ME6601 – DESIGN OF TRANSMISSION SYSTEMS

PART – A

UNIT – I
1) Give the relationship of ratio of tensions in a V-belt drive. (M-8)
2) Define maximum tension in a belt. (M-8)
3) How is a wire rope specified? (M-9)
4) Give the condition for maximum power transmission in terms of centrifugal tension in case of
belt drive. (M-9)
5) Sketch the cross section of a V-belt and label its important parts. (N-9)
6) Why is the face of a pulley crowned? (N-9)
7) How are the ends of flat- belt joined? (M-10)
8) What are the five parts of roller chain? (M-10)
9) State reasons for V-belt drive being preferred to flat belt drive? (N-10)
10) What do you mean by galling of roller chains? (N-10)
11) Distinguish between open drive and cross drive of a belt drive. Which is better? (M-11)
12) Give any three applications of chain drives. What are their limitations? (M-11)
13) What are the factors on which the coefficient of friction between the belt and pulley depend?
(M-12)
14) What do you mean by galling of roller chains? (M-12)
15) How is a wire rope specified? Give an example. (N-12)
16) Mention the parts of roller chain. (N-12)
17) What are the materials used for belt-drive? (M-13)
18) Why slip is less in the case of v-belts when compared with flat belts? (M-13)
19) What are the factors upon which "the .coefficient of friction between the belt and pulley depends?
(M-14)
20) Brief the term "Crowning of Pulley". (M-14), (N-16)
21) What do you understand by 6 x 19 construction in wire ropes? (N-14)
22) Mention the losses in belt drives. (N-14)
23) In what ways the timing belts are superior to ordinary V belts. (M-15)
24) What is meant by 'Chordal action . of chain'? Also name a co m pa ny t h a t produces driving chains.
(M-15)
25) What is centrifugal effect on belts? (N-15)
26) What is chrodal action in chain drives? (N-15)
27) Name the few materials for belt drives. (M-16)
28) Under what circumstances chain drives are preferred over V belt drives? (M-16)
29) What factors will affect the working conditions of the chain drive? (N-16)
30) A longer belt will last more than a shorter belt, why? (M-17)
31) List the advantages of wire ropes compared to chains (M-17)
32) List the chain drive failures. (n-17)
33) Write the advantages of V belts over flat belts. (N-17)
 UNIT - II

1) What is backlash in gears? (M-8)

2) What is the advantage of helical gear over spur gear? (M-8)
3) Mention a few gear materials. (M-9)
4) State an advantage and a disadvantage of helical gear. (M-9)
5) What condition must be satisfied in order that a pair of spur gears may have a constant
velocity ratio? (N-9)
6) What is a herringbone gear? Where is it used? (N-9)
7) Why is tangential component of gear tooth force called useful component? (M-10)
8) Compare the contact between mating teeth of spur and helical gears. (M-10)
9) In a pair of spur gears, the module is 6mm. Determine the circular pitch and the
diametric pitch, (N-10)
10) If the radial force component of the bevel gear is 1200N (+ y direction), determine
the axial component of the pinion in the gear drive. Also write down the relation
between axial force and tangential force component. (N-10)
11) Define module. (M-11), (M-13), (N-15)
12) What are the common forms of gear tooth profile? (M-11)
13) List the various types of gear tooth failure. (M-12) (M-13)
14) Define the various pitch in a helical gear. (M-12)
15) Why is pinion made harder than gear? (N-12)
16) Compare the features of spur and helical gears. (N-12)
17) What is pressure angle? What is the effect of increase in. pressure angle? (M-14)
18) What condition-must be satisfied irr order that a pair of spur gears may have a constant
velocity ratio? (M-14)
19) Specify the effects of increasing the pressure angle in gear design. (N-14)
20) Why is a gear tooth subjected to dynamic load? (N-14)
21) State the law of Gearing. (M-15)
22) What is pressure angle? What is the effect of Increase in pressure angle? (M-15)
23) Differentiate double helical and herringbone gears. (N-15) (M-17)
24) What are the profiles of a spur gear? (M-16)
25) What is herringbone gear? (M-16)
26) Define Backlash. What factors influence backlash? (N-16)
27) A helical gear has a normal pressure angle of 200, a helix angle of 450, normal module of 4 mm and
has 20 teeth. Find the pitch diameter. (N-16)
28) What are the effects of increasing of decreasing the pressure angle in gear design? (M-17)
29) What is meant by stub tooth in gear drives? (N-17)
30) Define virtual number of teeth in helical gears. (N-17)
 UNIT – III

1) State the use of bevel gears. (M-8)

2) State the advantage of worm gear drive in weight lifting machines. (M-8)
3) When is bevel gear preferred? (M-9)
4) Calculate the angle between the shafts of a crossed helical gears made of two right
handed helical gears of 15° helix angle each. (M-9)
5) What are the various forces acting on a bevel gear? (N-9)
6) Usually worm is made of hard material and worm gear is made of softer material -
Justify. (N-9)
7) When do we employ crossed helical gear? (M-10)
8) Mention two characteristics of hypoid gear. (M-10)
9) A pair of worm gears is designated as 2 / 54 / 10 I 5. Find the gear ratio. (N-10)
10) Mention the reason for .irreversibility in worm gears. (N-10)
11) Under what situation, bevel gears are used? (M-11)
12) In worm gear drive, only the wheel is designed. Why? (M-11)
13) List the various types of bevel gears. (M-12)
14) What are the various losses in the worm gear drive? (M-12)
15) When do we employ crossed helical gear? (N-12)
16) Mention the types of failure in worm gear drives. (N-12)
17) What are the forces acting on bevel gear? (M-13)
18) Where do we use warm gear? (M-13)
19) Define the following terms: (a) Cone distance, (b) Face angle: (M-14)
20) What. is virtual number of teeth in bevel gears? (M-14),(N-14)
21) Mention the advantages of worm gear drive, (N-14)
22) State the advantages of herring bone gear. (M-15)
23) What is a Zerol bevel gears? (M-15)
24) What is the difference between an angular gear and a miter gear? (N-15)
25) What kind of contact occurred between worm and wheel? How does this differ from other
gears.(N-15)
26) How bevel gears are manufactured? (M-16)
27) What is helical angle of worm? (M-16)
28) What is a crown gear? (N-16)
29) Write some applications of worm-gear drive. (N-16)
30) What is known as formative number of teeth on bevel gears? (M-17)
31) Write the conditions of self locking of worm gears in terms of lead and pressure angles. (M-17)
32) What are the disadvantages of worm gear drive? (N-17)
33) What is meant by mitre gear? (N-17)
 UNIT – IV

