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EASWARI ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING
ME-6601 DESIGN OF TRANSMISSION SYSTEMS
QUESTION BANK FOR VI SEM (2016-2017)

UNIT 1 :DESIGN OF TRANSMISSION SYSTEMS FOR FLEXIBLE ELEMENTS

PART - A
1. What is a power drive? Mention their types.
The power drive is a set of machine members employed to transmit power or energy produced
in one machine to another machine. Their main *types (1) Mechanical, (2) Hydraulic, (3) Pneumatic
and (4) Electrical drives.
2. What is meant bymechanical drives? Classifythem.
The drives which transmit power by means of contact forces are called as mechanical drives.
They can be classified based on
(a) Wayof power transmission. (i)Friction drives [e.g. Belt drives, Rope drives] (ii) Toothed drives
[e.g... Gear drives, Chain drives]
(b)Centre distance between power shafts (i)Long distance drives (e.g. Belt drives, chain drives, rope
drives) (ii) Short distance drives (e.g. Gear drives)
(c) Intermediate link between driving and driven members. (i) No intermediate link (e.g. Gear drives)
(ii)With intermediate link (e.g. Belt, ropedrives, chain drives)
3. State the -Law of Belting?
The law of belting states that the centre line of the belt when it approaches the pulley must lie
in the mid plane of that pulley which should be perpendicular to the axis of the pulley. Otherwise the
belt will run off the pulley.
4. Explain the term crowning of pulleys.
Pulleys are provided a slight conical shapes (or), convex shapes in their rim's r surface in
order to prevent the belt from running off the pulley due centrifugal force. This is known as crowning,
of pulley. Usually the crowning height t maybe 1/96 of pulleyface width.
5. Briefly explain about friction and its applications
Friction is said to be a resisting force that is developed between two relatively -moving
surfaces. For some machines, this frictional force may be an unwanted force and hence it is to be
reduced to the maximum level for some other machines. Bearings brakes, clutches are the good
examples.
6. What are the types of belts?
(a) Flat Belts (b)V Belts. (ii)Multiple V belt. (iii) Ribbed Belt. (c) Toothed or Timing
(d),Round, Belts.
7. State the materials for belts.
Leather, cotton fabrics, rubber, animal's hair, silk, rayon, woollenetc.
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8.Indicate some merits and demerits of belt-drive;

Merits .
1.Belt drives are used for long distance power transmission. 2,their operations are smooth and
flexible. 3.Simple in design and their manufacturingcost is lower.
Demerits.
1.Theyneed large space. 2.Loss of power due to friction is more. 9.Bywhat materials, belt-pulleys are
made? Belt-pulleys are made of cast-iron or steel
10. What is meant bythe plyof belt?
Flat belts are made of thin strips and laminated one over the other in order to get thick belt.
These thin strips or sheets are called as plies of belt. Usually flat belts are made of 11 ply, 4 ply, 5 ply,
6 ply and 8 plybelt etc. And 4 plybelt is thicker ham 3 plybelt and so-on.
11.Mention the different types of joints employed for joining flat-belts.
(I) Cemented joints (ii) Laced joints (iii) Crest joints. (iv)Hinged joints
12. What conditions should be followed when flat belt drive is installed?
1.The axes of power transmitting shafts should be parallel. 2.It should have, optimum centre
distance between the shafts'. 3.The tight-side of the drive should be at the bottom side of the pulley.
13. What is belt rating?
Flat-belts are made of different sizes such as 3 ply, 4 ply and V - belts are made of different
grades such as A, B, C, D and E grade belts. Belt rating is defined as the power transmitting capacity
of unit size flat belt or a particular grade singleV belt.
14. Specify the application of round belt.
Round-belt is applied, in sewing machine.
15. Specifythe purpose of crowning of bets.
To prevent slipping from pulleydue to centrifugal force
16. What factors should beconsidered duringthe selection of a belt drive?
a) Amount of power to be transmitted. b) Peripheral and angular speeds. c) Speed ratio. A)
Efficiency. e) Centre distance between staffs f) Spaceavailable. g) Working environment.
17. Explain creep in belts.
Since the tensions produced by the belt on the two sides of the pulley are not equal, the belt
moves with a very negligible velocity, due to the difference of two tensions. This slow movement of
the belt over the pulleyis known as creep of belt and it is generally neglected.
18. How is a V-belt designated?
V-belt is designated by a grade letter followed by its inside length in code number, year of
coding. For example, D 3048: IS 2494: 1964. M belts are designated by the grade letter and inside
length only such D - 3048. Sometimes, the inside length maybe denoted in inches as D
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19. In what ways, timing belts are superior to ordinaryV-belts?

