Unit Wise Theory and Numerical Question Bank

MIT Art Design & Technology University, Pune
MIT School of Engineering, Pune

Department of Mechanical Engineering
Unit 1: Design of Machine Tool Gear Box
Q. Question
No.
1 Explain the following terms with reference to machine tool gear box. How these parameters are
decided while designing machine tool drives
i) Range ratio ii) Number of transmission groups or stages iii) Transmission Range.
2 Draw the structure and gear box diagrams for the following equations of twelve speed gear box
and determine the maximum transmission range for each equation:
i) Z= 2(6) 2(1) 3(2)
ii) Z = 2(3) 2(6) 3(1)
iii) Z = 2(6) 2(3) 3(1)
3 How are preferred number series used in the design of a multispeed gear box
4 A three stage, twelve speed gear box is to be designed for spindle speed varying between 60
r.p.m and 2880 r.p.m The second stage consists of three speed steps.
If the gear box is driven by 5 kW, 1440 r.p.m. electric motor: (i) draw the ray
diagram; (ii) draw the gearing diagram; and (iii) determine the number of teeth on gears. Assume
same module for all gears.
5 What are the various laws for stepped regulation of speeds in multi-speed gear
boxes? State their relative advantages and limitations.
6 Design a 9 speed gear box to give output speeds between 280 and 1800 rpm. The Input power is
5.5 KW at 1400 rpm. Draw the kinematic layout diagram and the speed diagram. Determine the
number of teeth on all gears.
7 Design the layout of a 12 speed gear box for a lathe. The minimum and maximum speeds are 100
and 1200 rpm. Power is 5 KW from 1440 rpm. Draw the speed and kinematic diagram. Also
calculate the number of teeth on all gears.
8 For a load lifting arrangement transmitting 10 KW with electric motor running at 1400 rpm,
constant mesh type speed reducer is required with reduction ratio 12.
Design a suitable arrangement and make a neat sketch.
9 Select speeds for a 12 speed gear box for a minimum speed of 16 rpm and Maximum speed of
900 rpm. Drive speed is 900 rpm. Draw speed diagram and draw kinematic arrangement of the
gear box showing the number of teeth in all the gears.
10 Design a sliding mesh nine speed gear box for a machine tool with speed ranging from 36 rpm to
550 rpm. Draw the speed diagram and kinematic arrangement showing number of teeth in all
gears.
11 An all geared headstock of a lathe requires a 12 speed gear box with minimum and maximum of
110 rpm and 1440 respectively. Draw speed diagram and show the details of number of teeth in
Mechanical System Design (18BTME701) Prof. Ajaykumar Ugale
all the gears in a kinematic layout.

12 A gear box is to be designed with the following specifications:
Power=14.72 KW, number of speeds =18 Minimum speed = 16 rpm, step ratio =1.25
Motor speed = 1400 rpm. The 18 speeds are obtained as 2*3*3
1. Sketch the layout of the gear box.
2. Draw the speed diagram.
13 The minimum and maximum speed of a six speed gear box is to be 160 and 500 rpm. Construct
the kinematic arrangement and the ray diagram of the gear box. Also find the number of teeth of
all gears.
14 Design a 12 speed gear box for an all geared headstock of a lathe. Maximum and minimum
speeds are 600 rpm and 25 rpm respectively. The drive is from an electric motor giving 2.25 KW
at 1440 rpm.
15 What are preferred numbers?
16 What are the possible arrangements to achieve 12 speeds from a gear box?
17 Calculate standard step ratio for six speed gear box with speed ranging between
100 and 560 rpm
18 Select 3 pairs of gears with total teeth for each pair 60 and speed ratio 1, 1.41and 2
19 What is step ratio in gear box?
20 What is meant by ray diagram?
21 Distinguish between structural diagram and speed diagram.
22 What are the methods of lubrication in speed reducers?
23 What are the possible arrangements to achieve 12 speeds from a gear box?
24 What are the points to be considered while designing a sliding-mesh type of Multi speed gear
box?
25 List the ways by which the number of intermediate steps may be arranged in a Gear box
26 Which type of gear is used in constant mesh gear box? Justify
27 Compare sliding mesh and synchronous gear box.
28 Where is multi speed gear boxes employed?
29 Name the series in which speeds arranged in multi-speed gear boxes.
30 Sketch the kinematic layout of gears for 3 speeds between two shafts
31 List six standard speeds starting from 18 rpm with a step ratio 1:4.
32 List out the basic rules to be followed for optimum gear box design
33 What is step ratio? Name the series in which speeds of multispeed box are arranged.
34 Give some applications of constant mesh gear box.
35 Draw the ray diagram for a six speed gear box.
36 What is need of multispeed gearbox in a machine tool or automobile?
37 A multispeed gearbox is to be designed for speed varying from 200 rpm to 2000 rpm.

