Theoretical

questions

1. How are the gears classified and what are the various terms used in spur gear terminology? 2. Mention four important types of gears and discuss their applications, the materials used for them and their construction.

3. What condition must be satisfied in order that a pair o spur gears may have a constant velocity ratio? 4. State the two most important reasons for adopting involute curves for a gear tooth profile. 5. What is interference in gears? How can you remove it?

6. Write the expressions for static, limiting wear-load and dynamic load for spur gears and explain various terms 7. 8. 9. (a) Numerical Discuss How Explain Helix are the the the angle design shaft following (b) and used procedure arms terms normal for used pitch for spur in (c) spur gears helical axial therein. gears designed? gears: pitch Questions

1. A spur steel pinion (s0 =200 MN/m2) is to drive a spur steel gear (s0=140MN/ m2) . The diameter of the pinion is to be 100mm and the center distance 200mm. The pinion is to transmit 5Kw at 900RPM. The teeth are to be 20o full depths. Determine the necessary module and face width to give the greatest no of teeth. 2. Two spur gears are to be used for a rock crusher and are to be minimum size. The gears are to be design for following requirements: power to be transmitted 18Kw, speed of pinion 1200RPM angular velocity ratio 3.5:1, tooth profile 20o stub, s0 value of pinion 100 MN/m2, s0 value for gear 70 MN/ m2. Design the gear. 3. A pair of spur gears transmitting power from motor to pump impeller shaft is to be designed with as small center distance as possible. The forged steel pinion s0 =160MN/ m2) is to transmit 4Kw at 600 RPM to a cast steel gear (s0=100MN/ m2) with a transmission ratio 9/2 to 1, and 20ofull depth involute teeth are to be used. Determine the necessary face width and module.

4. A cast steel 24-tooth spur pinion operating at 1150 RPM transmits 3Kw to a cast steel 56 Tooth spur gear. The gears have the following specifications: module 3 , s0 =160MN/ m2, face width 35mm 14.5o tooth profile design the gear.

5. A cast steel pinion (s0=103MN/ m2) rotating at 900 RPM is to drive a cast iron gear (s0=55MN/ m2) at 144RPM. The teeth are to have standard 20o stub involute profiles and maximum power to be transmitted is 25Kw. determine the proper module, no. of teeth and face width for these gear for stand point of strength ,

dynamic

load

and

wear.

Pinion

is

surface

hardened

to

BHN

250.

6. A 80mm diameter steel pinion (s0=140MN/ m2) drives a gray iron 240 mm diameter gear (s0=100MN/ m2). The pinion operates at 1200 RPM and transmits 5Kw. The teeth are 20o stub. Determine the greatest no. of teeth and necessary face width

7. A Bronze spur gear (s0=83MN/ m2) is to drive a mild steel pinion (s0=103MN/ m2). The angular velocity ratio is to be 3.5 to 1 . The pressure angle is to be 14.5o. Determine the smallest diameters gears that can be used and the necessary face width to transmit 5Kw at 1800RPM of the pinion no less than 15 teeth are to be used on either gear. Design the gear.

8. A compressor running at 300RPM is driven by a 15Kw 1200RPM. Motor through a 20-degree full depth involute gear. The center distance is 375. Choosing the suitable material for pinion and gear, Design the drive completely. Assume medium shock condition.

9. The counter shaft of lathe runs at 250RPM. The back gear (reverted train) of the lathe required to reduce the speed to 25RPM approximately. Keeping the center distance between the axis of the lathe axis of the gear shaft 150mm, Determine module and no. of teeth of gear wheels of the train. A set of gears having teeth from 20 to 120 rising by 4 available for the purpose.

10. A 45 Kw motor running at 100RPM is required to drive rotatary mill at 120RPM through a pair of spur gears. The distance between axis of the motor and mill shaft is to be about 1m. Design the spur gear to go with the mill shaft. Assume a shaft diameter of 1000mm for the mill. Gear material may be assumed to be cast steel.

11. A reciprocating compressor is to be driven by electric motor running at 900RPM. The compressor speed is 300RPM and it requires a steady torque of 200N-m. Assuming a starting torque 25% greater than mean torque, design a suitable pair of spur gear for the drives. Assume the motor shaft and compressor diameters as 30mm and 37mm respectively.

