Scheme of Valuation

ME 1352 Design of Transmission Systems

Results attained are applicable to the assumed stress values. Answers will vary if
other stresses are assumed in the given range. Hence, Examiners are requested to
value accordingly.
PART A
1 Initial Slag: Lubrication and Adjustment of sprockets
2 Specification of wire rope:
Two digit system is adopted. First digit represents the number of strands. Second digit
represents the number of wires in a single strand.
3 Labeling addendum and flank over a simple gear tooth profile
4 Gear tooth profile: Involute and Cycloidal
5 Use of Bevel gears: When power is required to be transmitted between intersecting
shafts, bevel gears are employed.
6 Material for worm & worm gear:
Worm: Carbon steel & Alloy steel
Worm Wheel: Gray Cast Iron & Bronze
7 Step ratio: It is the ratio between one speed and the next lower speed of a gear box. In
general R20 series is employed to arrange the speeds of a multi speed gear box.
8 Applications of constant mesh gear box: Cars, Passenger vehicles
9 Cam profile: Cycloidal cam
10 Brakes: Explanation about self locking & sense of taking moment about the fulcrum.
PART B
11(a) Design of V Belt:
Given: Power = 16 kW; N
1
= 1440 rpm; i = 3.6
Selection of belt type: Since P = 16 kW, C type cross section is selected. 2 marks
1
Determination of Centre distance: - 3 marks
Selection of d
min
= 200mm
Considering the effect of F
b
, Calculation of d
max
= 820mm
Using
D
C
=1, Centre distance C = 820 mm.
Check:
Calculation of Cmin = 0.55(D+d)+T = 575 mm
Cmax = 2(D+d) = 2040 mm
Since Cmin < C < Cmax, Calculation of C is correct.
Determination of Pitch length - 2 marks
C
d D d D
C L
4
) (
2
) (
2
2

+
+
+

= 3359 mm
Selection of various modification factors. - 2 marks
Correction factor for length =F
c
= 0.99
Service factor = F
a
=1.3
Arc of contact =
0 0
60 180
,
_

C
d D
= 134.6
0

Arc of contact factor = 0.88
Calculation of maximum power capacity - 2 marks
KW =
S S
d
S
e
) 10 34 . 2
7 . 142
47 . 1 (
2 4 09 . 0

= 7.129.
Determination of number belts - 3 marks
d c
a
b
F F KW
F P
n

= 4 belts.
Calculation of actual centre distance - 2 marks
432 . 439
8 4

,
_

+

d D L
A
48050 8 / ) (
2
d D B
3 . 820
2
+ B A A C
2
Actual centre distance = 820.3 mm.
OR
11(b) Design of wire rope:
Given: Load = 32 kN; weight of crane hook = 6 kN; g = 1.2 m/s
2
Selection of FOS: For Crane application, FOS = 6. 1 mark
Selection of wire type: 6 x 37 1 mark
Dead weight on the rope = 38 kN.
Design Load = 456 kN 2 marks
Determination of c/s area of wire A =
u
d
P

= 268 mm
2
Determination of wire diameter, d = 8.3 mm 10 mm. 4
marks
Wire Specification: 2 marks
Type: 6 x 37
Wire diameter = 10 mm
Approximate weight of wire = 4.5 N/m
Breaking strength = 68 kN
Determination of actual FOS:
i. During normal working: - 3 marks
Calculation of bending load:
xE
D
d
Ax F
w
b
min

= 4.86 kN
Total load applied = 42.86 kN
FOS = Breaking strength / Total load = 68/42.86 = 1.59 < FOS)selected
Hence Design is safe.
ii. During Acceleration: - 3 marks
Force due to acceleration: Fa =
0
g
g
x F
t = 4.64 kN
Total load applied = 47.51 kN
FOS = Breaking strength / Total load = 68/47.51 = 1.43 < FOS)selected
Hence Design is safe.
3
12(a) Design of Spur gear:
Given: N
1
= 1440 rpm; N
2
= 480 rpm; Z
1
= 25; Material: C45 steel
Power is not given in the problem. Hence the problem is solved with the assumption
of P = 1 kW
1) Selection of material: - 1 mark
C45 steel
Core hardness < 350 BHN

