MACHINE DESIGN (ME 603)

Time Allotted: 3 Hours Marks: 70 The figures in the margin indicate full marks. Candidates are required to give their answers in their own words as far as practicable. Full

SUGGESTIONS

GROUP A (Multiple Choice Type Questions) 1. Choose the correct alternatives for the following: 1 = 10 10

i) In a full journal bearing, the angle of contact of the bearing with the journal is (a) 300 (b) 1800 (c) 2700 (d) 3600 ii) Surface endurance limit of gear material is dependent on its (a) Coefficient of elasticity (b) Brinell hardness test (c) Elastic strength (d) Yield strength iii) In case of a multiple disc clutch, if n1 are the number of discs on the driving shaft and n2 are the number of the discs on the driven shaft, then the number of pairs of contact surfaces will be (a) n1 + n2 (b) n1 + n2-1 (c) n1 + n2+1 (d) all of these iv) The contact ratio for gears is (a) zero (b) less than one (c) greater than one (d) none of these

v) Lewis equation in spur gears is applied (a) only to the pinion (b) only to the gear (c) to stronger of the pinion or gear (d) to weaker of the pinion or gear vi) The rolling contact bearings are known as (a) thick lubricated bearings (b) thin lubricated bearings (c) plastic bearings (d) Antifriction bearings vii) A brake commonly used in motor car is (a) Internal expanding brake (b) Band brake (c) shoe brake (d) band and block brake viii) For bearing number 306, what is the bore diameter of the bearing in mm (a) 30 (b) 16 (c) 20 (d) 25 ix) The minimum number of teeth on the pinion in order to avoid interference for 14.5 stub system is (a) 14 (b) 18 (c) 12 (d) 24 x) A jaw clutch is essentially a (a) positive action clutch (b) cone clutch (c) disc clutch (d) friction clutch

GROUP B

(Short Answer Type Questions) Answer any three of the following. = 15 1. 2. 3. 4. 5. 6. 35

What is band and block brake? Deduce expression for greatest tension to least tension for this brake. Compare the involute and cycloidal profile for the gear teeth. Describe, with the help of a neat sketch, a centrifugal clutch and deduce an expression for the total frictional torque transmitted. Derive Lames equation and Clavarinos equation for pressure vessel. Explain the phenomenon of interference in involute gears. What are the conditions to be satisfied in order to avoid interference? A thick cylindrical shell of internal diameter 160 mm has to withstand an internal fluid pressure of 50 N/mm2. Determine its thickness so that the maximum stress in the section does not exceed 140 MPa. What are rolling contact bearings? Discuss their advantages over sliding contact bearings. How do you express the life of a bearing? What is an average or median life?

7.

GROUP C (Long Answer Type Questions) Answer any three of the following. 15 = 45 3

8. (a) A multiple disc clutch has radial width of friction material as 1/5th of

the maximum radius. The co-efficient of friction is 0.25. Find the total number of discs required to transmit 60 kW at 3000 r.p.m. The maximum diameter of the clutch is 250 mm and the axial force is limited to 600 N. Also find the mean unit pressure on each contact surface. [7] (b)A centrifugal friction clutch has a driving member consisting of a spider carrying four shoes which are kept from contact with the clutch case by means of flat springs until increase of centrifugal force overcomes the resistance of the springs and the power is transmitted by the friction between the shoes and the case. Determine the necessary mass and size of each shoe if 25 kW is to be transmitted at 800 r.p.m. with engagement beginning at 75% of the running speed. The inside diameter of the drum is 300 mm and the radial distance of the centre of gravity of each shoe from the shaft axis is 125 mm. Assume = 0.25. [8] 9. A differential band brake, as shown in Fig., has a drum diameter of 500 mm and the angle of contact is 240. The brake band is 5 mm thick and 100 mm wide. The coefficient of friction between the band and the drum is 0.25. If the band is subjected to a stress of 55 MPa, find :a) The least force required at the end of a 600 mm lever, and (b). The torque applied to the brake drum shaft.

10. A helical cast steel gear with 30 helix angle has to transmit 40 kW at 2000 r.p.m. If the gear has 25 teeth, find the necessary module, pitch diameters and face width for 20 full-depth involute teeth. The static stress for cast steel may be taken as 100 MPa. The face width may be taken as 3 times the normal pitch. What would be the end thrust on the gear? The tooth form factor for 20 full-depth involute gear may be taken as

y = 0.154 0.912 / TE , where TE represents the equivalent number of teeth. The velocity factor is given by Cv = 6 / (6+v) , where v is the peripheral speed of the gear in m/s. 11. (a)A pressure vessel has an internal diameter of 1 m and is to be subjected to an internal pressure of 2.75 N/mm 2 above the atmospheric pressure. Considering it as a thin cylinder and assuming the efficiency of its riveted joint to be 79%, calculate the plate thickness if the tensile stress in the material is not to exceed 88 MPa. [7] (b) A full journal bearing of 50 mm diameter and 100 mm long has a bearing pressure of 1.4 MPa. The speed of the journal is 875 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 75C may be taken as 0.011 kg/m-s. The room temperature is 35C. Find: (i) the amount of artificial cooling required, and (ii) 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 1.85 kJ/kg/C. [8] 12. A punching press pierces 35 holes per minute in a plate using 10 kN-m of energy per hole during each revolution. Each piercing takes 40% of the time needed to make one revolution. The punch receives power through a gear reduction unit which in turn is fed by a motor driven belt pulley 800 mm diameter and turning at 210 r.p.m. Find the power of the electric motor if overall efficiency of the transmission unit is 80%. Design a cast iron flywheel to be used with the punching machine for a co-efficient of steadiness of 5, if the space considerations limit the maximum diameter to 1.3 m. Take the allowable shear stress for the shaft material as 50 MPa, allowable tensile stress for cast iron as 4 MPa and density of cast iron as 7200 kg/m3. 13. A 90 bevel gearing arrangement is to be employed to transmit 4 kW at 600 r.p.m. from the driving shaft 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 N/mm2 and the gear is made of cast iron with a static stress of 55 N/mm 2. The tooth profiles of the gears are of 14 composite form. The tooth form factor may be taken as y = 0.124 0.684 / T E , 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 1/3 rd of the slant height of the pitch cone. Determine the module, face width and pitch diameters for the pinion and gear, from the stand point of strength and check the design from the stand point of wear. Take surface endurance limit as 630 MPa and modulus of elasticity for the material of gears is E P = 200 kN/ mm2 and EG = 80 kN/mm2.