12. Design a pair of helical gear to transmit 40 Kw from a shaft running at 1500RPM .to another shaft with a speed reduction of 6. Select the suitable materials for pinion and gear. Assume medium shock condition. 13. A 10 Kw, 750RPM induction motor is to drive a pump at 150 RPM through a pair of helical gear. The starting torque of the motor is taken as 2.5times rated torque. Design the gear pair completely and check for dynamic and wear loads

14. A pair of straight spur gears are required to reduce speed from 500 to 100 RPM for 12 hours running time per day continuously. The pinion is made of 40C8 steel normalized and has 20 teeth. The wheel is of cast iron of grade FG200 and has 100teeth. The gear is of 8mm module; 100mm face width and 20-degree pressure angle. Calculate the power rating.

15. A compressor running at 360RPM is driven by a 150 Kw, 1440-RPM motor through a pair of 20o full depth helical gears having helix angle of 25 degree. The center distance is approximately 400mm. the motor pinion is to be forged steel and the driven gear is to be cast steel. Assume medium shock conditions. Design

the

gear

pair.

16. Two helical gears having 14.5-degree normal pressure angle and a helix angle of 23o connect two parallel shaft. The pinion has 48 teeth, the gear has 240 teeth and the module is 3. The pinion has an BHN 250 and the gear has the BHN 200. The face width is 250mm. Determine the wear load

17. Two parallel shafts are connected by a pair of steel helical gear. The pinion transmits 10Kw at 400RPM of the pinion. Both gear made of same material, hardened steel with allowable stress (s0=100MN/ m2). If the velocity ratio is 4.5:1, determine the smallest diameter gears that may be used having sufficient strength. No less than 30 teeth are to be used for either gear, the teeth are of 20 degree stub in diametral plane and the helix angle is 45o.

18. For a helical gear drive an expression for the virtual no of teeth Nf in terms of helix angle and actual no. of teeth N.

19. A pair of helical gears are used to transmit 15Kw. The teeth are 20o stub in diametral plane and have a helix angle of 45 degree. The pinion has an 80mm pitch diameter and operates at 10000RPM. The gear has a 320mm pitch diameter. If the gears are made of cast steel (s0=100MN/ m2) , determine a suitable module and face width . The pinion is heat treated to BHN of 3000 and the gear has a BHN of 200. 20. A pair of helical gears with a 23o helix angle is to transmit 2.5 Kw at 10000RPM of the pinion. The velocity ratio of 4:1. Both the gear are made of hardened steel with an allowable stress (s0=100MN/ m2) fro each gear. The gears are 20o stub and the pinion is to have 24 teeth. Determine the minimum diameter gear that Mini Spur In the following may be used, Project gear problems, assume that and the required BHN. Problems problems :

- gears with any tooth number up to 120 are procurable ( constraints are more severe in practice) - all gears are of steel, to the 20 degree full depth system unless otherwise indicated mid-range profile shifts apply, where relevant.

The program Steel Spur Gears should be used to assist solution of asterisked problems, and may be used to check longhand solution of other fatigue problems. 1. Tooth numbers of certain gears in the epicyclic train are indicated; all gears are of the same module. Gear A rotates at 1000 rev/min clockwise while E rotates anticlockwise at 500 rev/min. Determine the speed and direction of rotation of the ring-gear D and of the arm shaft F. If the power output through each of D and F is 1 kW, what are the power transfers through A and E? [ 371 rev/min anticlockwise; 40 rev/min clockwise; 8.77 kW input; 6.77 kW output.

2. The arm of the epicyclic train is driven clockwise at 1450 rev/min by a 5 kW motor. What torque is necessary to lock the 33 teeth gear? What is the speed of the 31 tooth gear? Note the reduction[ 16.3 kNm clockwise, 2.92 rev/min clockwise ]

3. The sun wheels A and D are integral with the input shaft of the compound epicyclic gear illustrated, and the annular wheel C is fixed. The planet wheel B rotates freely on an axle carried by the annular wheel F, and the planet E on an axle mounted on the output shaft's arm. Given the tooth numbers indicated, find the speed of the output shaft when the input shaft rotates at 1000 rev/min. Ans=524rev/min

4. In the epicyclic train illustrated, the gear C is fixed and the compound planet BD revolves freely on a spindle (a) Show which that if is zb ze > the coaxial zc zd then with input and the output on input shafts the and rotate in output the output same shafts. direction. shaft.

