Mech Vi-Sem QB

JEPPIAAR INSTITUTE OF TECHNOLOGY
Self Belief | Self Discipline | Self Respect
QUESTION BANK
ACADEMIC YEAR : 2019-2020
REGULATION: 2017
III YEAR – 06th SEMESTER
DEPARTMENT OF MECHANICAL
ENGINEERING
INSTITUTION VISION
Jeppiaar Institute of Technology aspires to provide technical education in
futuristic technologies with the perspective of innovative, industrial and social
application for the betterment of humanity.
INSTITUTION MISSION
➢ To produce competent and disciplined high quality professionals with the

practical skills necessary to excel as innovative professionals and
entrepreneurs for the benefit of the society.
➢ To improve the quality of education through excellence in teaching and

learning, research, leadership and by promoting the principles of scientific
analysis, and creative thinking.
➢ To provide excellent infrastructure, serene and stimulating environment

that is most conducive to learning.
➢ To strive for productive partnership between the Industry and the Institute
for research and development in the emerging fields and creating
opportunities for employability.
➢ To serve the global community by instilling ethics, values and life skills
among the students needed to enrich their lives.
DEPARTMENT VISION
To be the most sought-after Department in the field of Mechanical Engineering for

imparting Technical Education for the upliftment of the society.
DEPARTMENT MISION
• To provide innovative solutions for industrial problems which helps in

societal development.
• To inculcate students for a successful career in engineering and technology.
• To promote excellence in engineering and technology by motivating
students for higher studies.
• To motivate self-employment thereby reducing migration to urban areas.
• To maintain ethical values while assimilating diverse culture without
compromising with Indian value system.
• To motivate lifelong learning
PROGRAM OUTCOMES (POs) (Given in SAR)
Engineering Graduates will be able to:

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex engineering
problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of mathematics,
natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems and
design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research
methods including design of experiments, analysis and interpretation of data, and synthesis of the
information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern
engineering and IT tools including prediction and modeling to complex engineering activities
with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess
societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to
the professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional engineering
solutions in societal and environmental contexts, and demonstrate the knowledge of, and need
for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and
norms of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or leader
in diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend and write
effective reports and design documentation, make effective presentations, and give and receive
clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a member and
leader in a team, to manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in
independent and life-long learning in the broadest context of technological change.
BLOOM’S TAXONOMY
Definition:
Bloom’s taxonomy is a classification system used to define and distinguish different levels
of human cognition like thinking, learning and understanding.
Objectives:
➢ To classify educational learning objectives into levels of complexity and
specification. The classification covers the learning objectives in cognitive,
affective and sensory domains.
➢ To structure curriculum learning objectives, assessments and activities.
Levels in Bloom’s Taxonomy:
➢ BTL 1 – Remember - The learner recalls, restate and remember the learned
information.
➢ BTL 2 – Understand - The learner embraces the meaning of the information by

interpreting and translating what has been learned.
➢ BTL 3 – Apply - The learner makes use of the information in a context similar to
the one in which it was learned.
➢ BTL 4 – Analyze - The learner breaks the learned information into its parts to
understand the information better.
➢ BTL 5 – Evaluate - The learner makes decisions based on in-depth reflection,

criticism and assessment.
➢ BTL 6 – Create - The learner creates new ideas and information using what has
been previously learned.
REGULATION : 2017 ACADEMIC YEAR : 2019-20
TABLE OF CONTENT
ME8651 – Design of Transmission Systems

Unit No. Topic Page No.
Syllabus 1-1
I Design of flexible elements 1-3
II Spur gear and parallel axis helical gears 1-15
III Bevel, worm and cross helical gears 1-32
IV Gear boxes 1-48
V Cams, clutches and brakes 1-64
ME8691 – Computer Aided Design and Manufacturing
Syllabus 2-1
I Introduction 2-3
II Geometric modeling 2-26
III CAD Standards 2-41
IV Fundamental of CNC and part programming 2-54
V Cellular manufacturing and flexible manufacturing systems 2-71
ME8692 – Finite Element Analysis
Syllabus 3-1
I Introduction 3-3
II One dimensional problems 3-17
III Two dimensional scalar variable problems 3-28
IV Two dimensional vector variable problems 3-43
V Isoparametric formulation 3-62
ME8693 – Heat and Mass Transfer
Syllabus 4-1
I Conduction 4-3
II Convection 4-33
III Phase change heat transfer and heat exchangers 4-57
IV Radiation 4-84
V Mass Transfer 4-110
ME8694 – Hydraulics and Pneumatics
Syllabus 5-1
I Fluid power principles and hydraulic pumps 5-2
II Hydraulic actuators and control components 5-16
III Hydraulic circuits and systems 5-29
IV Pneumatic and electro pneumatic systems 5-40
V Trouble shooting and applications 5-49
ME8091 – Automobile Engineering
Syllabus 6-1
I Vehicle structure and engines 6-3
II Engine auxiliary systems 6-12
III Transmission systems 6-25
IV Steering, brakes and suspension systems 6-37
V Alternative energy sources 6-46
REGULATION: 2017 ACADEMIC YEAR: 2019-2020
ME8651 DESIGN OF TRANSMISSION SYSTEMS L TPC
3003
OBJECTIVES:
➢ To gain knowledge on the principles and procedure for the design of Mechanical power Transmission
components.
➢ To understand the standard procedure available for Design of Transmission of Mechanical elements.
➢ To learn to use standard data and catalogues.
UNIT I DESIGN OF FLEXIBLE ELEMENTS 9

Design of Flat belts and pulleys - Selection of V belts and pulleys – Selection of hoisting wire ropes and pulleys –
Design of Transmission chains and Sprockets.
UNIT II SPUR GEARS AND PARALLEL AXIS HELICAL GEARS 9

Speed ratios and number of teeth-Force analysis -Tooth stresses - Dynamic effects – Fatigue strength - Factor of
safety - Gear materials – Design of straight tooth spur & helical gears based on strength and wear considerations –
Pressure angle in the normal and transverse plane- Equivalent number of teeth-forces for helical gears.
UNIT III BEVEL, WORM AND CROSS HELICAL GEARS 9

Straight bevel gear: Tooth terminology, tooth forces and stresses, equivalent number of teeth. Estimating the
dimensions of pair of straight bevel gears. Worm Gear: Merits and demerits terminology. Thermal capacity,
materials-forces and stresses, efficiency, estimating the size of the worm gear pair. Cross helical: Terminology-helix
angles-Estimating the size of the pair of cross helical gears.
UNIT IV GEAR BOXES 9

Geometric progression - Standard step ratio - Ray diagram, kinematics layout -Design of sliding mesh gear box -
Design of multi speed gear box for machine tool applications - Constant mesh gear box -Speed reducer unit. –
Variable speed gear box, Fluid Couplings, Torque Converters for automotive applications.
UNIT V CAMS, CLUTCHES AND BRAKES 9

Cam Design: Types-pressure angle and under cutting base circle determination-forces and surface stresses. Design of
plate clutches –axial clutches-cone clutches-internal expanding rim clutches-Electromagnetic clutches. Band and
Block brakes - external shoe brakes – Internal expanding shoe brake.
TOTAL : 45 PERIODS
OUTCOMES:
➢ Upon completion of this course, the students can able to successfully design transmission components used
in Engine and machines
TEXT BOOKS:
1. Bhandari V, “Design of Machine Elements”, 3rd Edition, Tata McGraw-Hill Book Co, 2010.
2. Joseph Shigley, Charles Mischke, Richard Budynas and Keith Nisbett “Mechanical Engineering Design”, 8th
Edition, Tata McGraw-Hill, 2008.
REFERENCES:
1. Sundararajamoorthy T. V, Shanmugam .N, “Machine Design”, Anuradha Publications, Chennai, 2003.
2. Gitin Maitra, L. Prasad “Hand book of Mechanical Design”, 2nd Edition, Tata McGraw-Hill,2001.
JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS
/UNIT 1-5/QB+Keys/Ver1.0
1-1
3. Prabhu. T.J., “Design of Transmission Elements”, Mani Offset, Chennai, 2000.
4. C.S.Sharma, Kamlesh Purohit, “Design of Machine Elements”, Prentice Hall of India, Pvt. Ltd.,2003.
5. Bernard Hamrock, Steven Schmid, Bo Jacobson, “Fundamentals of Machine Elements”,2nd Edition, Tata
McGraw-Hill Book Co., 2006.
6. Robert C. Juvinall and Kurt M. Marshek, “Fundamentals of Machine Design”, 4th Edition, Wiley,2005
7. Alfred Hall, Halowenko, A and Laughlin, H., “Machine Design”, Tata McGraw-HillBookCo.(Schaum’s Outline),
2010
8. Orthwein W, “Machine Component Design”, Jaico Publishing Co, 2003.
9. Ansel Ugural, “Mechanical Design – An Integral Approach", 1st Edition, Tata McGraw-HillBook Co, 2003.
10. Merhyle F. Spotts, Terry E. Shoup and Lee E. Hornberger, “Design of Machine Elements”8th Edition, Printice
Hall, 2003.
11. U.C.Jindal : Machine Design, "Design of Transmission System", Dorling Kindersley, 2010

1-2
Subject Code:ME8651 Year/Semester: III /06

Subject Name: Design Of Transmission Systems Subject Handler: Mr.S.Kanna & S.Vignesh
UNIT I –DESIGN OF FLEXIBLE ELEMENTS
Design of Flat belts and pulleys - Selection of V belts and pulleys – Selection of hoisting wire ropesand
pulleys – Design of Transmission chains and Sprockets.
PART * A
Q.No. Questions
1 Give an expression for ratio of tensions in a flat belt drive. BTL3

𝑇1
= 𝑒 𝜇𝜃
𝑇2
Where, T1=Tension in tight side in N; T2=Tension in slack side in N; µ=Coefficient of friction;
θ=Angle of contact of driving pulley in radians.
2 How is a V-belt specified?BTL2
A typical example of its specification “C2032 IS 2494: 1964”. Here the ‘C’ denotes the section
type of the belt, ‘2032’ represents the nominal inside length of the belt and 1964 is referred to as
year of coding. The power transmitting capacity of section’C’ type of the belt is 1 kW to 12 kW.
3 What is meant by “Chordal action of chain”? Also name a company that produces driving
chains. (April/May 2015)BTL1
When chain passes over a sprocket, it moves as a series of chords instead of a continuous arc as
in the case of a belt drive. It results in varying speed of the chain drive. This phenomenon is
known as chordal action. Some of the company names producing chains are: Roto mechanical
equipment Chennai: Monal Chains Limited, Mumbai; Innotech Engineers Ltd., New Delhi.
4 Why tight-side of the belt should be at the bottom side of the pulley?BTL4
The positions of input and output pulleys are such that the tight side of the belt must be on the
bottom and slack side on the top of the pulleys. Otherwise, the angle of contact between the belt
and rim of the pulley reduces, decreasing the power transmission capacity of the belt.
5 Definethe term “Crowning of pulley”. (Nov/Dec-2016, May/June 2014)BTL1
The pulley rims are tapered slightly towards the edges. This slight convexity is known as
crowning. The crowning tends to keep the belt in centre on a pulley rim while in motion. These
flat belts stayed centered on pulleys without any guides or flanges. The key to keeping them
tracking centered on the pulleys is the use of "crowned pulleys"
6 A longer belt will last more than a shorter belt. Why? (Apr/May 2017)BTL4
The life of a belt is a function of the centre distance between the driver and driven shafts and
diameter of driver and driven pulleys. The shorter the belt, the more often it will be subjected to
additional bending stresses while running around the pulleys at a given speed. And also it will
be destroyed quickly due to fatigue. Hence the increased centre distance and diameter of pulley
1-3
will increase the belt life. Hence, a longer belt will last more than a shorter belt.
7 Mention the losses in belt drives. (Nov/Dec 2014)BTL2
The losses in a belt drive are due to:
➢ Slip and creep of the belt on the pulleys (about 3%)
➢ Bending of the belt over the pulleys (about 1%)
➢ Friction in the bearings of pulley (about 1%) and
➢ Windage or air resistance to the movement of belt and pulleys (usually negligible)
8 In what ways the timing belts are superior to ordinary V-belts? (April/May 2015)BTL4
Flat belt and V-belt drives cannot provide a precise speed ratio, because slippage occurs at the
sheaves. But certain applications require an exact output to input speed ratio. In such situations,
timing belts are used. Since the timing belts (aka. synchronous belts) possess toothed shape in
their -inner side, engagement with toothed pulley will provide positive drive without, belt-slip
where as in the case of ordinary V-belts, chances of slip are and hence positive drive is not
possible at all times. Hence toothed belts (I timing belts) are superior to ordinary V-belts.
9 Why are idler pulleys used in a belt drive?BTL4
Idler pulleys are used to take up slack, change the direction of transmission, or provide
clutching action in any industry, material handling or any other mechanical purpose. But they
don’t provide any mechanical advantage, nor does it transmit power. One such example of its
application is to improve belt drive performances as they reduce vibration by supporting a
segment of belt which is prone to vibration/oscillation. They are also used in car engines for
positive clutching action by running the idler pulley on the slack side of the flat-belt drive from
engine to transmission.
10 Name the few materials for belt drives. (May/June 2016)BTL2
➢ Leather
➢ Fabric and cotton
➢ Rubber
➢ Balata and
➢ Nylon.
11 State the law of belting.BTL1
Law of belting states that the centre line of the belt as it approaches the pulley must lie in a
plane perpendicular to the axis of that pulley or must lie in the plane of the pulley, otherwise
the belt will run off the pulley. “The centreline of the belt when it approaches a pulley must lie
in the midplane of the pulley”.
12 What is wipping? How it can be avoided in belt drives?BTL3
If the centre distances between two pulleys are too long then the belt begins to vibrate in a
direction perpendicular to the direction of motion of belt. This phenomenon is called as
wipping. Wipping can be avoided by using idler pulleys.
13 How are wire ropes designated? Give an example? (Nov/Dec 2012)BTL2
Wire ropes are designated (or specified) by the number of strands and the number of wires in
each strand. Standard Wire Rope, 6x7 Class Wire Rope, Strands: 6, Wires per Strand: 7, Core:
Fiber Core, Standard Grade(s): Improved Plow (IPS), Lay: Regular or Lang, Finish: Bright or
1-4
Galvanized
14 What do you understand by 6 x 19 constructions in wire ropes? (Nov/Dec 2014)BTL2
A 6 x 19 wire rope means a rope is made from 6 strands with 19 wires in each strand.
15 Give any three applications of chain drives. What are they limitations? (April/May
2011)BTL2
Chain drives are widely used in transportation industry, agricultural machinery, metal and wood
working machines.
Limitations: heavy height, sudden failure, intensive wear of the links in the joints
susceptibility to jerks and overloads.
16 What is the effect of chordal action in chain drives? How can you reduce that effect?
(April/May 2015)BTL4
As the chain enters and exits, it rises and falls as each pitch engages and disengages the
sprockets. This movement, called chordal action, causes chain speed variations (drive
roughness) that may be objectionable in some applications. These speed variations can normally
be minimized by increasing the size of the sprockets. Chordal action results in a pulsating and
jerk motion of a chain. In order to reduce the variation in chain speed, the number of teeth on
the sprocket should be increased.
17 What do you mean by galling of roller chains? (May/June 2012)BTL3
Galling is a stick-slip phenomenon between the pin and the bushing. When the load is
heavy and the speed is high, the high spots (i.e. joints) of the contacting surfaces are
welded together. This phenomenon of welding is called as galling of roller chains. Use high
quality, high pressure lubricants and ensure that the lubricant regime is such that the film of
lubricant is constantly maintained between the surfaces.
18 Under what circumstances chain drives are preferred over V belt drives? (May/June
2016)BTL4
The popularity of chain drives stems from their ability to transmit high torque levels in a small
package, at relatively low cost, while utilizing readily available stock components. While initial
costs of standard roller chain drives can be quite low, the cost of maintaining them can be
substantial. The ability to create any length of chain with connecting links. The availability of a
large selection of chains and sprockets.
19 What factors will affect the working conditions of chain drive? (Nov/Dec-2016)BTL2
➢ Tension in the chains
➢ Sizes of the pulley/gear
➢ Number of pulley/gear
➢ Length of the chain drive
➢ Friction between chains & pulley/gear
➢ Angle of contact.
20 List the advantages of wire ropes compared to chains.(Apr/May-2017)BTL1
➢ More reliable in operation
➢ Silent operation even at high working speeds
➢ Less danger for damage due to jerks.
1-5
21 What is centrifugal effect on belts? (Nov/Dec 2015)BTL4
As the belt moves round the pulley, it would experience a centrifugal force which has a tendency
to separate the belt from the pulley surface. To maintain contact between the pulley and belt, the
centrifugal force produce additional tension in the belt, which is known as centrifugal tension
(TC=mv2).
22 What are the factors upon which the coefficient of friction between the belt and pulley
depends? (May/June 2014, 2012)BTL2
The coefficient of friction between the belt material and pulley surface depends upon the belt
material, material of the pulley surfaces, belt speed and belt slip.
23 Name the types of belts used for transmission of power.(May/June 2013)BTL2
➢ Flat belts
➢ V-belts
➢ Ribbed belts
➢ Toothed or timing belts
24 List out the various stresses induced in the wire ropes. (May/June 2013)BTL1
➢ Direct stress due to the weight of the load to be lifted.
➢ Bending stress when the rope passes over the sheave
➢ Stress due to acceleration
➢ Stress due to starting and stopping
➢ Effective stress.
25 Mention the parts of roller chains.(Nov/Dec 2012)BTL2
➢ Inner (pin link or coupling link) and outer link plates (roller link)
➢ Pin
➢ Bushing and rollers.
PART * B
1 Design a flat belt drive to transmit 110 kW for a system consisting of two pulleys of
diameters 0.9m and 1.2m for a centre distance of 3.6m, belt speed of 20 m/s and coefficient
of friction is 0.3. There is a slip of 1.2% at each pulley and 5% friction loss at each shaft
with 20% overload. (13M)(Nov/Dec 2016) BTL5
Pulley diameters: d = 0.9m, D = 1.2m
Answer: Page: 1.31 – Dr.A.Baskar
Design power:(2M)
𝑅𝑎𝑡𝑒𝑑 𝑝𝑜𝑤𝑒𝑟 𝑋 𝐿𝑜𝑎𝑑 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 = = 135882 𝑊
𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑓𝑎𝑐𝑡𝑜𝑟
Type of belt: (2M)
Considering heavy duty and medium belt speed; Dunlop FORT 949 g belt is selected.
Load rating = 0.0578 kW per mm per ply
No. of plies = 8.
Standard belt width:(2M)
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟
𝐵𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ = = 294 𝑚𝑚
𝑙𝑜𝑎𝑑
1-6
Pulley width:(2M)
Pulley width above 250 mm upto including 375 mm is to be wider than belt width by 38 mm.
Pulley width = 343 mm.
Length of belt:(2M)
𝜋 (𝐷 − 𝑑)
𝐿 = 2𝐶 + (𝐷 + 𝑑) + = 10505 𝑚𝑚
2 4𝐶
Other pulley dimensions:(3M)
Number of arms = 6
Cross section of arms = elliptical
Radius of cross section of arm, r = 52.5 mm (small) & r = 57 mm (large).
Minimum length of bore, l = 230 mm (small) & l = 230 mm (large).
Speed of driver pulley = 430 rpm.
Speed of driven pulley = 319 rpm.
2 A V-belt drive is to transmit 15 kW to a compressor. The motor runs at 115 rpm and the
compressor is to run at 400 rpm. Determine (i) Belt specification, (ii) Number of belts, (iii)
Correct centre distance, (iv) Drive pulley diameters. (13M)(Nov/Dec 2015) BTL5
Belt cross section:(1M)
Nominal top width, W = 17 mm.
Nominal thickness, T = 11 mm.
Pulley diameters:(1M)
𝐷 𝑛1
𝑠𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜, 𝑖 = =
𝑑 𝑛2
Standard pulley diameter, D = 400 mm.
Centre distance, C;(1M)
Centre distance is assumed to be equal to 400 mm.
Nominal pitch length:(2M)
𝜋 (𝐷 − 𝑑)
𝐿 = 2𝐶 + (𝐷 + 𝑑) + = 1671.93 𝑚𝑚
2 4𝐶
Minimum power transmitting capacity in kW:(2M)
50.8
𝑘𝑊 = (0.79 × 7.53−0.09 − − 1.32 × 10−4 × 7.532 ) 7.53 = 2.22 𝑘𝑊
142.5
Number of belts:(2M)
𝐷−𝑑
𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 = 180° − 60° × = 138.75°
𝐶
𝑃 × 𝐹𝑎
𝑛𝑜. 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠 = = 11 𝑏𝑒𝑙𝑡𝑠
𝑘𝑊 × 𝐹𝑐 × 𝐹𝑑
Actual centre distance, C:(2M)
𝐿 𝜋(𝐷 + 𝑑)
𝐴= − = 217.33
4 8
(𝐷 + 𝑑)2
𝐵= = 9453.125
8
1-7
𝐶 = 𝐴 + √𝐴2 − 𝐵 = 411.7 𝑚𝑚
Dimensions of V grooved pulley:(2M)
Pitch width, lp = 14 mm.
Minimum distance down to pitch line, b = 4.2 mm.
Centre to centre distance, e = 19 mm.
Edge of pulley to first groove, f = 12.5 mm.
3 At the construction site, 1 tonne of steel is to be lifted upto a height of 20 m with the help of
2 wire ropes of 6x19 size, nominal diameter 12 mm and breaking load 75 kN. Determine the
factor of safety if the sheave diameter is 56d and wire rope is suddenly stopped in 1 second
while travelling at a speed of 1.2 m/s. What is the factor of safety if bending load is
neglected? (13M)(Nov/Dec 2014)BTL5
Wire rope type: 6 x 19 group.(2M)
Design load: Not required
Wire rope diameter, d and weight of rope, Wr:(2M)
D = 12 mm (given), Wr = 106 N.
Drum diameter, D = 56d = 672 mm.
Useful cross section area, A = 45.24 mm2.
Wire diameter, dw:(3M)
𝑅𝑜𝑝𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑
𝑑𝑤 = = 0.7493 𝑚𝑚
1.5 × √𝑁𝑜. 𝑜𝑓 𝑠𝑡𝑟𝑎𝑛𝑑𝑠 × 𝑁𝑜. 𝑜𝑓 𝑤𝑖𝑟𝑒𝑠 𝑝𝑒𝑟 𝑠𝑡𝑟𝑎𝑛𝑑
Effective load, Weq:(4M)
𝑊𝑑 = 𝑊 + 𝑊𝑟 = 9916 𝑁
𝑑𝑤
𝑊𝑏 = 𝐸 × × 𝐴 = 3959 𝑁
𝐷
𝑊 + 𝑊𝑟
𝑊𝑎 = × 𝑎 = 1213 𝑁
𝑔
𝑊𝑒𝑞 = 𝑊𝑑 + 𝑊𝑏 + 𝑊𝑎
Actual factor of safety:(2M)
𝐵𝑟𝑒𝑎𝑘𝑖𝑛𝑔 𝑙𝑜𝑎𝑑 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑒𝑙𝑒𝑐𝑡𝑒𝑑 𝑟𝑜𝑝𝑒
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 = = 10.34
𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑙𝑜𝑎𝑑
4 A bucket elevator is to be driven by a geared motor and a roller chain drive with the
information given below:
Motor output = 3 kW; speed of motor shaft = 100 rpm; elevator drive shaft speed = 42 rpm;
load = even; distance between centres of sprockets approximately = 1.2m; period of
operation = 16 hours/day; geared motor is mounted on an auxiliary bed for centre distance
adjustments. Design the chain drive. (13M)(Nov/Dec 2016)BTL5
Type of chain: Roller chain.(1M)
Preferred transmission ratio, i;(2M)

1-8
𝑧2 𝑛1
𝑖= = = 2.38
𝑧1 𝑛2
Number of teeth, z;(1M)
Z1 = 27; Z2 = 100 to 120 satisfied.
Standard pitch, p:(1M)
𝑎 𝑎
𝑝= 𝑡𝑜 = 40 𝑡𝑜 24 𝑚𝑚
30 50
The standard pitch of 15.875 mm is selected.
Minimum factor of safety, n:(2M)
𝑄. 𝑣
𝑁= 𝑖𝑛 𝑘𝑊
102𝑛𝑘𝑠
Chain velocity, v = 0.7144 m/s.
Service factor, ks = 1.0
𝑁×102×𝑛×𝑘𝑠
B𝑟𝑒𝑎𝑘𝑖𝑛𝑔 𝑙𝑜𝑎𝑑, 𝑄 = = 3341 𝑘𝑔𝑓
𝑣
Selection of chain:(1M)
Chain no.10 A-2 DR 50 is selected; Breaking area, A = 140 mm2
Check for actual factor of safety, [n]:(1M)
𝑄
[𝑛] = = 10.06
∑𝑃
Actual factor of safety is larger than assumed factor of safety. Hence the design is safe.
Check for bearing stress:(1M)
𝑁 × 102 × 𝑘𝑠
𝜎= = 3.15 𝑘𝑔𝑓/𝑚𝑚2
𝐴. 𝑣
Actual bearing stress is less than the allowable bearing stress. Hence the design is safe.
Actual length of chain, l:(1M)
𝑧2 −𝑧1 2
(𝑧1 + 𝑧2 ) ( 2𝜋 )
𝑙𝑝 = 2𝑎𝑝 + + = 198 𝑚𝑚
2 𝑎𝑝
𝑙 = 𝑙𝑝 . 𝑝 = 3143.25 𝑚𝑚
Exact centre distance, a;(1M)
𝑒 + √𝑒 2 − 8𝑚
𝑎= . 𝑝 = 1202.67 𝑚𝑚
4
Chain wheel profile dimensions:(1M)
Pitch diameter of small sprocket, d1 = 136.74 mm.
Tooth side radius, F = 15.88 mm.
Side relief, G = 1.60 mm.
Shroud depth, J = 3.43 mm.
Shroud radius, K = 0.76 mm.
5 A compressor is to run by a motor pulley running at 1440 rpm, speed ratio 2.5. Choose a
flat belt crossed drive. Centre distance between pulleys is 3.6 m. Take belt speed as 16 m/s.
Load factor is 1.3. Take a 5-ply, flat Dunlop belt. Power to be transmitted is 12 kW. High

1-9
speed load rating is 0.0118 kW/ply/mm width at v = 5 m/s. Determine the width and length
of the belt. (13M)(Nov/Dec 2014)BTL5
Pulley diameters: (2M)
𝐷 𝑛
𝑆𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜, 𝑖 = = = 2.5
𝑑 𝑁
d = 224 mm, D = 560 mm
Design power:(3M)
𝑅𝑎𝑡𝑒𝑑 𝑝𝑜𝑤𝑒𝑟 𝑋 𝐿𝑜𝑎𝑑 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 = = 16.28 𝑘𝑊
𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑓𝑎𝑐𝑡𝑜𝑟
Type of belt: (3M)
For high speeds, Dunlop HI-SPEED 878 g fabric belting is selected.
Load rating = 0.03776 kW/mm/ply
No. of plies = 5 (give).
Standard belt width:(3M)
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟
𝐵𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ = = 87 𝑚𝑚
𝑙𝑜𝑎𝑑
Length of belt:(2M)
𝜋 (𝐷 + 𝑑)
𝐿 = 2𝐶 + (𝐷 + 𝑑) + = 8474 𝑚𝑚
2 4𝐶
PART * C
1 Design a V-belt drive and calculate the actual belt tensions and average stress for the
following data:
Power to be transmitted = 7.5 kW; Speed of driving wheel = 1000 rpm; Speed of driven
wheel = 300 rpm; Diameter of driven wheel = 500 mm; Diameter of driver pulley = 150 mm
and centre distance = 925 mm. (15M)(April/May 2015)BTL5
Belt cross section:(1M)
Nominal top width, W = 17 mm.
Nominal thickness, T = 11 mm.
Pulley diameters:(1M)
d = 150 mm (given); D = 500 mm (given).
Centre distance, C = 925 mm (given)
Nominal pitch length:(2M)
𝜋 (𝐷 − 𝑑)
𝐿 = 2𝐶 + (𝐷 + 𝑑) + = 2904.13 𝑚𝑚
2 4𝐶
Minimum power transmitting capacity in kW:(3M)
50.8
𝑘𝑊 = (0.79𝑆 −0.09 − − 1.32 × 10−4 𝑠 2 ) 𝑆 = 2.7561 𝑘𝑊
𝑑𝑒
𝐷−𝑑
𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 = 180° − 60° × = 157.3°
𝐶
1-10
𝑃 × 𝐹𝑎
𝑛𝑜. 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠 = = 4 𝑏𝑒𝑙𝑡𝑠
𝑘𝑊 × 𝐹𝑐 × 𝐹𝑑
Actual centre distance, C:(3M)
𝐿 𝜋(𝐷 + 𝑑)
𝐴= − = 517.496
4 8
(𝐷 + 𝑑)2
𝐵= = 15312.5
8
𝐶 = 𝐴 + √𝐴2 − 𝐵 = 1019.98 𝑚𝑚
Actual belt tensions:(3M)
𝑇𝑜𝑡𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑
𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝑝𝑒𝑟 𝑏𝑒𝑙𝑡 = = 1875 𝑊
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠
𝑇1 (
𝜇𝜃
)
=𝑒 𝛽 sin
𝑇2
Tension on slack side, T1 = 15.19 N;
Tension on tight side, T2 = 254.04 N.
2 The transporter of a heat treatment furnace is driven by a 4.5 kW, 1440 rpm induction
motor through a chain drive with a speed reduction ratio of 2.4. The transmission is
horizontal with both type of lubrication. Rating is continuous with 3 shifts per day. Design
the complete chain drive.(15M)(Nov/Dec 2013)BTL5
Type of chain: Roller chain. (1M)
Preferred transmission ratio, i = 2.4 (given)
Number of teeth, z:(1M)
Z1 = 27 (assumed); Z2 = 65.
𝑎 𝑎
𝑝= 𝑡𝑜 = 16.6667 𝑡𝑜 10 𝑚𝑚
30 50
Available standard pitches are: 9.525 mm, 12.7 mm & 15.875 mm.
𝑄. 𝑣
102𝑛𝑘𝑠
B𝑟𝑒𝑎𝑘𝑖𝑛𝑔 𝑙𝑜𝑎𝑑, 𝑄 = = 1104.33 𝑘𝑔𝑓
𝑣
Chain no.08 B-3 R 1278H is selected;
Breaking load, Q = 2100 kgf;
Weight per meter = 0.75 kgf;
Breaking area, A = 54 mm2
1-11
𝑄
[𝑛] = = 33.23
∑𝑃
𝑁 × 102 × 𝑘𝑠
𝜎= = 1.55 𝑘𝑔𝑓/𝑚𝑚2
𝐴. 𝑣
𝑧 −𝑧 2
2 1
(𝑧1 + 𝑧2 ) ( 2𝜋 )
𝑙𝑝 = 2𝑎𝑝 + + = 125.669 𝑚𝑚
2 𝑎𝑝
𝑙 = 𝑙𝑝 . 𝑝 = 1600.2 𝑚𝑚
Exact centre distance, a:(2M)
𝑒 + √𝑒 2 − 8𝑚
𝑎= . 𝑝 = 502.12 𝑚𝑚
4
3 A 7.5 kW electric motor running at 1400 rpm is used to drive the input shaft of the gear box
of a special purpose machine. Design a suitable roller chain to connect the motor shaft to
the gear box shaft to give an exact speed ratio of 10 to 1. Assume the minimum centre
distance between driver and driven shafts as 600 mm.(15M)(May/June 2016)BTL5
Type of chain: Roller chain.(1M)
Preferred transmission ratio, i = 10 (given);
Number of teeth, z: (1M)
Z1 = 11 (assumed); Z2 = 110.
𝑎 𝑎
𝑝= 𝑡𝑜 = 20 𝑡𝑜 12 𝑚𝑚
30 50
𝑄. 𝑣
102𝑛𝑘𝑠
B𝑟𝑒𝑎𝑘𝑖𝑛𝑔 𝑙𝑜𝑎𝑑, 𝑄 = = 3877 𝑘𝑔𝑓
𝑣
1-12
Chain no.10 B-2 DR 1595 is selected;
Breaking load, Q = 4540 kgf;
Weight per meter = 1.82 kgf;
Breaking area, A = 134 mm2
𝑄
[𝑛] = = 10.06
∑𝑃
𝑁 × 102 × 𝑘𝑠
𝜎= = 3.15 𝑘𝑔𝑓/𝑚𝑚2
𝐴. 𝑣
𝑧2 −𝑧1 2
(𝑧1 + 𝑧2 ) ( )
𝑙𝑝 = 2𝑎𝑝 + + 2𝜋 = 198
2 𝑎𝑝
𝑙 = 𝑙𝑝 . 𝑝 = 3143.25 𝑚𝑚
Exact centre distance, a:(2M)
𝑒 + √𝑒 2 − 8𝑚
𝑎= . 𝑝 = 1202.67 𝑚𝑚
4
4 A V-belt drive is to be arranged between two shafts with 1.2 m as centre distance. The
driving pulley is of 250 mm effective diameter and is to be supplied with 20 kW power at
960 rpm. The follower pulley is to run at 460 rpm. Determine the number of belts required
from the following:
Arc of the belt cross section = 143 mm2; Mass density of the belt material = 100 kg/m3;
Permissible tensile stress = 2 N/mm2; Coefficient of friction = 0.3; Groove angle of the
pulley, 2β = 40º. (15M)(Nov/Dec 2015)BTL5
Note: since all the data are available, problem can be solved using basic equations.
Diameter of the driven pulley, D:(2M)
𝐷 𝑛1
𝑆𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜, 𝑖 = =
𝑑 𝑛2
960 𝑋 0.25
𝐷= = 522 𝑚𝑚
460
Mass of the belt per meter length:(2M)
𝑘𝑔
𝑚 = 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 × 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 = 0.143
𝑚
1-13
Centrifugal tension, Tc:(2M)
𝑇𝑐 = 𝑚𝑣 2 = 22.58 𝑁
Angle contact, θ:(2M)
𝐷−𝑑
𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 = 180° − 60° × = 166.4°
𝐶
Maximum tension in the belt, Tmax:(2M)
𝑇𝑚𝑎𝑥 = 𝜎 × 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 = 286 𝑁
Belt tensions:(2M)
𝑇1 (
𝜇𝜃
)
= 𝑒 sin 𝛽
𝑇2
Tension at tight side, T1 = Tmax – Tc = 263.42 N.
Tension at slack side, T2 = 20.63 N.
𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 = (𝑇1 − 𝑇2 )𝑣 = 3050.9 𝑊
𝑇𝑜𝑡𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠 = = 7 𝑏𝑒𝑙𝑡𝑠
𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝑏𝑦 𝑜𝑛𝑒 𝑏𝑒𝑙𝑡

1-14
UNIT II–SPUR GEARS AND PARALLEL AXIS HELICAL GEARS
Speed ratios and number of teeth-Force analysis -Tooth stresses - Dynamic effects – Fatigue strength-
Factor of safety - Gear materials – Design of straight tooth spur & helical gears based on strengthand
wear considerations – Pressure angle in the normal and transverse plane- Equivalent number ofteeth-
forces for helical gears.
PART * A
Q.No. Questions
1 Specify the conditions based on which gear cutters are selected.BTL4

