Chapter 1 - Gear Design: Sr. No. Questions

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Chapter 1 – Gear Design
May – 17
May – 18
May – 19
Nov – 16
Nov – 17
Dec – 18
Sr. No. Questions
Theory
Explain the following terms used in helical gears: 04
1. (a) Helix angle; (b) Normal pitch; (c) Axial pitch; (d) Normal Pressure angle
2. Explain in detail: (i) Law of gearing (ii) Gear tooth failures. 07
3. Explain: (i) Thermal rating of worm gearing (ii) Efficiency of worm gearing. 07
Why dissimilar materials are used for worm and worm wheel? 03
4.
And explain the designation 4/29/10.6/2.5/50 used for the pair of worm and worm gear.
5. Explain: Interference and undercutting of gears 02 04 04
6. How are the gears classified? Explain the role of pressure angle in the gears. 03
7. Explain different types of gear tooth failures. 04 07
8. Give classification of gears. 03
Prove that “The common normal to the tooth profile at the point of contact should always pass through a 07
9.
fixed point, in order to obtain constant velocity ratio”.
10. What is the minimum number of teeth on spur gear? Why? 03
Why are worm gear reduction units not preferred over other types of gearboxes for transmitting large 03
11.
powers?
12. What is herringbone gear? State two advantages of herringbone and double helical gear. 04
13. Why pressure angle is generally taken as 20? What is its effect? 03
14. Explain the aspect of heat generation in design of worm gears. 03
Machine Design (2171909)

Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
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15. List the merits and demerits of worm gear drives. 03
16. Derive the equation for formative number of teeth for helical gears. 04
17. How the bevel gears are classified? Explain with neat sketches. 03
Examples
A pair of straight teeth spur gears, having 20° involute full depth teeth is to transmit 12 kW at 300 r.p.m. 07
of the pinion. The speed ratio is 3:1. The allowable static stresses for gear of cast iron and pinion of steel
are 60 MPa and 105 MPa respectively. Assume the following:
1. Number of teeth of pinion = 16; Face width = 14 times module; Velocity factor (Cv) = 4.5/ (4.5 + v), v being
the pitch line velocity in m / s; and tooth form factor y = [0.154 – (0.912/No. of teeth)]. Determine the
module, face width and pitch diameter of gears. Check the gears for wear; given σes = 600 MPa; EP = 200
kN/mm2 and EG = 100 kN/mm2.
A 90° bevel gearing arrangement is to be employed to transmit 4 kW at 600 r.p.m. from the driving shaft 10
to another shaft at 200 r.p.m. The pinion has 30 teeth. The pinion is made of cast steel having a static
stress of 80 MPa and the gear is made of cast iron with a static stress of 55 MPa. The tooth profiles of the
gears are of 14.5° composite form. The tooth form factor may be taken as y' = [0.124 – (0.684 / TE)],
2. where TE is the formative number of teeth and velocity factor, Cv = 3/ (3 + v), where v is the pitch line
speed in m/s. The face width may be taken as 1/3rd of the slant height of the pitch cone. Determine the
module, face width and pitch diameters for the pinion and gears, from the standpoint of strength and
check the design from the standpoint of wear. Take surface endurance limit as 630 MPa and modulus of
elasticity for the material of gears is EP = 200 kN/mm2 and EG = 80 kN/mm2.
The speed reducer unit is to be designed for an input of 2 KW at 1600 rpm. The velocity ratio is 25. The 10
worm is to be made of hardened steel and the gear of phosphor bronze having a static stress of 70 MPa.
The approximate distance between two shafts is 120 mm. Taking a velocity factor Cv = 6/ (6 + v), Tooth
3.
form factor, y = [0.154 – (0.912/No. of teeth)] and a wear factor of a 0.7. Find Standard module of gear,
Face Width of the gear & length of worm and Check the design for wear load. Take tooth system 20° full
depth involute.
A pair of bevel gear with 20° pressure angle consists of a 20 teeth pinion meshing with a 30 teeth gear. 07
4. The module is 4 mm, while the face width is 20 mm. The material for pinion and gear is steel 50C4
(σut=750 N/mm2). The surface hardness of gear is 400 BHN. The pinion rotates at 500 rpm and receives
2.5 kW power from the electric motor. The service factor is 1.5. Determine the factor of safety against