1) List six standard speeds starting from 18 rpm with a step ratio 1.4. (M-8)
2) Sketch the kinematic layout of gears for 3 speeds between two shafts. (M-8)
3) Where is multi-speed gear boxes employed? (M-9)
4) Name the series in which speeds are arranged in multi-speed gear boxes.
5) Which type of gear is used in constant mesh gear box? Justify. (N-9)
6) Compare sliding mesh and synchromesh gear box. (N-9)
7) List the ways by which the number of intermediate steps may be arranged gear box. (M-
10)
8) What are the points to be considered while designing a sliding-mesh type of multi-
speed gear box? (M-10)
9) What are the possible arrangements to achieve 16· speeds from a gear box? Which is
the preferred arrangement? (N-10)
10) What does the ray diagram of gear box indicates? (N-10)
11) What are preferred numbers? (M-11) (M-13) ,(N-14)
12) What are the possible arrangements to achieve 12 speeds from a gear box? (M-11) (M-13)
13) Write short notes on the working principle of sliding mesh gear box. (M-12)
14) What does the ray diagram of gear box indicates? (M-12)
15) List four applications where constant mesh gear box is used. (N-12)
16) What are the conditions required for interchangeability in toothed gears? (N-12)
17) What is step ratio? Name. the series in which speeds of multi-speed gear box
18) are arranged. (M-14)
19) Sketch the kinematics layout of gears for 3 speeds between two shafts. (M-14)
20) Specify four types of gearboxes. (N-14)
21) Draw the ray diagram for a six speed gear ho~. (M-15)
22) In which gear-drive, self-lockingis available? (M-15)
23) Define progression ration. (N-15)
24) Write the significance of structural formula. (N-15)
25) What is multispeed gear box? (M-16)
26) What is R20 series? (M-16)
27) Differentiate ray diagram and structural diagram. (N-16)
28) List any two methods used for changing speeds in gear boxes. (N-16)
29) Why geometric progression is selected for arranging the speeds in gear boxes? (M-17)
30) What does the ray diagram of gear box indicate? (M-17)
31) Draw the ray diagram for 12 speed gear box? (N-17)
32) Write any two principles to be followed to obtain optimum design in gear box. (N-17)
 UNIT- V
1) State the advantage of cam over other reciprocating mechanisms. (M-8)
2) How the "uniform rate of wear" assumption is valid for clutches? (M-8)
3) Name four profiles normally used in cams. (M-9)
4) . Under what condition of a clutch, uniform rate of wear assumption is more valid? (M-
9)
5) Differentiate between self-energizing and self-locking brakes. (N-9)
6) Why is it necessary to dissipate the heat generated during clutch operation? (N-9)
7) What is the disadvantage of block brake with one short shoe? What is the remedy? (M-
10)
8) When do we use multiple disk clutches? (M-10)
9) List the characteristics of material used for brake lining. (N-10)
10) Define base circle and pitch circle with respect to cam. (N-10)
11) Name few commonly used friction materials. (M-11)
12) What is a self-locking brake? (M-11)
13) Sketch an internal shoe brake and name the various parts. (M-12)
14) In cone clutches semi-cone angle should be greater than 12°. Why? (M-12)
15) What is a self-locking brake? (N-12) (M-13)
16) Distinguish between a coupling and a clutch. (N-12)
17) What is the axial force required at the engagement and disengagement of cone clutch? (M-13)
18) Classify clutches based on the coupling methods. (M-14)
19) What is meant by a self-energizing brake? (M-14), (N-16) (N-17)
20) Differentiate between uniform pressure and uniform wear theories adopted in the design of
clutches. · (N-14)
21) In a hoisting machinery, what are the different energies absorbed by a brake system? (N-
14)
22) If a multidisc clutch has 6 discs in driving shaft and 7 discs in driven .shaft, then how many
number of contact surfaces it will have? (M-15)
23) Why in automobiles, braking action .when traveling m reverse .is not as effective as
when moving forward? (M-15)
24) Name the profile of cam that gives no jerk. (N-15)
25) What is meant by positive clutch? (N-15)
26) What is the function of clutch in a transmission system? (M-16)
27) What is the significance of pressure angle in cam design? (M-16)
28) Mention a few applications of cams. (N-16)
29) Differentiate a brake and a dynamometer. (M-17)
30) Double shoe brakes are preferred than single shoe brake, Why? (M-17)
31) Write the difference dry and wet clutch. (N-17)
 PART – B

UNIT - I
1) Design a V- belt drive to transmit 50KW at 1440rpm from an electric motor to a textile machine
running 24 hours a day. The speed of the machine shaft is 480 rpm.

2) A blower is to run at 600 rpm. Power to the blower is available from a motor
rated 8kW at 1500 rpm. Design a chain drive for the system if the centre distance is to
be 800 mm. (M-8)

3) Design a flat belt drive to transmit 25 kW at 720 rpm to an aluminium rolling

machine with a speed reduction of 3.0. The distance between the shafts is 3 m.
Diameter of rolling machine pulley is 1.2 m. (M-9)

4) Design a chain drive to activate a compressor from a 15Kw electric motor at 960 rpm.
The compressor speed is 300 rpm. The chain tension may be adjusted by shifting the
motor on rails. The compressor is to work 8 hrs/day. (M-9)

5) Design a flat belt drive to transmit 110KW for a system consisting of two pulleys of
diameters 0.9m and 1.2m respectively for a centre distance of 3.6m. belt speed of 20m/s
and coefficient of friction is 0.3. There is a slip of 1.2% at each pulley and 5% friction
loss at each shaft with 20% over load. (N-9), (M-16), (N-16)

6) A compressor is to be actuated from a 10 KW electric motor. The speed of the motor

shaft is 1000 rpm and the compressor speed being 350rpm. The minimum centre distance
is 500 mm. the compressor operates 16 hrs/day. Design a suitable chain drive. (N-9)

7) Design a flat belt drive to transmit 6 kW at 900 rpm of the driver pulley. Speed
reduction is to be 2.5:1. Assume that the service i s 16 hours a day. (M-10) (16)

8) Design a chain drive to transmit 6 KW at 900rpm of a sprocket pinion. Speed

reduction is 2.5:1. Driving motor is mounted on an adjustable base. Assume that load is
steady, drive is horizontal and service is 16 hrs/day. (M-10)

9) The reduction of speed from 36_0 rpm to 120 rpm is desired by the use of chain drive. The
driving sprocket has 10 teeth. Find the number of teeth on the drive~ sprocket. If the
pitch radius of the driven sprocket is 250mm and the centre to centre distance between
the two sprockets is 400mm, find the pitch and length of the chain. (N-10)

10) A V-belt drive consists of three V-belts in parallel on grooved pulleys of the same size.
The angle of groove is 30° and the coefficient of friction 0.12. The cross sectional area of
each belt is 800mm2 and the permissible safe stress in the belt material is 3 MPa. Calculate
the power that can be transmitted between two pulleys 400mm in diameter rotating at
960rpm. (N-10)
11) Select a flat belt to drive a mill at 250 rpm from a 10 kw, 730 rpm motor. Centre distance is
to be around 2m. The mill shaft pulley is of 1 m diameter. (M-11)

12) A truck equipped with a 9.5 kw engine uses a roller chain as the final drive to the rear
axle. The driving sprocket runs at 900 rpm and the driven sprocket at 400 rpm with a
centre distance of approximately 600 mm. Select the roller chain. (M-11)

13) For a flat belt drive, the following data are given: Power transmitted = 9kW,
Speed of motor = 1500 rpm. Speed of driven pulley= 500 rpm, Velocity of belt = 16
mis, Density of belt material = 9.8 kN/m3, Small diameter to thickness of belt
ratio = 36, Factor of safety = 8, Ultimate strength of belt material = 24 MPa, Centre
distance = 2. lm, Coefficient of friction= 0.36. Design the belt. (M-12)

14) A compressor running at 250 rpm requires 80kW.-'I'he drive is by V-belts from an
electric motor running at 800 rpm. The diameter of the pulley on the compressor shaft
should not be greater than lm while center distance . between pulleys is limited to
1.8 m. The belt speed should not exceed 1500 m/min. Determine the number of
belts required to transmit the power if each belt has a cross-sectional. area of 360
mm2, density 100 kg/m3 and allowable tensile stress of 2.5 N/mm2• The groove
angle of pulley is 36°. The coefficient of friction between the belt and the pulley is 0..3.
Also determine the length of belt. (M-12)

15) Select a suitable chain to transmit 15 kW at 1000 rpm of a sprocket pinion.