(b) 7.5 kW is fed into the input shaft at 500 rev/min, losses are negligible, and tooth numbers are sketched. Determine Ans=15.5kNm torque

5. Select spur gears suitable for speed ratios of (i) 1/2, and (ii) , to four significant figures. 6. Determine the practical limits of profile shift on a 6 mm module gear with 19 teeth. If a profile shift of 0.4 is implemented, what are the dedendum, base, pitch, extended pitch and addendum circle diameters of the gear Evaluate [ 103.8, the 107.1, base 114, pitch 118.8 and and the 130.8 angle mm. 17.7 of Fig mm, ? A. 6.47o]

7. What is the practical range of centre distance for a pair of 4 mm module spur gears with 19 and 35 teeth ? If they are manufactured with profile shifts of 1.5 mm and 2 mm respectively, evaluate the extended pressure [ 108.6 angle C and 112.8 the mm, contact 24.47 ,
o

ratio. 1.42 ]

8. Use the design procedure outlined in the Notes to determine gears suitable for a speed ratio of 2 0.5 % wheel and a centre distance of 200 1 mm. ] [ 6 mm module, with 27 and 38 teeth, and profile shifts of 0.45 say, for pinion and correspondingly 0.38 for

9. Evaluate the contact ratio and the fatigue geometric factors I and J for each of the following : (a) the pairs 13:35, 23:62 and 36:97 (which approximate the ratio 0.3711 to within 0.1%); (b)* results. 10. The transmission accuracy level number of a pair of open gears is 6. Further particulars of the 25 mm module 300 mm facewidth gears are as follows : allowable stresses, MPa contact 1100 1000 bending 290 280 speed, rev/min 150 23:62 teeth, assuming the minimum practical profile shifts for both gears; (c)* repeat (b) but use the maximum practical profile shifts. Comment upon the trends suggested by these

number of teeth pinion wheel 25 55

11. What life may be expected of the gears whilst transmitting 1 MW uniformly? [ 39 khr ]

Shock loading of the foregoing drive results from unsuspected torsional vibration. If the effective application factor is in fact 1.25, what life may now be expected? [ 5.4 khr ]

12. Two mating gears of commercial quality are to hand with 18 and 56 teeth. Their common facewidth is measured as 50 mm and their addendum diameters as 83.2 and 233.6 mm. Metallurgical analysis reveals that the expected contact and bending stresses of the gears' common material are 1100 and 300 MPa respectively. Estimate the pair's capacity (kW) for a 10 khr life in a shock-free application in which the pinion speed is 300 rev/min. The transmission accuracy level number is 6. [ 9.1 kW ]

13. A gear pair transmits 75 kW with an application factor of 1.5 and reliability of 99%. Particulars of the commercial 6-accuracy level gears are :

number of teeth pinion wheel 20 37

allowable stresses, MPa contact 1300 1250 bending 180 175

speed, rev/min 90 -

14.

Select

suitable

module

and

facewidth

for

life

of

15

khr.

16,

144

mm

15. Details of a pair of commercial gears having a transmission accuracy level of 8 are as follows :

number of teeth pinion wheel 10 36

allowable stresses, MPa contact 1320 1100 bending 380 360

speed, rev/min 200 -

16. Select a suitable module and facewidth for a design life of 16 khr whilst transmitting a uniform 125 kW with a reliability of 99%. [ 16, 187 mm ]

17. A commercial gear pair having a transmission accuracy level of 8 is required to transmit 100 kW in a shockfree application with 99% reliability. The speeds of pinion and wheel are 1450 and approximately 470 rev/min. Allowable stresses for contact and for bending of the pinion are 1450 and 400 MPa respectively; for the wheel 1300 and 350 MPa. Select suitable tooth numbers and profile shifts, along with a corresponding module and facewidth for a compact pair with a design life of 20 khr.

18. Estimate the life of a gear whose allowable contact stress is 1.2 GPa and which undergoes the stress spectrum:

contact stress speed duration

c N t

(GPa) (rev/min) (hours)

1.0 500 2

1.1 400 1

0.9 300 3

19. A pair of 8 mm module, 100 mm facewidth commercial gears is manufactured to a transmission accuracy level of 7 and employed in a periodic duty of 1.25 application factor. The 23 tooth pinion's allowable contact stress is 1.2 GPa at 99% reliability, the 47 tooth wheel's is 1.1 GPa. If power is transmitted to the following cycle, what life may be expected of the pair?

power pinion speed duration

P N1 t

(kW) (rev/min) (min)

60 200 10

45 150 20

35 100 30

Go to top Unit-2 an Objective idea Worm about their type gears, different Bevel engineering gears applications. Questions

Objective: Student should have knowledge about the design of worm, Bevel and Hypoid gear and also have

1. When bevel gears having equal teeth and equal pitch angle connect tow shafts whose axes intersect at right (a) angular angle, bevel gears (b) then crown bevel they gears (c) are internal bevel known gears (d) mitre as: gears

2. The worm gears are widely used for transmitting power at velocity ratios between non-intersecting shafts. (a) high (b) low

3. In worm gears, the angle between the tangent to the thread helix on the pitch cylinder and the Plane normal (a) 4. (a) Numerical 1. 2. Define What are the the virtual advantages of no. spiral of bevel teeth gears for over a straight bevel bevel The to pressure number single of the angle starts (b) on (b) the double axis lead worm for (c) a of angle velocity triple worm (c) ratio of (d) is helix 40 should called: angle be

quadruple Questions gear. gears?