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bending failure and against pitting failure.
A 17-tooth 20° pressure angle spur pinion rotates at 1800 rev/min and transmits 4 HP to a 52-tooth disk 07
gear. The diametral pitch is 0.4 teeth / mm, the face width is 38 mm, and the quality standard is No. 6. The
gears are straddle-mounted with bearings immediately adjacent. The pinion is a grade-1 steel with a
hardness of 240 Brinell tooth surface and through-hardened core. The gear is steel, through-hardened
also, grade 1 material, with a Brinell hardness of 200, tooth surface and core. Poisson’s ratio is 0.30, J P =
0.30, JG = 0.40, and Young’s modulus is 208 x 103 N/mm2. The loading is smooth because of motor and
5.
load. Assume a pinion life of 108 cycles and a reliability of 0.90, and use load cycle factor Y N =1.3558 N-
0.0178, ZN = 1.4488 N-0.023. The tooth profile is uncrowned. This is a commercial enclosed gear unit. Consider
following factors in the AGMA design of gear as per usual notations.

k0=1, kB=1, km=1.22, (ks) P =1.043, (ks) G=1.052, kT=1, kR=0.85, (St) P=31350, (St) G= 28260, kv=1.377.
(a) Find the factor of safety of the gears in bending.
(b) Find the factor of safety of the gears in wear.
A worm drive transmits 15 kW at 2000 rpm to a machine carriage at 75 rpm. The worm is a triple 07
threaded and has 65 mm pitch diameter. The worm gear has 90 teeth of 6 mm module. The tooth form is
6. to be 20° full depth involute. The coefficient of friction between the mating teeth may be taken as 0.10.
Calculate: 1. Tangential force acting on the worm 2. Axial thrust and separating force on worm 3.
Efficiency of the worm drive.
Design a spur gear drive to transmit 30 HP at 900 r.p.m. Speed reduction ratio is 2.5. Material for pinion 07
7. and wheel are C.I steel and Cast Iron respectively. Take pressure angle of 20. Design bending stress for
pinion material is 85 N/mm2 and surface endurance limit for pinion material is 620 N/mm2. Take the
following data for the given gears: Quality of the gears to be - Grade 12, Service factor = 1.5
Design the bevel gear pair for the following specification using Carl Barth velocity factor and wear 07
consideration:
Power transmitted: 40 kW
8. Input speed: 360 rpm
Reduction ratio: 3
Shaft angle: 90
Application: Agitator
A pair of spur gears consists of a 20 teeth pinion meshing with a 120 teeth gear. The module is 4 mm. 07
9. calculate (i) the center distance, (ii) the pitch circle diameter of the pinion and gear, (iii) the addendum
and dedendum, (iv) the tooth thickness, (v) the bottom clearance, and (vi) the gear ratio.
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A pair of bevel gears transmitting 7.5 kW at 300 rpm is shown in Figure 1. the pressure angle is 20. 07
Determine of the components the resultant gear tooth force and draw a free body diagram of forces acting
on the pinion and gear.
10.
Figure 1
Design a pair of CI spur gear to transmit 12 kW having pinion speed of 200 rpm. The speed reduction 07
required is 2:1. Assume face width as 3 times circular pitch. The minimum number of teeth on pinion is
11. 24. Check your design in all failures considering the following data; Pressure angel 14.5 full depth
involute, Factor of safety 1.5, The modulus of elasticity for pair is 0.8 * 105 N/mm2, Error in manufacturing
is not to exceed 0.05 mm, Allowable bending stress for CI as 45 N/mm2, Surface endurance stress as 280
N/mm2.
Design a helical gear to transmit 30 kW from the following data; 07
12. Helix angle = 30, Speed of pinion = 1500 rpm, Pressure angle = 20 FDI, Velocity ratio = 4,
No of teeth on pinion = 24, Static stress for CI = 55 N/mm2, BHN for pinion and gear material = 350,
Young’s modulus of elasticity for pinion and gear material = 2.1 * 105 N/ mm2.
13. A worm and worm wheel gear drive is designated as 2/41/10/8. The drive is used to obtain a speed 07
reduction of 20.5 from an input speed of 1450 rpm. Material of the worm wheel is Sand Cast and Chilled

