AUTOMOBILE DESIGN

Module 1

1. Mention the names of any seven types of kinematic pairs

2. A solid circular shaft is subjected to a bending moment of 3000 N-m and a torque of 10000
N-m the shaft is made of 45 C 8 Steel having ultimate tensile stress of 700MPa and a
ultimate shear stress of 500MPa. Assuming a factor of safety as 6, determine the diameter
of the shaft.
3. Write the classification of a machine design.
4. A hollow shaft of external and internal diameters 125, mm and 50mm is transmitting power
at 100 rpm. Find the power transmitted by *re shaft, if the shearing stress is not to exceed
45MPa
5. Sketch and explain the kinematic arrangements of a beam engine.
6. A solid shaft transmitting 560 kW power at 30O rpm. The maximum shear stress of the
material is 60 N/mm’? Find the diameter of the shaft.
7. Discuss the General procedure in design.
8. Sketch and explain the working of an elliptical trammel
9. A solid shaft is transmitting 1 MW at 240 rpm. Determine the diameter of the shaft, if the
maximum torque transmitted exceeds the mean torque by 2ooto. Take maximum allowable
shear stress as 60 MPa.
10. Give the classification of shafts.
11. explain the factors governing the design of machine elements.
12. Define inversions of a mechanism. give three inversions of four bar chain.
13. Write the purpose of thrust bearings? Give their types definitions in brief.
14. A line shaft rotating at 300 rpm is to transmit 32 kW. The shaft may be assumed to be made
of mild steel with an allowable shear stress of 42 MPa. Determine the diameter of the shaft,
neglecting the bending moment on the shaft.
15. List the classification of bearings.
16. Draw a neat sketch of crank and lever mechanism and indicate the links.
17. Explain the requirements of shaft couplings and mention the types.

Module 2
1. Give the classification of types of keys.
2. Describe the types of material used for belts.
3. A shaft runs at 400 rpm and drives another shaft at 600 rpm through belt drive. The
diameter of the driving pulley is 600 mm. Determine the diameter of the driven pulley in
the following cases. (i) Neglecting belt thickness; (ii) Taking belt thickness as 5 mm; (iii)
Assuming for case (1) a total slip of 5%; and (iv) Assuming for case (2) a slip of 2.5% on
each pulley
4. Design a muff coupling to connect two shafts transmitting 100 KW at 200 rpm. The
permissible shearing and crushing stresses for shaft and key material are 50 MPa and
100MPa respectively. The material of muff is cast iron with permissible shear stress of
15MPa. Assume that the maximum torque transmitted is equal to the mean torque
5. A flat key is used to transmit a toque of 470 N-m form a shaft of 50mm diameter to a
hub. Standard cross-section of the key is 16x10mm. Shearing and crushing stresses of
the key material are 40 MPa and 76MPa respectively. Determine length of the key.
6. Two parallel shafts 5 meters apart are provided with pulleys 500 mm and 750 mm in
diameter. Find the length of belt for following two conditions. @ For running the two
shafts in the same direction and (ii) For running the two shaft in opposite direction
7. A rectangular sunk key is used to connect a pulley to a 40mm diameter shaft. The
standard cross section of the key is 12 mm x 8 mm and 65mm long is required to
transmit 750 N-m torque. The key and shaft are made of same material. Determine
whether the length is sufficient if the permissible shear stress and crushing stresses are
limited to 60MPa and 150MPa respectively.
8. Explain the arrangement of compound belt drive with a sketch
9. Explain the reason for the slack side of the belt of a horizontal belt drive is preferable to
place on the top side.
10. A chain drive uses 1.25 cm pitch chain. The sprockets have 14 and 48 teeth and the
centre distance is 70 cm. Find the length of chain.
11. List the 6 advantages and 2 disadvantages of chain drive over belt drive.
12. Two pulleys 60 cm and 40cm diameters are connected by a belt. Centre distance
between the pulley is 6 meter Find the length of belt for (i) open belt drive, (ii) crossed
belt drive
13. Designarectangularsrnkkeyforashaftof6ftnmdiameter.Thepermissible shear stress is 35
N/mm'? and compression stress is 75 N/mm2
14. Give the classification of types of couplings
15. Two pulleys 60 cm and 40 cm diameter are connected by a belt. central distance '
between the pulleys is 6 m. Find the length of belt required for (i) open belt drive (ii)
Closed belt drive.
16. List 5 advantages and 2 disadvantages of chain drive
17. Design the rectangular key for a shaft of 50 mm diameter. The shearing and crushing
stresses for the key material arc 42 MPa and 70 MPa.
18. Discuss how shaft couplings are classified.
19. Two pulleys one 450 mm diameter and the other 200 mm diameter on parallel shafts
1.95 m apart are connected by a crossed belt drive. Find the length of the belt required,
velocity of the belt and the angle of contact between belt and each pulley when the
larger pulley rotates at 200 rpm.
20. Explain the various types of chains
21. Define keyway. State the effect of keyway cut into a shaft.
22. Design a muff coupling which is used to connect two steel shafts of diameter 55 mm.
The shafts transmit a power of 40 kW at 350 r.p.m. The material for the shaft and key is
plain carbon steel for which allowable shear and crushing stresses may be taken as 40
MPa and 80 MPa respectively. The material for muff is cast iron with an allowable shear
stress of 15 MPa.
23. A casting weighing 9 kN hangs freely from a rope which makes 2.5 tums round a drum of
300 mm diameter revolving at 30 r.p.m. The other end of the rope is pulled by a rnan.
The coefficient of friction is 0.25. Determine the force required by the man and power to
raise the casting.
 24. Briefly discuss the slip and creep related with belt