Recommended series is R5. It is to be driven by a motor running at 2880 rpm. Design the
optimum gearbox considering ‘Symmetric structure diagrams.’
38 Explain and compare different laws of stepped speed regulation.
39 Draw symmetric structure diagrams for following structure formulae and find out optimum
formula out of them along with the justification
2(1) 2(2) 3(4)
2(1) 2(6) 3(2)
2(2) 2(1) 3(4)
40 Prove that ‘Difference between number of teeth on adjacent gears in a change gear block
(compound gear) must be four or more’. Why this condition is applicable only if the compound
gear is a cluster of three gears and not of two gears.

Unit 2: Statistical Considerations in Design
Q. Question
No.
1 A beam of circular cross- section is subjected to pure bending moment M and the bending
stresses are given by the following equations :
𝜎 = 32 𝑀𝑏
𝜋𝑑3
Where d is the diameter of the beam. It has been observed that the diameter (d) of the beam is
a normally distributed random variable with a mean of 50 mm and a standard deviation of
0.125mm. The bending moment (Mb) is also a normally distributed random variable with
mean of 1750 N-m and a standard deviation of 150 N-m. Determine the mean and standard
deviation of the corresponding bending stress variable (𝜎).
Comment on the analysis.
Use the following equations :
2 Explain the factors to be considered while designing the components for castings.
3 A shaft and baring assembly have following dimensions: Shaft – 𝜙 40 ± 0.3 mm with standard
deviation of 0.1mm.Bearing bore – 𝜙 40.5 ± 0.3 mm with standard deviation of 0.1mm.
Find the percentage of assemblies with i) Clearance less than 0.25 mm and ii) Clearance
between 0.25 mm and 0.35mm. Areas under standardized normal distribution curves from -∞
to Z are as under
Assume linear interpolation for values in between.

4 Write a short on man-machine closed loop system. Also clearly highlight the factor which
influence this cycle.

5 With suitable sketches, explain the ergonomic considerations in Design of Displays and
Controls using some practical examples.
6 Define mechanical reliability and find the reliability in operating period of 1000 hrs, for a
device having failure rate of 1*10-6 failures/Hr. If there are 1000 items in the test, how many
failures are expected in 1000 hours.
7 With suitable sketches, explain the DFM principles in the design of casting and forgings.
8 Justify that the Display and Control elements of a music system are designed based on the
ergonomic considerations
9 If a device has failure rate of 40-6 failures/Hr, What is its reliability in 250 hours? If there are
1000 items in the test, how many failures are expected in 250 hours?
10 Write short note on ‘Design for Assembly’.
11 Write short note on : a)Probability b)Stochastic Variable c)Frequency distribution d)Class
Interval
12 With examples, clearly highlight the differences between arithmetic mean, mode and the
median of a sample.
13 Write a note on Gaussian distribution
14 What are statistical considerations for factor of safety?
15 What are basic types of product forms also, what do you understand by the term “Designing
for Appearance”?
16 What are the considerations in the design of controls and in the layout of panels?
17 Discuss advantages and limitations of the different forging processes.
18 Explain briefly the guidelines the designer has to follow to ensure safety in products.
19 Write a short note on the concept of design for manufacture
20 With examples, suggest methods to improve design while manufacturing components by the
process of powder metallurgy
21 A machine member made of plain carbon steel has mean yield strength of 250 Mpa and a
standard deviation of 30Mpa. This member is subjected to a bending stress with a mean of 160
Mpa and a standard deviation of 15 Mpa. Determine :
a) Probability of failure and the reliability of the machine member
b) The minimum factor of safety available
c) The average factor of safety available.
22 A straight bar is made of a material having tensile strength of 310 + 30 Mpa. Diameter of the
bar is 10 + 0.1 mm. load on the bar is expected to be 23.5 + 5 KN. Estimate the reliability of
withstanding the load by the bar.
23 What is mechanical reliability? Explain the folowing terms:
a)Hazard rate
b)MTBF