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Phosphor Bronze, while the worm is made of Case-hardened alloy steel. Determine the power
transmitting capacity of the drive based on beam strength.
Design a pair of straight teeth spur gears to transmit 20 kW when the pinion rotates at 300 r.p.m. The 07
velocity ratio is 1:3. The allowable static stresses for the pinion and gear materials are 120 MPa and 100
14. MPa respectively. The pinion has 15 teeth and its face width is 14 times the module. Assume steady load
condition and 8-10 hours of service per day. Take, the tooth form factor, y = 0.154 –(0.912/No. of teeth)
and the velocity factor, Cv = 3 / ( 3 + v ).
Considering static strength determine a suitable module and face width for a pair of helical gears that 07
transmit 15 kW. The teeth are 20° stub in diametral plane and have a helix angle of 45°. The pinion runs at
15. 10000 r.p.m. and has 80 mm pitch diameter. The gear has 320 mm pitch diameter. The gears are made of
cast steel having allowable static strength of 100 MPa. Assume endurance strength of gear material = 618
MPa. Also, check the gears for wear.

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Chapter 2 – Design of Gear Box for Machine Tools
May – 17
May – 18
May – 19
Nov – 16
Nov – 17
Dec – 18
Sr. No. Questions
Theory
1. What is structure diagram? Explain the method of drawing structure diagram of gear box. 07
What are the major advantages of using geometric progression of for speed regulation in a gear box? 07
2. And explain the design procedure of 8-speed gear box for machine tool application with the assumption
of suitable and necessary data.
3. Explain the rang ratio in gear box design. 03
4. Differentiate between Arithmetic, Geometric and Harmonic Progressions in case of design of gear box. 03
5. List the major advantages of using geometric progression of for speed regulation in a gear box. 03
Examples
1. Draw the ray and speed diagram for a 9 speed gear box. State the necessary assumptions taken. 05
A 2 x 2 drive is required to be designed for transmitting speeds starting from 400 rpm with a geometric 09
2. progression of 1.4. Draw a suitable structure and speed diagram. Also draw the layout of the gearbox and
determine the number of teeth on each gear.
Draw layout diagram of gear box, ray diagram and speed chart for a multi-speed gear box of a radial 07
drilling machine required to give eight steps. The power from motor to the input shaft of gear box is
3.
transmitted by a V-belt drive with a speed reduction of 1:6. The minimum and maximum spindle speeds
are 70 rpm and 1800 rpm respectively.
Find the range ratio, geometric progression ratio and spindle speeds for the following data: N min = 100 07
4.
r.p.m., Nmax = 1800 r.p.m. and number of speed steps = 8. Also, draw all possible structure diagrams