➢ The capacity of the machine size and shape of the gear
➢ Proper material selection
➢ The magnitude of production range
➢ The production time
➢ The technical experience of the machinist
➢ The economic viability of the machine
➢ The cutting forces
2 Define backlash. What factors influence backlash in gear drives? (Nov/Dec 2016)BTL1
Shortest distance between the non-contacting surfaces of the adjacent teeth is referred to as
backlash.
➢ Module and
➢ Pitch line velocity influence the backlash in gear drives.
3 What are the advantages of the helical gear over spur gear?BTL2
➢ Helical gears produce less noise than spur gears of equivalent quality because the total
contact ratio is increased.
➢ Helical gears have a greater load carrying capacity than equivalent size of spur gears.
➢ A limited number of standard cutters are used to cut a wide variety of helical gears
simply by varying the helix angle.
➢ Smoother engagement of the gear teeth.
➢ More teeth carry load at a given time so that they are more efficient – carry more load for
a given size.
4 What are the main types of gear tooth failure? (May/June2013, 2012)BTL1
➢ Tooth breakage (due to static and dynamic loads).
➢ Tooth wear (or surface deterioration): (a) Abrasion; (b) Pitting and(c) Scoring or seizure.
5 What are the assumptions made in deriving Lewis equation?BTL3
➢ The effect of radial component, which induces compressive stresses, is negligible.
➢ The tangential component is uniformly distributed across the full face width.
➢ The tangential force is applied to the tip of a single tooth.
1-15
➢ Stress concentration in the tooth fillet is negligible.
6 Why is pinion made harder than gear? (Nov/Dec 2012)BTL4
Since the teeth of pinion undergo more number of cycles than gear and hence quicker wear.
7 List out the various methods of manufacturing a gear.BTL2
➢ Gear milling,
➢ Gear generating,
➢ Gear hobbing,
➢ Gear shaping,
➢ Gear molding,
➢ Injection molding,
➢ Die casting and
➢ Investment casting.
8 What are the common forms of gear tooth profile? (Apr/May 2011)BTL1
➢ Involute tooth profile and
➢ Cycloidal tooth profile.
9 What are the standard interchangeable tooth profiles?BTL2
➢ 14½0 composite system
➢ 14½0 full depth involute system
➢ 200 full depth involute system and
➢ 200 stub involute system.
10 What are the effects of increasing and decreasing the pressure angle in gear design?
(April/May 2015, 2017&2014, Nov/Dec 2014)BTL4
➢ Increasing the pressure angle will increase the beam and surface strengths of tooth. But
gear becomes noisy.
➢ Decreasing the pressure angle will increase the minimum number of teeth required on
the pinion to avoid interference/ undercutting.
11 A helical gear has a normal pressure angle of 20 degrees, a helix angle of 45 degrees,
normal module of 4mm and has 20 teeth. Find the pitch diameter. (Nov/Dec 2016)BTL5
Solution : Pitch circle diameter (d) = (mn x Z)/ cosβ, = (4x20)/cos45 = 113.3 = 114mm
12 Differentiate double helical and herringbone gears. (Nov/Dec 2015, Apr/May 2017) BTL4
When there is groove in between the gears, then the gears are specifically known as double
helical gears. When there is no groove in between the gears, then the gears is known as
herringbone gears.
13 Write short notes on stub tooth system. (May/June2012)BTL1
In this system, the thickness of tooth at top surface and its root is more compare to full depth
tooth system. Also this kind of tooth possesses shorter addendum and larger pressure angle,
usually 200 and thus interference problem may be eliminated. For standard stub tooth system, the
tooth proportion are as Whole depth=1.8*module; Addendum==0.8*module;
Dedendum=1.0*module; Working Depth=1.6*module; Clearance=0.2*module;
14 What are the advantages of helical gears? [(Nov/Dec 2012)BTL2
➢ Transmit more power
1-16
➢ Provide smooth and
➢ Soundless operation.
15 What are the profiles of a spur gear? (May/June 2016)BTL1
Two constant velocity tooth profiles are the most commonly used in modern times:
the cycloid and the involute.
16 What is herringbone gear? (May/June 2016)BTL1
Herringbone gears, also called double helical gears, are gear sets designed to transmit power
through parallel or, less commonly, perpendicular axes. The unique tooth structure of
a herringbone gear consists of two adjoining, opposite helixes that appear in the shape of the
letter 'V'.Double helical gears are used in many applications such as cranes, fluid pumps and
power transmission to the propulsion screws in military ships for a quieter and less vibration
operation.
17 State the advantages of Herringbone gear. (April/May 2015, 2013)BTL1
Herringbone gears eliminate the existence of axial thrust load in the helical gears. Because,
in herringbone gears, the thrust force of the right hand is balanced by that of the left hand helix.
18 Why is a gear tooth subjected to dynamic load? (Nov/Dec 2014)BTL4
Dynamic loads are due to
➢ In accuracies of tooth spacing
➢ Irregularities in tooth profiles
➢ Elasticity of parts
➢ Misalignment between bearings
➢ Deflection of teeth under load
➢ Dynamic unbalance of rotating masses.
19 Compare the features of spur and helical gears. (Nov/Dec 2012)BTL4
Advantages of the spur gear:
➢ Spur gears are simplest, hence easiest to design and manufacture.
➢ A spur gear is more efficient if you compare it with helical gear of same size.
➢ Easy to assemble
Advantages of the helical gear:
➢ Silent operation
➢ Helical gears can be used for transferring power between non-parallel shafts.
➢ For same tooth size (module) and equivalent width, helical gears can handle more load
than spur gears because the helical gear tooth is effectively larger since it is diagonally
positioned.
20 Define the various pitch in a helical gear. (May/June 2012)BTL1
➢ Transverse circular pitch (Pt)
➢ Normal circular pitch (Pn)
➢ Axial Pitch (Pa)
➢ Normal diametral pitch (Pd)
21 State the law of gearing. (or) State the conditions of correct gearing. (Nov/Dec2012, April
/May 2015)(or) What conditions must be satisfied in order that a pair of spur gears may
1-17
have constant velocity ratio?(May/June 2014)BTL1
The law of gearing states that for obtaining a constant velocity ratio, at any instant of teeth the
common normal at each point of contact should always pass through a pitch point (fixed point),
situated on the line joining the centres of rotation of the pair of mating gears.
The angular velocity ratio of the gears of a gear-set must remain constant throughout the mesh.
22 State some materials used for manufacturing of gears. (May/June 2013)BTL1
Metallic gears: steel, cast iron and bronze. Non-metallic gears: wood, compressed paper and
synthetic resins.
23 Define module. (April/May 2011, May/June 2013, Nov/Dec 2015)BTL1
Module, m this indicates the tooth size and is the number of mm of pitch circle diameter (p.c.d.)
per tooth. For gears to mesh, their modules must be equal. Gear ISO standards and design
methods are now normally based on the module. EG a gear of module 3 has 16 teeth, its pitch
circle diameter is: 3 x 16 = 48 mm. In a pair of spur gears, the module is 6 mm.
24 What are the advantages of toothed gears over the other types of transmission
systems?BTL2
Advantages of gear drives over other drives, i.e. belt, rope and chain drives are
➢ It is very compact and need less space.
➢ It has a very high efficiency which is very useful in transmitting motion.
➢ The main advantage of gear drive is that it transmit same velocity ratio.
➢ Again a good advantage is that it is a very good reliable service.
➢ And last is that it can be used to transmit a very large power.
25 What is pressure angle? (April /May 2015 & 2014, Nov/Dec 2014)BTL1
It is the angle which the line of action makes with the common tangent to pitch circles of
mating gears. Simply refers to the angle through which forces are transmitted between
meshing gears. Ideally 20° of pressure angle (involute system) is preferred because the tooth
acting as a beam is wider at the base.
PART * B
1 A speed reducing unit using spur gear is to be designed. Power to be transmitted is 60 hp
and is continuous with moderate shock loads. The speeds of the shafts are 720 rpm and 144
rpm respectively. The centre distance is kept as small as possible. Select a suitable material
and design the gears. Give the details of the gears.(13M)(May/June 2016)BTL5
Gear ratio, i:(1M)
𝑁1
𝑖= =5
𝑁2
Material:(1M)
C45 is selected for both pinion and wheel.
Design bending stress, [σb] = 13734 X 104 N/m2
Design surface contact stress, [σc] = 49050 X 104 N/m2
Gear life: Not Given
Design torque, [Mt]:(1M)
1-18
60 × 𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 593.648 𝑁 − 𝑚
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 771.742 𝑁 − 𝑚
Calculation of Eeq, [σb] and [σc]:(1M)
Eeq = 210915 X 106 N/m2
[σb] = 13734 X 104 N/m2
[σc] = 49050 X 104 N/m2
Centre distance, a:(1M)
0.74 2 𝐸 × [𝑀𝑡 ]
3
𝑎 ≥ (𝑖 + 1) √( )
[𝜎𝑐 ] 𝑖×𝜓
𝑏
𝐴𝑠𝑠𝑢𝑚𝑒, = 0.3
𝑎
𝑎𝑚𝑖𝑛 = 376 𝑚𝑚
Number of teeth Z1 and Z2:(1M)
Z1 = 20 (assumed)
Z2 = i. Z1 = 100.
Module, m:(1M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.26 √ = 6 𝑚𝑚
𝑦[𝜎𝑏 ]𝜓𝑍1
Revised centre distance, a and number of teeth:(1M)
𝑚(𝑍1 + 𝑍2 )
𝑎=
2
Z1 = 25 teeth; Z2 = 105 teeth; a = 378 mm.
Face width, pitch circle diameter, pitch line velocity:(1M)
Face width, b = ψ . a = 113.4 mm
Pitch circle diameter, d1 = mZ1 = 126 mm.
Pitch line velocity, v = 4.75 m/s.
Quality of gear:(1M)
IS quality 8 is selected.
Revision of design torque:
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 865.539 𝑁 − 𝑚
Check for maximum induced bending stress, σb:(1M)
(𝑖 + 1)
𝜎𝑏 = × [𝑀𝑡 ] ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 13734 × 104 𝑁/𝑚2
Design is safe.
Check for maximum induced compressive stress, σc:(1M)
(𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = 0.74 × ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
1-19
4 2
𝜎𝑐 = 49050 × 10 𝑁/𝑚
Design is safe.
Basic dimensions of pinion and wheel:(1M)
Pinion:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 126 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1 (𝑓𝑜𝑟 𝑓𝑢𝑙𝑙 𝑑𝑒𝑝𝑡ℎ)
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐1 = (𝑍1 + 2𝑓0 )𝑚 = 138 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = (𝑍1 + 2𝑓0 )𝑚 − 2𝑐 = 111 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 13.5 𝑚𝑚
Wheel:
2 In a spur gear drive for a stone crusher, the gears are made of C40 steel. The pinion is
transmitting 30 kW at 1200 rpm. The gear ratio is 3. Gear is to work 8 hours per day, six
days a week and for 3 years. Design the drive.(13M)(Nov/Dec 2016)BTL5
Gear ratio, i:(1M)
𝑁1
𝑖= = 3 (𝑔𝑖𝑣𝑒𝑛)
𝑁2
Material:(1M)
C40 is selected for both pinion and wheel (given).
Gear life: N = 53.9136 X 107 cycles.
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 310.352 𝑁 − 𝑚
Eeq = 210915 X 106 N/m2
1.4𝑘𝑏𝑙 𝜎−1
[𝜎𝑏 ] = = 15525 × 104 𝑁/𝑚2
𝑛. 𝑘𝜎
[𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 62697 × 104 𝑁/𝑚2
30.74 2 𝐸 × [𝑀𝑡 ]
√
𝑎 ≥ (𝑖 + 1) ( )
𝑏
𝑎
1-20
Z1 = 20 (assumed)
Z2 = i. Z1 = 60.
Module, m:(1M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.26 √ = 4 𝑚𝑚
𝑚(𝑍1 + 𝑍2 )
𝑎=
2
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 334.416 𝑁 − 𝑚
(𝑖 + 1)
𝜎𝑏 = × [𝑀𝑡 ] ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 15525 × 104 𝑁/𝑚2
Design is safe.
(𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = 0.74 × ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
𝜎𝑐 = 62697 × 104 𝑁/𝑚2
Design is safe.
Pinion:
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 9 𝑚𝑚
Wheel:
1-21
3 Design a pair of straight gear drive for a stone crusher, the pinion and wheel are made of
C15 steel and cast iron grade 30 respectively. The pinion is to transmit 22 kW power at 900
rpm. The gear ratio is 2.5. Take pressure angle of 20º and working life of gear as 10000
hours.(13M)(Nov/Dec 2016)BTL5
Gear ratio, i:(1M)
𝑁1
𝑖= = 2.5 (𝑔𝑖𝑣𝑒𝑛)
𝑁2
Material:(1M)
Pinion – C15
Wheel – Cast iron, grade 30 (given).
Gear life: N = 10000 hrs (given)
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 303.4554 𝑁 − 𝑚
2𝐸1 𝐸2
𝐸𝑒𝑞 =
𝐸1 + 𝐸2
9 2
Eeq = 143.226 X 10 N/m
[𝜎𝑏 ] = = 10379 × 104 𝑁/𝑚2
𝑛. 𝑘𝜎
[𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 74487 × 104 𝑁/𝑚2
3 0.74 2 𝐸 × [𝑀𝑡 ]
𝑎 ≥ (𝑖 + 1) √( )
𝑏
𝑎
Z1 = 20 (assumed)
Z2 = i. Z1 = 50.
Module, m:(1M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.26 √ = 5 𝑚𝑚
𝑚(𝑍1 + 𝑍2 )
𝑎=
2
Face width, pitch circle diameter, pitch line velocity: (1M)
1-22
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 329.389 𝑁 − 𝑚
(𝑖 + 1)
𝜎𝑏 = × [𝑀𝑡 ] ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 2711 × 104 𝑁/𝑚2
Design is safe.
(𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = 0.74 × ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
𝜎𝑐 = 30375 × 104 𝑁/𝑚2
Design is safe.
Pinion:
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = (𝑍1 + 2𝑓0 )𝑚 − 2𝑐 = 127.5 𝑚𝑚
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 11.25 𝑚𝑚
Wheel:
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 11.25 𝑚𝑚
4 A pair of helical gears subjected to moderate shock loading is to transmit 30 kW at 1500
rpm of the pinion. The speed reduction ratio is 4 and the helix angle is 20º. The service is
continuous and the teeth are 20º FD in the normal plane. For gear life of 10,000 hours,
design the gear drive.(13M)(May/June 2016)BTL5
Gear ratio, i:(1M)
𝑁1
𝑁2
Material:(1M)
Assume 40 Ni2 Cr1 Mo 28 for both pinion and wheel (given).
Design bending stress, [σb] = 4000 kgf/cm2
1-23
2
Design surface contact stress, [σc] = 11000 kgf/cm
Gear life: (1M)
Equivalent mean life, N = 60nT = 90 X 107 cycles.
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 248.28 𝑁 − 𝑚
Eeq = 210915 X 106 N/m2
[𝜎𝑏 ] = = 240.345 × 106 𝑁/𝑚2
𝑛. 𝑘𝜎
[𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 1049.64 × 106 𝑁/𝑚2
30.7 2 𝐸 × [𝑀𝑡 ]
𝑎 ≥ (𝑖 + 1) √( )
𝑏
𝑎
𝑎𝑚𝑖𝑛 = 268.7 𝑚𝑚
Z1 = 20 (assumed)
Z2 = i. Z1 = 80.
Module, m:(1M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.15 cos 𝛽 √ = 3 𝑚𝑚
Revised centre distance, a and number of teeth:
𝑚(𝑍1 + 𝑍2 )
𝑎=
2cos 𝛽
Z1 = 34 teeth; Z2 = 136 teeth; a = 271.37 mm.
Face width, b = ψ . a = 82 mm
Pitch circle diameter, d1 = mZ1 /Cosβ = 108.55 mm.
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 280.75 𝑁 − 𝑚
0.7 × (𝑖 + 1) × [𝑀𝑡 ]
𝜎𝑏 = ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 31.65 × 106 𝑁/𝑚2
1-24
Design is safe.
0.74 × (𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
𝜎𝑐 = 387.5 × 106 𝑁/𝑚2
Design is safe.
Pinion:
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 108.55 𝑚𝑚
𝑍1
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑐1 = ( + 2𝑓0 ) 𝑚 = 114.55 𝑚𝑚
cos 𝛽
𝑍1
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = ( + 2𝑓0 ) 𝑚 − 2𝑐 = 101.05 𝑚𝑚
cos 𝛽
Wheel:
𝑚𝑛
𝑃𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑2 = × 𝑍2 = 434.18 𝑚𝑚
cos 𝛽
𝑍2
cos 𝛽
𝑍2
cos 𝛽
5 Design a helical gear drive to transmit a power of 15 kW at 1440 rpm to the following
specifications: Speed reduction is 3, pressure angle is 20º, helix angle is 15º, material of both
gears is C45 steel, allowable static stress is 180 N/mm2, Young’s modulus = 2 X 105
N/mm2.(13M)(Nov/Dec 2010)BTL5
Material:(1M)
C45 Steel (given)
Z1 = 20 (assumed)
Z2 = i. Z1 = 60.
Tangential load, Ft:(1M)
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠 12.488
𝐹𝑡 = =
𝑣𝑚 𝑚
Dynamic Load, Fd:(1M)

𝐹𝑑 = 𝐹𝑡 . 𝐶𝑉
12.488
𝐹𝑑 = × (1 + 260.25𝑚)
𝑚
1-25
Beam strength, Fs:(1M)
𝐹𝑠 = [𝜎𝑏 ]𝑚. 𝑏. 𝑌 = 594 × 106 𝑚2
Module, m:(1M)
𝐹𝑠 ≥ 𝐹𝑑 𝑓𝑜𝑟 𝑠𝑎𝑓𝑒 𝑑𝑒𝑠𝑖𝑔𝑛
12.488
× (1 + 260.25𝑚) = 594 × 106 𝑚2
𝑚
Module, m = 4 mm.
Face width, b = 10 X m = 40 mm
Pitch circle diameter of pinion, d1 = mZ1/cosβ = 82.82 mm.
Pitch circle diameter of wheel, d2 = mZ2/cosβ = 248.47 mm.
Revision of beam strength, Fs:(1M)
𝐹𝑠 = [𝜎𝑏 ]𝑚. 𝑏. 𝑌 = 9504 𝑁
Buckingham’s dynamic load, Fd:(1M)
0.164𝑉𝑚 (𝑐𝑏𝑐𝑜𝑠 2 𝛽 + 𝐹𝑡 ) cos 𝛽
𝐹𝑑 = 𝐹𝑡 + [ ] = 7942.96 𝑁
0.164𝑉𝑚 + 1.485√𝑐𝑏𝑐𝑜𝑠 2 𝛽 + 𝐹𝑡
Check for the design:
(Fd = 7942.96 N) < (Fs = 9504 N)
The design is safe.
Check for wear:(2M)
𝑏𝑑1 𝑄𝑘
𝑊𝑒𝑎𝑟 𝑙𝑜𝑎𝑑, 𝐹𝑤 = = 3130.4 𝑁
𝑐𝑜𝑠 2 𝛽
(Fw = 3130.4 N) < (Fd = 7942.96 N)
The design is not safe.
For increasing wear load, it is preferable to increase the [σc] by heat treatment to 9000 kgf/cm2.
Therefore, Fw = 8829 N
Now, (Fw = 8829 N) > (Fd = 7942.96 N)
Hence, the design is safe.
Pinion:
𝑍1
cos 𝛽
𝑍1
cos 𝛽
Wheel:
𝑚𝑛
cos 𝛽
1-26
𝑍2
cos 𝛽
𝑍2
cos 𝛽
PART * C
1 Design a straight spur gear drive to transmit 8 kW. The pinion speed is 720 rpm and the
speed ratio is 2. Both the gears are made of the same surface hardened carbon steel with 55
RC and core hardness less than 350 BHN. Ultimate strength is 720 N/mm 2 and yield
strength is360 N/mm2.(15M)(Nov/Dec 2015)BTL5
Gear ratio, i:(1M)
𝑁1
𝑁2
Material:(1M)
Surface hardened carbon steel (given)
Gear life: Not given
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 137.93 𝑁 − 𝑚
Eeq = 21095 X 106 N/m2
[𝜎𝑏 ] = = 13802.88 × 104 𝑁/𝑚2
𝑛. 𝑘𝜎
[𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 85837.5 × 104 𝑁/𝑚2
0.74 2 𝐸 × [𝑀𝑡 ]
3
𝑎 ≥ (𝑖 + 1) √( )
𝑏
𝑎
Z1 = 12 (assumed)
Z2 = i. Z1 = 24.
Module, m:(1M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.26 √ = 4 𝑚𝑚

1-27
𝑚(𝑍1 + 𝑍2 )
𝑎=
2
Revision of design torque:(1M)
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 334.41 𝑁 − 𝑚
(𝑖 + 1)
𝜎𝑏 = × [𝑀𝑡 ] ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 7012 × 104 𝑁/𝑚2
Design is safe.
(𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = 0.74 × ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
𝜎𝑐 = 29486 × 104 𝑁/𝑚2
Design is safe.
Pinion:
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 11.25 𝑚𝑚
Wheel:
𝑇𝑜𝑝 𝑑𝑒𝑝𝑡ℎ, ℎ = 2.25𝑚 = 11.25 𝑚𝑚
2 Design a spur gear drive required to transmit 45 kW at a pinion speed of 800 rpm. The
velocity ratio is 3.5:1. The teeth are 20º full depth involute with 18 teeth on the pinion. Both
the pinion and gear are made of steel with a maximum safe static stress of 180 N/mm2.
Assume medium shock conditions.(15M)(Nov/Dec 2015)BTL5
Material:(1M)
Steel for both pinion and wheel (given)
1-28
Z1 = 18 (given)
Z2 = i. Z1 = 63.
𝐹𝑡 = =
𝑣𝑚 𝑚

𝐹𝑑 = 𝐹𝑡 . 𝐶𝑉
77.586
𝐹𝑑 = × (1 + 125.7𝑚)
𝑚
𝐹𝑠 = [𝜎𝑏 ]𝑚. 𝑏. 𝑌 = 584.1 × 106 𝑚2
Module, m:(2M)
77.586
× (1 + 125.7𝑚) = 584.1 × 106 𝑚2
𝑚
Module, m = 8 mm.
𝐹𝑠 = [𝜎𝑏 ]𝑚. 𝑏. 𝑌 = 37382 𝑁
0.164𝑉𝑚 (𝑐𝑏 + 𝐹𝑡 )
𝐹𝑑 = 𝐹𝑡 + [ ] = 26417 𝑁
0.164𝑉𝑚 + 1.485√𝑐𝑏 + 𝐹𝑡
(Fd = 26417 N) < (Fs = 37382 N)
The design is safe.
Check for wear:(1M)
𝑊𝑒𝑎𝑟 𝑙𝑜𝑎𝑑, 𝐹𝑤 = 𝑑1 𝑄𝑘𝑏 = 36056 𝑁
(Fw = 36056 N) > (Fd = 26417 N)
The design is safe.
Pinion:
1-29
Wheel:
3 Design a pair of helical gears to transmit 10 kW at 1000 rpm of the pinion. Reduction ratio
of 5 is required. Pressure angle is 20º and the helix angle is 15º. The material for both the
gears is 40Ni2 Cr1 Mo28. Give the details of the drive in a tabular form.(15M)(Nov/Dec
2016)BTL5
Gear ratio, i:(1M)
𝑁1
𝑁2
Material:(1M)
40 Ni2 Cr1 Mo 28 for both pinion and wheel (given).
Design bending stress, [σb] = 392.4 X 106 N/m2
Design surface contact stress, [σc] = 1079.1X 106 N/m2
Gear life: Not Given
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 124.141 𝑁 − 𝑚
Eeq = 210915 X 106 N/m2
[σb] = 392.4 X 106 N/m2
[σc] = 1079.1 X 106 N/m2
30.7 2 𝐸 × [𝑀𝑡 ]
𝑎 ≥ (𝑖 + 1) √( )
𝑏
𝑎
Z1 = 20 (assumed)
Z2 = i. Z1 = 100.
Module, m:(1M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.15 cos 𝛽 √ = 2 𝑚𝑚

1-30
𝑚(𝑍1 + 𝑍2 )
𝑎=
2cos 𝛽
Z1 = 18 teeth; Z2 = 90 teeth; a = 111.8 mm.
Pitch circle diameter, d1 = mZ1 /Cosβ = 37.27 mm.
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 113.45 𝑁 − 𝑚
0.7 × (𝑖 + 1) × [𝑀𝑡 ]
𝜎𝑏 = ≤ [𝜎𝑏 ]
𝑎𝑚𝑏𝑦
𝜎𝑏 = 163.331 × 106 𝑁/𝑚2
Design is safe.
0.74 × (𝑖 + 1) (𝑖 + 1)𝐸[𝑀𝑡 ]
𝜎𝑐 = ×√ ≤ [𝜎𝑐 ]
𝑎 𝑖. 𝑏
𝜎𝑐 = 1076 × 106 𝑁/𝑚2
Design is safe.
Pinion:
𝑍1
cos 𝛽
𝑍1
cos 𝛽
Wheel:
𝑚𝑛
cos 𝛽
𝑍2
cos 𝛽
𝑍2
cos 𝛽

1-31
UNIT III–BEVEL, WORM AND CROSS HELICAL GEARS
Straight bevel gear: Tooth terminology, tooth forces and stresses, equivalent number of teeth.Estimating
the dimensions of pair of straight bevel gears. Worm Gear: Merits and demeritsterminology.Thermal
capacity, materials-forces and stresses, efficiency, estimating the size of theworm gear pair. Cross helical:
Terminology-helix angles-Estimating the size of the pair of cross helicalgears.
PART * A
Q.No. Questions
1 What is virtual or formative number of teeth in bevel gears? (Nov/Dec 2014, April/May
2017, May/June 2014)BTL1
An imaginary spur gear considered in a plane perpendicular to the tooth of the bevel gear at the
larger end is known as virtual spur gear. The number of teeth zv on this imaginary spur gear
is called virtual number of teeth in bevel gears. z v = z/cos δ where z = actual number of teeth
on the bevel gear and δ = pitch angle.
2 Define the following terms: (a) Cone distance (b) Face angle. (May/June 2014)BTL1
(a) Cone distance: In bevel gears, cone distance is the length of the pitch cone element. (b) Face
angle: It is the angle subtended by the face of the tooth at the cone centre.
3 Why is the efficiency of worm gear drive comparatively low?BTL4
The efficiency of worm gear drive is lower because of power loss due to friction caused
by sliding.
4 In which gear drive, self-locking is available? (April/May 2015, 2013)BTL3
In the worm gear drive, self-locking is available.
5 Write the conditions of self-locking of worm gears in terms of lead and pressure angle in
gear design. And also write the condition for over running drives. (Apr/May 2017)BTL3
➢ The drive is called self-locking, if µ ≥ cos α . tan γ
➢ The drive is called overrunning, if µ < cos γ . tan γ
6 Why is multistart worm more efficient than the single start one?BTL4
The efficiency of the worm depends mainly on pressure angle (also known as pitch angle of
the worm). For a single start worm this pressure angle will be less. In a multi start worm, this
pressure angle can be increased (of the order 45 0). That’s why multi start worm is more
efficient.
7 What is the difference between an angular gear and a miter gear? (Nov/Dec 2015)BTL4
➢ When the bevel gears connect two shafts whose axes intersect at an angle other than
a right angle, then they are known as angular bevel gears.
➢ When equal bevel gears (having equal teeth and equal pitch angles) connect two shafts
whose axes intersect at right angle, then they are known as miter gears.
8 A pair of worm gears is designated as 2/54/10/5. Find the gear ratio. BTL5
1-32
Solution: (2/54/10/5): (z1/z2/q/mx)Therefore, Gear ratio, i = z 2/z1 = 54/2 = 27
9 Why phosphor bronze is widely used for worm gears?BTL4
Phosphor bronze has high antifriction properties to resist seizure. Because in worm gear drive,
the failure due to seizure is more.
10 List out the main types of failure in worm gear drive. (Nov/Dec 2012)BTL2
➢ Seizure
➢ Pitting and rupture.
11 For transmitting large power, worm reduction gears are not generally preferred.
Why?BTL4
In worm drive, meshing occurs with sliding action. Since sliding occurs, the amount of
heat generation and power loss are quite high.
12 In worm gear drive, only the wheel is designed. Why? (Apr/May 2011)BTL4
Since always the strength of the worm is greater than the worm wheel, therefore only the worm
wheel is designed.
13 What are the forces acting on bevel gear? (May/June 2013)BTL2
➢ Tangential force
➢ Separating force: It is resolved into two components, they are axial radial force.
14 Under what situation, bevel gears are used? (Apr/May 2011)BTL3
Bevel gears are used to transmit power between two intersecting shafts.
15 Write some applications of worm gear drive. (Nov-Dec 2016)BTL2
Where do we use worm gears? (May/June2013)
It is commonly used in automotive differentials, Tuning Instruments , Elevators/Lifts, Gates and
Conveyor Belts
16 What are the main types of failures in worm gear drives?(Nov/Dec2012)BTL2
➢ Seizure
➢ Pitting
➢ Surface wear
17 What is the helical angle of worm? (May/June 2016)BTL1
In mechanical engineering, a helix angle is the angle between any helix and an axial line on its
right, circular cylinder or cone. Common applications are screws, helical gears, and worm gears.
The helix angle references the axis of the cylinder, distinguishing it from the lead angle, which
references a line perpendicular to the axis. Naturally, the helix angle is the geometric
complement of the lead angle. The helix angle is measured in degrees.
18 What is a crown gear? (Nov/Dec 2016, May/June 2013)BTL1
A crown gear (or a contrate gear) is a gear which has teeth that project at right angles to the face
of the wheel. In particular, a crown gear is a type of bevel gear where the pitch cone angle is 90
degrees.
19 How bevel gears are manufactured? (May/June 2016)BTL1
Bevel gears can be manufactured through the gear hobbing and machining process.
20 What kind of contact is required between worm and worm wheel? How does this differ
from other gears? (Nov/Dec 2015)BTL4
1-33
Sliding contact is required between worm and worm wheel. For other gears Line contact is
required for other gears.
21 What is a Zero Bevel Gears? (April/May 2015)BTL1
Spiral bevel gears with curved teeth but with a zero degree spiral angle are known as zero bevel
gears.
22 Mention the advantages of worm gear drive. (Nov/Dec 2014)BTL2
Worm gears are used to transmit power between two non-intersecting, non-parallel shafts. Worm
gears can be used for high speed reduction ratios as high as 300:1.
23 When do we employ crossed helical gear? (Nov/Dec 2012)BTL4
Crossed helical gear sets are used to transmit power and motion between non-intersecting and
non-parallel axes. Both of the gears that mesh with each other are involute helical gears, and a
point contact is made between them. They can stand a small change in the center distance and
the shaft angle without any impairment in the accuracy of transmitting motion.
24 List the various types of Bevel gears. (May/June 2012)BTL2
➢ Straight bevel gears
➢ Spiral bevel gears
➢ Zero bevel gears
➢ Hypoid gears
25 What are the various losses in the worm gear drive? (May/June 2012)BTL2
Worm drives have high power losses. A disadvantage is the potential for considerable sliding
action, leading to low efficiency. They produce a lot of heat. High-ratio units have a smaller gear-
tooth lead (helix) angle, which causes more surface contact between them. This higher contact
causes higher friction and lower efficiency. Typical worm-gear efficiencies range from 49% for a
300:1, double-reduction ratio, up to 90% for a 5:1, single-reduction ratio. For this reason, these
units are usually more suitable for low ratios.
PART * B
1 Design a bevel gear drive to transmit 3.5 kW with driving shaft speed is 200 rpm. Speed
ratio required is 4. The drive is non-reversible. Pinion is made of steel and wheel made of
CI. Assume a life of 25,000 hrs. (13M)(Nov/Dec 2016)BTL5
Gear ratio, i:(1M)
𝑁1
𝑁2
tan 𝛿2 = 𝑖
𝛿2 = 75.96°; 𝛿1 = 14.04°
Material:(1M)
Pinion: C45, Hardened steel.
Tensile strength, σu = 700 X 106 N/m2
Yield strength, σy = 360 X 106 N/m2
Wheel: CI Grade 30.
1-34
Gear life, N:(1M)
Life in number of cycles, N = 60 X (rpm, n) X (Life in hrs, T) = 30 X 107 cycles
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 217.25 𝑁 − 𝑚
Eeq = 166.77 X 109 N/m2
𝑃𝑖𝑛𝑖𝑜𝑛, [𝜎𝑏 ] = = 836.66 𝑘𝑔𝑓/𝑐𝑚2
𝑛. 𝑘𝜎
𝑃𝑖𝑛𝑖𝑜𝑛, [𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 6054.75 𝑘𝑔𝑓/𝑐𝑚2
𝑊ℎ𝑒𝑒𝑙, [𝜎𝑏 ] = = 513.1 𝑘𝑔𝑓/𝑐𝑚2
𝑛. 𝑘𝜎
𝑊ℎ𝑒𝑒𝑙, [𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 3782.35 𝑘𝑔𝑓/𝑐𝑚2
Minimum value is selected.

[σb] = 513.1 kgf/cm2
[σc] = 3782.35 kgf/cm2
Cone distance, R:(1M)
2
3 0.72 𝐸 × [𝑀𝑡 ]
𝑅≥ 𝜓 √𝑖 2 + 1 √( )
(𝜓 − 0.5)[𝜎𝑐 ] 𝑖
𝑅
𝐴𝑠𝑠𝑢𝑚𝑒, 𝜓 = =3
𝑏
𝑅 = 218 𝑚𝑚
Z1 = 18 (assumed)
Z2 = i. Z1 = 72.
Transverse Module, mt:(1M)
3 [𝑀𝑡 ]
𝑚𝑎𝑣 ≥ 1.28 √ = 5.096 𝑚𝑚
𝑏
𝑚𝑡 = 𝑚𝑎𝑣 + sin 𝛿 = 6 𝑚𝑚
𝑧
Revision of cone distance, R and number of teeth:
𝑅 = 0.5𝑚𝑡 𝑍1 √𝑖 2 + 1 = 222.65 𝑚𝑚
Z1 = 18 teeth; Z2 = 72 teeth;
Face width, b = 10.mt = 60 mm
Pitch circle diameter,
𝑅 − 0.5𝑏
𝑑1𝑎𝑣 = 𝑚𝑡 𝑍1 ( ) = 93.45 𝑚𝑚
𝑅
1-35
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 217.25 𝑁 − 𝑚
𝑅√𝑖 2 + 1. [𝑀𝑡 ] 1
𝜎𝑏 = 2
. ≤ [𝜎𝑏 ]
(𝑅 − 0.5𝑏) 𝑚𝑏𝑦 cos 𝛼
𝜎𝑏 = 41.8 × 106 𝑁/𝑚2
Design is safe.
0.72 (𝑖 2 + 1)3 𝐸[𝑀𝑡 ]
𝜎𝑐 = × √ ≤ [𝜎𝑐 ]
(𝑅 − 0.5𝑏) 𝑖. 𝑏
𝜎𝑐 = 365 × 106 𝑁/𝑚2
Design is safe.
Pinion:
𝑅𝑒𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑎𝑛𝑔𝑙𝑒, 𝛿1 = 14.04°
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎1 = 𝑚𝑡 (𝑍1 + 2𝑐𝑜𝑠𝛿1 ) = 138 𝑚𝑚
Wheel:
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = 𝑚𝑡 𝑍2 = 642 𝑚𝑚
2 A pair of cast iron bevel gears connects two shafts at right angles. The pitch diameters of
the pinion and gear are 80 mm and 100 mm respectively. The tooth profiles of the gears are
14½º composite form. The allowable static stress for both gears is 55 MPa. If the pinion
transmits 2.75 kW at 1100 rpm, find the module and number of teeth on each gear and
check the design. Take surface endurance limits as 630 MPa and modulus of elasticity for
cast iron as 84 kN/mm2.(13M)(Nov/Dec 2009)BTL5
Material:(1M)
Cast Iron (given) for both pinion and wheel.
We have to design pinion.
Gear ratio, i:(1M)
𝑁1
𝑖= = 1.25
𝑁2
tan 𝛿2 = 𝑖
𝛿2 = 51.34°; 𝛿1 = 38.66°
1-36
𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠 3575
𝐹𝑡 = = = 775.82 𝑁
𝑣𝑚 4.608

𝐹𝑑 = 𝐹𝑡 . 𝑁𝑠𝑓 . 𝑘𝑚 . 𝐶𝑉 = 1251 𝑁
Strength of gear tooth, Fs:(1M)
𝑏
𝐹𝑠 = [𝜎𝑏 ]𝑚𝑡 . 𝑏. 𝑌 (1 − )
𝑅
𝐹𝑠 = 0.294 × 106 × 𝑚𝑡 − 15.86 × 106 × 𝑚𝑡2
0.294 × 10 × 𝑚𝑡 − 15.86 × 106 × 𝑚𝑡2 = 1251
6
Module, m = 7 mm.
No. of teeth, mZ1 = 12, Z2 = 15.
Pitch circle diameter of pinion, d1 = mZ1 = 80 mm.
Pitch circle diameter of wheel, d2 = mZ2 = 100 mm (given).
𝑏
𝐹𝑠 = [𝜎𝑏 ]𝑚. 𝑏. 𝑌 (1 − ) = 1287 𝑁
𝑅
0.164𝑉𝑚 (𝑐𝑏 + 𝐹𝑡 )
𝐹𝑑 = 𝐹𝑡 + [ ] = 2516.5 𝑁
0.164𝑉𝑚 + 1.485√𝑐𝑏 + 𝐹𝑡
(Fd = 2616.5 N) > (Fs = 1287 N)
The design is not safe.
➢ d1 and d2 are given, and limited to 80 mm and 100 mm.
➢ No. of teeth Z1to be minimum 12 and hence ‘mt’ cannot be increased.
➢ B cannot be increased much, it will reduce ‘Fs’. ’R’ is also fixed 64 mm given.
➢ It is difficult to re-deign.
Check for wear:(1M)
𝑏𝑑1 𝑄𝑘
𝑊𝑒𝑎𝑟 𝑙𝑜𝑎𝑑, 𝐹𝑤 = = 4225 𝑁
cos 𝛿1
(Fw = 4225N) > (Fd = 2516.5 N)
Pinion:
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎1 = 𝑚𝑡 (𝑍1 + 2𝑐𝑜𝑠𝛿1 ) = 94.93 𝑚𝑚
1-37
Wheel:
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = 𝑚𝑡 𝑍2 = 113.75 𝑚𝑚
The design is safe.
3 Design a pair of straight bevel gears for two shafts whose axes are at right angle. The power
transmitted is 25 kW. The speed of pinion is 300 rpm and the gear is 120 rpm. Assume 15
Ni2 Cr1 Mo15 steel for both the pinion and wheel. Use Hertz stresses method.(13M)BTL5
Gear ratio, i:(1M)
𝑁1
𝑖= = 2.5
𝑁2
tan 𝛿2 = 𝑖
𝛿2 = 68.2°; 𝛿1 = 21.8°
Material:(1M)
Assumed: 15 Ni2 Cr1 Mo15 steel for both pinion and wheel.
[σb]= 313.92 X 106 N/m2
[σc]= 931.95 X 106 N/m2
Gear life, N:
Not available.
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 1034.51 𝑁 − 𝑚
Eeq = 210.915 X 109 N/m2
[σb]= 313.92 X 106 N/m2
[σc]= 931.95 X 106 N/m2
2
3 0.72 𝐸 × [𝑀𝑡 ]
√ 2 √
𝑅 ≥𝜓 𝑖 +1 ( )
(𝜓 − 0.5)[𝜎𝑐 ] 𝑖
𝑅
𝑏
𝑅 = 164 𝑚𝑚
Z1 = 20 (assumed)
Z2 = i. Z1 = 50.
3 [𝑀𝑡 ]
𝑚𝑎𝑣 ≥ 1.28 √ = 4.42 𝑚𝑚
1-38
𝑏
𝑧
Revision of cone distance, R and number of teeth:
𝑅 = 0.5𝑚𝑡 𝑍1 √𝑖 2 + 1 = 177.71 𝑚𝑚
𝑅 − 0.5𝑏
𝑑1𝑎𝑣 = 𝑚𝑡 𝑍1 ( ) = 129.77 𝑚𝑚
𝑅
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 1782.52 𝑁 − 𝑚
𝑅√𝑖 2 + 1. [𝑀𝑡 ] 1
𝜎𝑏 = 2
. ≤ [𝜎𝑏 ]
𝜎𝑏 = 279 × 106 𝑁/𝑚2
Design is safe.
0.72 (𝑖 2 + 1)3 𝐸[𝑀𝑡 ]
𝜎𝑐 = ×√ ≤ [𝜎𝑐 ]
(𝑅 − 0.5𝑏) 𝑖. 𝑏
𝜎𝑐 = 1077.8 × 106 𝑁/𝑚2
Design is not safe.
Increase face width, b = 1,
∴ [𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 1336.89 𝑁 − 𝑚
0.72 (𝑖 2 + 1)3 𝐸[𝑀𝑡 ]
𝜎𝑐 = ×√ ≤ [𝜎𝑐 ]
(𝑅 − 0.5𝑏) 𝑖. 𝑏
𝜎𝑐 = 830.9 × 106 𝑁/𝑚2
Hence, design is safe.
Pinion:
Wheel:
1-39
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = 𝑚𝑡 𝑍2 = 334.46 𝑚𝑚
4 2 kW power is applied to a worm shaft at 720 rpm. The worm is of quadruple start with 50
mm as pitch circle diameter. The worm gear has 40 teeth with 5 mm module. The pressure
angle in the diametral plane is 20º. Determine: (i) the lead angle of the worm, (ii) velocity
ratio and, (iii) centre distance. Also calculate efficiency of the worm gear drive and power
lost in friction.(13M)(May/June 2014)BTL5
Lead angle of the worm, γ:(3M)
𝑑1
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑞 = = 10
𝑚𝑥
𝑍
𝛾 = tan−1 = 21.8°
𝑞
Velocity ratio, i:(2M)
𝑧
𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖 = = 10
𝑍
𝑎 = 0.5𝑚𝑥 (𝑞 + 𝑧 + 2𝑥) = 125 𝑚𝑚
Efficiency of the worm drive, η:(2M)
tan 𝛾
𝜂= = 87.11%
tan(𝛾 + 𝜌)
Power lost in friction:(2M)
𝑃𝑜𝑤𝑒𝑟 𝑙𝑜𝑠𝑡 𝑖𝑛 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 = (1 − 𝜂)𝑃 = 257.79 𝑊𝑎𝑡𝑡𝑠
5 Design a worm gear drive to transmit 20 kW at 1440 rpm, speed of worm wheel is 60
rpm.(13M)(May/June 2016)BTL5
Gear ratio, i:(1M)
𝑛
𝑖= = 24
𝑛1
Material; No. of threads on worm, Z; No.of teeth on worm wheel, z:(1M)
Worm – steel
Worm wheel – bronze (assumed)
Z = 3 (assumed)
Z = i.Z = 72 teeth.
Design of worm wheel torque, [Mt]:(1M)
60 × 𝑃
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = × 𝜂 = 2546.48 𝑁 − 𝑚
2𝜋𝑛1
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 2546.48 𝑁 − 𝑚
Design bending stress, [σb] and surface compressive stress, [σc]:(1M)
For steel and bronze combination, [σc] = 156 X 106 N/m2
For bronze wheel chill casting, [σb] = 53.955 X 106 N/m2
Minimum centre distance, a:(1M)

1-40
2
𝑧 3
540
𝑎= ( + 1) √(𝑧 ) {[𝑀𝑡 ] × 105 }
𝑞 × [𝜎𝑐 ] 𝑞
𝐴𝑠𝑠𝑢𝑚𝑒, 𝑞 = 11 (𝑎𝑠𝑠𝑢𝑚𝑒𝑑)
𝑎 = 312.8 𝑚𝑚
Axial Module, mx:(1M)
3 [𝑀𝑡 ]
𝑚𝑥 = 1.24 √ = 8 𝑚𝑚
𝑦𝑞𝑧[𝜎𝑏 ]
Revision of centre distance, a:(1M)

𝑎 = 0.5𝑚𝑥 (𝑞 + 𝑧 + 2𝑥) = 332 𝑚𝑚
Pitch diameters, pitch line velocity of worm, sliding velocity:(1M)
Pitch diameter-worm,
𝑑1 = 𝑞𝑚𝑥 = 88 𝑚𝑚
Pitch diameter-worm wheel,
𝑑2 = 𝑧𝑚𝑥 = 576 𝑚𝑚
Sliding velocity,
𝑣1
𝑣𝑠 = = 6.877 𝑚/𝑠
cos 𝛾
Revision of [σc]:(1M)
For steel-bronze combination, vs = 6.877 m/s.
Assume [σc] = 146.2 X 106 N/m2
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 2546.5 𝑁 − 𝑚
Check for induced bending stress, σb:(1M)
1.9[𝑀𝑡 ]
𝜎𝑏 = 3 ≤ [𝜎𝑏 ]
𝑚𝑥 𝑞𝑧𝑦
𝜎𝑏 = 23.9 × 106 𝑁/𝑚2
Design is safe.
Check for induced compressive stress, σc:(1M)
𝑧 3
540 +1
𝜎𝑐 = 𝑧 × √[ 𝑏
] {[𝑀𝑡 ] × 105 } ≤ [𝜎𝑐 ]
(𝑏 ) 𝑎
𝜎𝑐 = 146.2 × 106 𝑁/𝑚2

