KUMARAGURU COLLEGE OF TECHNOLOGY, COIMBATORE

Department Of Mechanical Engineering

Design of Transmission Systems
QUESTION BANK

UNIT-I DESIGN OF TRANSMISSION SYSTEMS FOR FLEXIBLE ELEMENTS

Selection of V belts and pulleys – selection of Flat belts and pulleys - Wire ropes and pulleys –
Selection of Transmission chains and Sprockets. Design of pulleys and sprockets.

PART-A
BELT DRIVES
1. State the law of belting.
1. How a V-Belt section is selected?
2. State the significance of belt length correction factor and angle of wrap correction factor while
designing belt drive.
3. Brief the term “Crowning of Pulley”. Why it is provided?
4. List the factors influences the coefficient of friction between belt and pulley.
5. Why belt, wire rope and chain drives are called as flexible transmission systems?
6. List out various important factors upon which the selection of a belt drive depends.
7. Name the different types of belt drives.
8. Tell the materials used for belt drives.
9. Infer the different types of flat belt drives.
10. State the significance of quarter turn belt drive.
11. Give any two application of cone pulley belt drive.
12. Define slip and creep in belt drives.
13. Illustrate ‘fast and loose pulley’ with the help of a neat sketch.
14. State the Advantages and Disadvantages of V-belt Drive over Flat Belt Drive.
15. In what ways the timing belts are preferred to ordinary V-belts?

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16. Sketch the cross-section of a V-belt and label its important parts.
17. Derive the relation for the ratio of driving tensions of a V-belt.
18. What is the effect of centrifugal force in belt drive?

WIRE ROPE
1. List the advantages of wire rope drives.
2. How the wire ropes are classified.
3. Enumerate standard designation of ropes and their applications.
4. How do you designate 6x19 wire rope?
5. State the stresses induced in wire rope.
6. Distinguish regular lay and long lay ropes.

CHAIN DRIVES
1. State the advantages and Disadvantages of Chain Drive over Belt and Rope Drive.
2. Mention the important parts in chain.
2. What do you understand by simplex, duplex and triplex chains?
3. What is chordal action (Polygonal action) in chain drive?
4. What do you mean by galling of roller chains?
5. In what way silent chain is better than ordinary driving chain?
6. Odd number of teeth is preferred for chain-sprocket drive. Why?
7. How does a hosting chain differs from roller chain?

PART-B
BELT DRIVES
1. A leather belt drive should be designed to transmit 15 kW power. The driver and the driven
pulleys run at 1440 rpm and 480 rpm respectively. The centre distance between the pulleys is twice
the diameter of the bigger pulley. The belt should operate at a velocity of 20 m/s approximately
and the stresses in the belt should not exceed 2.25 N/mm 2. The density of the leather is 0.95 g/cc

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and the coefficient of friction is 0.35. The thickness of the belt is 5 mm. Calculate the diameters
of the pulleys, length & width of the belt and the belt tensions.
2. A V-belt drive is to transmit 45 kW in a heavy duty saw mill which works in two shifts of 8
hours each. The speed of motor shaft is 1400 rpm with the approximate speed reduction of 3 in the
machine shaft. Design the drive and calculate the average stress induced in the belt.
3. Select a flat belt to drive a mill at 250 rpm from a 10 kW, 730 rpm motor. Centre distance is to be
around 2000 mm. the mill shaft pulley is of 1000 mm diameter.

4. Calculate the power capacity of the leather belt of 9mm x 250mm is used to drive a CI pulley
900mm in diameter at 336rpm. If the active arc on the smaller pulley is 120° and stress in tight side is
2 Mpa. The density of the leather may be taken as 980 kg/m3 and coefficient of friction of leather on
CI is 0.35.

5. Design a flat belt drive for a fan running at 360rpm which is driven by a 10 KW at1440 rpm motor.
The belt drive is open type and the distance between the pulley Centers is 2000 mm. The diameter of
a driven pulley is 1 m.

6. Design a flat belt drive to transmit 20kW at 720rpm. The center distance is 3m and the speed ratio
is 3. Diameter of rolling pulley is 1.2 m.

7. Design a flat belt drive to transmit 15 KW at 480rpm from an engine to line shaft at 1200 rpm. The
center distance between the pulleys is 2 m .The diameter of engine pulley is 600 mm.

8. A flat belt drive is required to transmit 12 KW from a motor running at 720 rpm. The belt is 12 mm
thick and has mass density of 0.001 gm/mm3. Permissible stress in the belt not to exceed 2.5 N/mm2.
Diameter of driving pulley is 250 mm whereas the speed of driven pulley is 240 rpm. The two shafts
are 1.25 m apart, coefficient of friction is 0.25. Determine the width of the belt.

9. Design a suitable V-belt for a centrifugal pump running at 340 rpm is to be driven by 100 KW motor
at 1440 rpm. The drive is to work at least 20 hours every day. Centre distance is 1.2 m.

10. Design a V-belt drive to transmit 10 kW at 400 rpm. The speed ratio is 3. Centre distance between
the pulleys is 600 mm and the drive is crusher.

11. Design a V-belt drive and calculate the actual belt tension and average stress for the following
data. Driven pulley diameter, D= 500 mm, driver pulley diameter, d=150 mm, center distance C=925
mm, speed N1 = 1000 rpm, N2 = 300 rpm and power, P = 7.5kW.