GTU Paper Analysis
Chapter 3 – Journal Bearing
Nov – 16
Nov – 17
May– 17
May –18
Dec – 18
May –19
Sr. No. Questions
Theory
Explain the performance of a hydrodynamic bearing with neat curve of coefficient of friction versus
1. 07
bearing characteristic number.
2. Explain the thermal consideration in Journal Bearing design. 04
3. Classify the bearing and explain the properties of bearing lubricant. 07
4. Give the classification of hydrodynamic bearings based on lubrication. 03
5. Explain the significance of L/D ratio and minimum oil-film thickness in hydrodynamic bearings. 04
6. What are the difference between Hydrodynamic and Hydrostatic bearings. 03
7. Derive the Petroff’s equation with assumptions made there in. 04
8. Explain desirable properties of bearing materials used for sliding contact bearings. 04
9. Differentiate between Hydrodynamic and Hydrostatic bearings. 04
10. Explain the significance of L/D ratio and minimum oil-film thickness in hydrodynamic bearings. 03
Examples
Design a journal bearing from the following data: Radial load = 20 kN, Diameter of journal =100 mm,
Speed of journal =900 r.p.m. Oil SAE 10 with viscosity at 550C = 0.017 kg/m-sec, Ambient temperature =
1. 15.5 0C, Maximum bearing pressure = 1.5 MPa, Permissible rise in oil temperature = 100C, Heat 09
dissipation coefficient = 1232 W/m2/ C, L/D ratio = 1.6, Design parameter ZN/p = 28, Clearance ratio
=0.0013, Specific heat of oil = 1900 J/kg/ C.

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A 80 mm long journal bearing supports a load of 2800 N on a 50 mm diameter shaft. The bearing has a 07
2. radial clearance of 0.05 mm and the viscosity of the oil is 0.021 kg / m-s at the operating temperature.
Ifthe bearing is capable of dissipating 80 J/s, determine the maximum safe speed.
The following data is given for a 3600 hydrodynamic bearings: 07
Radial load : 3.1 kN
Journal diameter : 50 mm
Bearing length : 50 mm
Journal speed : 1440 rpm
Radial clearance : 50 microns
Viscosity of lubricant : 25 cP
Density of lubricant : 860 kg / m3
3. Sp. Heat of lubricant : 1.76 kJ / kg 0C
Assuming that the total heat generated in the bearing is carried by the total oil flow in the bearing.
Calculate:
i) Sommerfeld Number
ii) Minimum oil-film thickness
iii) The coefficient of friction
iv) The power lost in friction
v) The total flow rate of lubricant in liter /minute
vi) Side leakage
A Petroff’s sleeve bearing consists of a sleeve having a bore diameter of 100.1 mm and a length of 100 07
mm. A shaft having 100 mm diameter supports a load of 4000 N. A shaft runs at 2880 r.p.m in the sleeve.
If the frictional torque on the shaft is 10 N-m, find
4. i) The absolute viscosity of lubrication
ii) The bearing pressure
iii) The coefficient of friction and
iv) The power lost in bearing.
5. The dimensions of a hydrostatic thrust bearing with a rectangular oilgrooveA, are shown in Fig-2. The 07
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pressure distribution can beassumed to be linear, varying from supply pressure at the inner edgeof the
groove to atmospheric pressure at the outer edge of the pad. Theflow over the corners can be neglected.
The thrust load is 100 kN andthe film thickness is 0.02 mm. the viscosity of the lubrication oil is
300cP.Calculate: (i) supply pressure, and (ii) requirement of flow.
Fig. 2
Calculate the maximum radial load that the journal can carry and operate at hydrodynamic condition for 07
the following data of a full journal bearing. Journal diameter = 60 mm, bearing length = 60 mm, radial
6.
clearance = 0.06 mm, minimum film thickness = 0.006 mm, journal speed = 1440 rpm, viscosity of
lubricant = 20 cP. For the above calculated load, find the power lost in friction.
A 3600 full journal bearing operates under the following specifications: Journal Diameter = 70 mm, 10
bearing length = 70 mm, Journal speed = 960 rpm, steady radial load = 12 KN, Viscosity of lubricant = 16
cP, Mass density of oil = 880 kg/m3 , Specific heat = 1.76 kJ/kg 0C, bearing clearance ratio (r/c) = 800,
7.
Average heat transfer coefficient = 20 W/m2 - 0C. Determine the required flow rate of oil. Also find the
temperature of oil film and the bearing surface area for the desired heat transfer, if the ambient
temperature is 300C. Assume that all heat generated in the bearing is carried away by the oil.

