Machine Design II

Unit 4
1) Explain the methods of estimation of dynamic load on spur gear.
2) A spur gear with 200 full depth involute teeth consists of 21 teeth pinion
meshing with 40 teeth gear. Pinion and gear are made of steel with 600 N/mm2
and 400 N/mm2, ultimate tensile strength respectively.
The pinion shaft is connected to 5 kW at 720 rpm electric motor. The starting
torque of motor is approx. 1.25 the rated torque and factor of safety is 2.
Assume load concentration factor as 1.6. Calculate:
6
1) Module based on velocity factor C v = . Assume form factor for
6 +V
pinion 0.326 and form factor for gear 0.389.
2) Select the standard module and calculate gear dimensions
3) Specify the surface hardness of gear
Use following data:
2
 BHN 
• Load stress factor – K = 0.16   N/mm
2
 100 
• Standard module in mm – 1, 1.25, 2, 2.5, 3, 4, 5, 6, 8, 10
• Assume pitch line velocity V = 5 m/s for module calculation.
3) State and explain different types of gear tooth failures.
4) A pair of spur gear with 200 full depth involute teeth consists of 21 teeth pinion
meshing with 60 teeth internal gear. The pinion shaft is coupled to a 7.35 kW
electric motor running at 1440 rpm. The application factor is 1.5. The pinion as
well as gear are made of alloy steel (Sut = 1500 N/mm2). The module and the face
width of gears are 3 mm and 35 mm respectively. The gears are machined to meet
the specification of grade 8 and heat treated to a surface hardness 400 BHN. The
deformation factor is 11500. e, N/mm. assuming dynamic load accounted by
Buckingham’s equation calculate
1) Factor of safety against bending failure.
2) Factor of safety against pitting failure.
Use following data:
2.87
• Lewis form factor - γ = 0.484 −
z
2
 BHN 
• Load stress factor – K = 0.16  N/mm2
 100 
• [
For grade 8, e =16 +1.25 m + 0.25 d µm ]
21V (bc + Pt max )
• Buckingham’s equation Pd =
21V + bc + Pt max
Where Ptmax = ka km Pt
5) State and explain, factors to be considered while selecting the type of gear
drive for given application.
6) What is the effect of helix angle on the performance of helical gear?
7) What is pitting in gear? State causes and remedies.
8) A pair of spur gear with 200 pressure angle consist of 25 teeth pinion meshing
with 60 teeth gear. The module is 5 mm while the face width is 45 mm. the
pinion rotates at 500 rpm. The gear pair is made of steel (Sut = 600 N/mm2)
and heat treated to a surface hardness of 220 BHN. Assume dynamic load
 accounted by velocity factor. The service factor and factor of safety are 1.75
and 2 respectively while load deformation factor is unity. Calculate
1. Beam strength
2. Wear strength
3. Static load that the gear can transmit
4. Rated power that can be transmitted by gear
Use following data:
2.87
• Lewis form factor - Y = 0.484 −
z
3
• Velocity factor Cv =
3 +V
2
 BHN 
• Load stress factor – K = 0.16  N/mm2
 100 