c)Systm reliability
24 A shaft is subjected to a maximum load of 10KN. The shaft is desined to withsatnd a load of
15 KN. If the maximum load encounterd is normally distributed with a standard deviation of
2.5 KN, and if the shaft strength is normally distributed with standard deviation of 2.0 KN,
what failure percentage would be expected? The area under normal curve from zero to Z as
follows:
Z 1 1.2 1.4 1.6 1.8
Area 0.3413 0.3849 0.4192 0.4452 0.4641
Z 2.0 2.2 2.4 2.6 2.8
Area 0.4771 0.4861 0.4918 0.4953 0.4974
25 It has been observed from a sample of 200 bearing bushes that the internal diameters are
normally distributed with a mean of 30.010 mm and a standard deviation of 0.008 mm. the
upper and lower limits for the internal diameter, as specified by the deisgner are 30.02 and
30.00 mm repectively. Calculate the percntage of rejected bushes

Unit 3: Design of Belt Conveyer System for Material Handling
Q. Question
No.
1. What is the use of following in flat belt conveyor?

1. Scraper
2. Bend Pulleys
3. Tension take up device
4. Snub Pulley
2. Inclined belt conveyor with 200 inclinations is to be used for transporting bulk material with
specific weight 10000 N/m3. Belt width is 1000 mm and belt speed is 2 m/s .If flow factor is
2.5x10-4, find out capacity of conveyor.
3. Explain the capacity of conveyor in Tons/hr.
4. What are the design considerations in selecting the belt speed of conveyor?
5. What are different ergonomic considerations involved in the design of controls.
6. Explain concept of containerization and design considerations.
7. Explain the procedure to estimate the power requirement for belt conveyors.
8. A triple ply belt conveyor is required to transport 2 ton of iron ore per hour through a
distance of 1000m and a height of 300 m. The permissible belt speed is 90m/min. if the mass
density of iron ore is 2.5 ton per cubic meter, determine :
(i) the belt width; (ii) the diameter of drive pulley; and (iii) the reduction ratio of gear
reducer, if electric motor speed is 1440 r.p.m. Use following data:
Flow ability factor ‘k’:
Standard belt widths :

400,450,500,600,650,750,800,900,100,1200,1400,1600,1800,2000 mm material factor for
plies for Capron belt : K1 = 2.0; belt tension and arc of contact factor : K2 =80.
9. A belt conveyor is to be designed to carry bulk material at the rate 300×10 3 kg/hour with the
following details:
Bulk density of the material = 800 kg/m3; Angle of surcharge of bulk material = 15o; Belt
speed = 10 km/hour; Material factor for plies, k1= 2.0; Belt tension and arc of contact factor,
k2 = 63;
Number of plies for the belt = 4 suggest :
i) Suitable width for the belt.

ii) Diameter and length of the drive pulley.