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A full journal bearing of 50 mm diameter and 100 mm long has a bearing pressure of 1.4 N/mm 2 . The 07
speed of the journal is 900 r.p.m. and the ratio of journal diameter to the diametral clearance is 1000. The
bearing is lubricated with oil whose absolute viscosity at the operating temperature of 75 °C may be taken
8.
as 0.011 kg/m-s. The room temperature is 35 °C. Find : 1. The amount of artificial cooling required, and 2.
The mass of the lubricating oil required, if the difference between the outlet and inlet temperature of the
oil is 10°C. Take specific heat of the oil as 1850 J / kg / °C.

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Chapter 4 – Rolling Contact Bearing
Nov – 16
Nov – 17
May– 17
May - 19
May –18
Dec – 18
Sr. No. Questions
Theory
1. Explain the static load capacity, dynamic load capacity and equivalent dynamic load capacity of bearing. 05
2. Explain in detail the selection procedure of rolling contact bearing from manufacturer’s catalogue. 05
3. Static and Dynamic load carrying capacity of rolling contact bearings. 03 03
4. Derive the equation for equivalent dynamic load for bearing under cyclic loads. 04
Classify the rolling contact bearings. And explain how they are designated according to ISI code of 03
5.
practice.
Define the following terms: 04
(i) Rating life of rolling contact bearings
6. (ii) Median life
(iii) Equivalent dynamic load
(iv) Reliability of bearing
Establish the following relationship between the life and reliability of the rolling contact bearing; 07
1
1 𝑏
7. 𝐿 𝑙𝑜𝑔𝑒 (𝑅)
=[ 1
]
𝐿10 𝑙𝑜𝑔𝑒 (𝑅 )
90
8. Give selection criteria of bearings in a particular application. 04

9. Explain Load-Life relationship in context with bearing. 04
10. Explain in brief about mountings of bearings. 04
11 How the rolling contact bearings are designed having probability of survival other than 90 percent? 04

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12. Classify different types of bearings 04
13. Discuss advantages of rolling contact bearings over sliding contact bearings. 03
14. Derive the equation for equivalent dynamic load for bearing under cyclic loads. 04
Examples
It is required to select a ball bearing suitable for a 50 mm diameter shaft rotating at 1500 rpm. The
radialand thrust loads at the bearing are 4500 N and 1600 N respectively. The value of X and Y factors are
1. 0.56and 1.4 respectively. Select a proper ball bearing from the following table for the rating life of 22500 07
hr.the inner ring rotates and the service factor is 1.
Bearing No. 6010 6210 6310 6410
C (N) 21600 35100 61800 87100
A ball bearing is operating on a work cycle consisting of three parts – a radial load of 3000 N at 1440
2. rpmfor one quarter cycle, a radial load of 5000 N at 720 rpm for one half cycles, and radial load of 2500 N 07
at1440 rpm for the remaining cycle. The expected life of the bearing is 10000 h. Calculate the dynamic
loadcarrying capacity of the bearing.
07
A single-row deep groove ball bearing operated with the following work cycle. If the expected life of the
bearing is 13000 hours with reliability of 90%. Calculate the dynamic load rating of the bearing and
determine reliability of a system consisting of four such bearings. The work cycle is as follows:
Axial Radial Radial Thrust Race N % time
Gear Cs
3. load load Factor factor rotation rpm engaged
I 1.5 5 0.56 1.1 Inner 1.25 960 30 %
II 0.73 3.7 0.56 1.3 Outer 1.4 1440 40 %
III - - - - Outer - 720 50 %