Since the timing belts possess toothed shape in their -inner side, engagement with toothed
pulley will provide positive drive without, belt-slip where as in the case of ordinary V-belts, chances
of slip are and hence positive drive is not possible at all times. Hence toothed belts (I timing belts) are
superior to ordinaryV-belts.
20. What purpose does the housing of gear-box serve?
Gear-box -housing or casing is used as container inside which, the gears, shafts, bearings and
other components are "mounted.' Also it prevents the entry of dust inside the housing and reduces
noise of operation. That is, the housing Safe-guard the inner components.
PART-B
21. (i) A V- belt drive is to transmit 15kW to a compressor. The motor runs at 1150 rpm and the
compressor is to run at 400 rpm. Determine.1. Belt specifications2.Number of belts (8) (ii) A leather

If the mass of1m3 of leather is 1mg and the stress in the belt is not to exceed 2.75 Mpa, find the
maximum power that can be transmitted and the corresponding speed of the belt.
22. It is required to select a flat belt drive for a fan running at 360rpm.which is driven by a 10kw,
1440rpm motor. The belt drive is open type and space available for a center distance of 2m
approximately. The diameter of a driven pulley is 1000mm.
23. Design a belt drive to transmit20kw at 720rpm aluminium rolling machine, the speed ratio being
3. The distance between the pulley is3m.diameter of rolling machine pulley is 1.2m.
24. A truck equipped with a 9.5 kw engine uses a roller chain as the final drive to the rear axle .The
driving sprocket runs at 900 rpm and driven sprocket at 400rpm with center distance of approximately
600mm.Select the roller chain.
25. 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 Youngs modulus for the wire rope 0.8 x 105 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.
26. Design a chain drive to actuate a compressor from 15kW electric motor running at 1,000 r.p.m,
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
27. 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. (16)
28. 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.
29. A crane is lifting a load of 25 KN through a wire rope and a hook. The weight of the hook etc., is
15kN. The load is to be lifted with an acceleration of 1m/sec2. Design the rope drive.
30. 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 = 7.5 kW.
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UNIT 2 : SPUR GEARS AND PARALLEL AXIS HELICAL GEARS

