INSTITUTE OF TECHNOLOGY & MANAGEMENT

UNIVERSE

MECHANICAL ENGINEERING DEPARTMENT

SUBJECT: MACHINE DESIGN

SUBJECT CODE: 2171909
SEMESTER: VII
ACADAMIC YEAR: 2017-18

Faculty Involved:-
Bhoomika Shukla
Jay Shah
Nayan Kaneriya
Nand Jee Kanu
Bharat Kumar

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PROGRAME OUTCOME:

PO1] Learn to classify different types of gears, and get familiarize with their applications.
PO2] Apply the principles of mechanics, and heat transfer to the design and analysis of the
components.
PO3] Become aware of the relevance of environmental and social issues on the design
process of machine tools, bearings and material handling equipments..
PO4] Develop mathematical methods for designing components and systems.
PO5] Apply numerical methods to perform design calculations.
PO6] Advance proficiency in professional communications and interactions.
PO7] An ability to use the techniques, skills, and mechanical machine components.
PO8] An ability to work professionally in areas of thermal, design, automobile &
manufacturing of mechanical systems

TEACHING SCHEME

Teaching University
Exam(E) Mid Sem Practical.
Scheme(Hrs) Credits Total Marks
(M) (I)
Th. Tut Prac. Theory Practical
3 0 2 4 70 30 30 20 150

COURSE OUTCOME

On completion of this course students will:

1) Demonstrate a basic understanding of types of gears, their systems, and materials.

2) Demonstrate an understanding of the relationships between the design of the gears and
their material selection.
3) Identify types of design components..
4) Perform preliminary design of gearbox for any particular input data.
5) Analyse, the requirement of type of lubrication in journal bearings. They will also be able
to select proper bearing from the manufacturer’s catalogue.
6) Construct a model if gearbox and will be able to suggest different combinations for
different speed range.

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7) Determine and understand the effects of types of stresses, type of material and its
properties.
8) Prepare a written report on the design and the performance of material handling
equipments.
9) Demonstrate professionalism in interactions with colleagues, faculty, and staff.

MAPPING WITH PO/CO

PO →
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8
CO↓
1 Yes Yes Yes Yes Yes Yes
2 Yes Yes Yes Yes Yes Yes
3 Yes Yes
4 Yes Yes
5 Yes Yes Yes Yes Yes
6 Yes Yes Yes
7 Yes Yes Yes Yes Yes
8 Yes Yes
9 Yes

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 INDEX
SR.
CONTENT PAGE
NO. NO.

1 Design Of Spur Gears

2 Design Of Helical Gears
3 Design Of Bevel Gears
4 Design Of Worm Gears
5 Design Of Gear Boxes
6 Design Of Journal Bearings
7 Design Of Rolling Contact Bearings
8 Design Of IC Engine components
9 Design Of Material Handling Equipment

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 TUTORIAL 1

DESIGN OF SPUR GEAR.

Aim: To design spur gear

QUESTIONS.

Q.1 Answer the following questions.

(A) What do you mean by interference and undercutting of gear? How it can be avoided?
(B) What is contact ratio? How it can be increased?

Q.2 Discuss the causes and remedies of Gear Failure.

Q.3 Explain the Gear materials and their heat treatments.

Q.4 Explain standard system of gear tooth and advantage and disadvantages of 14.50 and 200
involutes system.

Q.5 A gear drive is required to transmit a maximum power of 22.5 kW. The velocity ratio is
1:2 and r.p.m. of the pinion is 200. The approximate centre distance between the shafts may
be taken as 600 mm. The teeth has 20° stub involute profiles. The static stress for the gear
material (which is cast iron) may be taken as 60 MPa and face width as 10 times the module.
Find the module, face width and number of teeth on each gear. Check the design for dynamic
and wear loads. The deformation or dynamic factor in the Buckingham equation may be
taken as 80 and the material combination factor for the wear as 1.4

Q.6 Design a pair of spur gear with 200 FD involute teeth to transmit 10 kW at 1440 rpm of
the pinion. The speed ratio is 4: 1. The pinion is made of plain carbon steel Fe 410 (S ut =
410 MPa) and the gear is made of grey cast iron FG 200(S ut = 200 MPa). The factor of
safety desired is 3 and the load is steady with medium shocks running for 8 to 10 hours per
day.

Q.7 A compressor running at 250 rpm is driven by a 15 kW 750 rpm electric motor through a
pair of 200 full depth spur gears. The pinion is made of 45C8 steel (heat treated) and gear of
40C8 steel (untreated). Estimate the module, face width, and number of teeth on each gear.
Check for dynamic and wear loads.

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 TUTORIAL 2

DESIGN OF HELICAL GEARS.

Aim: To design helical gear

QUESTIONS.

Q.1 What is formative number of teeth in helical gear? Derive the expression for formative
number of teeth in helical gears.

