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+
+
+
= 3359 mm
Selection of various modification factors. - 2 marks
Correction factor for length =F
c
= 0.99
Service factor = F
a
=1.3
Arc of contact =
0 0
60 180
,
_
C
d D
= 134.6
0
Arc of contact factor = 0.88
Calculation of maximum power capacity - 2 marks
KW =
S S
d
S
e
) 10 34 . 2
7 . 142
47 . 1 (
2 4 09 . 0
= 7.129.
Determination of number belts - 3 marks
d c
a
b
F F KW
F P
n
= 4 belts.
Calculation of actual centre distance - 2 marks
432 . 439
8 4
,
_
+
d D L
A
48050 8 / ) (
2
d D B
3 . 820
2
+ B A A C
2
Actual centre distance = 820.3 mm.
OR
11(b) Design of wire rope:
Given: Load = 32 kN; weight of crane hook = 6 kN; g = 1.2 m/s
2
Selection of FOS: For Crane application, FOS = 6. 1 mark
Selection of wire type: 6 x 37 1 mark
Dead weight on the rope = 38 kN.
Design Load = 456 kN 2 marks
Determination of c/s area of wire A =
u
d
P
= 268 mm
2
Determination of wire diameter, d = 8.3 mm 10 mm. 4
marks
Wire Specification: 2 marks
Type: 6 x 37
Wire diameter = 10 mm
Approximate weight of wire = 4.5 N/m
Breaking strength = 68 kN
Determination of actual FOS:
i. During normal working: - 3 marks
Calculation of bending load:
xE
D
d
Ax F
w
b
min
= 4.86 kN
Total load applied = 42.86 kN
FOS = Breaking strength / Total load = 68/42.86 = 1.59 < FOS)selected
Hence Design is safe.
ii. During Acceleration: - 3 marks
Force due to acceleration: Fa =
0
g
g
x F
t = 4.64 kN
Total load applied = 47.51 kN
FOS = Breaking strength / Total load = 68/47.51 = 1.43 < FOS)selected
Hence Design is safe.
3
12(a) Design of Spur gear:
Given: N
1
= 1440 rpm; N
2
= 480 rpm; Z
1
= 25; Material: C45 steel
Power is not given in the problem. Hence the problem is solved with the assumption
of P = 1 kW
1) Selection of material: - 1 mark
C45 steel
Core hardness < 350 BHN
2
720
mm
N
u
2
360
mm
N
y
2) Calculation of design stresses - 2 marks
[ ]
1
4 . 1
nK
K
bl
b
Where
50 ) ( 25 . 0
1
+ +
y u
= 119.5
2
mm
N
[ ]
2
740 .
mm
N
K HRC C
cl R c
3) Centre distance calculation - 4 marks
[ ]
[ ]
3
2
.
74 . 0
) 1 (
,
_
1
]
1
+
i
M E
i a
t
c
mm a 56 . 22
4) Calculation of module - 3 marks
[ ]
[ ]
3
1
26 . 1
Z y
M
m
m b
t
m 5.89 mm = 6 mm.
Adopt m = 6, Revise a
( )
2
2 1
z z m
a
+
= 300 mm
5) Calculation of Gear geometries - 2 marks
Pinion Diameter, d = 125 mm
Wheel diameter, D = 375 mm
Number of teeth in pinion, Z
1
= 25
Number of teeth in Wheel, Z
2
= 75
Face width of the gear b = 90 mm
6) Revise Design Torque
[ ]
t
M
- 1 mark
[ ] Nm M k k k M
t d o t
130 . . .
4
7) Check for induced stresses - 3 marks
( )[ ]
[ ]
b
t
b
amby
M i
<
+
1
2 2
5 . 119 58
mm
N
mm
N
<
[ ] [ ]
c t c
M E
ib
i
a
i
<
,
_
+ +
.
1 1
74 . 0
2 2
740 3 . 631
mm
N
mm
N
<
Hence the design is safe.
OR
12(b) Design of Helical gear:
Given: P = 30 kW; i = 4; N
1
= 2000 rpm; Material: 15 Ni2CrlMol5 steel
1) Selection of material - 1 mark
Both Pinion & Gear : 15 Ni2CrlMol5 steel
2 2
600 , 950
mm
N
mm
N
y u
2) Calculation of design stresses - 2 marks
[ ]
1
4 . 1
nK
K
bl
b
Where
1200 ) ( 35 . 0
1
+
u
= 894.5
2
mm
N
[ ]
2
1705 .
mm
N
K HRC C
cl R c
3) Centre distance calculation - 4 marks
[ ]
[ ]
3
2
.