PART - A
1. Mention some applications of gear drives.
Gear drives are employed in many fields such as from smaller instruments to the heaviest and
most powerful machismos, crushers etc. Some of the common applications of gears are in hoisting
machineries, rolling mill, machine tools such as lat machines, etc.
2. Whyare gear drives superior to belt drives or chain drives? the advantages of gear drives?
1. The gear drives possess high load carrying capacity, high compact layout. 2.Theycan
transmit power from verysmall values to several kilowatts.
3. How are gears classified?
Gears areclassified based on (a) Axes of gear shafts as i) Parallel e.g. spur, helical, herring-
bone gears. ii) Intersecting e.g. Bevel gears. iii) Nonparallel and non-intersecting e.g. - worm,
gears, Skew gears. (b)Profile of gear tooth I)Involutes gears. ii) Cycloidal gears. (c) Position of teeth
on wheel rim. Tooth parallel to axis of gear e.g. Spur gears. ii) Tooth inclined to axis of gear e.g.
Helical gears. (d) Pressureangle i)Gears with 201 pressure angle. ii) Gears with 14 1/20 pressureangle.
4. Illustratethe materials for making gears'.
1. Ferrous metals such as carbon steels, alloysteels of nickel, chromium and vanadium. 2.
Cast-iron of different grades. 3. Non-ferrous metals such as brass, bronze, etc. 4.Non-metals like
Phenolic resins nylon, Bakelite etc. Among them steel with proper heat treatment is extensively,
employed in many of 'the engineering applications.
5. Specifythe types of gears-failures.
a) Tooth breakage. b) Pitting of tooth surface. c) Abrasive- wears. d) Seizingof teeth etc.
6. At what occasions non-metallic gears are employed.
Non-metallic gears are employed 'where we require silent operation and low power transmission. For
example, in instruments like pressure gauge and so on.
7. Fill in the blanks of the following a) in a gear pair, the smaller gear is, called as.............................
and the bigger is called as.................................................................................... b) When the gear and
pinion are made of different materials, their design based on......... Answers a) Pinion, wheel or gear.
b) Weaker material.
8. What is meant byspur-gear?
Spur-gear is the gear in which teeth are cut at the circumference of a slab called as gear-blank
such that the teeth are parallel to gear-axis.
9. Define the following terms.
a) Tip circle or addendum circle is the circle which coincides crests or tops of all teeth.
b)Root circle or addendum circle is the circle which coincides with. Roots or bottoms of all teeth. c)
Pitch circle is the imaginarycircle in which the pair of gears rolls one over the other. This circle can be
visible when the pair of gears fast rotating. This will lie between tip circle and root circle.
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10. How are the followingterms defined?

a) Pressure angle (a) is the angle making by the line of action common- tangent to the pitch
circles of mating pars. b) Module m is the ratio of pitch circle diameter to the number d of gear teeth,
and is usually represented in millimetres.

11. Define the following terms.

a) Back lash is the difference between tooth thickness and the space into 'which it meshes,
measured along the pitch circle. If we assume the tooth thickness as t, and space width as t2 then
backlash = t2 t1
b)Gear ratio (i) is the ratio of number of teeth of larger gear to that of smaller gear. At is also
defined as the ratio of high speed to the low speed in a gear drive.Usually, the gear ratio should
always be greater than one.
12. Fill in the blanks of the following. a) The differencebetween tip circleradius and pitch circle -
radius is....... b) The differencebetween pitch circleradius and root circle radius is......................
Answers a) Addendum, b) addendum .
13. What factors influencebacklash?
The factors like errors in tooth thickness, pitch, tooth spacing, mounting misalignment, etc
influence the backlash.
14. What preliminarydesign considerations should be, adopted, when selecting gear drive?
All kinds of gears cannot be useful for all kinds of work. Hence following factors should be
considered for selecting a specific type of gear drive. i)The amount of power to be transmitted. ii)
Space availability. iii)Amount of gear ratio for singlestep. Iv)Causes for gear failures and their
preventing methods. v) Proper material vi) Life of gears required, usually10,000 hours.
15. What is interference in gears? How can you overcome it?
Gear profile usually starts, from base circle and ends with tip teeth are made in such a way
that their contact is along the pro the top surface of teeth is made, flat, the tip of the teeth of one gear
dig I into the bottom flank of matinggear. This action is called interference.
16. On what basis gear cutters are selected?
Gear cutters are selected based on the following conditions. 1)Properties of materials for work
piece and tools. 2)Cost of production. 3)Structure of gears such as spur gear, helical gears and so on.
4)Module of the gear.
17. How do gears fail?
Gears may fail due to tooth breakage by overload and misalignment of shafts. b) Corrosion of
teeth by improper lubricants. c) Tooth wear because of insufficient lubrication. d) Interference
because of no under-cut.
18. Fill in the blanks of the following. a) The size of gears are usually specified by their ......... b) the
commonly used gear tooth-profile is ......... Answers a) Outer diameter, module, number-of teeth. b)
Involutes profile.
19.What is working depth of a gear-tooth?
Working depth of gear is the radial distance between addendum circle and clearance circle.It
is equal to two times, the addendum value.
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20. What stresses areinduced in gear tooth?