Q.2 Explain the following terms used in helical gears :

(a) Helix angle; (b) normal pitch; and (c) axial pitch.

Q.3 A pair of parallel helical gears is having 20 teeth pinion and 80 teeth on the gear. The
pinion rotates at 750 rpm. The normal pressure angle is 200 and the helix angle is 300. The
face width is 50 mm and the normal module is 5 mm. Both the pinion and the gear are made
of 40 C8 steel (S ut = 600 MPa) and heat treated to a surface hardness of 300 BHN. The
service factor, load distribution factor and wear and lubrication factor are 1.5, 1.2 and 1.15
respectively. Calculate the power transmitting capacity of the gear pair assuming that velocity
factor accounts for the dynamic load. Factor of safety is 3.0.

Q.4 Design a pair of helical gears to transmit 50 kW. The pinion revolves at 4800 rpm and the
speed ratio is 3. Consider the following data. Material foe pinion: 45C8 (S ut = 630 MPa,
BHN = 229 core and 520 case), Material for gear: 30C8 (S ut = 500 MPa, BHN = 179),
Normal pressure angle, ɸ n = 200, Helix angle, Ψ = 250, Number of teeth on pinion, z p =20,
Normal module, m n =3 mm, FOS = 3.

Q.5 A pair of helical gears are to transmit 15 kW. The teeth are 20° stub in diametral plane
and have a helix angle of 45°. The pinion runs at 10 000 r.p.m. and has 80 mm pitch diameter.
The gear has 320 mm pitch diameter. If the gears are made of cast steel having allowable
static strength of 100 MPa; determine a suitable module and face width from static strength
considerations and check the gears for wear, given σ es = 618 MPa.

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 TUTORIAL 3

DESIGN OF BEVEL GEARS

Aim: To design bevel gear

QUESTIONS.

1. What is formative number of teeth in bevel gear? Derive the expression for formative
number of teeth in bevel gears.

2..A pair of straight bevel gears is mounted on shafts intersecting a t right angles.The number
of teeth on pinion and gear are 24 and 40 respectively.The pressure angle is 20 ⁰. The input
power to the pinion is 15 kW at 1440 rpm. The pinion and gear are made of 50C4 (Sut= 660
Mpa ) steel and heat treated to a surface hardness of 300 BHN and core hardness of 250
BHN. The gears are machined accurately by a hobbing process to Grad e 6. Determine the
module and the face width Of gears. The service is with light shocks working daily from 8 to
10 hours.

3. A pair of cast iron bevel gears connect two shafts at right angles. The pitch diameters of the
pinion and gear are 80 mm and 100 mm respectively. The tooth profiles of the gears are of 14
1 / 2 o composite form. The allowable static stress for both the gears is 55 MPa. If the pinion
transmits 2.75 kW at 1100 r.p.m., find the module and number of teeth on each gear from the
stand- point of strength and check the design from the standpoint of wear. Take surface
endurance limit as 630 MPa and modulus of elasticity for cast iron as 84 kN/mm 2 .

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 TUTORIAL 4

DESIGN OF WORM GEARS.

Aim: To design worm gear

QUESTIONS.
1. Explain thermal consideration while designing worm and worm wheel drive.
2. Give advantages and drawback of worm gear.
3. The speed reducer unit is to be designed for an input of 2 kW at 1600 rpm. The
velocity ratio is 25. The 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, kv = 6/6+v and tooth form factor, y =
0.154-0.912/zg and a wear factor of 0.7 find,
i. Standard module of gear
ii. Face Width of the gear & length of worm
iii. Check the design for wear load
4. 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.
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 200 involute. Take centre distance between
worm and worm wheel = x = 100 mm. pitch circle diameter of the worm =
x0.87B/1.416, worm is double start. Cv = 6/6+v. Form Factor, Y = 0.154-0.912/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 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 O full depths involute. Assume
double start worm. Design a worm and worm wheel.

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 TUTORIAL 5

DESIGN OF GEARBOX FOR MACHINE TOOLS

Aim: To design gearbox for machine tools

QUESTIONS.

1. Write down Procedure for Designing Multi – Speed Gear Box

2. Explain what is structural diagram and method of drawing structural diagram of gear box.

3. Give the Comparison between Structure Diagram and Speed (Ray) Diagram

4. Draw the structure diagrams and gear box layout for the following equations.
a) 2(1) 2(2)
b) 3(1) 2(3)
c) 2(1) 2(2) 2(4)
d) 3(1) 2(3) 2(6)

5. A three stage gear box with twelve speeds is to be designed based on R10 series with a
minimum spindle speed of 125 rpm. The electric motor is connected to the gear box through
a belt drive and runs at 1440 rpm and transmits power of 5 kW. Using standard spindle
speeds,
a) Draw the structure and speed diagram for the arrangement.
b) Determine the ratio of the belt pulley diameters.
c) Draw the gear box layout.