7 . 0
) 1 (
,
_
1
]
1
+
i
M E
i a
t
c
mm a 48 . 39
4) Calculation of module - 3 marks
[ ]
[ ]
3
1
15 . 1
Z y
M
Cos m
m b v
t
n
n
m
2.22 mm = 2.5 mm.
Corrected number of teeth
( ) 1
2
1
+
i m
aCos
Z
n
=20
Adopt m = 2.5mm, Revise a
( )
2
2 1
z z m
a
n
+
= 125 mm
5
5) Calculation of Gear geometries - 2 marks
Pinion Diameter, d = 50 mm
Wheel diameter, D = 200 mm
Number of teeth in pinion, Z
1
= 20
Number of teeth in Wheel, Z
2
= 80
Face width of the gear b = 37.5 mm
6) Revise Design Torque
[ ]
t
M
- 1 mark
[ ] Nm M k k k M
t d o t
2 . 171 . . .
7) Check for induced stresses - 3 marks
( )[ ]
[ ]
b
v n
t
b
by am
M i
<
+
1
7 . 0
2 2
5 . 895 2 . 127
mm
N
mm
N
<
[ ] [ ]
c t c
M E
ib
i
a
i
<
,
_
+ +
.
1 1
7 . 0
2 2
1705 15 . 310
mm
N
mm
N
<
Hence the design is safe.
13(a) Design of Bevel gear:
Given : P = 16.5 kW; N
1
= 500 rpm; N
2
= 200 rpm
1) Selection of material: - 1 mark
C45 steel with Case hardened
Core hardness > 350 BHN
2
720
mm
N
u
2
360
mm
N
y
2) Calculation of design stresses - 2 marks
[ ]
1
4 . 1
nK
K
bl
b
Where
50 ) ( 25 . 0
1
+ +
y u
= 186.5
2
mm
N
[ ]
2
740 .
mm
N
K HRC C
cl R c
3) Determination of Cone radius R - 4 marks
( )[ ]
[ ]
mm
i
M E
i R
t
c y
y
56 . 55
5 . 0
72 . 0
1
2
2
,
_
,
_
4) Determination of
t
m
- 2
marks
6
[ ]
[ ]
3
1
26 . 1
Z y
M
m
m b v
t
av
4.23 mm
Using,
( ) 5 . 0
y
y
av t
m m
= 5 mm
5) Revise R and find b. - 2 marks
Using mm z i m R
t
7 . 134 . 1 5 . 0
1
2
+
mm
R
b 9 . 44
3
6) Calculate
av av
d m
1
,
and pitch line velocity - 2
marks
mm
R
b R
m m
t av
17 . 4
5 . 0
,
_
mm m z d
av av
33 . 83
1 1
Pitch line velocity,
s
m
n d
V
av
18 . 2
1000 * 60
1 1
7) Revise k,
d
k
and
[ ]
t
M
- 1
mark
K=1.1
1
d
k
.4, for class 8 gears, V= 2.18 m/s,
[ ] Nm M
t
8 . 450
8) Check for induced stresses - 2 marks
( )
[ ]
2
2
2
1
3
2
740 34 . 263 .
1
5 . 0
72 . 0
mm N
mm
N
M E
ib
i
b R
t c
<
1
1
]
1
,
_
[ ]
( )
2 2
2
2
5 . 186 78 . 143
. 5 . 0
1
mm
N
mm
N
y m b b R
M i R
v av
t
b
<
+
Hence the design is safe.