1. Surface compressive stress. 2. Bending stress.
PART- B
21. (i) A pinion with 25 teeth and rotating at 1200rpm drives a gear which rotates at 200rpm and
module is 4mm.calculate the center distance between the gears. (8) (ii) A helical gear with 300 helix
angle has to transmit 35kW at 1500 rpm. With a speed reduction ratio 2.5. If the pinion has 24 teeth,
determine the necessary module for 200 full depths the teeth. Assume 15Ni 2Cr 1 Mo 15 material for
both pinion and wheel.
22. Design a spur gear drive required to transmit 45 Kw at pinion speed of 800 rpm. The velocity ratio
3.5:1. The teeth are 20 full depths involute with 18 teeth on the pinion. Both the pinion gear are made
of steel with a maximum safe static stress of 180N / mm2.
23. 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 250 and 200 respectively. The
number of teeth on the pinion may be taken as 30.
24. 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(16)
15 A motor shaft rotating at 1500 rpm has to transmit 15kW 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 200
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.
Also sketch the spur gear drive.
26. 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 200 pressure angles. Design a spur gear drive.
27. A pair of helical gears subjected to moderate shock loading is to transmit 37.5kW at 1750 r.p.m.
of the pinion. The speed reduction ratio is 4.25 and the helix angle is 150. The service is continuous
and the teeth are 200 FD in the normal plane. Design the gears, assuming a life of 10,000 hours.
28. A compressor running at 300 rpm is driven by a15 Kw, 1200 rpm motor through a 14 0 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.
29. Design a spur gear drive required to transmit 15 Kw at pinion speed of 1400 rpm to a low speed
shaft rotating at 500 rpm. The teeth are 20 degree full depth involute with 25 teeth on the pinion. Both
the pinion and gear are made of CI with a maximum safe static stress of 56 N / mm2.
30 A helical gear drive with the helix angle of 30 degree required to transmit 15 Kw at pinion speed
of 10000 rpm. The velocity ratio 4:1. The teeth are 20 degree full depth involute with 25 teeth on the
pinion. Both the pinion gear is made of hardened steel with a maximum safe static stress of 100N /
mm2. The face width may be taken as 14 times the module. Find the module and face width.
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UNIT 3 :BEVEL, WORM AND CROSS HELICAL GEARS

