GOVERNMENT ENGINERRING COLLEGE, VALSAD

MECHANICAL ENGINEERING DEPARTMENT

TUTORIAL
BE SEM 7

SUBJECT : MACHINE DESIGN (2171909)

ACEDEMIC YEAR 2019-20

 GOVERNMENT ENGINEERING COLLEGE, VALSAD
MECHANICAL ENGINEERING DEPARTMENT

CERTIFICATE

This is to certify that Mr./Miss_____________________________________________________ of

Mechanical Branch, Sem-VII, Enrollment No.__________________________, has

satisfactorily completed his/her term work for the subject Machine Design

(2171909) during odd term-2019.

Date :

Sign of Faculty Head of the Department

 GOVERNMENT ENGINEERING COLLEGE, VALSAD
MECHANICAL ENGINEERING DEPARTMENT

INDEX

Subject: Machine Design (2171909)

TUTORIAL SIGN OF
TITLE GRADE DATE
NO. FACULTY

1 DESIGN OF SPUR GEARS.

2 DESIGN OF HELICAL GEARS.

3 DESIGN OF BEVEL GEAR.

4 DESIGN OF WORM GEAR.

5 DESIGN OF GEARBOX.

6 DESIGN OF JOURNAL BEARING.

SELECTION OF ROLLING CONTACT

7
BEARING.
DESIGN OF IC ENGINE
8
COMPONENTS.

9 DESIGN OF CRANE COMPONENTS.

 GOVERNMENT ENGINEERING COLLEGE, VALSAD
MECHANICAL ENGINEERING DEPARTMENT

2171909-MACHINE DESIGN
B.E. SEM –7th FOR ODD TERM 2019-20

TUTORIAL-1 DESIGN OF SPUR GEAR

1. Explain different modes of gear teeth failures, stating their reasons?

2. Explain standard system of gear tooth and advantage and disadvantages

of 14.50 and 200 involutes system.

3. Differentiate between involute and cycloidal profile of the gears.

4. The pitch circle diameters of the pinion and gear are 100 &300 mm
respectively. The pinion is made of plain carbon steel 40C8 (σ ut = 600
N/mm2) while the gear is made of grey cast iron FG300 (σ ut = 300
N/mm2). The pinion receives 5 KW power at 500 rpm through its shaft.
The service factor and factor of safety can be taken as 1.5 each. The face
width of the gears can be taken as ten times that of the module. Assume
that the velocity factor accounts for the dynamic load. Calculate
1. Module
2. The number of teeth on the pinion and gear.

5. A pair of spur gear consists of 24 teeth pinion, rotating at 1000 rpm and
transmitting power to a 48 teeth gear. The module is 6 mm, while the
face width is 60 mm. both gears are made of steel with an ultimate
tensile strength of 450 N/mm2. They are heat treated to a surface
hardness of 250 BHN. Assume that velocity factor accounts for the
dynamic load.
Calculate
1. Beam strength
2. Wear strength
3. The rated power that the gear can transmit, if service factor and
the factor of safety are 1.5 and 2, respectively.
 TUTORIAL-2 DESIGN OF HELICAL GEARS

1. What is a crossed helical gear? Why crossed helical gears are not used
for high power transmission?

2. What are the advantages of helical gear over spur gear?

3. What is virtual or formative helical gear?

4. Design a pair of helical gears to transmit 50 kW at a speed of 1440 rpm

to a shaft required to run at 480 rpm. The helix angle is approximately
250 and 200 full depth teeth are used. Both the gear and pinion are made
of steel with permissible stress 80 N/mm 2 and 100 N/mm2 respectively.
Take minimum number of teeth on pinion 16. Check your design for
dynamic load and determine minimum hardness of teeth required.

5. A pair of parallel helical gears consists of 24 teeth pinion rotating at

5000 rpm and supplying 12 kW power to a gear. The speed reduction is
4:1. The normal pressure angle and helix angle are 20 0 and 230
respectively. Both gears are made of hardened steel (S ut= 600 N/mm2).
The service factor and factor of safety are 1.5 and 3 respectively.
Calculate
1. Module and face width of gears.
2. Surface hardness for the gears assuming a factor of safety of 1.5 for
wear consideration.

6. A pair of helical gears having a transmission ratio 8:3, with a steady load
condition, used for turbine. The maximum speed is 2400 r.p.m. The
pinion is to have 27 teeth and a face width of 100 mm. The circular
module is 6 mm. The material used for gears is heat treated steel with
250 BHN and have static stress of 210 MPa. The gears are carefully
cut. Calculate value of dynamic load and wear load.
 TUTORIAL-3 DESIGN OF BEVEL GEARS

1. What is a bevel gear? Where do we use bevel gear?

2. Where do you specify the dimensions such as module, addendum, and

dedendum in case of bevel gears?