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 TUTORIAL 8
DESIGN OF IC ENGINE COMPONENT

Aim: To design ic engine component

QUESTIONS.

1.What is the function of a valve gear mechanism? Explain with neat sketches the valve gear
mechanism in case of a vertical and horizontal engine.

2.Draw a neat diagram of the piston and explain the design requirements of piston in engine.

3.Explain the piston materials. What are the advantages and disadvantages of aluminium
piston over cast iron piston?

4.What are the different types of piston rings? State its functions. Why is more number of
thin piston rings preferred over small number of thick rings?

5. A four stroke diesel engine has the following specifications :

Brake power = 5 kW ; Speed = 1200 r.p.m. ; Indicated mean effective pressure = 0.35 N /
mm 2 ; Mechanical efficiency = 80 %. Determine : 1. bore and length of the cylinder ; 2.
thickness of the cylinder head ; and 3. size of studs for the cylinder head.

6. Design a cast iron piston for a single acting four stroke engine for the following Data:
Cylinder bore = 100 mm ; Stroke = 125 mm ; Maximum gas pressure = 5N/mm 2;
Indicated mean effective pressure = 0.75 N/mm2 ; Mechanical efficiency = 80% ; Fuel
consumption = 0.15 kg per brake power per hour ; Higher calorific value of fuel = 42 ×10 3
kJ/kg ; Speed = 2000 rpm. Any other data required for the design may be assumed.
7. Design a connecting rod for an I.C. engine running at 1800 r.p.m. and developing
a maximum pressure of 3.15 N/mm 2 . The diameter of the piston is 100 mm ; mass of the
reciprocating
parts per cylinder 2.25 kg; length of connecting rod 380 mm; stroke of piston 190 mm and
compression ratio 6 : 1. Take a factor of safety of 6 for the design. Take length to diameter
ratio for big end bearing as 1.3 and small end bearing as 2 and the corresponding bearing
pressures as 10 N/mm2 and 15 N/mm2 . The density of material of the rod may be taken as
8000 kg/m3 and the allowable stress in the bolts as 60 N/mm2 and in cap as 80 N/mm22 . The
rod is to be of I-section for which you can choose your own proportions.

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 TUTORIAL 6

DESIGN OF JOURNAL BEARINGS

Aim: To design journal Bearings

QUESTIONS:-

1. Explain following terms for Journal Bearing

Bearing Characteristic Number, Viscocity Index, Somerfied Number, Bearing Modulus.

2. Explain Petroff’s equation for hydrodynamic journal bearings.

3. Explain the design procedure for hydrodynamic journal bearings.

\4. Explain the thermal consideration in jouA four stroke diesel engine has the following
specifications : Brake power = 5 kW ; Speed = 1200 r.p.m. ; Indicated mean effective
pressure = 0.35 N / mm 2 ; Mechanical efficiency = 80 %.

Determine : 1. bore and length of the cylinder ; 2. thickness of the cylinder head ; and 3. size
of studs for the cylinder head.rnal bearing design.

5. Design a journal bearing for a centrifugal pump from the following data : Load on the
journal = 20 000 N; Speed of the journal = 900 r.p.m.; Type of oil is SAE 10, for which the
absolute viscosity at 55°C = 0.017 kg / m-s; Ambient temperature of oil = 15.5°C ; Maximum
bearing pressure for the pump = 1.5 N / mm 2 . Calculate also mass of the lubricating oil
required for artificial cooling, if rise of temperature of oil be limited to 10°C. Heat
dissipation coefficient = 1232 W/m 2 /°C.

6. The thrust of propeller shaft in a marine engine is taken up by a number of collars

integral with the shaft which is 300 mm is diameter. The thrust on the shaft is 200 kN and the
speed is 75 r.p.m. Taking μ constant and equal to 0.05 and assuming the bearing pressure as
uniform and equal to 0.3 N/mm 2 , find : 1. Number of collars required, 2. Power lost in
friction, and 3. Heat generated at the bearing in kJ/min
7. A footstep bearing supports a shaft of 150 mm diameter which is counter- bored at the end
with a hole diameter of 50 mm. If the bearing pressure is limited to 0.8 N/mm 2 and the speed
is 100 r.p.m.; find : 1. The load to be supported; 2. The power lost in friction; and 3. The heat
generated at the bearing. Assume coefficient of friction = 0.015

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 TUTORIAL 7

DESIGN OF ROLLING CONTACT BEARINGS

Aim: To design Rolling Contact Bearings

QUESTIONS:-

1 Explain following about rolling contact bearing

(a) the static load capacity,
(b) dynamic load capacity, and
(c) Equivalent dynamic load capacity of bearing.