PART - A
1.What is a bevel gear?
Bevel gear is the type of gear for which the teeth are cut on conical surface in contrast with
spur and helical gears for which the teeth are cut on cylindrical surfaces. The structure of bevel gear is
similar to and uniformlytruncated frustum of a cone.
2. When do we use bevel gears?
When the power is to be transmitted in an angular, direction, i.e., between the shafts whose
axes intersecting at an angle, bevel gears areemployed.
3. How are bevel gears classified?
Bevel gears are classified in two ways 1.Based on the shape of teeth. a) Straight bevel gears.
b) Spiral bevel gears
4. Define shaft angle?
Based on the included angle between the shaft axes, called as shaft angle a) External gears <
900) b)Internal gears > 90*) c) Crown gears =90
5. Whats a crown gear?
A crown gear is a type of bevel gear whose shaft angle is 90 degree and angle of pinion is not
equal to the pitch angle of gear. Let Shaft angle
6. What is the specific feature of mitre gear?
Mitre gear is the special type of crown gear in-t which the shaft,, 900 and the pitch angles of
pinion and gear are equal and each angle to 45'.
7. Fill in the blanks of the following a) Bevel gears having shaft, Angle of, 90" are known as........
.b)when the spiral angle of a. Bevel gear is zero, it is called as... Answers a) Crown gears. b) Zerol
bevel gear.
8.Define the following terms a) Cone distance or pitch cone radius. b) Face angle.
a) Cone distance or pitch cone radius is the slant length of pitch cone, i.e., distance between
the apex and the extreme point of tooth of bevel gear. b) Face angle is the angle subtended by the face
of the teeth at the cone centre. It is equal to the pitch angle plus addendum angle. It is also called as
tip angle.
9. In which gear-drive, self-lockingis available?
Self-locking is available in worm-gear drive.
10. When do we use worm-gears?
When we require transmitting power between nonparallel and non-intersecting shafts and
very high velocity ratio, of about 100, worm gears, can be employed. Also worm-gears provide self-
locking facility.
11. Write some applications of worm gear drive.
Worm gear, drive find wide applications like milling machine indexing head, table fan, and
steering rod of automobile and so on.
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12. What are the merits and demerits of worm gear drive?
Merits
1) Used for veryhigh velocityratio of about 100 2) Smooth and noiseless operation. 3) Self-locking
facilityis available.
2) Demerits 1) Low efficiency. 2) More heat will be produced and hence this drive can be operated
inside an oil reservoir or extra cooling fan is required in order to dissipate the heat from the drive. 3)
Low power transmission.
13. When do we employ crossed helical gear?
A pair of crossed-helical gears also known as spiral gears are used to connect and transmit
motion between two non-parallel and non- intersecting shafts. As the contact between the mating teeth
is always a point, these gears are suitable only for transmitting a small amount of power.
14. Mention two characteristics of hypoid gear.
They are similar in appearance to spiral-bevel gears. Their pitch surfaces are hyper bolides
rather than cones. Axis of pinion is offset from the axis of the gear.
15. What are the various forces acting on a bevel gear?
Tangential force, Axial force & Radial force
16. Usually worm is made of hard material and worm gear is made of softer material justify.
A material strength is set so that an amount of wear of the worm becomes larger that of the
worm wheel.
17. When is bevel gear preferred?
They are used to transmit power between two intersecting shafts.
18. Calculate the angle between the shafts of a crossed helical gears made of two right handed
helical gears of 15 helix angle each.
Shaft angle, = 1 + 2 = 2 = 2 (15) = 30
19. State the use of bevel gears.
They are used to transmit power between two intersecting shafts.
20. State the advantage of worm gear drive in weight lifting machine.
The worm gear drives are irreversible. It means that the motion cannot be transmitted from
worm wheel to the worm. This property of irreversible isadvantageous in load hoisting applications
like cranes and lifts.
PARTS B
21. A 10 kW motor running at 1200 rpm drives a compressor at 780 rpm through a 900 bevel gearing
arrangement. The pinion has 30 teeth. The pressure angle of the teeth is 200. 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.
22. Design a pair of bevel gears for two shafts whose axes are at right angles. The power transmitted
is 25kW. The speed of the pinion is 300 rpm and the gear is 120 rpm.
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23. A 2 kW power is applied to a worm shaft at 720 rpm. The worm is of quadruple start with 50mm
as pitch circle diameter. The worm is of quadruple start type with 50mm as pitch circle diameter. The
worm gear has 40 teeth with 5mm module. The pressure angle in the diametral plane is 200.
Determine (i) the lead angle of the worm, (ii) velocity ratio, and (ii) centre distance. Also, calculate
efficiency of the worm gear drive, and power lost in friction.
24. A pair of straight tooth bevel gears has a velocity ratio of 4/3. The pitch diameter of the pinion is
150 mm. The face width is 50mm. The pinion rotates at 240 rev/min. The teeth are 5mm module, 14
10 involutes. If 6 kW is transmitted, determine (i) the tangential force at the Mean radius (ii) the
pinion thrust force (iii) the gear thrust force. Draw the free body diagrams indicating the forces
25. Design a worm gear drive with a standard centre distance to transmit 7.5 kW from a warm rotating
at 1440 rpm to a warm wheel at 20 rpm
26. Design the teeth of a pair of bevel gears to transmit 18.75 kW at 600 rpm of thepinion. The
velocity ratio should be about 3 and the pinion should have about 20 teeth which are full depth 200
involutes. Find the module, face width, diameter of the gears and pitch core angle for both gears
27. A 900 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 has 15 teeth of pitch
circle diameter, 4, and the transmitted power is 8 HP at 550 pinion rpm (16)
28. 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 400 C.
Determine the required cooling area.
29. A speed reducer wait is to be designed for an input of 11.25kW 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 200 in volute.
30. 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.
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UNIT 4 :DESIGN OF GEAR BOXES