Design is safe.
Check for efficiency, η:(1M)
tan 𝛾
𝜂= = 92.63%
tan(𝛾 + 𝜌)
1-41

Worm:
𝑁𝑜. 𝑜𝑓 𝑠𝑡𝑎𝑟𝑡𝑠, 𝑍 = 3
𝑃𝑖𝑡𝑐ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑1 = 88 𝑚𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓0 = 1
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎1 = 𝑑1 + 2𝑓0 𝑚𝑥 = 104 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓1 = 𝑑1 − 2𝑓0 𝑚𝑥 − 2𝑐 = 68.8 𝑚𝑚
𝑀𝑖𝑛 𝐿𝑒𝑛𝑔𝑡ℎ, 𝐿 = (12.5 + 0.09𝑧)𝑚𝑥 = 154.24 𝑚𝑚
Worm Wheel:
𝑁𝑜. 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ, 𝑧 = 72
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = (𝑧 + 2𝑓0 +2𝑥)𝑚𝑥 = 592 𝑚𝑚
𝑅𝑜𝑜𝑡 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑓2 = (𝑧 − 2𝑓0 )𝑚𝑥 − 2𝑐 = 556.8 𝑚𝑚
PART * C
1 Design a pair of right angle bevel gears to transmit 15 kW at 75 rpm to another gear to run
at 250 rpm. Not less than 20 teeth are to be used on either gear. The pressure angle is 20º.
Assume a gear life of 12000 hrs.(15M)(Nov/Dec 2015)BTL5
Gear ratio, i:(1M)
𝑁1
𝑖= =3
𝑁2
tan 𝛿2 = 𝑖
𝛿2 = 75.57°; 𝛿1 = 14.43°
Material:(1M)
C45 steel for both pinion and wheel (assumed).
Yield strength, σy = 360 X 106 N/m2
Gear life, N:(1M)
Life in number of cycles, N = 60 X (rpm, n) X (Life in hrs, T) = 54X 107 cycles
2𝜋𝑁
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 248.28 𝑁 − 𝑚
Eeq = 210.915 X 109 N/m2
[𝜎𝑏 ] = = 82.076 × 106 𝑁/𝑚2
𝑛. 𝑘𝜎
[𝜎𝑐 ] = 𝐶𝑅 𝐻𝑅𝐶𝑘𝑐𝑙 = 593.97 × 106 𝑁/𝑚2
1-42
2
3 0.72 𝐸 × [𝑀𝑡 ]
𝑅≥ 𝜓 √𝑖 2 √
+1 ( )
(𝜓 − 0.5)[𝜎𝑐 ] 𝑖
𝑅
𝑏
𝑅 = 152 𝑚𝑚
Z1 = 20 (assumed)
Z2 = i. Z1 = 60.
3 [𝑀𝑡 ]
𝑚𝑎𝑣 ≥ 1.28 √ = 4.33 𝑚𝑚
𝑏
𝑧
Revision of cone distance, R and number of teeth:(1M)
𝑅 = 0.5𝑚𝑡 𝑍1 √𝑖 2 + 1 = 187.74 𝑚𝑚
𝑅 − 0.5𝑏
𝑑1𝑎𝑣 = 𝑚𝑡 𝑍1 ( ) = 101 𝑚𝑚
𝑅
[𝑀𝑡 ] = 𝑀𝑡 . 𝑘𝑑 . 𝑘 = 412.54 𝑁 − 𝑚
𝑅√𝑖 2 + 1. [𝑀𝑡 ] 1
𝜎𝑏 = 2
. ≤ [𝜎𝑏 ]
𝜎𝑏 = 73.527 × 106 𝑁/𝑚2
Design is safe.
0.72 (𝑖 2 + 1)3 𝐸[𝑀𝑡 ]

𝜎𝑐 = ×√ ≤ [𝜎𝑐 ]
(𝑅 − 0.5𝑏) 𝑖. 𝑏
𝜎𝑐 = 557.27 × 106 𝑁/𝑚2
Design is safe.
Pinion:
1-43
Wheel:
𝑇𝑖𝑝 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑𝑎2 = 𝑚𝑡 𝑍2 = 363 𝑚𝑚
2 A hardened steel worm rotates at 1440 rpm and transmits 12 kW to a phosphor bronze
gear. The speed of the worm gear should be 60 rpm. Design the worm gear drive if an
efficiency of atleast 82% is desired.(15M)(Nov/Dec 2016)BTL5
Material:(1M)
Worm-hardened steel (given)
Worm gear-phosphor bronze (given)
No.of threads on worm, Z and teeth on worm wheel, z:(1M)
Z = 3 (assumed)
𝑛
𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖 = = 24
𝑛1
No. of teeth on wheel, z = i.Z = 72 teeth.
Diameter factor, q and Lead angle, γ:(1M)
Q = 11 (assumed)
𝑍
𝛾 = tan−1 ( ) = 15.255°
𝑞
𝐹𝑡 = = 𝑁
𝑃𝑖𝑡𝑐ℎ 𝑙𝑖𝑛𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑤𝑜𝑟𝑚 𝑔𝑒𝑎𝑟 𝑚𝑥

6 + 𝑣𝑚𝑔 68.967
𝐹𝑑 = 𝐹𝑡 = + 2600
6 𝑚𝑥
𝐹𝑠 = [𝜎𝑏 ]𝑚𝑥 . 𝑏. 𝑌
𝐹𝑠 = 253.8 × 106 × 𝑚𝑥2 , 𝑁
68.967
253.8 × 106 × 𝑚𝑥2 = + 2600
𝑚𝑥
Module, mx = 8 mm.
Face width, b; Pitch diameter, d1; pitch line velocity of worm:(2M)
Face width, b = 8.25 X mx = 66 mm
Pitch diameter,
𝑑1 = 𝑞𝑚𝑥 = 88 𝑚𝑚
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Pitch line velocity of worm,
𝑣𝑚𝑔 = 226.195𝑚𝑥 = 1.81 𝑚/𝑠
𝐹𝑠 = 253.8 × 106 × 𝑚𝑥2 = 16243.2 𝑁
Revision of dynamic load, Fd:(1M)
68.967
𝐹𝑑 = [ ] + 2600 = 11220.9 𝑁
𝑚𝑥
(Fs = 16243.2 N) > (Fd = 11220.9 N)
Wear load, Fw:(1M)
𝐹𝑤 = 𝐷𝑔 . 𝑏. 𝑘𝑤 = 32818.5 𝑁
(Fw = 32818.5 N) > (Fd = 11220.9 N)
The design is safe.
tan 𝛾
𝜂= = 82%
tan(𝛾 + 𝜌)
Design is satisfactory.
Worm:
Worm Wheel:
3 The input to worm gear shaft is 18 kW at 600 rpm, speed ratio is 20. The worm is to be of
hardened steel and the wheel is made of chilled phosphor bronze. Considering wear and
strength, design worm and worm wheel.(15M)(Nov/Dec 2015)BTL5
Material:(1M)
Worm-hardened steel (given)
Worm wheel – chilled phosphor bronze (given)
Design bending stress (worm wheel) for chilled bronze, [σb] = 98.1 X 106 N/m2

1-45
No. of threads on worm, Z and teeth on worm wheel, z:(1M)
Z = 3 (assumed)
𝑛
𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖 = = 20 (𝑔𝑖𝑣𝑒𝑛)
𝑛1
No. of teeth on wheel, z = i.Z = 60 teeth.
Diameter factor, q and Lead angle, γ:(1M)
Q = 11 (assumed)
𝑍
𝛾 = tan−1 ( ) = 15.255°
𝑞
𝐹𝑡 = = 𝑁
𝑃𝑖𝑡𝑐ℎ 𝑙𝑖𝑛𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑤𝑜𝑟𝑚 𝑔𝑒𝑎𝑟 𝑚𝑥
Dynamic Load Fd:(1M)

6 + 𝑣𝑚𝑔 124.14 + 3900.065𝑚𝑥
𝐹𝑑 = 𝐹𝑡 = ,𝑁
6 𝑚𝑥
𝐹𝑠 = [𝜎𝑏 ]𝑚𝑥 . 𝑏. 𝑌
𝐹𝑠 = 317.25 × 106 × 𝑚𝑥2 , 𝑁
124.14 + 3900.065𝑚𝑥
317.25 × 106 × 𝑚𝑥2 =
𝑚𝑥
Module, mx = 8 mm.
Face width, b; Pitch diameter, d1; pitch line velocity of worm:(2M)
Face width, b = 8.25 X mx = 66 mm
Pitch diameter,
𝑑1 = 𝑞𝑚𝑥 = 88 𝑚𝑚
Pitch line velocity of worm,
𝑣𝑚𝑔 = 226.195𝑚𝑥 = 1.508 𝑚/𝑠
𝐹𝑠 = 317 × 106 × 𝑚𝑥2 = 20304.32 𝑁
Revision of dynamic load, Fd:(1M)
124.14 + 3900.065𝑚𝑥
𝐹𝑑 = = 19417.565 𝑁
𝑚𝑥
(Fs = 20304.32 N) > (Fd = 19417.565 N)
Wear load, Fw:(1M)
𝐹𝑤 = 𝐷𝑔 . 𝑏. 𝑘𝑤 = 27348.71 𝑁
(Fw = 27348.71 N) > (Fd = 19417.565 N)
1-46
The design is safe.
tan 𝛾
𝜂= = 87.78%
tan(𝛾 + 𝜌)
Design is satisfactory.
Worm:
Worm Wheel:

1-47
UNIT IV–GEAR BOXES
Geometric progression - Standard step ratio - Ray diagram, kinematics layout -Design of sliding mesh
gear box - Design of multi speed gear box for machine tool applications - Constant mesh gear box -Speed
reducer unit–Variable speed gear box, Fluid Couplings, Torque Converters for automotive applications.
PART * A
Q.No. Questions
1 Calculate standard step ratio for six speed gear box with speed ranging between 100 and
560rpm.BTL5
ɸ = [NMax/NMin]1/n-1
= [560/100]1/6-1
=1.411
2 Comment on the number of gears to be used in the output shaft. (May/June 2012)BTL3
It is practiced in the gear box that output shaft is fixed with maximum of three gears.
3 What are the methods of lubrication in speed reducers?BTL2
➢ Splash or spray lubricating method and
➢ Pressure lubrication method.
4 List any two methods used for changing speeds in gear boxes. (Nov/Dec 2016)BTL2
➢ Sliding mesh gear box and
➢ Constant mesh gear box
5 Write any two requirements of a speed gear box.BTL2
➢ Gear box should provide the designed series of spindle speeds.
➢ Gear box should transmit the required amount of power to the spindle.
6 Differentiate ray diagram and structural diagram. (or) What does the ray diagram of gear
box indicates? (May/June 2012, Nov/Dec 2016)BTL4
The ray diagram is a graphical representation of the drive arrangement in general form. It serves
the specific values of all the transmission ratios and speed of all the shafts in the drive.
The structural diagrams are drawn from the structural formulae which is a graphical tool used to
find the range ratio of transmission groups. The structural diagram gives information about the

1-48
number of shafts and the number of gears on each shaft.
7 Write the structural formula for a six speed gear box.BTL3
A typical ray diagram for a six speed gear box, for the preferred structural formula 3(1) 2(3), is
shown below.
8 Select 3 pairs of gears with total teeth for each pair 60 and speed ratios 1, 1.41, and 2.BTL4
z1+ z2=z3+ z4= z5+ z6=60;
i= z2/ z1=1; i=z4/ z3=1.41; i= z6/ z5=2
z1=30; z2=30; z3=25: z4=36: z5=20: z6=40
9 State any three basic rules to be followed while designing a gear box.BTL1
➢ The transmission ratio in a gear box is limited by ¼ ≤ i ≤ 2.
➢ For stable operation, the speed ratio of any stage should not be greater than 8. i.e., N max/
Nmin ≤ 8.
➢ In all stages except in the first stage, N max ≥ Ninput> Nmin
10 What is the function of spacers in a gear-box?BTL1
The function of spacers is to provide the necessary distance between the gears and the bearings.
11 List out the possible arrangements to achieve 16 speed gear box.BTL2
➢ 4 x 2 x 2 scheme
➢ 2 x 4 x 2 scheme and
➢ 2 x 2 x 4 schemes
12 What are the possible arrangements to achieve 12 speeds from a gear box? (April/May
2011, May/June 2013)BTL3
The possible arrangements are:
➢ 3 x 2 x 2 scheme
➢ 2 x 3 x 2 scheme and
➢ 2 x 2 x 3 scheme.
13 Sketch the kinematics layout of gears for 3 speeds between two shafts.BTL3
14 What are preferred numbers? (Apr/May 2011,2013, Nov/Dec 2014)BTL2

Name the series in which speeds of multi speed gear box are arranged. [May/June 2014]
Preferred numbers are the conventionally rounded off values derived from geometric series.
There are five basic series, denoted as R 5, R 10, R 20, R 40 and R 80 series.
15 What does the ray-diagram of gear box indicates? (May/June 2012, Apr/May 2017)BTL3
The ray diagram is a graphical representation of the drive arrangement in general form. It
serves to determine the specific values of all the transmission ratios and speeds of all the shafts
1-49
in the drive.
16 What is step ratio? (or) Define progression ratio. (Nov/Dec 2015, May/June 2014)BTL1
When the spindle speeds are arranged in geometric progression, then the ratio between the two
adjacent speeds is known as step ratio or progression ratio.
17 Draw the ray diagram for 12 speed gear box. (May/June 2013)BTL3
18 What is a speed reducer?BTL1

Speed reducer is a gear mechanism with a constant speed ratio, to reduce the angular speed of
output shaft as compared with that of input shaft.
19 Specify four types of gear box.(Nov/Dec 2014)BTL2
➢ Sliding mesh gear box,
➢ constant mesh gear box,
➢ synchromesh gearbox,
➢ planetary gearbox.
20 What is multispeed gear box? (May/June 2016)BTL1
A gearbox that converts a high speed input into a number of different speed output it is called a
multi-speed gear box. Multi speed gear box has more than two gears and shafts. A multi speed
gearbox reduces the speed in different stages.
21 Why geometric progression is selected for arranging the speeds in gear box? (Apr/May
2017)BTL2
When the speeds are arranged in G.P, it has the following advantages over the other
progressions.
➢ The speed loss is minimum
➢ No.of gears to be employed is minimum
➢ G.P provides a more even range of spindle speeds at each step.
➢ The lay out is comparatively very compact.
➢ G.P m/c tool spindle speeds can be selected easily from preferred numbers, because
preferred numbers are in geometric progression.
22 What is R20 series? (May/June 2016)BTL1
In industrial design, preferred numbers (also called preferred values, preferred
series or convenient numbers are standard guidelines for choosing exact product dimensions
within a given set of constraints. Product developers must choose numerous lengths, distances,
1-50
diameters, volumes, and other characteristic quantities.
Preferred numbers represent preferences of simple numbers (such as 1, 2, and 5) and their
powers of a convenient basis, usually 10. The R5, R10 and R20 series refers to the Renard 5
(first-choice sizes 60 % increments), Renard 10 (second-choice sizes 25 % increments) and
Renard 20 (third-choice sizes 12 % increments) series of preferred numbers standardized in
ISO3.
23 Write the significance of structural formula. (Nov/Dec 2015)BTL1
Structural formula is used to find the number of speeds (n) available at the spindle and through
no. Stages it can be achieved.
n = p1 (X1) .p2 (X2).p2 (X3)
p= stages in the gear box,
X = Characteristic of the stage.
24 List four application where constant mesh gear box is used. (Nov/Dec 2012)BTL2
Vehicles which use this type of gearboxes are farm trucks, motorcycles, and heavy
machinery. The availability of such mechanisms like constant mesh gearbox which create
less noise and are cost effective.
25 What are the conditions required for interchangeability of toothed Gears?
(Nov/Dec 2012)BTL3
For interchangeability of all gears, the set must have the same circular pitch, module,
diameter pitch, pressure, angle, addendum and dedendum and tooth thickness must be one
half of the circular pitch.
PART * B
1 Sketch three possible ray diagrams for a 6 speed gearbox with 2x3 arrangement. Choose the
best possible ray diagram. Give suitable explanation for the same. (13M)(April/May
2010)BTL5
(6M)
➢ Three ray diagrams are drawn keeping the input speed same.(6M)
➢ Ray diagram (ii): Two output speeds are same as input speed in stage 2. This is not
preferable.

1-51
➢ Ray diagram (i): One speed reduction is very high in stage 1. This is not preferable.
➢ Ray diagram (iii): Do not have any such speeds and hence this is the preferable ray
diagram.
𝑁𝑚𝑖𝑛 1 𝑁𝑚𝑎𝑥
≥ 𝑎𝑛𝑑 ≤ 2 𝑠ℎ𝑜𝑢𝑙𝑑 𝑏𝑒 𝑠𝑎𝑡𝑖𝑠𝑓𝑖𝑒𝑑 𝑎𝑡 𝑒𝑎𝑐ℎ 𝑠𝑡𝑎𝑔𝑒
𝑁𝐼𝑛𝑝𝑢𝑡 4 𝑁𝐼𝑛𝑝𝑢𝑡
Overlapping speed gearbox:(1M)
➢ Maximum possible speeds = Required number of speeds.
➢ Sometimes: Required number of speeds < Maximum possible speeds.
2 A sliding mesh gearbox is to be used for 4 forward and 1 reverse speeds. First gear speed
ratio is 5.5 and reverse gear ratio is 5.8. Clutch gear on clutch shaft and gear (in constant
mesh) on lay shaft has speed ratio of 2. Calculate the number of teeth on all the gears.
Assume that the minimum number of teeth on any gear should not be less than 18.
Calculate actual gear ratios. Assume that the geometric progression for gear ratios, top gear
(fourth), third gear, second and first gear is 1:x:x2:x3. (13M)(Nov/Dec 2014)BTL5
The GP ratio:(1M)
i1 = x3 = 5.5; x = 1.765.
Gear ratios are:
1:1.765:3.116:5.5
𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑖𝑟𝑠𝑡 𝑑𝑟𝑖𝑣𝑒𝑟 𝑔𝑒𝑎𝑟
𝑆𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜, 𝑖 =
𝑆𝑝𝑒𝑎𝑑 𝑜𝑓 𝑙𝑎𝑠𝑡 𝑑𝑟𝑖𝑣𝑒𝑛 𝑔𝑒𝑎𝑟
Max gear ratio, imax:(1M)
𝑍2 𝑍8
𝑖𝑚𝑎𝑥 = ×
𝑍1 𝑍7
Zmin = 18 (given)
Let, Z7 = 18 and Z8 = 50.
Z1 + Z2 = Z7 + Z8 = 69
Z1 = 23 and Z2 = 46
Second gear ratio, i2:(1M)
𝑍2 𝑍6
𝑖2 = × = 3.116
𝑍1 𝑍5
Z1 + Z2 = Z7 + Z8 = Z5 + Z6 = 69
Z5 = 27 and Z6 = 42
Third gear ratio, i3:(1M)
𝑍2 𝑍4
𝑖3 = × = 1.765
𝑍1 𝑍3
Z1 + Z2 = Z7 + Z8 = Z5 + Z6 = Z3 + Z4 = 69
Z3 = 37 and Z4 = 32
Reverse gear ratio, iR:(1M)
𝑍2 𝑍8
𝑖𝑅 = × = 5.8
𝑍1 𝑍9
1-52
Z8 = 51 (already found) and Z9 = 18.
Actual gear ratios:(5M)
𝑍2
𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = =2
𝑍1
𝑍2 𝑍8
𝐹𝑖𝑟𝑠𝑡 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖1 = × = 5.6667
𝑍1 𝑍7
𝑍2 𝑍6
𝑆𝑒𝑐𝑜𝑛𝑑 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖2 = × = 3.1111
𝑍1 𝑍5
𝑍2 𝑍4
𝑇ℎ𝑖𝑟𝑑 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖3 = × = 1.7297
𝑍1 𝑍3
𝑍2 𝑍8
𝑅𝑒𝑣𝑒𝑟𝑠𝑒 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜, 𝑖𝑅 = × = 5.6667
𝑍1 𝑍9
Kinematic Layout:(3M)
3 Design a four speed gearbox to have following speed ratio. First gear is 5:1, second gear is
3:1, third gear is 1.5:1 and the top gear is 1:1. The centre distance between the input and
output shafts is 150 mm. All gears are of 4 mm module, Determine the number of teeth of
all wheels, pitch circle diameter of all wheels and sketch the diagrammatic arrangement of
the gear box. (Assume number of teeth not less than 20 and pressure angle
20º.(13M)(Nov/Dec 2015)BTL5
𝑆𝑝𝑒𝑒𝑑 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑖𝑟𝑠𝑡 𝑑𝑟𝑖𝑣𝑒𝑟 𝑔𝑒𝑎𝑟
𝑆𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜, 𝑖 =
𝑆𝑝𝑒𝑎𝑑 𝑜𝑓 𝑙𝑎𝑠𝑡 𝑑𝑟𝑖𝑣𝑒𝑛 𝑔𝑒𝑎𝑟
Max gear ratio, imax:(2M)
𝑍2 𝑍8
𝑖𝑚𝑎𝑥 = × =5
𝑍1 𝑍7
Assuming same ratio between any pair of gears;
1-53
𝑍2 𝑍8
= = √5
𝑍1 𝑍7
Given centre distance, a:(2M)
𝑚(𝑍1 + 𝑍2 )
𝑎= = 150
2
Z1 + Z2 = 75.
Z2 = 2.2361Z1 and Z8 = 2.2361Z7
Also, Z1 +Z2 = Z7 + Z8 = Z5 + Z6 = Z3 + Z4 = 75
Z1 = 23 and Z2 = 52.
Also, Z8 = 2.2361Z7 and Z7 + Z8 = 75
Z7 = 23 & Z8 = 52.
Second gear ratio, i2:(1M)
𝑍2 𝑍6
𝑖2 = × =3
𝑍1 𝑍5
Z5 = 32 and Z6 = 43.
Third gear ratio, i3:(1M)
𝑍2 𝑍4
𝑖3 = × = 1.5
𝑍1 𝑍3
Z3 = 45 and Z4 = 30.
Pitch circle diameter of all gears:(4M)
d1 = mZ1 = 92 mm ; d2 = mZ2 = 208 mm; d3 = mZ3 = 180 mm; d4 = mZ4 = 120 mm
d5 = mZ5 = 128 mm; d6 = mZ6 = 172 mm; d7 = mZ7 = 92 mm; d8 = mZ8 = 208 mm
Kinematic layout:(3M)
4 A gear box is to give 18 speeds for a spindle of a milling machine. Maximum and minimum
speeds of the spindle are to be around 650 and 35 rpm respectively. Find the speed ratios
which will give the desired speeds and draw the structural diagram and kinematic
arrangement of the drive.(13M)(Nov/Dec 2015)BTL5
1
𝑁 ( )
𝑛−1
𝑆𝑡𝑒𝑝 𝑟𝑎𝑡𝑖𝑜, ∅ = ( 𝑁𝑚𝑎𝑥 ) = 1.1875(2M)
𝑚𝑖𝑛
1-54
Range of speeds:(1M)
R40 Series:
35.5, 42.5, 50, 60, 71, 85, 100, 118, 140, 170, 200, 236, 280, 335, 400, 475, 560, 670 rpm.
Structural formula:(1M)
1 × 3(1) × 3(3) × 2(9)
Ray Diagram:(2M)
𝐶𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛 𝑡𝑜 𝑏𝑒 𝑠𝑎𝑡𝑖𝑠𝑓𝑖𝑒𝑑, ≥ 𝑎𝑛𝑑 ≤2
At stage 3:
𝑁𝑚𝑖𝑛 = 35.5 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 142 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 170 𝑟𝑝𝑚
At stage 2:
𝑁𝑚𝑖𝑛 = 85 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 340 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 236 𝑟𝑝𝑚
At stage 1:
Diagram: (5M)
Kinematic arrangement:(2M)

1-55
5 A nine speed gear box, used as a head stock gearbox for a turret lathe, is to provide a speed
range of 180 rpm to 1800 rpm. Using standard step ratio, draw the speed diagram and
kinematic layout.(13M)(May/June 2011)BTL5
1
𝑁 ( )
𝑛−1
𝑆𝑡𝑒𝑝 𝑟𝑎𝑡𝑖𝑜, ∅ = ( 𝑁𝑚𝑎𝑥 ) = 1.3335(2M)
𝑚𝑖𝑛
R40 Series:
180, 236, 315, 425, 560, 750, 1000, 1320, 1800 rpm.
1 × 3(1) × 3(3)
Ray diagram:(2M)
𝐴𝑡 𝑎𝑛𝑦 𝑠𝑡𝑎𝑔𝑒, ≥ 𝑎𝑛𝑑 ≤2
At stage 2:
At stage 1:

1-56
Diagram: (5M)
Kinematic Arrangement:(2M)
PART * C
1 Draw the kinematic diagram and speed diagram of the head stock gearbox of a turret lathe
arrangement for 9 spindle speeds, ranging from 31.5 rpm to 1050 rpm. Calculate the
number of teeth on each gear. Minimum number of teeth on a gear is 25. Also calculate the
percentage deviation of the obtainable speeds.(15M)(May/June 2016)BTL5
1
𝑁 ( )
𝑛−1
𝑆𝑡𝑒𝑝 𝑟𝑎𝑡𝑖𝑜, ∅ = ( 𝑁𝑚𝑎𝑥 ) = 1.5501(1M)
𝑚𝑖𝑛
R40 Series:
31.5, 50, 80, 125, 200, 315, 500, 800, 1250 rpm.
1 × 3(1) × 3(3)
Ray diagram:(1M)
1-57
At stage 2:
𝑁𝑚𝑖𝑛 = 31.5 𝑟𝑝𝑚; 𝑁𝑖𝑛𝑝𝑢𝑡 = 125 𝑟𝑝𝑚; 𝑁𝑚𝑎𝑥 = 500 𝑟𝑝𝑚
At stage 1:
Number of teeth on each gear:(2M)
Z1 = 37; Z2 = 148; Z3 = 52; Z4 = 133
Z5 = 25; Z6 = 160; Z7 = 63; Z8 = 62
Z9 = 100; Z10 = 25; Z11 = 25; Z12 = 100
Diagram: (4M)
Obtainable speeds:(2M)
Input speed, N = NG = 800 rpm.
𝑍1 𝑍7 𝑍1 𝑍9
𝑁1 = 𝑁 × × = 203.23 𝑟𝑝𝑚 𝑁2 = 𝑁 × × = 800 𝑟𝑝𝑚
𝑍2 𝑍8 𝑍2 𝑍10
1-58
𝑍1 𝑍11 𝑍3 𝑍7
𝑁3 = 𝑁 × × = 50 𝑟𝑝𝑚 𝑁4 = 𝑁 × × = 317.83 𝑟𝑝𝑚
𝑍2 𝑍12 𝑍4 𝑍8
𝑍3 𝑍9 𝑍3 𝑍11
𝑁5 = 𝑁 × × = 1251.13 𝑟𝑝𝑚 𝑁6 = 𝑁 × × = 78.20 𝑟𝑝𝑚
𝑍4 𝑍10 𝑍4 𝑍12
𝑍5 𝑍7 𝑍5 𝑍9
𝑁7 = 𝑁 × × = 127.02 𝑟𝑝𝑚 𝑁8 = 𝑁 × × = 500 𝑟𝑝𝑚
𝑍6 𝑍8 𝑍6 𝑍10
𝑍5 𝑍11
𝑁9 = 𝑁 × × = 31.25 𝑟𝑝𝑚
𝑍6 𝑍12
Arranging in ascending order;
Obtained speeds; 31.25, 50, 78.2, 127.02, 203.23, 317.83, 500, 800, 1251.13 rpm.
Percentage deviation of obtainable speeds from the calculated speeds (1M)
𝑁𝑜𝑏𝑡 − 𝑁𝐶𝑎𝑙
%𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 = × 100
𝑁𝐶𝑎𝑙
Speed No Nobt (rpm) Ncal (rpm) % deviation
1 31.25 31.5 -0.79
2 50 50 0
3 78.2 80 -2.25
4 127.02 125 1.62
5 203.23 200 1.62
6 317.83 315 0.90
7 500 500 0
8 800 800 0
9 1251.13 1250 0.09
2 Sketch the arrangements of a six speed gearbox. The minimum and maximum speeds
required are around 460 and 1400 rpm. Drive speed is 1440 rpm. Construct speed diagram
of the gearbox and obtain various reduction ratios. Use standard output speeds and
standard step ratio. Calculate number of teeth in each gear and verify whether the actual
output speeds are within ±2% of standard speeds.(15M)(May/June 2014)BTL5
1
𝑁 ( )
𝑛−1
𝑆𝑡𝑒𝑝 𝑟𝑎𝑡𝑖𝑜, ∅ = ( 𝑁𝑚𝑎𝑥 ) = 1.2493(1M)
𝑚𝑖𝑛
R40 Series:
450, 560, 710, 900, 1120, 1400 rpm.
1 × 2(1) × 3(2)

1-59
Ray diagram:(1M)
At stage 2:
At stage 1:
Diagram: (3M)
Z1 = 37; Z2 = 148; Z3 = 52; Z4 = 133; Z5 = 25;
Z6 = 160; Z7 = 63; Z8 = 62; Z9 = 100; Z10 = 25.
Obtainable speeds:(2M)
Input speed, N = NF = 1440 rpm.
𝑍1 𝑍5
𝑁1 = 𝑁 × × = 871.58 𝑟𝑝𝑚
𝑍2 𝑍6
𝑍1 𝑍7
𝑁2 = 𝑁 × × = 1394.53 𝑟𝑝𝑚
𝑍2 𝑍8
𝑍1 𝑍9
𝑁3 = 𝑁 × × = 544.74 𝑟𝑝𝑚
𝑍2 𝑍10
𝑍3 𝑍5
𝑁4 = 𝑁 × × = 702.44 𝑟𝑝𝑚
𝑍4 𝑍6
𝑍3 𝑍7
𝑁5 = 𝑁 × × = 1123.90 𝑟𝑝𝑚
𝑍4 𝑍8
1-60
𝑍3 𝑍9
𝑁6 = 𝑁 × × = 439.02 𝑟𝑝𝑚
𝑍4 𝑍10
Arranging in ascending order;

Obtained speeds; 439.02, 544.74, 702.44, 871.58, 1123.90, 1394.53 rpm.
Percentage deviation of obtainable speeds from the calculated speeds (2M)
𝑁𝑜𝑏𝑡 − 𝑁𝐶𝑎𝑙
%𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 = × 100
𝑁𝐶𝑎𝑙
Speed No Nobt (rpm) Ncal (rpm) % deviation
1 439.02 450 -2.44
2 544.74 560 -2.725
3 702.44 710 -1.065
4 871.58 900 -3.158
5 1123.90 1120 0.348
6 1394.53 1400 -3.907
3 A six speed gearbox is required to provide output speeds in the range of 125 to 400 rpm,
with a step ratio of 1.25 and transmit a power 5 kW at 710 rpm. Draw the speed diagram
and kinematic diagram. Determine the number of teeth, module and face width of all gears,
assuming materials for gears. Determine the length of the gearbox along the axis of the gear
shaft.(15M)(May/June 2016)BTL5
R40 Series:
125, 160, 200, 250, 315, 400 rpm.
1 × 2(1) × 3(2)
Ray diagram:(1M)

1-61
At stage 2:
At stage 1:
Diagram: (3M)
Z1 = 23; Z2 = 37; Z3 = 20; Z4 = 40; Z5 = 26;
Z6 = 26; Z7 = 32; Z8 = 20; Z9 = 20; Z10 = 32.
Minimum module, m:(3M)
3 [𝑀𝑡 ]
𝑚 ≥ 1.26 × √
𝑦[𝜎𝑏 ]𝜔𝑚 𝑍1
𝐷𝑒𝑠𝑖𝑔𝑛 𝑡𝑜𝑟𝑞𝑢𝑒, [𝑀𝑡 ] = 𝑀𝑡 × 𝑘 × 𝑘2 = 3.10349 × 105 𝑁 − 𝑚𝑚
𝑚 ≥ 3.873 𝑚𝑚
Taking higher standard, m = 5 mm.
Face width, b = 50 mm.
Length of gear box, L:(2M)
𝐿 = 2𝛿 + 4𝑏 + 𝑐 + 7𝑏 + 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑎𝑠𝑠𝑢𝑚𝑒𝑑 = 645 𝑚𝑚

1-62

1-63
UNIT V – CAM, CLUTCHES AND BRAKES
Cam Design: Types-pressure angle and under cutting base circle determination-forces and
surfacestresses. Design of plate clutches –axial clutches-cone clutches-internal expanding rim clutches-
Electromagnetic clutches. Band and Block brakes - external shoe brakes - Internal expanding shoebrake.
PART * A
Q.No. Questions
1 What are the desirable properties of friction material to be used for clutches?BTL2
➢ A high and uniform coefficient of friction.
➢ Good resiliency
➢ The ability to withstand high temperatures, together with good heat conductivity.
➢ High resistance to wear, scoring and galling.
➢ Friction materials are basically composite materials made up of strands and fiber
composites.
2 Classify clutches based on the coupling methods. (May/June 2014)BTL2
➢ Positive contact clutches
➢ Frictional clutches
➢ Overrunning clutches
➢ Magnetic clutches and
➢ Fluid couplings.
3 What is fade? (May/June 2012, May/June 2013)BTL1
When the brake is applied continuously over a period of time, the brake becomes overheated
and the coefficient of friction drops. This results in sudden fall of efficiency of the brake. This
phenomenon is known as ‘fade’ of ‘fading’.
4 Distinguish between coupling and a clutch. (Nov/Dec 2012)BTL4
Couplings are used as permanent connecting elements between two power transmitting
elements whereas clutches are used as temporary connecting elements. Thus periodical
engagement is possible in clutch connection.
5 Why in automobiles, braking action when travelling in reverse is not as effective as when
moving forward? (April/May 2015)BTL2
When an automobile moves forward, the braking force acts in the opposite direction to the
direction of motion of the vehicle Whereas in reverse travelling the braking force acts in the
same direction to the direction of motion of the vehicle. So it requires more braking force to
apply brake.
6 What is the axial force required at the engagement and disengagement of cone clutch?
(May/June2013)BTL2
➢ For engagement: We = Wn (1 + µ cot α),
1-64
➢ For disengagement: Wd= Wn (1 - µ cot α).
7 What is the function of a clutch in a transmission systems? (May/June 2016)BTL1
The clutch is a mechanical device which is used to connect or disconnect the source of power at
the operator’s will.
8 What is a self-locking brake? (Apr/May 2011, May/June 2013, Nov/Dec 2012)BTL1
When the frictional force is sufficient enough to apply the brake with no external force, then the
brake is said to be self-locking brake.
9 What you meant by self-energizing brake? (Nov/Dec 2016, May/June 2014, 2013)BTL1
When the moment of applied force (F. l) and the moment of the frictional force (µ . R N . c) are
in the same direction, then frictional force helps in applying the brake. This type of brake is
known as a self-energizing brake.
10 How can pressure angle be reduced in cam design? (May/June 2012)BTL2
It can be reduced by increasing the cam size or by adjusting the offset. Higher the pressure
angle higher the side thrust and higher the chances of jamming the translating follower in its
guide ways.
11 If a multidisc clutch has 8 discs in driving shaft and 9 discs in driven shaft, then how
many number of contact surfaces it will have? (April/May 2015)BTL5
Given data : n1 = 8; n2 = 9
Solution : Number of pair of contact surface, n = n 1 + n2 -1 = 8+9-1 = 16
12 Name different types of clutch. BTL2
➢ Single Plate clutch
➢ Multi plate Clutch
➢ Cone Clutch
➢ Centrifugal Clutch
13 How does the function of a brake differ from that of a clutch? BTL4
Clutch used to engage and disengage the engine from the transmission system when applied.
Brake is used to stop the vehicle when applied due to frictional power.
14 What is the significance of pressure angle in CAM design? (May/June 2016)BTL3
It is the measure of steepness of the cam profile. The angle between the direction of the
follower movement and the normal to the pitch curve at any point is called pressure
angle. Pressure angle varies from maximum to minimum during complete rotation.
15 Mention a few applications of Cams.(Nov/Dec 2016)BTL2
Cam mechanisms are used in various areas of machine building, such as internal-combustion
engines, metal-cutting machines, and machines of the food industry, in which the cam
mechanism performs a programmed operation, as well as in automated machines, in which cam
mechanisms perform control functions, connecting and disconnecting working parts at the
proper moment.
16 Differentiate between uniform pressure and uniform wear theories adopted in the design
of clutches.(Nov/Dec 2014)BTL4
➢ For uniform pressure theory Mean radius of friction surface (R) = 2/3[r 13 – r23/r12-r22]
➢ For uniform wear theory Mean radius of friction surface (R) = [r 1 +r2] /2
1-65
r1 = External radius of frictional surface
r2 = Internal radius of frictional surface
17 Double shoe brakes are preferred than single shoe brakes. Why? (April /May 2017)BTL4
If only one block is used for braking, then there will be side thrust on the bearing of wheel
shaft. This drawback can be removed by providing two blocks on the two sides of the drum.
The double shoes on the drum reduce the unbalanced force on the shaft.
18 What are the effects of temperature rise in clutches? (May/June 2013)BTL2
Because the temperature rise beyond the permissible range in brakes will cause:
➢ Excessive wear
➢ Distortion of the brake linings and
➢ Surface cracks due to thermal stresses.
19 Differentiate a brake and a dynamometer.(April /May 2017)BTL4
➢ Brake is a mechanical device by means of a body is retarded for slowing down or to
bring it to rest, by applying artificial frictional resistance.
➢ A dynamometer is a brake incorporating a device to measure the frictional resistance
applied. This is used for measuring the driving forces or torque transmitted and hence
the power developed by the machine.
20 Name four materials used for lining of friction surfaces in clutches. (or) Name few
commonly used friction materials. BTL2
➢ Wood
➢ Cork
➢ Leather
➢ Asbestos based friction materials and
➢ Powdered metal friction materials.
21 In a hoisting machinery, what are the different energies absorbed by a brake system?
(Nov/Dec 2014)BTL2
In hoists and elevators, the potential energy released by the objects during the braking period is
absorbed by the brake.
22 In cone clutches semi-cone angle should be greater than 12 deg. Why? (May/June
2012)BTL4
The semi cone angle is kept greater than a certain value to avoid self-engagement; otherwise
disengagement of clutch would be difficult. This is kept around 12.5deg.if the angle is less than
this value than the clutch is liable to jam in engagement
23 Sketch the internal shoe brake and name the various parts.(May/June 2012)BTL3

1-66
24 Name the profile of cam that gives no jerk. (Nov/Dec 2015)BTL2

Cycloidal curve profile of cam that gives no jerk.
25 What is meant by positive clutch? (Nov/Dec 2015)BTL1
Positive-contact clutches have interlocking engaging surfaces to form a rigid mechanical
junction.
PART * B
1 A single shoe brake is shown. The diameter of drum is 250 mm and angle of contact is 90º.
If the operating force of 750 N is applied at the end of the lever and µ = 0.35, determine the
torque that may be transmitted by the brake.(13M)(Nov/Dec 2016)BTL5
i) Drum rotates in anticlockwise direction:
(2M)
𝑃𝑎
𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑓𝑜𝑟𝑐𝑒, 𝐹 = 𝑏 = 592.65 𝑁(2M)
+𝑒
𝜇
𝐷
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = 𝐹 × 2 = 74.08 𝑁 − 𝑚 (2M)
ii) Drum rotates in clockwise direction:

1-67
(3M)
𝑃𝑎
𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑓𝑜𝑟𝑐𝑒, 𝐹 = 𝑏 = 718.88 𝑁(2M)
+𝑒
𝜇
𝐷
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = 𝐹 × 2 = 89.86 𝑁 − 𝑚(2M)
2 A power of 20 kW is to be transmitted through a cone clutch at 500 rpm. For uniform wear
condition, find the main dimensions of clutch and shaft. Also determine the axial force
required to engage the clutch. Assume coefficient of friction as 0.25, the maximum normal
pressure on the friction surface is not be exceeds 0.08 MPa and take the design stress for the
shaft materials as 40 MPa.(13M)(April/May 2015)BTL5
(2M)
60×𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑤𝑎𝑡𝑡𝑠
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = = 382 𝑁 − 𝑚(2M)
2𝜋𝑛
Clutch shaft diameter, d:(2M)
𝜋
[𝑀𝑡 ] = [𝜏]𝑑3 ; 𝑑 = 37 𝑚𝑚
16
Dimensions of clutch:
Assume semi cone clutch, α = 12º.
Face width, b:(2M)
𝑟𝑚
𝑏=
2
[𝑀𝑡 ] = 2𝜋𝜇𝑝𝑟𝑚2 𝑏; 𝑟𝑚 = 0.183 𝑚
For uniform wear,(2M)
𝑟𝑚𝑖𝑛 + 𝑟𝑚𝑎𝑥
𝑀𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑟𝑚 =
2
𝑟𝑚𝑖𝑛 + 𝑟𝑚𝑎𝑥 = 0.366 𝑚
From geometry;