2 Explain classification of rolling contact bearing in detail.

3 Explain in brief about selection of bearing life.

4 Explain design steps for cyclic loads and speeds in case of rolling contact bearing.

5 What is the reliability of rolling-contact bearing selected from the manufacturer’s

catalog?

6 A shaft rotating at constant speed is subjected to variable load. The bearings

supporting the shaft are subjected to stationary equivalent radial load of 3 kN for 10
per cent of time, 2 KN for 20 per cent of time, 1 KN for 30 per cent of time and no
load for remaining time of cycle. If the total life expected for the bearing is 20 × 10 6
revolutions at 95 per cent reliability, calculate dynamic load rating of the ball bearing.

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 TUTORIAL 8

DESIGN OF IC ENGINE COMPONENTS

AIM : TO DESIGN IC ENGINE COMPONENT

QUESTIONS

1.What is the function of a valve gear mechanism? Explain with neat sketches the valve gear
mechanism in case of a vertical and horizontal engine.

2.Draw a neat diagram of the piston and explain the design requirements of piston in engine.

3.Explain the piston materials. What are the advantages and disadvantages of aluminium
piston over cast iron piston?

4.What are the different types of piston rings? State its functions. Why is more number of
thin piston rings preferred over small number of thick rings?

5. A four stroke diesel engine has the following specifications :

Brake power = 5 kW ; Speed = 1200 r.p.m. ; Indicated mean effective pressure = 0.35 N /
mm 2 ; Mechanical efficiency = 80 %. Determine : 1. bore and length of the cylinder ; 2.
thickness of the cylinder head ; and 3. size of studs for the cylinder head.

6. Design a cast iron piston for a single acting four stroke engine for the following Data:
Cylinder bore = 100 mm ; Stroke = 125 mm ; Maximum gas pressure = 5N/mm 2;
Indicated mean effective pressure = 0.75 N/mm2 ; Mechanical efficiency = 80% ; Fuel
consumption = 0.15 kg per brake power per hour ; Higher calorific value of fuel = 42 ×10 3
kJ/kg ; Speed = 2000 rpm. Any other data required for the design may be assumed.
7. Design a connecting rod for an I.C. engine running at 1800 r.p.m. and developing
a maximum pressure of 3.15 N/mm 2 . The diameter of the piston is 100 mm ; mass of the
reciprocating parts per cylinder 2.25 kg; length of connecting rod 380 mm; stroke of piston
190 mm and compression ratio 6 : 1. Take a factor of safety of 6 for the design. Take length to
diameter ratio for big end bearing as 1.3 and small end bearing as 2 and the corresponding
bearing pressures as 10 N/mm2 and 15 N/mm2 . The density of material of the rod may be
taken as 8000 kg/m3 and the allowable stress in the bolts as 60 N/mm 2 and in cap as 80
N/mm22 . The rod is to be of I-section for which you can choose your own proportions.
Draw a neat dimensioned sketch showing provision for lubrication. Use Rankine formula for
which the numerator constant may be taken as 320 N/mm 2 and the denominator constant 1 /
7500.

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 TUTORIAL 9

DESIGN OF MATERIAL HANDLING EQUIPEMENTS

Aim: To design Material Handling Equipments

QUESTIONS.

1.Describe the basic objectives of material handling system. State the basic principles in selection
of material handling equipment.

2. Explain desig n procedure of wire rope drum.

3.What do you understand by 6 x 37 ropes? Explain with neat sketch the different rope section.

4. Why trapezoidal section is used for hook? Draw a neat sketch of single hook and show the
critical section on it.

5.At the construction site, 1 tonne of steel is to be lifted up to a height of 20 m with the help of 2
wire ropes of 6 X 19 size, nominal diameter 12 mm, tensile designation 1770. Determine
factor of safety if the sheave diameter is 56d and if wire rope is suddenly stopped in 1 second
when travelling at a speed of 1.2 m/s. what is factor of safety if bending load is neglected?

6.A workshop crane is lifting a load of 25 KN through a wire rope and a hook. The weight of
hook etc. is 15 KN. The rope drum diameter may be taken as 30 times the diameter of rope.
The load is to be lifted with an acceleration of 1 m/s 2. . Calculate the diameter of wire rope.
Take factor of safety of 6 and young’s modulus for wire rope 80 KN/mm. 2. . The ultimate
stress may be taken as 1800 MPa. The cross -section area of wire rope may be taken as 0.38
times square of wire rope diameter, diameter of wire may be take n as 0.063d.

7.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 ARRENGEMENT.

8.A single point hook is made from a 50 mm M.S. bar with 84 mm bed diameter. Calculate the
safe load that can be taken by this hook, if the design permissible stress is limited to 160
MPa. If the hook section is changed to trapezoidal section from triangular section for the
same bar what will be the change in load carrying capacity?

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