Speed reduction is 2:5:1. Driving motor is mounted on an adjustable base.
Assume that load is steady, drive is horizontal and service is 12 hours/day. (N-12)
A belt is to transmit 25 kW at 720 rpm to a rolling machine with a speed ratio of 3.
Center distance between the pulleys is 2.8 m. Design a suitable belt drive if the rolling
machine pulley diameter is 0.9 m. (N-12)

16) Design a V-belt drive to the following specifications : (M-13) (N-17)

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.

17) 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. (M-13)

18) A V-belt drive is to .transmit 45 kW in a heavy duty saw mill which works in two
shifts of 8 hours each. The speed 'of motor shaft-is 1400 rpm with the approximate
speed reduction .of 3 in the machine shaft. Design the drive and calculate the average
stress induced in the belt. (M-14)
19) Design a chain drive to actuate a compressor from 15 kW electric motor .running
at 1,000 r.p.m., the compressor speed being 350 rpm. The minimum centre
distance is 500 mm. The compressor operates 15 hours per day. The chain tension may
be .adjusted by shifting the motor. (M-14)

20) A compressor is to run by a motor pulley running at 1440 rpm, speed ratio 2.5.
Choose a flat belt crossed drive. Centre distance between pulleys is 3.6m. Take
belt speed as 16 mis. Load factor is 1.3. Take a 5-ply, flat Dunlop belt. Power to be
transmitted is 12kW. High speed load rating is 0..0118 kW/ply/mm width at V=5m/s.
Determine the width and length of the belt… (N-14)

21) At the construction .site, 1 tonne· of steel is to be lifted up to a height of 20 m

with the help of 2 wire ropes of 6 · x 19 size, nominal diameter 12 'mm, and
breaking load 78 kN. Determine the factor of safety if the sheave diameter is 56 d
and if wire rope is suddenly stopped in 1 second when travelling at a .speed of 1.2
m/s. What is the factor of safety if bending load is neglected? (N-14)

22) Design a V-Belt drive and calculate the actual belt tensions and average stress for the following
data. Power to be transmitted = 7.5KW, Speed of driving wheel = 1000 rpm, Speed of driven wheel
= 300 rpm, Diameter of driven pulley = 500mm, Diameter of driver pulley = 150mm and Center
distance = 925mm. (M-15)

23) A 7.5KW electric motor running at 1400 rpm is used to drive the input shaft of the gearbox of a
machine. Design a suitable roller chain to connect the motor shaft to the gear box shaft to give an
exact speed ratio of 10:1. The center to center distance of the shaft is to be approximately 600mm
(M-15) , (M-16)

24) Select a suitable V-belt and design the drive for a wet grinder. Power is available from a 0.5 kW
motor running at 750 rpm. Drum speed is to be about 100 rpm. Drive is to be compact. (N-15)

25) Select a wire rope for a vertical mine hoist to lift a load of 20 Kn from a depth of 60 meters. A
rope speed of 4 m/sec is to attained in 10 seconds. (N-15)

26) A bucket elevator is to be driven by a geared motor and a roller chain drive with the
information given below: (N-16)
Motor output = 3 kw
Speed of motor shaft = 100 rpm
Elevator drive shaft speed = 42 rpm
Load – even
Distance between centres of sprockets approximately = 1.2m
Period of operation = 16 hrs/day
Geared motor is mounted on an auxiliary bed for centre distance adjustments. Design the chain
drive.

27) Two shafts whose centers are 1m apart are connected by a V- Belt drive. The driving
pulley is supplied with 100 Kw and has an effective diameter of 300 mm. it runs at 1000
rpm, while the driven pulley runs at 375 rpm. The angle of groove on the pulleys is 40 0. The
permissible tension in 400 mm 2 cross sectional area of belt is 2.1 Mpa. The density of the
belt is 1100 kg/m3. Taking µ = 0.28, estimate the number of belts required. Also calculate the
length of the each belt. (M-17)

28) A truck equipped with a 9.5 kw engine uses a roller chain as the final drive to the rear
axle. The driving sprocket runs at 900 rpm and the driven sprocket at 400 rpm with a
centre distance of approximately 600 mm. Select the roller chain. Number of teeth on driving
sprocket can be taken as 27 and the pitch value can be taken at the middle of P max and Pmin
values. (M-17)

29) Select a wire rope for a vertical mine hoist to lift a load of 20 KN from a depth of 500 meters.
A rope speed of 3 m/sec is to attained in 10 seconds. (N-15)
 UNIT – II

1) A motor shaft rotating at 1500 rpm has to transmit 15 kW to a low speed shaft with a
speed reduction of 3:1. Assume starting torque to be 25% higher than the running
torque. The teeth are 20 ° involute with 25 teeth on the pinion. Both the pinion
and gear are made of C45 steel. Design a spur gear drive to suit the above
conditions and check for compressive and bending stresses and plastic deformation. Also
sketch the spur gear drive. (M-8)

2) A helical gear with 30° helix angle has to transmit 35 kW at 1500 rpm. with a speed
reduction ratio 2.5. If the pinion has 24 teeth, determine the necessary module, pitch
diameter and face width for 20 ° full depth teeth. Assume 15Ni 2Cr 1 Mo15 material for
both pinion and wheel. (M-8)

3) In a spur gear drive for a rock crusher, the gears are made of case hardened alloy steel. The
pinion is transmitting 18 KW at 1200 rpm with a gear ratio of 3.5. The gear is to work 8 hrs/day
for 3 years. Design the drives major dimensions. Check for compressive and bending stresses
and sketch the arrangement. (M-9)

4) A pair of helical gears subjected to heavy shock loading is to transmit 37.5 KW at 1750 rpm
of the pinion. The speed reduction ratio is 4 and the helix angle is 15°. The service is continuous
and the teeth are 20° full depth in the normal plane. Select suitable material and design the gears.
Check for working stresses and sketch the drive. (M-9)

5) A motor shaft rotating at 1440 rpm has to transmit 15 KW to a low speed shaft rotating at 500
rpm. The teeth are 200 involute with 25 teeth on the pinion. Both the pinion and gear are made
of C.I. with a maximum safe stress of 56Mpa. A safe stress of 35Mpa ma y be taken for the shaft
on which the gear is mounted. Design and sketch the spur gear drive to suit the above conditions.
The starting torque may be assumed as 1.25 times the running torque. (N-9)

6) A helical gear speed reducer is to be designed. The rated power of the speed
reducer is 75 kW at a pinion speed of 1200 rpm. The speed ratio is 3 to 1. For medium
shock conditions and 24 hours operation; determine, the module, face width, number of
teeth in each gear. The teeth are 20° full depth in the normal plane. Assume suitable
material. (N-9)