4. A single row deep groove ball bearing No. 6002 is subjected to an axial thrust of 1000 N and a radial load 07

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of 2200 N. Find the expected life that 50% of the bearing will complete under this condition.
04
A deep groove ball bearing has a rated static and dynamic load capacity of 4150 N and 4750 N
5. respectively. The bearing has to take an axial load of 2075 N and a radial load of 4000 N. Find the
expected life of the bearing
04
A bearing is subjected to the following work cycle: radial load of 4450 N, 6675 N and 2225 N at 150 rpm,
600 rpm, and 300 rpm for 30 % of time, 10 % of time, and for remaining time of the cycle respectively.
6. The inner ring rotates and the loads are steady. Find the expected life of this bearing in hours, by
considering the static and dynamic load carrying capacities of the bearing as 10013 N and 14952 N
respectively.
07
Select a single row deep groove ball bearing for a radial load of 4000 N and an axial load of 5000 N,
7. operating at a speed of 1600 r.p.m. for an average life of 5 years (300 days/year) at 10 hours per day.
Assume uniform and steady load.

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Chapter 5 – I. C. Engine Components
May – 17
May – 18
May – 19
Nov – 16
Nov – 17
Dec – 18
Sr. No. Questions
Theory
1. Why an I-section is usually preferred to round section in case of connecting rods? 04
2. Explain the design procedure of cylinder of an I.C. engine. 04
3. Explain the construction and working of valve gear mechanism with neat sketch. 05
Why the cylinder liners are being used in I.C. Engine? What are the desirable properties of the materials 03
4.
for the cylinder liners.
5. What are the functions of I.C. Engine piston? List the elements involved in the I.C.Engine piston. 04
6. What is the criterion for design of push rod? 03
7. Name the materials used for engine cylinder and engine piston. 04
8. Why is the area of inlet valve port more than that of an exhaust valve? 03
9. What are the design requirements of piston? 04
10. What is the function of cylinder liners in IC Engines? List down the reasons for liner distortion 03
11. What are the two most usual causes of failures of the crank shafts? 03
12. Discuss the different types of piston rings and function of each one of it. 03
With neat sketch explain the ‘inertia bending forces’ acting on connecting rod of an Internal Combustion 03
13.
(IC) engine.
14. Describe the design procedure of a crank shaft of an Internal Combustion (IC) engine 04
Examples

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The following data is given for a single cylinder four stroke diesel engine having CI Piston:
Cylinder bore = 0.30 m
Stroke length = 0.375 m
Speed = 500 rpm
Break Mean effective pressure=1.15 MPa
1. Maximum gas pressure = 8 MPa 10
Allowable tensile stress = 37.5 N/ mm2
Break specific fuel consumption = 0.22 kg/ kW –h
Temperature difference between centre and edge of piston head is 220° C
Assume 5% of the total heat is developed in cylinder is transmitted by piston.
Design (1) Piston Head (2) Piston pin.
Determine the dimensions of an I-section connecting rod for a petrol engine from the following data:
Diameter of the piston = 110 mm; Mass of the reciprocating parts = 2 kg; Length of the connecting rod
2. 10
from centre to centre = 325 mm; Stroke length = 150 mm; R.P.M. = 1500 with possible over speed of
2500; Compression ratio = 4:1; Maximum explosion pressure = 2.5 N/mm2.
The following data is given for a connecting rod having I-cross-section dimensions (4t x 5t):
Engine speed = 1800 rpm, Length of connecting rod = 350 mm, Length of stroke = 175 mm, Density of
3. material = 7800 kg/m3, Thickness of web or flanges (t) = 8 mm, Mass of reciprocating parts = 2.5 kg, 09
Permissible tensile stress for bolts = 60 N/mm2. Calculate: (i) Nominal diameter of bolts (ii) Whipping
stress in the connecting rod.
Design the following parts of a cast iron piston for a single acting four stroke engine for the below given
data.(i) Piston Head (ii) Piston Skirt (iii) Piston Pin.
Cylinder bore=100 mm, Stroke=125 mm, Maximum gas pressure= 5 N/mm2, Indicated mean effective
4. 09
pressure=0.75 N/mm2, Mechanical efficiency=80%, Fuel consumption=0.15 kg per brake power per hour,
Higher calorific value of fuel=42 x 103 kJ/kg, Speed=2000 rpm. Take for cast iron material σt=38 N/mm2,
Thermal conductivity (k) =46.6 W/m/°C and TC - TE=220 °C.
The bore of a cylinder of the four-stroke diesel engine is 150 mm. the maximum gas pressure inside the 07
5.
cylinder is limited to 3.5 MPa. The cylinder head is made of grey cast iron FG 200 (Sut = 200 N/mm 2)
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andthe factor of safety is 5. Determine the thickness of the cylinder head. Stud are used to fix the cylinder
head to the cylinder and obtain a leakage proof joint. They are made of steel FeE (Syt = 250 N/mm2) and
the factor of safety is 5. Calculate (i) number of studs, (ii) nominal diameter of studs, (iii) pitch of studs.
The following data is given for the piston of a four-stroke diesel engine: cylinder bore = 250 mm, material 07
for piston rings = grey cast iron, allowable tensile strength = 100 N/mm2, allowable radial pressure on
cylinder wall = 0.03 MPa, thickness of piston head = 42 mm, number of piston rings = 4. Calculate,
1. Radial width of the piston rings.
2. Axial thickness of the piston rings.
6.
3. Gap between the free ends of the piston ring before assembly.
4. Gap between the free ends of the piston ring after assembly.
5. Width of the top land.
6. Width of the ring grooves.
7. Thickness of piston barrel.
The following data is given for the piston of a four-stroke diesel engine: 07
Cylinder bore : 250 mm
Material of piston rings : Gray C.I.
Allowable tensile stress : 100 N / mm2
Allowable radial pressure on
cylinder wall : 0.03 MPa
Thickness of piston head : 42 mm
No. of piston rings : 4
7.
Calculate:
i) Radial width of the piston rings
ii) Axial thickness of the piston rings
iii) Gap between the free ends of the piston rings
before and after the assembly
iv) Width of the top land
v) Width of the ring grooves
vi) Thickness of the piston barrel

