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B.E / B.Tech. PRACTICAL END SEMESTER EXAMINATIONS

Sixth Semester

AT8611- Computer Aided Engine and chassis Design Lab

(Regulations 2017)

Time : 3 Hours Answer any one Question Max. Marks 100

Aim/Principle/Apparatus Tabulation/Circuit/ Calculation Viva-Voce Record Total

required/Procedure Program/Drawing & Results
10 40 30 10 10 100

1 Design and draw a connecting rod assembly for a petrol engine from the following
data.

Diameter of piston = 100 mm, Stroke length = 120 mm, weight of

reciprocating part = 2kg length of the connecting rod = 320 mm, Engine
speed = 3000 rpm; max explosion pressure = 2.5MPa.

Suitable assumptions may be made with proper justification.

2 Design and draw a cast iron piston, piston pin and rings for a single acting four
stroke engine for the following data:

Cylinder bore = 100mm,

Stroke = 125 mm,

Maximum gas pressure = 5 N/mm2

Indicated mean effective pressure = 0.75 N/mm2.

Mechanical efficiency = 80%,

Fuel consumption = 0.3kg per brake power per hour

Higher calorific value of the fuel = 42 x 103 kJ/kg,

Engine speed = 2000 rpm.

Suitable assumptions may be made with proper justification.

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3 Design and draw a single throw centre crank shaft for IC engine for the following
data. The engine develops 6 kW at 1500 rpm. Stroke – 275 mm, cylinder bore –
225mm, length of the connecting rod 4.5 times crank radius. Maximum gas
pressure 2.5 N/mm2, gas pressure when the torque is maximum is 1.7 N/mm 2 when
crank angle is at 35 aTDC. The distance between bearings is 400 mm. Suitable
assumptions may be made with proper justification.

4 Design and draw a single throw, double view crank shaft made of forged steel for a
single cylinder IC engine having cylinder diameter of 110 mm and stroke length
130 mm. The engine develops 7 kW at 1800 rpm. The combustion pressure is 3.5
N/mm2. The maximum torque is developed when the piston is at 25 degree aTDC.
The burnt gas pressure at that moment is 2 N/mm 2. The crank shaft man bearings
are 320 mm apart. Suitable assumptions may be made with proper justification

5 A single cylinder diesel engine develops 15KW of power with stroke length of 300
mm. The engine is expected to run at 750rpm with the maximum gas pressure of
3.5N/mm2. The valve opens and closes at constant acceleration and deceleration
for each half of the lift. The length of rocker arm on either side of the fulcrum is
100mm with the included angle of 30º . The mass of the valve is 0.5 kg. Design
and draw the components of the valve mechanism. Suitable assumptions may be
made with proper justification

6 Design and draw a cast iron flywheel for a 4 stroke engine developing 60kW at
3200 rpm. The work done during power stroke is 1.2 times the average work done
during full cycle. The mean diameter of the flywheel is 0.4m.the total fluctuating
speed is limited to 5% of the mean speed. Suitable assumptions may be made with
proper justification

7 The following data refer to a circular are cam which operates flat faced follower:
Least radius- 50 mm, Total Lift – 25 mm, Flank Radius – 50 mm, Angle of lift –
70 degrees.
Calculate the principle dimensions and the draw the cam profile. Suitable
assumptions may be made with proper justifications
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8 A Four speed gear box is to be designed for a passenger car using helical teeth
for all gear trains except the low and reversed speed.

Gear ratios:

1st gear = 3.862:1

2nd gear = 2.562:1

3rd gear = 1.470:1

4th gear = 1:1

Maximum engine torque = 14.75kgf-m at 2450 rpm, Engine displacement = 1200

cc

Centre distance between the axes of main and lay shaft = 3.23 x 3√T (cm)

Where T= Maximum engine torque in kgf-m.

First reduction ratio = III speed ratio

 Minimum number of teeth in the smallest pinion for first speed = 20

 Effective wheel radius = 26.5 cm
 Rear axle ratio = 4.25:1
 Gross vehicle weight = 1250 kgf
 Assume any further data required suitably
Calculate:
I) Number of teeth in different gear providing forward speeds
ii) Actual gear ratios, the error is preferably within 5%
iii) Percentage of error between proposed and actual gear ratios
iv) If the second speed is in engagement calculate
a) The resultant axial loads at the front and rear bearings
b) The resultant radial loads at the front and rear bearings
With the following data:
The distance between front and rear bearings = 22.5 cm
The distance from front bearing to first reduction train = 4.75 cm
The distance from front bearing to second speed train = 16.25 cm

9 Design a single plate clutch friction discs and coil springs with the following
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data:
 Maximum engine torque = 17.50 kgf-m.
 Pressure intensity on the friction disc = 11.77/ √do kgf/cm2
 Mean radius of the spring coil = 20mm
 Maximum allowable shear stress for the spring wire material = 5250 kfg/
cm2
 Number of active coils = 6
 Number of springs used = 6.
10 The pinion A on the propeller shaft has a 12teeth and the gear with crown wheel
B of 60 teeth, shafts R and S form the rear axles to which the road wheels are
attached as shown in figure.

a) Show that the speed of casing is the mean of the speed of the two rear wheels
when the vehicle is taking turn
b) If the propeller shaft has a speed of 1000rpm and the road wheel which is
driven by C has a speed of 210rpm. What is the speed of road wheel driven by
D?
C) In which direction the vehicle is staking a turn?
Draw the assembly drawing of a final drive with the calculated dimensions using
design software.