9) A spur gear pair is used to transmit 7.5 kW power from an electric motor
running at 1440 rpm to a machine tool at 370 rpm. the pinion and gear are
made of plain carbon steel (Sut = 720 N/mm2 ) and steel (Sut = 600 N/mm2 )
respectively. The tooth system is 200 full depth involute and no. of teeth on
pinion are 18. The service factor and load concentration factor are 1.25 and 1.2
respectively. The factor of safety is 1.2 while the face width is 12 x module.
The gears are machined to meet the specification of grade 7. Design the gear
3
pair by using velocity factor Cv = and Buckingham’s equation for
3 +V
dynamic load.
Also suggest the surface hardness of gear pair.
Use following data:
2.87
• Lewis form factor - Y = 0.484 −
z
2
 BHN 
• Load stress factor – K = 0.16  N/mm2
 100  
• [
For grade 7, e = 11 .0 + 0.9 M n + 0.25 d µm ]
 E p Eg 
• Deformation factor c = 0.111 e  , N/mm
 E p + E g 
• Modulus of elasticity for pinion and gear = 210 x 103 N/mm2 each
i.e. Ep = Eg = 210 x 103 N/mm2
21V (bc + Pt max )
• Buckingham’s equation Pd =
21V + bc + Pt max
• Standard module in mm – 1, 1.25, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, 16.
10) A spur pinion having 21 teeth made of plain carbon steel 55C8 (Sut = 720
N/mm2) meshing with a gear made of 40C8 (Sut = 580 N/mm2). The gear pair
required to transmit 22 kW power from an IC engine running at 1000 rpm to a
machine running at 300 rpm. The starting torque is 200 % of rated torque,
while the load distribution factor is 1.5. The factor of safety is 1.5. The face
width is 10 x module and tooth system is 20o full depth involute. The gears are
machined to meet the specification of grade 6. The gear and pinion are case
hardened to 400 BHN and 450 BHN respectively. The deformation factor for
gear pair is 11500.e N/mm.
 6
Design the gear pair by using the dynamic factor. Cv = and Buckingham’s
6 +V
equation for dynamic load.
Use following data:
2.87
• Lewis form factor - Y = 0.484 −
z
2
 BHN 
• Load stress factor – K = 0.16  N/mm2
 100  
• [
For grade 6, e = 8.0 + 0.63 M + 0.25 d µm ]
21V (bc + Pt max )
• Buckingham’s equation Pd =
21V + bc + Pt max
• Standard module in mm – 1, 1.25, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, 16.
11) What are the effects of increasing or decreasing pressure angle in design of gear?
12) What are the advantages and disadvantages of addendum modification factor?
13) A spur gear pair with 200 full depth involute teeth consists of 20 teeth pinion
meshing with 41 teeth gear. The module is 3 mm while the face width is 40 mm.
Material for pinion as well as gear is steel with an ultimate tensile strength 600
N/mm2. The gears are heat treated to a surface hardness 400 BHN. The pinion rotates
at 1450 rpm and service factor 1.75. Assume velocity factor accounts for dynamic
load. Determine the rated power that the gears can transmit. Assume factor of safety
1.5. Use following data:
2.87
• Lewis form factor - Y = 0.484 −
z
2
 BHN 
• Load stress factor – K = 0.16   N/mm2
 100 
6
• Velocity factor Cv =
6 +V
14) Explain the methods of estimation of dynamic load on spur gear.
15) What is pitting? State its causes and remedies.
Unit 5
Helical and Bevel Gears

1) A helical pinion having 14 teeth made of alloy steel (Sut = 800 N/mm 2) is mesh
gear made of plain carbon steel (Sut = 720 N/mm2 ). The gear pair is required to
transmit 30 kW power from an electric motor running at 720 rpm to machine at
225 rpm. The application factor and load concentration factor are 1.3 and 1.1
respectively while the factor of safety is 2. The face width is 10 x normal
module (10 Mn ) and tooth system is 200 full depth involute. Deformation factor
for gear pair is 11000. e, N/mm. design the gear pair by using the velocity factor
and Buckingham’s equation for dynamic load. Also suggest suitable surface
hardness for gear pair.
Use following data:
2.87
• Lewis form factor - γ = 0.484 − /
z
5.6
• Velocity factor v =
5.6 + V
• [
For grade 7, e = 11 .0 + 0.9 M n + 0.25 d µm ]
 21V (bc Cos 2ψ + Pt max ) Cos ψ
• Buckingham’s equation - Pd =
21V + bc Cos 2ψ + Pt max
2
 BHN 
• Load stress factor – K = 0.16   N/mm2
 100 
• Standard module in mm – 1, 1.25, 2, 3, 4, 5, 6, 8, 10,12,14