12. Select a V-belt drive for 15 KW, 1440 rpm motor, which drives a centrifugal pump running at a
speed of 576 rpm for a service of 8-10 hours per day. The distance between the driver and the driven
shaft is approximately 1.2 m. service factor, Ks = 1.1, design factor Na = 1.0, V R = 2.5.

13. Design a V-belt drive to the following specifications: Power to be transmitted 75 kW, Speed of
driving wheel is 1440 rpm, Speed of driven wheel is 400 rpm, Diameter of driving wheel is 300 mm,
Center distance is 2500 mm, and Service is 16 hours/day.

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14. Select a suitable V-belt and design the drive for a wet grinder. Power is available from a 0.5 kW
motor running at 750 rpm. Drum speed is to be about 100 rpm. Drive is to be compact.

15. Two shafts whose centres are 1 m apart are connected by a V-belt drive. The driving pulley is
supplied with 100 kW and has an effective diameter of 300 mm. It runs at 1000 rpm, while the driven
pulley runs at 375 rpm. The angle of groove on the pulley is 40˚. The permissible tension in 400 mm2
cross sectional area of belt is 1100 kg/m3. Taking μ=0.28, estimate the number of belts required. Also
calculate the length of the each belt.

WIRE ROPE
1. A temporary elevator is assembled at the construction site to raise building materials, such as cement,
to a height of 20 m. it is estimated that the maximum weight of the material to be raised is 5 kN. It is
observed that the acceleration in such applications is 1m/s 2, 10 mm diameter, 6x19 construction wire
ropes with fibre core are used for this application. The tensile designation of the wire is 1570 and the
factor of safety should be 10 for preliminary calculations. Determine the number of wire ropes required
for this application. Neglect bending stresses.

2. Select a wire rope for a vertical mine hoist to lift a load of 20 kN from a depth of 500 meters. A rope
speed of 3 m/s is to be attained in 10 s.

3. A workshop crane carries a load of 30 kN using wire ropes and a hook. The hook weighs 15 kN
Diameter of the rope drum is 30 times the diameter of the rope. The load is lifted with an acceleration
of 1 m/s2. Find the diameter of the rope. FS=6, Er=80 kN/mm2, σu=180 kN/mm2, cross section of the
rope=0.4x(dia of rope)2

4. At the construction site, 1 tonne of steel is to be lifted up to a height of 20 m with the help of 2 wire
ropes 6x19 size, nominal diameter 12 mm and braking load 78 kN Determine the factor of safety if the
sheave diameter is 56 d and wire rope is suddenly stopped in 1 seconds when travelling at a speed of
1.2 m/s. What is the factor safety if the bending load is neglected?

5. At the construction site, 1 tonne of steel is to be lifted up to a height of 20 m with the help of 2 wire
ropes 6x19 size, nominal diameter 12 mm and braking load 78 kN Determine the factor of safety if the
sheave diameter is 56 d and wire rope is suddenly stopped in 1 seconds when travelling at a speed of
1.2 m/s. What is the factor safety if the bending load is neglected?

6. A crane is used to lift a load of 32 kN through wire rope. A weight of crane hook is 6 kN. The load
is to be lifted with an acceleration of 1.2 m/s2. Design the drive.

7. A crane is lifting a load of 18 KN through a wire rope and a hook. The weight of the hook etc., is
10kN. The load is to be lifted with an acceleration of 1m/sec2. Calculate the diameter of the wire rope.
The rope diameter may be taken as 30 times the diameter of the rope. Take a factor of safety of 6 and
Young’s modulus for the wire rope 0.8x105 N/mm2. The ultimate stress may be taken as 1800 N/mm2.
The cross-sectional area of the wire rope may be taken as 0.38 times the square of the wire rope
diameter.

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8. Select a wire rope for a vertical mine hoist to lift 10,000 KN of coal from a depth of 750m in each
8hr shift. Assume a two compartment shaft with hoisting skips in balance. Assume rope velocity 750
m/min, acceleration and declaration periods of each 10sec. and rest period of each 10sec. for
discharging and loading. Assume skip velocity to be half of that of the load. E=8x104 N/mm2.

9. A rope drive is to transmit 250 kW from a pulley 1.5 m diameter running at a speed of 200 rpm.
The angle of lap may be taken as 180° .The groove half angle is 22.5°. The ropes are of 50 mm in
diameter. The mass of rope is 1.25 kg per meter length and each rope has a safe maximum pull of
2300 N. The coefficient of friction between rope and pulley is 0.3.Determine the number of ropes
required.

