Sinhgad Technical Education Societys

Sinhgad Academy of Engineering, Kondhwa (Bk), Pune.

DEPARTMENT OF MECHANICAL ENGINEERING Preliminary Examination: Machine Design II 2011-12 Sem-II

Instructions: 1. Answer three questions from section I and three questions from section II. 2. Answer to two sections should be written in separate books. 3. Draw suitable neat diagrams, wherever necessary. 4. Assume suitable data, if required. ----------------------------------------------------------------------------------------------------------------------SECTION - I Unit - I Q.1 a) Discuss different types of rolling contact bearing. [6] b) A single row deep groove ball bearing is used to support the lay shaft of a [12 ] four-speed automobile gearbox. It is subjected to following loads in respective speed ratios. Gear First gear Second gear Third gear Forth gear Axial Load (N) 3150 575 75 Nil Radial Load (N) % time engaged 4500 3250 3250 Nil 2 5 23 70

The lay shaft is fixed to the engine shaft and rotates at 1600 rpm. The static and dynamic load carrying capacities of the bearing are 11800 N and 17300 N respectively. The bearing is expected to be in use for 4500 hours of operation. Find out the reliability with which life could be expected. Refer the following data: Table: X and Y factors for single Row Deep Groove Ball Bearings
Pa/Co 0.025 0.040 0.070 0.130 0.250 0.500 Pa/Pr <=e X 1 1 1 1 1 1 Y 0 0 0 0 0 0 Pa/Pr >e X 0.56 0.56 0.56 0.56 0.56 0.56 e Y 2.0 1.8 1.6 1.4 1.2 1.0 0.22 0.24 0.27 0.31 0.37 0.44

Q.2

OR a) Derive stribecks equation for rolling contact bearing

[6]

b) A single row deep groove ball bearing operates with following work cycle. Type of load Heavy shocks Light shocks Moderate shocks No shocks Thrust load(N) 1200 1000 1500 2000 Radial load(N) 2000 1500 1000 1200 Service factor 3 1.5 2 1 Speed RPM 400 500 600 800 Fraction of cycle 1/10 1/10 1/5 Remaining

[12 ]

Assume radial and axial load factors to be 1 and 1.5 respectively and inner race rotates. If the expected life of the bearing is 15000 hours with reliability of 95%. Select the bearing from SKF manufacturers catalogue based on 90% reliability. If there are 8 such bearings in the system, what is the probability that all bearings will survive for 15000 hours. Data for bearing selection SKF Bearing No Dynamic load capacity (KN) Use Q.3 L /L10 = 4.48 [ ln (1/R)]1/1.5 6015 31 6215 52 6315 90 6415 120

Unit II a) Explain the mechanism of pressure development in oil film and draw radial [6] & axial pressure distribution for hydrodynamic journal bearing. b) Following data is given for 360 hydrodynamic bearing Radial load = 6.5 KN Journal diameter = 60mm Journal speed = 1200rpm Bearing Length = 60 mm [10 ]

Minimum oil film thickness = 0.009 mm The class of fit is H7e7 (fine) normal running fit. For this fit Tolerances H7 e7 +0.03 -0.06 60 +0.00 -0.09 Specify the viscosity and the flow rate of the lubricating oil that you will recommend for this application. Q.4 OR a) Following data is given for hydrostatic bearing Supply pressure = 5MPa Shaft speed = 1000rpm [12 ] Diameter (mm)

Shaft diameter = 500mm Recess diameter = 300mm Viscosity of lubricant = 35cP Specific gravity of lubricant = 0.86 Specific heat of lubricant = 2 kJ / kg oc Calculate i) Load carrying capacity ii) Optimum oil film thickness iii) Flow rate of lubricant iv) Total power loss v) Temperature rise b) Explain the mechanism of pressure development in oil film of hydrodynamic [4] journal bearing. Unit III Q.5 a) A transmission shaft having an ultimate tensile strength of 600 MPa and [12 ] yield strength of 380 MPa is subjected to a fluctuating torque of -200 Nm to +800 Nm. The factor of safety is 2 and the expected reliability is 50%. The surface factor is 0.8 and the size factor is 0.85. Assuming that there is no stress concentration, determine the diameter of the shaft for infinite life. Assume the distortion energy theory of failure. Also determine the diameter of shaft, if only the fluctuating torque is changed to -10Nm to +800Nm b) Explain endurance limit & endurance strength OR Q.6 [4]

A steel cantilever beam as shown in figure is subjected to a transverse [16 ] loading at its end that varies from 45 N up to 135 N down and an axial load varies from 110 N ( Compressive ) to 450 N ( Tensile) . Determine the diameter at change of cross section for infinite life using a factor of safety 2 The properties of material are. Yield strength in tension and compression = 470 MPa Endurance limit = 275 MPa; Theoretical stress concentration factor for axial loading is 1.63. Theoretical stress concentration factor for bending loading is 1.44. Correction factor for reverse bending is 1. Correction factor for reverse axial is 0.7. Size Correction factor is 0.85. Surface Correction factor is =0.9.