2) What is formative number of teeth in helical gear? Derive the expression for
the same with sketch.
3) Following data is given for a helical gear pair transmitting 15 kW power fro an
electric motor running at 720 rpm to a machine running at 360 rpm.
• No. of teeth on pinion = 18
• Centre distance = 180 mm
• Helix angle = 260
• Face width = 12 x Normal module
• Tooth system = 200 full depth involute
• Permissible bending stress for steel pinion and gear = 150 N/mm2
• Service factor = 1.25
• Load concentration factor = 1.1
• Combine teeth error = 40 microns
• Deformation factor = 11600 x error N/mm
Assuming dynamic load accounted by Buckingham’s equation. Determine:
i. Factor of safety against bending failure
ii. Factor of safety against pitting failure
Use following data:
2.87
• Lewis form factor - γ = 0.484 − /
z
21V (bc cos 2 ψ + Pt max ) Cos ψ
• Buckingham’s equation - Pd =
21V + bc cos 2 ψ + Pt max
• Ptmax = Cs km Pt
• Assuming surface hardness – 350 BHN.
4) State two advantages and disadvantages of Herringbone gear and double
helical gear with sketch.
5) A pair of helical gear consists of 24 teeth pinion rotating at 5000 rpm and
supplying 2.5 kW power to a gear. The speed reduction is 4:1. the normal
pressure and helix angle are 200 and 230 respectively. Both the gears are made
of hardened steel (Sut = 750 N/mm2). The service factor and factor of safety
are 1.5 and 2.0 respectively. The gears are finish to meet the specifications of
grade -4.
a) In the initial stage of gear design assume velocity factor accounts
dynamic load and face width is 10 x module and assume pitch line
velocity V = 10 m/s for estimating normal module.
b) Select first preference module and calculate dimensions of gear.
c) Determine the dynamic load by Buckingham’s equation also calculate
factor of safety in bending.
d) Specify surface hardness at factor of safety 2.0
Use following data:
 2.87
• Lewis form factor - γ = 0.484 −
z/
5.6
• Velocity factor v =
5.6 + V
• [
For grade 4, e = 3.20 + 0.25 M n + 0.25 d µm ]
21V (bc Cos 2ψ + Pt max ) Cos ψ
• Buckingham’s equation - Pd =
21V + bc Cos 2ψ + Pt max
• First preference module in mm – 1, 1.25, 2, 2.5, 3, 4, 5, 6, 8, 10,12,16
and 20

6) With neat sketch explain straddle mounting of bevel pinion and gear.
7) With the help of neat sketch, explain the difference between the spiral bevel
gears and the hypoid gears. State the advantages of hypoid gears over the
spiral bevel gears.
8) Compare straight bevel gear, spiral bevel gear and hypoid gear with sketch.
9) A straight bevel pinion having 24 teeth pinion meeting with straight bevel gear
with 32 teeth. The axis of the pinion and gear intersect at right angle. The
pinion and gear are made of plain carbon steel and grey cast iron with Sut =
580, and Sut = 350 respectively. The gear pair is manufactured by generation.
The pinion is connected to 10 kW, 1000 rpm electric motor. The starting
torque of motor is 1.75 times the rated torque. If the surface hardness of gear
pair is 300 BHN, design the gear pair for factor of safety 1.5.
Assume velocity factor accounts for dynamic load. Use following data:
Use following data:
2.87
• Lewis form factor - γ = 0.484 − /
z
2
 BHN 
• Load stress factor – K = 0.16  N/mm2
 100 

Cs Pt
• Effective load Peff =
Cv
• First preference module in mm – 1, 1.25, 2, 2.5, 3, 4, 5, 6, 8, 10,12 and
16
10) A pair of straight bevel gears is mounted on shafts which are intersecting at
right angles. The no. of teeth on pinion and gear are 21 and 28 respectively.
The pressure angle is 200. The pinion shaft is connected to electric motor
developing 5 kW rated power at 1440 rpm. The application factor can be taken
as 1.5. The pinion and gear are made of steel with Sut = 750 N/mm 2 and both
are heat treated to a surface hardness of 380 BHN. The gears are machined in
such a way that the combine teeth error between meshing teeth is 10 micron.
The module and face width are 4 mm and 20 mm respectively. Determine
i) Factor of safety in bending
ii) Factor of safety in pitting
Use following data:
2.87
• Lewis form factor - Y = 0.484 − ,
z
 2
 BHN 
• Load stress factor – K = 0.16  N/mm2
 100 