CHAIN DRIVES
1. A roller chain drive is used between a driver shaft running at 1440 rpm and a driven shaft running
approximately at 720 rpm. The power transmitted is 15 kW. The drive is to be used for 2 shifts/day
with 8 hours/shift. The centre distance is approximately 1000 mm and the chain tension can be
adjusted by moving the motor in the rails. Design the drive.
2. The transporter of a heat treatment furnace is driven by a 4.5 KW, 1440 rpm induction motor
through a chain drive with a speed reduction ratio of 2.4. The transmission is horizontal with bath
type of lubrication. Rating is continuous with 3 shifts per day. Design the complete chain drive.
Assume center distance as 500 mm and service factor as 1.5.
3. Design a chain drive to actuate a compressor from 15kW electric motor running at 1,000 rpm,
the compressor speed being 350 rpm. The minimum centre distance is 500 mm. The compressor
operates 15 hours per day. The chain tension may be adjusted by shifting the motor.
4. Design a chain drive to actuate a compressor from a 12 kW electric motor at 900 rpm, the
compressor begins 250 rpm. Minimum centre distance should be 500 mm; the chain tension may
be adjusted by shifting the motor on rails. The compressor is to work 8 hour/day.
5. A 15 kW squirrel cage motor, 1250 r.p.m. is driving a centrifugal pump at 550 r.p.m. The
centrifugal pump is located at 700 mm form the motor. Design a chain drive.
6. Design a chain drive to drive a centrifugal compressor from an electric motor 15 kW at 1000
rpm. The speed reduction ratio required is 2.5. The compressor is to work for 16 hours a day. State
solutions for common problems encountered in continuous operation of the drive.
7. Design a chain drive to run a compressor from an 11 KW electric motor running at 970 rpm, the
compressor speed being 330 rpm. The compressor operates 16 hr per day. The center distance
should be approximately500mm. The chain tension can be adjusted by shifting the motor on slides.
8. A bucket elevator is to be driven by geared motor and a roller chain drive with the information
given below: Motor output=30 kW, Speed of motor shaft=100 rpm, Elevator drive shaft speed=42
rpm, Load=even, Distance between centers of sprocket approximately=1.2 m, Period of

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operation=16 hours/day. Geared motor is mounted on an auxiliary bed for centre distance
adjustments. Design the chain drive.
9. A truck equipped with a 9.5 kW engine uses a roller chain as the find drive to the rear axle. The
driving sprocket runs at 900 rpm and the driven sprocket at 400 rpm with a center distance of
approximately 600 mm. select the roller chain.
10. The reduction of speed from 360 rpm to 120 rpm is desired by the use of chain drive. The
driving sprocket has 10 teeth. Find the number of teeth on the driven sprocket. If the radius of
driven sprocket is 250mm and the center to center distance between the two sprockets is 400mm,
find the pitch and length of the chain. 9. Design a chain drive to connect at 15 KW, 1440 rpm
electric motor to a transmission shaft running at 350 rpm. The operation involves, moderate
shocks.
11. Select a suitable chain to transmit 15 kW at 1000 rpm of a sprocket pinion. Speed reduction is
2.5:1. Driving motor is mounted on an adjustable base. Assume that load is steady, drive is
horizontal and service is 12h hours/day.
12. Design a chain drive for a blower, which is to run at 600 rpm. Input power is 15 kW at1440
rpm .The center distance is 800 rpm.
13. Design a chain drive to transmit 3 kW from a motor to a crusher. The motor speed is 960 rpm
and the crusher speed is to be around 240 rpm. The drive is horizontal and is to work for 16 hours
/ day.

UNIT-II SPUR GEARS AND PARALLEL AXIS HELICAL GEARS

Gear Terminology-Speed ratios and number of teeth-Force analysis -Tooth stresses - Dynamic
effects - Fatigue strength - Factor of safety - Gear materials – Module and Face width-power rating
calculations based on strength and wear considerations - Parallel axis Helical Gears – Pressure
angle in the normal and transverse plane- Equivalent number of teeth-forces and stresses.
Estimating the size of the helical gears.

PART-A
SPUR GEAR

1. Write a short note on gear drives giving their merits and demerits.
2. How are the gears classified and what are the various terms used in spur gear terminology?
3. Define pressure angle. State the effect of increase in pressure angle.

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4. Describe backlash and how it is raised?
5. Explain undercutting in gears.
6. Discuss the condition that must be satisfied by the spur gear in order to have constant velocity
ratio.
7. Why pressure angle of 20° is preferred than a 14 1/2° spur gear system?
8. Describe the following (i) Pressure angle (ii) Diametrical pitch
9. State law of gearing.
10. Compare involute and cycloid gear tooth profiles.
11. Interference in involute gears. How it can be avoided.
12. Enumerate the causes of gear tooth failure.
13. State the two most important reasons for adopting involute curves for a gear tooth profile.
14. Define module and state its effect on gear size.
15. Compare the features of spur and helical gear.
16. What is Lewis (tooth) form factor?
17. Why pinion is made harder than gear?

HELICAL GEAR
1. State the drawback of single helical than double helical gear.
2. Describe virtual number of teeth in helical gear?
3. Illustrate herringbone gear and its application.
4. Differentiate the following terms with respect to helical gears.
(a) Transverse circular pitch, (b) Normal circular pitch, (c) Axial pitch.
5. What are the advantages of helical gear over spur gear?