OR
13(b) Design of Worm gear:
Given : P = 20 kW; Worm speed = 1440 rpm; i = 24
1) Selection of materials - 1 mark
a) Worm - steel
b) Wheel bronze (sand cast)
7
[ ]
2
2
/ 50
/ 390
mm N
mm N
b
u
<
= 326 mm
3) Calculation of axial module - 2 marks
( ) z q a m
x
+ / 2
= 10mm
4) Revise a and obtain d
1
- 2 marks
( )
mm qm d
mm z q m a
x
x
110
415 5 . 0
1
+
5) Revise k, k
d
and
[ ]
t
M
for actual pitch line velocity of the wheel. - 2
marks
1000 60
1440
2
a
zp
V
=2.2 m/s
6) Determination of induced stresses - 2 marks
( ) [ ]
10
1 /
/
540
3
t
c
M
a
q z
q z
1
]
1
+
= 127 N/mm
2
[ ]
v x
t
b
qzy m
M
3
9 . 1
= 50 N/mm
2
7) Efficiency - 2 marks
( )
tan
tan
8
= 0.847 = 85 %
8) Determination of Housing area - 2 marks
( ) 1 Input power = K
t
(t
o
-t
a
) A
A= 8.6 m
2
Calculation of Heat generated, H
g
= 3 kW
Calculation of Heat dissipated, H
d
= 73.44kW
Since H
d
> H
g
, No external cooling is required
14(a) Design of 9 speed gear box:
Given: N = 9; N
min
= 100 rpm;
= 1.25; P = 4 kW; N
motor
= 1400 rpm;
Using, N
max
/ N
min
=
1 9
25 . 1
,
The speeds are 100, 125, 160, 200, 250, 315, 400, 500, 630 rpm. 2 marks
Construction of Ray diagram - 5 marks
Construction of kinematic arrangement - 5 marks
Calculation of number of teeth & % of error - 6 marks
Between Input & Intermediate Shaft:
Using Z
1
+Z
2
= Z
3
+Z
4
= Z
5
+ Z
6
= 94 & Speed ratio,
Determination of Z
1
= 19; Z
2
= 75; Z
3
= 34; Z
4
= 60; Z
5
= Z
6
= 47
Between Output & Intermediate Shaft:
Using Z
7
+ Z
8
= Z
9
+ Z
10
= Z
11
+ Z
12
= 50
Determination of Z
7
= 22; Z
8
= 28; Z
11
= 28; Z
12
= 22; Z
9
= Z
10
= 25
Output speed & % of error calculation
Speed
Number
Output speed Standard
speed
% error
1 99.7 100.0 0.30
2 125.6 125.0 -0.48
3 158.3 160.0 1.063
4 198.4 200.0 0.80
9
5 250.0 250.0 0.0
6 315.0 315.0 0.0
7 396.8 400.0 0.80
8 500.0 500.0 0.0
9 630.0 630.0 0.0
The permissible deviation =
( ) % 5 . 2 % 1 10 t
The deviations are well within the permissible limits.
OR
14(b) Design of 12 speed gear box:
Given: N = 12; N
min
= 16 rpm; N
max
= 900 rpm.
Calculation of speed ratio, N
max
/ N
min
=
900/16 =
1 12
,
= 1.44 - 2
marks
The speeds are
16, 22.4, 31.5, 45, 63, 90, 125, 180, 250, 355, 500, 710 rpm - 2 marks
Construction of Ray diagram - 6 marks
Construction of kinematic arrangement - 6 marks
Calculation of number of teeth - 4 marks
10
Between Input & Intermediate Shaft1:
Using Z
1
+Z
2
= Z
3
+Z
4
= 76 & Speed ratio,
Determination of Z
1
= 20; Z
2
= 36; Z
3
= 20; Z
4
= 36;
Between Intermediate shaft1& Intermediate Shaft2:
Using Z
5
+ Z
6
= Z
7
+ Z
8
= 76 & Speed ratio,
Determination of Z
5
= 26; Z
6
= 56; Z
7
= Z
8
=38
Between Output & Intermediate Shaft2:
Using Z
9
+ Z
10
= Z
11
+ Z
12
= Z
13
+ Z
14
= 70 & Speed ratio,
Determination of Z
9
= 29; Z
10
= 42; Z
11
= 35; Z
12
= 35; Z
13
= 29; Z
14
= 41
15(a) Design of Clutch:
Given:
Case 1: n
1
= 3; n
2
= 2; Number of contacts = 4; d
o
= 240 mm; d
i
= 120 mm;
=0.3;
Uniform pressure; P = 25 kW; N = 1575 rpm.
Case2: Number of springs = 6; k = 13kN/m; = 1.25 mm.
Case1:
Using Power equation, determination of Torque transmitted,
T = 151.5 N-m 2 marks
Determination of mean radius R =
1
]
1
2
2
2
1
3
2
3
1
3
2
r r
r r
= 93.3 mm 3 marks
11
Determination of total spring load W =
R n
T
= 1353 N 3
marks
Case2:
Determination of axial load = 573 N 2 marks
Determination of mean radius R = 0.09m 2 marks
Determination of torque transmitted, T = 62 N-m 2 marks
Determination of Power transmitted = 10.23 kW. 2 marks
OR
15(b) Design of Cam:
Given: Type of motion : UAR;
R O
= 60
0
;
D
= 20
0
; S = 37.5 mm; R = 50 mm;
r = 25 mm
Construction of displacement diagram - 3 marks
Construction of cam profile - 9 marks
Determination of maximum velocity during outstroke = 71.62
mm/sec 1
mark
Determination of maximum velocity during return stroke = 71.62
mm/sec 1
mark
Determination of maximum acceleration during outstroke = 136.78
2
mm/sec
2
1 mark
Determination of maximum acceleration during return stroke = 136.78
2
mm/sec
2
1 mark
12