6
• Velocity factor Cv =
6 +V
21V (bc + Pt max )
• Buckingham’s equation Pd =
21V + bc + Pt max
11) A straight bevel pinion and gear made of alloy steel with ultimate tensile strength
800 N/mm2. The axis of pinion and gear intersect at right angle. The gear pair
required to transmit 15 kW power from a spindle running at 600 rpm to a machine
running at 300 rpm. The starting torque is 110 % to the rated torque. The factor of
safety required is 1.75. The tooth system is 200 full depth involute. The gears are cut
to meet the specification of grade 6. The pinion and gear are case hardened to 350
BHN. The deformation factor is 11000 x e N/mm. Design the gear. Use
Buckingham’s equation for dynamic load.
• No. of teeth on pinion = 21
2.87
• Lewis form factor - Y = 0.484 − ,
'

z
2
 BHN 
• Load stress factor – K = 0.16   N/mm2
 100 
6
• Velocity factor Cv =
6 +V
21V (bc + Pt max )
• Buckingham’s equation Pd =
21V + bc + Pt max
• Standard module in mm – 1, 1.25, 2, 2.5, 3, 4, 5, 6, 8, 10 and12.
• For grade 6 e = 8.0 + 0.63 [m + 0.25 d ] µm

Unit 5
Worm Gears
1) Write a short note on thermal considerations in worm gear.
2) What are the advantages of double enveloping worm gear drive over single
enveloping worm gear with neat sketch?
3) Why worm gear always governs the design in worm gear pair?
4) What is self locking of worm gear pair? Explain factors affecting the
efficiency of worm gear.
5) With neat sketches, describe any three types of construction of worm gears.
6) A pair of worm and worm gear is designated as 2/30/10/8. Calculate:
i) the centre distance;
ii) the reduction ratio;
iii) the dimensions of worm;
iv) the dimensions of worm gear.
7) A pair of worm gear designated as 2/52/10/4 transmit 10 kW power at 720
rpm supplied to worm shaft. The coefficient of friction is 0.04 and pressure
angle is 200. Assume worm PS above the worm gear and rotates clockwise
direction when viewed from left. If worm is left hand, determine
i) Component of tooth forces acting on worm and worm gear.
ii) Efficiency of worm gear.
8) A worm and worm gear drive has following specifications.
Pitch circle diameter of worm = 48 mm
 Pitch circle diameter of worm gear = 192 mm
Axial pitch of worm = 18.85 mm
Pressure angle in normal plane = 200
Lead of worm = 18.85 mm
Effective width of worm gear teeth = 36 mm
Worm speed = 3500 rpm
Permissible bending stress for worm gear = 90 N/mm2
Worm gear wear factor = 0.83 N/mm2
Coefficient of friction between worm and worm gear = 0.025
Overall heat transfer coefficient without fan = 16 w/m2 0C
Overall heat transfer coefficient with fan = 15.2 + 8.25 x 10-3 x Nworm w/m2
0
C
Effective area of housing = 9 x 10-5 x (a)1.88 m2 (a = centre distance)
Frictional losses in bearing = 4.5 % of total input power
Determine:
1) dimensions of worm gear pair
2) input power rating on strength basis
3) temperature rise of lubricating oil with or without fan.
Is fan necessary? Comment.
Use,

2.87
• Lewis form factor - Y = 0.484 −
z
6
• Velocity factor Cv =
6 +V
cos α − µ tan γ
• Efficiency = cos α + µ cot γ
Where , α = normal pressure angle
γ = Lead angle
µ = Coefficien t of friction

Unit 1
Rolling Contact Bearings

1) Explain the various types of failures in rolling contact bearings.