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 PART-B
SPUR GEAR
1. Design a spur gear which is required to transmit 10 kW power. The speed of the driving motor
and the driven machine are 400 rpm and 200 rpm respectively. The approximate center distance
may be taken as 600 rpm. The teeth have 20° full depth involute profile. Assuming that the gear is
made of cost iron FG200, Having allowable strength 75 N/mm2 and 180 BHN Core hardness.
2. A 27.5 kW power is transmitted at 450 rpm to a shaft running at approximately 112 rpm through
a spur gear drive. The load is steady and continuous. Design the gear drive and check the design.
Assume the following materials: Pinion-heat treated cast steel; Gear-High grade cast iron.
3. Design a spur gear drive required to transmit 45 KW at pinion speed of 800 rpm. The velocity
ratio is 3.5:1. The teeth are 200 full depth involute with 18 teeth on the pinion. Both the pinion and
gear are made of steel with a maximum safe static stress of 180 N/mm2. Assume medium shock
condition.
4. Design a straight spur gear drive to transmit 8 kW. The pinion speed is 720 rpm and the speed
ratio is 2. Both the gears are made of the same surface hardened carbon steel with 55RC and core
hardness less than 350 BHN. Ultimate strength is 720 N/mm2 and yield strength is 360 N/ mm2.
5. A motor shaft rotating at 1500 rpm has to transmit 15 kW to a low speed shaft with a speed
reduction of 3:1. Assume starting torque to be 25% higher than the running torque. The teeth are
20° involutes with 25 teeth on the pinion. Both the pinion and gear are made of C45 steel. Design
a spur gear drive to suit the above conditions and check for compressive and bending stresses and
plastic deformations.
6. Design a spur gear to transmit 2 KW at 1440 rpm. Desired speed ratio is 3. Use C45 steel for
gears.
7. An electric motor is to be connected to a reciprocating pump through a gear pair. The gears are
overhanging in their shafts. Motor speed = 1440 rpm. Speed reduction ratio=5. Motor power =
36.8 kW. The gears are to have 20° pressure angles. Design a spur gear drive.
8. Design a pair of spur gears for the requirement: Power of 15000 kW, pinion speed of 450 rpm,
wheel speed of 80 rpm, centre distance of less than 1.5 m and assuming a life of 10,000 hours.
9. A compressor running at 300 rpm is driven by a15 Kw, 1200 rpm motor through a 141⁄2 °full
depth spur gears .The centre distance is 375 mm .The motor pinion is to be of C30 forged steel
hardened and tempered, and the driven gear is to be of cast iron. Assuming medium shock
condition, design the gear drive.
10. Design a pair of straight spur gear drive for a stone crusher, the pinion and wheel are made of
C 15 steel and cast iron grade 30 respectively. The pinion is to transmit 22 kW power at 900 rpm.
The gear ratio is 2.5. Take pressure angle of 20° and working life of gears as 10000 hours.

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HELICAL GEAR
1. A pair of helical gears subjected to moderate shock loading is to transmit 37.5 kW at 1750
rpm of the pinion. The speed reduction ratio is 4.25 and the helix angle is 15°. The service is
continuous and the teeth are 20° FD in the normal plane. Design the gears, assuming a life of
10,000 hours.
2. Design a pair of helical gears to transmit 20 kW power at 1000 rpm of the pinion and reduction
ratio of 5.
3. A helical gear with 30° helix angle has to transmit 35 kW at 1500 rpm. With a speed reduction
ratio 2.5. If the pinion has 24 teeth, determine the necessary module, pitch diameter and face width
for 20°full depths the teeth. Assume 15Ni 2Cr 1 Mo 15 material for both pinion and wheel.
4. Design a pair of helical gears to transmit 30kW power at a speed reduction ratio of 4:1.The input
shaft rotates at 2000 rpm. Take helix and pressure angles equal to 25° and 20° respectively. The
number of teeth on the pinion may be taken as 30.
5. A helical gear speed up drive is required to drive a centrifugal compressor running at 3000rpm.
The helical gear speed up unit is driven by an electric motor running at 1000rpm. The compressor
requires a nominal input power of 12.5 KW. The helix angle of 250 may be assumed for the gears.
Standard involute profile 20° full depth system will be used for the gear teeth. The gear pair is
required to last for at least 10,000 hrs. Design the gear drive for the following materials. Pinion:
Heat treated cast steel, Gear: High grade cast iron
6. Design a helical gear to transmit 15 KW at 1400 rpm to the following specification. Speed
reduction is 3, Pressure angle is 20° and helix angle is 15 degree. The material for both the gears
is C45 steel. Allowable static stress is 180 N/mm2. Surface endurance limit is 800 N/mm2 and
Young’s Modulus of material is 2 x 105 N/mm2.
7. Design a pair of helical gears to transmit 30KW power at a speed reduction ratio of 4:1. The
input shaft rotates at 2000 rpm. Take helix angle and normal pressure angles equal 25° and 20°
respectively. Both pinion and gear are made of steel .The number of teeth on the pinion may be
taken as 30.
Name of the part Permissible stress BHN
Pinion 55MPa 340
Gear 40MPa 30
8. Design a pair of helical gears to transmit 30 kW power at a speed reduction ratio of 4:1. The
input shaft rotates at 2000 r.p.m. Take helix and pressure angles equal to 25° and 20° respectively.
The number of teeth on pinion may be taken as 30.
9. Design a helical gear for the following specification: Power - 12.5KW, Pinion speed -1200 rpm,
Gear Ratio - 3.5, Pressure angle is 200, helix angle is 15 degree. Gear are expected to work 6
hours/day for 10 years.

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10. Design a carefully cut helical gear to transmit 15 KW at 1400 rpm to the following
specifications. Speed reduction is 3. Pressure angle is 20°, helix angle is 15°. The material for both
the gears is C45 steel. Allowable static stress is 180 N/mm2, surface endurance limit 800 N/mm2.
Young’s modulus of the material = 2x105 N/mm2. Assume minimum number of teeth as 20 and
medium shock conditions, v= 15 m/s.

UNIT-III BEVEL, WORM AND CROSS HELICAL GEARS

Straight bevel gear: Tooth terminology, tooth forces and stresses, equivalent number of teeth.
Estimating the dimensions of pair of straight bevel gears.

Worm Gear: Merits and demerits- terminology. Thermal capacity, materials-forces and stresses,
efficiency, estimating the size of the worm gear pair.

Cross helical: Terminology-helix angles-Estimating the size of the pair of cross helical gears.