2
720
mm
N
u

2
360
mm
N
y

2) Calculation of design stresses - 2 marks
[ ]
1
4 . 1

nK
K
bl
b
Where
50 ) ( 25 . 0
1
+ +
y u

= 119.5
2
mm
N
[ ]
2
740 .
mm
N
K HRC C
cl R c

3) Centre distance calculation - 4 marks
[ ]
[ ]
3
2
.
74 . 0
) 1 (

,
_

1
]
1

+
i
M E
i a
t
c

mm a 56 . 22
4) Calculation of module - 3 marks

[ ]
[ ]
3
1
26 . 1
Z y
M
m
m b
t

m 5.89 mm = 6 mm.
Adopt m = 6, Revise a
( )
2
2 1
z z m
a
+
= 300 mm
5) Calculation of Gear geometries - 2 marks
Pinion Diameter, d = 125 mm
Wheel diameter, D = 375 mm
Number of teeth in pinion, Z
1
= 25
Number of teeth in Wheel, Z
2
= 75
Face width of the gear b = 90 mm
6) Revise Design Torque
[ ]
t
M
- 1 mark
[ ] Nm M k k k M
t d o t
130 . . .
4
7) Check for induced stresses - 3 marks
( )[ ]
[ ]
b
t
b
amby
M i
<
+

1

2 2
5 . 119 58
mm
N
mm
N
<
[ ] [ ]
c t c
M E
ib
i
a
i
<
,
_

+ +
.
1 1
74 . 0

2 2
740 3 . 631
mm
N
mm
N
<
Hence the design is safe.
OR
12(b) Design of Helical gear:
Given: P = 30 kW; i = 4; N
1
= 2000 rpm; Material: 15 Ni2CrlMol5 steel
1) Selection of material - 1 mark
Both Pinion & Gear : 15 Ni2CrlMol5 steel
2 2
600 , 950
mm
N
mm
N
y u

2) Calculation of design stresses - 2 marks
[ ]
1
4 . 1

nK
K
bl
b
Where
1200 ) ( 35 . 0
1
+
u

= 894.5
2
mm
N
[ ]
2
1705 .
mm
N
K HRC C
cl R c

3) Centre distance calculation - 4 marks
[ ]
[ ]
3
2
.
7 . 0
) 1 (

,
_

1
]
1

+
i
M E
i a
t
c

mm a 48 . 39
4) Calculation of module - 3 marks

[ ]
[ ]
3
1
15 . 1
Z y
M
Cos m
m b v
t
n

n
m
2.22 mm = 2.5 mm.
Corrected number of teeth
( ) 1
2
1
+

i m
aCos
Z
n

=20
Adopt m = 2.5mm, Revise a
( )
2
2 1
z z m
a
n
+
= 125 mm
5
5) Calculation of Gear geometries - 2 marks
Pinion Diameter, d = 50 mm
Wheel diameter, D = 200 mm
Number of teeth in pinion, Z
1
= 20
Number of teeth in Wheel, Z
2
= 80
Face width of the gear b = 37.5 mm
6) Revise Design Torque
[ ]
t
M
- 1 mark
[ ] Nm M k k k M
t d o t
2 . 171 . . .
7) Check for induced stresses - 3 marks
( )[ ]
[ ]
b
v n
t
b
by am
M i
<
+

1
7 . 0

2 2
5 . 895 2 . 127
mm
N
mm
N
<
[ ] [ ]
c t c
M E
ib
i
a
i
<
,
_

+ +
.
1 1
7 . 0

2 2
1705 15 . 310
mm
N
mm
N
<
Hence the design is safe.
13(a) Design of Bevel gear:
Given : P = 16.5 kW; N
1
= 500 rpm; N
2
= 200 rpm
1) Selection of material: - 1 mark
C45 steel with Case hardened
Core hardness > 350 BHN