Q.7

SECTION II Unit IV a) A multiplate clutch has three discs on the driving shaft and two discs on the [12 ] driven shaft. Outside and inside diameters of clutch facings are 240 mm and 120 mm respectively. Assuming uniform pressure condition, find the total spring force pressing the plates together to transmit 28 kW at 1440 rpm. Assume coefficient of friction to be 0.27. If there are six springs each having a stiffness of 15 kN/m and each of the contacting surfaces has worn away by 1.5 mm, what will be the maximum power that can be transmitted at the same speed. Assuming uniform wear condition. b) Discuss the desirable properties of friction materials and list out the two [4] friction materials. OR a) An automobile vehicle weighing 14 kN is moving on a level road at a speed [12 ] of 90 km/hr. When the brakes are applied, it is subjected to a uniform deceleration of 6 m/s2. There are brakes on all four wheels. The tyre diameter is 750 mm. The kinetic energy of rotating parts is 15% of the kinematic energy of moving vehicle. The mass of each brake drum assembly is 12 kg and specific heat capacity is 470 J/kgC. Calculate i) braking time ii) braking distance iii) total energy absorbed by each brake iv) total capacity of each brake, and v) temperature rise of brake drum assembly. b) Explain construction and working of Disc brake. Unit V a) Explain the methods of estimation of dynamic load on spur gear.

Q.8

[4]

Q.9

[4]

b) Following data given for steel spur gear pair transmitting 7.5 kW power from [12 ] an electric motor running at 1440 rpm to a machine running at 480 rpm. No. of teeth on pinion 18 Centre distance 216mm Face width - 10 times module

 Allowable bending stress for pinion and gear - 160 N/mm2 Surface hardness 300 B.H.N. Combine teeth error 0.012 mm Deformation factor- 11500 x error N/mm Assuming dynamic load accounted by Buckinghams equation calculate, 1) Factor of safety against bending failure 2) Factor of safety against pitting failure Use following data: Tooth system 20 full depth involute

2.87 Z 2 BHN N Load stress factor K = 0.16 2 100 mm 21V ( bC + Pt max ) N Dynamic load Pd = 21V + bC + Pt max
Lewis form factor

Y = 0.484

OR Q.10 a) [12 A pair of helical gear consists of 24 teeth pinion rotating at 5000 rpm and ] supplying 2.5 kW power to gear. The speed reduction is 4:1. The normal
0 0

pressure angle and helix angle 20 and 23 respectively. Both the gears are
ut 2

made of hardened steel (S = 750N/mm ). The service factor and factor of safety are 1.5 and 2.0 respectively. The gears are finish to meet the specification of grade 4 1) In initial stage of gear design assume velocity factor accounts dynamic load and face width is 10xmodule and assume pitch line velocity V = 10m/s for estimating normal module. 2) Select first preference module and calculate dimensions of gear. 3) Determine dynamic load by Buckingham equation. Also calculate factor

of safety in bending. 4) Specify the surface hardness at factor of safety 2.0 Use following data. Lewis form factor Velocity factor Cv =

Y ' = 0.484
5 .6 5.6 + V

2.87 Z'

Buckinghams equation Pd = For grade 4

21V bC cos 2 + Pt max cos 21V + bC cos 2 + Pt max

e4 = 3.20 + 0.25 mn + 0.25 d m

First preference module in mm 1, 1.25,1.5, 2.0, 2.5, 3.0, 4.0, 5.0, 6.0, 8.0, 10.0, 12.0 16.0 and 20.0 b) What is pitting in gear? State causes and remedies. Unit VI Q.11 a) With neat sketch explain straddle mounting of bevel pinion and gear. b) [12 A straight bevel pinion and gear made of alloy steel with ultimate tensile ]
2

[4] [6]

strength 800 N/mm . The axis of pinion and gear intersect at right angle. The gear pair required to transmit 15 kW power from a spindle running at 600 rpm to a machine running at 300 rpm. The starting torque is 110% to the rated torque. The factor of safety required is 1.75. The tooth system is 20 full depth involute. The gears are to be cut to meet the specification of grade 6. The pinion and gear are case hardened to 350 BHN. The deformation factor is 11000e N/mm. Design the gear. Use Buckinghams equation for dynamic load.

Use following data: Standard module in mm 1, 1.25, 1.5, 2.0,3,4,5, 6,8,10 and 12. No. of teeth on pinion = 21

2.87 Z' 2 BHN N Load stress factor K = 0.16 2 100 mm For grade 7 e = 8.0 + 0.63 m + o.25 d m 6 Velocity factor Cv = 6 +V 21V ( bC + Pt max ) N Dynamic load Pd = 21V + bC + Pt max
Lewis form factor

Y ' = 0.484

OR Q.12 a) A pair of worm and worm wheel is designated as 2/72/10/6. The worm is [14 ] transmitted 8 kW at 1800 rpm to a worm wheel. The permissible bending strength is 110 N/mm2. The wear load factor is 0.83 N/mm2. The coefficient of friction is 0.05 and normal pressure angle is 20. Find: 1) Factor of safety in Bending 2) Factor of Safety in wearing 3) Factor of safety in heat dissipation Use following Data: Lewis form factor Y = 0.484 2.87/Z Barth factor Cv = Input kWh 6 6 +V

a1.7 34.5(i + 5)

Where a = centre distance in mm

i=Gear ratio.

b) What is self locking of worm gear pair? Explain factors affecting the [4] efficiency of worm gear. ------------------------------------------------------------------------------------------------------------------Table 1: Dimensionless performance parameters for full journal bearing

/d ho/c 1 0.0 0.03 0.1 0.2 0.4 0.6 0.8 0.9 1.0

1.0 0.97 0.9 0.8 0.6 0.4 0.2 0.1 0.0

S 0 0.00474 0.0188 0.0446 0.121 0.264 0.631 1.33

(r/c)f 0 0.514 1.05 1.70 3.22 5.79 12.8 26.4

Q/rcns --4.82 4.74 4.62 4.33 3.99 3.59 3.37 3.142

Qs/Q 1 0.973 0.919 0.842 0.680 0.497 0.280 0.150 0

P max/p --6.579 4.048 3.195 2.409 2.066 1.890 1.852 ---