PART-A
BEVEL GEAR
1. What are zero bevel gears?
2. List the merits of using worm gears.
3. Define the terms. (a) Cone Distance (b) Face angle
4. What are the various forces acting on a bevel gear?
5. How the bevel gears are classified? Explain with neat sketches.
6. Define: Miter gear & Crown gear.

WORM GEAR
1. Show when do you prefer worm and worm wheel drive?
2. List the advantages and disadvantages of worm gear drive.
3. Define the terms of worm gear drive. 1. Helix angle 2. Lead angle
4. Describe in which gear drive self-locking is available?
5. Generalize what is irreversibility in worm gears and how is it obtained?
6. Explain why worm is made of harder material than worm wheel
7. List the materials used for the manufacture of worm and worm wheel.
8. Efficiency of worm gear is less compared to other gears. Why?

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9. Why multi start worm more efficient than the single start one?
10. Define the term normal pitch in worm gear.
11. What kind of contact occurred between worm and wheel? How it differs from other gears?

CROSS HELICAL GEAR

1. State the purpose of crossed helical gears.
2. Where do we use skew gear?

3. Why the crossed helical gear drive not used for power transmission?
4. Calculate the angle between the shafts of a crossed helical gears made of two right handed
helical gears of 15° helix angle each.

PART-B
BEVEL GEAR
1. A 90° degree straight bevel gear set is needed to give a 3:1 reduction. Determine the pitch cone
angle, pitch diameter, and gear forces if the, 25 degree pressure angle pinion as 15 teeth of pitch
circle diameter, 4, and the transmitted power is 8 HP at 550 pinion rpm.

2. Design a pair of bevel gears for two shafts whose axes are at right angles. The power transmitted
is 25 kW. The speed of the pinion is 300 rpm and the gear is 120 rpm.

3. Design a bevel gear drive to transmit 3.5 kW with the following specifications: speed ratio = 4;
driving shaft speed = 200 r.p.m.; drive is non-reversible; material for pinion is steel; material for
wheel is cast iron; and life 25000 hours.

4. A 10 kW motor running at 1200 rpm drives a compressor at 780 rpm through a 90° bevel gearing
arrangement. The pinion has 30 teeth. The pressure angle of the teeth is 20°. Both the pinion and
gear are made of heat treated cast iron grade 35. Determine the cone distance, average module and
face width of the gears.

5. Design a bevel gear drive to transmit 7 kW at 1600 rpm for the following data. Gear ratio is 3,
Material for pinion and gear is C 45 steel, life of gear is 10000 Hrs.

6. Design the teeth of a pair of bevel gears to transmit 18.75 kW at 600 rpm of the pinion. The
velocity ratio should be about 3 and the pinion should have about 20 teeth which are full depth 20°
involutes. Find the module, face width, diameter of the gears and pitch core angle for both gears.

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7. Design a straight bevel gear drive between two shafts at right angles to each other. Speed of the
pinion shaft is 360 rpm and the speed of the gear wheel shaft is 120 rpm. Pinion is of steel and
wheel of cast iron. Each gear is expected to work 2 hour/day for 10 years. The drive transmits 9.37
kW.

8. Design a bevel gear drive to transmit 7.36 kW at 1440 rpm for the following data: Gear ratio =
3; Material for pinion and gear = C45 surface hardened.

9. Design a bevel gear drive to transmit 7.5 kW; Speed ratio is 4. Driving shaft speed is 400 rpm.

10. Design a bevel gear drive to transmit 15 kW at 150 rpm. Gear ratio is 3.5. Material for pinion
and gear is C45 Steel. Minimum no of teeth is to be 25.

WORM GEAR
1. Design a worm gear drive to transmit a power of 22.5 kW. The worm speed is 1440 r.p.m. and
the speed of the wheel is 60 r.p.m. The drive should have a minimum efficiency of 80% and above.
Select suitable materials for worm and wheel and decide upon the dimensions of the drive.

2. Design a worm gear drive to transmit 22.5 kW at a worm speed of 1440 rpm. Velocity ratio is
24:1. An efficiency of at least 85% is desired. The temperature rise should be restricted to 40 0 C.
Determine the required cooling area.

3. A hardened steel worm rotates at 1440 r.p.m and transmits 11 kW to a phosphor bronze gear
with gear ratio of 15. Design worm gear drive and determine the power loss by heat generation.

4. Design a worm gear drive with a standard centre distance to transmit 7.5 kW from a worm
rotating at 1440 rpm to a warm wheel at 20 rpm.

5. Design a worm drive for a speed reducer to transmit 15 kW at 1440 rpm of the worm shaft. The
desired wheel speed is 60 rpm. Select suitable worm and wheel materials.

6. A speed reducer wait is to be designed for an input of 11.25 kW with a transmission ratio of 20.
The speed of the hardened steel worm is 1500 rpm. The worm wheel is to be made of bronze. The
tooth form is to be 20 degree involute.

7. The input to worm gear shaft is 18 kW at 600 rpm. Speed ratio is 20. The worm is to be hardened
steel and the wheel is made of chilled phosphor bronze. Considering wear strength, design worm
and worm wheel.

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8. A hardened steel worm rotates at 1440 rpm and transmits 20 kW to a phosphor bronze gear. The
speed of the worm gear should be 60 rpm. Design the worm gear drive if an efficiency of at least
82% is desired.