1-68
𝑟𝑚𝑎𝑥 − 𝑟𝑚𝑖𝑛
sin 𝛼 =
𝑏
Already assumed,
𝑟𝑚
𝑏= = 0.0915 𝑚
2
𝑟𝑚𝑎𝑥 − 𝑟𝑚𝑖𝑛 = 0.019 𝑚
Solving:(1M)
Inner radius of friction surface, rmin = 0.1735 m.
Outer radius of friction surface, rmax = 0.1925 m.
Axial force required to engage the clutch, QE:(2M)
𝑄 = 𝑝 × 2𝜋𝑟𝑚 (𝑏. sin 𝛼)
𝑄
𝑄𝑛 = = 8417 𝑁
sin 𝛼
𝑄𝐸 = 𝑄𝑛 (𝜇 cos 𝛼 + sin 𝛼) = 3808 𝑁
3 A 50 kg wheel, 0.5 m in diameter turning at 150 rpm in stationary bearings is brought to
rest by pressing a brake shoe radially against the rim with a force of 100 N. If the radius of
gyration of wheel is 0.2 m, how many revolution will the wheel make before coming to rest?
Assume that the coefficient of friction between shoe and rim has the steady value
0.25.(13M)(May/June 2016)]BTL5
Mass moment of inertia, I:(2M)
𝐼 = 𝑚𝑘 2 = 2.0 𝑘𝑔 − 𝑚2
Angular velocity, ω:(2M)
2𝜋𝑛 𝑟𝑎𝑑
𝜔= = 15.708
60 𝑠
1
𝐸𝑛𝑒𝑟𝑔𝑦 𝑠𝑡𝑜𝑟𝑒𝑑 𝑖𝑛 𝑡ℎ𝑒 𝑟𝑜𝑡𝑎𝑡𝑖𝑛𝑔 𝑤ℎ𝑒𝑒𝑙, 𝐸 = 2 𝐼𝜔2 = 246.74 𝑁 − 𝑚 (2M)
Braking torque, Mt:(4M)
𝑊𝑜𝑟𝑘𝑑𝑜𝑛𝑒 𝑑𝑢𝑟𝑖𝑛𝑔 𝑏𝑟𝑎𝑘𝑖𝑛𝑔 = 𝐵𝑟𝑎𝑘𝑖𝑛𝑔 𝑡𝑜𝑟𝑞𝑢𝑒 × 𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑑𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 𝑑𝑢𝑟𝑖𝑛𝑔 𝑏𝑟𝑎𝑘𝑖𝑛𝑔
𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑓𝑜𝑟𝑐𝑒, 𝐹 = 𝜇 × 𝑁 = 25𝑁
𝐷
𝐵𝑟𝑎𝑘𝑖𝑛𝑔 𝑡𝑜𝑟𝑞𝑢𝑒, 𝑀𝑡 = 𝐹 × = 6.25𝑁 − 𝑚
2
𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑑𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡 𝑑𝑢𝑟𝑖𝑛𝑔 𝑏𝑟𝑎𝑘𝑖𝑛𝑔, 𝜃 = 𝐴𝑛𝑔𝑙𝑒 𝑡𝑢𝑟𝑛𝑒𝑑 𝑖𝑛 𝑜𝑛𝑒 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛 ×
𝑁𝑜. 𝑜𝑓 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛𝑠 𝑚𝑎𝑑𝑒 𝑑𝑢𝑟𝑖𝑛𝑔 𝑏𝑟𝑎𝑘𝑖𝑛𝑔 𝑏𝑒𝑓𝑜𝑟𝑒 𝑐𝑜𝑚𝑖𝑛𝑔 𝑡𝑜 𝑟𝑒𝑠𝑡(2M)
𝜃 = 2𝜋𝑛𝑏
𝐸 = 𝑀𝑡 × 𝜃𝑏
No. of revolutions, nb = 6.293. (1M)
4 A radial cam rotates at 1200 rpm with translating flat face follower rising 20 mm with
simple harmonic motion in 150º of cam rotation. The base circle radius is 38 mm. Check
whether undercutting will occur. (13M)(Nov/Dec 2016)BTL5
2𝜋𝑁
𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑐𝑎𝑚, 𝜔 = 60
= 125.664 𝑟𝑎𝑑/𝑠(2M)

1-69
For flat follower;
1 𝑑2 𝑦
𝜌𝑐 𝑚𝑖𝑛 = 𝑅𝑏 + (𝑦 + 𝜔2 . 𝑑𝑡 2 ) > 0(3M)
For SHM;
𝑑2 𝑦 ℎ 𝜋𝜔 2 𝜋𝜃
𝐴𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑖𝑜𝑛, 𝑎 = = 2 ( 𝛽 ) . cos (3M)
𝑑𝑡 2 𝛽
The min acceleration occurs at θ = β and y = h.
−ℎ 𝜋𝜔 2
𝑎= ( 𝛽 ) … . . cos 𝜋 = cos 180 = −1(2M)
2
1 −ℎ 𝜋𝜔 2
𝜌𝑐 𝑚𝑖𝑛 = 𝑅𝑏 + [ℎ + 𝜔2 . ( 2 ( 𝛽 ) )] > 0(2M)
20 × 𝜋 2
= 38 + [20 − ]
2 × (2.618)2
𝜌𝑐 𝑚𝑖𝑛 = 43.6 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠 > 0; (𝑝𝑜𝑠𝑖𝑡𝑖𝑣𝑒)(1M)
Thus undercutting will not occur.
5 An automobile single plate clutch consists of two pairs of contacting surfaces. The inner and
outer radii of friction are 120 mm and 250 mm respectively. The coefficient of friction is
0.25 and the total axial force is 15 kN. Calculate the power transmitting capacity of the
clutch plate at 500 rpm using: (i) Uniform wear theory and, (ii) Uniform pressure
theory.(13M)(May/June 2013)BTL5
i) Uniform wear theory:
𝑟𝑚𝑖𝑛 +𝑟𝑚𝑎𝑥
𝑀𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑟𝑚 = = 0.185 𝑚(2M)
2
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = 2𝜇𝑄𝑟𝑚 = 1387.5 𝑁 − 𝑚(2M)
2𝜋𝑛𝑀𝑡
𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑃 = = 72649 𝑊𝑎𝑡𝑡𝑠(2M)
60
ii) Uniform pressure theory:
2 𝑟3 −𝑟 3
𝑀𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑟𝑚 = 3 [𝑟𝑚𝑎𝑥 𝑚𝑖𝑛
] = 0.1926 𝑚(3M)
2 −𝑟 2
𝑚𝑎𝑥 𝑚𝑖𝑛
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑀𝑡 = 2𝜇𝑄𝑟𝑚 = 1444.59 𝑁 − 𝑚(2M)
2𝜋𝑛𝑀𝑡
𝑃𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑, 𝑃 = = 75639 𝑊𝑎𝑡𝑡𝑠(2M)
60
PART * C
1 A multi plate clutch with both sides effective transmits 30 kW at 360 rpm. Inner and outer
radii of the clutch discs are 100 mm and 200 mm respectively. The effective coefficient of
friction is 0.25. An axial load of 600 N is applied. Assuming uniform wear conditions, find
the number of discs required and the maximum intensity of pressure developed.
(15M)(May/June 2016)BTL5
Torque, Mt: (4M)
𝑀𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑟𝑚 = = 0.15 𝑚
2

1-70
2𝜋𝑛
Design torque, [Mt]:
[Mt] = Mt = 795.77 N-m (assumed) (2M)
Clutch shaft diameter, d – not asked for.
Allowable pressure, Pa:(3M)
𝑄
𝑃𝑎 = = 9549.3 𝑁/𝑚2
2𝜋𝑛 × 𝑟𝑚𝑖𝑛 × (𝑟𝑚𝑎𝑥 − 𝑟𝑚𝑖𝑛 )
Torque transmitted per pair of friction surface, [Mt]1:(2M)
[𝑀𝑡 ]1 = 2𝜇𝑄𝑟𝑚 = 22.5 𝑁 − 𝑚
Number of pairs of friction surfaces, i:(2M)
[𝑀𝑡 ]
𝑖= = 36 𝑝𝑎𝑖𝑟𝑠 𝑜𝑓 𝑠𝑢𝑟𝑓𝑎𝑐𝑒𝑠
[𝑀𝑡 ]1
Number of plates = Number of friction surfaces + 1 = 37. (2M)
2 The displacement function of a cam follower mechanism is given by y(θ) = 100(1-cosθ) mm;
0≤θ≤2π, where y is the follower displacement and θ is the cam rotation. The cam speed is
1000 rpm. The spring constant is 20 N/mm and the spring has an initial compression of 10
mm, when the roller follower is int its lowest position. The weight of the mass to be moved
including the follower is 10 N, length of the follower outside the guide A = 40 mm, length of
the guide B = 100 mm, Rb = 50 mm, Rr = 10 mm and the coefficient of friction between the
guide and the follower = 0.05. Compute normal force and the cam shaft torque when the
cam has rotated 60º. (15M) (Nov/Dec 2011)BTL4
2𝜋𝑁
𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑐𝑎𝑚, 𝜔 = = 104.72 𝑟𝑎𝑑/𝑠(2M)
60
𝑑𝑦 𝑑𝑦 𝑑𝜃 𝑑𝑦
𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑣 = = 𝑑𝜃 . 𝑑𝑡 = 𝑑𝜃 𝜔(4M)
𝑑𝑡
𝑣 = 100𝜔. 𝑠𝑖𝑛𝜃
𝑑𝑦
tan 𝛼 = 𝑑𝜃
(3M)
𝑅𝑝 +𝑦𝜃
𝛼 = 38.212°
Normal force, Pn;(4M)
𝑃 = 𝑆𝑝𝑟𝑖𝑛𝑔 𝑠𝑡𝑖𝑓𝑓𝑛𝑒𝑠𝑠 × 𝑡𝑜𝑡𝑎𝑙 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 = 1200 𝑁
𝑃
𝑃𝑛 = 2𝐴+𝐵
= 1644 𝑁
cos 𝛼 − 𝜇 ( 𝐵 ) . sin 𝛼
Cam shaft torque, Mt:(2M)
𝑃. 𝑣
𝑀𝑡 = = 103.93 𝑁 − 𝑚
𝜔
3 A multi plate clutch steel on bronze is to transmit 6 kW power at 750 rpm. The inner radius
of contact surface is 4 cm and outer radius is 7 cm. The clutch plates operate in oil, so the
coefficient of friction is 0.1. The average pressure is 0.5 N/mm2. Determine (i) the total
number of steel and bronze friction discs, (ii) actual axial force required, (iii) actual average
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pressure, (iv) actual maximum pressure.(15M)(Nov/Dec 2016)BTL5
Torque transmitted: (2M)
𝑀𝑒𝑎𝑛 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑟𝑚 = = 0.055
2
2𝜋𝑛
[Mt] = Mt = 76.39 N-m (assumed)
Clutch shaft diameter, d – not asked for.
Average pressure, Pav = 0.35 N/mm2
Torque transmitted per pair of friction surface, [Mt]1:(2M)
[𝑀𝑡 ]1 = 2𝜇𝜋 [𝑃𝑎𝑣 ( )] (𝑟𝑚𝑎𝑥 + 𝑟𝑚𝑖𝑛 )𝑟𝑚 = 19.96 𝑁 − 𝑚
2
Number of pairs of friction surfaces, i:(3M)
[𝑀𝑡 ]
𝑖= = 4 𝑝𝑎𝑖𝑟𝑠 𝑜𝑓 𝑠𝑢𝑟𝑓𝑎𝑐𝑒𝑠
[𝑀𝑡 ]1
Number of plates = Number of friction surfaces + 1 = 5.
Actual average pressure, σ:(2M)
[𝑀𝑡 ]
𝜎= = 334927 𝑁/𝑚2
2𝜋 × 4𝑖 × 𝑏 × 𝜇(𝑟𝑚 )2
Axial force required:(2M)
𝑄 = 2𝜋 [𝑃𝑎𝑣 ( )] (𝑟𝑚𝑎𝑥 + 𝑟𝑚𝑖𝑛 ) = 3472 𝑁
2
Actual maximum pressure, Pa:(2M)
𝑃𝑎 . 𝑟𝑚𝑖𝑛 = 𝑃𝑚𝑖𝑛 . 𝑟𝑚𝑎𝑥 = 𝑃𝑎𝑣 ( )
2
𝑃𝑎 = 453750 𝑁/𝑚2

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REGULATION :2017 ACADEMIC YEAR : 2019-2020
ME8691 COMPUTER AIDED DESIGN AND MANUFACTURING L T PC

3 0 03
OBJECTIVES:
• To provide an overview of how computers are being used in mechanical componentdesign
• To understand the application of computers in various aspects of Manufacturing viz., Design,
Proper planning, Manufacturing cost, Layout & Material Handling system.
UNITI INTRODUCTION 9
Product cycle- Design process- sequential and concurrent engineering- Computer aided design –
CAD system architecture- Computer graphics – co-ordinate systems- 2D and 3D transformations-
homogeneous coordinates - Line drawing -Clipping- viewing transformation-Brief introduction to
CAD and CAM – Manufacturing Planning, Manufacturing control- Introduction to CAD/CAM –
CAD/CAM concepts ––Types of production - Manufacturing models and Metrics – Mathematical
models of Production Performance
UNITII GEOMETRIC MODELING 9

Representation of curves- Hermite curve- Bezier curve- B-spline curves-rational curves-Techniques
for surface modeling – surface patch- Coons and bicubic patches- Bezier and B-spline surfaces. Solid
modeling techniques- CSG andB-rep
UNITIII CAD STANDARDS 9

Standards for computer graphics- Graphical Kernel System (GKS) - standards for exchange images-
Open Graphics Library (OpenGL) - Data exchange standards - IGES, STEP, CALS etc. -
communication standards.
UNITIV FUNDAMENTAL OF CNC ANDPART PROGRAMING 9

Introduction to NC systems and CNC - Machine axis and Co-ordinate system- CNC machine tools-
Principle of operation CNC- Construction features including structure- Drives and CNC controllers-
2D and 3D machining on CNC- Introduction of Part Programming, types - Detailed Manual part
programming on Lathe & Milling machines using G codes and M codes- Cutting Cycles, Loops, Sub
program and Macros- Introduction of CAM package.
UNITV CELLULAR MANUFACTURING

ANDFLEXIBLEMANUFACTURINGSYSTEM(FMS) 9
Group Technology(GT),Part Families–Parts Classification and coding–Simple Problems in Opitz Part
Coding system–Production flow Analysis–Cellular Manufacturing–Composite part concept–Types of
Flexibility - FMS – FMS Components – FMS Application & Benefits – FMS Planning and Control–
Quantitative analysis in FMS
JIT-JEPPIAAR/MECH/Mr.S.VIGNESH & Mr.M.KALAIMANI/IIIrdYr/SEM 06 /ME8691/COMPUTER AIDED DESIGN AND

MANUFACTURING/UNIT 1-5/QB+Keys/Ver1.0
2-1
Upon the completion of this course the students will be able to

CO1 Explain the 2D and 3D transformations, clipping algorithm, Manufacturing models
and Metrics
CO2 Explain the fundamentals of parametric curves, surfaces and Solids
CO3 Summarize the different types of Standard systems used in CAD
CO4 Apply NC & CNC programming concepts to develop part programme for Lathe
& Milling Machines
CO5 Summarize the different types of techniques used in Cellular Manufacturing and FMS
TEXT BOOKS:
1. Ibrahim Zeid “Mastering CAD CAM” Tata McGraw-HillPublishingCo.2007
2. Mikell.P.Groover “Automation, Production Systems and Computer Integrated
Manufacturing”, Prentice Hall of India,2008.
3. Radhakrishnan P, SubramanyanS.andRaju V., “CAD/CAM/CIM”, 2nd Edition, New Age
International (P) Ltd, NewDelhi,2000.
REFERENCES:
1. Chris McMahon and Jimmie Browne “CAD/CAM Principles", "Practice and Manufacturing
management “ Second Edition, Pearson Education,1999.
2. Donald Hearn and M. Pauline Baker “Computer Graphics”’. Prentice Hall,Inc,1992.
3. Foley, Wan Dam, Feiner and Hughes - "Computer graphics principles & practice" Pearson
Education-2003
4. William M Neumann and Robert F.Sproul “Principles of Computer Graphics”, McGraw Hill Book
Co. Singapore,1989.

2-2

Subject Name: Computer Aided DesignAnd Manufacturing
Subject Handler: Mr.M.Kalaimani &Mr. S.Vignesh
UNIT I – INTRODUCTION
Product cycle- Design process- sequential and concurrent engineering- Computer aided design – CAD
system architecture- Computer graphics – co-ordinate systems- 2D and 3D transformations-
homogeneous coordinates - Line drawing -Clipping- viewing transformation-Brief introduction to CAD
and CAM – Manufacturing Planning, Manufacturing control- Introduction to CAD/CAM –CAD/CAM
concepts ––Types of production - Manufacturing models and Metrics – Mathematical models of
Production Performance
PART * A
Q.No. Questions
1 Mention any four applications of computer aided design in mechanical engineering. (or)
What is CAD? (or) What are the steps involved in CAD? BTL1- Nov/Dec 15
Computer Aided Design (CAD) is the technology concerned with the use if computer systems to
assign the creation, modification, analysis and optimization of a design. CAD process is the
subset of the design process.
The application of computer aided design in mechanical engineering cover all type of
manufacturing operation such as milling, turning, Wire cut EDM, punching, etc.
(a) Design engineering.
(b) Computer graphics.
(c) Geometric modelling.
2 List the type of 2D geometric transformation (or) Define transformation?BTL1Nov/Dec 15
a) Windowing and viewing transformation
b) Clipping transformation
c) Reflection transformation
d) Zooming transformation.
e) Panning transformation.
f) Transmitting information on a network.
g) Graphics libraries.
Transformation converts the geometry from one coordinate system to another coordinate system.
By means of transformation, the images can be enlarged in size or reduced, rotate or moved on
the screen.
3 Generate the conical surface obtained by rotation of the line segment AB around the Z-axis
with A=(1,0,1) and B=(7,0,7). BTL3 - Nov/Dec 15

2-3
4 List the various stages in life cycle of a product. May/June’16 (or) What are the types of
product process? BTL1
Product cycle is the process of managing the entire life cycle of a product from starting, through
design and manufacture, to repair and removal of manufactured products.
This product undergoes the following two process.
(a) Design process.
(b) Manufacturing process.
5 What is the design process? Mention the steps involved in shigelys model for the design
process. (or) Mention some design models included in design process? BTL1, May/June’16
Product design is the process of creating a new product to be sold by a business to its customers.
It is essentially the efficient and effective generation and development of ideas through a process
that leads to new products.
(a) Shighely model.
(b) Ohsuga model.
(c) Earle model.
(d) Paul bietz model.
6 What is homogeneous coordinate? Nov/Dec’16, BTL1

2-4
Homogeneous coordinates are ubiquitous in computer graphics because they allow common
vector operations such as translation, rotation, scaling and perspective projection to be
represented as a matrix by which the vector is multiplied. P’=P×M1+M2
(a) For translation:
1 0 𝑇𝑥
𝑃′ = 𝑃 × +
0 1 𝑇𝑦
Where M1 = identity matrix or unit matrix which is denoted by T
M2 = Translation matrix.
(b) For rotation:

𝑐𝑜𝑠𝜃 𝑠𝑖𝑛𝜃 0
𝑃′ = 𝑃 × +
−𝑠𝑖𝑛𝜃 𝑐𝑜𝑠𝜃 0
Where M1 = rotational matrix which is denoted by R.
M2 = 0
7 What do you mean by synthesis of design? BTL1, Nov/Dec’16
Design Synthesis is the process of taken the functional architecture developed in the Functional
Analysis and Allocation step and decomposing those functions into a Physical Architecture (a set
of product, system, and/or software elements) that satisfy system required functions.
The following process are involved in synthesis of design:
(a) Design need.
(b) Design specification.
(c) Feasibility study with collecting design information.
8 State any two benefits of CAD. BTL1 May/June’17
a) Easy editing: Drawing editing and modifications can be easily and quickly done.
b) Copies of the same drawing can be duplicated without sacrificing image quality.
c) High quality: Created drawings are more neat, precise and sharp.
d) Drawings can be plotted quickly in different scales.
e) Information about length, area, perimeter, volume, mass are calculated easily.
f) Compact storage: Drawings can be stored in CDs, DVDs. Or hard disks.
g) Three dimensional can be seen from any view point for better visualization.
9 Mention some advantages of computer graphics?BTL2
a) Concurrent Engineering is a methodology of reconstructing the product development
activity in a manufacturing organization using a cross functional team approach.
b) Product responsibility lie on the team of multi-disciplinary group.
c) Integration of design, process planning and production will be achieved.
d) Most of the modification changes are carried out in the planning stage itself.
e) Rapid prototyping and frequently review of design and development process.
10 Mention some advantages of computer graphics? BTL1

2-5
a) Various views of the object such as orthographic, isometric, axonometric or

perspective projections can be easily created.
b) Accurate drawing can be made.
c) Sectional drawings can be easily created.
d) Modification of geometric model of objects is easy.
e) The object drawings can be denoted by its geometric model in three dimensions. Ie.,X,
Y and Z coordinates.
11 List out the types of computer graphics? And write its applications? BTL2
Types:
a) Passive computer graphics.
b) Interactive computer graphics.
Application:
a) Paint programs: it allows rough free hand sketching. It is stored as bitmaps and easily
can be edited.
b) Design program: it supports more than the paint program particularly for drawing
curved lines. The images are usually stored vector based formats. And it is called as
draw program.
c) Presentation graphics software: bar chart, pie chart, graphics and other types of images
for slide show and reports are created. The charts based data imported from spread
sheet application.
d) Cad software: it enables architects and engineer to draft design.
12 Define modelling and viewing? BTL1
a) Modelling is the process of creating an object in the computer by using the basic
primitives such as points, lines, arc, circle, edges, area, surface, and volumes.
b) Viewing refers to looking of the model in various angles, zooming, orthographic and
isometric.
13 Define clipping and write its applications? BLT1
Clipping is the process of determining the visible portion of a drawing lying within a window
and discarding the rest.
a) Identify the visible surface in three dimensional views.
b) Displaying multi window environment.
c) Antialiasing line segments or object boundaries.
d) Creating objects using solid modeling procedures.
e) Drawing and painting operation.
14 State some advantages and disadvantages of DDA algorithm. BLT1
Advantages:
a) It is the simplest algorithm and it does not need special skill for implementation.
b) It is far method to calculate pixel position than the direst use of straight line equation
which is given by y= mx + c. it eliminates the multiplication of necessary increments
2-6
applied in x or y directions to find the pixel positions along the line path.
Disadvantage:
a) Floating point arithmetic in DDA algorithms still time consuming.
b) The algorithm is oriented dependent. Therefore, end point accuracy is poor.
15 Define zooming and scaling? BLT1
Zooming transformation is a combination of scaling, translation and clipping transformation
processes.
Zooming = scaling + Translation + clipping.
Scaling is the transformation applied to change the scale of an entity. It is done by increasing the
distance between points of the drawing.
16 What is concentration transformation and what is meant by working station

transformation? BLT1
a) It is a single transformation by combining many transformations linked one after the
other to perform the final task.
b) The transformation which maps the normalized device coordinates to physical devices
coordinates is called workstation transformation.
17 What is concurrent Engineering? May/June’17 write some characteristics of concurrent
engineering?BLT1
Concurrent engineering is a methodology of restricting the product development activity in a
manufacturing organization using a cross functional team approach.
a) Product responsibilities lies on the team of multi-disciplinary group.
b) Integration of design, process planning and production will be achieved.
c) Product lead time will be less because cross functional activities are started
simultaneously.
d) Most of the modification charges are carried out in the planning stages itself.
PART * B
1 Rotate the rectangle (0,0), (2,0), (2,2), (0,2) shown in fig.1, 30o counter clockwise about its
centroid andthe new coordinate of the rectangle. BTL5 - N/D’15 (13 marks)

2-7

2-8

2-9
A’ (0.634, -0.366), B’ (2.366, 0.634), C’ (1.366, 2.366) and D’ (-0.366, 1.366) - Ans
2 Given the triangle, described by the homogeneous points matrix below, scale it by a factor

2-10
3/4, keeping the centroid in the same location. Use (1) separate matrix method and (2)
condensed matrix for transformation. BTL5 - N/D’15, (13 marks)

2-11

2-12

2-13

2-14
3 Write short notes on concurrent engineering. BTL5 - N/D’15 (8 marks)

2-15
In the conventional manufacturing method both design and manufacturing are separated.
Because of this quality may be lost and design modifications cannot be possible at the last stage
of production.
To achieve this in the product planning stage itself a cooperation work between design
and manufacturing and other specialists has to be made. It is known as concurrent engineering or
simultaneous engineering or parallel engineering.
For example, planning activity is made as concurrent shown in fig.Therefore an intensive
team work between product development, production planning and manufacturing team is
essential for effective implementation of concurrent engineering in an organisation figure shows:
Selection of Product Material
venders planning planning
Quality control Human resource

planning Planning planning
Production Process Production

control planning planning facility planning
Figure 1.11 Concurrent workflow in the planning stage
4 Rotate the rectangle shown in Fig 2, 30o counter clockwise about the line EF and find the
new coordinates of the rectangle. BTL5 - N/D’15. (13 marks)

2-16

2-17

2-18

2-19
5 Compare and contrast sequential and concurrent Engineering with suitable examples?
BTL4 M/J’17 (8 marks)
S.No Sequential Engineering Concurrent Engineering
1 Sequential engineering is the term used Concurrent Engineering is the term used
to explain the method of production in a to explain the method of production in
linear system. The various steps are non-linear system. It is also called as
done one after another, with all parallel engineering.
attention and resources focused on that
single task.
2 Sequential engineering is a system by Concurrent engineering is a method by
which a group within an organization which several groups within an
works sequentially to create new organization work simultaneously to
products and services. create new products and services.
3 The sequential engineering is a linear The concurrent engineering is a non-
product design process during which all linear product design process during
stages of manufacturing operate in which all stages of manufacturing operate
serial. at the same time.
4 Both process and product design run in Both product and process design run in
a serial and take place in the different parallel and take place in the same time.
time.
5 Process and product are not matched to Process and product are coordinated to
attain optimal matching. attain optimal matching of requirements
for effective quality and delivery.
6 Decision making done by only group of Decision making involves full team
experts. involvement.
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6 Explain with block diagram, the cad process with suitable examples? BTL4 - M/J’17 (13
marks)
➢ Two types of activities: Synthesis and analysis.

➢ Synthesis is largely qualitative and hard to capture on computers.
➢ Analysis can be greatly enhanced with computers.
➢ Once analysis is complete, design evaluation-rapid prototyping’s are done.
Software graphics device

CAD/CAM/CAE
System
computing
hardware
machine
CAD Hardware:
These are basically two types of devices that constitutes CAD hardware: (a) Input devices,
(b). Output devices.
(a). Input Devices:
❖ These are the devices that we use for communicating with computer, and providing our
input in the form of text and graphics.
❖ The text input is mainly provided through keyboard. For graphic input, there are several
devices available and used according to the work environment.
❖ A briefly description of these devices are given.
(b). Mouse:
❖ This potentiometric device, which contains several variable resistors that send signals to
the computer.
❖ The functions of a mouse include locating a point on the screen, sketching, dragging an
object, entering values, accepting a software command, etc.
❖ Joystick and trackballs are analogous to a mouse device, and operate on the same
principle.
(c). Digitizer:
❖ Digitizers are used to trace a sketch or other 2-D entities by moving cursor over a flat
surface (which contains the sketch).
❖ The position of the cursor provides a feedback to the computer connected with the device.
❖ There are electrical wires embedded in orthogonal directions that receive a pass signals

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between the device and the computer.

❖ The device is basically a free moving pen shaped stylus, connected to a tablet.
(d). Light pens:

❖ Lockheed’s CAD/CAM software utilized this device to carry out the graphic input.
❖ A light pen looks like a pen and contains a photocell, which emits an electronics signal.
❖ When the pen is pointed at the monitor screen, it senses light, which is converted to
signal.
❖ The signal is sent to another computer for determination of the exact location of the pen
on the monitor screen.
(e). Touch sensitive screens:

❖ This device is embedded in the monitor screens, usually, in the form of an overlay.
❖ The screen senses the physical contact of the user.
❖ The new generation of the laptop computer is a good example of this device
(f). Other graphic input devices:

❖ In additional to the devices described above, some CAD software will accept input via
image scanners, which can copy a drawing or schematic with a camera and light beam
assembly and convert it into a pictorial database.
❖ Resolution.
❖ Accuracy.
❖ Repeatability.
❖ Linearity.
(g). Output devices:

❖ After creating CAD modelling we often need a hard copy, using an output device plotters
and printers are used for this purpose.
❖ A plotter is often used to produce large drawings and assemblies, whereas laser jet printer
is adequate to provide a 3D view of a model.
❖ Most CAD software require a plotter for producing a shaded or a rendered view.
7 Describe various stages of design process with an example. BTL4 - N/D’16 (8 marks)

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i.Recongination of Need: Identification of need of the product by market survey, research or

consumer feedback form.
ii.Definition:The above needs the idea involves a through specification of the product to be
designed.
iii. Synthesis and Analysis: Functionality and uniqueness of the product are all determined
during synthesis.
iv. Analysis and Optimization: The components and sub systems are synthesized during
optimization to offer optimized performance with in constraints imposed by designer.
v.Evaluation: The product qualities are measured agaist the standard and specifications set
during definition phase.
vi. Presentation: Phase of this process is to present the design by name of drawings, Material
specifications, assembly lists etc.
8 Explain a line drawing algorithm.BTL5 N/D’16. (8 marks)

Bresenham’s Algorithm
Consider a line with initial point (x1, y1) and terminal point (x2, y2) in device space. If
Δx = x2−x1and Δy = y2 − y1, we define the driving axis (DA) to be the x-axis if |Δx| ɛ | Δy|, and
the y-axis if |Δy| > |Δx|.Δ The DA is used as the “axis of control” for the algorithm and is the axis
of maximum movement.
Within the main loop of the algorithm, the coordinate corresponding to the DA is
incremented by one unit. The coordinate corresponding to the other axis (usually denoted the
passive axis or PA) is only incremented as needed.
The best way to describe Bresenham’s algorithm is to work through an example. Consider
the following example, in which we wish to draw a line from (0, 0) to (5, 3) in device space.
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Bresenham’s algorithm begins with the point (0, 0) and “illuminates” that pixel. Since x is
the DA in this example, it then increments the x coordinate by one.
Rather than keeping track of the y coordinate (which increases by m = Δy/Δx, each time
the x increases by one), the algorithm keeps an error bound ɛ at each stage, which represents the
negative of the distance from the point where the line exits the pixel to the top edge of the pixel
(see the figure).
This value is first set to m − 1, and is incremented by m each time the x coordinate is
incremented by one. If ɛ becomes greater than zero, we know that the line has moved upwards
one pixel, and that we must increment our y coordinate and readjust the error to represent the
distance from the top of the new pixel – which is done by subtracting one from ɛ.
9 Define clipping. Also explain the working of a simple line clipping algorithm. BTL5 N/D’16
(8 marks)
Clipping, in the context of computer graphics, is a method to selectively enable or disable
rendering operations within a defined region of interest.
Cohen-Sutherland Algorithm
You may assume that this case takes place when you have projected the three dimensional
object into the projection plane, and therefore we have a rectangular window in the projection
plane, given by (WL, WR, WB, WT). The algorithm tries to replace unnecessary calculations,
which should be done in floating point arithmetic, with bits operations.
Input: Two endpoints of a line segment
Output: Two points, or none.
It extends the sides of the window to infinity, to divide the plane into 9 regions. To the
points of each region, we assign a four bits code btbbbrbl. See figure.

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Figure 1
bt will be assigned the value of 1 if y > WT , 0 otherwise.
bb will be assigned the value of 1 if y < WB , 0 otherwise.
br will be assigned the value of 1 if x > WR , 0 otherwise.
bl will be assigned the value of 1 if x < WL , 0 otherwise.
Consider the endpoints P1 and P2, of a line segment, with coordinates (x1 , y1) and (x2 ,
y2)and compute code(P1) and code(P2).
I - If code(P1) & code(P2) (bitwise and) gives a code with anything but zeros, discard the line.
II - If code(P1) | code(P2) (bitwise or) gives a code with only zeros, keep the segment line.
III – Assume that P1 is such that code(P1) is not identically zero (otherwise switch points).

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UNIT II – GEOMETRIC MODELING

Representation of curves- Hermite curve- Bezier curve- B-spline curves-rational curves-Techniques for
surface modeling – surface patch- Coons and bicubic patches- Bezier and B-spline surfaces. Solid
modeling techniques- CSG and B-rep
PART * A
Q.No. Questions
1 What do you mean by zero order, first order and second order continuity? BTL1
a) Zero order continuity (C0) means simply that the curves meet.
b) First order continuity (C1) means that the first parametric derivatives of the coordinate
function for two successive curve sections are equal at their joining points.
c) Second order (C2) refers that both first and second parametric derivatives of two
curves sections are the same at the intersection.
2 State limitations of B-spline curve? BTL1
a) The number of specified polygon vertices fixes the order of the resulting polynomial
which defines the curve. The only way to reduce the degree of the curve is to reduce the
number of vertices and vice versa.
b) Bezier curve is considered as a single curve controlled by all control points. Because of
this, with an increase in the number of control points, the order of the polynomial
representing the curve increases. It increases the complexity of the curve and its
calculation.
c) A change in one vertex is felt throughout the entire curve because of the global nature of
the Bernstein basis. It means that the value of blending function is non-zero for all
parametric values over the entire curve.
3 Write down hermite matrix and What are limitations of hermite curves? BTL2 N/D’15
2 −2 1 1
Hermite curve = −3 3 −1−1
0 0 0 0
1 0 0 0
The curve is defined by two data points that lie at the beginning at the end of the curve, along
with the slopes at these points. When two end points and their slope define a curve, the curve is
called a hermite cubic curve.
4 State the advantages of rotational splines? BTL1
a) Rotational splines have the following two important advantages compared to non-rotational
splines.
b) Rational splines provide an exact representation for quadratic curves (conics) such as circles
and ellipses. Non-rotational splines which are polynomial can only approximate conics. It
allows graphics packages to model all curve shapes with one representation rotational splines

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without needing a library of curve functions to handle different design shapes.

c) Rational splines are invariant with respect to a perspective viewing transformation. It means,
we can apply a perspective viewing transformation to control points of the rotational curve
and we will obtain the correct view of the curve. Non-rational splines, on the other hand, are
not invariant with respect to a perspective viewing transformation.
5 Differentiate between analytical curves, interpolated curves and approximated curves.
BTL1 N/D’15
S.No Analytical curves Interpolated curves Approximated curves
1 These curves are An interpolated curve These curves provide the
represented by a simple is drawn by most flexibility in drawing
mathematical equation. interpolating the given curves of very complex
data points. shapes.
2 They have a fixed form These curves have The model of a curved
and cannot be modified some limited automobile fender can be
to achieve a shape that flexibility in shape easily created with the help
violates the creation. of approximate curves and
mathematical equations. surfaces.
6 What are the advantages and disadvantages of wire frame modelling? BTL2- M/J’16
a) Advantages of this type of model include ease of creation and low level hardware and
software requirements. Additionally, the data storage requirements are slow.
b) The main disadvantage of a wire frame model is that it can be very confusing to
visualize. For example, a blind hole in a box may look like a solid cylinder.
7 What is called plane surface? How is ruled surface produced? How is tabulated surface
generated? How are coons surface generated? BLT1
a) The most elementary and simplest form of the surface types is the plane surface which
may be defined between two parallel straight lines through three points or through a line
and a point.
b) A ruled surface is produced by linear interpolation between two different boundary curves
that define the surface.
It is surface generated by translating a planar curve for a given distance along a
specified direction.
A coon’s patch or surface is generated by the interpolation of four edges curves.
8 Define curve and State advantages of Bezier Curves. BTL 1 M/J’16

Curve is a continuous map from one dimensional space to n dimensional space.The curve is a
straight line if and only if all the control points are collinear. The start and end of the curve is

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tangent to the first and last section of the Bezier polygon, respectively. A curve can be split at any
point into two sub curves, or into arbitrarily many sub curves, each of which is also a Bezier
curve.
9 Mention the advantages of CGS? BTL2
a) It creates fully valid geometrical solid model.
b) Complex shapes may be development relatively quicker with the available set of
primitives.
c) Less skill is enough.
d) The data file of CSG is concise.
e) CSG guarantees automatically in which objects drawn by CSG are valid.
f) CSG is more user friendly.
g) Algorithms for converting CSG into B-rep have been developed.
10 Why B-rep modelling approach are widely followed than CSG approach? BTL2 N/D’16
Boundary Representation (B – Rep) approach allows the designer to draw a boundary or an
outline of an object in the CRT screen for displaying various views like left side view, top view,
and front view. The boundaries of the views are interlinked with edges, faces and vertices.
11 What are the disadvantages of CSG? BTL1
a) More computational effort and time are required whenever the model is to be
displayed in the screen.
b) Getting fillet, chamfer and taperness in the model are very difficult.
c) CSG database contains information about a solid in an unevaluated form.
d) The validity of a feature of an object cannot be assessed without evaluating the entire
tree.
e) The tree is not unique for the same part design.
12 Why B-rep scheme is more widely used? BTL1
a) In CSG, the number of basis primitives available is limited but it is not so in B-rep.
b) The performance of B-rep scheme is very much superior to that of CSG scheme for
complex engineering models.
c) Conversion of CGS to B-rep is possible but the conversion from B-rep to CSG is not
possible.
d) Combining the wire frame and surface model is possible only through B-rep solid
representation.
13 State any four advantages and disadvantages of B-rep? BTL2
a) Advantages: computational effort and time required to display the model are less
compared with CSG.
b) Combining wireframe and surface model are possible.
c) Complex engineering objects can be easily modelled compared with CSG, Examples
are aircraft fuselage and automobile body styling.
d) The information is complete especially for adjacent topology relation.

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e) Disadvantage: The data to be stored is more and hence, it requires more memory. So,
it is not suitable for tool path generation.
f) Sometimes, geometrically valid solids are not possible.
g) There is no guarantee for the created objet to check whether it is valid or not.
h) It is generally less robust than the half space method.
14 What are the rules to be followed in topological consistency? BTL1
a) Face should be bound by a simple loop of edges and they should be not intersected by
itself.
b) Each edge should exactly adjoin two faces and each edge should have a vertex at each
end.
c) At least three edges, it should meet at each vertex.
15 What is the significance of CGS? BTL1 - M/J’17
a) Constructive solid geometry (CGS) is one of the most popular methods of representing
and building complex solids.
b) In this scheme, simple primitives are combined in certain order by means of
regularized Boolean set operators which are directly included in the representation.
16 Define quadratic Bezier curve. BTL1 M/J’17
a) The shape of Bezier curve is controlled by its defining points only.
b) The curves do not pass through the given data points. Instead, these points are used to
control the shape of the resulting curves.
c) Flexibility of Bezier curve is more.
17 Write down the difference between Bezier curve and cubic spline curves? BTL1
S.No Bezier curve Cubic spline curve
1 The shape of Bezier curve is controlled First order derivatives are used in the
by its defining points. curve development.
2 The curve does not pass through the The curves pass through the given
given data points. Instead, these points data points exactly.
are used to control the shape of the
resulting curves.
3 Bezier curve permits higher order The order or the degree of cubic
continuity as the degree or order of spline is fixed one. It is always cubic
Bezier curve is variable and it is for a spline segment.
depending on the number of defining
data points. For example, n + 1 points
define nth degree curve.

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4 The shape of the Bezier curve is It is not much smoother as Bezier

smoother than the cubic spline curve curve.
because of its higher order continuity.
PART – B
1 Briefly explain the different schemes used to generate a solid model. N/D’15 (or) Explain in
detail B-rep solid modelling approach. BTL5 - N/D’16, (13 marks)
A representation scheme is defining as a relation which maps a valid point set into a valid
model. For example, a constructive solid geometry (CSG) scheme maps the valid primitive into
the valid solid via Boolean operations. It possesses the following properties,
• It is closed regular set. There should not be any dangling portions.

• It is a semi - analytic set. It does not oscillate infinitely fast anywhere in the set.
Out of which, the following two basic approaches are important from our subject point of view.
(1) Constructive solid geometry (CSG)
(2) Boundary representation (B - rep)
1. Constructive solid geometry (CSG):

Constructive solid geometry (CSG) is one of the most popular methods of representing and
building complex solids. The type of Boolean operations is used in CSG are Union (U),
difference (-), and intersection (ᴖ).
Simple Boolean operations have been already described in earlier topics of this chapter.
The data representation of CSG objects is represented by a binary tree. Directed graph scheme is
used to store the model in the data structure.
The general form of the tree – type data structure used in CSG approach is shown in
figure 2.41. Any node may have one parent node and two child node.
A balanced tree can be defined as a tree whose left and right subtrees have almost an equal
number of nodes. The creation of balanced or an unbalances tree is entirely dependent on the user
and it is related to how the primitives are combined.