3.

Differentiate

between

the

mitre

and

crown

bevel

gear.

4. A cast iron bevel gear has a pitch diameter of 600mm and a pitch angle of 30degree. The module is 2.5. Determine the permissible endurance load. The teeth are 20-degree full depth.

5. Two cast iron bevel gears having pitch diameters of 80 mm and 100mm respectively and to transmit 11/4 Kw at 1100RPM of the pinion. The tooth profile are of 20 degree full depth. Take (s0=55MN/ m2) (a) (b) determine Check the the face width from and stand the required of module dynamic from load stand and point wear of C=110 strength kN/m design point

6. A cast steel (s0=100MN/ m2) bevel gear pinion has pitch diameter of 225mm and pitch angle of 30 degree. The module is 4. The gear rotates at 600RPM. From the standpoint of strength only how much power should this gear be capable of transmitting?

7. Two steel bevel gears connects shaft at right angle. The pinion has a BHN of 300 and the gear has hardness 200. The teeth are 14.5 full depth and the module is 3. The number of teeth on pinion has 64. The face width is 40mm. determine the wear load.

8. A 100 kW, 750-RPM motor is required to drive a centrifugal pump continuously at 250 RPM by means of straight bevel gears connected at 90m-degree shaft angle. The starting torque is 20% greater that rated torque (a) Design the gears. (b) Could the same pinion is use to drive the another pump at 150RPM? Give brief explanation.

9. A pair of 4 pitch 20 degree involutes machine cut bevel gear have a2:1 reduction . The pitch diameter of the driver is 250mm and runs at 200RPM. Selecting the suitable material for the pinion and the gear determine the various parameter of gear set.

10. A pair of bevel gear are mounted on shafts that are at 90 degree apart. The set is to transmit 90 Kw at 300RPM. The pinion has 150mm outside pitch diameter; 50 mm face width, a diametral pitch of 6, and 20 degree full depth. For a velocity ratio 0.4. Determine the forces acting on gear tooth.

11. Find the power transmitted by a pair of 20o bevel gears with Tp = 40 and Tg = 60 teeth. Gears are made of steel and are hardened to 350BHN. Module is 6.5mm. width of face is 60mm but thickness of the blanks is 35mm. Pinion rotates at 600rpm. The shaft angle is 90o. Safe static stress for gears = 105Mpa. Assume Kv =6 / (6 +v); C for dynamic load calculation = 250 kN/m.

12. Design a pair of bevel gears to transmit 12kW at 600rpm. Gear ratio is 2: 1 and pinion has 24 teeth of 20o involute full depth. The material for both the wheels is the same with safe static stress of 105Mpa. b = l/3. Find module, face width, cone distance and pitch circle diameters of both the wheels. Assume Kv =3.5/(3.5+ V), Where V is peripheral velocity in m/sec. Shaft angle is 90o. Check the design for wear strength and dynamic tooth load. Given that Ses = 600Mpa, Ep=Eg= 2x105Mpa, c = dynamic load tooth Y= Lawis form factor factor = = 0.154 300kN/m, (0.912/Tf).

13. For the above example determine the diameter of the shaft carrying gear if the mean plane of the gear is 150mm away from the bearing.

14. A pair of straight bevel gear is used to transmit 18.5kW at 600rpm. The gear ratio is 2 and shaft angle is 90o. Pinion has 28 teeth of 20o involute profile. The safe static stress for the pinion as well as gear material may be taken as 105Mpa. The module is 6mm. Determine the necessary face width b of the gears to carry the given safety.

15. A spindle of a drilling machine is to be driven by means of a pair of 20o straight bevel gears. The pinion is to be mounted on horizontal drive shaft. The reduction ratio is 3.5:1. The drilling operation requires 195Nm at 350rpm design the gear pair, if the safe static stress for the gears is limited to 145Mpa. 16. A double threaded worm has a pitch circle diameter of 84mm with a axial pitch of 20 mm determine the helix angle

17. A hardened steel worm transmits power to a phosphor bronze with a velocity ratio 20 the centre ceutic distance a)Axial if worm rotates at750 is 400 mm determine, module rpm

b) Lead Angle (helix angle) c)Power rating based on heat dissipation criterion d)Power rating based on wear

18. For a worm and worm wheel the a centre distance is given as 225mm worm is made of hardened steel and rotates at 1250 rpm worm transmits power to a phosphor bronze gear (b=35 Mpa with a transmission ratio of 15 the tooth on gear are 20 degree full depth involute(y=0.125) determine all the design parameters and recommitted safe power that the drive can transmit.