2
720
mm
N
u

2
360
mm
N
y

2) Calculation of design stresses - 2 marks
[ ]
1
4 . 1

nK
K
bl
b
Where
50 ) ( 25 . 0
1
+ +
y u

= 186.5
2
mm
N
[ ]
2
740 .
mm
N
K HRC C
cl R c

3) Determination of Cone radius R - 4 marks
( )[ ]
[ ]
mm
i
M E
i R
t
c y
y
56 . 55
5 . 0
72 . 0
1
2
2

,
_

,
_

4) Determination of
t
m
- 2
marks
6

[ ]
[ ]
3
1
26 . 1
Z y
M
m
m b v
t
av

4.23 mm
Using,
( ) 5 . 0

y
y
av t
m m

= 5 mm
5) Revise R and find b. - 2 marks
Using mm z i m R
t
7 . 134 . 1 5 . 0
1
2
+
mm
R
b 9 . 44
3

6) Calculate
av av
d m
1
,
and pitch line velocity - 2
marks
mm
R
b R
m m
t av
17 . 4
5 . 0

,
_

mm m z d
av av
33 . 83
1 1

Pitch line velocity,
s
m
n d
V
av
18 . 2
1000 * 60
1 1


7) Revise k,
d
k
and
[ ]
t
M
- 1
mark
K=1.1
1
d
k
.4, for class 8 gears, V= 2.18 m/s,
[ ] Nm M
t
8 . 450
8) Check for induced stresses - 2 marks
( )
[ ]
2
2
2
1
3
2
740 34 . 263 .
1
5 . 0
72 . 0
mm N
mm
N
M E
ib
i
b R
t c
<
1
1
]
1

,
_

[ ]
( )
2 2
2
2
5 . 186 78 . 143
. 5 . 0
1
mm
N
mm
N
y m b b R
M i R
v av
t
b
<

+

Hence the design is safe.
OR
13(b) Design of Worm gear:
Given : P = 20 kW; Worm speed = 1440 rpm; i = 24
1) Selection of materials - 1 mark
a) Worm - steel
b) Wheel bronze (sand cast)
7

[ ]
2
2
/ 50
/ 390
mm N
mm N
b
u

<

2) Calculation of center distance - 3 marks

( ) [ ]
( )[ ]
[ ]
3
2
10 /
540
1 /
t
c
M
q z
q z a
1
]
1

= 326 mm
3) Calculation of axial module - 2 marks
( ) z q a m
x
+ / 2
= 10mm
4) Revise a and obtain d
1
- 2 marks
( )
mm qm d
mm z q m a
x
x
110
415 5 . 0
1

+
5) Revise k, k
d
and
[ ]
t
M
for actual pitch line velocity of the wheel. - 2
marks

1000 60
1440
2

a
zp
V
=2.2 m/s
6) Determination of induced stresses - 2 marks
( ) [ ]
10
1 /
/
540
3
t
c
M
a
q z
q z
1
]
1

+

= 127 N/mm
2
[ ]
v x
t
b
qzy m
M
3
9 . 1

= 50 N/mm
2
7) Efficiency - 2 marks
( )

tan
tan
8
= 0.847 = 85 %
8) Determination of Housing area - 2 marks
( ) 1 Input power = K
t
(t
o
-t
a
) A
A= 8.6 m
2
Calculation of Heat generated, H
g
= 3 kW
Calculation of Heat dissipated, H
d
= 73.44kW
Since H
d
> H
g
, No external cooling is required
14(a) Design of 9 speed gear box:
Given: N = 9; N
min
= 100 rpm;