10. What are the design considerations in selecting the belt speed of a conveyor?
11. Determine the belt capacity of a flat horizontal belt, if the effective width of the material on
the belt is ‘b’, belt velocity is ‘v’ and the surcharge angle is 15o.
12. A flat horizontal belt conveyer is used for transporting crushed rock having a mass density of
2 t/m3. The belt is 800 mm wide and has a speed of 1.75 m/s. Determine the capacity of the
conveyer. The surcharge angle may be taken as 25 o. The effective width b (in meters), of the
material carried by the belt safely is given by the following equation:
13. What are the advantages of belt conveyer over others conveyers?
14. Write a note on the following:
a. Hopper based loading
b. Processing unit based loading
c. Head end discharge
d. Both end discharge
15. What are the factors important for conveyer design?
16. Derive the expression for power requirements of belt conveyers.
17. Write a short note on conveyer pulleys.
18. Enlist the basic principles of material handling equipment while selecting of materials?
Write any one in brief.
19. A belt conveyer has a pitch of 0.5 m. If the mass of the belt is 16kg/m and the mass of the
material conveyed is 40kg/m, determine the minimum tension required in the belt, if the sag
is not exceed 2 percent of the pitch.
20. A belt conveyer is to be designed to carry bulk material at the rate 300x103 kg/hour with the
following details:
Bulk density of the material = 800 kg/m3
Angle of surcharge of bulk material = 15o
Belt speed= 10km/hour
Material factor for plies, k1= 2.0
Belt tension and arc of contact factor, k2 = 63
No of plies for the belt = 4
21. How are cranes classified?
22. What are the classes of cranes? On what basis is the class of a particular crane decided?

Unit 4: Design of Cylinders and Pressure Vessels
Q. Question
No.
1. What is meant by pre-stressing of a cylinder? What is its necessity? Explain any one method
of prestressing cylinder
2. A hydraulic cylinder with closed ends is subjected to an internal pressure of 15 Mpa. The
inner and outer diameters of the cylinder are 200mm and 240 mm respectively. The cylinder
material is cast iron FG300. Determine the factor of safety used in design. If the cylinder
pressure is further increased by 50%, What will be the factor of safety?
3. A hydraulic cylinder made of Grey C.I. with 220 mm inside diameter is subjected to internal
pressure of 18MPa.Using appropriate theory of failure find the required thickness of
cylinder with factor of safety 2.0.
4. Explain the various failure modes of pressure vessel.
5. Derive Clavarino’s equation. State its applications.
6. Explain with the help of neat sketches, the different types of formed heads used as end
closures in cylindrical pressure vessels. State their advantages, disadvantages and
applications.
7. The cover of a cylindrical pressure vessel made of cast iron is shown in fig.1 The inner
diameter of the cylinder is 500 mm and the internal pressure is limited to 2MPa. The cover
is fixed to the cylinder by means of 16 bolts with a nominal diameter of 20 mm. Each bolt is
initially tightened with a preload of 20 KN. The bolts are made of steel FeE250 (Syt = 250
N/mm2).
Assume E for steel = 207 KN/mm2, cast iron = 100 KN/mm2 and E for Zinc = 90KN/mm2.
Determine the factor of safety for bolts considering the effect of the gasket.
8. Explain the design of openings in pressure vessels by’ area for method of compensation’
9. A 103 capacity cylindrical pressure vessel with torispherical heads is to be used to store
water at a temperature of 160o C (Water vapour pressure 6.4 bar absolute). The crown and

