AT- 6601 AUTOMOTIVE ENGINE COMPONENT DESIGN

TWO MARKS QUESTION BANK

UNIT – 1 INTRODUCTION
1. What is mean by fatigue?
When a material is subjected to repeated stress, it fails at below the yield point; such type
failure of the material is called fatigue.
2. What are the factors does fatigues depends on?
 Size of the component.
 Static load.
 Fluctuating load
 No. of load reversal
3. Define endurance limit.
It is the limiting stress below which the infinite number of cycles time, the stress acting on
the material without failure. It is also called as safe maximum stress.
4. What is meant by stress concentration?
Whenever a machine component changes the shape of it cross section, the stress
distribution is irregular or discontinuity. The irregular stress distribution is caused by abrupt
changes of form, size is called stress concentration.
5. Define stress concentration.
It is defined as the ration of maximum stress to nominal stress
𝒇𝒎𝒂𝒙
Kt =
𝒇
6. What are the methods of reducing stress concentration?
 Avoid stress like hole and notches
 Free from corrosion
 Good surface finish
 Making additional holes
 Gradual rise of size in the components
7. Define notch sensitivity
It is the degree of stress concentration reached in the material due to stress rises.
𝒌𝒇 − 𝟏
𝒒=
𝒌𝒕 − 𝟏
8. What is meant by tolerance?
It is defined as permissible variation in the dimension of the component.
Two types (i) Unilateral (ii) Bilateral
9. Define fits.
When two parts are to be assembled the relationship resulting from the difference between
their sizes before assembly is called fit.
Types of fits (i) Clearance fit (ii) Interference fit (iii) transition fit
10. What is meant by fluctuating stress?When a machine member subjected to
completely reversed stress, the maximum value of compressive stress is not equal to maximum
value of tensile stress. The variation in stress is known as fluctuating stress.
11. Define Resilience.
It is ability of the material to absorb shocks or energy within elastic range.
12. Draw the stress-strain curve.

13. Define Factor of Safety (F.O.S).

It is the ratio of failure stress to allowable stress

𝒇𝒂𝒊𝒍𝒖𝒓𝒆 𝒔𝒕𝒓𝒆𝒔𝒔
N=
𝒂𝒍𝒍𝒐𝒘𝒂𝒃𝒍𝒆 𝒔𝒕𝒓𝒆𝒔𝒔

14. Define Toughness.

It is the ability to absorb energy within elastic and plastic range.
15. How do you select materials for design? Or What are the important factors in selecting
an engineering material?
Mechanical properties are the significant importance in the selection of material. The
material should be able to withstand stresses and also cost and availability.
Some of the Mechanical properties
(i) Strength (ii) elasticity (iii) stiffness (iv) toughness (v) resilience (vi) brittleness (vii)
hardness
16. What is use of selective assembly and its necessity?
It is a process of sorting the manufactures components into different groups according
to their sizes and then assembling the components of one group to the corresponding components
of matching group. In this method, larger shafts are assembled with large holes and smaller shaft
with smaller holes.
17. Why hole basis system is mostly preferred in tolerance?
Holes are machined by standard drills or reamers having fixed dimension whereas,
shafts can be turned or ground to any dimension. Due to this reason hole basis system preferred.
18. What is the role of surface roughness in interference fit?
Roughness surfaces have a reduced contact area in interference fits, which reduces the holding
capacity of the joints.
19. Define fatigue life.
It is defined as the number of stress cycles that the standard specimen can complete during
the test before the appearance of the first fatigue crack.
20. Difference between failure due to static load and fatigue failure.

Sl Failure due to static load Fatigue Failure

no.
 1. Failure due to static load are gradual Fatigue failure is sudden
2. There is a sufficient plastic Fatigue cracks are not visible till they reach
deformation prior to failure, which the surface of the component and by that time
gives a warning in advance failure has already taken place

21. Define fracture mechanics.

It is the science of predicting the influence of cracks and crack like deflect on the brittle
fracture of component.
22. What is meant by stress intensity factor and fracture toughness?
It specifies the stress intensity at the tip of the crack is known as stress intensity factor.
𝑲𝒐 = 𝝈 √ 𝝅 𝒂
It is the critical value of stress intensity at which crack extension occurs is known as fracture
toughness.

𝑲𝑰 = 𝒚 𝑲 𝒐
23. Define Clearance fit.
It is a fit which always provides a positive clearance between the hole and the shaft over
the entire range of tolerance.
24. What you meant by interference fit and transition fit?
It is a fit which always provides a positive interference over the whole range of tolerance
is called as Interference fit.
It is a fit which may provides either a clearance or interference, depending upon the actual
values of the individual tolerance of the mating components is called as Transition fit.
25. What are the factors in selection of interference fit?
 Materials and diameter
 Surface finish and machining method
It is also necessary to calculate the maximum and minimum interference in each case
26. Give any 2 applications of interference Fit.
Holding bushing in housing, inserting dowel pins in holes, attaching sprockets or gears to the
shaft.
27. What is tolerance grade?
According to Indian standards the system of limits and fits comprises 18 grades of fundamental
tolerances i.e grades of accuracy of manufacture and 25 types of fundamental deviations
indicated by letters and symbols for both hole and shafts .These are called standard tolerance or
tolerance grades,(IT01,IT0,IT1 to IT16.
28. Why surface roughness is important in assembly.
During mating of two parts in order to prevent the stress concentration and proper functioning.