7) The pitch circles of a train of spur gears are shown in Fig. Gear A receives 3.5KW power at
700 rpm through its shaft and rotates in clockwise direction. Gear B is the idler gear
while gear C is the driven gear. The number of teeth on gears A, B and C are 30,
60 and 40 respectively, while the module is 5 mm. Calculate the torque on each gear shaft;
and the components of gear tooth forces. Draw a free-body diagram of forces and
determine the reaction on The idler gear shaft. Assume the 20° involute system for the
gears. (M-10)

8)A pair of helical gears is to transmit 14 KW. The teeth are 20o stub and helix angel is 450 .
Pinion runs at 10,000 rpm and has 80 mm PCD. Wheel has 320 mm PCD. Both gears are made
of cast steel. Design the gear pair and obtain the basic dimensions assuming a life of 1000 hours.
(M-10)

9) A 27.5 kW power is transmitted at 450 rpm to a shaft running at approximately 112

rpm through a spur gear drive. The load is steady and continuous. Design the gear drive and
check the design. Assume the Following materials: Pinion-heat treated cast steel; Gear-High
grade iron. (N-10)

10) A pair of helical gears subjected to moderate shock loading is to transmit 20kW at 1500
rpm of the pinion. The speed reduction ratio is 4 and the helix angle is 20°. The service is
continuous and the teeth are 20° full depth in the normal plane. For the gear life of 10,000
hours, design the gear drive. (N-10)

11) In a spur gear drive for a stone crusher, the gears are made of C40 steel. The pinion is
transmitting 20 kw at 1200 rpm. The gear ratio is 3. Gear is to work 8 hrs per day, six days a
week and for 3 years. Design the drive. (M-11)

12) Design a pair of helical gears to transmit 10 kw at 1000 rpm of the pinion. Reduction
ratio of 5 is required. (M-11)

13) Design a spur gear drive to transmit 15 kW at 900rpm of forged steel pinion 120
mm diameter to a cast steel gear to run at 300 rpm. Take pressure angle of 20° and
working life of the gears as lOOOOhrs. (M-12)
14) A pair of helical gears for a turbine has a transmission ratio of 10:1. The pinion rotates
at 5000 rpm and made of carbon steel and the gear wheel is made of high grade cast
iron. Power transmitted = 90 kW. The gear pair is required to last for atleast 12000
hrs. Select suitable gear materials. (M-12)

15) Design a spur gear drive to transmit 10 kW at 1440 rpm, speed reduction is 3. Take
pressure angle as 20° and working life of the gears as 15,000 hrs. Assume the materials
for pinion and wheel as heat treated cast steel and high grade cast iron respectively. (N -
12)

16) Deduce the expressions for forces acting on a gear tooth of a helical gear with the aid
of a schematic diagram. (N-12)

17) 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. (M-13)

18) 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. (M-13)

19) (i) Explain the phenomenon of interference in involute gears.

(ii) Design and draw spur gear drive transmitting 30 kW at 400 r.p.m.

to another shaft running approximately at 1000 r.p.m. The load is steady and continuous
.. The material for the pinion is cast steel and for gear is cast iron. Take module as 10
mm. Also check the design for dynamic load and wear. (M-14)

20) A single stage helical gear reducer is to receive power from a 1440 r.p.m., 25 kW
induction motor. The gear tooth profile is involute· full depth with 20° normal pressure
angle. The helix angle is 23°, 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 90 MPa and hardness 250
B.H.N. (M-14)

21) (i). Design the gears for 0% overload carrying capacity from the standpoint
of bending strength and wear. (10)

(ii)If the incremental dynamic load of 8 kN is estimated in tangential plane, what will .be
the safe power transmitted by the ·pair at the Same speed? (6) ·

22) Design a· spur gear drive for a stone crusher where the gears are made of C40 steel.
The pinion is transmitting 30 kW at 1200 rpm. The gear ratio is 3. Take the working life
of the gears as 7500 hrs. (N-14)
23) Design a helical gear drive to connect an electric motor to a reciprocating pump. Gears
are overhanging in their shafts. Motor speed = 1440 rpm. Speed reduction ratio = 5,
Motor power = 37 kW Pressure angle = 20° Helix angle= 25°. (N-14)

24) Design a spur gear drive to transmit 8 KW at 720 rpm and the speed ratio is 2. The pinion
and wheel are made of the same surface hardened carbon steel with 55 RC and core hardness
less than 350 BHN. Ultimate strength is 720 N/mm2 and yield strength is 360 N/mm2 (M-15)

25) Design a helical gear drive to transmit the power 14.7 KW. Speed ratio 6, pinion speed 1200
rpm, helix angle is 250. Select suitable materials and design the gear. (M-15)

26) Design a spur gear drive required to transmit 45 KW at pinion speed of 800 rpm. The
velocity ratio is 3.5:1. The teeth are 200 full depth involute with 18 teeth on the pinion. Both the
pinion and gear are made of steel with a maximum safe static stress of 180 N/mm2. Assume
medium shock condition. Assume medium shock conditions Vm = 12 m/s and steel is hardened
to 200 BHN (N-15) (M-17)

26) Design a pair of helical gears to transmit 10 kW at pinion speed of 1000 rpm. The reduction
ration is 5. Assume suitable materials and stresses. (N-15)

27) A pair of helical gears subjected to moderate shock loading is to transmit 30kW at 1500
rpm of the pinion. The speed reduction ratio is 4 and the helix angle is 20°. The service is
continuous and the teeth are 20° full depth in the normal plane. For the gear life of 10,000
hours, design the gear drive. (M-16)

28) A speed reducing unit using spur gear is to be designed. Power to be transmitted is 60 Hp
and is continuous with moderate shaft loads. The speeds of the shafts are 720 rpm and 144 rpm,
respectively. The center distance is kept as small as possible. Select a suitable material and
design the gears. Give the details of the gears. (M-16)

29) Design a pair of straight spur gear drive for a crusher, the pinion and wheel are made of
C15 steel and castiron grade 30 respectively. The pinion is to transmit 22 kw power at 900 rpm.
The gear ratio is 2.5. take pressure angle of 200 and working life of gears as 10,000 hrs. (N -16)

30) Design a pair of helical gears to transmit 10 kw at 1000 rpm of the pinion. Reduction
ratio of 5 is required. Pressure angle is 200 and the helix angle is 150. The material for both the
gears is 40Nicr1Mo28. Give the details of the drive in a tabular form. (N-16)

31) For intermittent duty of an elevator, two cylindrical gears made of alloy steel 40Ni 2 Cr 1
Mo 28, and have to transmit 12.5 Kw at a pinion speed of 1200 rpm. Design the gear pair for the
following specifications: gear ratio 3.5, pressure angle 200 , involute full depth, helix angle 150.
Gears are expected to work 6 hours a day for 10 years. Minimum number of teeth on pinion can
be taken as 20 and IS quality 8. (M-17)

32) Design a pair of helical gears to transmit 10 kW at 1000 rpm. of the pinion. Speed ratio 5.
Take 40Ni 2Cr 1 Mo15 steel as material for both pinion and wheel. Assume minimum number of
teeth as 20 and tabulate the results. (N-17)