9. Design a worm gear drive to transmit 12kW at 1440 rpm with a speed ratio of 20. Use steel
worm and cast iron wheel.

10. Design a worm gear drive to transmit 20 HP from a worm at 1440 rpm to the worm wheel.
Assume the bronze is sand chill cast. The speed of the wheel should be 40 ± 2% rpm; initial sliding
velocity can be assumed as 3 m/s and efficiency as 80%.

UNIT-IV DESIGN OF GEAR BOXES

Geometric progression - Standard step ratio - Ray diagram, kinematics layout -Design of sliding
mesh gear box -Constant mesh gear box. – Design of multi speed gear box.

PART-A
1. List the function of structural diagram.
2. Define step ratio.
3. Where do we use speed reducers?
4. Demonstrate the general structural diagram of gear box.
5. Describe about preferred numbers in gearbox design.
6. Distinguish between structural diagram and ray diagram.
7. Explain multi speed gear box
8. List the use of gear box in machine tool
9. Explain the basic rules to be followed for optimum gear box design.
10. Formulate the ray diagram for a six speed gear box.
11. Give number of possible arrangements to achieve 12 speeds from a gear
12. Give number of possible arrangements to achieve 9 speeds from a gear
13. Explain the possible arrangements to achieve 18 speeds from a gear box
14. Draw the ray diagram for a 14 speed gear box.
15. Give some applications of constant mesh gear box.
16. State any three basic rules followed in designing a gear box.

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17. What are the possible arrangements to achieve 16 speeds from a gear box? Which is the
preferred arrangement?
18. Define progression ratio.
19. Why Geometric Progression is preferred for selecting speeds in gear box.

PART-B
1. A six speed gear box is required to provide output speeds in the range of 125 to 400 rpm with a
step ratio of 1.25 and transmit a power of 5 kW at 710 rpm. Draw the speed diagram and kinematics
diagram. Determine the number of teeth module and face width of all gears, assuming suitable
materials for the gears.

2. Design a 9 speed gear box for the following data. Minimum speed: 100rpm, step ratio: 1.25.
The input is from a 4KW, 1440rpm motor. Draw the speed diagram, kinematic diagram and
indicate the number of teeth on each gear.

3. Design a nine – speed gear box for a machine to provide speeds ranging from 100 to 1500 rpm.
The input is from a motor of 5 kW at 1440 rpm. Assume any alloy steel for the gear.

4. A machine tool gear box is to have 9 speeds. The gear box is driven by an electric motor whose
shaft rotational speed is 1400 rpm. The gear box is connected to the motor by a belt drive. The
maximum and minimum speeds required at the gear box output are 1000 rpm and 200 rpm
respectively. Suitable speed reduction can also be provided in the belt drive. What is the step ratio
and what are the values of 9 speeds? Sketch the arrangement. Obtain the number of teeth on each
gear and also the actual output speeds.

5. Select speeds for a 12 speed gear box for a minimum speed of 16 rpm and a maximum speed of
900rpm. Draw the speed diagram, kinematic diagram and indicate the number of teeth on each
gear.

6. Design the layout of a 12 speed gear box for a milling machine having an output of speeds
ranging from 180 to 2000 rpm. Power is applied to the gear box from a 6 kW induction motor at
1440 rpm. Choose standard step ratio and construct the speed diagram. Decide upon the various
reduction ratios and number of teeth on each gear wheel sketch the arrangement of the gear box .

7. Design the headstock gear box of a lathe having nine spindle speeds ranging from 25 to 1000
rpm. The power of the machine may be taken as 6 kW and speed of the motor is 1450 rpm.
Minimum number of teeth on the gear is to be 25.
a) Draw the speed diagram
b) Sketch the layout of the gear box.
c) Calculate the number of teeth on all gears.

P.D.Devan/AP/Mech/KCT
8. A gear box is to be designed for the following specifications:
Power to be transmitted = 5.5KW
Number of speeds = 9
Minimum speed = 280 rpm
Maximum speed = 1800 rpm
Input motor speed = 1440 rpm
Draw the kinematic layout diagram and the speed diagram. Determine the number of teeth on all
gears.

9. Draw the ray diagram and kinematic lay out of a gear box for an all geared headstock of a lathe.
The maximum and minimum speeds are to be 600 and 23 rpm respectively. The number of steps
is 12 and drive is from a 3 kW electric motor running at 1440rpm.

10. Select speeds for a 12 speed gear box for a minimum speed of 112 rpm and maximum speed
of 1400 rpm. Drive speed is 1400 rpm. Draw speed diagram and a kinematic arrangement of the
gear box showing the number of teeth in all the gears.

11. The spindle of a pillar drill is to run at 12 different speeds in the range of 100rpm and 135 rpm.
Design a three stage gear box with a standard step ratio. The gear box receives 5KW from an
electric motor running at 360rpm. Sketch the layout of the gear box, indicating the number of teeth
on each gear. Also sketch the speed diagram.

12. Design a 16 speed gear box for the following data. Minimum speed: 100rpm, step ratio: 1.25.
The input is from a 5KW, 1000rpm motor. Draw the speed diagram, kinematic diagram and
indicate the number of teeth on each gear.

13. In a milling machine, 18 different speeds in the range of 35 rpm and 650 rpm are required.
Design a three stage gear box with a standard step ratio. Sketch the layout of the gear box,
indicating the number of teeth on each gear. The gear box receives 3.6 kW from an electric motor
running at 1440 rpm. Sketch also the speed diagram.

