Design of Spur Gear

Tutorial No: ____ Date: __________

1. A spur gear having 22 teeth to be made of plain carbon steel 40C8 (Sut=580N/mm2) is
to be mesh with a gear having 88 teeth to be made of grey cast iron FG260
(Sut=260N/mm2).The pinion shaft is connected to 12KW, 1440 rpm electric motor. The
starting torque of the motor is approximately twice the rated torque. The tooth system is
20° full depth involute. The face width is 10 times module for which the load distribution
factor is 1.4. The gear are to be machined to meet the specifications of grade 7 for which
deformation factor is 240 N/mm.
(i) If factor of safety require against bending failure 1.0, design the gear pair by using
6
velocity factor, Velocity factor = 6+𝑣 and Buckingham’s equation for dynamic load.
(ii) If the factor of safety required against pitting failure is 1.5, specify surface hardness.
Y= 0.484 - 2.87/Z,
21 𝑣 (𝑏𝑐+𝐹𝑡𝑚𝑎𝑥)
Buckingham’s equation Fd = Ft +
√21 𝑣 (𝑏𝑐+𝐹𝑡𝑚𝑎𝑥)

K= 0.18(BHN/100)2 for steel pinion and cast iron

Standard module are 4,5,6,8,10,12,16, Service factor=2, Load concentration factor=1.4
2. A pair of spur gear with 20o, full depth involutes teeth needs to be designed.
Input shaft rotates at 800 rpm and receives 6 kW power. Speed reductions of output
shaft by 5 times. Pinion and gear are made of steel with σut= 450 N/ mm2
Service factor is 1.3. The gears are machined to accuracy of grade 10. Assume a pitch
line velocity of 3.6 m/s and FOS is 2. Estimate the module of the gear teeth.
Determine static and dynamic load from Spott’s equation. Specify the surface hardness
of gear teeth assuming that strength in bending is the same as strength in wear.

3. The following data refers to a spur gear pair:

Pinion Gear
Material C-50 Steel C35 Mn75 Steel
Ultimate Strength 700 MPa 600 MPa
BHN 240 225
Pitch Diameter 48 mm 144 mm
No of teeth 24 72 (20 full depth)
RPM 1440 480
Service factor = 1.5 Dynamic load factor = 230 N/mm
Lewis’s form factor Y = Π [0.154 – 0.912/Z]
Velocity factor = 3 / 3 + v
Wear factor = 0.156 [BHN/ 100]2 MPa
Specify the kW capacity of the gear unit.
4. A pair of straight teeth spur gears, having 20° involute full depth teeth is to transmit 12
kW at 300 r.p.m. of the pinion. The speed ratio is 3:1. The allowable static stresses for
gear of cast iron and pinion of steel are 60 MPa and 105 MPa respectively.
Assume the following:
Number of teeth of pinion = 16;
Face width = 14 times module;
Velocity factor (Cv) = 4.5/ (4.5 + v), v being the pitch line velocity in m/s;

Gandhinagar Institute of Technology 3171917 DME

 Tooth form factor Y = [0.912 – (0.154/No. of teeth)].

Determine the module, face width and pitch diameter of gears. Check the gears for
wear; given es = 600 MPa; EP = 200 kN/mm2 and EG = 100 kN/mm2

5. Design a 20° full depth involute spur gear pair using velocity factor and check the
design by Buckingham’s equation for dynamic load with following data:
Power to be transmitted = 8 kW, Pinion speed = 1500 rpm, Gear speed = 500 rpm,
No. of teeth on pinion = 20, Ultimate strength of steel pinion & gear = 600 MPa,
Service factor, Ka = 1.25, Factor of safety = 1.5, Face width = 10 times module,
IS Grade of machining = Grade7, Surface hardness = 400 BHN

6. What is pitting and scoring? Explain the different causes of gear tooth failure and
suggest possible remedies to avoid such failures.

Gandhinagar Institute of Technology 3171917 DME

 Design of Helical Gear

Tutorial No: _____ Date: __________

1. Design a gear pair of helical gear :

Gear Pinion
Material 50C4 60C4
Ultimate Strength MPa 660 750
BHN 241 255
Pressure Angle in degree 20 20
Number in teeth 70 35
Normal module in mm 5 5
Face width in normal plane, mm 50 50
Modulus of elasticity GPa 205 200
Assume service factor 1.5 and factor of safety 3. Check wear and dynamic strength of
Gear. Helix angle is 25°, speed of pinion is 720 rpm.
Material Error 0.02 Error 0.04

Steel 20 Involute 228 456

6
Velocity factor =
6+𝑣

K=(( σes)2 sin(𝜙n)/1.4)(1/Ep+1/Eg) , σes = 2.75(BHN) - 70

Fw = DpbQK/COS2

2. A stock helical gear has normal pressure angle of 20o, a helix angle of 25o, and a
transverse diametral pitch of 6 teeth / in, and has 18 teeth. find:
a) The pitch diameter
b) The transverse, the normal and axial pitches
c) The normal diametral pitch
d) The transverse pressure angle.