33) Design a pair of spur gears to transmit 20 kW at 1400 rpm. The transmission ratio is 4..
Pinion and gear are made of 15Ni 2Cr 1 Mo15 and C45 steels respectively. Assume pressure
angle 200 and minimum number of teeth 20. (N-17)
 UNIT – III
1) A 25 kW motor running at 1200 rpm drives a compressor at 780 rpm through a
900 bevel gearing arrangement. The pinion has 30 teeth. The pressure angle of the teeth
is 20 ° . Both the pinion and gear are made of heat treated cast iron grade 35.
Determine the cone distance, average module and face width of the gears. (M-8)

2) A 2 kW power is applied to a worm shaft at 720 rpm. The worm is of quadruple

start type with 50 mm as pitch circle diameter. The worm gear has 40 teeth with
5 mm module. The pressure angle in the diametral plane is 20 ° .
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. (M-8)
(16)

3) Design a bevel gear drive to transmit 10 kW at 1440 rpm. Gear ratio is 3, material for
pinion and gear is C45 steel. Minimum number of teeth is to be 20. (M-9)

4) A hardened steel worm rotates at 1440 rpm and transmits 11 kW to a phosphor

bronze gear with gear ratio of 15. Design the worm gear drive and determine the power
loss by heat generation. (M-9)

5) A pair of cast iron bevel gears connect two shafts at right angles. The pitch
diameters of the pinion and gear are 80 mm and 100 mm respectively. The
tooth profiles of the gears are of 14 t composite form. The allowable static stress for
both the gears is 55 MPa. If the pinion transmits 2.75 kW at 1100 rpm, find the
module and number of teeth on each gear and check the design. Take surface
endurance limit as 630 MPa and modulus of elasticity for cast iron as 84 kN/mm2• (N -9)

6) Design worm and gear speed reducer to transmit 22 kW at a speed of 440 rpm.
The desired velocity ratio is 24: 1. An efficiency of atleast 8f>% is desired. Assume that
the worm is made of hardened steel and the gear of phosphor bronze. Take the centre
distance as 100 mm. (N-9)

7) Design a pair of castiron bevel gears for a special purpose machine tool to transmit 3.5KW
from a shaft at 500 rpm to another at 800 rpm. The gears overhanging in their shafts. Life
required is 8000 hours. (M-10)

8) Design a worm gear drive with a standard centre distance to transmit 7.5 kW from
a worm rotating at 1440 rpm to a worm wheel at 20 rpm. (M-10) (16)

9) Design a cast iron bevel gear drive for a pillar drilling machine to transmit 1.5kW
at 800rpm to a spindle at 400 rpm. The gear is to work for 40 hours per week for 3 years.
Pressure angle is 20°. Check the design and calculate the basic dimensions. (N-10)

10) A hardened steel worm rotates at 1440 rpm and transmits 12 kW to a phosphor bronze
gear. The speed of the worm wheel should be 60 ± 3%rpm. Design the worm gear drive
if an efficiency of at least desired. (N-10)

11) Design a bevel gear drive to transmit 7.36 kw at 1440 rpm for the following data.
Gear ratio = 3. Material for pinion and gear C45 surface hardened. (M-11)
12) Design a worm drive for a speed reducer to transmit 15 kw at 1440 rpm of the worm shaft.
The desired wheel speed is 6 rpm. Select suitable worm and wheel materials. (M-11)

13) A pair of 20° full depth involute teeth bevel gears are to be designed to connect two
shafts at right angles having velocity ratio 4: 1. The gear is made of cast steel and the
pinion is made of C 40 material. The pinion transmits 40 kW at 720 rpm. Design the gears
completely. Expected gear life is 10000 hrs. (M-12)

14) Design a worm gear drive to transmit 12 kW at 1200 rpm. Speed reduction
desired is 30:1. The worm is made of hardened steel and the wheel· of phosphor
bronze. Check the heating capacity of gears and determine the efficiency. (M-12)

15) A pair of bevel gears is to be used to transmit 8 kW from a pinion rotating at

240 rpm to a gear mounted on a shaft which intersects the pinion shaft at an angle of
70°. Assuming that the pinion is to have an outside pitch diameter of 180 mm, a
pressure angle of 20°, a face width of 30 mm, and the gear shaft is to rotate at 80 rpm,
determine the forces on the gears and the torque produced about the shaft axis. (N -12)

16) Design a worm gear drive for a speed reducer to transmit 15 kW at 1440 rpm of the
worm shaft. The desired wheel speed is 60 rpm. Select suitable worm and wheel
materials. (N-12)

17) Design a bevel gear drive to transmit 7 kW at 1600 rpm for the following data. (M-13)

Gear ratio : 3

Material for pinion and gear : C45 steel

Life : 10,000 hrs.

18) Design a worm gear drive a 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
400C. Determine the required cooling area. (M-13)

19) A 2 kW power is applied to a worm shaft at 720 mm. The worm is of quadruple
start with 5_0 mm as pitch circle diameter. The worm gear has 40 teeth with 5' mm
module. The pressure angle in the diametral plane is 20°. 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. (M-14)

20) Design a bevel gear drive to transmit 10 kW power at 1440 rpm. Gear ratio is 3,
and life of gears 10,000 hrs. Pinion and gear are made of C45 steel and minimum
no. of teeth is 20. (M-14)

21) Derive expressions for determining the forces acting on a bevel gear with suitable
illustrations. (N-14)

22) A hardened steel worm rotates at 1440 rpm and transmits 12 kW to a phosphor
bronze gear. The speed of the worm wheel should be 60 ± 3% rpm. Design a worm gear
drive if an efficiency of atleast 82% is desired. (N-14)
23) Design a pair of straight bevel gears for two shafts whose axis are at right angles. The power
transmitted is 25 KW. The speed os pinion is 300 rpm and of the gear is 120 rpm. (M-15)

24) 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 ratio should be restricted to
400C . Determine the required cooling area. (M-15) (N-17)

25) Design a straight bevel gear drive between two shafts at right angles to each other. Speed of
the pinion shaft is 360 rpm and the speed of gear wheel shaft is 120 rpm. Pinion is made of steel
and wheel is made of cast iron. Each gears are expected to work 2 hrs./day for 10 years. The
drive transmits 9.37 KW. (N-15)

26) The input to worm gear shaft is 18 kW at 600 rpm. Speed ration is 20. 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. (N-15)

27) Design a bevel gear drive to transmit 3.5 KW. Speed ratio = 4. Driving shaft speed = 200
rpm. The drive is non-reversible. Pinion is of steel and wheel of C.I. assume a life of 25,000 hrs.
(M-16), (N-16)

28) Design a worm gear drive to transmit 20 KW at 1440 rpm speed of worm wheel is 60
rpm.(M-16)

29) A hardened steel worm rotates at 1440 rpm and transmits 12 KW to a phosphor bronze gear.
The speed of the worm wheel should be 60 ± 3% rpm. Design the worm gear drive if an
efficiency of at least 82% is desired. (N-16)

30) Design a worm gear drive to transmit 20HP from a worm at 1440 rpm to the worm wheel.
Assume the bronze is sand chill cast. The speed of the wheel should be 40±2% rpm, initial
sliding velocity can be assumed as 3m/s and efficiency as 80%. (M-17)

31) Design a bevel gear drive to transmit 7.5 kw at 1440 rpm. Gear ratio 3. Pinion and gear are
made of forged C45 steel. Life of gears 10,000 hrs. Assume surface hardened heat treatment and
IS quality 6. (M-17)

32) Design a bevel gear drive to transmit 7.36 kW at 1440 rpm. for the following data. Gear
ratio is 3, material for pinion and gear is C45 surface hardened. (N-17)
 UNIT – IV