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A balanced and unbalanced method of building the same subject is shown in figure 2.42.
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For example, to create a model as shown in figure 2.43, four primitives – two rectangular blocks
and two cylinders are required.
To create the final object following Boolean operation has to be carried out. Applying the
same operation to two objects which are initially the same can yield two different results as
shown in figure 2.44.
The object shown in may be defined by different CSG operations shown in (b) and (c).
The modification of the top face of (b) and (c) upward yields different objects shown in (d) and
(e).
Advantages:
• Since the data to be stored are less and the memory required will be less.
• It creates fully valid geometrical solid model.
• CSG is more user friendly.
• Algorithms for converting CSG into B-Rep have been developed.
2 Boundary representation (B - rep)? BTL5 (13 marks may ask in individual)
Boundary representation (also known as B-rep) is based on the concept. A physical object
is bounded by a set of faces.
This approaches widely used in most of the solid modellers. This scheme describes an
object in terms of its surface boundaries: vertices, edges and faces.
Some B-reps are restricted to planer, polygonal boundaries and it may even require faces
to be convex polygons or triangles.
Only the boundary surfaces of the model are stored and the volumetric properties are
calculated by the Gauss Divergence theorem which relates the volume integral to surface
integrals.
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It is illustrated with a simple example of tetrahedron shown in figure 2.45 (a). The
tetrahedron is composed of four vertices namely A, B, C and D. the coordinate of these vertices is
stored in the database.
Figure 2.45 (b) shows how the vertices are connected to form edges (a, b, c, d, e, and f)
and how these edges are connected together to form the face (ABC, BCD, ACD, ABD) which
makes the complete solid of tetrahedron.
This connectivity to form the solid is popularly known as topology.
For better understanding of the difference between CSG and B-ref schemes the
information contained in a same solid both in the schemes are given in figure 2.46.
As stated earlier, in B-ref scheme, the solid is made of a set of faces. These faces are
subsets of closed and orientable surfaces.
A closed surface is one and it is continuing without break. In an orientable surface, it is
possible to distinguish two sides by using the direction of the surface normal to point inside or
outside the solid model. Each face is bounded by edges and each edge is bounded by vertices.

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Advantages:
• Computational effort and time required to display the model are less compared with CSG.
• Combining wire frame and surface model are possible.
2. Complex engineering objects can be easily modelled compared with CSG. Example are aircraft
fuse lase and automobile body styling.
• The information is complete especially for adjacent topology relations.
3 Explain different types of geometric modelling with suitable examples? BTL5 M/J’17
(13 marks)
Geometric modelling is the starting point of the product design and manufacture
process.Functions of Geometric Modelling are:
Design Analysis
❖ Evaluation of area, volume, mass and inertia properties
❖ Interference checking in assemblies
❖ Analysis of tolerance build-up in assemblies
❖ Kinematic analysis of mechanisms and robots
❖ Automatic mesh generation for finite element analysis
Drafting
❖ Automatic planar cross-sectioning
❖ Automatic hidden lines and surface removal
❖ Automatic production of shaded images
❖ Automatic dimensioning
❖ Automatic creation of exploded views of assemblies

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Manufacturing
❖ Parts classification
❖ Process planning
❖ NC data generation and verification
❖ Robot program generation
Production Engineering
❖ Bill of materials
❖ Material requirement
❖ Manufacturing resource requirement
❖ Scheduling
Inspection and quality control
❖ Program generation for inspection machines
❖ Comparison of produced parts with design
WIRE FRAME MODELING

It uses networks of interconnected lines (wires) to represent the edges of the physical objects
being modeled
Also called ‘Edge-vertex’ or ‘stick-figure’ models
Two types of wire frame modeling:
1. 2 ½ - D modeling
2. 3 – D modeling
3-D Wire frame models: These are
Simple and easy to create, and they require relatively little computer time andmemory;
however, they do not give a complete description of the part.
They contain little information about the surface and volume of the part and cannot
distinguish the inside from the outside of part surfaces.
They are visually ambiguous as the model can be interpreted in many different ways because
in many wire frame models hidden lines cannot be removed.
Section property and mass calculations are impossible, since the object has no faces attached
to it. It has limited values a basis for manufacture and analysis
2 ½ - D Wire frame models:
Two classes of shape for which a simple wire-frame representation is often adequate are
those shapes defined by projecting a plane profile along its normal or by rotating a planar profile
about an axis.
Such shapes are not two-dimensional, but neither do they require sophisticated three-
dimensional schemes for their representation. Such representation is called 2 ½ - D.

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TECHNIQUES IN SURFACE MODELLING

The various methods for representing the solids are:
1. Half-space method
2. Boundary representation method (B-rep)
3. Constructive solid geometry (CSG and C-rep)
4. Sweep representation
5. Analytical solid modelling (ASM)
6. Primitive instancing
7. Spatial partitioning representation
a. Cell decomposition.
b. Spatial occupancy enumeration.
c. Octree encoding.
Boundary representation method (B-rep)
❖ In solid modelling and computer-aided design, boundary representation often abbreviated
as
❖ B-rep or BREP—is a method for representing shapes using the limits.
❖ A solid is represented as a collection of connected surface elements, the boundary
between solid and non-solid.
❖ Boundary representation models are composed of two parts:
❖ Topology, and
❖ Geometry (surfaces, curves and points).
The main topological items / primitives of b-rep are:
❖ Vertex (V): It is a unique point (an ordered triplet) in space
❖ Edge (E): It is finite, non-self-intersecting, directed space curve bounded by two vertices
that are not necessarily distinct.
❖ Face (F): It is defined as a finite connected, non-self-intersecting, region of
a closed oriented surface bounded by one or more loops
❖ Loop (L): It is an ordered alternating sequence of vertices and edges
❖ Genus(G): It is the topological name for the number of handles or through holes in an

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object
❖ Body/Shell(B): It is a set of faces that bound a single connected closed volume. A
minimum body is a point.
❖ A minimum body is a point; topologically this body has one face, one vertex, and no
edges. It is called a seminal or singular body.
Geometry
❖ Open polyhedral objects
4 Explain various curve generation techniques with suitable examples? Or Write short notes
on approximated synthetic curves. BTL5 N/D’15 (13 marks)
Bezier curves
✓ Hermite curves
✓ B-spline curves
✓ NURBS curves
BEZEIR CURVES
❖ Splines draw their name from the traditional drafting tool called “French curves” or
“splines”.
❖ Cubic splines use cubic polynomials. A cubic polynomial has four co-efficient and thus
required four condition to evaluate.
❖ These condition could be combination of points and tangent vectors.
❖ A cubic splines uses four data points.
❖ The herniate cubic spline uses two data points at its ends and two tangent vectors at these
points.
❖ The parametric equation of a cubic spline segment is given below
❖ 𝑃(𝑢) = ∑3𝑖=0 Ciui0 ≤ u ≤ 1-----------------------------------------------------------------(1)
❖ Where u is the parameter and Ci are the polynomial co efficient.
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❖ In scalar form the equation is written as

❖ X(u)=C3X U3 + C2X U2 + C1X U + C0X
X(u)=C3Y U3 + C2Y U2 + C1Y U + C0Y --------------------------------------------(2)
X(u)=C3Z U3 + C2Z U2 + C1Z U + C0Z
❖ In expand vector from equation (1) can be written as
P(u) = C3 U3 + C2 U2 + C1X U + C0 ---------------------------------------------------------(3)
❖ Equation 3 can also write in matrix form
P(u) = UTC ------------------------------------------------------------------------------(4)
3 2 1 T
Where U = [U U U ]
And C = [C3 C2 C1]T
C is called co-efficient vector
❖ The tangent vector to the curve at any point is given by differentiating eqn(1) with respect
to u to give
P'(u) = ∑3𝑖=𝑜 Ci iui-1 0 ≤ u ≤ 1 ----------------------------------------- --------------------(5)
❖ In order to find the co-efficient C1, consider the cubic spline segment with the two end
points P0 and = P1 shown in figure.
❖ Applying the boundary condition P0 and P1at u = 0 and P1, P1 at u = equation (1) and (5)
P0 = C0
P’0 = C1
P1 = C3 + C2 + C1 + C0
P1 = 3C3 + 2C2 + C1 ----------------------------------------------------------------------------(6)
Solve these four equation simultaneously for the co-efficient gives
C0 = P0
C1 = P’0
C2 = 3(P1 – P0) – 2P'0 - P'1
C3 = 3(P0 – P1) + P'0 + P'1 ----------------------------------------------------------------------(7)
2 -2 1 1
-3 3 -2 -2
A =
[MH] 0 0 10
1 0 0 0
5 Explain different features of a Bezier curve with construction details. BTL5 N/D’16 (13
marks)
Bezier curves are extensively applied in CAD to model smooth curves. As the curve is
totally limited in the convex hull of its control points P0, P1, P2& P3, the points can be
graphically represented and applied to manipulate the curve logically.
The control points P0 and P3 of the polygon lie on the curve. The other two vertices
described the order, derivatives and curve shape. The Bezier curve is commonly tangent to first
and last vertices.
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Cubic Bezier curves and Quadratic Bezier curves are very common. Higher degree Bezier
curves are highly computational to evaluate.
When more complex shapes are required, Bezier curves in low order are patched together
to produce a composite Bezier curve. A composite Bezier curve is usually described to as a ‘path’
in vector graphics standards and programs.
For smoothness assurance, the control point at which two curves meet should be on the
line between the two control points on both sides.
Linear Bezier curves

The given points P0 and P1, a linear Bezier curve is merely a straight line between those
two points. The Bezier curve is represented by
Quadratic Bezier curves

As shown in the figure, a quadratic Bezier curve is the path defined by the function B(t),
given points P0, P1, and P2,
This can be interpreted as the linear interpolate of respective points on the linear
Bezier curves from P0 to P1 and from P1 to P2 respectively. Reshuffle the preceding equation
gives:
The derivative of the Bezier curve with respect to the value ‘t’ is
From which it can be finished that the tangents to the curve at P0 and P2 intersect
at P1. While ‘t’ increases from zero to one, the curve departs from P0 in the direction of P1, then
turns to land at P2 from the direction of P1.
The following equation is a second derivative of the Bezier curve with respect to ‘t’:
A quadratic Bezier curve is representing a parabolic segment. Since a parabola curve is a conic
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section, a few sources refer to quadratic Beziers as ‘conic arcs’.
6 Derive the transformation matrix for a Hermite Curve. BTL5 - N/D’16 (8 marks)
AHermitecurveisasplinewhereeverypieceisathirddegreepolynomialdefinedinHermite form: that is,
by its values and initial derivatives at the end points of the equivalent domain interval. Cubic
Hermite splines are normally used for interpolation of numeric values defined at certain dispute
valuesx1, x2, x3,…...,xn,toachieveasmoothcontinuousfunction.Thedatashouldhavethepreferred
function value and derivative at each Xk.
The Hermite f o r m u l a i s u s e d t o e v e r y i n t e r v a l (Xk, Xk+1) individually. The resulting
spline become continuous and will have first derivative. Cubic polynomial splines are specially
used in computer geometric modeling to attain curves that pass via defined points of the plane
in3Dspace.
In these purposes, each coordinate of the plane is individually interpolated by a cubic spline
function of a divided parameter ‘t’. Cubic splines can be completed to functions of different
parameters, in several ways. Bicubic splines are frequently used to interpolate data on a common
rectangular grid, such as pixel values in a digital picture.
The following vectors needs to compute a Hermite curve:
• P1: the start point of the Hermite curve
• T1: the tangent to the start point.
• P2: the endpoint of the Hermite curve
• T2: the tangent to the endpoint
ThesefourvectorsarebasicallymultipliedwithfourHermitebasisfunctionsh1(s),h2(s),h3(s)
and,h4(s)and added together.
h1(s) = 2s3-3s2 +1
h2(s) = -2s3+3s2
h3(s) = s 3 - 2s2 + s
h4(s) = s 3 - s2

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UNIT III CAD STANDARDS

Standards for computer graphics- Graphical Kernel System (GKS) - standards for exchange images-
Open Graphics Library (OpenGL) - Data exchange standards - IGES, STEP, CALS etc. -
communication standards.
PART * A
Q.No. Questions
1 What is meant by CAD data exchange? Mention its importance. BTL1 N/D’15
CAD data exchange involves a number of a software technologies and methods to
translate data from one computer-aided design system to another CAD file format. The exchange
process targets primarily the geometric information of the CAD data but it can also target other
aspects such as metadata, knowledge, manufacturing information, tolerances and assembly
structure. There are three options available for CAD data exchange: direct model translation,
neutral file exchange and third-party translators.
2 What are the importance’s of standards in CAD? BTL1 M/J’16
• Openness, accessibility: availability and willingness to respond.
• Truthfulness: unconditional honesty is the only policy.
• No secrets: our behaviour, our attitudes, our plans and positive.
• In the engineering world, CAD is extremely important and widely used to design and
develop products to be used by consumers.
• This knowledge is a hot commodity for those employing engineers, because of its benefits
in the engineering workplace.
3 Write any three CAD Standards for exchange of modelling data. BTL1 - M/J’16
• Graphics Kernel System (GKS)
• Initial Graphics Exchange Specification
• DXF (Drawing/Data Exchange Format)
• STEP (Standard for the Exchange of Product model data)
4 State the needs for data exchange standards. BTL1 N/D’16
CAD data exchange is a modality of data exchange used to translate data between different
Computer-aided design (CAD) authoring systems or between CAD and other downstream CAx
systems. Data exchange allows data to be shared between different computer programs. It is
similar to the related concept of data integration except that data is actually restructured (with
possible loss of content) in data exchange. There may be no way to transform an instance given
all of the constraints.
5 What is GKS cell array? BTL1 N/D’16

The GKS cell array function displays raster like images in a device-independent manner. The
cell array function takes the two corner points of a rectangle that you specify, a number of
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divisions (M) in the X direction and a number of divisions (N) in the Y direction. It then
partitions the rectangle into M x N sub-rectangles called cells. You assign each cell a color and
create the final cell array by coloring each individual cell with its assigned color. At level 0A, cell
array has no associated attributes.
6 Define Graphical Kernel system? BTL1 M/J’17
GKS basically a set of procedures which can be called by user programs to carry out certain
generalized functions such as arc, circle, ellipse etc. GKS is defined in terms of number of levels
describing the level of support in terms of facilities. Graphical Kernel System provides a set of
drawing features for two dimensional vector graphics suitable for charting and similar duties.
7 What is open graphics library? BTL1 M/J’17
Open GL draws primitives into a structured buffer focus to a various selectable mode. Every
point, line, polygon, or bitmap are called as a primitive. Each mode can be modified separately;
the parameters of one do not affect the parameters of others. Open graphics Library (Open GL) is
a cross language multi-platform Application Programming Interface (API) for rendering 2D and
3D vector graphics. It is extensively used in the field of CAD, virtual reality, scientific
visualization, information visualization, flight simulation and video games.
8 Mention the need for graphic standards. BTL2
✓ There is need for portability of the geometric model among different hardware platforms.
✓ Where there is situation to exchange drawing database among software packages.
✓ There is need for exchanging graphic data between different computer systems.
✓ To understand the graphic kernel system and its extension for developing the graphic
software systems.
9 What are the features of GKS? BTL2
✓ It is an independent device. So it can work with all types of input and output devices.
✓ All text and annotation can be prepared and stored in natural languages.
✓ Graphic functions are defined for both 2D and 3D.
✓ It includes all types of display elements.
✓ GKS supports picture data into two routines.
10 Classify GKS. BTL1
✓ Control function
✓ Output function
✓ Output primitives
✓ Segment function
✓ Transformation
✓ Input function
✓ Meta file function
11 List down the output primitives in GKS. BTL2
✓ Polyline
✓ Polymakers
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✓ Text
✓ Fill area
12 State the segment used in GKS inquiry functions. BTL1
✓ Segment storage
✓ Segment creation, deletion and renaming
✓ Segments name
✓ Segment association, copying and insertion
✓ Pick identifier
✓ Segment redrawing
13 What are the reasons and requirements of exchanging data? BTL1
✓ All use the same CAD packages.
✓ Special translator application is used to change the data from one format to another format
✓ A neutral format is used to data exchange.
Requirements for the Exchange
Shape data: both geometric and topological information, part and form features. Fonts, color,
annotation are considered part of the geometric information. • Non-shape data: graphics data such
as shaded images, and model global data as measuring units of the database and the resolution of
storing the database numerical values.
Design data: information that designers generate from geometric models for analysis purposes.
Mass property and finite element mesh data belong to this type of data.
Manufacturing data: information as tooling, NC tool paths, tolerancing, process planning, tool
design, and bill of materials (BOM).
14 Brief about DXF format. BTL2
DXF/DWG: DXF formats were developed by AutoDesk.
• After creating drawings, designers can export data in DXF/DWG formatted files and import the
2D geometric data contained in a DXF/DWG file into other drawing tools.
DXF File Structure:
• Header Section
• Tables Section
• Block Section
• Entities Section
15 Explain the IGES file structure and format. BTL1
1.Global section (G) – The Global Section includes properties and descriptions of the pre-
processor and information that are needed by postprocessor to interpret the file. It is recognize by
letter "G" in the IGES file.4. Directory section (D) – Index for the file and attribute information
like colour, line type etc.
2.Data Entry Section (D) -Directory entry section defines the attributes or features of the entity
like line , color, transformation matrix, etc.
3. For every geometric element within an IGES file there is one Directory Entry. This consists of
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two 80-character lines i.e. 20 right-justified fields of 8 characters each

4. Parameter Entry section (P) Directory entry section defines the attributes or features of the
entity like line , color, transformation matrix, etc. For every geometric element within an IGES
file there is one Directory Entry. This consists of two 80-character lines i.e. 20 right-justified
fields of 8 characters each
5. Terminate section – The terminal section contains only one record which shows the number of
records in each section. This is used for checking purpose.
16 Brief about STEP (Standard for the Transfer and Exchange of Product model
data)file.BTL1
The broad scope of STEP is as follows:
– The standard method of representing the information necessary to completely define a product
throughout its entire life, i.e., from the product conception to the end of useful life.
– Standard methods for exchanging the data electronically between two different systems.
STEP AP203 / AP214 format (Standard for the Exchange of Product model data)
• It supports geometry and assembly structures and handles topology (shells, solids) on export and
import.
• STEP files are human readable
• Other STEP APs are available, e.g. electronics data
17 State the importance of PDES. BTL2
PDES (PRODUCT DATA EXCHANGE STANDARD)
(Then Product Data Exchange Using STEP)
• To support any industrial application such as mechanical, electric, plant design, and architecture
and engineering construction
• To include all four types of data which is relevant to the entire life-cycle of a product: design,
analysis, manufacturing, quality assurance, testing, support, etc. PDES is a much more
comprehensive and complex standard than IGES or any other predecessors
18 Compare the shape based and product data based exchange standards. N/D’15
S. No. Shape based exchange standards Product data based exchange standards
All data exchange files are neutral
1 It has specific file formats.
files.
It consists of a three layered architecture
It has section of header, table, block,
2 such as application, logical and physical
entities and end
layers.
These files do not have any software These file must have any software specific
3
specific function. function.
4 Example, DXF and IGES Example, STEP, SDF, EDIF, and PDES.
PART-B

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1 Write a notes on (i) Open graphics Library (Open GL) BTL5 N/D’15 (16)
• Open graphics Library (Open GL) is a cross language multi-platform Application
Programming Interface (API) for rendering 2D and 3D vector graphics. API is typically used
to interact with a Graphics Processing Unit (GPU) to obtain hardware accelerated rendering.
• It is extensively used in the field of CAD, virtual reality, scientific visualization, information
visualization, flight simulation and video games.
• It describes an abstract of API for drawing 2D and 3D graphics. Although it is possible for
the API to implement entirely in software, it is mainly designed to implement in hardware.
• API is defined as a number of functions which may be called by the client program alongside
a number of named integer constants.
• Open GL ES 2.0, for 3D rendering from within a web browser, the C bindings WGL, GLX
and CGL, the binding provided by IOS and the Java and C bindings provided by android.
• In addition to language independent, Open GL is also an independent platform. The
specification explains obtaining and managing an OpenGL context. For the same reason,
Open GL is purely concerned with rendering provide no APIs related to input, audio or
windowing.
Features of Open GL
(i) Based on IRIS GL:
Open GL is supported on silicon graphics Integrated Raster Imaging System (IRIS), Graphics
Library (IRIS GL).
(ii) Low-level:
A critical target of Open GL is to suggest device independence while still permitting the
total contact to hardware.
(iii) Fine grained control:
Due to minimize the needs of application utilizing, the Application Programmers Interface
(API) must save and present its information.
(iv) Modal:
A model API arises in executions in which process function in parallel on various primitives.
(v) Geometry and images:
Open GL supports to manage both 3D and 2D geometry. An API for utilizing with geometry
should also provide guidance for reading, writing and copying images because geometry and
images are regularly joint when a 3D view is laid over a background image.
Advantages:
• Industry standard
• Reliable and portable
• Easy to use
• Well documented
Simplified software development, speeds time to market

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2 Standards for computer graphics. BTL5 N/D’15 (8)

Need for graphics standards:
• There is a need for portability of the geometric model among different hardware
platforms.
• Where there is a situation to exchange drawing data base among software packages.
• There is a need for exchanging graphic between different computer systems.
• To understand the graphic kernel system and its extensions for developing the graphic
software systems.
• There is a need for requirement of graphic data exchange formats and their details such as
IGES, DXF and STEP.
• Dimensional measurement interface specification for communication between coordinate
measuring machine and CAD data.
Standardising certain elements at each stage is to minimize the company investment on
certain software and hardware without much modification on the newer and different systems. So,
there should be some compatibility between various software elements as also between the
hardware and software.
There are interface standards at various levels as follows:
• GKS (Graphical Kernel System)
• PHIGS (Programmers Hierarchical Interface for Graphics)
• CORE (ACM-SIGGRAPH)
• GKS-3D
• IGES (Initial Graphics Exchange Specification)
• DXF (Drawing Exchange Format)
• STEP (Standard for the Exchange of Product Model Data)
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• DMIS (Dimensional Measurement Interface Specification)

• VDI (Virtual Device Interface)
• VDM (Virtual Device Metafile)
• GKSM (GKS Metaflie)
• NAPLPS (North American Presentation Level Protocol Syntax)
3 Explain the IGES structure and methodology with suitable examples?Explain IGES file
format. BTL5 N/D’15, N/D’16, M/J’17 (16)
However, the IGES is the most comprehensive standard and is designed to transmit the entire
product definition including that of manufacturing and any other associated information. A brief
description of the IGES version 3.0 is given below highlighting the philosophy of the conversion
methodology.
In IGES the records are present with 80 column fields, with columns 1 to 72 providing the
data and columns 73 to 80 providing a sequence number for the record with identification as to
the location of the sub-section. This sequence number is utilized as a pointer for the data. The
IGES file consists of the following 6 sub sections.
(a). Flag Section:
This is optional and used to indicate the form in which the data is specified, Originally,
the initial versions contained the data in ASCII format with a very detailed structure. This has
been criticized by a number of people in view of the very large sizes. From version 3.0 onwards
the format has been standardized in the following three modes.
• ASCII mode – default option.
• Binary form.
• Compressed ASCII form.
IGES specification defines the format of the file, language format, and the product definition
data in these formats. The product definition includes geometric, topological, and non-geometric
data. The geometry part defines the geometric entities to be used to define the geometry. The
topology part defines the entities to describe the relationships between the geometric entities. The
geometric shape of a product is described using these two parts (i.e. geometry and topology). The
non-geometric part can be divided into annotation, definition, and organization. The annotation
category consists of dimensions, drafting notations, text, etc. The definition category allows users
to define specific properties of individual or collections of entities. The organization category
defines groupings of geometric, annotation, or property elements.
An IGES file consists of six sections: Flag, Start, Global, Directory Entry, Parameter Data, and
Terminate. Each entity instance consists of a directory entry and parameter data entry. The
directory entry provides an index and includes attributes to describe the data. The parameter data
defines the specific entity. Parameter data are defined by fixed length records, according to the
corresponding entity. Each entity instance has bi-directional pointers between the directory entry

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and the parameter data section. The size of IGES files and consequently the processing time are
practical problems. IGES files are composed of fixed format records and each entity has to have
records in both the directory entry section and the parameter data section with bi-directional
pointers. This causes also errors in pre- and post-processor implementations.
The other two option provided will help in reducing the bulk of the drawing exchange file
size. The sequence number has a starting character signifying the sub section, they are
1. S for Start section.
2. G for Global section.
3. D for Directory entry section.
4. P for Parameter entry section.
5. T for terminate section.
(b). Start section:
This section contains a man-readable prologue to the file. The information contained in
this section is essentially for the person who would be post processing this for any other
application.
Any number of lines can be contained in this section. A sample listening an IGES file for the
drawing shown.
(c). Global Section:
This contains information about detail of the product, the person originating the product,
name of the company originating it, date, the detail of the system which generated it, drafting
standard used and some information required for its post processing on the host computer.
(d). Directory entry section:
For each entity present in the drawing is fixed in the size and contains 20 fields of 8
characters each. The purpose of this section is to provide an index for the file and to contain
attribute information.
Some of the attribute information such as color, line type, transformation matrix, etc., may be
present directly or through a pointer (to a record in the same file) where the necessary information
is stored.
It also contains the pointer to the parameter data section entry which actually contains the
requisite parameter data.
(e). Parameter data section.
This contains the data associated with entities. A free format is allowed for maximum
convenience. It may contain any number of records. The total number of entities that are present
in IGES version 5.1.
(f). Terminate section:
This contains the sub total of the records presented in each of the earlier sections. This would
always contain a single record.
4 Write a short note on STEP? BTL5 M/J’17 (16)
New CAD data standard is developed through world wide effort known as STEP in year
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1997. The ability to share data across application, across vendor, platforms and between
contractors, suppliers and customers is the main objective of STEP standard.
STEP seeks to address a number of limitations of IGES. In IGES does not clearly between
the logical specification of the standard (the meaning of the data fro CA system point of view),
the applications requirements (how the data will be used in particular application) and the
physical specification for the storage of data in exchange files.
Data loss:
Similar to any language translation, there is always information loss during the product
data information translation.
Examples:
i. A design tolerance is captured as a text string placed on a drawing and its numerical
values are lost.
ii. Circular cylinders (a hole) is represented by NURBS.
iii. The offset information is lost in offset surfaces.
The board scope of STEP is as follows:
i. The standard method of representing the information necessary to completely define a
product throughout its entire life, ie., from the product conception to the end of useful life.
ii. Standard methods for exchanging the data electronically between two different systems.
STEP uses the formal model for the data exchange which is described using an information
modelling language called EXPRESS. It is both human readable and computer processable. STEP
has three layers architecture which enables the multiple application views and implements to be
defined.
The STEP documentation has eight major areas which are described below.
1. Introductory:
It contains the details about general introduction and overview of the standard. It forms
the part 1 of the ISO standard 10303. It comprises of part 1 which has overview and general
principles.
2. Description method:
When compared to other standard, the application protocols are planned to reach vendors. So
a new descriptive formal information modelling language called EXPRESS is developed and
defined. It is given in part 11 to 13.
3. Implementation method:
It describes how express map physical files and storage mechanisms are represented for the
data exchange. In refers the actual implementation level. These details are given in part 21 to 26.
4. Conformance testing methodology and frame work:
It provides the methods for testing implementation and test suits to be used during
conformance tasting. It also gives the specification for conformance testing of the processors,
guidance for creating abstract – test suites and the responsibilities of testing laboratories. These
details are given in part 31to 35.
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5. Integrated – generic resources:

It contains the specifications of the information models about generic resources such as
geometry and structure representation. The specifications are geometric and topological
representation, product structure organization, materials, visual presentation, tolerances, form
features and process structures, and properties.
These details are given in part 41- 99
6. Application information models:
They specify the information models used for the particular application areas such as
draughting, finite element analysis, kinematic, building core model and engineering analysis core.
The details are given in part 101.
conformance testing and test
layer 3 - Application protocol

suits.
layer 2 - Resource information models
layer 1 - Implementation methods

(express)
Physical files
7. Application protocols:
In described implementations of STEP specific to a particular industrial application and they
are associated with implementation methods to form the basis of a STEP implementation which
provides test suits for each of the application protocol.
It is also defining the context for the use of product data for a specific industrial need. More
complex models are used to illustrate the specific product data application.
It uses the integrated information resources in well-defined combination and configuration to
represent a particular data model of some phase of product life. The information is given in 201.
8. Application interpreted control:

It describes the various model entity construct and specific modelling approach. They relate
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to the specific resources useful for defining the geometric structures useful for applications.
In this case, the information can be reused. So it makes the process easier to express the
identical semantics in more than one application protocol.
5 Explain about various layers of GKS. BTL5 N/D’15, N/D’16 (16)

Graphical Kernel System (GKS) provides a set of functions for the purpose of generating 2D
pictures on vector graphics and/or raster devices. It also supports operator input and interaction
by supplying basic functions for graphical input, picture segmentation and subsequent storage,
retrieval and dynamic modification of graphical information.
Different Layers of GKS

GKS provides a functional interface between an application program and a configuration of
graphical input and output devices. The functional interface contains all basic functions for
interactive and non-interactive graphics on a wide variety of graphical equipment.
The geometric information (coordinates) contained in the output primitives, attributes and
logical input values can be subjected to transformations. These transformations perform mapping
between three coordinate systems, namely:
(a) World Coordinates (WCS) used by the application programmer to describe graphical
information to GKS.
(b) Normalized Device Coordinates (NDC) used to define a uniform coordinate system for all
workstations.
(c) Device Coordinates (DC), one coordinate system per workstation, representing its display
surface coordinates. Input containing coordinates are expressed to GKS by the device using DC
values.
Output primitives and attributes are mapped from WC to NDC by normalization
transformation, from NDC to NDC by segment transformation (as indicated by a transformation
matrix defining rotation, scaling and shift factors) and from NDC to DC by workstation
transformation. Input from the display surface (expressed in DC) is mapped by an inverse
workstation transformation from DC to NDC and by one of the inverse normalization
transformation from NDC to WC.
Output primitives and primitive attributes may be grouped together in a segment. Segments
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are units for manipulation and change. Manipulation includes creation, deletion, and renaming
while change includes transforming a segment, changing its visibility and also highlighting
segments, i.e., causing segments to "flash". Segments also form the basis for workstation
independent storage of pictures at run time.
GKS primitives
❖ GKS output primitive is a collection of functions to display 2D images.
❖ It consists of Line, polygon, Spline, Dimension, Text etc.,
❖ Attributes refer the Parameters Such as Colour , line Style etc.,
❖ Circle is a primitive, its attributes may be Colour, line width and line type.
❖ POLYLINE to draw a set of connected straight-line vectors
❖ POLYMARKER to draw a set of markers or shapes
❖ FILL AREA to draw a closed polygon with interior fill
❖ TEXT to create characters
❖ GDP (Generalized Drawing Primitive) to specify the standard drawing entities like circle,
ellipse etc.
❖ The attribute functions define the appearance of the image e.g. color, line-type etc.
❖ Current level of GKS is GKS-3D, which provides several other functions. GKS-3D is an
extension to GKS, which allows the production of 3-D objects.
6 Write short note on : Drawing Exchange Format (DXF) Standard. BTL5 M/J’16 (8)
DXF (Data eXchange Format) was originally developed by Autodesk, Inc., the vendor of
AutoCAD. It has become a "de-facto" standard among most CAD vendors and is in wide use to
exchange 2D/3D wireframe data. All implementations of AutoCAD accept this format and are
able to convert it to and from their internal representation. A DXF file is a complete representation
of the AutoCAD drawing database thus some features or concepts can't be used by other CAD
systems. The DXF version R13 supports wireframe, surface, and solid representations.
A DXF file consists of four sections: Header, Table, Block, and Entity section. The header section
contains general information about the drawing. Each parameter has a variable name and an
associated value. The table section contains definitions of line types, layers, text styles, views, etc.
The block section contains entities for block definitions. These entities define the blocks used in
the drawing. The format of the entities in the block section is identical to entities in the entity
section. The entity section contains the drawing entities, including any block references. Items in
the entity section exist also in the block section and the appearance of entities in the two sections
is identical. Variables, table entries, and entities are described by a group that introduces the item,
giving its type and/or name, followed by multiple groups that supply the values associated with the

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item. In addition, special groups are used for separators such as markers for the beginning and end
of sections, tables, and the file itself. Group codes are used to describe the type of the value, and
the general use of the group.
.

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UNIT IV FUNDAMENTAL OF CNC ANDPART PROGRAMING

Introduction to NC systems and CNC - Machine axis and Co-ordinate system- CNC machine tools-
Principle of operation CNC- Construction features including structure- Drives and CNC controllers- 2D
and 3D machining on CNC- Introduction of Part Programming, types - Detailed Manual part
programming on Lathe & Milling machines using G codes and M codes- Cutting Cycles, Loops, Sub
program and Macros- Introduction of CAM package.
PART * A
Q.No. Questions
List the differences between NC and CNC.BTL 1
1. NC stands for Numerical Control whereas CNC stands for Computer Numerical Control.
In NC Machine the programs are fed into the punch cards. The cost of the NC machine is
less as compared with the computer control machines.
Define linear bearings.BTL 1
A linear-motion bearing, or linear slide is a bearing designed to provide free motion in one
2 direction. There are many different types of linear motion bearings. Motorized linear slides such
as machine slides, XY tables, roller tables and some dovetail slides are bearings moved by drive
mechanisms.
Mention the type of ball screws. BTL 3
3 A ball screw is a mechanical linear actuator that translates rotational motion to linear motion with
little friction. A threaded shaft provides a helical raceway for ball bearings which act as a
precision screw.
Define feed drives. BTL 1
4 Feed drive Computer. An optical drive that grabs the disc after it is partially inserted in the slot
and pulls it onto the drive spindle.
Discuss the types of motion control system used in NC machines. BTL 1
Numerical control (NC) (also computer numerical control (CNC)) is the automated control of
5 machining tools (drills, boring tools, lathes) by means of a computer. An NC machine alters a
blank piece of material (metal, plastic, wood, ceramic, or composite) to meet precise
specifications by following programmed instructions and without a manual operator.
Express the meaning of APT language. BTL 2
6 APT or Automatically Programmed Tool is a high-level computer programming language most
commonly used to generate instructions for numerically controlled machine tools. ... APT is a
language and system that makes numerically controlled manufacturing possible.
Discuss closed loop NC system with open loop system. BTL 1
In CNC systems, open and closed loop systems describes the two primary types of control
7 systems: Open Loop: Refers to a system using a stepper motor, where the communication
between the controller system and motor is one way This is considered a drawback to theopen
loop system.
Give the uses of preparatory function. How is it important in CNC programming? BTL 3
Preparatory Functions. Preparatory functions are G codes. These codes are the most important
8 functions in CNC programming because they direct the CNC system to process the coordinate
data in a particular manner. Some examples are rapid traverse, circular interpolation, linear
interpolation, and drilling.
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Illustrate the limitations of CNC machine tools. BTL 2

The computer numerical control includes machine tool and also non-machine tools. The CNC
system are mainly used in the milling machine, lathe machine, drill press, grinding, sheet metal
process, laser machine working. There is an automatic changing of the cutting tool operation that
9 is developed in the CNC machining process. In Non-machine tools it includes the welding
machines, electronic assembly, coordinate measuring machine, and tape laying, filament winding
machines for composites.
a) Short production runs
b) On conventional machining it requires expensive jigs and fixtures
c) Parts with complicated outlines
Examine - canned cycle. BTL 3
A canned cycle is a way of conveniently performing repetitive CNC machine operations. Canned
10 cycles automate certain machining functions such as drilling, boring, threading, pocketing, etc...
Canned cycles are so called because they allow a concise way to program a machine to produce a
feature of a part.
Define NC. BTL 1
11 Numerical control, popularly known as the NC is very commonly used in the machine tools. In
other words, the numerical control machine is defined as the machined that is controlled by the
set of instructions called as the program.
Explain the major elements of NC machines. BTL 1
12 The machine tool can be any machine like lathe, drilling machine, milling machine etc. The
machine tool is the controlled part of the NC system. In case of the CNC machines, the
microcomputer operates the machine as per the set of instructions or the program.
Compare the different NC machines. BTL 4
13 The machine tool can be any machine like lathe, drilling machine, milling machine etc. The
machine tool is the controlled part of the NC system. In case of the CNC machines, the
microcomputer operates the machine as per the set of instructions or the program.
Compare incremental and absolute system. BTL 1
Measurement solutions come in two flavors: Absolute and incremental. With an absolute
14 measurement system, the system will generate an absolute signal, e.g. the position. An
incremental system counts the number of steps between two positions. The clock isan absolute
measurement system, it will tell you a point in time.
Explain the role of computer for NC machine tool.BTL 4
CNC is a computer assisted process to control general purpose machines from instructions
15 generated by a processor and stored in a memory system. ... The controller uses a permanent
resident program called an executive program to process the codes into the electrical pulses that
control the machine.
PART * B
1 Describe the spindle drives used in CNC machine tools. (13M) (Nov.2017) BTL 2
Answer: Page 469Dr.R.PANNEERDHASS

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Diagram(4M) Principle(4M)Construction(3M)Advantages and Disadvantages(2M
2 Discuss about slide ways used in CNC machine tools. (13M) (Nov. 2017) BTL 3
a) Diagram(4M) Principle(4M) Construction(3M) Advantages and Disadvantages(2M)

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3 Describe various type of CNC machine based on tool motion. (13M) (May 2017) BTL 3
Answer: Page 440 Dr.R.PANNEERDHASS
Point to point system:
Tool is accurately located at some specified position. The spindle is first brought to the
starting point, then moved to the next location (hole 1 along the marked path). On that
location drilling operation is performed and then tool moves to next location.
Straight line system:
The cutting tool can be moved along a straight line only, which is parallel to the principal axes
of motion. It is not possible to combine the motion of axes. Hence the tool motion is only
along the X- axis, Y-axis and Z-axis. Due to this angular cuts cannot be produced.
Continuous system:
In this there is relative motion between the tool and workpiece during the whole operation.
Due to this relative motion, different curves and profiles can be cut. Actually, it is a
combination of point to point and straight cut system.
a) Diagram(4M)
b) Principle(4M)
c) Construction(3M)
Advantages and Disadvantages(2M)
4 Explain the M code and G code with respect to manual part programming: (13M) (May
2017) BTL 3
Answer: Page 469, 477Dr.R.PANNEERDHASS
M-codes are miscellaneous machine commands that do not command axis motion. The
format for an M-code is the letter M followed by two to three digits; for example:
[M02 End of Program]
[M03 Start Spindle- Clockwise]
[M04 Start Spindle- Counter Clockwise]
[M05 Stop Spindle]
[M06 Tool Change]
[M07 Coolant On]

[M53 Retract Spindle] (raises tool spindle above current position to allow operator to do whatever
they would need to do)
M Codes are essential in ALL CNC programs to ensure a functioning line of code. All complete
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CNC programs have an M code in both the first and last line of code.(7 M)
G-codes are used to command specific movements of the machine, such as machine moves or
drilling functions. The format for a G-code is the letter G followed by two to three digits; for
example G01. G-codes differ slightly between a mill and lathe application.
for example:
[G00 Rapid Motion Positioning]
[G01 Linear Interpolation Motion]
[G02 Interpolation Motion-Clockwise]
[G03 Circular Interpolation Motion-Counter Clockwise]
[G04 Dwell (Group 00) Mill]
[G10 Set offsets (Group 00) Mill]
[G12 Circular Pocketing-Clockwise]
[G13 Circular Pocketing-Counter Clockwise] (6 M)
5 Write the part program for drilling holes in the part shown below. The plate thickness is
20mm. (13M) (Nov. 2016) BTL4

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6 With a neat sketch explain the working of ATC. (13M) (Nov. 2016) BTL 5

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2-61

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7 List any five motions and control statements of computer assisted NC programming and
explain. (13M) (May 2016) BTL 2
Point to point system:

Tool is accurately located at some specified position. The spindle is first brought ot the starting p
moved to the next location (hole 1 along the marked path). On that location drilling operation is p
and then tool moves to next location.
Straight line system:

The cutting tool can be moved along a straight line only, which is parallel to the principal axes o
It is not possible to combine the motion of axes. Hence the tool motion is only along the X-axi
and Z-axis. Due to this angular cuts cannot beproduced.
Continuous system:
In this there is relative motion between the tool and workpiece during the whole operation. Due
to this relative motion, different curves and profiles can be cut. Actually, it is a combination of
point to point and straight cut system.
a) Diagram(4M)
Principle(4M)

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8 Describe in brief the basic components of a tape operated NC machine tool. (13M) (May
2015) BTL 6
Answer: Page429 Dr.R.PANNEERDHASS
Load-N/C program controller- own memory - entire program - encoded paper or magnetic tape
- execute commands - one block at a time.
Controller - built-in memory (a CNC type of N/C machine)- three methods. The first method -
keying program directly --multi thousand dollar controller and machine tool - keyed in one
command at a time
(8M)

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PART * C
1 Write CNC part program for the component shown in fig mention the assumptions made. (15M)
(May 2017) BTL 5

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2-66

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UNIT V CELLULAR MANUFACTURING ANDFLEXIBLE

MANUFACTURINGSYSTEM(FMS)
Group Technology (GT),Part Families–Parts Classification and coding–Simple Problems in
Opitz Part Coding system–Production flow Analysis–Cellular Manufacturing–Composite part
concept–Types of Flexibility - FMS – FMS Components – FMS Application & Benefits –
FMS Planning and Control– Quantitative analysis in FMS
Q.No. Questions
PART - A
1 Define Group Technology (GT).(BTL1)
Identical or similar components grouped processed together during design,
process planning and manufacturing so that a wide variety of components can be manufactured, at the
least expense of time, inventory, man hours and material handling.
2 List out the stages in Group Technology.(BTL2)
• Production planners to setup the GT database.
• Grouping the parts or components into part-families with some similar characteristics.
• Re-design the shop-floor arrangement according to common shape, function or manufacturing
process and tooling.
3 Define Part family. (BTL1)
collection of parts which are similar in terms of geometricshape, size,
and similar processing steps required in manufacturing, so flow of materials through the plant
improves"
4 List the general methods used for grouping parts into families.(BTL2)
• Visual Inspection
• Parts classification and coding system
• Production flow analysis.
5 What is Production Flow Analysis (PFA)?(BTL1)
Identifying part families and associated machine groupings that uses the information contained on
production route sheets rather on part drawings.
6 List the steps involved in PFA.(BTL2)
• Data Collection
• Sortation of process routings
• Preparation of PFA chart
• Cluster analysis.
7 List out the 3 basic code structures used in GT applications.(BTL1)
• Hierarchical codes
• Attribute codes
• Decision tree-codes.
8 What is the main difference between hierarchical codes and attribute code structures?(BTL1)
Interpretation of each symbol in the sequence depends on the value of preceding symbols. Whereas in
attribute/polycode structure, the interpretation of each symbol in the sequence does not depend on the
value of preceding symbols.
9 List any six coding systems that are widely recognized in industries.(BTL2)
• Optiz classification system
• MICLASS system
JIT-JEPPIAAR/MECH/Mr.S.VIGNESH & Mr.M.KALAIMANI/IIIrdYr/SEM 06 /ME8691/COMPUTER AIDED DESIGN

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• DCLASS system
• KK-3 System
• CODE system
• CUTPLAN system
10 What is cellular manufacturing?(BTL1)
Application of GT in which dissimilar machines have beenaggregated into cells, each of which is
dedicated to the production of a part family.
11 List any four design considerations guiding the cell formation.(BTL2)
• Parts/products to be fully completed in the cell.
• Higher operator utilization
• Fewer operations than equipment
• Balanced equipment utilization in the cell.
12 What is Process planning?(BTL1)
• Preparing a set of instructions that describe how to fabricate apart or build an assembly
which will satisfy engineering design specifications.
• Systematic determination of the methods by which product is to be manufactured, economically
and competitively.
13 List the activities associated with process planning. (BTL2)
• Analyzing finished part equipment’s
• Determining operating sequence
• Selecting machines
• Selecting material parameters
• Calculating process times
• Documenting process planning
14 What is meant by CAPP?(BTL1)
CAPP refers to computer aided process planning. CAPP is used to overcome the drawbacks
of manual process planning. With the use of computers in the process planning, one can reduce the
routine clerical work of manufacturing engineers. Also it provides the opportunity to generate rational,
consistent and optimal plans.
What are the approaches the CAPP will recognize?(BTL1)
• Two approaches to CAPP are traditionally recognized: the variant approach and the
15
generative approach.
• Many CAPP systems combine both approaches.
16 Why CAPP systems are called as variant system?(BTL1)
• The investment is less and the development time is shorter. Especially for medium sized
companies which want to establish their own research groups.
• The development costs and hardware costs are lower. Especially for some small companies
where the products do not vary much and who still have process planners.
17 Give the main component of generative CAPP systems.(BTL1)
CAPP system contains of two main components.
• Manufacturing data base (part description, machine tool library etc.)
• Decision logic (to represent the process planner)
18 List out the basic approaches of CAPP. (BTL1)
• Retrieval (or variant) CAPP system
• Generative CAPP system.
19 List out the results of Process Planning?(BTL1)
• Routings which specify operations, operation sequences, work centers, standards, tooling and
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fixtures.
• Process plans which typically provide more detailed, step-by-step work instructions including
dimensions related to individual operations, machining parameters, set-up instructions, and
quality assurance checkpoints.
• Fabrication and assembly drawings to support
20 List out the factors should be considered in selection of tooling.(BTL1)
• The type and amount of the material to be cut.
• The surface finish required
• The rigidity and shape of the part.
• The capacity and condition of the available equipment
21 List out the prerequisites for process planning.(BTL1)
• Part list
• Annual demand/ batch size
• Accuracy and surface finish requirement
• Equipment details
• Data on cutting fluids, tools, jigs and fixtures, gauges.
• Standard available stock sizes.
• Machining data, data on handling and setup.
22 What is the weakness of PFA?(BTL1)
Data used are derived from production route-sheets. But the process-sequences have been prepared by
different process lanners and the difference is reflected on to these route-sheets.
23 List some commercially available CAPP. (BTL2)
• Some of the commercial variant CAPP systems include CUTPLAN. COMCAPP V, DCLASS
and INTELLICAP.
• Some of the commercial generative CAPP systems include AUTAP, CMPP, GENPLAN and
LO CAM.
24 What is CMPP?(BTL1)
CMPP stands for computer-managed process planning.It is a commercial generative process planning
system capable of automatically making process decisions.
PART – B
1 Explain the various DCCLASS coding systems. (BTL2)
Answer: Page.1.68 - Dr.V.Jayakumar
• The first segment (three digits) is used to denote the basic shape. (2M)
• The second segment (4th digit) is used to specify the complexity of the parts. (2M)
• The third segment (5th digit) is used to specify the overall size of the coded part.(2M)
• The fourth segment (6th digit) represents precision.(2M)
• The final segment (two digits) is used to denote the material type.(2M)
Explanation of coding system (3M)

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2 Explain OPTIZ CODINGsystem?(13M)BTL2

Answer:Page.1.68 - Dr.V.Jayakumar
Optiz(7 M)
Classification System:(4 M)
The optiz system was developed by H. Optic of Aachen University, Germany. In fact it was
the most popular and one of the first published classification and coding systems schemes for
mechanical parts.
This system uses alpha numeric symbols to represent the, various attributes of the part.
The optiz coding system uses the following digit sequence:(4 M)
Example: 12345 6789 ABCD.
The first five (12345) digits code the major design of the part and are called the "Form Code".
The next for digits (6789) are for coding manufacturing related attributes and are called
"Supplementary Code".