19. Or the above example , determine the diameter of the shaft of worm as well as the worm gear for the arrangement of the bearing assume coefficient of friction M=0.1

20. Design a pair of bevel gears for two shafts whose axes are at right angles. Speed of pinion shaft is 300 rpm and that of Gear shaft is 120 rpm. The power transmitted is 80 kW.

Go to top Unit-3 methods Theory 1. 2. 3. On what How factors does What will the selection you of a of designing of and is classify bearing for a Ball Antifriction and roller bearings from design bearing charts Problems a the particular application bearing? bearings? depend?

Objective: Student should have knowledge about different type of bearings its engineering applications and

Numerical

4.

Describe

the

various

stages

of

friction

in

the

case

of

plain

bearings.

5. Differentiate between Hydrodynamic, Wedge film lubrication and Squeeze film lubrication. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21 22 How What What Give Enumerate How What the the will are Compare are bearings are the called is What What Give the Describe s the Define Define meant applications advantages you four ball rolling Needle and classify main and by Distinguish What are the between factors Name is the advantages the importance to Hydrodynamic be considered bearings while selecting and the Hydrostatic material for plain bearings. bearing? metals. in oils lubrication oils Bearing Sommerfeld Self limitations of rolling of a roller bearings Give their contained of rolling sliding contact contact ball grooves in and bearings? greases. devices. bearings? modulus. number. bearings? bearings. bearings. bearings? bearing? bearings. manufactured? applications.

various function and of disadvantages various of

bearing lubrication of

disadvantages the parts and contact

bearings?

23 What is the primary characteristic difference between a deep groove ball bearing and angular contact bearing? 24 here do we prefer to use taper roller bearing?

25 What is antifriction bearings. Discuss the materials that are used for manufacturing of bearings.

26 27 Where

Explain do we

rating use thrust

life bearing?

and Explain the

basic basis for

load bearing

rating. failure.

28 What is approximate friction power loss in a single radial ball bearing having a bore diameter of 55mm and subjected to a radial load of 225KN? The shaft rotates at 600RPM.

29 Determine the approximate friction torque expected in single deep groove ball bearing under a radial load of 30KN. The bore of the bearing is 50mm.

30 A bearing has a specific dynamic radial capacity of 24.5KN. What radial load the bearing can carry at 1200RPM if the desired life is 2000hours (for 90% group of bearing).

31 A radial load of 5Kn acts for 5 revolutions and reduces to 4.5Kn for 10 revolutions . The load variations then repeat itself. What is the mean cubic load?

32 Determine the 6200 series bearing which will be suitable for a radial load of 1.8Kn with the operation at 1200RPM for 2000hours. Loading is steady. Basic load capacity of various series can be see from DDB. 33 A 300 mm bore (dimension series 02) single row angular contact ball bearing has a 30 degree contact angle. If the bearing carries a 3.5 KN radial load and a 6 KN thrust load and the inner ring rotates at 1500 RPM, Determine the rating life in hours.

34 Mention the relative advantages of rolling bearings and sliding bearing. What do you understand by static capacity and dynamic capacity of ball bearing? Explain how you will determine the equivalent load on a bearing when simultaneously acting radial and thrust load are known.

35 A certain bearing is to carry a radial load of 5 at KN a speed of 10RPM of 20% of the time, a load of 30 KN at a speed of 60RPM for 50% of time and a load of 30 KN at 100RPM during 30% of the time with a desired life of 5,000 hours. No thrust load acts on bearing. What will be dynamic capacity of the bearing? 36 A shaft is subjected to the varying load cycle as follows; 3KN for 1 Sec, 1 KN for 1s and 0.5KN for 3s. If the shaft rotates at the constant speed of 500RPM, What basic load rating for each fraction of cycle should be used in selecting the ball bearing with a life of 15000 hours?

37 A 6203 single row deep groove ball bearing has a basic load rating of 4500 n and a basic dynamic capacity 7350N. What is the life expectancy (that 90% bearing reach or exceed) for a radial load of 1350N and a thrust load of 1260N? The outer ring is stationary.