= 1.25; P = 4 kW; N
motor
= 1400 rpm;
Using, N
max
/ N
min
=
1 9
25 . 1

,
The speeds are 100, 125, 160, 200, 250, 315, 400, 500, 630 rpm. 2 marks
Construction of Ray diagram - 5 marks
Construction of kinematic arrangement - 5 marks
Calculation of number of teeth & % of error - 6 marks
Between Input & Intermediate Shaft:
Using Z
1
+Z
2
= Z
3
+Z
4
= Z
5
+ Z
6
= 94 & Speed ratio,
Determination of Z
1
= 19; Z
2
= 75; Z
3
= 34; Z
4
= 60; Z
5
= Z
6
= 47
Between Output & Intermediate Shaft:
Using Z
7
+ Z
8
= Z
9
+ Z
10
= Z
11
+ Z
12
= 50
Determination of Z
7
= 22; Z
8
= 28; Z
11
= 28; Z
12
= 22; Z
9
= Z
10
= 25
Output speed & % of error calculation
Speed
Number
Output speed Standard
speed
% error
1 99.7 100.0 0.30
2 125.6 125.0 -0.48
3 158.3 160.0 1.063
4 198.4 200.0 0.80
9
5 250.0 250.0 0.0
6 315.0 315.0 0.0
7 396.8 400.0 0.80
8 500.0 500.0 0.0
9 630.0 630.0 0.0
The permissible deviation =
( ) % 5 . 2 % 1 10 t
The deviations are well within the permissible limits.
OR
14(b) Design of 12 speed gear box:
Given: N = 12; N
min
= 16 rpm; N
max
= 900 rpm.
Calculation of speed ratio, N
max
/ N
min
=
900/16 =
1 12
,

= 1.44 - 2
marks
The speeds are
16, 22.4, 31.5, 45, 63, 90, 125, 180, 250, 355, 500, 710 rpm - 2 marks
Construction of Ray diagram - 6 marks
Construction of kinematic arrangement - 6 marks
Calculation of number of teeth - 4 marks
10
Between Input & Intermediate Shaft1:
Using Z
1
+Z
2
= Z
3
+Z
4
= 76 & Speed ratio,
Determination of Z
1
= 20; Z
2
= 36; Z
3
= 20; Z
4
= 36;
Between Intermediate shaft1& Intermediate Shaft2:
Using Z
5
+ Z
6
= Z
7
+ Z
8
= 76 & Speed ratio,
Determination of Z
5
= 26; Z
6
= 56; Z
7
= Z
8
=38
Between Output & Intermediate Shaft2:
Using Z
9
+ Z
10
= Z
11
+ Z
12
= Z
13
+ Z
14
= 70 & Speed ratio,
Determination of Z
9
= 29; Z
10
= 42; Z
11
= 35; Z
12
= 35; Z
13
= 29; Z
14
= 41
15(a) Design of Clutch:
Given:
Case 1: n
1
= 3; n
2
= 2; Number of contacts = 4; d
o
= 240 mm; d
i
= 120 mm;

=0.3;
Uniform pressure; P = 25 kW; N = 1575 rpm.
Case2: Number of springs = 6; k = 13kN/m; = 1.25 mm.
Case1:
Using Power equation, determination of Torque transmitted,
T = 151.5 N-m 2 marks
Determination of mean radius R =
1
]
1

2
2
2
1
3
2
3
1
3
2
r r
r r
= 93.3 mm 3 marks
11
Determination of total spring load W =
R n
T

= 1353 N 3
marks
Case2:
Determination of axial load = 573 N 2 marks
Determination of mean radius R = 0.09m 2 marks
Determination of torque transmitted, T = 62 N-m 2 marks
Determination of Power transmitted = 10.23 kW. 2 marks
OR
15(b) Design of Cam:
Given: Type of motion : UAR;
R O

= 60
0
;
D

= 20
0
; S = 37.5 mm; R = 50 mm;
r = 25 mm
Construction of displacement diagram - 3 marks
Construction of cam profile - 9 marks
Determination of maximum velocity during outstroke = 71.62

mm/sec 1
mark
Determination of maximum velocity during return stroke = 71.62

mm/sec 1
mark
Determination of maximum acceleration during outstroke = 136.78

2
mm/sec
2

1 mark
Determination of maximum acceleration during return stroke = 136.78

2
mm/sec
2

1 mark
12