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3 Give the form code for the part family using any one coding system. (BTL2)
Coding is a systematic process of establishing an alphanumeric value for parts based on
selected part features. Classification is the grouping of parts based on code values.(3M)
Design and manufacturing attributes (2M)
• Systems based on part design attributes
• Systems based on part manufacturing attributes
• Systems based on both design and manufacturing attributes.
Coding system (2M)
• Hierarchical codes
• Attribute codes
• Decision tree codes
Explanation of any one system : OPTIZ / MICLASS / DCLASS (6M)
4 Discuss how group technology is used in designing manufacturing cells. (BTL2)
• Once parts have been grouped into part families by parts classification and coding or
production flow analysis, the next problem would be determining how to arrange the
machines in the shop.(2 M)
• Facility layout, also known as plant layout, refers to the physical arrangements of
production facilities. It is the configuration of departments, work centers, and
equipment in the conversion process.(2M)
• The objective of facility layout is to design a physical arrangements that most
economically meets the required output quantity and quality.(2M)
There are three basic ways to arrange machines in a shop. They are (2M)
• Line (or product) layout,
• Functional (or process) layout
• Group (or combination) layout.
Explanation of any one layout (5M)
PART – C
1. Discuss ERP with suitable modules. (BTL3)
Answer: Page 2.78 -Dr.V.Jayakumar
ERP : Enterprise Resource Planning (2 M)
List of different Modules: Finance module
• Manufacturing module
• Distribution module
• Service module
• Transportation module
• Process module
• Project module
• Tools module(5M)
Explanation of any two modules
• Accounting – oriented information system
• Effective planning and control (8M)

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2 Briefly discuss various benefits of implementing a GT in a firm. Also bring out the advantages
and limitations of using group technology. (BTL3)Answer:Page.1.68 - Dr.V.Jayakumar
Benefits of group technology
• Product design
• Tooling and setups
• Materials handling
• Production and inventory control
• Process planning
• Management and employees( 5 M)
Advantages of GT
• GT facilitates: efficient retrieval of similar parts
• GT encourages standardization of designs, tooling, fixing and setups
• GT facilities: Development of a computer-aided process planning (CAPP)
• Times and costs for material handling and waiting between stages are reduced.
• Production planning and control is simplified
• Part and product quality are improved
• Better employee involvement and increases workers satisfaction(10 M)
3 Discuss arranging machines in a GT Cell in detail with holier method. (BTL3)
After part-machine groupings have been identified (by rank order clustering algorithm) and next
problem is to arrange the machines into the most logical sequence.
Design the cellular manufacturing system are:
• The determination of the most logical machine sequence in each cell
• The development of a feasible layout plan for each cell
Literature to determine the most logical machine in a GT Cell, the Holier method 2 (7M)
Procedure of Holier method

• Develop the From-TO chart from part routing data
• Calculate the “’From/To ratio” for each machine
• Arrange Machines in a GT Cell in order of decreasing “From/To ratio”(4M)
Performance measures for Machine sequences in a GT Cell
• Percentage of In sequences in a GT Cell
• Percentages of Bypassing moves
• Percentages of backtracking moves. (4M)
4 Explain composite part concept in cellular manufacturing. (May/June 2013).(BTL2)
Answer:Page.1.68 Dr.V.Jayakumar
A composite part is a hypothetical part which includes all of the design and manufacturing
attributes of a family. The composite is a single hypothetical part that can be completely
processed in manufacturing cell .(3M)
Let us consider that there are four number of parts as shown in figure a, all of whom have
similar machining operations to be done, Then it is possible to construct a new composite part
as shown in figure b that has all the features identified in the four parts from figure b(4 M)

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(8M)

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ME8692 FINITE ELEMENT ANALYSIS L T P C

3 0 0 3
OBJECTIVES:
• To introduce the concepts of Mathematical Modeling of Engineering Problems.

• To appreciate the use of FEM to a range of Engineering Problems.
UNIT I INTRODUCTION 9
Historical Background – Mathematical Modeling of field problems in Engineering – Governing
Equations – Discrete and continuous models – Boundary, Initial and Eigen Value problems–
Weighted Residual Methods – Variational Formulation of Boundary Value Problems – Ritz
Technique – Basic concepts of the Finite Element Method.
UNIT II ONE-DIMENSIONALPROBLEMS 9
One Dimensional Second Order Equations – Discretization – Element types- Linear and Higher
order elements – Derivation of Shape functions and Stiffness matrices and force vectors-
Assembly of Matrices - Solution of problems from solid mechanics and heat transfer.
Longitudinal vibration frequencies and mode shapes. Fourth Order Beam Equation –Transverse
deflections and Natural frequencies of beams.
UNIT III TWO DIMENSIONAL SCALAR VARIABLE PROBLEMS 9
Second Order 2D Equations involving Scalar Variable Functions – Variational formulation –
Finite Element formulation – Triangular elements – Shape functions and element matrices and
JIT - JEPPIAAR
vectors. Application to Field Problems - Thermal problems – Torsion of Non circular shafts –
Quadrilateral elements – Higher Order Elements.
UNIT IV TWO DIMENSIONAL VECTOR VARIABLE PROBLEMS 9

Equations of elasticity – Plane stress, plane strain and axisymmetric problems – Body forces and
temperature effects – Stress calculations - Plate and shell elements.
UNIT V ISOPARAMETRIC FORMULATION 9

Natural co-ordinate systems – Iso parametric elements – Shape functions for iso parametric
elements – One and two dimensions – Serendipity elements – Numerical integration and
application to plane stress problems - Matrix solution techniques – Solutions Techniques to
Dynamic problems – Introduction to Analysis Software
TOTAL: 45 PERIODS
OUTCOMES:
Upon completion of this course, the students can able to understand different mathematical
Techniques used in FEM analysis and use of them in Structural and thermal problem
TEXT BOOK:
JIT-JEPPIAAR/MECH/Mr.S.Arun & Mr.D.Arunkumar /III Yr/SEM 06/M8692/FINITE ELEMENT ANALYSIS/UNIT 1-
5/QB+Keys/Ver1.0
3-1
1. Reddy. J.N., “An Introduction to the Finite Element Method”, 3rd Edition, Tata McGraw-
Hill, 2005
2. Seshu, P, “Text Book of Finite Element Analysis”, Prentice-Hall of India Pvt. Ltd., New
Delhi,2007.
REFERENCES:
1. Rao, S.S., “The Finite Element Method in Engineering”, 3rd Edition, Butterworth
Heinemann,2004
2. Logan, D.L., “A first course in Finite Element Method”, Thomson Asia Pvt. Ltd., 2002
3. Robert D. Cook, David S. Malkus, Michael E. Plesha, Robert J. Witt, “Concepts and
Applications of Finite Element Analysis”, 4th Edition, Wiley Student Edition, 2002.
4. Chandrupatla&Belagundu, “Introduction to Finite Elements in Engineering”, 3rd
Edition,Prentice Hall College Div, 1990
5. Bhatti Asghar M, "Fundamental Finite Element Analysis and Applications", John Wiley
& Sons,2005 (Indian Reprint 2013)
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Subject Code: ME8692 Year/Semester: III /06

Subject Name: Finite Element Analysis Subject Handler: Mr.S.Arun & Mr.D. Arunkumar
UNIT I INTRODUCTION
Historical Background – Mathematical Modeling of field problems in Engineering – Governing

Equations – Discrete and continuous models – Boundary, Initial and Eigen Value problems– Weighted
Residual Methods – Variational Formulation of Boundary Value Problems – Ritz Technique – Basic
concepts of the Finite Element Method.
PART * A
Q.No. Questions
What should be considered during piecewise trial functions?(APRIL 2011)BTL1

1.
Continuity of the field variable and its derivatives at the junctions are considered.
Mention the basic steps of Rayleigh-Ritz method. (APRIL 2011)BTL1
Basic steps of Rayleigh-Ritz method are, '
2 • Assume a displacement field
• Evaluation of the total potential
• Setup and solve the system of equations.
What is meant by node or joint?(APRIL 2019)BTL1
Each kind of finite element has a specific structural shape and is interconnected with the
3
adjacent element by nodal point or nodes. At the nodes, degrees of freedom are located. The
forces will act only at nodes at any others place in the element.
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What is the basic of finite element method? BTL1

4 Discretization is the basis of finite element method. The art of subdividing a structure in to
convenient number of smaller components is known as discretization.
What are the types of boundary conditions?(APRIL 2019)BTL1
5 • Primary boundary conditions
• Secondary boundary conditions
State the methods of engineering analysis. (APRIL 2010) BTL1
• Experimental methods
6
• Analytical methods
• Numerical methods or approximate methods
State the three phases of finite element method.(APRIL 2019)BTL1
• Preprocessing
7
• Analysis
• Post Processing
What is nonstructural problem? (APRIL 2014) BTL1
8 Temperature or fluid pressure at each nodal point is obtained. By using these values properties
such as heat flow fluid flow for each element can be calculated.
What is structural problem? (APRIL 2013) BTL1
9 Displacement at each nodal point is obtained. By these displacements solution stress and strain in
each element can be calculated.
What are the methods are generally associated with the finite element analysis? BTL1
10
• Force method
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• Displacement or stiffness method.

Explain stiffness method. BTL1
11 Displacement or stiffness method, displacement of the nodes is considered as the unknown of the
problem. Among them two approaches, displacement method is desirable.
What is meant by post processing? BTL1
12 Analysis and evaluation of the solution result is referred to as post processing. Postprocessor
computer program help the user to interpret the result by displaying them in graphical form.
Name the variation methods. BTL1
13 • Ritz method
• Ray-Leigh Ritz method
What is meant by degrees of freedom? BTL1
When the force or reaction act at nodal point node is subjected to deformation. The deformation
14
includes displacement rotation, and or strains. These are collectively known as degrees of
freedom.
What is meant by discretization and assemblage? BTL1
The art of subdividing a structure in to convenient number of smaller components is known as
15
discretization. These smaller components are then put together. The process of uniting the various
elements together is called assemblage.
What is truss element? BTL1
17 The truss elements are the part of a truss structure linked together by point joint which transmits
only axial force to the element.
What is Aspect ratio? BTL1DYARTHIPLUS.COM
• It is defined as the ratio of the largest dimension of the element to the smallest dimension.
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18 • In many cases, as the aspect ratio increases the in accuracy of the solution increases.
• The conclusion of many researches is that the aspect ratio should be close to unity as
possible
What is Rayleigh-Ritz method?BTL1
It is integral approach method which is useful for solving complex structural problem,
19
encountered in finite element analysis. This method is possible only if a suitable function is
available.
What are the h and p versions of finite element method? BTL1
• It is used to improve the accuracy of the finite element method.
• In h version, the order of polynomial approximation for all elements is kept constant and
20
the numbers of elements are increased.
• In p version, the numbers of elements are maintained constant and the order of polynomial
approximation of element isincreased.
PART * B
Find the nodal displacement and elemental stresses for the bar shown in fig.(13M) (APRIL
2015,APRIL 2019) BTL3
1
Answer: page – 1.07 Dr. S.Senthil

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Given
Area of element1= 15 cm2
Length of element1= 75 cm
Find
Nodal displacement
Elemental Stress
Solution
Finite element equation for one dimensional two noded bar element
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(4 M)
(2 M)
Result

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(7 M)
Calculate nodal displacement and elemental stresses for the truss shown in fig. E= 70 Gpa.
Cross sectional area A= 2 cm2 for all truss members. (13 M) (APRIL 2011) BTL3
Given
Youngs modulus = 70 Gpa
Area = 2 cm2
Point load = P sin30◦
Point load = - P cos30◦
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Find
1. Nodal displacement
2. Stress in the member
Solution
(3 M)

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(7 M)
Result
Nodal displacement at node3 = - 0.3256 mm
Nodal displacement at node4 = - 5.110 mm
Elemental stresses at 1= -37.98 N/mm2
Elemental stresses at 2= 272.51 N/mm2
Elemental stresses at 3= 0 N/mm2(3M)
The following differential equation is available for a physical phenomenon AE d 2y/dx2 +q0
=0 with the boundary condition y(0)=0, x=L, dy/dx=0, find the value of f(x) using the
weighted residual method. (13M) (APRIL 2014)BTL3
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(7M)

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(6M)
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We know that, linearly varying pressure acting on the side J, K,N =0 Determine the
expression for the deflection and bending moment in a simply supported beam subjected
to uniformly distributed load over the entire span. Find the deflection and moment at
midspan and compare with exact solution using Rayleigh Ritz method Use y = a1sin (πx/l)
+ a2 sin(3πx/l). (13M) (NOVEMBER 2008)BTL2
4
To find :
1. Deflection and Bending moment at midspan.
2. Compare with exact solutions.
SOLUTION

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(7M)
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(6M)
Explain briefly General steps of the finite element analysis. (13M) (NOVEMBER
2014)BTL2
5 Step 1: Discretization of structure

A bar and beam elements are considered as one dimensional element has two nodes,
one at each end as shown.

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(ii) Two Dimensional element: -

Triangular and Rectangular elements are considered as 2D element. These elements are located
by their own place.
’(4M)
Step 2: Numbering of nodes and elements

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Step 3: selection of a displacement function

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(9M)
PART * C
Find the solution for the following differential equation.
d2y/dx2+50=0, 0<x<10
Trial function is y=a1x(10-x)
Boundary conditions are y(0)=0 Y(10)=0.
Find the value of the parameter a1 by the following methods
(i)point collocations,
(ii)subdomain collocation,
(iii)least square method,
(iv)galerkins (15m) (May 2014) BTL4
1 Answer: page – 1.101 Dr. S.Senthil
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(6M)
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(9M)
Determine the expression for the deflection and bending moment in a simply supported
beam subjected to uniformly distributed load over the entire span. Find the deflection and
moment at midspan and compare with exact solution using Rayleigh Ritz method Use y =
2
a1sin (πx/l) + a2 sin(3πx/l). (15M) (November 2008,APRIL 2019)BTL2

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(5M)
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(5M)

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(5M)
The differential equation of a physical phenomenon is given by d2y/dx2 + 500x2=0 ;0<x<1 by

using the trial function, Y=a1(x-x3) + a2(x-x5), calculate the value of the parameter a1 and a2
by the following methods. (15M)(NOVEMBER 2019)BTL2
(i)point collocation
(ii)subdomain method JIT - JEPPIAAR
(iii)least square
(iv)galerkins

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(10M)
(5M)
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UNIT II ONE-DIMENSIONALPROBLEMS
One Dimensional Second Order Equations – Discretization – Element types- Linear and Higher order
elements – Derivation of Shape functions and Stiffness matrices and force vectors- Assembly of
Matrices - Solution of problems from solid mechanics and heat transfer. Longitudinal vibration
frequencies and mode shapes. Fourth Order Beam Equation –Transverse deflections and Natural
frequencies of beams.
PART * A
Q.No. Questions
When do we resort to 1 D quadratic spar elements? (APRIL 2011) BTL1

(i) Better accuracy.
1.
(ii) Representation of curved boundaries.
(iii) Faster convergence.
What is the difference between static and dynamic analysis?(APRIL 2019) BTL1
a. Static analysis:
The solution of the problem does not vary with time is known as static analysis
2 Example: stress analysis on a beam
b. Dynamic analysis:
The solution of the problem varies with time is known as dynamic analysis.
Example: vibration analysis problem. JIT - JEPPIAAR
Differentiate between global and local axes. BTL1

a. Local axes are established in an element. Since it is in the element level, they change with the
3 change in orientation of the element. The direction differs from element to element.
b. Global axes are defined for the entire system. They are same indirection for all the elements
even though the elements are differently oriented.
Name any four FEA software. BTL1
a. ANSYS
4
b. NASTRAN
c. COSMOS
List the two advantages of post processing. BTL1
5 a. Required result can be obtained in graphical form.
b. Contour diagrams can be used to understand the solution easily and quickly.
During discretization, mention the places where it is necessary to place anode? BTL1
a. Concentrated load acting point
6 b. Cross-section changing point
c. Different material interjections
d. Sudden change in point load
Distinguish between potential energy function and potential energy functional. BTL1
If a system has finite number of degree of freedom (q1, q2,and q3), then the potential energy
7 expressed as,
π = f (q1, q2, and q3)IPLUS.COM
It is known as function. If a system has infinite degrees of freedom, then the potential
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What are the types of loading acting on the structure? BTL1

a. Body force (f)
8
b. Traction force (T)
c. Point load (P)
Define traction force. BTL1
Traction force is defined as distributed force acting on the surface of the body. Unit: Force per
9
unit area.
Example: Frictional resistance, viscous drag, surface shear
Define the body force. BTL1
A body force is distributed force acting on every elemental volume of the body Unit: Force per
10
unit volume.
Example: Self weight due to gravity
What is point load? BTL1
11
Point load is force acting at a particular point which causes displacement
What are the basic steps involved in the finite element modeling.(NOVEMBER 2009)BTL1
12 a. Discretization of structure.
b. Numbering of nodes.
What is discretization? BTL1
13 The art of subdividing a structure in to a convenient number of smaller components is known as
discretization.
What are the classifications of coordinates?(APRIL 2011) BTL1
a. Global coordinates
14
b. Local coordinates JIT - JEPPIAAR
c. Natural coordinates
What is Global coordinates? BTL1
15 The points in the entire structure are defined using coordinates system is known as global
coordinate system.
How do you calculate the size of the global stiffness matrix?(APRIL 2011) BTL1
17
Global stiffness matrix size = Number of nodes X Degrees of freedom per node
What is natural coordinates? BTL1
A natural coordinate system is used to define any point inside theelement by a set of
18
dimensionless number whose magnitude neverexceeds unity. This system is very useful in
assembling of stiffness matrices.
Define shape function. BTL1
Approximate relation φ (x,y) = N1 (x,y) φ1 + N2 (x,y) φ2 + N3(x,y) φ3
Where φ1, φ2, and φ3 are the values of the field variable at the nodes N1, N2, and N3 are the
19
interpolation functions.
N1, N2, and N3 are also called shape functions because they are used to express the geometry or
shape of the element.
What are the characteristic of shape function?(APRIL 2019)BTL1
20 a. It has unit value at one nodal point and zero value at other nodalpoints.
b. The sum of shape function is equal to one.
PART * B
1 Find the nodal displacement developed in the planer truss shown in figure when a
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vertically downward load of 1000 N is applied at node 4. The required data are given in the
Table 1. (13M) (NOVEMBER 2014)BTL2
Find
Nodal displacements
Solution JIT - JEPPIAAR
(8M)
Result
Nodal displacements
U5=0.0265 cm
U6= 0.0088 cm
U7= 0.3479 cm
U8= -0.5600 cm(5M)
Consider the triangular element shown in figure. The element is extracted from a thin
plate of thickness 0.5 cm. The material is hot rolled low carbon steel. The nodal
coordinates are x1 = 0, y1 = 0; xj 0; yj – 1, xk =2, yk = -2. Determine the elemental stiffness
2 matrix. Assuming plane stress analysis, take µ = 0.3 and E = 2.1 x 107 N/cm2. (13M)
(NOVEMBER 2010)BTL2
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Solution
(5M)
Result
JIT - JEPPIAAR
(8M)
What is one dimensional element? Explain their types? (13M) (MAY 2010,NOVEMBER
2019 )BTL2
Bar and beam elements are considered as One Dimensional elements. These
Elements are often used to model trusses and frame structures.
1.Bar, Beam and Truss
Bar is a member which resists only axial loads. A beam can resist axial, lateral and twisting
3 loads. A truss is an assemblage of bars with pin joints and a frame is an assemblage of beam
elements.
2.Stress, Strain and Displacement

Stress is denoted in the form of vector by the variable x as σx, Strain is denoted in the form of
vector by the variable x as ex, Displacement is denoted in the form of vector by the variable x as
ux.(5M)
3. Types of Loading

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(1) Body force (f)

It is a distributed force acting on every elemental volume of the body. Unit is
Force / Unit volume. Ex: Self weight due to gravity.
(2) Traction (T)
It is a distributed force acting on the surface of the body. Unit is Force / Unit area.
But for one dimensional problem, unit is Force / Unit length. Ex: Frictional
resistance, viscous drag and Surface shear.
(3) Point load (P)
It is a force acting at a particular point which causes displacement.
(4)Finite Element Modeling

It has two processes.
(1) Discretization of structure
(2) Numbering of nodes(8M)
The loading and other parameters for a two bar truss element is shown in Fig.
Determine
(i) the element stiffness matrix for each element
(ii) global stiffness matrix
(m) nodal displacements JIT - JEPPIAAR
(iv) reaction forces

(v) the stresses induced in the elements. Assume E = 200 GPa.(13M) BTL 2
Solution

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(3M)
JIT - JEPPIAAR
(10M)
Explain about the beam element and formulate the stiffness matrix. (13M) (NOVEMBER
2009) BTL 2
• A beam is a long, slender structural member generally subjected to transverse loading

that produces significant bending effects as opposed to twisting or axial effects. An
elemental length of a long beam subjected to arbitrary loading is considered for analysis.
• For this elemental beam length L, we assign two points of interest, i.e., the ends of the
5
beam, which become the nodes of the beam element.
• The bending deformation is measured as a transverse (vertical) displacement and a
rotation (slope). Hence, for each node, we have a vertical displacement and a rotation
(slope) – two degrees of freedom at each node.
• For a single 2- noded beam element, we have a total of 4 degrees of freedom. The
associated “forces” are shear force and bending moment at each node.(6M)

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(7M)
PART * C
Find the slopes at the supports and support reaction forces and support reaction moments
JIT - JEPPIAAR
for the beam shown in Figure. Take E=210 GPa, I = 2×10-4 m4(15M) (MAY 2009)BTL3
(6M)
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(6M)
JIT - JEPPIAAR
(3M)
Given that E=210 GPa and I=4×10-4m4, cross section of the beam is constant. Determine
the deflection and slope at point C. calculate the reaction forces and moments. (15M)
(NOVEMBER 2015)BTL2

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(5M)
JIT - JEPPIAAR

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(5M)
JIT - JEPPIAAR
(5M)
Derive the 1-d 2-noded cubic beam element matrices. (15M) (MAY 2009) BTL2
• A single 1-d 2-noded cubic beam element has two nodes, with two degrees of freedom at
3 each node (one vertical displacement and one rotation or slope).
• There is a total of 4 dof and the displacement polynomial function assumed should have
4 terms, so we choose a cubic polynomial for the vertical deflection.
• Slope is a derivative of the vertical deflections. (4M)

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(8M)
JIT - JEPPIAAR
(3M)

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UNIT III TWO DIMENSIONAL SCALAR VARIABLE PROBLEMS
Second Order 2D Equations involving Scalar Variable Functions – Variational formulation –Finite
Element formulation – Triangular elements – Shape functions and element matrices and vectors.
Application to Field Problems - Thermal problems – Torsion of Non circular shafts –Quadrilateral
elements – Higher Order Elements.
PART * A
Q.No. Questions
What are higher order elements and why are they preferred? (APRIL 2011) BTL1
• For any element, if the interpolation polynomial is the order of two or more, that element
is known as higher order elements.
1.
• It is used to represent the curved boundaries.
• The number of elements is reduced when compared with straight edge elements to model
geometry
State the properties of stiffness matrix. BTL1
• It is a symmetric matrix.
2
• The sum of elements in any column must be equal to zero
• It is an unstable element. So, the determinant is equal to zero.
Write down the expression of shape function N and displacement u for one dimensional
bar element.(APRIL 2011) BTL1 JIT - JEPPIAAR
3 U= N1u1+N2u2
N1= 1-X / l N2 = X / l
Define total potential energy.
4
Total potential energy, π = Strain energy (U) + potential energy of the external forces(w)
State the principle of minimum potential energy.(November 2015)BTL1
Among all the displacement equations that satisfied internal compatibility and the boundary
5
condition those that also satisfy the equation of equilibrium make the potential energy a
minimum is a stable system.
What is truss? BTL1
6
A truss is defined as a structure made up of several bars, riveted or welded together.
States the assumption are made while finding the forces in a truss.(APRIL 2012) BTL1
7 • All the members are pin jointed. The truss is loaded only at the joint
• The self weight of the members is neglected unless stated.
State the principles of virtual energy? BTL1
8 A body is in equilibrium if the internal virtual work equals the external virtual work for the
every kinematically admissible displacement field
What is essential boundary condition? BTL1
9 Primary boundary condition or EBC Boundary condition which in terms of field variable is
known as Primary boundary condition.
Naturalboundary conditions? BTL1
10 Secondary boundary natural boundary conditions which are in the differential form of field
variable is known as secondary boundary condition
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How do you define two dimensional elements?(APRIL 2013) BTL1

• Two dimensional elements are defined by three or more nodes in a two dimensional
11
plane.
• The basic element useful for two dimensional analysis is the triangular element.
What is CST element? BTL1
• Three noded triangular elements are known as CST.
12
• It has six unknown displacement degrees of freedom (u1, v1, u2, v2, u3, v3).
• The element is called CST because it has a constant strain throughout it.
What is LST element?(November 2012)BTL1
• Six nodded triangular elements are known as LST.
13
• It has twelve unknown displacement degrees of freedom.
• The displacement function for the elements are quadratic instead of linear as in the CST.
What is QST element?(November 2012)BTL1
14 Ten nodded triangular elements are known as Quadratic strain triangle. It is also called as cubic
displacement triangle.
What meant by plane stress analysis? BTL1
15 Plane stress is defined to be a state of stress in which the normal stress and shear stress directed
perpendicular to the plane are assumed to be zero
Define plane strain analysis.(November 2015)BTL1
16 Plane strain is defined to be state of strain normal to the xy plane and the shear strains are
assumed to be zero.
State the assumption in the theory of pure torsion. (November 2012)BTL1
• The material of the shaft is homogeneous, perfectly elastic and obeys Hooks law.
JIT - JEPPIAAR
• Twist is uniform along the length of the shaft.

17
• The stress does not exceed the limit of proportionality.
• Strain and deformation are small.
Write down the stress-strain relationship matrix for plane strain condition. (November
2012) BTL 1
For plane strain problems, stress-strain relationship matrix is
18
Where, E = Youngs modulus

V = Poisson’s ratio
19 Write a strain-displacement matrix for CST element. (November 2012) BTL2

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Write down the expression for the shape function for a constant straintriangular
element.BTL2
20
PART * B
Derivation of stiffness matrix and finite element equation for a truss element.(13M)
JIT - JEPPIAAR
(NOVEMBER 2009) BTL2

There are two joints for an arbitrarily inclined single truss element (at an angle θ,
positivecounter-clockwise from +vex-axis). For each joint i, there are two degrees of freedom,
i.e.,a joint can have horizontal displacement (u1)and vertical displacement (v1). Hence, for
asingle truss element, there are 4 degrees of freedom. The nodal displacement degrees offreedom
and the nodal force degrees of freedom are shown in the following figure.
(3M)
Note that the deformations occurring in the truss members are so small that they are only axial.
The axial displacement of the truss can be resolved along horizontal x-axis and vertical y-axis.
But in our derivation, let us resolve the horizontal and vertical displacements (in xy-axes) of a
joint along and perpendicular to the truss member (in x y -axes). Refer to the Figure in the
next page. Note sin θcomponent acting towards negative y -direction and all other components
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acting towards in +vex and y directions.
(5M)
JIT - JEPPIAAR
(5M)
Formulate the development of element equation. (13M) (NOVEMBER 2009) BTL2

2

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(6M)
JIT - JEPPIAAR
(7M)
Derive the shape function for the constant strain triangular element. (13M) (November
2012) BTL2
3

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Figure shows a 2-D two-variable linear triangular element with three nodes and the two
dof at each node. The nodes are placed at the corners of the triangle. The two variables (dof) are
displacement in x-direction (u) and displacement in y-direction (v). Since each node has two dof,
a single element has 6 dof. The nodal displacement vector is given by
JIT - JEPPIAAR
(5M)

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(5M)
JIT - JEPPIAAR
(3M)
Determine the stiffness matrix for the straight-sided triangular element of thickness t = 1
mm, as shown. Use E = 70 GPa, n = 0.3 and assume a plane stress condition. (13M)
4 (November 2012) BTL2

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(5M)
JIT - JEPPIAAR
(5M)

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(3M)
Consider a thin plate having thickness t= 0.5 in. being modeled using two CST elements, as
shown. Assuming plane stress condition, (a) determine the displacements of nodes 1 and 2,
and (b) estimate the stresses in both elements. (13M)(November 2012) BTL2
JIT - JEPPIAAR

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(5M)
JIT - JEPPIAAR

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(5M)
JIT - JEPPIAAR

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(3M)
PART * C
For the constant strain triangular element shown in figure. Assemble strain-displacement
matrix. Take t = 20 mm, E = 2 X 105 N / mm2. (15M)(November 2012)BTL3
JIT - JEPPIAAR

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(5M)
JIT - JEPPIAAR
(5M)
(5M)
Determine the shape functions N1, N2 and N3 at the interior point P for the triangular
2 element shown in figure. (15M)(November 2012) BTL3
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JIT - JEPPIAAR
(5M)

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(8M)
Result
JIT - JEPPIAAR
(2M)

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UNIT IV TWO DIMENSIONAL VECTOR VARIABLE PROBLEMS
Equations of elasticity – Plane stress, plane strain and axisymmetric problems – Body forces and
temperature effects – Stress calculations - Plate and shell elements.
PART * A
Q.No. Questions
What is axisymmetric element?(MAY 2008)BTL1

1. Many three dimensional problem in engineering exhibit symmetry about an axis of rotation such
type of problem are solved by special two dimensional element called the axisymmetric element
What are the conditions for a problem to be axisymmetric?BTL1
a. The problem domain must be symmetric about the axis of revolution
2
b. All boundary condition must be symmetric about the axis of revolution
c. All loading condition must be symmetric about the axis of revolution
What is the purpose of Isoparametric element? BTL1
It is difficult to represent the curved boundaries by straight edges finite elements. A large
3
number of finite elements may be used to obtain reasonable resemblance between original body
and the assemblage.
Define super parametric element.(MAY 2008)BTL1
4 If the number of nodes used for defining the geometry is more than of nodes used for defining
the displacement is known as super parametric element.
Define sub parametric element. BTL1 JIT - JEPPIAAR
5 If the number of nodes used for defining the geometry is less than number of nodes used for
defining the displacement is known as sub parametric element.
What is meant by Isoparametric element? BTL1
6 If the number of nodes used for defining the geometry is same as number of nodes used for
defining the displacement is known as Isoparametric element.
Is beam element an Isoparametric element?(MAY 2009)BTL1
7 Beam element is not an Isoparametric element since the geometry and displacement are defined
by different order interpretation functions.
What is simple natural coordinate? BTL1
8
A simple natural coordinate is one whose value between -1 and 1.
Give example for essential boundary conditions.
9
The geometry boundary condition are displacement, slope.
Write down the shape functions for 4 noded rectangular elements using natural
coordinate system.(MAY 2010)BTL1
10 N1 = 1 (1-e)(1-h) N2 = 1 (1+e)(1-h)4 4
N3 = 1 (1 +e)(1+h) N4 = 1 (1 -e)(1 +h)4 4
Give example for non essential boundary conditions. BTL1
11
The natural boundary conditions are bending moment, shear force
What is meant by degrees of freedom? BTL1
When the force or reaction act at nodal point node is subjected to deformation. The deformation
12
includes displacement rotation, and or strains. These are collectively known as degrees of
freedom.
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What is QST element? BTL1

13 Ten noded triangular elements are known as Quadratic strain triangle. It is also called as cubic
displacement triangle.
Write down the stiffness matrix equation for two dimensional CST elements.(MAY
2012)BTL1
Stiffness matrix [K ]=[B ]T [D ][B ]
14
[B]T -Strain displacement
[D]-Stress strain matrix
[B]-Strain displacement matrix
State the assumptions made in the case of truss element. (MAY 2008)
The following assumptions are made in the case of truss element,
15 • All the members are pin jointed.
• The truss is loaded only at the joints
• The self weight of the members are neglected unless stated.
PART * B
Derive the shape function equation for the Axisymmetric element. (13M) (Nov/Dec’10)
BTL2
JIT - JEPPIAAR
(6M)

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JIT - JEPPIAAR
(5M)
(2M)
Derive the Strain Displacement Matrix for the Axisymmetric element. (13M) (November
2011) BTL2
2

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(6M)
JIT - JEPPIAAR

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(7M)
Derive the Stress Strain Relationship matrix for the Axisymmetric triangular element.
(13M) (November 2013) BTL2
JIT - JEPPIAAR
(3M)
(6M)

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(4M)
The nodal co-ordinates for an axisymmetric triangular element are given below. r1= 10
mm, r2= 30 mm, r3= 30 mm z1 = 10 mm, z2 = 10 mm, z3 = 40 mm. Evaluate [B] Matrix for
the element. (13M) (November 2014) BTL2
JIT - JEPPIAAR

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(7M)
JIT - JEPPIAAR
(4M)

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(2M)
The nodal coordinates for an Axisymmetric triangular element are given below r1= 20 mm,
r2= 40 mm , r3= 30 mm z1 = 40 mm, z2 = 40 mm, z3 = 60 mm. Evaluate [B] Matrix for the
element. (13M) (November 2015) BTL2
JIT - JEPPIAAR

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JIT - JEPPIAAR
(6M)

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3-51
(5M)
JIT - JEPPIAAR
(2M)
PART * C
For the element shown in fig, determine the stiffness matrix. Take E = 200Gpa and v =
0.25. The co-ordinates shown in fig are in millimeters. (15M) (November 2013) BTL2
1

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JIT - JEPPIAAR
(3M)

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(6M)
JIT - JEPPIAAR
(6M)
2 For the axisymmetric elements shown in fig, determine the stiffness matrix. Let E = 2.1 x
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105 N/mm2 and v = 0.25. The co-ordinates shown in fig are in millimeters. (15M)
(November 2012) BTL2
JIT - JEPPIAAR
(4M)

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(5M)
JIT - JEPPIAAR

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3-56
JIT - JEPPIAAR
(3M)

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3-57
JIT - JEPPIAAR
(3M)
For the axisymmetric elements shown in fig. Determine the element stresses. Let E = 210
Gpa and v = 0.25. The coordinates are in millimeters. The nodal displacements are u 1=
3 0.05 mm, u2= 0.02 mm, u3= 0 mm, w1 = 0.03 mm, w2 = 0.02 mm, w3 = 0 mm. (13M)
(November 2014) BTL3

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JIT - JEPPIAAR

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3-59
JIT - JEPPIAAR
(5M)

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3-60
JIT - JEPPIAAR
(10M)

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UNIT V ISOPARAMETRIC FORMULATION
Natural co-ordinate systems – Iso parametric elements – Shape functions for iso parametric elements –
One and two dimensions – Serendipity elements – Numerical integration and application to plane stress
problems - Matrix solution techniques – Solutions Techniques to Dynamic problems – Introduction to
Analysis Software.
PART * A
Q.No Questions
What meant by plane stress analysis?(November 2014)BTL1