38 Select bearing for a60m diameter shaft that rotates uniformly at 1800RPM. Due to bevel gear mounted on the shaft, the bearing will have to withstand a 5KN radial load and a 2KN thrust load. With any restriction of the type of a bearing select one that is satisfying for a rating life of 20,000 hours.

39 A single row deep groove ball bearing has a specific dynamic capacity of 46.3Kn(for 1000000 revolutions

or 500hours at 33.3RPM , That90% of group of bearing will complete or exceed) if the speed of rotation is 1800RPM and the actual radial load applied to the bearing is 9 KN what is the life in revolutions 40 41 In the What above is problem the how many hours life of that operation can can be be expected for in the above? 7

average

expected

prob.

42 An SKF self aligning ball bearing no.1310 has a specific capacity 33.5KN (that is the rating of 33.5Kn such that 90% of group of bearing will last 500hours at 33.3RPM). If the equivalent radial load actually applied to the bearing is P=44.5KN determine the life in millions of revolutions expected (such that 90% of a group of bearing of same nos. will survive) the speed of rotation being 1800RPM. & the life in hours for 90% of Go to top Unit-4 Lubrication and sliding bearing Objective: This chapter able the students to understand requirements of lubrication, method of lubrication in journal bearing and design of journal bearing. Theory 1. 2. 3. 4. 5. 6. What What is Define Define Define What are a the and a is various type bearing? journal the of Define bearing What is Numerical and the hydrostatic lubricants viscosity and the used and in viscosity long bearing Problems bearing. bearing? bearings? index. bearing. modulus? the bearings.

hydrodynamic a short

sommerfeld

number.

7. What is the condition for full film lubrication How should be the minimum oil film thickness. 8. Name few of the bearing materials. What is the effect of small increase in bearing clearance on film temperature? 9. A 75mm long full journal bearing of diameter 75mm support a load of 12 KN on a journal rotating at 1800RPM. Assume D/C ratio of 1000, and a oil having viscosity 0.01kg/ms at the operating temperature Determine 10. In the the coefficient above problem of friction. the Take amount L?D of heat ratio 1.

determine

generated

11. A journal bearing 75MM long supports a load of 7.3KN on a 50mm diameter journal turning at 750RPM. The dimeteral clearance is 0.07mm. What should be the viscosity of oil if the operating temperature of the

bearing

surface

is

to

be

limited

to

75degree

centigrade

when

in

still

air

at

20oC.

12. A 100 diameter shaft operating at 2000RPM is supported by means of a 150mm long full journal bearing which is subjected to a radial load of 43KN . Operating temperature of the oil is limited to 80oC and the surrounding air temp. Is 38oC. Assume P=30*10-6 determine the coefficient of friction, bearing pressure, heat generated, heat dissipated, oil use. Is artificial cooling is required.

13. A 50mm medium weight full journal bearing has a length of 100mm and support a load of 2.5KNwhen the shaft rotates at 800RPM. Assuming a temperature difference of 40oC between the operating temps. Of the bearing surface and the surrounding still air , which coefficient of friction .00432,.00615,.00715,.00816 or.00256 14. 15. Journal Bearing Radial Journal Radial load A will be required the journal length clearance speed = = 1 in order to eliminate the of the = = = need for film following artificial cooling? lubrication. specifications 75mm 55mm .055mm 22,000RPM KN

Explain full

mechanism bearing has

diameter

The power loss in the bearing was found to be 3KW find (a) viscosity of the lubricant at effective film temp. (b) The coefficient of friction at the given operating temp.

16. An electric motor whose speed is 1750RPM has bearing 100mm long and 75mm diameter. The oil used has an absolute viscosity of 15 cp under running conditions. The clearance is .0015mmpermm and the load is 0.7MN/m2 . If = 90 degree, Determine total power loss in the bearing and the minimum oil film thickness. 17. Design a bearing and journal to support a load of 4KN at 600RPM using a hardened steel journal and a bronze backed Babbitt bearing. The oil viscosity is 250s Saybolt at 37.7oC and specific gravity is 0.90 at 15.6oC . The bearing is relived for 20 degree from normal to the load line. Abundance supply of oil is maintained. 18. Determine the necessary length of bearing, running clearance, side relives, and loss of power due to friction for a journal which has 60mm diameter and rotates at 175RPM. The total load on bearing due to belt pull and the weight of the pulley is 6KN and the load is steady. Use a lubricating oil which has a Saybolt viscosity of 270s at 37.7oC and for which gamma =0.905 at 15.5oC.