11 A cone clutch is used to connect an electric motor running at 1440 rpm with a
machine which is stationary. The machine has equivalent to a rotor of mass 150 kg
and radius of gyration as 250mm. The machine has to be brought to the full speed
1440 rpm from a stationary condition in 40 s. The semi cone angle is 12.5°. The
mean radius of clutch is twice the face width. The co-efficient of friction is 0.2 and
the normal intensity of pressure between contacting surfaces shouldn’t exceed
0.1N/mm2. Assume uniform wear. Find
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a. The inner & outer diameter

b. The face width of friction lining

c. The force required to engage the clutch

d. The amount of heat generated during engagement of clutch

Draw the assembly drawing of the cone clutch with the above dimensions
using design software.

12 A sliding contact mess type gear box with forward speed and one speed is to be
designed. The gear box should have the following gear ratios approximately 1,
1.38, 2.24, 3.8 and the gear ratio on reverse gear is 3.8. Assume layout shaft or
counter shaft speed is half that of engine speed and the smallest gear is not to have
less than 15 teeth. Calculate the number of teeth of the various gears and draw the
assembly drawing of sliding mesh gear box when it is in reverse gear position.
Draw the assembly and layout drawing of the sliding mesh gear box with the above
dimensions using design software.

Design and draw a trunk type of piston for a single cylinder diesel engine running
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at 1000 rpm, other element data are: (a) Max explosion pressure = 3.5 N ¿ m 2 (b)
Mean effective pressure is 0.5 MPa (c) piston diameter = 102 mm (d) stroke
length = 200 mm (e) connecting rod length = 450mm (f) BSFC = 0.27 kg/kW/hr.
14 Discuss the design of ring gear of flywheel and draw it.

Design and draw a connecting rod for a petrol engine form the following data:
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Diameter of the piston = 100 mm (b) stroke Length = 140 mm (C) length of
connecting rod = 222 mm (d) Weight of reciprocating parts = 2 kg (E) Maximum
Explosion pressure = 2.25 N¿ mm2.
16 Explain the design procedure of the inlet and exhaust valves and draw the valve
assembly.

Design and draw a plain steel centre crankshaft for a single cylinder 4 stroke CI
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engine for following data: Bore = 400 mm, stroke = 600 mm, Engine speed = 200
rpm, NTP = 0.5 N /mm2, Maximum combustion pressure = 0.25 N /mm2, Weight of
fly wheel 50 kN, total beet pull + 6.5kN, Weight of the crank has turned through
35° from the TDC the pressure on the piston in N /mm2, and the torque the crank is
max. The ratio of the connecting rod length to the overall ratio is 5. Assume any
other data required for the design.
18 Explain the design procedure of cam and cam shaft and draw the same.
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Design and draw a fly wheel for a multi-cylinder four stroke petrol engine
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developing the power of 55 kW at 2500 rpm, assume the co-efficient fly wheel
speed Cs = 0.01.
20 Assume suitable dimensions and draw the single plate clutch assembly.

21 The load distribution between the front and the rear axle of a motor vehicle
weighing 13500 N is that 48% of the load is taken by the front axle. The width of
the track is 140 cm and the distance between the centers of the spring pads is 66
cm. Design a suitable I section for the front axle assuming that the width of the
flange and its thickness are 0.6 and 0.2 of the overall depth of the section
respectively and the thickness of the web 0.25 of the width of the flange. Assuming
a working stress of 9150 N/cm2. Draw the front axle.

22 Draw the assembly drawing of a three speed gear box.

A cone clutch with a cone semi-angle of 120° is to transmit 11.19 kW at 750 rpm.
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The width of the face is 1/4th of the mean diameter and the normal pressure
between the contact faces is not to exceed 8.27 X 104 Pa allowing the co efficient
of friction of 0.2, Determine the main dimensions of the clutch and the axial force
required. Draw the clutch components.
24 Explain the procedure to calculate the bearing loads in a gear box. Draw the
bearings.

A gear box with three speeds forward and one reverse is to provide the speed
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reduction as follows. Top is 5.1:1, intermediate 8.8:1, low 15.5:1, reverse 19.8:1
with a constant reduction of 5.5:1 at the rear axle. Assuming that the smallest
pinion has not less than 15 teeth and speed of the lay shaft half of the main driving
shaft, find the suitable number if teeth of different gears. Draw the layout of the
gear box.
26 Explain how the bearings can be selected for a gear box. Draw any two types of
bearings.