14. For a load lifting arrangement transmitting 7.5 KW with electric motor running at 1440 rpm,
constant mesh type speed reducer is required with reduction ratio 16. Design a suitable
arrangement and make a neat sketch.

15. An 18 speed gear box is required to give output speeds are ranging from 35 rpm to 650 rpm. The
input power is 3.75 kW at 1440 rpm. Draw the structural diagram and kinematic arrangement of gears.

P.D.Devan/AP/Mech/KCT
 UNIT-V DESIGN OF CAM, CLUTCHES AND BRAKES

Cam Design: Types-pressure angle and under cutting base circle determination-forces and surface
stresses.
Design of plate clutches –axial clutches-cone clutches-internal expanding rim clutches-internal and
external shoe brakes

PART-A
CAM
1. What is the function of a cam?
2. Define the terms with respect to cams: Stroke; Point of Inflection
3. What are the different types of followers?
4. State the advantage of cam over other reciprocating mechanisms.
5. What is jerk? Name the profile of the cam that gives no jerk.
6. Define base circle and pitch circle with respect to cam.
7. What is undercutting in cams?
8. Explain the term undercutting in CAM?
9. Integrate the importance of pressure angle in CAM design.

CLUTCHES
1. Explain the function of a clutch.
2. Integrate the desirable properties of lining materials frictional surface.
3. Describe the important properties of friction material to be used for clutches
4. Name four materials used for lining of friction surfaces in clutches.
5. What is fading of brakes?
6. What is meant by a self – energizing brake?
7. In automobiles braking action when travelling in reverse is not as effective as when moving
forward? Why?
8. Give the reason for left and right shoes of internal expansion brakes having different actuating
forces.

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9. How does the function of a brake differ from that of a clutch?
10. List the characteristics of material used for brake lining.
11. What is meant by positive clutch?
12. Why uniform wear theory is preferred to design clutches.
13. List the advantages and applications of multi-plate clutch.

BRAKES
1. Difference between self-energizing and self-locking brakes.
2. Classify the different types of brakes.
3. List few properties of brake friction materials.
4. Differentiate clutch and brake.
5. Explain the term" fading of brakes".
6. Explain why braking action is not effective when travelling is reverse in automobiles.
7. What is back stop action in band brakes? Explain the condition for it.
8. List the important factors upon which the capacity of a brake depends.
9. Discuss the different types of brakes giving at least one practical application for each.
10. Brief about the qualities does a brake lining materials should possess.

PART-B
CAM
1. Design a cam for operating the exhaust valve of an oil engine. It is required to give equal uniform
acceleration and retardation during opening and closing or the valve, each of which corresponding
to 60° of cam rotation. The valve should remain in the fully open position for 20° of cam rotation.
The lift of valve is 37.5mm and the least radius of the cam is 50 mm, the follower is provided with
a roller of 50mm diameter and its line of stroke passes through the axis of the cam.

2. Draw the displace time, velocity time and the acceleration time curves for the follower in order
to satisfy the following conditions (1) Stroke of the follower 25 mm (2) Outstroke takes place with
SHM during 90 °of cam rotation (3) Return stroke takes with SHM during 75° of cam rotation (4)
Cam rotates with a uniform speed of 800 rpm.
3. A cam is to give the following motion to a knife-edged follower:

P.D.Devan/AP/Mech/KCT
Outstroke during 60° of cam rotation; Dwell for the next 30° of cam rotation; Return stroke during
next 60° of cam rotation and Dwell for the remaining 210 ° of cam rotation. The stroke of the
follower is 40 mm and the minimum radius of the cam is 50 mm. The follower moves with uniform
velocity during both the outstroke and return strokes. Draw the profile of the cam when the axis
of the follower passes through the axis of the cam shaft.

4. A radial cam rotates at 1200 rpm with the follower rising 20mm with SHM in 1500 of the cam
rotation .The roller is 32mm in diameter and the prime circle is 80mm in diameter. Check whether
undercutting will occur.

5. A cycloidal cam with a central roller follower has a rise of 25 mm in cam angle of 70°. Base
circle radius is 90 mm and the follower roller radius is 20 mm. Speed of cam is 5000 rpm. Mass
of follower is 0.5 kg. Find the maximum value of acceleration of the follower, corresponding
pressure angle, stiffness of the spring used with the follower and maximum cam force. The friction
between the follower and the guide may be ignored.

6. Design a cam for operating the exhaust valve of an oil engine. It is required to give equal uniform
acceleration and retardation during opening and closing of the valve, each of which corresponding
to 60° of cam rotation. The valve should remain in the fully open position for 20° of cam rotation.
The lift of the valve is 37.5 mm and the least radius of the cam is 50 mm, the follower is provided
with a roller of 50 mm diameter and its line of stroke passes through the axis of the cam.

CLUTCHES
1. A single plate sketch, effective on both sides, is required to transmit 25 kW at 3000 rpm.
Determine the outer and inner diameter of frictional surfaces if the coefficient of friction is 0.25,
ratio of diameter is 1.25 and the maximum pressure is not to exceed 0.1 N/mm 2. Determine (i) the
face width required and (ii) the axial spring force necessary to engage the clutch.

2. A dry single plate clutch is to be designed for an automotive vehicle whose engine is rated to
give 100 kW at 2400 rpm and maximum torque 500 N-m. The outer radius of the friction plate is
25% more than the inner radius. The intensity of pressure between the plates is not to exceed 0.07
N/mm2. The coefficient of friction may be assumed to be equal to 0.3. The helical springs are
required by this clutch to provide axial force necessary to engage the clutch are 8. If each spring
has a stiffness of 40 N/mm, determine the dimensions of the friction plate and initial compression
in the springs.