19. Design a bearing and journal to support a load of 4900KN at 600RPM using a hardened steel journal and bronze backed Babbitt bearing. An abundance of oil is supplied by means of oiling rings. The oil viscosity is 250s Saybolt at 37.8oC and the specific gravity is 0.90 at 15.6oC . The bearing is relived for 20 degree from normal to the load line.

20. A pressure fed bearing with an annular central groove has a length of 45mm and diameter of 45mm.

The bearing supports a load of 4400N at the journal speed of 1000RPM. The radial clearance is 0.025mm and the oils SAE30. Determine the equilibrium temperature and minimum oil film thickness. Assume attitude Master angle 70o. problems

1. In a journal bearing of 100 mm diameter with a bearing clearance of 0.2 mm, it is found suitable to use lubricating oil with viscosity 60 cP. The shaft runs at 375 r.p.m. and develops a bearing pressure of 1.5 N/mm2. Determine (a) bearing pressure when the shaft speed is increased to 500 rpm, other parameters remaining same. (b) Viscosity at 0.15 mm bearing clearance, 450 rpm of shaft and 2.0 N/mm2 bearing pressure. 2. Following data refers to a 360o(full) hydrodynamic bearing; Journal diameter d = 75 mm, bearing length l = 75mm, radial clearance C = 0.05 mm, minimum film thickness ho= 0.02 mm, Journal speed N =420 rpm, radial (a) (b) (c) (d) The load W = 3500 N, Cp for oil = 1.75 kJ/ KgoC, of of heat of oil pumped friction generated, through the of oil oil, = 0.9 gm/cc. Z , Hg bearing. Calculate Required The The amount coefficient viscosity

3. A 360o hydrodynamic bearing is subjected to a radial load of 10kN. The journal speed is 1500 rpm.The diameter of journal and length of bearing are 60 mm each. The class of fit between journal and bearing is H7e7 (fine), normal running fit with the limits as 60+0.00, thickness is 0.009 mm. Specify the viscosity of
+0.03

mm and 60-0.06, oil

-0.09

. The minimum oil film for this application.

lubricating

required

4. A 100 mm diameter shaft operating at 2000 rpm is supported in a 150 mm long Full journal bearing subjected to a radial load of 43 kN. Operating temperature of oil is limited to 80oC and surrounding temperature is 38oC, assume ZN/P = 30 x 10-6. Using Mckee and Lasche equation, determine coefficients of friction, 5. bearing data pressure, are given Hg for a and 360 Hd degree and viscosity Z of with
-9

the usual
2

lubricant. notations:

Following

hydrodynamic

bearing

D = 50 mm, l =50 mm, C = 0.06 mm, ho = 0.012 mm, N = 1440 rpm, Z = 20 x 10

Nsec/mm , of oil =

900 Kg/m3, Cp of oil = 1.75 KJ/ Kg degreeC . Calculate the maximum radial load that the journal can carry and still operate under hydrodynamic conditions. For this load, calculate power lost in friction and resultant temperature rise.

6. A 50 mm diameter and 75mm long journal bearing is loaded with a bearing pressure 2 Mpa. The journal speed is 500rpm. The heat lost from the bearing surface at the rate of 1.16 x 10-5(J/s) / ( mm2oC). The housing area is 8 times projected area. If the room temperature is 28oC, Determine the surface temperature of bearing. Co-efficient of friction is 0.0015. Assume Hg = Hd

7. A 90mm shaft rotating at 1200 rpm is supported by 110 mm long bearing. The journal carries 50kN load. Given that To = 70oC , Ta = 250C and ZN/P = 20 x 10-6 Specify the viscosity of the lubricating oil to be used

and

calculate

heat

generated.

State

weather

external

cooling

is

required

for

the

bearing.

Go to top Unit-5 Engine parts

Objective: It gives the basic knowledge about the design of different engine parts like connecting rod crank shaft, 1. 2. 3. 4. 5. Brake Speed I.M.E.P. Mechanical efficiency = 80% Calculate the Why A What Why are the What the area of the rings main function in the the valve port is of Piston the piston piston .What of are an the type than has = = = dimension of the cylinder and the the area internal various of of the combustion type of etc engine. liners ?

provided are inlet four

various made larger

crankshafts. exhaust port?

horizontal

stroke power

diesel

engine

the

following

specifications 5KW 1200RPM 0.35N/mm2 cylinder head.