An engine develops 29.5 kW at 2000 rpm when the torque developed is maximum.
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The bottom gear ratio is 3:1 and the back axle reduction is 4.5:1. The load on each
driving axle is 7357.5 N. When the car is fully loaded, diameter of road wheel over
the tyre is 0.6. If the permissible stress in the material of the shaft is not allowed to
exceed 220725 X 104 Pa, find the diameter of the axle shaft. Draw the axle shaft.
28 Explain the design procedure of a propeller shaft. Draw the propeller shaft
assembly.
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Calculate the maximum bending moment and maximum section modulus of the
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frame assuming the following particulars: Wheel base = 180 cm; Overall length =
360 cm; Equal overhang on both sides; 2700 N acting at CG of load 45cm in front
of front axle; 800 N acting at CG of load 45 cm behind front axle; 80kgf acting at
CG of load 45cm in front of rear axle; 675 N acting at CG of load 45 cm behind
the rear axle. In addition there is a uniformly distributed load of 17.5 N per cm run
over the entire length of the chassis. Assume dynamic stress = twice the static
stress induced. Also assume allowable bending Stress is 6000 N/cm2. Draw the
frame.
30 Discuss the design details of final drive and draw its assembly drawing.

A torque of 350 Nm is transmitted through a cone clutch having a mean diameter if

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300 mm and a semi cone angle of 15 deg. The maximum normal pressure at the
mean radius is 150 kN/m2. The coefficient of friction is 0.3. Calculate the width of
the contact surface. Also find the axial force to engage the clutch. Draw the clutch.
32 Explain the design details of full floating and semi floating axles. Draw any one.

33 Design a piston for the following specification. Bore dia 100 mm, stroke length
125 mm, max gas pressure is 5N/mm2, IMEP is 0.75 N/mm2, ɳm = 80%, mass of
fuel consumed I 0.15 kg/bp hour and HCV of fuel is 42000 kJ/kg, engine speed is
2000 rpm.

34 Design a connecting rod for an I.C. Engine running at 1800 r.p.m and developing a
maximum pressure of 3.15N/mm2. The diameter of the piston is 100mm , mass of
the reciprocating part per cylinder is 2.25 kg , length of the connecting rod is
380mm, stroke of the piston 190mm and compression ratio 6:1 . take a factor of
safety of 6 for the design. Take length to diameter ratio for big end bearing as 1.3
and small end bearing as 2 and the corresponding bearing pressure as 10 N/mm2
and 15 N/mm2. The density of the material is 6000kg/mm3 and allowable stress in
the bolts as 60 N/mm2. The rod is to be of I-section for which you can choose your
proportions.

35 Design a plain carbon steel centre crank shaft for a single acting four stroke single
cylinder engine for the following data: Bore=400mm, speed=200 r. p. m . Mean
effective pressure= 0.5 N/m2, maximum combustion pressure=2.5 N/mm2, weight
of the flywheel used as a pully= 50kN, total belt pull=6.5 Kn. When the crank has
turned through 35o from the top dead centre, the pressure on the piston is 1 N/mm2
and the torque on the crank is maximum. The ratio of the connecting rod length to
the crank radius is 5. Assume any other data required.

36 Design a CI flywheel with six arms for four stroke engine developing 70 kw at 300
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rpm. The fluctuation of speed ±2.5% of main speed. The work done during power
stroke is 1.4 times the average work done during the whole cycle. Peripheral
velocity is limited to 30m/s. Allowable shear stress for the crank shaft and the key
material is 40N/mm2 and the tensile stress for CI is 20N/mm2, b=2t and the major
axis of the elliptical arm is twice the minor axis.

37 Design a conical valve of an I. C. Engine is 60 mm in diameter and is subjected to

a maximum gas pressure of 4N/mm2. The safe stress in the bending for the valve
material is 46 Mpa. The valve is made of steel for which K=0.42. The angle at
which the valve disc seat is tapered is 300.

38 Design the various components of the clutch and to decide upon the major
dimensions. A single dry plate clutch is to be designed to transmit 7.5 KW at 9000
r.p.m. find.

1. diameter of the shaft

2. mean radius and face width of the lining assuming the ratio of the mean radius
to the face width as 4

3. outer and inner radii of the clutch plate.

4. dimensions of the spring, assuming the number of springs are 6 and spring
index=6. The allowable shear stress for the wire may be taken as 420Mpa.

39 Design a sliding type gear box with four forward and one reverse speeds and
explain clearly how the different speed ratios will be obtained in the following
cases.

Gear ratio on top gear = 1:1

Gear ratio on third gear = 1.38:1

Gear ratio on second gear = 2.24:1

Gear ratio on first gear = 3.8:1

Gear ratio on reverse gear = 3.8:1

Assume counter shaft or lay shaft speed is half that of the engine speed and the
smallest gear is not to have less than 15 teeth.

40 Design of propeller shaft an automobile develops 28 Kw of 1500 rpm and its

bottom gear ratio 3.06. It a propeller shaft 40 mm outside is to be used find the
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inner dia. And length of the shaft mild steel to be used. Assume the shear stress of
55*103Kpa for mild steel shaft.