3. A multi disk clutch consists of five steel plates and four bronze plates. The inner and outer
diameters of friction disks are 75 mm and 150 mm respectively. The coefficient of friction is 0.1

P.D.Devan/AP/Mech/KCT
and the intensity of pressure is limited to 0.3. N/mm2. Assuming the uniform wear theory, calculate
(i) the required operating force, and (ii) power transmitting capacity at 750 rpm.

4. A plate clutch has 3 discs on the driving shaft and 2 discs on the driven shaft, providing 4 pairs
of contact surfaces. The OD of contact surface is 240 mm and ID is 120mm. Assuming uniform
pressure and μ=0.3, find the total spring load for pressing the plates together to transmit 25 kw at
1575 rpm. If there are 6 springs each of stiffness 13KN/m and each of contact surfaces have worn
away by 1.25 mm, find the power that can be transmitted, assuming uniform wear.

5. A hydraulically operated clutch is to be designed for an automatic lathe. Determine the number
of plates and operating force required for the clutch to transmit 35 N-m. The clutch is to be
designed to slip under 300% of rated torsional moment to protect the gears and other part of the
drive. The limits for the diameter of friction surfaces due to space limitation are 100 mm and 62.5
mm. This clutch is to operate in an oily atmosphere.

6. A multi disc wet clutch is to be designed for a machine tool driven by an electric motor of 12.5
KW running at 1440 rpm. Space restrictions limit the outside disc diameter to 100 mm.
Determine the appropriate value of inside diameter, total number of discs and clamping force.

7. An engine developing 45 kW at 1000 rpm id fitted with a cone clutch built inside the fly wheel.
The cone has a face angle of 12.5 degree and a maximum mean diameter of 500 mm. The
coefficient of friction is 0.2. The normal pressure on the clutch face is not exceeded 0.1 N/mm2.
Determine (i) The face width required (ii) the axial spring force necessary to engage the clutch.

8. A cone clutch has a cone angle of 11.5o, a mean frictional diameter of 320 mm, and face width
of 60 mm. The clutch is to transmit a torque of 200 Nm. The coefficient of friction is 0.26. Find
the activating force and pressure using the assumption of uniform pressure.

9. A power of 20 kW is to be transmitted through a cone clutch at 500 rpm. For uniform wear
condition, find the main dimensions of the clutch and shaft. Also determine the axial force required
to engage the clutch. Assume the coefficient of friction as 0.25, the maximum normal pressure on
the friction surface is not to exceed 0.08 MPa and take the design stress for the shaft material as
40 MPa.

10. A cone clutch is to transmit 7.5KW at 900rpm. The cone has a face angle of 12°. The width of
the face is half of the mean radius and the normal pressure between the contact faces is not to
exceed 0.9 N/mm2. Assuming uniform wear and the coefficient of friction between contact faces
as 0.2, find the main dimensions of the clutch and the axial force required to engage the clutch.

P.D.Devan/AP/Mech/KCT
BRAKES

1. A single block brake, the diameter of drum is 250mm and the angle of contact is 90.The
operating force of 700 N is applied at the end of lever which is at 250 mm from the centre of the
brake block. Determine the torque that may be transmitted. Fulcrum is at 200mm from the centre
of brake block with an offset of 50mm from the surface of contact. The coefficient of friction is
0.35
2. Calculate the average bearing pressure and the initial and average braking powers for the block
shoe shown in fig. The diameter of the drum is 400 mm and it rotates at 200 rpm. Coefficient of
friction is 0.2 and drum width is 75 mm.

3. A 360 mm radius Brake drum contacts a single shoe as shown in figure and resists a torque of
250 N-m at 500 rpm. The co-efficient of friction is 0.3. Determine
(i) The normal reaction on the shoe,
(ii) The force to be applied at the lever end for counter clockwise rotation of the drum if e= 0
(iii) The force to be applied at the lever end for clockwise rotation of the drum if e= 42 mm.
(iv)The force to be applied at the lever end for counter clockwise rotation of the drum if e = 42
mm.

P.D.Devan/AP/Mech/KCT
3. A rope drum of an elevator having 650mm diameter is fitted with a brake drum of 1m diameter.
The brake drum is provided with 4 cast iron brake shoes each subtending an angle of 45o .The
mass of elevator when loaded is 200 kg and moves with a speed of 2.5m/s. The brake has sufficient
capacity to stop the elevator in 2.75m. Assuming the coefficient of friction as 0.2, find (i) Width
of shoe if the allowable pressure on the brake shoe is limited to 0.3 N/mm2. (ii) Heat generated in
stopping the elevator.

4. The double shoe brake shown in figure must provide a braking torque of 280.5Nm at 720rpm.
Assuming coefficient of friction 0.3 for brake lining and pV=1100 KPa m/s, determine (a) Spring
force P required to set the brake (b) Width of shoes (c) Which shoe will have greater rate of wear?

5. The layout of a double block brake is shown in figure. The brake is rated at 250N-m at 650 rpm.
The drum diameter is 250 mm.assuming the co-efficient of friction as 0.3 and for conditions of
service a pV value of 1000(kPa) m/s may be assumed. Determine (i) The spring force “S” required
to set the brake (ii) Width of shoes (iii) Which shoe will have greater rate of wear?

P.D.Devan/AP/Mech/KCT