PART - A
1.What purpose does the housing of gear-box serve?
Gear-box -housing or casing is used as container inside which, the gears, shafts, bearings and
other components are "mounted.' Also it prevents the entry of dust inside the housing and reduces
noise of operation. That is, the housing Safe-guard the inner components.
2.What is the function of spacers in a gear-box? (6r) what arespacers as applied to a gear-box?
Spacers are sleeve like components, which are mounted, in shafts in-between gears and
bearings or one gear and another gear in order to maintain the distance between them so as to avoid
interruption between them.
3.Fill in the blanks of the following. (a) The number of gears employed in a gear-box is kept to the
minimum byarranging the. Speed of the spindle is.......................... Series (b) In a gear- box, -for a set
of gears, if the centre distance and module are same, then the sum of teeth of engaging pair will be.....
Answers a) Geometric series. b) Equal.
4. What is a speed diagram? (Or) What is the structural diagram-of -&.gear-box?
Speed diagram or structural diagram is the graphical representation different speeds of output
shaft, motor shaft and intermediate shafts.

5. For what purpose we are using gear-box?

Since the gear-box is provided with number of gears of different size arranged is different
forms, we can get number of output speeds byoperated motor at single speed.
6. Name the types of speed reducers.
a) Single reduction speed reduces. b) Multi reduction speed reducers.
7. What does the ray-diagram of gear-box indicate?
The ray-diagram or kinematic arrangement of a gear box indicates arrangement of various
gears in various shafts of the gear box in order to obtain the different output speeds from the single
speed of the motor.
8. What is step ratio?
Step ratio is the ratio of one speed of the shaft to its previous lower speed since the spindle
speeds are arranged in geometric progression, theratios adjacent speeds (i.e., step ratios) are constant.
If Nr is; the maximum speed and N, is the minimum speed, then,
Nr (r-1) = (Step ratio) Nr-1
9. What are the points to be considered while designing a sliding mesh type of multi-speed gear
box?
i) The transmission ratio in a gear box is limited by <i< 2
ii) Speed ratio of any stage should not be greater than 8.
10. Which type of gear is used in constant mesh gear box? Justify.
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Helical gears are used in constant mesh gear boxes to provide quieter and smooth operation.
11. Compare sliding mesh and synchromesh gear box.
Sliding mesh gear box: It derives its name from the fact that the meshing ofthe gears take
place by sliding of gears on each other. With sliding mesh gear box, double de-clutching is necessary
to bring the two sets of dog teeth to the same speed so that they can be slid into engagement quietly.
Synchromesh gear box: To eliminate the need to de-clutch, the synchromesh gear box was introduced.
The basic gear box is laid out in the same manner as the constant mesh, but with the addition of a
cone clutch fitted between the dog and gear members.
12. Where is multi-speed gear boxes employed?
They are employed wherever the variable spindle speeds are necessary.
13. Name the series in which speeds are arranged in multi-speed gear boxes.
Basic series of preferred numbers are R5, R10, R20, R40& R80.
14. List six standard speeds starting from 18 rpm with a step ratio 1.4.
For the step ratio = 1.4, the R20 series, the standard speeds are 18, 20, 22.4, 25, 28 & 31.5
rpm.
15. Differentiate ray diagram and structural diagram.
Ray diagram is a graphical representation of the structural formula.
Structural diagram is a kinematic layout that shows the arrangement of gears in a gear box.

16. List out the basic rules to be followed for optimum gear box design.
i) The transmission ratio in a gear box is limited by < =i< 2
ii) Speed ratio of any stage should not be greater than 8.
17. What is step ratio? Name the series in which speeds of multi-speed gear box are arranged.
When the spindle speeds are arranged in geometric progression, then the ratio between the
two adjacent speeds is known as speed ratio.Basic series are R5, R10, R20& R40.