3. The following data given for a pair of helical gears made of steel:
Normal module = 4 mm, Face width = 40 mm, No of teeth on pinion = 20,
Pinion speed = 1000 rpm, Centre distance = 132 mm, Normal pressure angle = 20°,
Ultimate strength = 450 MPa, Surface hardness = 300 BHN, Service factor, Ka = 1.5,
Factor of safety = 2.

Determine the power transmitting capacity using velocity factor for dynamic load.

4. A pair of helical gears with pinions 26 teeth and gear 100 teeth supplies power 5 kW at
2000 rpm of pinion (np). Normal pressure angle is 200 and helix angle of teeth is 150.
Both pinion and gears are made of hardened steel with σut = 660 N/mm2. Gears are
finished to the accuracy of grade 8. Assuming service factor = 1.5, factor of safety 1.8,
and pitch line velocity of gears as 10 m/s, determine normal module of gear teeth as per
beam strength. Specify the hardness of the surface of gears if wear strength (Sw) = b*Sb
(beam strength) = 12mn, where b= face width. Check the safety of design as per
Spott’s equation for accuracy of grade 8.

Gandhinagar Institute of Technology 3171917 DME

 Given Error, e (micron) = 16.0 + 1.25Ø,
where Ø = mn + 0.25. Take tooth form factor (Y) =0.351.

𝑒𝑛𝑝 𝑧𝑝 𝑏𝑟1 𝑟2
Use Spott’s equation for Dynamic load (Pd) =
2530√𝑟12 +𝑟22
Where, Zp = virtual number of teeth, r1 and r2 = Pitch circle radius for pinion and
gear respectively.

5. The following data is given for a pair of helical gears made of steel:
Normal module = 5 mm, Face Width = 50 mm, No. of Pinion Teeth = 30,
No. of Gear Teeth = 60, Centre distance = 245 mm, Normal Pressure angle =20,
Pinion speed = 1000 r.p.m, surface hardness = 300 BHN, FOS = 2,
Service Factor = 1.5, Grade of machining = 8, Tooth form factor (Y) = 0.385,
Permissible σb for pinion and gear material = 150N/mm2.
Determine:
a) Helix angle
b) Beam strength
c) Max. static load that gear can
d) Power transmitting capacity

Gandhinagar Institute of Technology 3171917 DME

 Design of Bevel Gear

Tutorial No: _____ Date: __________

1. It is required to design a pair of bevel gears, which are mounted on shafts

intersecting at right angles. The pinion receives 20 kW power through its shaft and
rotates at 720 rpm. The number of teeth on pinion and gear are 30 & 45
respectively. The pressure angle is 20° full depth teeth form. The gears are made of
plain carbon steel with permissible bending stress as 200 MPa. The gears are case
hardened and the surface hardness is 300 BHN. Take service factor = 1.25.

2. A pair of high grade cast iron bevel gears having shaft at right angle are to have an
angular velocity ratio of driver to driven of 2 to 3. The driver is to rotate at 175
rev/min and is to transmit 10 KW. It is 0.4 meter in pitch diameter. Take the width of
face as about one third of the length of pitch element and determine the pitch of the
gear. Assume 24 hours/day operation.
6 0.912
Velocity factor Cv = , Levis factor = Y = 0.154 -
6+𝑣 𝑁𝑜.𝑜𝑓 𝑡𝑒𝑒𝑡ℎ
Beam strength = fef m Y (1-F/L)
High grade cast iron fef = 84 MPa, fes for cast iron =630 MPa, Ep = Eg= 105 GPa.

3. Two shafts at right to each other are connected by a bevel pair having full depth
involute teeth. The pinion having 20 teeth transmits 40 kW at 750 rpm to gear shaft
running at 375 rpm. Take allowable static stress for pinion and gear materials 100
N/mm2 and 70 N/mm2 respectively. Determine module, pitch diameters and face
width from strength considerations.

4. A pair of straight bevel gears, manufactured by generation, consists of 14 teeth

pinion meshing with 85 teeth gear. The module at large end is 5.5 mm while the
face width is limited to 0.25 times the slant height. The pinion is made of steel
having ultimate tensile strength is 750 N/mm2 and surface hardness of 210 BHN.
The gear is made of cast iron having ultimate tensile strength 260 N/mm2 and
surface hardness of 210 BHN. The shaft angle is 90°. If the pinion rotates at 750
rpm, estimate the power that gear pair can transmit.