1) Sketch the arrangements of a six speed gear box. The minimum and maximum
speeds required are around 460 and 1400 rpm. Drive speed is 1440 rpm. 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. (M-8)

2) Design the layout of a 12 speed gear box for a milling machine having an output of
speeds ranging from 180 to 2000 rpm. Power is applied to the gear box from a 6 kW
induction motor at 1440 rpm. Choose standard step ratio and construct the speed
diagram. Decide upon the various reduction ratios and number of teeth on each gear
wheel. Sketch the arrangement of the gear box. (M-8)

3) Design a 12 speed gear box for an all geared headstock of a lathe by drawing
speed diagram. Show the details in a kinematic lay out. The maximum and minimum
speeds are to be 1400 rpm and 112 rpm respectively. Take the input drive speed to
be the 1400 rpm. (M-9)

4) Design a nine speed gear box for a minimum speed of 35 rpm and a maximum speed of 560
rpm. Draw the speed diagram and kinematic arrangement showing number of teeth in all gears.
Check whether all the speed obtained through the selected gears are within ±3%. (M-9)

5) The maximum and minimum speeds of nine speed gear box are to be 600 rpm
and 100 rpm respectively. The drive is from an electric motor giving 3 kW at 1440
rpm. Design the gear box. Construct the speed diagram and sketch the arrangement
of gear box. (N-9)

6) Design a 12 speed gear box for a headstock of a lathe. The maximum and minimum
speeds are 600 rpm and .25 rpm respectively. The drive is from a electric motor
giving 2.25 kW at 1440 rpm. Construct the speed diagram and sketch the arrangement
of the gear box. (N-9)

7) An all geared speed gear box is to be designed for a radial drilling machine with
the following specifications
Maximum size of the drill to be used = 50mm
Minimum size of the drill to be used= lOmm
Maximum cutting speed (drilling)= 40 m/min .
Minimum cutting speed (reaming, tapping, and boring)= 6m/min.
Number of speeds= 12 Choose a 3 x 2 x 2 arrangement.
8) Sketch the layout of the gearbox and the speed diagram. Calculate the percentage
deviation of the obtainable speeds from the calculated ones. (M-10)

9) Sketch three possible ray diagrams for a 6-speed gear box with 2 x 3 arrangement.
Choose the best possible ray diagram. Give suitable explanation for the same.
(M-10)

10) A gear box is to be designed for the following specifications :

Power to be transmitted = 5.5kW

Number of speeds = 9
Minimum speed = 280 rpm
Maximum speed = 1800 rpm
Input motor speed = 1400 rpm

11) Draw the kinematic layout diagram and the speed diagram; Determine the number of
teeth on all gears. (N-10)

12) The spindle of a pillar drill is to run at 12 different speeds in the range of lOO rpm and
356rpm. Design a three stage gear box with a standard ratio. The gear box receives 5kW
from an electric motor running at 360rpm. Sketch the layout of the gear box, indicating the
number of teeth on each gear. Also sketch the speed diagram. (N-10)

13) The minimum and maximum speed of a six speed gear box are to be 160 and 500 rpm.
Construct the kinematic arrangement and the ray diagram of the gear box. Also find the
number of teeth on all gears. (M-11)

14) Design a 12 speed gear box for an all geared headshock of a lathe. Maximum and
minimum speeds are 600 rpm and 25 rpm respectively. The drive is from an electric motor
giving 2.25 kw at 1440 rpm. (M-11)

15) Construct the speed diagram, and the kinematic layout Tor a nine speed gear box
for the head stock of a turret lathe. The gear box is to provide a speed range of 100 rpm
to 600 rpm. Determine the number of teeth on all gears. Also calculate the diameter of
shafts in different stages of gear box. (M-12)

16) Construct the ray diagram and kinematic layout for a 18 speed gear box used in a
milling machine. The drive is from an electric motor of 3.75 kW at 1440 rpm. The
maximum and minimum speeds of the machine spindle are to be around 650 rpm and 35
rpm respectively. (M-12)

17) A nine speed gear box is to be designed with a minimum speed of 280 rpm and a
maximum speed of 1800 rpm. The motor speed is 1400 rpm, Sketch the layout of the
gear box and draw the ray diagram. Determine the number of teeth in the gears. (N -12)
18) 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. (M-13)

19) 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 kilometre diagram. Also
calculate the number of teeth on all gears. (M-13)

20) Sketch the arrangements of a six speed gear box. The minimum 'and maximum
speeds· required are around 460 and 1400 rpm. Drive speed is 1440 rpm. 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. (M-14)

21) Draw the ray diagram and kinematic lay out 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 3000 W electric motor running at
1440 rpm: (M-14)

22) A sixteen speed gear box is required to furnish output speeds in the range of
100 to 560 rpm. Sketch the kinematic arrangement and draw the speed diagram.(N -14)

23) A sliding mesh gear box is to be used for '4'·forward and '1' reverse speeds. First gear
speed ratio is 5.5 and reverse gear speed ratio is 5.8. Clutch gear on clutch shaft and
gear (in constant mesh) on lay shaft has speed ratio of 2. Calculate the number of teeth
on all the gears. Assume that the minimum number of teeth on any gear should not
be less than 18. Calculate actual gear ratios. Assume that the geometric: progression
for gear ratios, top gear · (fourth), third gear; second and first gear is 1:X:X2:X3
(N-14)

24) Design a nine speed gear box for a machine to provide speeds ranging from 100 rpm to 1500
rpm. The input is from a motor of 5 KW at 1440 rpm. Assume any alloy steel for the gears. (M-
15)

25) Design a 12 speed gear box for a lathe. The minimum and maximum speeds are 100 and
1200 rpm. Power is 5 KW from 1440 rpm induction motor. (M-15)

26) Design a 9 speed gear box for the following data. Minimum speed: 180rpm,
Maximum speed: 1800rpm. Using standard step ratio, draw the speed diagram, kinematic
layout. Also find the number of teeth on each gear. (N-15)
27) A gear box is to give 18 speeds for a spindle of a milling machine. Maximum and minimum
speeds of the spindle are to be around 650 and 35 rpm respectively. Find the speed ratios which
will give the desired speeds and draw the structural diagrams and kinematic arrangement of the
drive. (N-15)

28) A six speed gear box is required to provide output speeds of is required to provide output
speeds in the range of 125 to 400 rpm, with a step ration of 1.25 and transmit a power 5 kw at
710 rpm. Draw the speed diagram and kinematic diagram. Determine the number of teeth
module and face width of all gears, assuming materials for gears. Determine the length of the
gear box along the axis of the gear shaft. (M-16)

29) Draw the kinematic diagram and speed diagram of the head stock gear box of a turret lathe
having arrangement for 9 spindle speeds. Ranging from 31.5 rpm to 1050 rpm. Calculate the
number of teeth on each gear. Minimum number of teeth on a gear is 25. Also calculate the
percentage deviation of the obtainable speeds from the calculated ones. (M-16)

30) Design the layout of a 12 speed gear box for a milling machine having an output of
speeds ranging from 25 to 600 rpm. Power is applied to the gear box from a 2.25 kW
induction motor at 1440 rpm.. Construct the speed diagram. Using standard speed ratio.
Calculate the number of teeth on each gear and sketch the arrangement of the gear box.
(N-16)