1. Plane stress is defined to be a state of stress in which the normal stress and shear stress directed
perpendicular to the plane are assumed to be zero.
Define plane strain analysis. BTL1
2 Plane strain is defined to be state of strain normal to the x,y plane and the shear strains are
assumed to be zero.
What is truss element? BTL1
3 The truss elements are the part of a truss structure linked together by point joint which transmits
only axial force to the element.
List the two advantages of post processing. (November 2013) BTL1
4 a. Required result can be obtained in graphical form.
b. Contour diagrams can be used to understand the solution easily and quickly.
What are the h and p versions of finite element method?(NOVEMBER 2019)BTL1
JIT - JEPPIAAR
It is used to improve the accuracy of the finite element method. In h version, the order of
5 polynomial approximation for all elements is kept constant and the numbers of elements are
increased. In p version, the numbers of elements are maintained constant and the order of
polynomial approximation of element is increased.
During discretization, mention the places where it is necessary to place a node? BTL1
a. Concentrated load acting point
6 b. Cross-section changing point
c. Different material inter junction point
d. Sudden change in point load
What is the difference between static and dynamic analysis? BTL1
Static analysis: The solution of the problem does not vary with time is known as static analysis
7 Example: stress analysis on a beam
Dynamic analysis: The solution of the problem varies with time is known as dynamic analysis
Example: vibration analysis problem.
What is meant by discretization and assemblage? BTL1
The art of subdividing a structure in to convenient number of smaller components is known as
8
discretization. These smaller components are then put together. The process of uniting the
various elements together is called assemblage.
What is Rayleigh-Ritz method?(November 2014)BTL1
It is integral approach method which is useful for solving complex structural problem,
9
encountered in finite element analysis. This method is possible only if a suitable function is
available.
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How do you define two dimensional elements? BTL1

10 Two dimensional elements are defined by three or more nodes in a two dimensional plane. The
basic element useful for two dimensional analysis is the triangular element.
State the principles of virtual energy? (November 2015) BTL1
11 A body is in equilibrium if the internal virtual work equals the external virtual work for the
every kinematically admissible displacement field.
Define Eigen value problem. BTL1
12
The problem of determining the constant is called eigen value problem.
What is non-homogeneous form? BTL1
13 When the specified values of dependent variables are non-zero, the boundary condition said to
be non-homogeneous.
What is homogeneous form? BTL1
14 When the specified values of dependent variables is zero, the boundary condition are said to be
homogeneous.
Define initial value problem. BTL1
15 An initial value problem is one in which the dependent variable and possibly is derivatives are
specified initially.
Define boundary value problem. BTL1
16 A differential equation is said to describe a boundary value problem if the dependent variable
and its derivatives are required to take specified values on the boundary.
PART * B
For the isoparametric quadrilateral element shown in fig determine the local co-
ordinates of the point P which has Cartesian co-ordinates (7,4). (13M)(November
JIT - JEPPIAAR
2014)BTL2

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JIT - JEPPIAAR
(3M)
(5M)

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JIT - JEPPIAAR
(5M)
𝟏
Evaluate the integeral 𝑰 = ∫−𝟏(𝟐 + 𝒙 + 𝒙𝟐 ) and compare with exact solution.(13M)BTL2
2
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𝟏
Given integral 𝑰 = ∫−𝟏(𝟐 + 𝒙 + 𝒙𝟐 )
(3M) JIT - JEPPIAAR
(6M)

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(4M)
JIT - JEPPIAAR
Derive the shape functions for 4 noded rectangular parent element by using natural co-
ordinates system and co-ordinate transformation. (13M)(November 2015) BTL2

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JIT - JEPPIAAR
(6M)

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JIT - JEPPIAAR
(7M)
𝟏
Evaluate the integral by using Gaussian Quadrature 𝑰 = ∫−𝟏 𝒙𝟐 𝑑𝑥. (13M)(November
2010,APRIL 2019)BTL2
4

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3-69
JIT - JEPPIAAR
(8M)

5/QB+Keys/Ver1.0
3-70
(5M)
Derive the element stiffness matrix equation for 4 noded isoparametric
quadrilateral element. (13M)(November 2011)BTL2
JIT - JEPPIAAR
(3M)

5/QB+Keys/Ver1.0
3-71
JIT - JEPPIAAR
(5M)

5/QB+Keys/Ver1.0
3-72
JIT - JEPPIAAR

5/QB+Keys/Ver1.0
3-73
JIT - JEPPIAAR
(6M)

5/QB+Keys/Ver1.0
3-74
PART * C
𝟏
Evaluate the integral 𝑰 = ∫−𝟏(𝒙𝟒 − 𝟑𝒙 + 𝟕) 𝑑𝑥. (15M)(November 2011)BTL2
(4M)
1
JIT - JEPPIAAR
(3M)

5/QB+Keys/Ver1.0
3-75
JIT - JEPPIAAR
(6M)
(2M)
𝟏 𝒄𝒐𝒔 𝒙
Evaluate the integral by applying 𝑰 = ∫−𝟏 𝟏−𝒙𝟐 𝑑𝑥3 point Gaussian quadrature.
2 (15M)(November 2011)BTL2
5/QB+Keys/Ver1.0
3-76
JIT - JEPPIAAR
(5M)
(3M)

5/QB+Keys/Ver1.0
3-77
JIT - JEPPIAAR
(7M)
𝟏 𝟏
Evaluate the integral by applying 𝑰 = ∫−𝟏(𝟑𝒆𝒙 + 𝒙𝟐 + 𝒙+𝟐 )𝑑𝑥3 point Gaussian quadrature.
(15M)(November 2014)BTL2
(3M)

5/QB+Keys/Ver1.0
3-78
(5M)
JIT - JEPPIAAR

5/QB+Keys/Ver1.0
3-79
JIT - JEPPIAAR
(7M)

5/QB+Keys/Ver1.0
3-80
ME8693 HEAT AND MASS TRANSFER L T P C

3 2 0 4
OBJECTIVES:
• To understand the mechanisms of heat transfer under steady and transient conditions.
• To understand the concepts of heat transfer through extended surfaces.
• To learn the thermal analysis and sizing of heat exchangers and to understand the basic concepts
of mass transfer.
(Use of standard HMT data book permitted)
UNIT I CONDUCTION 9+6
General Differential equation of Heat Conduction– Cartesian and Polar Coordinates – One Dimensional
Steady State Heat Conduction –– plane and Composite Systems – Conduction with Internal Heat
Generation – Extended Surfaces – Unsteady Heat Conduction – Lumped Analysis – Semi Infinite and
Infinite Solids –Use of Heisler’s charts.
UNIT II CONVECTION 9+6
Free and Forced Convection - Hydrodynamic and Thermal Boundary Layer. Free and Forced Convection
during external flow over Plates and Cylinders and Internal flow through tubes.
UNIT III PHASE CHANGE HEAT TRANSFER AND HEAT EXCHANGERS 9+6
Nusselt’s theory of condensation - Regimes of Pool boiling and Flow boiling. Correlations in boiling and
condensation. Heat Exchanger Types - Overall Heat Transfer Coefficient – Fouling Factors - Analysis –
LMTD method - NTU method.
UNIT IV RADIATION 9+6
Black Body Radiation – Grey body radiation - Shape Factor – Electrical Analogy – Radiation Shields.
Radiation through gases.
UNIT V MASS TRANSFER 9+6
Basic Concepts – Diffusion Mass Transfer – Fick’s Law of Diffusion – Steady state Molecular Diffusion –
Convective Mass Transfer – Momentum, Heat and Mass Transfer Analogy –Convective Mass Transfer
Correlations.
TOTAL : 75 PERIODS
JIT-JEPPIAAR/MECH/Dr.B.RAJESHKUMAR & S.GEJENDHIRAN/IIIrdYr/SEM 06/ME8693/HEAT AND MASS TRANSFER/UNIT 1-

5/QB+Keys/ Ver1.0
4-1
OUTCOMES:
Upon the completion of this course the students will be able to
CO1: Apply heat conduction equations to different surface configurations under steady state and transient
conditions and solve problems
CO2: Apply free and forced convective heat transfer correlations to internal and external flows
through/over various surface configurations and solve problems
CO3: Explain the phenomena of boiling and condensation, apply LMTD and NTU methods of thermal
analysis to different types of heat exchanger configurations and solve problems
CO4: Explain basic laws for Radiation and apply these principles to radiative heat transfer between
different types of surfaces to solve problems
CO5: Apply diffusive and convective mass transfer equations and correlations to solve problems for
different applications
TEXT BOOKS:
1. Holman, J.P., "Heat and Mass Transfer", Tata McGraw Hill, 2000
2. Yunus A. Cengel, "Heat Transfer A Practical Approach", Tata McGraw Hill, 5th Edition 2015
REFERENCES:
1. Frank P. Incropera and David P. Dewitt, "Fundamentals of Heat and Mass Transfer", John Wiley &
Sons, 1998.
2. Kothandaraman, C.P., "Fundamentals of Heat and Mass Transfer", New Age International, New
Delhi, 1998.
3. Nag, P.K., "Heat Transfer", Tata McGraw Hill, New Delhi, 2002
4. Ozisik, M.N., "Heat Transfer", McGraw Hill Book Co., 1994.
5. R.C. Sachdeva, “Fundamentals of Engineering Heat & Mass transfer”, New Age International
Publishers, 2009

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4-2
Subject Code : ME6502 Year/Semester : III/ 06
Subject Name: Heat and Mass Transfer
Subject Handler: Dr.B.Rajeshkumar & S.Gejendhiran
UNIT I CONDUCTION
General Differential equation of Heat Conduction– Cartesian and Polar Coordinates – One Dimensional
Steady State Heat Conduction –– plane and Composite Systems – Conduction with Internal Heat
Generation – Extended Surfaces – Unsteady Heat Conduction – Lumped Analysis – Semi Infinite and
Infinite Solids –Use of Heisler’s charts
PART * A
Q.No. Questions
Define Heat Transfer. BTL1

1. Heat transfer can be defined as the transmission of energy from one region to another region due to
temperature difference.
What are the modes of Heat Transfer?(Nov 2018, Dec 2016, May 2013)BTL2
2
Conduction , Convection , Radiation
Define Conduction. BTL2

Heat conduction is a mechanism of heat transfer from a region of high temperature to a region of
3 low temperature within a medium (solid, liquid or gases) or between different medium in direct
physical contact.
In condition energy exchange takes place by the kinematic motion or direct impact of molecules.
Pure conduction is found only in solids.
Explain Convection (Apr 2012). BTL1
4 Convection is a process of heat transfer that will occur between a solid surface and a fluid medium
when they are at different temperatures.
Convection is possible only in the presence of fluid medium.
Define Radiation. BTL1

5
The heat transfer from one body to another without any transmitting medium is known as radiation.
It is an electromagnetic wave phenomenon.
State Fourier’s Law of conduction. (Dec 2019, May 2017, Dec 2016, May 2014) BTL1
6
The rate of heat conduction is proportional to the area measured – normal to the direction of heat
flow and to the temperature gradient in that direction.

5/QB+Keys/ Ver1.0
4-3
dT dT
Q - A , Q = - KA , where A – are in m2 ,
dx dx
dT
- Temperature gradient in K/m, K – Thermal conductivity W/mK.
dx
Define Thermal Conductivity.(Dec 2016, May 2015) BTL2

7
Thermal conductivity is defined as the ability of a substance to conduct heat.
Write down the equation for conduction of heat through a slab or plane wall. BTL3
Toverall
Heat transfer Q = , Where  T = T1 – T2
R
8
L
R= - Thermal resistance of slab , L = Thickness of slab
KA
K = Thermal conductivity of slab, A = Area
State Newton’s law of cooling or convection law. (Nov 2018, Dec 2016, May 2013)BTL2
Heat transfer by convection is given by Newton’s law of cooling

9 Q = hA (Ts - T) Where , A – Area exposed to heat transfer in m2
h - heat transfer coefficient in W/m2K, Ts – Temperature of the surface in K
T - Temperature of the fluid in K.
Write down one dimensional, steady state conduction equation without internal heat
generation. BTL3
10
 2T
=0
x 2
Write down the general equation for one dimensional steady state heat transfer in slab or
plane wall without heat generation. BTL3
11  2T  2T  2T 1 T
+ + =
x 2 y 2 z 2  t
Where, α thermal diffusivity, Temperature gradient
Define overall heat transfer co-efficient. [April ’12] BTL2

The overall heat transfer by combined modes is usually expressed in terms of an overall
12
conductance or overall heat transfer co-efficient ‘U’.
Heat transfer Q = UA T.

5/QB+Keys/ Ver1.0
4-4
Write down the general equation for one dimensional steady state heat transfer in slab with
heat generation. [Oct. ’16] BTL3
13
 2T  2T  2T q 1 T
+ + + =
x 2 y 2 z 2 K  t
What is critical radius of insulation (or) critical thickness? [Oct. ’17] BTL2
Critical radius = rc Critical thickness = rc – r1
14 Addition of insulating material on a surface does not reduce the amount of heat transfer rate always.
In fact under certain circumstances it actually increases the heat loss up to certain thickness of
insulation. The radius of insulation for which the heat transfer is maximum is called critical radius
of insulation, and the corresponding thickness is called critical thickness.
Explain fins (or) Extended surfaces. BTL2

15
It is possible to increase the heat transfer rate by increasing the surface of heat transfer. The surfaces
used for increasing heat transfer are called extended surfaces or sometimes known as fins.
Define Fin efficiency. [Nov. ’16, Oct. ’17] BTL4

The efficiency of a fin is defined as the ratio of actual heat transfer by the fin to the maximum
16 possible heat transferred by the fin.
Q fin
 fin =
Qmax
Define Fin effectiveness. [Apr. 2012] BTL2

Fin effectiveness is the ratio of heat transfer with fin to that without fin
17
Q with fin
Fin effectiveness =
Qwithout fin
What is meant by Transient heat conduction or unsteady state conduction? BTL2

18 If the temperature of a body varies with time, it is said to be in a transient state and that type of
conduction is known as transient heat conduction or unsteady state conduction.
Explain Lumped heat analysis?[Oct. 16] BTL2

19
In a Newtonian heating or cooling process the temperature throughout the solid is considered to be
uniform at a given time. Such an analysis is called Lumped heat capacity analysis.
What is the significance of Biot number? [Nov.12] BTL2

20 Biot number is used to find Lumped heat analysis, semi-infinite solids and infinite solids
If Bi< 0.1 L → Lumped heat analysis

5/QB+Keys/ Ver1.0
4-5
Bi = →Semi infinite solids
< Bi< 100 → Infinite solids.
What are Heisler charts? (Dec 2019, May 2017, Dec 2016, May 2014)BTL1
21 In Heisler chart, the solutions for temperature distributions and heat flows in plane walls, long
cylinders and spheres with finite internal and surface resistance are presented. Heisler’s charts are
nothing but a analytical solutions in the form of graphs.
Part B
A wall of 0.6m thickness having thermal conductivity of 1.2 W/mK. The wall is to be insulated
with a material having an average thermal conductivity of 0.3 W/mK. Inner and outer surface
temperatures are 1000 C and 10C. Heat transfer rate is 1400 W/m2 calculate the thickness of
insulation. (Nov ‘12)(13 M)-BTL5
Answer: Page 1.26-Dr.S.Senthil
Toverall
Q= [From equation (13)] (or) [HMT Data book page No. 34]
R
Where,
 T = Ta– Tb (or) T1 – T3 (2M)
1 L L L 1
R= + 1 + 2 + 3 + (2M)
ha A K1 A K 2 A K3 A hb A
1 [T1 − T3 ]
Q= (2M)
1 L1 L L 1
+ + 2 + 3 +
ha A K1 A K 2 A K 3 A hb A
Heat transfer coefficient ha, hb and thickness L3 are not given. So neglect that terms.
 Q=
T1 − T3 
L1 L
+ 2
K1 A K 2 A
Q  T1 − T3 
 = 
A L1 L2
+
K1 K 2
1273 − 283
1400 =
0.6 L2
+
1.2 0.3
L2 = 0.0621 m
(7M)
5/QB+Keys/ Ver1.0
4-6
An external wall of a house is made up of 10 cm common brick (K = 0.7 W/mK) followed by a
4 cm layer of zibsum plaster (K = 0.48 W/mK). What thickness of loosely packed insulation (K
= 0.065 W/mK) should be added to reduce the heat loss through the wall by 80%.(13 M) (May
12) -BTL5
Toverall
Heat flow rate Q =
R
Where
1  1 L1 L2 L3 1 
R=  + + + + 
A  ha K1 K 2 K 3 hb 
[The terms ha , hb is not given so neglect that terms]. (3M)
1  L1 L2 L3 
R =  + + 
A  K1 K 2 K 3 
2 Considering two slabs

T
Q= [Assume heat transfer (Q) = 100 W]
L1 L2
+
K1 K 2
(4M)
T
100 =  A = 1m 2 
0.1 0.04
+
0.7 0.48
T = 22.619 K
Heat loss is reduced by 80% due to insulation, so heat transfer is 20 W.
T
Q= [ A = 1m2 ]
1  L1 L2 L3 
 + + 
A  K1 K 2 K 3 
22.619
20 =
1  0.1 0.04 L 
+ + 3
1  0.7 0.48 0.065 
L3 = 0.0588 m
(6M)
A thick walled tube of stainless steel [K = 77.85 kJ/hr mC] 25 mm ID and 50 mm OD is covered with a
25 mm layer of asbestos [K = 0.88 kJ/hr mC]. If the inside wall temperature of the pipe is maintained
at 550C and the outside of the insulator at 45C. Calculate the heat loss per meter length of the pipe.
3
(13 M)(Nov 2018, Dec 2016, May 2013)-BTL5

5/QB+Keys/ Ver1.0
4-7
Heat flow through composite cylinder is given by
Toverall
Q= (2M)
R
Where
 T = Ta– Tb
 r  r  
 In  2  In  3  
+  1+  2+
1  1 r r 1 
R= (5M)
2 L  h a r1 K1 K2 hb r3 
 
 
Convective heat transfer co-efficient are not given so neglect ha and hb terms.
Ta − Tb
Q =
  r2   r3  
 In   In   
1   r1 
+  2 
r
2 L  K1 K2 
 
 
(3M)
Ta − Tb
 Q/L =
  r2   r3  
 In   In   
1   r1 
+  2 
r
2  K1 K2 
 
 
550 - 45
Q/L =
  0.025   0.05  
In In 
1   0.0125  0.025  
 +   (3M)
2  21.625 0.244 
 
Q / L = 1103.9 W/m
A hollow sphere (K = 65 W/mK) of 120 mm inner diameter and 350 mm outer diameter is
covered 10 mm layer of insulation (K = 10 W/mK). The inside and outside temperatures are
500C and 50C respectively. Calculate the rate of heat flow through this sphere.(13 M) –
(Oct ’15) BTL5

4
Heat loss through hollow sphere is given by
Toverall
Q= (2M)
R
Where
 T = Ta– Tb

5/QB+Keys/ Ver1.0
4-8
1  1 1 1 1  1  1 1  1 
R=  +  − +  − + 
4  h a r12
K1  r1 r2  K 2  r2 r3  hb r32 
Ta − Tb (5M)
Q =
1  1 1 1 1 1 1 1
 1 
 +  − +  − + 
4  h a r1 2
K1  r1 r2  K 2  r2 r3  hb r32 
ha, hb not given so neglect that terms.
Ta − Tb
Q=
1 1  1 1  1  1 1 
  −  +  − 
4  K1  r1 r2  k2  r2 r3  
773 -323

1 1  1 1  1  1 1 
− + −
4  65  0.060 0.175  10  0.175 0.185  
 Q = 28361 W
Heat transfer = Q = 28361 W (6M)
A wire of 6 mm diameter with 2 mm thick insulation (K = 0.11 W/mK). If the convective heat transfer
co-efficient between the insulating surface and air is 25 W/m2L, find the critical thickness of insulation.
And also find the percentage of change in the heat transfer rate if the critical radius is used.(13
M)(Dec 2019, May 2017, Dec 2016, May 2014)-BTL5
K
1. Critical radius rc = (2M)
h
0.11
5 rc = = 4.4  10−3 m
25 (2M)
−3
rc = 4.4  10 m
Critical thickness = rc – r1
= 4.4  10−3 − 0.003
= 1.4  10−3 m
Critical thickness t c = 1.4  10-3 (or) 1.4 mm
(2M)
2. Heat transfer through an insulated wire is given by

5/QB+Keys/ Ver1.0
4-9
Ta − Tb
Q1 =
  r2  
 In   
1   r1  1 
+
2 L  K1 hbr2 
 
 
From HMT data book Page No.35

2 L (Ta − Tb )
= (3M)
  0.005  
 In  0.003  
  + 1

 0.11 25  0.005 
 
2 L (Ta − Tb )
Q1 =
12.64
Heat flow through an insulated wire when critical radius is used is given by
Ta − Tb
Q2 = r2 → rc 
  rc  
 In   
1   r1  1 
+
2 L  K1 hbrc 
 
 
2 L (Ta − Tb )
=
 4.4  10 −3 
In  
 0.003  + 1
0.11 25  4.4  10 −3
2 L (Ta − Tb )
Q2 =
12.572 (2M)
Q2 − Q1
 Percentage of increase in heat flow by using Critical radius =  100
Q1
1 1
−  100
= 12.57 12.64
1 (2M)
12.64
= 0.55%

5/QB+Keys/ Ver1.0
4-10
A current of 200 A is passed through a stainless steel wire (K = 19 W/mK) 3 mm in diameter.
The resistivity of the steel may be taken as 70  cm and the length of the wire is submerged
in a liquid at 110C with heat transfer co-efficient h = 4 kW/m2C. Calculate the centre
temperature of the wire. (13 M) – (May 2013) BTL5
The maximum temperature in the wire occurs at the centre.

qr 2
Tmax = Tc = Tw + ........(A) [From Equation No.12]
4K
Resistivity  Length
Re sis tance of wire R =
Area
−2
70  10  10  1
-6
=
 ( 3  10−3 )2
4
R = 0.099 
(3M)
We know that
Q = I2R
6 = (200)2 (0.099)
Q = 3960 W (3M)
Q 3960
Heat generated q = =
V  d2  L
4
3960
q=
4(
 3  10 −3 )  1
2
q = 560  106 W / m3
(3M)
Substituting q value in Equation (A)
560  106  (1.5  10−3 )2

Tmax = Tc = 383 +
4  19
Tc = 399.5 K
(4M)
A sphere of 100 mm diameter, having thermal conductivity of 0.18 W/mK. The outer surface
temperature is 8C and 250 W/m2 of energy is released due to heat source. Calculate
1. Heat generated
7 2. Temperature at the centre of the sphere.(13M) -BTL5
Q
Heat generated q =
V
5/QB+Keys/ Ver1.0
4-11
Q/ A
 q/ A = Here Q/A = 250 W/m2 
V
Q/ A
 q/ A = Here Q/A = 250 W/m2 
V
250
 q/ A =
4 / 3 r 3
q 250
 =
4 r 2
4 / 3 r 3
250  4    (0.050)2
q=
4 / 3  (0.50)3
 q = 15,000 W/m3
(8M)
Temperature at the centre of the sphere
qr 2
Tc = Tw + [From Equation No.16]
6K
15000  (0.050)2
= 281 +
6  0.18
Tc = 315.7 K
(5M)
One end of the long solid rod of 50 mm diameter is inserted into a furnace with the other end
is projecting the atmosphere at 25C. Once the steady state is reached, the temperature of the
rod is measured at two points 20 cm apart are found to be 150C and 100C. The convective
heat transfer co-efficient between the rod and the surrounding air is 30 W/m 2K. Calculate the
thermal conductivity of the rod material.(13M) -BTL5
Since the rod is long, it is treated as long fin. So, temperature distribution
T − T
8 = e− mx (2M)
Tb − T
373 - 298
 = e−m(0.20)
423 - 298
 0.6 = e-m (0.20)
 In (0.6)= -m  (0.20)
 - 0.51 = -m  (0.20)
m = 2.55 m-1 (4M)
We know that,

5/QB+Keys/ Ver1.0
4-12
hP
m= [From HMT data book
KA
(CPK) Page No.41]
hP
2.55 = .............(A)
KA
h – heat transfer co-efficient = 30 W/m2K
P – Perimeter = d =  0.050
P = 0.157 m

A − Area = d2
4

= (0.050)2
4
A = 1.96  10−3 m2 (4M)
30  0.157
(A)  2.55 =
K  1.96  10 −3
30  0.157
 6.50 =
K  1.96  10-3
K = 369.7 W/mK (3M)
An aluminium alloy fin of 7 mm thick and 50 mm long protrudes from a wall, which is
maintained at 120C. The ambient air temperature is 22C. The heat transfer coefficient and
conductivity of the fin material are 140 W/m2K and 55 W/mK respectively. Determine
1. Temperature at the end of the fin.
2. Temperature at the middle of the fin.
3. Total heat dissipated by the fin.(13M) -BTL5
9
T − T cos h m [L -x]
= .......(A)
Tb − T cos h (mL)
(i) Temperature at the end of the fin, Put x = L

5/QB+Keys/ Ver1.0
4-13
T - T cos h m [L-L]
(A)  =
T - T 1
 = ...(1)
where
hP
m= (2M)
KA
P = Perimeter = 2  L (Approx)
= 2  0.050
P = 0.1 m
A – Area = Length  thickness = 0.050  0.007

A = 3.5  10−4 m2
hP
 m=
KA
140  0.1
=
55  3.5  10−4 (3M)
m = 26.96
T - T 1
(1)  =
Tb − T cos h (26.9  0.050)
T - T 1
 =
Tb − T 2.05
T - 295 1
 =
393 - 295 2.05
 T - 295 = 47.8
 T = 342.8 K
Temperature at the end of the fin Tx =L = 342.8 K
(3M)
(ii) Temperature of the middle of the fin,
Put x = L/2 in Equation (A)

5/QB+Keys/ Ver1.0
4-14
T - T cos hm [L-L/2]
(A)  =
 0.050 
cos h 26.9 0.050 -
T - T  2 
 =
Tb − T cos h  26.9  (0.050)
T- 295 1.234
 =
393 - 295 2.049
T - 295
 = 0.6025
393 -295
T = 354.04 K
Temperature at the middle of the fin
Tx =L / 2 = 354.04 K
(2M)
(iii) Total heat dissipated
 Q = (hPKA)1/2 (Tb − T )tan h (mL)

 [140  0.1  55  3.5  10-4 ]1/ 2  (393 − 295)
 tan h (26.9  0.050)
Q = 44.4 W (3 M)
Ten thin brass fins (K = 100 W/mK), 0.75 mm thick are placed axially on a 1 m long and 60
mm diameter engine cylinder which is surrounded by 35C. The fins are extended 1.5 cm
from the cylinder surface and the heat transfer co-efficient between cylinder and atmospheric
air is 15 W/m2K. Calculate the rate of heat transfer and the temperature at the end of fins
when the cylinder surface is at 160C.(13M)(May 2019, Dec 2015)-BTL5

10
Heat transferred Q = (hPKA)1/2 (Tb - T) tan h (mL)….(A)
Where
P – Perimeter = 2  Length of the cylinder
P = 2m
A = Area = length of the cylinder  thickness

A = 0.75  10−3 m2

5/QB+Keys/ Ver1.0
4-15
hP
m=
KA
15  2
= (2M)
100  0.75  10 -3
m = 20
 Q = (hPKA)1/2 (Tb − T ) tan h (mL)
 [15  2  100  0.75  10 −3 ]1/ 2  (433 − 300)

 tan h (20  1.5  10−2 )
Q = 1.5  133  0.29
Q = 58.1 W
(2M)
Heat transferred per fin = 58.1 W

The heat transfer for 10 fins = 58.1  10
Q1 = 581 W ....(B)
Heat transfer from unfinned surface due to convection is

Q2 = h A T
= h  ( dL - 10  t  L) (Tb − T )
[ Area of unfinned surface = Area of cylinder - Area of
(2M)
fin]
= 15  [  0.060  1] − [10  0.75  10 −3  1.5  10 −2 ]
[433 - 300]
Q2 = 375.8 W ..........(C)
So, Total heat transfer Q = Q1 + Q2

Q = 581 + 375.8
Total heat transfer Q = 956.8 W (2M)
Temperature distribution [short fin, end insulated]

T − T cos h m [L-x]
=
Temperature at the end of fin, so put x = L

5/QB+Keys/ Ver1.0
4-16
T-T 1
 =
Tb − T cos h (20  1.5  10-2 )
1
=
0.95
Tb − T
 T - T =
0.95 (5M)
Tb − T
 T = T +
0.95
433 - 300
= 300 +
0.95
T = 440 K
An aluminium cube 6 cm on a side is originally at a temperature of 500C. It is suddenly immersed in

a liquid at 10C for which h is 120 W/m2K. Estimate the time required for the cube to reach a
temperature of 250C. For aluminium  = 2700 kg/m3, C= 900 J/kg K, K = 204 W/mK.(13M) (Nov
2018, Dec 2016, May 2013)-BTL5
For Cube,
L
Characteristic length Lc =
6
0.06
=
6
Lc = 0.01 m
(2M)
11 We know
hLc
Biot number Bi =
K
120  0.01
=
204
Bi = 5.88  10−3  0.1 (3M)
Biot number value is less than 0.1. So this is lumped heat analysis type problem
For lumped parameter system,

 − hA 
T − T  t 
C  V  
= e  ....(1) (3M)
T0 − T
[From HMT data book Page No.48]
We know,
V
Characteristics length Lc =
A
5/QB+Keys/ Ver1.0
4-17
 −h 
 t 
T-T C L  
(1)  = e   c 
T0 − T
 −120 
523 - 283  t 
 = e  9000.012700  (3M)
773 - 283
-120
 In (0.489) = t
900  0.01 2700
 t = 144.86 s
Time required for the cube to reach 250C is 144.86 s. (2M)

A steel ball (specific heat = 0.46 kJ/kgK. and thermal conductivity = 35 W/mK) having 5 cm
diameter and initially at a uniform temperature of 450C is suddenly placed in a control
environment in which the temperature is maintained at 100C. Calculate the time required
for the balls to attained a temperature of 150C. Take h = 10W/m2K. (May 2010)(13M) -BTL5
Density of steel is 7833 kg/m3

 = 7833 kg/ m3
For sphere,
R
Characteristic Length Lc =
3
0.025
=
3
Lc = 8.33  10−3 m
12 (2M)
We know,
hLc
Biot number Bi =
K
10  8.3  10−3
=
35
Bi = 2.38  10-3< 0.1 (2M)
Biot number value is less than 0.1. So this is lumped heat analysis type problem.
For lumped parameter system,

 − hA 
T − T  t 
C  V  
= e  ……….(1) (2M)
T0 − T

We know,
5/QB+Keys/ Ver1.0
4-18
V
A
 −h 
 t 
T-T C L  
(1)  = e   c 
T0 − T
 −10 
423 - 373  −3
t 
 = e  4608.3310 7833  (5M)
723 - 373
423 - 373 −10
 In = t
723 - 373 460  8.33  10 −3  7833
 t = 5840.54 s
Time required for the ball to reach 150C is 5840.54 s. (2M)

A large steel plate 5 cm thick is initially at a uniform temperature of 400C. It is suddenly
exposed on both sides to a surrounding at 60C with convective heat transfer co-efficient of
285 W/m2K. Calculate the centre line temperature and the temperature inside the plate 1.25
cm from themed plane after 3 minutes. (Apr ’13)(13M) -BTL5
For Plate :
L
2
0.05
=
2 (2M)
Lc = 0.025 m
We know,
13
hLc
Biot number Bi =
K
285  0.025
=
42.5
 Bi = 0.1675 (2M)
0.1 < Bi< 100, So this is infinite solid type problem.
Infinite Solids
Case (i)
[To calculate centre line temperature (or) Mid plane temperature for infinite plate, refer
HMT data book Page No.59 Heisler chart].

5/QB+Keys/ Ver1.0
4-19
t
X axis → Fourier number =
Lc 2
1.19  10-5  180
=
(0.025)2 (3M)
X axis → Fourier number = 3.42
hLc
Curve =
K
285  0.025
= = 0.167
42.5
hLc
Curve = = 0.167
K
X axis value is 3.42, curve value is 0.167, corresponding Y axis value is 0.64
T0 − T
Y axis = = 0.64
Ti − T
T0 − T
= 0.64
Ti − T
T0 − T
 = 0.64
Ti − T
T0 − 333
 = 0.64
673 − 333
 T0 = 550.6 K
Center line temperature T0 = 550.6 K
(2M)
Case (ii)
Temperature (Tx) at a distance of 0.0125 m from mid plane
[Refer HMT data book Page No.60, Heisler chart]

hL
X axis → Biot number Bi = c = 0.167
K
x 0.0125
Curve → = = 0.5
Lc 0.025
X axis value is 0.167, curve value is 0.5, corresponding Y axis value is 0.97.

5/QB+Keys/ Ver1.0
4-20
Tx − T
= 0.97 (2M)
T0 − T
Tx − T
Y axis = = 0.97
T0 − T
Tx − T
 = 0.97
T0 − T
Tx − 333
 = 0.97
550.6 − 333
 Tx = 544 K
Temperature inside the plate 1.25 cm from the mid plane is 544 K. (2M)
A steel pipe of 120 mm inner diameter, 140 mm outer diameter with thermal conductivity 55
W/mK is covered with two layers of insulation each having a thickness of 55 mm. The thermal
conductivity of the first insulation material is 0.05 W/mK and that of the second is 0.11
W/mK. The temperature of the inside tube surface is 240C and that of the outside surface of
the insulation is 60C.Calculate the loss of heat per meter length of pipe and the interface
temperature between the two layers of insulation. (May ’12) (13 M) BTL4
Heat flow through composite cylinder is given by
Toverall
14 Q= (2M)
R
Where
 T = Ta– Tb(or) T1-T4 (2M)

𝑟 𝑟 𝑟
𝑙𝑛 2 𝑙𝑛 3 𝑙𝑛 4
𝑟 𝑟2 𝑟3
R= 1/2πL ( 𝐾 1 + + ) (2M)
1 𝐾2 𝐾3
T1−T4
Q/L = 𝑟 𝑟 𝑟
𝑙𝑛 2 𝑙𝑛 3 𝑙𝑛 4
=75.83 W/m (5M)
𝑟 𝑟 𝑟
1/2πL ( 1 + 2 + 3 )
𝐾1 𝐾2 𝐾3
T1−T2
Q/L = 𝑟
𝑙𝑛 2
==➔ T2=512.7 K (1M)
𝑟1
1/2πL ( )
𝐾1

5/QB+Keys/ Ver1.0
4-21
T2−T3
Q/L = 𝑟
𝑙𝑛 3
==➔ T3=372.7 K (1M)
𝑟2
1/2πL ( )
𝐾2
(i) An electric current is passed through a plane wall of thickness 150 mm which generates
heat at the rate of 50000 W/m3. The convective heat transfer coefficient between wall and
ambient air is 65 W/m2K, ambient air temperature is 28C and the thermal conductivity of
the wall material is 22 W/mK. Calculate (i) Surface temperature (ii) Maximum temperature
in the wall. (6M) BTL4
𝑞𝐿
𝑇𝑤 =𝑇∞ + 2ℎ = 358.6 K (3M)
𝑞𝐿2
𝑇𝑚𝑎𝑥 =𝑇𝑤 + = 364.9 K (3M)
8𝑘
(ii) A copper wire of 40 mm diameter carries 250A and has a resistance of 0.25 x 10 -4 ohm
15 cm/length surface temperature of copper wire is 250C and the ambient air temperature is
10C. If the thermal conductivity of the copper wire is 175 W/mK, Calculate (i) Heat transfer
co-efficient between wire surface and ambient air, (ii) Maximum temperature in the wire.
(6M) BTL4
𝑸 𝑾
Q=𝑰𝟐 𝑹 = 𝟏. 𝟓𝟔𝟐 𝑾/𝒄𝒎 = 156 W/m , 𝒒̇ = = 𝟏𝟐𝟒𝟏𝟒𝟎 (1M)
𝑽 𝒎𝟑
𝑞𝑟 2
𝑇𝑚𝑎𝑥 =𝑇𝑤 + = 523.07 K (3M)
4𝑘
𝑟𝑞̇
Surface temperature, 𝑇𝑤 =𝑇∞ + 2ℎ= 5.17 W/𝑚2 𝐾(3M)
Part-C
A wall is constructed of several layers. The first layer consists of masonry brick 20 cm. thick
of thermal conductivity 0.66 W/mK, the second layer consists of 3 cm thick mortar of thermal
1 conductivity 0.6 W/mK, the third layer consists of 8 cm thick lime stone of thermal
conductivity 0.58 W/mK and the outer layer consists of 1.2 cm thick plaster of thermal
conductivity 0.6 W/mK. The heat transfer coefficient on the interior and exterior of the wall

5/QB+Keys/ Ver1.0
4-22
are 5.6 W/m2K and 11 W/m2K respectively. Interior room temperature is 22C and outside air
temperature is -5C.Calculate
a) Overall heat transfer coefficient

b) Overall thermal resistance
c) The rate of heat transfer
d) The temperature at the junction between the mortar and the limestone. (May ’13)(15
M) -BTL5
Answer: Refer Class Notes

Toverall
Heat flow through composite wall is given by Q = [From equation (13)] (or) [HMT
R
Data book page No. 34], Where,  T = Ta– Tb
1 L L L L 1
R= + 1 + 2 + 3 + 4 +
ha A K1 A K 2 A K 3 A K 4 A hb A
Ta − Tb
Q=
1 L1 L2 L L 1
+ + + 3 + 4 +
ha A K1 A K 2 A K 3 A K 4 A hb A (3M)
295 − 268
Q/ A =
1 0.20 0.03 0.08 0.012 1
+ + + + +
5.6 0.66 0.6 0.58 0.6 11
Heat transfer per unit area Q/A = 34.56 W/m2
We know
Heat transfer Q = UA (Ta – Tb) [From equation (14)]
Where U – overall heat transfer co-efficient
Q
U =
A  (Ta − Tb )
34.56
U = (3M)
295 − 268
Overall heat transfer co - efficient U = 1.28 W/m2 K
We know
Overall Thermal resistance (R)
1 L L L L 1
R= + 1 + 2 + 3 + 4 + (1M)
ha A K1 A K 2 A K3 A K 4 A hb A
For unit Area

5/QB+Keys/ Ver1.0
4-23
1 L1 L2 L3 L4 1
R= + + + + +
ha K1 K 2 K 3 K 4 hb
1 0.20 0.03 0.08 0.012 1
= + + + + + (2M)
56 0.66 0.6 0.58 0.6 11
R= 0.78 K / W
Interface temperature between mortar and the limestone T3
Interface temperatures relation
Ta − T1 T1 − T2 T2 − T3 T3 − T4 T4 − T5 T5 − Tb
Q= = = = = =
Ra R1 R2 R3 R4 Rb
Ta − T1
Q=
Ra
295-T1  1 
Q=  Ra = 
1/ ha A  ha A 
295 − T1
Q/ A= (3M)
1/ ha
295 − T1
 34.56 =
1/ 5.6
 T1 = 288.8 K
T1 − T2
Q=
R1
288.8 − T2  L1 
Q=  R1 = 
L1  k1 A 
K1 A

5/QB+Keys/ Ver1.0
4-24
288.8 − T2
Q/ A=
L1
K1
288.8 − T2
 34.56 =
0.20
0.66
 T2 = 278.3 K
T2 − T3
Q =
R2
278.3 − T3  L2 
Q=  R2 = 
L2  K2 A 
K2 A
278.3 − T3
Q/ A=
L2
K2
278.3 − T3
 34.56 =
0.03
0.6
 T3 = 276.5 K (3M)
Temperature between Mortar and limestone (T3 is 276.5 K)
A composite slab is made of three layers 15 cm, 10 cm and 12 cm thickness respectively. The
first layer is made of material with K = 1.45 W/mK, for 60% of the area and the rest of
material with K = 2.5 W/mK. The second layer is made of material with K = 12.5 W/mK for
50% of area and rest of material with K = 18.5 W/mK. The third layer is made of single
material of K = 0.76 W/mK. The composite slab is exposed on one side to warn at 26C and
cold air at -20C. The inside heat transfer co-efficient is 15 W/m2K. The outside heat transfer
co-efficient is 20 W/m2K determine heat flow rate and interface temperatures. (Dec ‘14)(15
M)-BTL5

2 Toverall
Heat flow Q =
R
Where
 T = Ta– Tb
1  1 L1 L2 L3 1 
R=  + + + + 
A  ha K1 K 2 K 3 hb 
1 L L L 1
= + 1 + 2 + 3 + (2M)
Aa ha A1 K1 A2 K 2 A3 K 3 Ab hb
R = R a + R1 + R2 + R3 + Rb

5/QB+Keys/ Ver1.0
4-25
Ta − Tb
Q = ....( A)
R a + R1 + R2 + R3 + Rb
Where
1 1
Ra = =
Aa ha 1 15
Ra = 0.066 K / W
R1a  R1b
R1 = .....(1)
R1a + R1b
L1 0.15
R1a = =
K1a  A1a 1.45  0.6
R1a = 0.1724 K/W
L1 0.15
R1b = =
K1b  A1b 2.5  0.4 (2M)
R1b = 0.15 K/W
Substitute R1a and R1b value in (1)
0.1724  0.15
(1)  R1 =
0.1724 + 0.15
R1 = 0.08 K / W
Similarly,
R2 a  R2b
R2 = .....(2)
R2 a + R2b
L2 0.1
R 2a = =
K 2 a  A2 a 12.5  0.5
R2 a = 0.016 K/W
L2 0.1
R 2b = =
K 2b  A2b 18.5  0.5
R2b = 0.0108 K/W
0.016  0.0108
(2)  R2 =
0.016 + 0.0108
R2 = 0.0064 K / W

5/QB+Keys/ Ver1.0
4-26
L3 0.12
R3 = =  A 3 = 1m 2 
A3 K 3 1 0.76
R3 = 0.15789 K/W
1 1
Rb = =  A b = 1m 2 
Aa hb 1 20
Rb = 0.05 K/W
299 − 253
( A)  Q =
0.066 + 0.08 + 0.0064 + 0.15789 + 0.05 (4M)
Q = 127.67 W
(ii) Interface températures (T1, T2, T3 and T4)
We know
Ta − Tb Ta − T1 T1 − T2 T2 − T3
Q= = = =
R Ra R1 R2
(1M)
T3 − T4 T4 − Tb
= = .....(B)
R3 Rb
Ta − T1
(B)  Q =
Ra
299 − T1
=
0.066
299 − T1
127.67 =
0.066
T1 = 290.57 K
T1 − T2
(B)  Q =
R1
290.57 − T2
127.67 =
0.08
T2 = 280.35 K
T2 − T3
(B)  Q =
R2
280.35 − T3
127.67 =
0.0064
T3 = 279.532 K

5/QB+Keys/ Ver1.0
4-27
T3 − T4
(B)  Q =
R3
279.532 − T4
127.67 = (6M)
0.15789
T4 = 259.374 K
A 12 cm diameter long bar initially at a uniform temperature of 40 C is placed in a medium

at 650C with a convective co-efficient of 22 W/m2K. Determine the time required for the
center to reach 255C. For the material of the bar, K = 20 W/mK, Density = 580 kg/m 3,
specific heat = 1050 J/kg K. (15 M)-BTL5

For cylinder,
R
2
0.06
=
2 (3M)
Lc = 0.03 m
We know,
hLc
Biot number Bi =
K
22  0.03
=
20
3
Bi = 0.033 < 0.1 (3M)
For lumped parameter system, (2M)
 − hA 
T − T  t 
C  V  
= e  ……….(1) (3M)
T0 − T
We know,
V
A
 −h 
 t 
T-T C L  
(1)  = e   c 
T0 − T
 −22t 
528 - 923  
 = e 10500.03580  (4M)
313 - 923
 t = 360.8 s
5/QB+Keys/ Ver1.0
4-28
Alloy steel ball of 2 mm diameter heated to 800C is quenched in a bath at 100C. The material
properties of the ball are K = 205 kJ/m hr K,  = 7860 kg/m3, C = 0.45 kJ/kg K, h = 150 KJ/ hr m2 K.
Determine (i) Temperature of ball after 10 second and (ii) Time for ball to cool to 400C. (15 M)-
BTL5
Case (i) Temperature of ball after 10 sec.
For sphere,
R
3
0.006
=
3 (3M)
Lc = 0.002 m
We know,
hLc
Biot number Bi =
K
41.667  0.002
=
56.94
4
Bi = 1.46  10-3< 0.1 (3M)
For lumped parameter system,(2M)
 − hA 
T − T  t 
C  V  
= e  ……….(1)
T0 − T
We know,
V
A
 −h 
 t 
T-T C L  
(1)  = e   c  ..........(2)
T0 − T
 −41.667 
T - 373  10 
 = e  4500.0027860  (3M)
1073 - 373
 T = 1032.95 K

5/QB+Keys/ Ver1.0
4-29
Case (ii) Time for ball to cool to 400C
T = 400C + 273 = 673 K
 −h 
 t 
T-T C L  
(2)  = e   c  .......(2)
T0 − T
 −41.667 
673 - 373  t 
 = e  4500.0027860  (4M)
1073 - 373
 673 - 373  −41.667
 In   = t
1073 - 373  450  0.002  7860
 t = 143.849 s
A long steel cylinder 12 cm diameter and initially at 20C is placed into furnace at 820C with
h = 140 W/m2K. Calculate the time required for the axis temperature to reach 800C. Also
calculate the corresponding temperature at a radius of 5.4 cm at that time. Physical properties
of steel are K = 21 W/mK,  = 6.11  10-6 m2/s. (15 M)-BTL5
For Cylinder,
R 0.06
Characteristic Length Lc = = (1M)
2 2
Lc = 0.03 m
We know,
hL c
Biot number Bi =
K
5 140  0.03
=
21
 Bi = 0.2
0.1 < Bi<100, So this is infinite solid type problem.(2M)
Infinite Solids
Case (i)
Axis temperature 

(or)  T0 = 800C
Centre line temperature 
To = 800C + 273 = 1073 K
Time (t) ?
[Refer HMT data book Page No.61. Heisler’s chart]

5/QB+Keys/ Ver1.0
4-30
hR
Curve =
K
140  0.06
= = 0.4
21
T0 − T
Y axis =
Ti − T
1073 - 1093
=
293 - 1093
Y axis = 0.025
Curve value is 0.4, Y axis 0.025, corresponding X axis value is 5.
T0 − T
= 0.025
Ti − T
t
 X axis = =5
R2
5  (0.06)2
 t= (6M)
(6.11 10-6 )
t = 2945.9 s
Case (ii)
Intermediate radius r – 5.4 cm = 0.054 m
[Refer HMT data book Page No.62]
r 0.054
Curve = = = 0.9
R 0.06
hR
X axis =
K
140  0.06
= = 0.4
21
Curve value is 0.9, X axis value is 0.4, and corresponding Y axis value is 0.84.
Tr − T
 Y axis = = 0.84
T0 − T

5/QB+Keys/ Ver1.0
4-31
Tr − T
 = 0.84
T0 − T
Tr − 1093
 = 0.84 (6M)
1073 − 1093
 Tr = 1076.2 K
1. Time required for the axis temperature to reach 800C is 2945.9 s.