knuckle radii for the torispherical heads are taken as 0.75 di and 0.125 di respectively. The
shell as well as heads is made of plain carbon steel with allowable tensile stress of 85
N/mm2. The single welded butt joints with backing strips are used to fabricate the vessel.
The total length of the vessel is limited to 5m.
i) Which class vessel is to be used for this purpose?
ii) Determine minimum vessel diameter and the corresponding thickness of the vessel shell.
iii) Determine dimensions of the torispherical head. Assume weld joint efficiency or shell &
head = 0.9
10. An air receiver consists of a cylindrical portion of 2 m length and 1 m diameter. It is closed
by hemispherical ends. The pressure is not to exceed 2 N/mm2. If the material is steel having
yield point 250N/mm2 and if a factor of safety 3.5 is used, calculate the required wall
thickness of the cylinder and the thickness of hemispherical ends. Assume joint efficiency as
0.8 for the shell and 0.9 for the end. Also determine the storage capacity of the vessel.
11. An accumulator is required to store 150 liters of water at a pressure 20MPa. Assuming the
length of the stroke to be 3 m, determine
a. The diameter of the ram
b. The internal diameter of the cylinder, assuming a clearance of 40mm.
c. The thickness of the cylinder, if the permissible stress of the cylinder (made of CI) is
60N/mm2.
12. A thick cylinder of size ø30 x ø60 is subjected to an internal pressure of 75N/mm 2. Plot the
stress distribution in the wall thickness.
13. A high pressure cylinder consists of a steel tube with 20 and 35mm as inner and outer
diameters respectively. It is jacketed by outer steel tube with 50mm outer diameter. The
tubes are assembled by shrinking process in such a way that the maximum principal tensile
stress induced in any tube is resisted to 100MPa. Calculate the shrinkage pressure and
original dimensions of the tube. Sketch the distribution of principal stresses in compound
cylinder.
14. A cylindrical vessel is subjected to an internal pressure of 1MPa. The plate material has
yield strength of 200MPa and a corrosion allowance of 1.5mm. The joints are spot radio
graphed double butt type. The vessel inner diameter is to be 2.3m. Determine the thickness
of the shell. Also find the head thickness if the ends are:
a. Hemispherical
b. Ellipsoidal with k=2
c. Torispherical with knuckle radius= 6% of crown radius which may be assumed as
1.9m
d. Conical, with semi-cone angle α=20o
15. When do use Lame’s equation, Clavarino’s equation and Birnie’s question for cylinder wall
thickness?
16. What is thin cylinder and give practical examples of it?

17. Distinguish between thin and thick cylinders.
18. What do you understand by the term working pressure and design pressure?
19. What are the Class 1, 2 and 3 types of pressure vessels and their uses?
20. What are the objectives of providing openings in pressure vessel?
21. What is joint efficiency?
22. What are the advantages and disadvantages of the following heads of pressure vessels:
a. Hemispherical
b. Semi-ellipsoid
c. torispherical

Unit 5: Design of I.C. Engine Components
Q. Question
No.
1 What is a desirable property of I.C. engine piston material? State the materials used for I.C.
engine piston.
2 The following data is given for a four- stroke diesel engine :
Cylinder bore = 250 mm
Length of stroke = 300 mm
Speed = 600 rpm
Indicated mean effective pressure = 0.6 Mpa, Mechanical efficiency = 80 %, Maximum gas
pressure = 4 Mpa, Fuel consumption = 0.25 kg per BP per hr, Higher calorific value of fuel =
44000 KJ/kg, Assume that 5% of total heat developed in the cylinder is transmitted by the
piston. The piston is made of gray C.I FG 200 (Sut = 200 N/mm2 and K = 46.6 W/m/oC) and
the factor of safety is 5.The temperature difference between the center and the edge of the
piston head is 220oC.
i) Determine the thickness of piston head by strength consideration and thermal consideration.
ii) State whether the ribs are required, IF so calculate the number and thickness of ribs.
iii) State whether a cup is required in the top of piston head, If so calculate the radius of the
cup
3 What is the criterion for design of push rod?
4 Why the connecting rod is made of I sections
5 What are the cooling systems for engine cylinders? Where do you use them?
6 What are the advantages and disadvantages of aluminum piston over cast iron piston?
7 The cylinder of a four-stroke diesel engine has the following specifications
Brake power=3 kw
Speed=800rpm
Indicated mean effective pressure=0.3 Mpa
Mechanical efficiency=80%
Determine the bore and length of the cylinder liner
8 Why piston is made lightweight?
9 Name two criteria for calculating the thickness of piston head
10 Why piston clearance is necessary? What is its usual value?
11 Why do inlet and exhaust valves have conical heads and seats?
12 The cylinder of a four-stroke diesel engine has the following specifications
Cylinder bore= 150 mm
Maximum gas pressure=3 Mpa