3. What is virtual number of teeth on bevel gears?

4. A pair of straight bevel gear is mounted on shaft, which are intersecting

at right angles. The number of teeth on the pinion and gear are 21 & 28
respectively. The pressure angle is 20 0. The pinion shaft is connected to
an electric motor developing 5 KW rated power at 1440 rpm. The
service factor can be taken as 1.5. the pinion and the gear are made of
steel (σut = 750 N/mm2) and heat treated to a surface hardness of 380
BHN. The gear are machined by manufacturing process, that limits the
error between meshing teeth to 10 µm. the module and face width are
4mm and 20 mm respectively.
Determine the factor of safety for bending as well as for pitting.

5. Two shafts at right to each other are connected by a bevel pair having
full depth involute teeth. The pinion having 20 teeth transmits 40 kW at
750 rpm to gear shaft running at 375 rpm. Take allowable static stress
for pinion and gear materials 100 and 70 N/mm respectively. Determine
module, pitch diameters and face width from strength considerations.

6. It is required to design a pair of bevel gears, which are mounted on

shafts intersecting at right angles. The pinion receives 20 kW power
through its shaft and rotates at 720 rpm. The number of teeth on pinion
and gear are 30 & 45 respectively. The pressure angle is 20 0full depth
teeth form. The gears are made of plain carbon steel with permissible
bending stress as 200 MPa. The gears are case hardened and the surface
hardness is 300 BHN. Take service factor = 1.25.
 TUTORIAL-4 DESIGN OF WORM GEARS

1. Explain the importance of thermal considerations in worm and worm gear

design.

2. Give advantages and drawback of worm gear.

3. What are main types of failures in worm gear drive?

4. A speed reducer unit is to be designed for an input of 5 kW with a

transmission ratio of 25. The speed of the hardened steel worm is 1750 rpm.
The worm wheel is to be made of chilled bronze. The tooth form is to be 20 0
full depths involute. Assume double start worm. Design a worm and worm
wheel.

5. A speed reducer unit is to be designed for an input of 1.1 kW with

transmission ratio 27. The speed of hardened steel worm is 1440 rpm. The
worm wheel is to made from phosphor bronze. The tooth form is to be 20 0
involute. Take center distance between worm and worm wheel = x = 100
mm. Pitch circle diameter of worm=X.875/1.416 worm is double start Form
factor y =0.154 - .912/T .Allowable stress for phosphor bronze = 84 MPa,
flexural endurance limit for phosphor bronze = 168 MPa, load stress factor = k
= 0.55, check for (1) Tangential load- power transmitted due to tangential
load, (2) Dynamic load,(3) Static load or endurance strength , (4) Wear load
,(5) Heat Dissipation.

6. A triple threaded worm rotating at 1200 r.p.m. drives a worm gear having 36
teeth and transmits 15 KW power. The teeth are of 20º full depth involute
profile .The axial pitch of the worm is 30 mm and pitch diameter of 60 mm.
The co-efficient of friction is 0.03. Calculate (1) Helix angle of worm (2) Speed
ratio (3) Centre distance between two shafts, (4) Apparent stress in the worm
gear. (5) Efficiency of drive.
 TUTORIAL-5 DESIGN OF GEARBOX

1. Explain the procedure of designing multi speed gear box.

2. Draw speed ray diagram and layout for a six speed gear box .The output speed
are 160 r.p.m. minimum and 1000 r.p.m. maximum. The motor speed
is 1440 r.p.m

3. A three stage gear box with twelve speeds is to be designed based on R10
series with minimum spindle speed of 125 rpm. The second stage consists of
three speed steps. The electric motor is connected to the gear box through a
belt drive and runs at 1440 rpm and transmits of 5 kW. Using standard
spindle speeds,
1. Draw the structure and speed diagram for the arrangement.
2. Determine the ratio of the belt pulley diameters.
3. Draw the gear box layout.
4. Determine the number of teeth on each gear of the gear box.

4. Design & draw a 2 stage spur gear reduction gear box pairs for operating a
set of two belt conveyor for following data:
 Maximum conveyor speed = 1.5 m/s
 Effective diameter of driving pulley of conveyor = 250 mm
 Amount of torque transmitted by each driving pulley of conveyor =
200 Nm.
 Speed of input shaft = 1920 rpm.
 Use design data book.

5. Design a suitable speed gear box for a head stock of a lathe that has a variation
of speed from 105 r.p.m. to 690 r.p.m. in 9 steps. The power is supplied by an
electric motor of 10 KW capacities running at 1000 r.p.m. and having driving
the input shaft through a V-belt drive having speed ratio of 2: 1. Draw the
structural diagram, speed chart and determine the number of teeth on each
gear.
 TUTORIAL-6 DESIGN OF JOURNAL BEARING

1. What is a bearing? Classify the bearings.

2. What is the difference between thick-film and thin film lubrication?

3. Explain the following:

a. Viscosity b. SUS
c. Kinematic viscosity d. Sommerfield number

4. What is hydrostatic bearing? What are its advantages over

hydrodynamic bearing?