31) Sketch the arrangements of a six speed gear box. The minimum and maximum
speeds required are around 460 and 1400 rpm. Drive speed is 1440 rpm. 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. The drive is form an
electric motor giving 2.25 KW at 1440 rpm. (N-16)

32) Design a 9 speed gear box for a milling machine with speeds ranging from 56 to 900 rpm.
The output speed is 720 rpm. Make a neat sketch of the gear box. Indicate the number of teeth
on all the gears and their speeds. Assuming the gears and shafts are made of C45. Calculate
module, centre distance and diameter of the spindle. (M-17)

33) Design a 12 speed gear box. The required speed range is 100 to 355 rpm. Draw the ray
diagram. Kinematic arrangement and find the number of teeth on each gear. Check for the
interference. (M-17)

34) Draw the kinematic diagram and speed diagram of the head shock of a turret lathe having
arrangement for 9 spindle speeds ranging from 31.5 rpm to 1050 rpm. Calculate the number of
teeth on each gear. Minimum number of teeth on gear is 25. Also calculate the percentage
deviation the obtainable speeds from the calculated ones. (N-17)

35) The spindle of a pillar drill is to run at 12 different speeds in the range of 100 rpm and 355
rpm. Design the gear box. Sketch the layout of the gear box. Indicating the number of teeth on
each gear. The gear box receives 5 Kw from an electric motor running at 36 rpm. Also sketch the
speed diagram. (N-17)
 UNIT – V

1) A multi-disk clutch consists of five steel plates and four bronze plates. The inner
and outer diameters of friction disks are 75 mm and 150 mm respectively. The
coefficient of friction is 0.1 and the intensity of pressure is limited to 0.3 N/mm2.
Assuming the uniform wear theory, calculate (i) the required operating force, and (ii)
power transmitting capacity at 750 rpm. (M-8) (16)

2) An automotive type internal-expanding double-shoe brake is shown in figure 15 b.

The face width of the friction lining is 40 mm and the intensity of normal pressure
is limited to 1 N/mm2• The coefficient of friction is 0.32. The angle 81 can be
assumed to be zero. Calculate (i) the actuating force P, and (ii) the torque absorbing capacity
of the brake. (M-8)

3) A single plate clutch is used for an engine that develops a maximum torque of 120N -m.
Assume a factor of safety of 1.5 to account for slippage at full engine torque. The permissible
intensity of pressure is 350 Kpa and the coefficient of fiction is 0.35. Calculate the inner and
outer diameters of the friction lining and the axial force to be exerted by the springs to engage
the clutch. (M-9)

4) A 360 mm radius Brake drum contacts a single shoe as shown in Figure 15

(b) and resists a torque of 225 Nm at 500 rpm. The co-efficient of friction is 0.3.
Determine (i) the normal reaction on the shoe, (ii) the force to be applied at the lever
end for counter clockwise rotation of the drum if e = 0 (iii) the force to be applied at
the lever end for clockwise rotation of the drum if e = 40 mm, (iv) the force to be applied
at the lever end for counter clockwise rotation of the drum if e = 40 mm. (M-9
5) A friction clutch is required to transmit 25 kW at 2000 rpm. It is to be of single plate
disc type with both sides. The pressure is exerted by means of springs and limited to
70 kN/m2• If the maximum possible outer diameter of the clutch plate is 300 mm,
find the required inner diameter of the clutch plate and the total force exerted by the
springs. Assume the wear to be uniform and coefficient of friction as 0.3. (N-9)

6) An internal expanding shoe brake has the following dimensions : Diameterof

the drum = 300 mm, distance between the fulcrum centers = 80 mm, distance of
fulcrum centers and that of cam axis, both from the drum centre = 100 mm, distance of
line of action of braking force from the cam axis =· 90 mm, distance between the points
where the cam acts on the two brake shoes = 30 mm. Each shoe subtends an angle of
90° at the drum centre. If the braking force is 750 N and the coefficient of friction is
0.3.

7) Find the braking torque on the drum. Assume the reactions between the brake shoes
and the drum passes through the points bisects the contact angle. Also assume that
forces exerted by the cam ends on the two shoes are equal. (N-9)

The displacement specifications of follower are given below:

Stroke of the follower 25 mm

Outstroke takes place with SHM during 90◦ of cam rotation

Return stroke takes place with SHM during 75◦ cam rotation

Cam rotates with a uniform speed of 800 rpm.

8) Determine the induced contact stress, assuming follower mass as 0.25kg and spring stiffness
as 100 N/mm. when the cam rotation 15◦. Take the thickness of the plate cam as 10mm. the base
circle radius and the follower roller radius are 25mm and 10mm respectively. Material used is
steel. (M-10)

9) A block brake with a short shoe is shown in Fig.. It is to be designed so that the product
'pv' is limited to 2, where 'p' is the normal pressure between friction lining and the
brake drum (N/mm2) and 'v' is the peripheral velocity of brake drum (m/s). (M-10)

10) The coefficient of friction between the brake drum and the friction lining is 0.2. the cable
drums is connected to the brake drum by means of a pair of spur gears. The brake drum rotates
four times as fast as the cable drum. The permissible intensity of pressure on friction lining is 1
N/mm2.

Calculate:

(i) The magnitude of the brake shoe force (P) (6)

(ii) The area of friction lining (4)

(iii) The uniform velocity at which the mass can be lowered. What happens at higher speeds?
(6)

11) A cam is to give the following motion to a knife-edged follower

(i) Outstroke during 60° of cam rotation;

(ii) Dwell for the next 30° of cam rotation;

 (iii) Return stroke during next 60° of cam rotation; and (iv) Dwell for the remaining
210° of cam rotation. The stroke of the follower is 40mm and the minimum radius of
the cam is 50mm. The follower moves with uniform velocity during both the outstroke
and return strokes. Draw the profile of the cam when the axis of the follower
passes through the axis of the cam shaft

12) A cone clutch is to transmit 7.5kW at 900 rpm. The cone has a face angle of 12° The width
of the face is half of the mean radius and the normal pressure between the contact faces
is not to exceed 0.09 N/mm2• Assuming uniform wear and the coefficient of fricti on
between contact faces as 0.2, find the main dimensions of the clutch and the axial force
required to engage the clutch.

