ME! BE MECH. HANICAL Code No. 2384/.N FACULTY OF ENGINEERING B.E. 3/4 (MIP) Il-Semester (Main) Examination, April / May 2013 ‘Subject : Machine Design Time : 3 Hours ‘Max. Marks: 75 Note: Answer all questions of Part - A and answer any five questions from Part-B, PART—A (25 Marks) 1. What is concentric spring? Enumerate the advantages. What is nip of leaf spring? Explain. ‘Compare the beam strength of spur and helical gears. ‘Sketch bevel and worm gears and show the forces acting on it. Describe the assumptions in differential equation derived by Osbome Reynold for theory of hydrodynamics lubrication. 6. Whatiis Lio and Lyanlife of the bearing? 7. Describe the materials used and their properties for piston and connecting rod. 8. What are design considerations for the fly wheel used in IC Engines? 9. How curved beam theory of bending is different from straight bending ? Explain. 10, Mention the criteria for the design of machine frames, PART —B (5x10=50 Marks) 14. A helical compression spring is required to deflect through 25mm when the ‘external force acting on it vaties from 500 to 1000N. The spring index is 8. The ‘spring has square and ground ends. There should be a gap of 2mm between adjacent coils when the spring is subjected to the maximum force of 1000N. The ‘spring is made of cold drawn steel wire with ultimate tensile strength of 1000 MPa, and permissible shear strength is 500 MPa, G=81370 MPa. Design the ‘spring the calculate : ()) wire diameter (i) Mean coil diameter (ii) number of active Coils (v) total number of coils (v) solid length (vi) free length. 12. Asemi eliptic leaf spring used for automobile suspension consists of three extra fulllongth leaves and 15 graduated leaves including the master leaf. The centre to centre distance between two eyes ofthe spring is 1.5m. The maximum force acting fn spring is 100 kN. For each leaf the ratio of width to thickness is ®:1.£=200GPa, the leaves are prestressed in such a way that when the force is maximum, the siresses induced in all leaves are same and equal to 450MPa. Determine () the ‘width and thickness of leaves, (ji the intial nip; and (ii) the initial preload roquired to close the gap C between extra full length leaves and graduated length loaves. 13. Astee! pinion with 20° full depth involute teeth is transmiting 7.5 KW power at 41000 rpm from an electric motor. The starting torque of the motor is twice the rated torque. The number of teeth on pinion is 25, while module is 4mm, The face width is 45mm. Assuming that velocity factor accounts for the dynamic calculate () the effective load on the gear tooth; and (i) the bending stresses in gear tooth.14, 15, 16. 17. Code No. 2384 /N ‘A pal of straight bevel gears consists of a 24 teeth pinion meshing with a 48 teoth ‘gear. The module at the outside diameter is 6mm, while face width is SOmm. The {gears are made of grey cast from FG 220 (Sut=220 MPa), pressure angle is 20°. ‘The teeths are generated and assume that velocity factor accoutns for the dynamic load. The pinion rotates at 300 rpm and the service factor is 1,5, calculate () the beam strength of the tooth, (i) the static load that the gears can, transmit with a ‘actor of safety of 2 for bending consideration and (i) the rated power that the gears can transmit. ‘A ball bearing with a dynamic load capacity of 22.8KN is subjected to a radial loads of 10KN. Calculate (i) the expected life in milion revolutions that 90% of the bearings will reach (i) the corresponding life in hours, if the shaftis rotating at 1500 ‘pm; and (i) the fife that 50% of the bearings will complete or exceed before fatigue failure, ‘The following data is given for the cap and bolts of big end of connecting rod; engine speed = 1500 rpm, Length of connecting rod = 320mm, Length of stroke=140mm, Mass of reciprocating parts = 1.76 kg, Length of crane pin=S4mm, Diameter of cranks pin = 38mm, Permissible tensile stress for bolts = 120 MPa, permissible bending stress for cap=120MPa, calculating the nominal diameter of bolts and thickness of cap of the big ond. Design a crane hook with the load lifting capacity ofthe crane as 260 KW. The weight of the hook is SOkN.si. 7 BE MECC MECHANICAL FACULTY OF ENGINEERING Code No. 2385 /N B.E. 3/4 (Mech.) It~ Semester (New) (Main) Examinat‘on, April / Way 2013 ‘Subject : Metal Cutting and Machine Tool Engineering Time : 3 hours ‘Max. Marks : 75 Note: Answer all questions from Part-A. Answer any FIVE questions from Part-B. PART A (25 Marks) 1. Sketch the geomety of twist drill and name all anglas and edges. @ 2. What are the types and functions of chip breakers in metal cutting? 3 3. What are types and properties of cutting fluids? s 4, Define machinability. How metals are rated? 2 5. Differentiate between shaper, planer and siotter. 3 6. Enlist work holding and tool holding devices in Lathe, Milling and Drilling machine. 3 7. Sketch various lathe operation carried out on a lathe machine. 2 8. Briefly describe the principle of thread grinding 2 9. What are the various quick ctamping devices? 3 40. What are the advantages of unconventional machining? 2 PART —B (5 x 10 = 50 Marks) 11.a) List various cutting tool materials, their properties and applications. 6 'b) Explain the nomenclature of single point cutting tool by ASA system. 4 12.a) Explain the temperature measurement by tool-work thermocouple method. 4 ') The following data were obtained while orthogonal cutting of M.S rod of 120 mm diameter with 10° rake angle tool, cutting speed 25 m/min, food 0.20 mmirev, length of chip is 150mm, cutting force 1500 N, feed force 650 N. Calculate i) Shear plane angle ii) Chip thickness, ii) Chip velocity and iv) Power required for cutting. (Missing data may be suitably assumed) 6 413.a) Define tool life. What are the factors effecting too ife. 5 ) Explain various operations carried out on milling machine. 5 14.2) Discuss the center less grinding with help of a neat sketch, 4 ) Explain the following |) Honing, il) Burnishing and. ii) Gear shaping. 6 15.) What are the design principles for clamping and location? 5 b) Explain the working principle of EDM with aid of neat sketch 5 16.a) Differentiate between driling and boring machines. 5 b) Explain the full type broaching operation with help of neat sketch 5 17. Write short notes on any TWO of the following (10) a) Merchant's theory b) Tool wear mechanism ©) AJM and ECM 4) Indexing methods