6. Design the piston. Piston rings and gudgeon pin for single acting four stroke engine for the following given Cylinder Stroke Maximum B.M.E.P. Fuel Speed consumption = gas bore = pressure = = = = data. 100mm 125mm 5MPa 0.6MPa 0.15kg/BrakekW/h 2000RPM

7. Design and draw a piston for a single acting four stroke engines from following data using design data book. Cylinder Stroke: Maximum Indicated Mechanical Fuel Higher Any consumption calorific other data : value required bore 125mm gas mean efficiency 0.15 of for fuel the kg : design : speed pressure effective : per 42 may brake *10 KJ/ be
3

75 : : pressure:

mm 2000RPM 5N/mm2 0.75N/mm2 80% power Kg assumed.

8. Design and draw a connecting rod of a petrol engine from following data using design data book. Also generate Dia of the program Piston : in c 110 language. mm

Mass Length Stroke Speed Maximum Any other

of of

reciprocating connecting : : explosion data required pressure for

parts rod :

2 325

Kg mm 150mm 1500RPM

: design may

2.5 be

Mpa. assumed.

9. A connecting rod is to be designed for a four stroke petrol engine having the following specifications: Piston Stroke Length Mass Speed Compression ratio of of diameter length connecting reciprocating = = parts rod = = = = 2 150mm 150mm 320mm Kg 1500RPM 4:1

10. Design a center crank shaft for a single acting four stroke single cylinder engine for the following data: Piston Stroke Speed I.M.E.P. Maximum Gas Ratio Total Assume pressure of at combustion maximum length belt any of torque CR pull other = diameter = = = pressure 1MPa to at Crank = missing 35 = degree radius crank = = 400mm 600mm 200RPM 0.5MPa 2.5MPa angle 5 6.5KN data

11. Design a crankshaft for a 400mm* 600mm single acting four stroke single acting four stroke single cylinder engine to operate at 200RPM. The mean effective pressure is 0.5 MPa and the maximum combustion pressure is 2.75MPa. The maximum torque is at 35degree of crank angle when gas pressure is 1MPa. The ratio of length of connecting rod to the radius of crank is 4.8. The flywheel is used as a pulley whose weight is 55KN. The total belt pull is 6750N.

12. Design and draw the exhaust valve gear for a horizontal diesel engine for following Data using Design Data Brake Bore Stroke Speed Maximum Back Suction Mean velocity gas pressure pressure of gas through : pressure : : the port : 0.4 0.025 : 2100 power : : 475 3.5 : 140 8 book. Kw mm 270mm RPM Mpa Mpa Mpa RPM

The valves open 33 degree before outer dead center and closer 1 degree after inner dead center. It opens and closes with constant acceleration and deceleration for each half of the lift. The length of the rocker arm on either side of the fulcrum is 150mm and the included angle is 60 degree the weight of the valve is 3N..

13. Design the various components of a valve gear mechanism for a horizontal diesel engine having the following Brake Bore Stroke Speed Maximum gas power = = = pressure = = specifications: 10KW 140mm 270mm 500RPM 3.5Mpa

The valves open 33 degree before top dead center and closer 20 degree after bottom dead center. It opens and closes with constant acceleration and deceleration for each half of the lift. The length of the rocker arm on either side of the fulcrum is 150mm and the included angle is 135 degree . The mass of the valve is 300g. 14. Design a plain carbon steel centre crankshaft for a single acting four stroke single cylinder engine for the following data: Ore = 400 mm; Stroke = 600 mm; Engine speed = 200rpm; Mean effective pressure = 0.5 N/mm2; Maximum combustion pressure = 2.5 N/ mm2; Weight of flywheel used ad a pulley = 50 kN; Total belt pull = 6.5 kN. When the crank has turned through 35 degree from the top dead centre, the pressure on the piston is 1N/mm2 and the torque on the crank is maximum. The ratio of the connecting rod length to the crank radius is 5. Assume any other data required for the design.

15. The conical valve of an I.C. engine is 60mm in diameter and is subjected to a maximum gas pressure of 4N/mm2. The safe stress in bending for the valve material is 46Mpa. The valve is made of steel for which k= 0.42. The angle at which the valve disc seat is tapered is 30 degree

16. Design a rocker arm, and its bearings, tappet, roller and valve spring for the exhaust valve of a four stroke I.C. engine from the following data: Diameter of the valve head = 80mm; Lift of the valve =25 mm; Mass of associated parts with the exhaust valve opens is 0.4 N/mm2 and the greatest suction pressure is 0.02 N/mm2 below atmosphere. The rocker arm is to be I-section and the effective length of each arm may be taken as 180mm; the angle between the two arms being 135 degree. The motion of the valve may be assumed S.H.M., without dwell in fully opened position. Choose your own materials and suitable values for the stresses. Draw fully dimensioned sketches of the valve gea