratio of diameters is
1.25 and the maximum pressure is not to exceed 0.1 N/mm2. Also, determine the axial thrust to be
provided by springs. Assume theory of uniform wear.
(NOV-2012)
5. A leather faced conical clutch has cone angle of 300.The pressure between the contact surfaces is
limited to .35N/mm2 and the breath of the conical surface is not to exceed 1/3 of the mean radius. Find
the dimensions of the contact surface to transmit 22Kw at 2000 rpm .Also calculate the force required
to engage the clutch. .Take μ =0.15. (NOV-2013)
6. Draw the displace time, velocity time and the acceleration time curves for the follower in order to
satisfy the following conditions MAY-2011)
1. Stroke of the follower 25mm
2. Outstroke takes place with SHM during 900 of cam rotation
3. Return stroke takes with SHM during 750 of cam rotation
4. Cam rotates with a uniform speed of 800 rpm

Extra Questions UNIT – 5

1. What are the factors upon which the torque capacity of a clutch depends?(Nov2011)

Torque capacity of a clutch depends on (i) number of pair of contact surfaces, (ii) coefficient of friction (iii) axial
thrust exerted by the spring and mean radius of friction surfaces.

2. Name four profiles normally used in cams. (May 2009)

1. Uniform velocity, 2. Simple Harmonic Motion 3. Uniform Acceleration and Retardation 4. Cycloidal motion

3. Give the reason for left and right hand shoes of internal expanding brakes having different actuating forces.
(May2007)

Depending upon the direction of the drum rotation, one should be leading shoe another shoe is trailing shoe.
The leading shoe is self energizing where as the trailing shoe is not. In the leading shoe, the friction force helps
the applied force and hence more actuating force than the trailing force

4. Name the profile of the cam that gives no jerk (May 2007)

Circle-arc cam gives no jerk. Because the derivative of acceleration of cam is zero
5. What is fade? (Dec2004)?

When the brake is applied continuously over the period of time, the brake becomes overheated and coefficient
of friction drops. This result in sudden fall of efficiency of the brake. This is known as Fade or Fading

Part B

1. A multidisc clutch has three discs on the driving shaft and two on the drive shaft is to be designed for a
machine tool, driven by electric motor of 22kw running at 1440 rpm. The inside diameter of the contact
surfaces is 130mm. The maximum pressure between the surfaces is limited to 0.1 N/mm^2. Design the clutch.
Take µ=0.3, n1=3; n2=2(Apr 2011)

2. Determine the capacity and main dimension of double block brake for the following data:

The brake sheave is mounted on the drum shaft. The hoist with its load weights 45kn and moves downwards
with a velocity of 1.15m/s. The pitch diameter of the hoist drum is 1.25 m. The hoist must be stopped with in a
distance of 3.25m. The K.E of the drum may be neglected. (Apr 2011)

3. Design a cam for operating the exhaust valve of an oil engine. It is required to give equal uniform
acceleration and retardation during opening and closing of valve, each of which corresponding to 60° of cam
rotation. The valve should remain in the fully open position for 20° of cam rotation. The lift of the valve is 32
mm and the least radius of the cam is 50 mm, the follower is provided with a roller of 30mm diameter and its
line of stroke passes through the axis of cam. (Jun 2012)

4. The displacement function of cam-follower mechanism is given by y(Ө) =100 (1-cosӨ) mm; 0≤Ө≤2π, where
y is the follower displacement and Ө is the cam rotation. The cam speed is 1000rpm. The spring constant is 20
N/mm and the spring has an initial compression of 10 mm, where the roller follower is in its lowest position.
The weight of the mass to be moved including the follower is 10 N, length of the follower outside the guide A =
40 mm, length of guide B = 100mm, Rb =50mm, Rr= 10mm and the coefficient of friction between the guide
and the follower µ =0.05. Compute the normal force and the cam shaft torque when the cam has rotated 60
degrees. (Dec2011)

5. A friction clutch is required to transmit 25 KW at 2000rpm. It is to be of single plate disc type with both
sides. The pressure is exerted by means of springs and limited to 70KN/m^2. If the maximum possible outer
diameter of the clutch plate is 300mm, find the required inner diameter of the clutch plate and the total force
excerted by the springs. Assume the wear to be uniform and coefficient of friction as 0.3(Dec2009)