PART B
21. (i) The maximum and minimum speeds of a 6 speed gear box are to be 1600 rpm and 500 rpm
respectively. Construct the speed diagram and the kinematic arrangement of the gearbox. (8) (ii)
Design a gearbox, for the following data: No of speeds required=16; min speed=100rpm; max
speed=560rpm;Draw diagram and kinematic arrangement.
22. Design a 12 speed gear boxThe speed range required is 100 to 355rpm a) Draw the ray diagram,
b) Draw the kinematic arrangement c) Calculate the no. of teeth on each gear.
23. A gearbox is to give 18 speeds for a spindle of a milling machine. The drive is from an electric
motor of 3.75kw at 1440rpm. Maximum and minimum speeds of the spindle are to be around 650rpm
and 35rpm respectively. Find the speed ratios which will give the desired speeds and draw the
structural diagram and kinematic arrangement of the drive.
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24. Design a nine speed gear box for a milling machine with speed ranging from 56-900rpm. The
output speed is 720rpm; make a neat sketch of the gearbox. Indicate the no of teeth on all the gears
and their speeds.
25. The min and max speeds of a six speed box are to be 160 and 1500rpm.Construct the kinematic
arrangement and the ray diagram of the gearbox and also calculate the no of teeth of all gears.
26 A gearbox is to be designed to provide 12 output speeds ranging from 160 to 200rpm. The input
speed of motor is 1600rpm. Choosing a standard speed ratio construct the speed diagram and the
kinematic arrangement calculate the no of teeth of all gears.
27. A six speed gear box is required to provide output speeds in the range of 125 to 400 r.p.m. with a
step ratio of 1.25 and transmit a power of 5 kW at 710 r.p.m. 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. Determine the length of the gear box along the axis of the gear shaft.
28. 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 r.p.m. 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 r.p.m. and 200 r.p.m.
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.
29. Design a 9 speed gear box for a machine to provide speeds ranging from 200 r.p.m to 1000 rpm.
The input is from a motor of 5 kW at 1440 rpm. Assume any alloy steel for the gear.
30. 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 n each gear. The gear box receives 3.6 kW from an electric motor running at 1,440
rpm. Sketch also the speed diagram.
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UNIT 5 :DESIGN OF CAM, CLUTCHES AND BRAKES

PART - A
1.What is cam?
Cam is a rotating mechanical member used for transmitting desired motion to a Follower
bydirect contact
2. Classification of cam?
(i) Accordingto cam shape (ii) According to follower movement (iii) According to manner of
constraint of the follower
3. Classify cam based on a shape?
(i) Wedge cam (ii) Radial cams (iii) spiral cams (IV) drum cams (v) Spherical cams
4. Classification of follower?
(i) Accordingto follower shape (ii)Accordingto motion of follower
5. What is roller follower?
In place of a knife edge roller is provided at the contactingend of the follower
6. Spherical follower?
In the contacting end of the follower is of spherical shape.
7. Angle of ascend?
The angle of rotation of the cam from the position when the follower begins to rise till it
reaches its highest points it is denoted by
8. Angle of descend?
The angle through which the cam rotates during the time the follower returns to the initial
position. It is denoted by r.
9. Angle of dwell?
It is the angle through which the cam rotates while the follower remains stationary at the
highest or the lowest.
10. Angle of action?
The total angle moved by the cam during its rotation between the beginning of rise and the
end of return of the follower
11. What is radial or disc cams?
In radial cams the follower reciprocates or oscillates in a direction perpendicular to the cam
axis. The cams are all radial rams. In actual practice, radial cams are widely used due to their
simplicity and compactness.
12. What is dwell?
The zero displacement or the absence of motion of the follower during the motion of the cam
is called dwell.
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13. What is classification of followers according to follower shape?