Allowable tensile stress=50 N/mm2
Determine the thickness of cylinder wall. Also; calculate the apparent and net circumferential
and longitudinal stresses in cylinder wall.
13 The following data is given for the connecting rod of a diesel Engine.
Cylinder bore = 85 mm
Length of connecting rod = 350mm
Maximum gas pressure = 3 Mpa
Factor of safety against buckling failure= 5
(ℓ/𝑑) ratio for piston pin bearing = (1.5)
(ℓ/𝑑) ratio for crank pin bearing =
(1.25)
Allowable bearing pressure for piston pin bearing = 13Mpa
Allowable bearing pressure for crank pin bearing = 11 Mpa.
length of stroke = 140 mm
Mass of reciprocating parts = 1.5 kg Engine speed = 2000 rpm
Thickness of bearing bush = 3 mm Material of cap = 40 C8 (Syt =380 N/mm2)
Material of bolts=Alloy steel (Syt=450N/mm2)
Factor of safety for cap and bolts = 4 and 5 respectively.
Density of connecting rod = 7800 kg/m3
Determine :
i) Dimensions of the cross-section of connection rod.
ii)Dimensions of small and big and of bearings.
iii) Nominal diameters of bolts for
the cap
iv) Thickness of cap; and
v) Magnitude of whipping stress
14 What are the desirable properties of cylinder materials?
15 What is the function of cup on piston head?
16 The following data is given for the piston of four-stroke diesel engine
Cylinder bore=100mm
Maximum gas pressure=5MPa
Allowable bearing pressure for skirt=0.45 Mpa
Ratio of side thrust on linear to maximum gas load on piston=0.1
Width of top land=18 mm
Width of ring grooves=2.5 mm
Total number of piston rings=3 mm
Calculate
1. Length of skirt
2. Length of piston
17 What is the force on bolts of big end of connecting rod?
18 What is the difference between center and overhung crankshaft?
19 What is the purpose of valve spring?
20 What is the manufacturing method for crankshaft?
21 Why is area of inlet valve port more than that of an exhaust valve?
22 Why is the piston pin located at or above the middle of the skirt length?
23 Name two design criteria for piston pin
24 What are the functions of engine cylinder?
25 What are the forces acting on the connecting rod
26 What is the function of rocker arm? Why is rocker arm made of I section?

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MIT Art Design & Technology University, Pune

MIT School of Engineering, Pune

Unit 1: Design of Machine Tool Gear Box

all the gears in a kinematic layout.

Mechanical System Design (18BTME701) Prof. Ajaykumar Ugale

Mechanical System Design (18BTME701) Prof. Ajaykumar Ugale

Unit 2: Statistical Considerations in Design

Assume linear interpolation for values in between.

Mechanical System Design (18BTME701) Prof. Ajaykumar Ugale

Mechanical System Design (18BTME701) Prof. Ajaykumar Ugale

Area 0.3413 0.3849 0.4192 0.4452 0.4641

Z 2.0 2.2 2.4 2.6 2.8

Area 0.4771 0.4861 0.4918 0.4953 0.4974

Mechanical System Design (18BTME701) Prof. Ajaykumar Ugale

Unit 3: Design of Belt Conveyer System for Material Handling

1. What is the use of following in flat belt conveyor?

Standard belt widths :

Mechanical System Design (18BTME701) Prof. Ajaykumar Ugale

ii) Diameter and length of the drive pulley.

Mechanical System Design (18BTME701) Prof. Ajaykumar Ugale

Unit 4: Design of Cylinders and Pressure Vessels

Mechanical System Design (18BTME701) Prof. Ajaykumar Ugale

16. What is thin cylinder and give practical examples of it?

Mechanical System Design (18BTME701) Prof. Ajaykumar Ugale

Unit 5: Design of I.C. Engine Components

Maximum gas pressure=3 Mpa

Mechanical System Design (18BTME701) Prof. Ajaykumar Ugale

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