5. Following data is given for full hydrodynamic bearing :

Radial load =22 kN , Journal speed = 960 rmp , Unit pressure in bearing
=2.4 MPa, l/d = 1:1, viscosity of lubricant =20cP, ratio of (h0/C) = 0.2=
(Minimum oil thickness/ Radial clearance). Determine (a) dimension of
the bearing, (b) minimum film thickness, (c) requirements of oil flow.

6. The following data is given for a 3600 hydrodynamic bearing:

Radial load = 3.6kN, Journal diameter =55 mm, Bearing length =27.5
mm, Radial clearance = 0.05 mm, Viscosity of lubricant = 25cP. If the
Sommerfield number for bearing is 0.0923, determine: (a) journal speed,
(b) co-efficient of friction, (c) power lost in friction, (d) flow
requirement, (e) temperature rise.

7. A journal bearing is proposed for a centrifugal pump. The diameter of

the journal is 0.15 m and the load on it is 40kN and its speed is 900
rev/min. complete the design calculation for the bearing.
 TUTORIAL-7 DESIGN OF ROLLING CONTACT BEARING

1. Classify the rolling contact bearings. Compare ball and roller bearing.

2. What are the four main parts of a ball bearing?

3. Enumerate the advantage and disadvantage of rolling contact bearing.

4. What do you mean by static load and dynamic load for a ball bearing?

5. A radial ball bearing has a basic load rating of 50 kN . if the desired rating life
of the bearing is 6000 hours, what equivalent radial load can the bearing
carry at 500rev/min.

6. Find the “rating life” of 50mm bore, light series, ball journal bearing under a
6800 N radial load at 600rev/min. The load is out of balance and, therefore,
rotates with the inner rign. There is no shock loading.

7. A ball bearing supporting a bevel gear shaft is subjected to radial load of

1600 N and a thrust load of 550 N. select the proper bearing for a speed of
150 rev/min. life expectancy is 50 x 103 cycles.
 TUTORIAL-8 DESIGN OF IC ENGINE COMPONENTS

1. Explain the piston materials.

2. Why ‘I’ section is chosen for the connecting rod in the design of I.C.Engine ?

3. Describe the criteria for deciding the size of suction and exhaust valve of an
I.C. engine.

4. What are the merits and demerits of wet and dry cylinder liners?

5. Design a connecting rod for a petrol engine from the following data:
Diameter of piston = 110 mm; Mass of reciprocating parts = 2 kg; Length of
connecting rod = 325 mm; Stroke = 150 mm; Speed = 1500 rpm with
possible over speed of 1850 rpm; Compression ratio = 4:1; Factor of safety
= 4; Maximum explosion pressure = 5.5 MPa ,Select suitable material and
permissible stresses for its.

6. Determine the principle dimensions of cylinder for a vertical 4 stroke

compression ignition engine from the following data: Brake power = 4.5
kW, Speed = 1200 rpm, Indicated mean effective pressure = 0.35 MPa,
Mechanical efficiency = 80%.

7. The cylinder of a four stroke diesel engine has the following specifications:
Brake power = 7.5 kW; Speed = 1400 rpm; Maximum gas pressure = 3.5
MPa; Indicated mean effective pressure = 0.35 MPa; Mechanical efficiency =
80 %; The cylinder liner and head are made of grey cast iron (Sut= 260 MPa
and µ = 0.25). The factor of safety for all parts is 6. Calculate:
1.Bore and length of the cylinder liner
2.Thickness of the cylinder liner (Take, C= 3.2 mm)
3.Thickness of the cylinder head
 TUTORIAL-9 DESIGN OF CRANE COMPONENTS

1 Explain Wire ropes with its designation. What are the advantages of wire
ropes? Explain selection of wire ropes.

3 Explain design procedure designing belt conveyors.

4 Classify the conveyors. Explain construction and working of each

conveyor

5 What are the basic objectives of a material handling system?

6 What are the basic principles in selecting the type of material handling
equipment?

7 With neat sketches, explain the different types of idler used in

conveyors.

8 Differentiate between screw conveyor and vibratory conveyor.

9 Classify the material handling equipment’s.

11 Design a single rope drum to transmit a torque of 8 kN.m with a 32 mm

rope. Assume the height of the load to be raised as 2.7 meter and the
ratio of the pulley system as 2. The mean diameter of the drum is 576
mm. Assume the drum to be made of Grey cast iron, grade 20 having
allowable shear strength of 33 MPa. Make a neat sketch of the
arrangement.

12 The following data refers to a flat belt conveyor for transporting crushed
rock ,Mass density =2 tons/m3, belt speed =1.5 m/s , belt width(B)
=.8m, surcharge angle =25º , effective width of the material carried by
the belt safely=b=(0.9B - 0.05)

14 Design a crane hook for lifting capacity of 5 tonnes. It is made from

forged steel and has triangular section. Take permissible tensile stress
80 N/mm2 .Use data design book to standardize the dimension of hook.