INTEGRATED MECHANICAL DESIGN

UNIT - I

FUNDAMENTALS AND DESIGN OF SHAFTS

2 MARKS:

1. Define Design.

2. What is 'Adaptive Design'?

3. What is the purpose of Adaptive Design.

4. What are the uses of Adaptive Design.

5. What are the various phases of design process?

6. List some factors that influnce machine design.

7. Explain 'Design for manufacture'.

8. What you mean by optimum design?

9. Describe material properties hardness, stiffness and resilience.

10. What is an S-N curve ?

11. What is a Shaft ?

12. What are the different measures followed to control the lateral deflection?

16 MARKS:

1. Explain the various phases of design process

2. Write short notes on the following

i) Interchangebility

ii) Tolerance

iii) Allowance

iv) Fits

3. A journal of nominal or basic size of 75mm runs in a bearing with close running fit.
Find the limits of shaft and bearing .What is the maximum and minimum clearance ?

4. A pulley is keyed to a shaft midway between two bearings. The shaft is made of cold
drawn steel for which the ultimate strength is 550Mpa and the yield strength is 400Mpa.
the bending moment at the pulley varies from -150N-m to +400N-m as the torque on the
shaft varies from -50N-m to +150N-m. Obtain the diameter of the shaft for an indefinite
life. The stress concentration factors for the keyway at the pulley in bending and in
torsion are 1.6 and 1.3 respectively. Take the following values

Factor of safety = 1.5

Load correction factors = 1.0 in bending ,and 0.6 in torsion

Size effect factor = 0.85

Surface effect factor = 0.88

5. Explain the theories of failure.

6.Explain the various Factors influencing machine design.

UNIT-II

DESIGN OF GEARS AND GEAR BOXES

2 MARKS:

1. Define a module?

2. Define transmission ratio with reference to spur gears?

3. What are the advantages of toothed gears over the other types of transmission

systems?

4. What are the materials used for gear manufacturing?

5. What does AGMA stands for?

6. Define axial pitch of helical gears?

7. What helix angle is adopted for a double helical gear?

8. Differentiate double helical and herring bone gear?

9. What are spiral gears?

10. Where do we use skew or spiral gears?

11. What is zerol bevel gear?

12. What is crown gear?

16 MARKS:

1.Two shafts 300mm apart transmitting 7.46 kW are to be connected by a steel pinion
meshing with a cast iron gear .The velocity ratio of the drive is 3:1 and the pinion runs
at 600rpm. Assuming 20 involute tooth profile , design the drive.

2. Design a pair of spur with the following data. Centre distance =340mm
(approximately).Power to be transmitted = 77.28kw,RPM of the pinion =720, speed
reduction ratio =5:1. Material to be used (a) C14 and (b) Crl.

3.A general purpose enclosed gear train based on parallel helical gears, specified life is
36,000 hours .Torque at driven shaft is 411Nm. Driving shaft speed is 475 rpm. Velocity
ratio is 4. It is desired to have standard centre distance.

4.Design a bevel gear drive to transmit 3.5 kW. speed ratio=4. Driving shaft speed
=200rpm .The drive is non reversible .Pinion is of steel and wheel of CI. Assume a life of
25,000 hours.

5. A gear box is to be designed with the following specifications:

Power =14.72kW. Numbers of speed =18. Minimum speed 16rpm. Step ratio =1.25.
Motor speed =1400rpm. the speed are obtained as 233. Sketch the layout of the gear
box and the speed diagram of the shafts and the number of teeth on the gears.

UNIT_III

BRAKES

2 MARKS :

1. What is the function of a brake?

2.Differentiate a brake and a clutch.

3. Differentiate a brake and a dynamometer?

4. Give examples for radial and axial brakes?

5. What are the types of brake linings?

6. What is a self-locking brake?

7. What do you mean by self-energizing brake?

8. Two blocks diametrically opposite to each other are used in a block brake. why?

9. Write an expression for the ratio between the tight and slack sides of a band and
block brake?

10. What types of brakes are used in automobiles?

16 MARKS :

1.Classify Brakes with neat bolck diagram and explain the various type of Brake linings
used.

2.Two externally closing shoes 120mm wide and subtending angles of 90 each at the
drum centre are applied on drum whose diameter is 450nn and width
150mm.Determine the heat dissipated by the brake.The Radiation heat transfer
coefficient is given by

C=Co(1+ t , where Co =2.9W/m2K and =0.076 per K

3.Determine the capacity and the main dimensions of a 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 1.15mps (i.e.,1.15m/s). The pitch diameter of
the hoist drum is 1.25m. The hoist must be stopped within a distance of 3.25m. The
kinetic energy of the drum may be neglected.

4.A differential band used for a winch, is wound round a drum of 0.75 m diameter,
keyed to the shaft. The two ends of the band are attached to the pins on the opposite
sides of the fulcrum of thebrake lever at distance of 25mm and 100mm from the
fulcrum.

The angle of lap on the drum is 240 .The coefficient of friction is 0.25.Find the
torque which can be applied by the brake when a force of 500N is applied to the lever
(a)upwards , (b)downwards ,at adistance of 1m from the fulcrum.Consider both
directions of rotation.

5.Explain the construction and working principle of External contracting shoe brake
with neat sketch.
 UNIT-IV

INTEGRATED DESIGN

2 MARKS:

1. What is bearing?

2. Classify the types of bearings.

3. Define antifriction bearings.

4. What are the types of rolling contact bearings?

5. Define the term Bearing life.

6. What is a Spring.

7. What are the various types of springs.

8. Define Leaf springs

9. What are active coils?

10. What is pitch.

16 MARKS:

1.A compression helical spring is required to exert a minimum force of 250N and
maximum force of 600N and the deflection for this change in load is to be 15mm.The
spring must fit in a hole of 30mm diameter .The load ids static .Ultimate tensile stress is
1393MPa and shear stress is 606MPa.

2. A helical spring is subjected to a load from 400N to 1000N having spring index of 6
and the design factor of safety is 1.25. The compression of the spring at the maximum
load is 30mm. Design the helical compression spring. Take yield stress in shear as
110N/mm2 , endurance stress in shear as 350N/mm2 and the modulus of rigidity for the
spring material as 80x103 N/mm2.

3. Design a semi elliptical leaf spring for the rear axle of car .The load on the rear axle
of the car is 10kN. The span is 1m long and the width of clamp is 100mm. In all, 12
leaves are used out of which two are main leaves and the remaining are graduated
leaves .Assume suitable material.

4. Select a suitable spherical roller bearing from SKF series 222C to support a radial
load of 4kN and an axial load of 2kN. Minimum life required is 10,000 hours at
1000rpm. For the selected bearing ,find

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.

5.Design a journal bearing for 12Mw,1000 rpm steam turbine, which is supported by
two bearings. Take the atmospheric temperature as 16 c and operating temperature

of oil as 60 .Assume viscosity of oil as 23 centipoise.

6.Design a rim type C.I flywheel for a four-stroke engine to the following data. Power
=75kW; speed=250rpm; fluctuation of speed= 2.5% work done during power stroke
is 30 higher than average work done during whole cycle. For shaft, allowable shear
stress is 45N/mm2.