5. Design a pair of bevel gears for two shafts whose axes are at right angles. Speed of
pinion shaft is 240 rpm and that of gear shaft is 120 rpm. Power at gear shaft is 75
kW.

Gandhinagar Institute of Technology 3171917 DME

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Gandhinagar Institute of Technology 3171917 DME

 Design of Worm Gear

Tutorial No: _____ Date: __________

1. A speed reducer unit is to be designed for an input of 5 kW with a transmission ratio

of 25. The speed of the hardened steel worm is 1750 rpm. The worm wheel is to be
made of chilled bronze. The tooth form is to be 20° full depth involute. Assume
double start worm. Design a worm and worm wheel.

2. The speed reducer unit is to be designed for an input of 2 kW at 1600 rpm. The
velocity ratio is 25. The worm is to be made of hardened steel and the gear of
phosphor bronze having a static stress of 70 MPa. The approximate distance between
6
two shaft is 120 mm. Take velocity factor Cv = and tooth form factor
6+𝑣
0.912
Y = 0.154 - and wear factor is 0.7. Find (i) standard module of gear
𝑍𝑔
(ii) Face Width of the gear & length of worm (iii) Check the design for wear load.

3. A speed reducer unit is to be designed for an input of 1.1 kW with transmission ratio
27. The speed of hardened steel worm is 1440 rpm. The worm wheel is to be made
from phosphor bronze. The tooth form is to be 20° involute. Take center distance
between worm and worm wheel = x =100 mm.
Pitch circle diameter of worm = x0.875/1.416, worm is double start.
6 0.912
Cv = , Form factor y = 0.154 -
6+𝑣 T
Allowable stress for phosphor bronze = 84 MPa, flexural endurance limit for
phosphor bronze = 168 MPa, load stress factor = k = 0.55. Check for
(a) Tangential load- power transmitted due to tangential load, (b) Dynamic load,
(c) Static load or endurance strength, (d) Wear load, and (e) Heat dissipation.

4. A triple threaded worm rotating at 1200 r.p.m. drives a worm gear having 36 teeth
and transmits 15 KW power. The teeth are of 20° full depth involute profile. The axial
pitch of the worm is 30 mm and pitch diameter of 60 mm. The co-efficient of friction
is 0.03.
Calculate:
(a)Helix angle of worm
(b) Speed ratio
(c) Centre distance between two shafts
(d) Apparent stress in the worm gear
(e) Efficiency of drive

Gandhinagar Institute of Technology 3171917 DME

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Gandhinagar Institute of Technology 3171917 DME

 Design of Gearbox

Tutorial No: _____ Date: __________

1. Draw the ray and speed diagram for a nine speed gear box if the transmission
range ration violation does not occur with the preferred structure equation.
z = 3(1)3(3)

2. Draw the structure and speed diagram for a gear box having operating speed
range from 56 rpm to 1000 rpm. Use R4 series, with standard spindle speed. The
gear box is connected to a motor driven by a pair of pulleys. Assume the
motor speed to be 1440 rpm. Draw the gear box layout diagram.

3. Design (draw only structural diagram and speed chart ) a speed gearbox for the following
specifications for a head stock of a lathe machine:
Motor Power = 10 Kw;
Gearbox input shaft speed = 500 r.p.m.
Maximum speed = 630 r.p.m.;
Minimum speed = 100 r.p.m.
No. of step = 9

4. Design a two stage six speed gear box having 250 rpm minimum speed and 800 rpm
maximum speed. The gear box is connected to a 1440 rpm electric motor through a belt
drive. The speed at input shaft of gear box is 800 rpm.

5. A 3 stage 12 speed gearbox is to be used in machine tool for spindle speeds ranging
between 25 rpm and 1500 rpm. The second stage of gear box consists of three speed
steps. If the gear box is driven by 3.7 kW, 750 rpm electric motor through the belt
drive:
(a) Draw the ray diagram
(b) Select diameter of pulley for belt drive
(c) Determine the maximum torque acting on all shafts

Gandhinagar Institute of Technology 3171917 DME

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Gandhinagar Institute of Technology 3171917 DME

 Design of Journal Bearing

Tutorial No: _____ Date: __________

1. A full journal bearing of 50 mm diameter and 100 mm long has a bearing pressure of
1.4 N/mm2. The speed of journal is 900 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 77o C may taken as 0.011 kg/m-s. The room
temperature is 35° C. Find:
The amount of artificial cooling required
The mass of lubrication oil required, if the difference between the outlet and inlet
temperature of the oil is 10° C.
Take Specific heat of the oil as 1850 J/kg°C.