MODULE #

1. A single plate clutch, effective on both sides is required to transmit 25 KW at 3000 rpm.
Determine the outer and inner diameters of friction surface if coefficient of friction is 0.255,
ratio of diameters is 1.25 and the maximum pressure is not to exceed 0.1 N/mm2 . Also,
determine the axial thrust to be provided by springs. Assume the theory of uniform wear.
2. Explain the design considerations of a friction clutch.
3. For an automobile engine calculate thickness of connecting rod and size of cap bolt, given Bore
and stroke = 63x76mm, the diameter and length of crank pin are 41.27mm and 27.78mm
respectively. The thickness of shell bearing = 1.65 mm, weight of revolving parts of connecting
rod = 4.5N. Maximum engine speed 4500rpm. Maximum combustion force = 6750N.
Permissible stress on cap material = 105N/mm2 and permissible tensile stress in the bolt =
175/mm2.
4. Sketch and mark the parts of a single plate clutch.
5. List design considerations for an I.C. engine connecting rod.
6. Discuss the design considerations of an I.C. engine piston, Explain the procedure for designing
the piston barrel
7. List four forces acting on the connecting rod.
8. Derive the equation for mean radius of the friction surface of a single plate clutch considering
uniform pressure.
9. Write down the points to be considered during the design of a piston.
10. A multiple disc clutch has five plates having four pain of active friction surfaces. If the intensity
of pressure is not to exceed 0.127 Vnun2, find the power transmitted at 500 r.p.m. The outer
and inner radius of friction surfaces any, 125 mm and 75 mm respectively. Assume uniform
wear and take coefficient of friction as 0.3. O) Explain the procedure adopted for determining
the dimensions of cross section of the connecting rod.
11. A multiple - disc clutch transmits 50 kw of power at 1400 rpm. Axial intensity of pressure not to
exceed 0.121 N/mm2, and the coefficient of friction of the friction surfaces is 0.12 the inner
radius of the discs is 80 mm, and is 0.7 times the outer radius. Determine number of disc
required to transmit the given power. Assume uniform wear condition.
12. List the types of clutches used for power transmission
13. A single plate clutch with both sides effective, is required to transmit 25 kw at 900 rpm. The
outer diameter of the plate is 350 mm. the maximum intensity of pressure over the friction
surface is not to exceed 0.1 N/mm2. Considering uniform wear criteria and assuming
coefficient of friction as 0.251 determine (i) the inner diameter of the plate, (ii) axial force
required to engage the clutch.
14. Write any 7 design parameters of piston and write the materials used for the piston of an
engine.
15. Enumerate 6 functions performed by clutch.
16. A single plate clutch with both sides effective has outer and inner diameters 300 mm and
200mm respectively. The maximum intensity of pressure at any point in the contact surface is
 not to exceed 0.1N/mm2. If the coefficient of friction is 0.3, determine the power transmitted
by the clutch at a speed of 2500 r.p.m
17. A multiple disc clutch has 5 plates having 4 pairs of active friction surfaces. If the intensity of
pressure is not to exceed 0.1 27 N/mm2, find the power transmitted at 500 r.p.m. The outer
and inner radii of friction surfaces are 125 mm and 75mm respectively. Assume uniform wear
and take coefficient of friction is 0.3.
18. Illustrate a single plate clutch and mark various parts
19. Explain how the piston skirt is designed
20. A dry single plate clutch to be designed for an automobile vehicle whose engine is rated to give
100 kW at 2400 r.p.m and maximum torque 500 Nm. The outer radius of the friction plate is
25% more than the inner radius. The intensity of the pressure between the plate is not to
exceed 0.07 N/mm2. The coefficient of friction may be assumed equal to 0.3. Determine the
dimensions of the friction plate
21. A multiple disc clutch has five plates Having four pain of active friction surfaces. .The intensity
of pressure is not to exceed 0.153 N/mm2. Find the power transmitted at 450 r.p.m. The outer
and inner radius of friction surf-aces are 130 mm and 85 mm respectively Assume uniform
wear theory and take p as 0.3.
22. Express in words the function of the following parts of an I.C. engine piston.
(i) Head (ii) Skirt (iii) Piston pin (iv) Piston rings.
23. Design the crown part gf a piston for a four stoke engine for the following data. Bore: 100 mm,
stroke : 125 mm, maximum gas pressure : 5 N/mm2. Imep: 0.75 N/mm2, Mechanical efficiency
:80% , b.s.f.c= 0.15 kg/brake power/hr., calorific value = 42 MJ/kg. speed=2000 r.p.m