GTU Paper Analysis
The cylinder of a four-stroke diesel engine has the following specifications: Break Power = 7.5 kW, Speed 07
= 1400 rpm, Indicated mean effective pressure = 0.35 MPa, Mechanical efficiency = 80 %, Maximum gas
pressure = 3.5 MPa. The cylinder liner and head are made of grey cast iron FG 260 having UTS 260
8.
N/mm2 and poisons ratio 0.25. The studs are made of plaincarbon steel having yield stress 380 N/mm 2.
The factor of safety for all parts is 6. Calculate: (i) bore and length of the cylinder liner, (ii) thickness of the
cylinder liner, (iii) thickness of cylinder head, (iv) size, number and pitch of studs.
Design a cast iron piston for a single acting four stroke engine for the following specifications. Cylinder 07
bore = 100mm, stroke = 120 mm, maximum gas pressure = 0.65 MPa, Fuel consumption = 0.227
9.
kg/kW/hr, speed = 2200 rpm. Assume the following data; Allowable stresses in CI = 37.5 N/mm 2 ,
Allowable stresses for piston rings = 90 N/mm2 , Assume suitable data.
A four stroke diesel engine has the following specifications : Brake power = 5 kW; Speed = 1200 r.p.m.; 07
Indicated mean effective pressure = 0.35 N/mm2 ; Mechanical efficiency = 80 %. Determine: 1. Bore and
10. length of the cylinder; 2. Thickness of the cylinder head; and 3. Size of studs for the cylinder head. Take,
Allowable circumferential stress for cylinder material = 42 MPa, and Allowable tensile strength of
material for stud = 65 MPa.

