Tutorial Sheet-II

MEC3110/317 (Machine Design II)

Q.1 A taper roller bearing has a dynamic load capacity of 26 kN. The desired life for 90% of the
bearings is 8000 hr and the speed is 300 rev/min. Calculate the equivalent radial load that the
bearing can carry.
Q.2 A single-row deep groove ball bearing No. 6002 is subjected to an axial thrust load of 1000 N
and a radial load of 2200 N. Find the expected life that 50% of the bearings will complete under
the condition. Take C0 = 2500 N and C = 5590 N.
Q3 A certain application requires a ball bearing with the inner ring rotating, with a design life of
30000 hour at the speed of 300 rev/min. The radial load is 1.898 kN and an application factor
of 1.2 appropriate. The reliability goal is 0.90. the catalogue rating C 10 . Choose a 02-series
deep-groove ball bearing from Table (Refer table 11-2 from Shigley), and estimate the
reliability in use.
Q.4 An angular contact, inner ring rotating, 02 series ball bearing is required for an application in
which the life requirement is 50000 hour at 480 rev/min. The design radial load is 2715 N. The
application factor is 1.4. The reliability goal is 0.90. Find the catalogue rating C 10. Choose a
bearing and estimate the existing reliability in service.
Q.5 A transmission shaft rotating at 720 rpm and transmitting power from pulley P to spur gear G
shown in fig. 1. The belt tensions and gear tooth forces are as follows : P1=498N , P2=166N,
Pt=497N, Pr=181N. The weight of the pulley is 100N. The diameter of the shaft at bearings
B1 and B2 is 10mm and 20mm respectively. The load factor is 2.5 and expected life for 90%
of the bearing is 8000hr. Select single row deep groove ball bearings at B1 and B2.
Q.6 A shaft transmitting 50 KW at 125 rpm from gear G1 to gear G2 and mounted on two single –
row deep groove ball bearings B1 and B2 is shown in fig. 2. The gear tooth forces are
Pt1=15915N, Pt2=9549N, Pr1=5793N, Pr2=3476N. The diameter of the shaft at bearings B1
and B2 is 75mm.The load factor is 1.4 and the expected life for 90% of the bearings is 10000hr.
Select suitable ball bearings.
Q.7 The figure (Pr. 11.11, Shigley) is a schematic drawing of a counter shaft that supports two V-
belt pulleys. The counter shaft runs at 1200 rev/min and the bearings are to have a life of 60 kh
at a combined reliability of 0.999. The belt tension on the loose side of pulley A is 15 percent
of the tension on the tight side. Select deep groove bearing from Table (Refer table 11-2
Shigley), for use at O and E, Each to have a 25 mm bore, using an application factor of unity.
Q.8 Determine the proper pitch, module face, number of teeth, and outside diameters of a pair of
20o involute full depth spur gears to transmit 112.5 kW, from a pinion running at 750 rev/min
to a gear running at 140 rev/min. The service is intermittent with light shocks.
Q.9 It’s required to design a spur gear speed reducer for a compressor running at 250 rpm driven
by a 7.5kW, 1000 rpm electric motor. The center distance between axes of the gear shafts
 should be exactly 250 mm. The starting torque of the motor can be assumed to be 150% of the
rated torque. The gears are made of carbon steel 50C4 (Sut= 700 N/mm2). The pressure angle
is 20o. The factor of safety is 2 for preliminary design based on the use of velocity factor.
(i) Design of the gears and specify their dimensions
(ii) Assume that the gears are manufactured to meet the requirements of grade 6 and
Calculate the dynamic load by using Buckingham’s equation.
(iii) Calculate the effective load.
(iv) What is the actual factor of safety against bending failure?
(v) Using the same factor of safety against fitting failure, specify suitable surface
hardness for the gears.
Q.10 The following data is given for a pair of parallel helical gears made of steel:
Power transmitted = 20 kW
Speed of pinion = 720 rpm
No. of teeth on pinion = 35
No. of teeth on gear = 70
Center distance = 285 mm
Normal module = 5 mm
Face width = 50 mm
Normal pressure angle = 20o
Ultimate tensile strength = 600 N/mm2
Surface hardness = 300 BHN
Grade of machining = Gr. 6
Service factor = 1.25