MODULE 4

1. Draw the profile of a cam operating flat face follower from the following data. (a) Lift
through 30mm during 90 degrees with SAM. (b) The follower remains rest for next 60
degrees. (c) The follower then falls to its original position during 90 degrees rotation of cam
with S.H.M. (d) The follower remains rest for remaining part of revolution. Assume minimum
radius of cam is 30mm.
2. Gear ratios for a small passenger car are as first gear 4.2:1, second gear 2.56:1, third gear
1.56:1 and top gear is 1:1. Inverse of the diametral pitch of each gear may be assumed as
3.25mm. The smallest pinion in the gear train must have at least 15 teeth, speed of the
engine shaft is 1.52 times speed of lay shaft in gear box. Calculate (a) Centre distance
between shaft and lay shaft (b) No. of teeth in each gear wheel (c) Actual gear ratios on the
basis of result of 2 above.
3. What are the different types of followers in cam mechanism.
4. A cam with 30 mm as minimum diameter is rotating clock wise at a uniform speed of 1200
rpm and has to grve the following motion to a roller follower 10 mm in diameter. (t)
Follower to complete outward stoke of 25 mm during 120degree of cam rotation with equal
uniform acceleration and retardation. ii) Follower to dwell for 60degree of cam rotation. iii)
Follower to return to its initial position during 90degree of cam rotation with equal uniform
acceleration and retardation. (iv) Follower to dwell for the remaining 90degree of cam
 rotation. Draw the cam profile if the axis of the roller follower passes through the axis of the
cam. 15
5. Two parallel shafts 600 mm apart are connected by spur gearing. The gears rotate at 120
rpm and 360 rpm respectively. Calculate the number of teeth required on each wheel, if the
diametral pitch of the teeth is 0.25 mm.
6. Explain reverted gear arrangement with a sketch.
7. Explain the classification of gears
8. A wheel has 48 teeth’s and a circular pitch of 24 mm. Find (i) pitch circle diameter, (ii)
diametral pitch. (b) Explain 7 terminologies of spur gears with a sketch. Ott (a) Draw the cam
profile for following conditions : Follower type = Knife edged. in-line ; lift = 50mm base circle
radius : 50mm; out stroke with SHM, for 60, cam rotation; dwell for 45degree cam rotation;
return stoke with SHM, for 90degree cam rotation; dwell for the remaining period, if the
cam rotates at 1000 rpm in clockwise direction.
9. List and explain different types of gears used for power transmission.
10. Describe 6 Cam terminologies with a sketch of cam and follow
11. A gear of 44 teeth has pitch circle diameter of 352mm. What is its module' circular pitch and
dedendum ?
12. Mention 5 advantages and 2 disadvantages of gear drive as compared to belt and chain
drive.
13. Draw the profile of a cam operating a knife edge follower from following data : (i) Lifts the
follower trough 40 mm during 60 degrees with S.H.M. (ii) The follower remains at rest for
next 45 degrees of rotation of cam. (iii) The follower then descends to its original position
during 90 degrees rotation of cam with S.H.M. (iv) The follower remains at rest for the
remaining part of the revolution. List radius of the cam is 25mm.
14. Sketch the displacement diagram when the follower moves wi*r uniform velocity and mark
the details.
15. With the aid of a diagram, show the terminology of radial cams.
16. A cam drives a flat reciprocating follower in the following manner. Out stroke through a
distance of 20 mm during 120degree of cam rotation with simple harmonic motion. Dwell
for the next 30 degree. The follower returns with simple harmonic motion for next 120
degree. Dwell during remaining 90 degree. Draw the profile of the cam when the line of
stroke of the follower passes through the axis of the camshaft. The minimum radius of the
cam is 25 mm.
17. Briefly mention about various tops of gears.
18. Explain with a neat sketch 1he compound gear train.
19. Sketch and explain a simple gear train
20. Explain how followers are classified according to the surface in contact.
21. A cam is to be designed for a knife edge follower with the following data. Cam lift : 40 mm
during 90degree of cam rotation with simple harmonic motion. Dwell for the next 30degree.
The follower returns with simple harmonic motion for next 60o. Dwell during remaining
180". The radius of the base circle of the cam is 40 mm. Draw the profile of the cam when
the line of stroke of the follower passes through the axis of the camshaft.
22. Write any ten terminology used to describe a gear.
23. Explain with a neat sketch the reverted gear train.
24. Write the different types of motion with which a follower can move.
25. discuss the advantages of gear drive