2. The following data is given for a 360 O hydrodynamic bearing:

Radial Load = 10 kN, L/D ratio = 1
Radial Clearance = 20 microns
Specific Gravity of Lubricants = 0.86
Specific Heat of Lubricant= 2.09 kJ/kg°C.
Journal Speed = 1450 r.p.m.
Bearing Length = 50 mm
Eccentricity = 15 microns
Calculate:
a) The minimum oil-film thickness
b) The coefficient of friction
c) The power lost in friction
d) The viscosity of lubricant in cP
e) The total flow rate of lubricant in l/min
f) The side leakage
g) The average temperature, if make-up oil is supplied at 30 °C

3. The following data is given for the hydrostatic step bearing:

Thrust Load = 450 kN
Shaft Speed = 450 r.p.m.
Shaft Diameter = 400 mm
Recess Diameter = 250 mm
Viscosity of lubricant = 30 cP
Specific Gravity of Lubricant = 0.86
Specific heat of Lubricant = 2 kJ/kg°C
Calculate:
a) The optimum oil-film thickness for minimum power loss
b) The frictional power loss
c) The pumping power loss
d) The temperature rise, assuming the total power loss in bearing is connected

Gandhinagar Institute of Technology 3171917 DME

 into the frictional heat.
Show the variation of power loss against the oil-film thickness.

4. Design a journal bearing for a centrifugal pump from the following data :
Load on the journal = 20 000 N
Speed of the journal = 900 r.p.m.
Type of oil is SAE 10; for which the absolute viscosity at 55°C = 0.017 kg/m-s;
Ambient temperature of oil = 15.5°C ;
Maximum bearing pressure for the pump = 1.5 N / mm2.
Also calculate mass of the lubricating oil required for artificial cooling, if rise of
temperature of oil be limited to 10°C.
Heat dissipation coefficient = 1232 W/m2/°C.

5. A 150 mm diameter shaft supporting a load of 10 kN has a speed of 1500r.p.m.

The shaft runs in a bearing whose length is 1.5 times the shaft diameter.
If the diametrial clearance of the bearing is 0.15 mm and the absolute viscosity of
the oil at the operating temperature is 0.011 kg/m-s, find the power wasted in
friction.

Gandhinagar Institute of Technology 3171917 DME

 Selection of Rolling Contact Bearing

Tutorial No: _____ Date: __________

1. A shaft rotating at constant speed is subjected to variable load. The bearings supporting
the shaft are subjected to stationary equivalent radial load of 3 kN for 10 per cent of time,
2 kN for 20 per cent of time, 1 kN for 30 per cent of time and no load for remaining time
of cycle. If the total life expected for the bearing is 20 × 106 revolutions at 95 per cent
reliability, calculate dynamic load rating of the ball bearing.

2. Select a single row deep groove ball bearing for a radial load of 4000 N and an axial load
of 5000 N, operating at a speed of 1600 r.p.m. for an average life of 5 years at 10 hours
per day. Assume uniform and steady load.

3. A single row angular contact ball bearing number 310 is used for an axial flow
compressor. The bearing is to carry a radial load of 2500 N and an axial or thrust load of
1500 N. Assuming light shock load, determine the rating life of the bearing.

4. Select a single row deep groove ball bearing with the operating cycle listed below, which
will have a life of 15 000 hours.

Fraction of Radial Thrust Speed Service

Type of load
cycle (N) (N) (R.P.M.) factor

1/10 Heavy shocks 2000 1200 400 3.0

1/10 Light shocks 1500 1000 500 1.5

1/5 Moderate shocks 1000 1500 600 2.0

3/5 No shocks 1200 2000 800 1.0

Assume radial and axial load factors to be 1.0 and 1.5 respectively and inner race
rotates.
5. A deep-groove ball bearing having bore diameter of 60 mm and rotating at 1440 r.p.m.
is subjected to a radial force of 2500 N and an axial force of 1200 M. The radial and
thrust factors are 0.56 and 2.0 respectively. The load factor is 1.2. If the expected rating
life is 25,000 hours, calculate the required basic dynamic capacity of the bearing.