GTU Paper Analysis
Chapter 6 – Design of Cranes
Nov – 16
Nov – 17
Nov – 18
May– 17
May –18
May –19
Sr. No. Questions
Theory
1. Explain design procedure of wire rope drum. 07 07
2. What do you understand by 6 x 37 ropes? Explain with neat sketch the different rope section. 07
3. Describe the basic objectives of material handling system. State the basic principles in selection ofmaterial 07
handling equipment.
4. What are the basic objectives of material handling systems? 03
5. What are the different types of ropes used in EOT cranes? How they are designated and selected in the 04
hoisting mechanism.
6. Draw rope sheave and drum with usual notations. 03
7. Give classification of cranes. 04
8. Discuss stresses in wire rope with usual formulae. 07
9. When do you use Johnson’s equation for buckling columns? 03
10. Write advantages of wire rope. Draw cross section of 7,19 and 37 wires in strand of wire rope. 04
11. Give Classification and application of various Material handling equipment. 07
12. Give the classification of wire ropes and explain its construction with neat sketches. 04
13. Explain the classification cranes using different standards. 04
14. What is material handling? What are the essentials of good material handling system? 04
15. List the basic objectives of material handling systems. 03
16. Explain with neat sketches : Construction and designation of steel wire ropes. 04

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17. Explain different types of loads handled by material handling equipments. 03
18. Explain the need of material handling equipments. Also, Classify material handling equipments. 07
Examples
Design a crane hook for lifting capacity of 50 KN. It is made from forged steel and has triangular section.
1. 10 07
Take permissible tensile stress 80 N/mm2. Select the most suitable cross section for the hook.
Design the following components of EOT cranes for the following requirements: 07
Application : class – II
Load to be lifted : 8 tones
2. Hoisting speed : 4 m / min
Maximum lift of the load : 12 m
(i) Select through design procedure a suitable wire rope
(ii) Sheave in a snatch block assembly of crane.
An elevator at the construction site is required to raise building materials weighing 5.5 KN. A maximum 07
velocity of 1 m/s is attained in one second while raising the materials. The lift of material is 25 m. The
3. drum diameter is 40 times the rope diameter. Find the number of 6 X 19 wire ropes required if 12 mm
diameter ropes are used. Assume: diameter of wire dw= 0.063 d, area of rope Ar= 0.38 d2, mass of rope =
0.0036 d2 kg/m, Er = 84000 N/m2 , breaking strength = 385 d2 , factor of safety = 5. d is diameter of rope.
A crane is lifting a load of 25 kN through a wire rope and a hook. The weight of hook, etc. is 15 kN. The 04
rope drum diameter may be taken as 3 times the diameter of the rope. The load is to be lifted with an
4. acceleration of 1 m/s2. Calculate the diameter of the wire rope. Take f.o.s. of 6 and Young’s modulus for
the wire rope 80 kN/mm2. The ultimate stress may be taken as 1800 Mpa. The cross-sectional area of the
wire rope may be taken as 0.38 times the square of the wire rope diameter.
A crane hook having an approximate trapezoidal section is shown in Figure 1. The hook is made of plain 07
5. carbon steel 45C8 (yield strength = 380 MPa) and the f.o.s. is 3.5. Determine the load carrying capacity of
the hook.

GTU Paper Analysis


Chapter 1 - Gear Design: Sr. No. Questions

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GTU Paper Analysis

Chapter 1 – Gear Design

Machine Design (2171909)

Machine Design (2171909)

following factors in the AGMA design of gear as per usual notations.

Machine Design (2171909)

Machine Design (2171909)

Machine Design (2171909)

Chapter 3 – Journal Bearing

Machine Design (2171909)

Machine Design (2171909)

Machine Design (2171909)

Chapter 4 – Rolling Contact Bearing

8. Give selection criteria of bearings in a particular application. 04

Machine Design (2171909)

II 0.73 3.7 0.56 1.3 Outer 1.4 1440 40 %

III - - - - Outer - 720 50 %

Machine Design (2171909)

Machine Design (2171909)

Chapter 5 – I. C. Engine Components

Machine Design (2171909)

Machine Design (2171909)

Machine Design (2171909)

Chapter 6 – Design of Cranes

Machine Design (2171909)

Machine Design (2171909)

Machine Design (2171909)

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