13) A multi – disc clutch has three discs on the driving shaft and two on the driven shaft is to be
designed for a machine tool, driven by an electric motor of 22 kw running at 1440 rpm. The
inside diameter of the contact surface is 130mm. The maximum pressure between the
surfaces is limited to 0/N/mm2. Design the clutch. Take µ = 0.3 ; n1 = 3; n2 = 2. (M-11)

14) 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 45 kN and
moves downwards with a velocity of 1.15 m/s. The pitch diameter of the hoist drum is 1.25m.
The hoist must be stopped with in a distance of 3.25 m. The kinetic energy of the drum may
be neglected. (M-11)

15) A square threaded power screw has a nominal diameter of 44 mm and a pitch of 7
mm with double threads. The load on the screws is 6 kN and mean diameter of the thrust
washer is 50 mm. If co-efficient of friction is 0.12, determine
(i) torque required to raise the load,
(ii) torque required to lower the load,
(iii) efficiency and
(iv) whether the screw is of self locking type
16) Design a multiplate clutch to transmit 15 kW at 1500 rpm. The clutch is fitted with
steel and phosphor bronze plates arranged alternately and run in oil. The maximum
torque to the transmitted {s 30% greater than the mean torque. Sketch the arrangement of
plates.. (M-12)

17) A gear box is to be designed for the following specifications: (N-12) Power to be
transmitted = 12 kW. Number of speeds = 18. The speed and motor speed are 16 rpm and
1400 rpm respectively. Step ratio is 1.25. The 18 speeds are obtained as 2 x 3 x 3. Sketch
the layout of the gear box and the draw the speed diagram.
18) A square threaded bolt of 25 mm nominal diameter and 5 mm pitch is tightened by
screwing a nut, whose mean diameter of the bearing is 35 mm. If the coefficient of
friction for the nut and bolt is 0.12, and for end of a 250 mm long spanner, when the load
on the bolt is 12 kN. (N-12)

19) An automobile single plate clutch consists of two pairs of contacting surfaces. The inner and
outer radii of friction plate are 120 mm and 250 mm respectively. The coefficient of friction is
0.25 and the total axial force is 15kN. Calculate the power transmitting capacity of the clutch
plate at 500 rpm using (M-13)
(i) Uniform wear theory and
(ii) Uniform pressure theory.
20) Describe with the help of a neat sketch the design procedure of an internal expanding shoe
brake. Also deduce the expression for the braking torque. (M-13)

21) A plate clutch with maximum diameter 6 cm has maximum lining pressure of
350 kPa. The power to be 135 kW and µ = 0.3. Find inside diameter transmittedat
400. rpm is and spring force required to engage the clutch. Springs with spring index 6 and
material of the spring is steel with safe shear stress 600 Mpa are used. Find the diameters if 6,
springs are used. (M-14)

22) A hydraulically operated clutch is to be designed for an automatic lathe. Determine the
number of’ plates and operating force required for the clutch to transmit 35 Nm. The
clutch is to be designed to slip under 300% of rated torsional moment to protect the gears
and other part of the drive. The limits for the diameter of friction surfaces due to space
limitation are 100 mm and 62.5 mm, This clutch is to operate in an oily atmosphere. (M-14)

23) An automobile engine has an output of 80 Kw at 3000 rpm. The mean diameter of the clutch
is 200 mm with a permissible pressure of 0.2 N/mm2. Friction lining is of asbestos with µ =
0.22. What should be the inner diameter of the disc? Take both sides of plates with friction
lining as effective. There are 8 springs and axial deflection in spring is limited to 10 m m. Given
G = 80 KN/mm2. Spring index may be taken as 6. (N-14)

24) Derive the expression to determine the braking torque for an internal expanding shoe brake.
(N-14)

25) A power of 20 KW is to be transmitted through a cone clutch at 500 rpm. For uniform we ar
condition, find the main dimensions of clutch and shaft. Also determine the axial force required
to engage the clutch. Assume coefficient of friction of 0.25, the maximum normal pressure on
the friction surface is not to exceed 0.08 Mpa and take the design stress for the shaft materials as
40 Mpa. (M-15)
26) Design a differential band brake for a winch lifting a load 20Kn through a steel wire rope
wound around a barrel of 600 mm diameter. The brake drum, keyed to the barrel shaft is 800
mm diameter and the angle of lap of the band over the drum is about 2400. Operating lever is
1.6m. (M-15)

27) 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 the valve, each of which
corresponding to 600 of cam rotation. The valve should remain in the fully open position for 200
of cam rotation. The lift valve is 50 mm and the least radius of the cam is 50 mm, the follower is
provided with a roller of 50 mm diameter and its line of stroke passes through the axis of the
cam. (N-15)

28) Explain with a neat sketch the working of a single plate clutch. Derive an expression for the
torque to be transmitted by clutch assuming (N-15)
(i) Uniform pressure condition and
(ii) Uniform wear condition

29) A multiplate clutch with both sides effective transmits 30 KW at 360 rpm. Inner and outer
radii of the clutch discs are 100 mm and 200 mm respectively. The effective coefficient to
friction is 0.25. an axial load of 600 N is applied. Assuming uniform wear conditions, find the
number of discs required and the maximum intensity of pressure developed. (M -16)

30) A 50 kg wheel, 0.5 m in diameter turning at 150 rpm in stationary bearings is brought to rest
by pressing a brake shoe radially against the rim with a force of 100 N> if the radius of gyration
of wheel is 0.2 m, how many revolutions will the wheel make before coming to rest?. Assume
that the coefficient of friction between shoe and rim has the steady value of 0.25. (M-16)

31) A multiplate clutch, steel on bronze is to transmit 6 KW power at 750 rpm. The inner radius
of contact surface is 4 cm and outer radius is 7 cm. the clutch plates operate in oil, so the
coefficient of friction is 0.1. the average pressure is 0.35 N/mm2. Determine (i) the total number
of steel and bronze friction discs (ii) actual axial force required (iii) actual average pressure (iv)
actual maximum pressure. (N-16)

32) A single shoe brake is shown in fig. the diameter of drum is 250 mm and angle of contact is
900. If the operating force of 750N is applied at the end of the lever and µ = 0.35, determine the
torque that may be transmitted by the brake. (N-16)
33) A multi disc clutch, steel on bronze is to transmit 20 kw at 1440 rpm. The clutch is to be
operated in oil with the co-efficient of friction 0.08 and the average pressure 0.3 Mpa. Space
limitation permits only 230mm as outside diameter of the clutch. Assuming uniform pressure,
determine (i) Size of the clutch. If the ratio of mean radius to face width is 3 (ii) actual axial
force required (iii) actual maximum pressure (iv) Actual average pressure. The ratio of Ri/Ro
can be chosen between 0.5 to 0.75. Suitably and logically. (M-17)

34) A 400 mm radius brake drum contacts a single shoe as shown in fig. and sustains 200 N-m
torque at 500 rpm. For a coefficient of friction 0.25. determine (i) Normal force on the shoe. (ii)
Required force F to apply the brake for clockwise rotation (iii) Required force mF to apply the
brake for counter clockwise rotation. (iv) The dimension C required to make the brake self -
locking, assuming other dimensions remain same. (v) Heat generated. (M-17)

35) A differential band brake is operated by a lever of length 500 mm. The brake drum has a
diameter of 500 mm and the maximum torque on the drum is 1000 Nm. The band brake
embraces 2/3 rd of the circumference. One end of the band is attached to a pin 100 m from thye
fulcrum and the other end to another pin 80mm from the fulcrum and on the other side of it
when operating force is also acting. Coefficient of friction 0.3. find the operating force. Design
the steel band, shaft and key. The permissible stresses may be taken as 70 Mpa in tension, 50
Mpa in shear and 20 Mpa in bearing. The bearing pressure for the brake lining should not exceed
0.2 N/mm2. (N-17)

36) A single dry plate clutch is to be designed to transmit7.5 KW at 900 rpm. Find (i) diameter
of the shaft (ii) mean radius and face width of the friction lining assuming the ratio of the mean
radius to the face width as 4. (iii) outer and inner radii of the clutch plate. (iv) Dimensions of the
spring, assuming that the number of springs are 6 and spring index 6. Shear stress for the haft
material 40 Mpa. Coefficient of friction 0.25, pressure 0.07 Mpa. Allowable shear stress for
spring wire may be taken as 420 Mpa. (N-17)