Gandhinagar Institute of Technology 3171917 DME

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Gandhinagar Institute of Technology 3171917 DME

 Design of IC Engine Components

Tutorial No: _____ Date: __________

1. Following data refer to a 4-stroke petrol engine:

Brake power=7.5 KW,
Indicated mean effective pressure=0.45 N/mm2,
Maximum explosion pressure=3.2 N/mm2,
Mechanical efficiency = 80%,
Allowable stress for C.I. cylinder = 40 MPa,
Allowable stress for Ni-steel bolt = 70 N/mm2.
Find:
a) Bore and Stroke of engine taking L/D=1.25,
b) Thickness of cylinder wall and flange,
c) Size and number of bolts required to join the cylinder head.

2. Design a cast iron piston for a single acting four stroke diesel engine for following
data:
Cylinder bore = 100 mm,
Stroke = 125 mm,
Pmax = 5.8 N/mm2,
Pmean = 0.8 N/mm2,
ƞm = 85 %, Speed = 1500 rpm,
Fuel consumption = 0.16 kg/BP/hr,
H.C.V. = 40 x 103 kJ/kg,
Constant C = 0.05,
K = 46.6 W/m/°K,
σt (C.I.) = 30 N/mm2
For piston: μ = 0.1, Pb = 0.45 N/mm2
For piston rings: pw = 0.030 N/mm2, σt = 80 N/mm2
For piston pin: Pb = 20 N/mm2, σb = 120 N/mm2, τ = 60 N/mm2.

3. Design a connecting rod for a 4 - stroke petrol engine from the following data:
Cylinder bore = 100 mm
Stroke length = 140 mm Engine
Speed = 1500 rpm
Possible over speed of engine = 2500 rpm
Maximum explosion pressure = 2.5 MPa
Weight of reciprocating parts = 18.5 N
Length of connecting rod = 315 mm
Yield strength of connecting rod material = 320 MPa
Factor of safety = 5
Permissible bearing pressure for big end = 12.5 MPa
Permissible bearing pressure for small end = 15 MPa

4. Design a plain carbon steel centre crankshaft for a single acting four stroke, single
cylinder engine for the following data:
Piston diameter = 250 mm; Stroke = 400 mm;
Maximum combustion pressure = 2.5 MPa;
Weight of the flywheel = 5 kg;

Gandhinagar Institute of Technology 3171917 DME

 Total belt pull = 100 N;
Length of connecting rod = 950 mm.
The flywheel is used as a pulley.

When the crank has turned through 30° from top dead centre, the pressure on
the piston is 1 MPa and the torque on the crank is maximum.

Any other data required for the design may be assumed.

5. Design the various components of a valve gear mechanism for a horizontal gas
engine with the following data:
Diameter of port is 70 mm, its weight is 5 N, and its lift is 25 mm.
The maximum combustion pressure is 4.5 MPa.
The valve opens 33° before O.D.C. and closes 1° after I.D.C. and it is to open
with constant acceleration and deceleration for each half of the lift. The gas
pressure in cylinder when the exhaust valve start to opens is 0.34 N/mm2.
The pressure on the top side of the valve may be taken as 0.1 N/mm2 absolute
and the greatest suction pressure is 0.035 N/mm2 below atmospheric. The
engine runs at 350 rpm. The effective length of each arm of the rocker lever is
175 mm and the included angle is 140°.

Gandhinagar Institute of Technology 3171917 DME

 Design of Crane Components

Tutorial No: _____ Date: __________

1. A single point hook is made from a 50 mm M.S. bar with 84 mm bed diameter. Calculate
the safe load that can be taken by this hook, if the design permissible stress is limited to
160 MPa. If the hook section is changed to trapezoidal section from triangular section
for the same bar what will be the change in load carrying capacity?

2. Design a single rope drum to transmit a torque of 8 kN.m with a 32 mm rope. Assume
the height of the load to be raised as 2.7 meter and the ratio of the pulley system as 2.
The mean diameter of the drum is 576 mm. Assume the drum to be made of Grey cast
iron, grade 20 having allowable shear strength of 33 MPa. Make a neat sketch of the
arrangement.

3. Select the ropes, pulley and drum for an overhead travelling crane with a lifting
magnet.
Lifting capacity = 5000 kg (mass)
Weight of lifting magnet = 200 kg
(mass) Weight of lifting tackle = 120
kg (mass) Lifting height = 8 m
No. of rope parts = 4

Gandhinagar Institute of Technology 3171917 DME

 4. Design a crane hook for lifting capacity of 5 tonnes. It is made from forged steel and
has triangular section. Take permissible tensile stress 80 N/mm2. Use data design
book to standardize the dimension of hook.

5. Why trapezoidal section is used in hook? Draw neat sketch of single hook and
also mention its critical section.

6. What do you understand by 6 x 37 ropes? Explain with neat sketch the different
rope section?

Gandhinagar Institute of Technology 3171917 DME