(i) Knife edge follower (ii) Roller follower (iii)Mushroom or flat faced follower and
(iv)Spherical faced or curved shoe follower
14. What is classification of follower accordingto the motion of the follower?
(i) Reciprocatingor translating follower (ii) Oscillating or rotatingfollower
15. What is classification of followers according to the path of motion?
(i) Radial follower and (ii)Offset follower
16. What are the motions of the follower?
The follower can have anyof the following four types of motions (i) Uniform velocity (ii)
Simple harmonic motion (iii) Uniform acceleration and retardation (iv) cycloidal motion.
17. What is the application of cam?
Closingand opening of inlet and exit value operatingin IC engine.
18. What are the necessaryelements of a cam mechanism?
(i) Cam-The driving member is known as the cam (ii) Follower-The driven member is known
as the follower. (iii) Frame-It supports the cam and guider the follower.
19. What is translating angle?
The wedge is replaced by a flat plate with a groove. The plate cam moves back and forth
imparting a translator or motion to the follower. Thus these cams are also known as translating cams.
20. Write the formula for maximum velocity?
Vo (max) = 2s o
V r (max = 2 s o
PART B
21. A single plate clutch, both side being effective is required to connect a machine shaft to a driver
shaft which runs at 500rpm .The moment of inertia of the rotating parts of the machine is 1Kgm2.The
inner and the outer radii of the friction discs are 50mm&100mm respectively .Assuming uniform
pressure of 0.1N/mm2 and = 0.25 , determine the time taken for the machine to reach full speed
when the clutch is suddenly engaged . Also determine the power transmitted by the clutch, the energy
dissipated during the clutch slip and the energy supplied to the machine during engagement.
22. A multi disk clutch consists of five steel plates and four bronze plates. The inner and outer
diameters of friction disks are 75mm and 150mm respectively. The coefficient of friction is 0.1 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.
23. In an automotive type internal expanding double shoe brake he face width of the friction lining
is 40 mm and the intensity of normal pressure is limited to 1 N/mm2 . The coefficient of friction is
0.32. The angle 1 can be assumed to be zero. Calculate (i) the actuating force P, and (ii) the torque
absorbing capacity of the brake.
24. A leather faced conical clutch has cone angle of 300.The pressure between the contact surfaces is
limited to .35N/mm2 and the breath of the conical surface is not to exceed 1/3 of the mean radius.
Find the dimensions of the contact surface to transmit 22Kw at 2000 rpm .Also calculate the force
required to engage the clutch. .Take =0.15.
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25. 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 25mm (2) Outstroke takes place with SHM
during 900 of cam rotation (3) Return stroke takes with SHM during 750 of cam rotation (4) Cam
rotates with a uniform speed of 800 rpm.
26. .A radial cam rotates at 1200 rpm with the follower rising 20mm with SHM in1500of the cam
rotation .The roller is 32mm in diameter and the prime circle is 80mm in diameter. Check whether
undercutting will occur.
27. A multi disk clutch has 3 disks on the driving shaft and two on the driven shaft. The inner and
outer diameters of friction disks are 120mm and 240mm respectively. The coefficients of friction is
0.3 and find the max axial intensity of pressure between the discs for transmitting 25 kW at 1575 rpm
.Assuming the uniform wear theory.
28. A single plate clutch transmits 25 kW at 900 rpm. The max. Pressure intensity between the plates
is 85 kN/m2. The ratio of radii is 1.25. Both the sides of the plate are effective and the coefficient of
friction is .25. Determine (i) the dia of the plate (ii) the axial force to engage the clutch. Assuming the
uniform wear theory. (16) 20. (i) What is a self-energizing brake? When a brake becomes self-
locking?. Discuss (ii) What is positive clutch? Describe the types.
29.In a band and block brake, the band is lined with 14 blocks, each of which subtends an angle of
20degrees at the drum centre. One end of band is attached to the function of the brake lever and the
other to a pin 150mm from the fulcrum. Find the force required at the end of the lever 1 m long from
the fulcrum to give a torque of 4kN-m. The diameter of the brake drum is 1m and the co-efficient of
friction between the blocks and the drum is 0.25.