2) A single row deep groove ball bearing is used to support to the lay shaft of a
four speed automobile gearbox. It is subjected to the following loads in
respective of speed ratios.
Gear Axial load (N) Radial load (N) % time engaged
First gear 3150 4500 2
Second gear 575 3250 5
Third gear 75 3250 23
Fourth gear Nil Nil 70

The lay shaft is fixed to the engine shaft and rotates at 1600r.p.m.the static and
dynamic load carrying capacities of the bearing are 11800N and 17300Nrespectively.
The bearing is expected to be in use for 4500hr.of operation find out the reliability
with which life could be expected.
Refer the following data;
Table: x and y factor for single Row Deep Groove ball bearing.
3) Sketch ‘back to back’and ‘face to face’ arrangements of two roller bearings to
mount a stepped shaft.
4) 20 kW, 1440 rpm electric motor is directly coupled to a shaft of 30 mm diameter,
which is supported by two cylindrical roller bearings. The shaft transmits power to
another line shaft through flat pulley of 250 mm diameter, which is placed midway
between two bearings. The coefficient of friction between the belt and pulley is 2.2
while the angle of lap is 1800. The belt is horizontal. The load factor is 1.75. if the
expected life of the bearing is 60000 hours. Find the dynamic load carrying capacity
of the bearing, so that bearing can be selected from the manufacturer’s catalogue.
5) Explain the causes and various types of failures in rolling contact bearings.
6) What is preloading of bearing? Draw one typical bearing mounting showing
preloading arrangement.
7) Derive Stribeck’s equation for the basic static capacity of bearing. State the
assumptions made.
8) Compare ball bearing with roller bearings. State the applications of rolling contact
bearing.
9) What do you understand by rating life and median life of the bearing?
Unit 2
Friction Clutches & Brakes
1) Compare the asbestos based friction materials with sintered metal friction
materials used in clutches.
2) A single plate clutch which consists of two pairs of contacting surfaces is used
to connect an electric motor running at 1440 rpm with a machine. The
machine is equivalent to a rotor of mass 125 kg and radius of gyration of 350
mm. the inner and outer diameters of contacting surface are 120 mm and 240
mm respectively. The coefficient of friction is 0.18 and intensity of pressure is
limited to 0.25 N/mm2. the clutch is engaged suddenly so as to contact the
stationary machine with the electric motor. Assuming the clutch is new
determine i) Power transmitting capacity of the clutch
ii) Time required by the machine to obtain its full speed
iii) Amount of heat generated during engagement
3) The semi cone angle in cone clutches is usually 12.50. Justify the statement
giving reasons.
4) A multiplate clutch is used to transmit 12 kW at 1440 rpm. The inner and
outer diameters of contacting surfaces are 70 mm and 100 mm respectively.
The coefficient of friction and average allowable pressure intensity for the
friction lining may be assumed as 0.12 and 380 KPa respectively. Determine
i) No. of plates
ii) Axial force required to transmit power
iii) The actual avg. pressure
iv) Actual max. pr. Intensity after wear
5) Draw a labeled sketch of a multi-plate clutch.

Unit 3
Belt, Rope and Chain Drives
1) Explain the need for pre-tensioning of belts. Also describe any one of the pre-
tensioning device with suitable sketch.
2) What are silent chains? Sketch and explain their advantages over roller chains.
3) Explain the causes and various types of failures in roller chains.
4) Draw a labeled neat sketch of 6 x 7 wire rope.
5) A single V belt is used to transmit power from a grooved pulley of pitch
diameter of 210 mm running at 1440 rpm to a flat pulley of diameter 500 mm.
the center distance between the pulleys is 950 mm. the mass of the belt is 0.4
kg/m. the coefficient of friction between the belt and pulley is 0.22. The V belt
groove angle 400.
If the allowable tension in the belt is 850 N, determine:
i) the power transmitting capacity of the belt
ii) the initial tension required in the belt
6) Write a short note on lubrication and failure of roller chain.
7) Explain polygonal effect in chains.
8) Draw the neat sketch of rope drum constructions and explain its design
procedure.
9) A pulley of 1000 mm diameter is driven by an open type flat belt from 20 kW,
1440 rpm electric motor. The pulley on the motor shaft is 250 mm in diameter
and the center distance between two shafts is 2.0 m. the allowable tensile
stress for the belt material is 2 N/mm2 and the coefficient of friction between
the belt and pulley is 0.28. The density of the belt material is 900 kg/m3.
If the width of the belt is 125 mm determine
i) the thickness of belt
ii) the length of the belt
iii) the initial tension required in the belt.