Calculate the helix angle, the beam strength, the wear strength, the static load , the dynamic
load by Buckingham’s equation, the effective load, the effective factor of safety against
bending failure and the effective factor of safety against pitting failure.
Q.11 A transmission shaft, rotating at 720 rpm and transmitting power from the pulley P to the spur
gear G (Fig. 1.) The belt tensions and the gear tooth forces are as follows:
P1=498 N, P2= 166 N, Pt=497 N, Pr = 181 N
The weight of the pulley is 100 N. The diameter of the shaft at bearing B1 and B2 is 10 mm and
20 mm respectively. The load factor is 2.5 and the expected life for 90% of the bearing is 8000
h. Select single-row deep groove ball bearing at B1 and B2.
Q.12 A shaft transmitting 50 kW at 125 rpm from the gear G1 to the gear G2 (Fig. 2), and mounted
on two single-row deep groove ball bearing B1 and B2. The gear tooth forces arePt1= 15915
N, Pr1=5793 N, Pt2= 9549 N, Pr2= 3476 NThe diameter of the shaft at bearing B1 and B2 is 75
mm. The load factor is 1.4 and the expected life for 90% of the bearing is 10000 h. Select
suitable ball bearing.
Q.13 A ball bearing subjected to a radial load of 3000 N is expected to have a satisfactory life of
10000 h at 720 rpm with a reliability of 95%. Calculate the dynamic load carrying capacity of
the bearing, so that it can be selected from a manufacturer’s catalogue based on 90% reliability.
If there are four such bearings, each with a reliability of 95% in a system, what is the reliability
of the complete system?
Q.14. It is required to design a helical compression spring subjected to a force of 500 N. The
deflection of the spring corresponding to this force is approximately 20 mm. The spring index
should be 6. The spring is made of cold-drawn steel wire with ultimate tensile strength of
1000N/mm2. The permissible shear stress for the spring wire can be taken as 50% of the
ultimate tensile strength (G= 81370 N/mm2). Design the spring and calculate:
(i) Wire diameter,
(ii) Mean coil diameter,
(iii) Number of active coils,
(iv) Total number of coils,
(v) Free strength of the spring, and
(vi) Pitch of the coils.
Assume a gap of 1 mm between adjacent coils under maximum load conditions. The spring
has square and ground ends.
Q.15. In an automotive plate clutch, six helical compression springs arranged in parallel provide the
axial thrust of 1500 N. The springs are compressed by 10 mm to provide this thrust force. The
springs are identical and the spring index is 6. The springs are made of cold-drawn steel wires
with ultimate tensile strength of 1200 N/mm2. The permissible shear stress for the spring wire
can be taken as 50% of the ultimate tensile strength (G=81370 N/mm2). The spring have square
and ground ends. There should be a gap of 1 mm between adjacent coils when the springs are
subjected to the maximum force. Design the springs and calculate:
(i) Wire diameter,
(ii) Mean coil diameter,
(iii) Number of active coils,
(iv) Total number of coils,
(v) Solid length,
(vi) Free length,
(v) Required spring rate, and
(vi) Actual spring rate.
Q.16. A semi-elliptic leaf spring consists of two extra full-length leaves and six graduated-leaves,
including the master leaf. Each leaf is 7.5 mm thick and 50 mm wide. The centre-to-centre
distance between the two eyes is 1 m. The leaves are pre-stressed in such a way that when the
load is maximum, stresses induced in all the leaves are equal to 350 N/mm 2. Determine the
maximum force that the spring can withstand.
Q.17. A semi-elliptic leaf spring consists of two extra full-length leaves and eight graduated-length
leaves, including the master leaf. The centre-to-centre distance between the two eyes of the
spring is 1 m. The maximum force acting on the spring is 10 kN and the width of each leaf is
50 mm. The spring is initially pre-loaded in such a way that when the load is maximum, the
stresses induced in all the leaves are equal to 350N/mm2. The modulus of elasticity oh the leaf
material is 207000 N/mm2. Determine
(i) The thickness of leaves, and
(ii) The deflection of the spring at maximum load.

Figure - 1

Figure - 2