2. Temperature (Tr) at a radius of 5.4 cm is 1076.2 K

5/QB+Keys/ Ver1.0
4-32
UNIT II CONVECTION
Free and Forced Convection - Hydrodynamic and Thermal Boundary Layer. Free and Forced Convection
during external flow over Plates and Cylinders and Internal flow through tubes.
PART * A
Q.No. Questions
Define Reynolds number (Re). BTL1

1. Inertia force
It is defined as the ratio of inertia force to viscous force. Re =
Viscous force
Define Prandtl number (Pr). BTL1

2 Momentum diffusivity
It is the ratio of the momentum diffusivity of the thermal diffusivity. Pr =
Thermal diffusivity
Define Nusselt number (Nu). BTL1

It is defined as the ratio of the heat flow by convection process under an unit temperature gradient
to the heat flow rate by conduction under an unit temperature gradient through a stationary
3 thickness (L) of metre.
Q
Nusselt number (Nu) = conv .
Qcond
What is Grashoff number? BTL1

It is defined as the ratio of product of inertia force and buoyancy force to the square of viscous
4 force.
Inertia force  Buyoyancy force
Gr =
(Viscous force)2
ExplainNewtonion and non – Newtonion fluids? BTL2

5 The fluids which obey the Newton’s Law of viscosity are called Newtonion fluids and those which
do not obey are called non – newtonion fluids.
What is meant by laminar flow and turbulent flow? BTL2

Laminar flow: Laminar flow is sometimes called stream line flow. In this type of flow, the fluid
moves in layers and each fluid particle follows a smooth continuous path. The fluid particles in each
layer remain in an orderly sequence without mixing with each other.
6
Turbulent flow: In addition to the laminar type of flow, a distinct irregular flow is frequency
observed in nature. This type of flow is called turbulent flow. The path of any individual particle is
zig – zag and irregular. Fig. shows the instantaneous velocity in laminar and turbulent flow.
State Newton’s law of convection. BTL2

7
Heat transfer from the moving fluid to solid surface is given by the equationQ = h A (Tw – T) ,This
equation is referred to as Newton’s law of cooling. Where , h – Local heat transfer coefficient in
5/QB+Keys/ Ver1.0
4-33
W/m2K, A – Surface area in m2,Tw – Surface (or) Wall temperature in K, T - Temperature of fluid
in K.
Define free or natural convection.(AUMay2004,Dec2004,June 2006, May 2004)BTL2

8 If the fluid motion is produced due to change in density resulting from temperature gradients, the
mode of heat transfer is said to be free or natural convection.
Define forced convection.(AU May 2004, Dec 2004, June 2006, May 2004) BTL2
9 If the fluid motion is artificially created by means of an external force like a blower or fan, that type
of heat transfer is known as forced convection.
Define boundary layer thickness. BTL2

10 The thickness of the boundary layer has been defined as the distance from the surface at which the
local velocity or temperature reaches 99% of the external velocity or temperature.
Give the form of equation used to calculate heat transfer for flow through cylindrical pipes.
11 BTL3
Nu = 0.023 (Re)0.8 (Pr)n , n = 0.4 for heating of fluids, n = 0.3 for cooling of fluids
Name the dimensionless parameters used in forced convection. BTL2

12 1. Reynolds number (Re)
2. Nusselt number (Nu)
3. Prandtl number (Pr)
Define hydrodynamic boundary layer. BTL2
13
In hydrodynamic boundary layer, velocity of the fluid is less than 99% of free stream velocity.
14
Explain thermal boundary layer. BTL2
In thermal boundary layer, temperature of the fluid is less than 99% of free stream velocity.
Define Stanton number (St). BTL1

It is the ratio of Nusselt number to the product of Reynolds number and Prandtl number.
15
Nu
St =
Re Pr
Indicate the significance of boundary layer. BTL2

In boundary layer concept the flow field over a body is divided into two regions: (i) A thin region
16 near the body called the boundary layer where the velocity and the temperature gradients are large.
(ii) The region outside the boundary layer where the velocity and the temperature gradients are very
nearly equal to their free stream values.
An electrically heated plate dissipates heat by convection at a rate of 8000 W/m2 in to the
ambient air at 25ºC. If the surface of the hot plate is at 125ºC, calculate the heat transfer
17 coefficient for convection between the plate and air. (Nov 2018, Dec 2016, May 2013)BTL 4.
Heat Transfer Q=hA(Tw-Tα), 8000= h x 1 (398-298) = 80 W/m2K.

5/QB+Keys/ Ver1.0
4-34
Sketch the boundary development of a plate.BTL 1
18
Define displacement thickness.BTL 2

19 The displacement thickness is the distance, measured perpendicular to the boundary, by which the
free stream is displaced on account of formation of boundary layer.
Explainmomentum thickness? (Dec 2019, May 2017, Dec 2016, May 2014)BTL 2
20
The momentum thickness is defined as the distance through which the total loss of momentum per
second be equal to if it were passing a stationary plate.
Define energy thickness. BTL 1

21
The energy thickness can be defined as the distance, measured perpendicular to the boundary of the
solid body, by which the boundary should be displaced to compensate for the reduction in kinetic
energy of the flowing fluid on account of boundary layer formation.
Part-B
Air at 20C, at a pressure of 1 bar is flowing over a flat plate at a velocity of 3 m/s. if the plate
maintained at 60C, calculate the heat transfer per unit width of the plate. Assuming the
length of the plate along the flow of air is 2m. (13 M)-BTL5
Tw + T
Film temperature Tf =
2
60 + 20
1 =
2
Tf = 40C
Properties of air at 40C:
Density  = 1.129 Kg/m3
Thermal conductivity K = 26.56  10−3 W / mK,
Kinematic viscosity v = 16.96  10−6 m2 / s.

5/QB+Keys/ Ver1.0
4-35
Prandtl number Pr = 0.699
We know,
UL
Reynolds number Re =
v
32
=
16.96  10 −6
= 35.377  10 4
Re = 35.377  104  5  105 (4 M)
Reynolds number value is less than 5  105, so this is laminar flow.

For flat plate, Laminar flow,
Local Nusselt Number Nux = 0.332 (Re)0.5 (Pr)0.333
Nux = 0.332 (35.377  10 4 )0.5  (0.699)0.333

Nux = 175.27
We know that,
hs  L
Local Nusselt Number Nux =
K
hs  2
 175.27 =
26.56  10−3
Local heat transfer coefficient hx = 2.327 W/m2K (4 M)
We know, Average heat transfer coefficient h = 2 hx

h = 2  2.327 =➔h = 4.65 W/m2K
Heat transfer Q = h A (Tw - T)

= 4.65  2 (60 − 20)
[ Area = width  length = 1 2 = 2]
Q = 372 Watts. (5 M)
Air at 20C at atmospheric pressure flows over a flat plate at a velocity of 3 m/s. if the plate is
1 m wide and 80C, calculate the following at x = 300 mm. 1. Hydrodynamic boundary layer
thickness, 2. Thermal boundary layer thickness, 3. Local friction coefficient,4. Average
2 friction coefficient, 5. Local heat transfer coefficient, 6. Average heat transfer coefficient,7.
Heat transfer.(13 M)BTL5

5/QB+Keys/ Ver1.0
4-36
Tw + T
2
80 + 20
=
2
Tf = 50C
Properties of air at 50C
Density  = 1.093 kg/m3
Kinematic viscosity v = 17.95  10 -6m2 / s
Pr andt l number Pr =0.698
Thermal conductivity K = 28.26  10 -3 W / mK
UL
We know, Reynolds number Re =
v
3  0.3
=
17.95  10−6
Re = 5.01 104  5  105 (4 M)
Since Re < 5  105, flow is laminar

For Flat plate, laminar flow,
1. Hydrodynamic boundary layer thickness:
 hx = 5  x  (Re)−0.5
= 5  0.3  (5.01 104 )−0.5
 hx = 6.7  10−3 m (1 M)
2. Thermal boundary layer thickness:
 TX =  hx (Pr)−0.333
( )
  TX = 6.7  10−3 (0.698)−0.333
 TX = 7.5  10−3 m (1 M)
3. Local Friction coefficient:
Cfx = 0.664(Re)−0.5
= 0.664 (5.01 104 )−0.5
Cfx = 2.96  10-3 (1 M)
4. Average friction coefficient:

5/QB+Keys/ Ver1.0
4-37
CfL = 1.328 (Re)-0.5

= 1.328 (5.01 10 4 )−0.5
= 5.9  10-3
(1 M)
CfL = 5.9  10 −3
5. Local heat transfer coefficient (hx):

Local Nusselt Number
Nux = 0.332 (Re)0.5 (Pr)0.333
= 0.332 (5.01 104 ) (0.698)0.333

Nux = 65.9
We know
hx  L
Nux =
K
hx  0.3
65.9 =  x = L = 0.3m
23.26  10 −3
 hx = 6.20 W/m2K (1 M)
Local heat transfer coefficient h x = 6.20 W / m2K
6. Average heat transfer coefficient (h):
h = 2  hx
= 2  6.20
h = 12.41 W / m2K (2 M)
7. Heat transfer:
We know that,
Q = h A(Tw − T )
= 12.41 (1 0.3) (80-20)
Q = 23.38 Watts (2 M)
Air at 30C, Flows over a flat plate at a velocity of 4 m/s. The plate measures 50  30 cm and is
3 maintained at a uniform temperature of 90C. Compare the heat loss from the plate when the
air flows (a) Parallel to 50 cm, (b) Parallel to 30 cm, Also calculate the percentage of heat
loss. (13 M)BTL5

5/QB+Keys/ Ver1.0
4-38
Tw + T
2
90 + 30
=
2
Tf = 60C
Properties of air at 60C,
 = 1.060 Kg/m3
 = 18.97  10 −6 m2 / s
(2 M)
Pr = 0.696
K = 28.96  10-3 W/mK
Case (i) :When the flow is parallel to 50 cm.
UL
v
4  0.50
=
18.97  10 −6
Re = 1.05  105  5  105 (2 M)
Since Re <5  10 ,flow is laminar
5
Local nusselt number NUx = 0.332(Re)0.5(Pr)0.333
NUx =0.332 (1.05  105 )

0.5
 (0.696)0.333
Local nusseltnumberNUx =95.35

We know
h xL
NUx =
K
hx  0.50
95.35 = (3 M)
28.96  10−3
Local heat transfer coefficient hx = 5.52 W/m2K
We know
Average heat transfer coefficient h = 2  hx (2 M)

5/QB+Keys/ Ver1.0
4-39
 h = 2  5.52
h = 11.04 W/m2K
Heat transfer Q1 = h A(Tw − T )
= 11.04  (0.5  0.3)  (90 − 30)
Q1 = 99.36 W (1 mark)
Case (ii) :When the flow is parallel to 30 cm side.
UL
v
4  0.3
=
18.97  10 −6
Re = 6.3  104  5  105
Since Re<5  105 , flow is laminar
For flat plate, laminar flow,

NUx = 0.332 (Re)0.5 (0.696)0.333

= 0.332 (6.32  10 4 )0.5 (0.696)0.333
NUx = 74.008
h xL
We know that, NUx =
K
hx  0.30
74.008 =
28.96  10−3 (1 M)
 hx = 7.141 W/m2K
Local heat transfer coefficient h x = 7.141 W/m2K
Average heat transfer coefficient h = 2hx

5/QB+Keys/ Ver1.0
4-40
h = 2  7.14
h = 14.28 W/m2K
We know
Heat transfer Q 2 = h  A  (Tw − T )
= h  L  W (Tw − T )
= 14.28  0.3  0.5  (363 − 303)
Q2 = 128.5W (1 M)
Case (iii):
Q2 − Q1
% heat loss =  100
Q1
128.5-99.36
=  100 (1 M)
99.36
% heat loss = 29.3%
Air at 290C flows over a flat plate at a velocity of 6 m/s. The plate is 1m long and 0.5 m wide.
The pressure of the air is 6 kN/m2. If the plate is maintained at a temperature of 70C,
estimate the rate of heat removed from the plate. (13 M)(Nov 2018, Dec 2016, May 2013)BTL5
Tw + T
We know , Film temperature Tf =
2
70 + 290
=
2
4 Tf = 180C
Properties of air at 180C (At atmospheric pressure)
 = 0.799 Kg/m3
 = 32.49  10-6 m2 / s
Pr = 0.681
K = 37.80  10-3 W/mK
Patm
Kinematic viscosity  =  atm  (2 M)
Pgiven

5/QB+Keys/ Ver1.0
4-41
1 bar
  = 32.49  10 −6
6  103N / m2
 Atmospheric pressure = 1 bar 
105 N / m2
= 32.49  10 −6 
6  103 N / m3
 1 bar = 1 105N/ m2 
Kinematic viscosity v = 5.145  10-4m2 / s.
We know,
UL
v
6 1
=
5.145  10 −4
Re = 1.10  104 − 5  105
Since Re< 5  105 , flow is laminar (4 M)
For plate, laminar flow,

Local nusselt number
NUx = 0.332 (Re)0.5 (Pr)0.333

= 0.332 (1.10  10 4 )0.5 (0.681)0.333
NUx = 30.63
h xL
We know, NUx=
K
hx  1
30.63 = [ L = 1 m]
37.80  10−3
Local heat transfer coefficient h x = 1.15 W/m2K (2 M)
We know
Average heat transfer coefficient h = 2hx
h = 2  1.15
(2 M)
h = 2.31 W/m2K

5/QB+Keys/ Ver1.0
4-42
We know
Heat transferred Q = h A (T − Tw )
= 2.31 (1 0.5)  (563 − 343)
Q = 254.1 W
Heat transfer from both side of the plate = 2  254.1= 508.2 W. (3 M)
Air at 15C, 30 km/h flows over a cylinder of 400 mm diameter and 1500 mm height with
surface temperature of 45C. Calculate the heat loss.(13 M)(Dec 2019, May 2017, Dec 2016,
May 2014)BTL5

We know
Tw + T
2
Tf = 30C
UD
Reynolds Number Re =
v
8.33  0.4
=
16  10−6
5
ReD = 2.08  105
(4 M)
We know
Nusselt Number Nu = C (Re)m (Pr)0.333
 NU = 0.0266  (2.08  105)0.805 (0.701)0.333
NU = 451.3
We know that,
hD
Nusselt Number NU =
K
h  0.4
 451.3 =
26.75  10-3
 h = 30.18 W/m2K (4 M)

5/QB+Keys/ Ver1.0
4-43
Heat transfer coefficient h = 30.18 W/m2K

Heat transfer Q = hA (Tw − T )
= h    D  L  (Tw − T )
[ A =  DL]
= 30.18    0.4  1.5  (45 -15)
Q = 1706.6 W (5 M)
Air at 30C, 0.2 m/s flows across a 120W electric bulb at 130C. Find heat transfer and power
lost due to convection if bulb diameter is 70 mm.(13 M)(May 2019, Dec 2015)BTL5
Tw + T
1. Film temperature Tf =
2
130 + 30
=
2
Tf = 80C
 = 1 Kg/m3
 = 21.09  10-6 m2 / s
Pr = 0.692
6 K = 30.47  10-3 W/mK
We know
UD

0.2  0.070
= = 663.82
21.09  10−3
Re = 663.82 (4 M)
We know
Nusselt Number Nu = 0.37 (Re)0.6
= 0.37 (663.82)0.6
Nu = 18.25
We know

5/QB+Keys/ Ver1.0
4-44
hD
Nusselt number Nu =
K
h  0.070
 18.25 =
30.47  10-3
 h = 7.94 W/m2K (4 M)
Heat transfer coefficient h = 7.94 W/m2K
We know
Heat transfer Q2 = h A (Tw - T)
= h  4 r 2 [Tw − T ] [ A = 4 r 2 ]
2
 0.070 
= 7.94  4       (130 − 30)
 2 
Heat transfer Q2 = 12.22 W
Q2
2. % of heat lost =  100
Q1
12.22
=  100
120
= 10.18% (5 M)
Air at 40C flows over a tube with a velocity of 30 m/s. The tube surface temperature is 120C.
Calculate the heat transfer for the following cases. 1. Tube could be square with a side of 6
cm.2. Tube is circular cylinder of diameter 6 cm.(13 M) BTL 5
7 We know,
Tw − T
2
120 + 40
=
2

5/QB+Keys/ Ver1.0
4-45
Tf = 80C
 = 1 Kg/m3
(2 M)
 = 21.09  10-6 m2 / s
Pr = 0.692
K = 30.47  10-3 W/mK
Case (i): Tube is considered as square of side 6 cm

i.e., L = 6cm = 0.06m
UL
v
30  0.06
=
21.09  10 −6
Re = 0.853  105
Nusselt Number Nu = C  (Re)n (Pr)0.333
For square, n = 0.675
(4 M)
C = 0.092
 Nu = 0.092 (0.853  105 )0.675  (0.692)0.333
 Nu = 173.3
hL
We know that, NU =
K
h  0.06
173.3 =
30.47  10−3
Heat transfer coefficient h = 88 W/m2K
Case (ii)
Tube diameter D = 6cm = 0.06 m
UD

30  0.06
= (2 M)
21.09  10 −6
Re = 0.853  105
Nusselt number Nu = C (ReD )m (Pr)0.333
Re value is 0.853  105 , so corresponding C and m values are 0.0266 and 0.805 respectively.

5/QB+Keys/ Ver1.0
4-46
 Nu = 0.0266  (0.853  105 )0.805  (0.692)0.333
Nu = 219.3 (3 M)
hD
We know Nu =
K
h  0.06
 219.3
30.47  10-3
 h = 111.3 W/m2K
 Heat transfer coefficient h = 111.3 W/m2K (2 M)
When 0.6 Kg of water per minute is passed through a tube of 2 cm diameter, it is found to be
heated from 20C to 60C. The heating is achieved by condensing steam on the surface of the
tube and subsequently the surface temperature of the tube is maintained at 90C. Determine
the length of the tube required for fully developed flow. (13 M) (Dec 2016) BTL5
Tmi + Tmo
Bulk mean temperature Tm =
2
20 + 60
=
2
Tm = 40C
Properties of water at 40C:
 = 995 Kg/m3
 = 0.657  10 -6m2 / s
8
Pr = 4.340
K = 628  10-3 W/mK
CP = 4.178 KJ/KgK = 4178 J/KgK
Mass flow rate m =  A U
m
 U=
A
0.01
=

995 (0.02)2
4
Velocity U = 0.031 m/s (4 M)
Let us first determine the type of flow

UD
Re =


5/QB+Keys/ Ver1.0
4-47
0.031 0.02
 Re =
0.657  10−6
Re = 943.6 (2 M)
Since Re < 2300, flow is laminar
For laminar flow,

Nusselt number NU = 3.66
We know
hD
NU =
K
h  0.02
 3.66 =
628  10-3
 h = 114.9 W/m2K
Heat transfer Q = mCP t
= mCP (Tmo − Tmi )
= 0.01 4178  (60-20)
Q = 1671.2 W (2 M)
We know that Q = h A 
= h    D  L  (Tw − Tm )
= 1671.2 =114.9    0.02  L  (90-40)
L = 4.62m (5 M)
Water at 50C enters 50 mm diameter and 4 m long tube with a velocity of 0.8 m/s. The tube
wall is maintained at a constant temperature of 90C. Determine the heat transfer coefficient
and the total amount of heat transferred if exist water temperature is 70C.(13 M) BTL5
9
Tmi + Tmo
Bulk mean temperature Tm =
2

5/QB+Keys/ Ver1.0
4-48
50 + 70
=
2
Tm = 60C
Properties of water at 60C:
 = 985 Kg/m3
 = 0.478  10-6m2 / s
Pr = 3.020
K = 651.3  10-3 W/mK
Let us first determine the type of flow:
UD
Re =

0.8  0.05
=
0.478  10-6
Re = 8.36  104
Since Re > 2300, flow is turbulent (4 M)
L 4
= = 80
D 0.05
L
= 80 > 60
D
Re = 8.36  10 4  10,000
Pr = 3.020  0.6 < Pr < 160
L
ratio is greater than 60. Re value is greater than 10,000 and Pr value is in between 0.6 and 160 so,
D
(3 M)
Nusselt number NU = 0.023 (Re)0.8 (Pr)n
[Inlet temperature 50C, Exit temperature 70C
 Heating Process, So n = 0.4]
 Nu = 0.023  (8.36  10 4 )0.8  (3.020)0.4

Nu = 310
hD
We know that Nu=
K
h  0.05
310 =
651.3  10 −3

5/QB+Keys/ Ver1.0
4-49
Heat transfer coefficient h = 4039.3 W/m2K (2 M)
Heat transfer Q = h A (Tw – Tm)
= h    D  L  (Tw − Tm )
= 4093.3    0.05  4  (90 - 60)
Q = 76139 W (4 M)
Air at 333K, 1.5 bar pressure, flow through 12 cm diameter tube. The surface temperature of
the tube is maintained at 400K and mass flow rate is 75 kg/hr. Calculate the heat transfer
rate for 1.5 m length of the tube. (13 M) BTL5

 = 1.060 Kg/m3
 = 18.97  10-6 m2 / s
Pr = 0.696 (2 M)
K = 28.96  10-3 W/mK
UD

We know
Mass flow rate m p  U

10

0.020 = 1.060   D2  U
4

 0.020 = 1.060   (0.12)2  U
4
 U = 1.668 m/s
UD
(1)  Re =

1.668  0.12
=
18.97  10-6
Re = 10551.3 (2 M)
Since Re > 2300, so flow is turbulent
For turbulent flow, general equation is (Re>10000)
Nu = 0.023  (Re)0.8  (0.696)0.4
Nu = 32.9 (3 M)

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hD
We know Nu =
K
h  0.12
 32.9 =
28.96  10-3
 h = 7.94 W/m2K
Heat transfer rate Q = h A (Tw − Tm )
= h  (  D  L)  (Tw − Tm )
= 7.94  (  0.12  1.5)  (127 − 60)
Q = 300.82 W (3+3 M)
A vertical plate of 0.7 m wide and 1.2 m height maintained at a temperature of 90ºC in a room
at 30ºC. Calculate the convective heat loss.(13 M) BTL4
Properties of air at Tf=60ºC(2M)
𝑔𝛽𝐿3 ∆𝑇
𝐺𝑟 = = 8.4 𝑥 109 (2M)
𝜗2
𝐺𝑟. 𝑃𝑟 =5.9 x 109 > 109 Turbulent flow (2M)

Nusselt number, Nu = 0.10 (Gr.Pr)0.333 =179.3 (2M)
Nu = hl/K ➔ h=4.32 W/m2K (2M)
Heat loss Q = hA(Tw-Tα)=218.16 W (3M)
Part-C
For a particular engine, the underside of the crank case can be idealized as a flat plat
measuring 80 cm  20 cm. The engine runs at 80 km/hr and the crank case is cooled by air
flowing past it at the same speed. Calculate the loss of heat from the crank case surface of
temperature 75C to the ambient air temperature 25C. Assume the boundary layer becomes
1
turbulent from the loading edge itself.(15 M)(Nov 2018, Dec 2016, May 2013)BTL5

1. Heat loss

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Tw + T 75 + 25
Film temperature Tf = =
2 2
Tf = 50C
 = 1.093 Kg/m3 (2 M)
 = 17.95  10 m / s
-6 2
Pr = 0.698
K = 28.26  10 −3 W/mK
We know
UL
Re ynolds number Re =
v
22.22  0.8
= [ L = 0.8m]
17.95  10−6
Re = 9  105
Re = 9  105  5  105
Since Re>5  105 , Flow is turbulent (2 M)
Local Nusselt number} NUx = 0.0296 (Re)0.8 (Pt)0.333

NUx = 1524.6
hxL
We know that, NUx =
K
hx  0.8
1524.6 = [ L = 0.8m]
28.26  10−3
hx = 53.85 W/m2K (5 M)
Local heat transfer coefficient} hx= 53.85 W/m2K
For turbulent flow, flat plate
Average heat transfer coefficient} h = 1.24 hx
h = 1.24  53.85 (3 M)
h = 66.78 W/m2K
We know,
Heat loss Q = h A (Tw - T)

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= 66.78  0.16 (75 – 25)
Q = 534.2 W (3 M)
Air at 30C, 6 m/s flows over a rectangular section of size 300  800 mm. Calculate the heat
leakage per meter length per unit temperature difference.(15 M) BTL5
:
 = 1.165 Kg/m3
 = 16  10-4 m2 / s
Pr = 0.701
K = 26.75  10-3 W / mK
Equivalent diameter for 300  800 mm2 cross section is given by
4A 4  (0.3  0.8)
De = =
P 2 (0.3 + 0.8)
Where P - Perimeter = 2 (L+W)
 De = 0.436 m (3 M)
2
UDe

6  0.436
=
16  10−6
Re = 16.3  10 4 (3 M)
Since Re > 2300, flow is turbulent.
For turbulent flow general equation is (Re > 10000)
Nu = 0.023 (Re)0.8 (Pr)n
Assuming the pipe wall temperature to be higher than a temperature. So heating process 
n = 0.4
 Nu = 0.023 (16.3  104 )0.8 (0.701)0.4

Nu = 294.96
We know

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hDe
Nusselt Number Nu =
K
h  0.436
 294.96 =
26.75  10-3
Heat transfer coefficient  h = 18.09 W/m2K (5 M)

Heat leakage per unit per length per unit temperature difference
Q=hP
= 18.09  2  (0.3 + 0.8
Q = 39.79 W (4 M)
250 Kg/hr of air are cooled from 100C to 30C by flowing through a 3.5 cm inner diameter
pipe coil bent in to a helix of 0.6 m diameter. Calculate the value of air side heat transfer
coefficient if the properties of air at 65C are K = 0.0298 W/mK ; = 0.003 Kg/hr – m ;Pr =
0.7 ; = 1.044 Kg/m3.(15 M) BTL5
UD


Kinematic viscosity  =

0.003
Kg / s − m
3
3600
1.044 Kg/m3
v = 7.98  10 −7 m2 / s (2 M)
Mass flow rate in =  A U

0.056 = 1.044   D2  U
4
 U = 55.7 m/s
UD
(1)  Re =

55.7  0.035
=
7.98  10-7
Re = 2.44  106 (3 M)

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Nu = 0.023  (Re)0.8  (Pr)0.3
This is cooling process, so n = 0.3
(4 M)
 Nu = 0.023  (2.44  106 )0.8  (0.7)0.3
Nu = 2661.7
hD
We know that, Nu =
K
h  0.035
2661.7 =
0.0298
Heat transfer coefficient h = 2266.2 W/m2K (4 M)
Engine oil flows through a 50 mm diameter tube at an average temperature of 147C. The
flow velocity is 80 cm/s. Calculate the average heat transfer coefficient if the tube wall is
maintained at a temperature of 200C and it is 2 m long. (15 M)BTL5
Properties of engine oil at 147C
UD

0.8  0.05
4 =
7  10−6
Re = 5714.2 (5 M)
Since Re < 2300 flow is turbulent
L 2
= = 40
D 0.050
L
10   400
D
For turbulent flow, (Re < 10000)

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0.055
0.8 0.33 D
Nusselt number Nu = 0.036 (Re) (Pr) L
 
0.055
 0.050 
Nu = 0.036 (5714.2)0.8
 (116)0.33
 
 2 
Nu = 142.8
hD
We know Nu =
K
h  0.050
 142.8 =
133.8  10-3
 h = 382.3 W/m2K (5+5 M)
A thin 100 cm long and 10 cm wide horizontal plate is maintained at a uniform temperature
of 150ºC in a long tank full of water at 75ºC. Estimate the rate of heat to be supplied to the
plate to maintain constant plate temperature as heat is dissipated from either side of the plate.
(15M) BTL4
Properties of air at Tf=112.5ºC(2M)
𝑔𝛽𝐿𝑐 3 ∆𝑇
𝐺𝑟 = = 1.0853 𝑥 109 (2M)
𝜗2
𝐺𝑟. 𝑃𝑟 =1.682 x 109 > 109 Gr.Pr values lies between 8x106<Gr.Pr<1011(2M)
5
For horizontal plate, upper surface heated,
Nu=hulc/K ➔ h=2419.7W/m2K (2M)
For horizontal plate, lower surface heated,
Nu=hllc/K ➔h=746.94 W/m2K (2M)
Heat loss Q = (hu+hl)A(Tw-Tα)=(hu+hl)(WxL)(Tw-Tα)=23749.8 W (3M)

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UNIT III PHASE CHANGE HEAT TRANSFER AND HEAT EXCHANGERS
Nusselt’s theory of condensation - Regimes of Pool boiling and Flow boiling. Correlations in boiling
and condensation. Heat Exchanger Types - Overall Heat Transfer Coefficient – Fouling Factors -
Analysis – LMTD method - NTU method.
PART * A
Q.No. Questions
Define boiling. BTL1

1.
The change of phase from liquid to vapour state is known as boiling.
What is meant by condensation? BTL2

2
The change of phase from vapour to liquid state is known as condensation.
Give the applications of boiling and condensation. BTL2

Boiling and condensation process finds wide applications as mentioned below.
3
1. Thermal and nuclear power plant.
2. Refrigerating systems
3. Process of heating and cooling Air conditioning systems
Define pool boiling. BTL2
If heat is added to a liquid from a submerged solid surface, the boiling process referred to as
4 pool boiling. In this case the liquid above the hot surface is essentially stagnant and its motion
near the surface is due to free convection and mixing induced by bubble growth and
detachment.
What are the modes of condensation? BTL2
5 There are two modes of condensation

1. Film wise condensation
2. Drop wise condensation
What is meant by Film wise condensation?[(Dec 2016, May 2015)BTL2
6 The liquid condensate wets the solid surface, spreads out and forms a continuous film over the
entire surface is known as film wise condensation.
Write short note on drop wise condensation. [April 2000 MU Oct 2000 MU] BTL2
7 In drop wise condensation the vapour condenses into small liquid droplets of various
sizes which fall down the surface in a random fashion.
8 What is heat exchanger? BTL2

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A heat exchanger is defined as an equipment which transfers the heat from a hot fluid to a cold
fluid.
Give classifications of heat exchanger.BTL2

The types of heat exchangers are as follows
1. Direct contact heat exchangers
9 2. Indirect contact heat exchangers
3. Surface heat exchangers
4. Parallel flow heat exchangers
5. Counter flow heat exchangers
6. Cross flow heat exchangers
7. Shell and tube heat exchangers
8. Compact heat exchangers.
What is meant by Direct heat exchanger (or) open heat exchanger? BTL2
10 In direct contact heat exchanger, the heat exchange takes place by direct mixing of hot and
cold fluids.
What is meant by Indirect contact heat exchanger? BTL2

11 In this type of heat exchangers, the transfer of heat between two fluids could be carried out by
transmission through a wall which separates the two fluids.
What is meant by Regenerators?(Dec 2019, May 2017, Dec 2016, May 2014) BTL2
12
In this type of heat exchangers, hot and cold fluids flow alternately through the same
space.Examples: IC engines, gas turbines.
Define recuperators (or) surface heat exchangers.BTL2

13 This is the most common type of heat exchangers in which the hot and cold fluid do not come
into direct contact with each other but are separated by a tube wall or a surface.
What is meant by parallel flow heat exchanger? BTL2

14
In this type of heat exchanger, hot and cold fluids move in the same direction.
What is meant by counter flow heat exchanger? BTL2

15
In this type of heat exchanger hot and cold fluids move in parallel but opposite directions.
What is meant by cross flow heat exchanger? BTL2

16
In this type of heat exchanger, hot and cold fluids move at right angles to each other.
What is shell and tube heat exchanger? BTL2

17
In this type of heat exchanger, one of the fluids move through a bundle of tubes enclosed by a
shell. The other fluid is forced through the shell and it moves over the outside surface of the
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tubes.
Define compact heat exchangers. (Dec 2016, May 2015) BTL2
18 There are many special purpose heat exchangers called compact heat exchangers. They are
generally employed when convective heat transfer coefficient associated with one of the fluids
is much smaller than that associated with the other fluid.
What is meant by LMTD? BTL2

We know that the temperature difference between the hot and cold fluids in the heat exchanger
varies from point in addition various modes of heat transfer are involved. Therefore based on
concept of appropriate mean temperature difference, also called logarithmic mean temperature
19 difference, also called logarithmic mean temperature difference, the total heat transfer rate in
the heat exchanger is expressed as
Q = U A (T)m , Where , U – Overall heat transfer coefficient W/m2K
A – Area m2 , (T)m – Logarithmic mean temperature difference
What is meant by Fouling factor? BTL2

We know the surfaces of a heat exchangers do not remain clean after it has been in use for
20 some time. The surfaces become fouled with scaling or deposits. The effect of these deposits
the value of overall heat transfer coefficient. This effect is taken care of by introducing an
additional thermal resistance called the fouling resistance.
Part- B
Water is to be boiled at atmospheric pressure in a polished copper pan by means of an

electric heater. The diameter of the pan is 0.38 m and is kept at 115C. Calculate the
following, 1. Power required to boil the water, 2. Rate of evaporation, 3. Critical heat
flux. (13 M)BTL4
1
We know saturation temperature of water is 100C
i.e. Tsat = 100C
Properties of water at 100C

(From HMT data book Page No.13)

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Density 1 = 961 kg/m3
Kinematic viscosity  = 0.293  10 -6 m2 / s
Prandtl number Pr = 1.740
Specific heat cpl = 4.216 kj/kg K = 4216/Kg K
Dynamic viscosity 1 = 1 
= 961 0.293  10-6
1 = 281.57  10 −6 Ns/m2
From steam table R.S. Khurmi Steam table Page No.4 (1 M)
At 100C, Enthalpy of evaporation hfg = 2256.9 kj/kg, hfg = 2256.9  103 j/kg
Specific volume of vapour, vg = 1.673 m3/kg
1
v =
vg
1
Density of vapour,
1.673
 v = 0.597 kg / m3
 = Excess temperature = Tw − Tsat = 115 − 100 = 15C
T = 15C  50C. So this process is nucleate pool boiling.

1. Power required to boil the water.
For nucleate boiling
3
Q g  (1 − v ) Cpl  T
Heat flux = l  hfg 
a  Csf  hfgPr1.7
Q
(1)  = 281.57  10−6  2256.9  103
A

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4-60
0.5
9.81 961 − 597
58.8  10 −3
3
4216  T
.013  2256.9  10   (1.74)1.7
Q
Heat flux = 151.1 10 3 W/m 2
A
Heat transfer Q = 151.1 10 3  A

= 151.1 103  d2
4

= 151.1 103  (0.38)2
4
Q = 17.1 10 W 3
Q = 17.1 103 = p
power = 17.1 103 W (4 M)
2. Rate of evaporation (m)

We know heat transferred
Q = m hfg
Q 17.1 103
m= =
hfg 2256.9  103 (4 M)
m = .0075 kg / s
3. Critical heat flux

We know for nucleate pool boiling. Critical heat flux
Q   g  (l -  )
= 0.18 hfg   0.25
A v2
From HMT data book Page No.142

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0.18  2256.9  103  0.597
0.25
58.8  10 −3  9.81 961 − .597
.5972
Q (4 M)
= 1.52  106 w/m2
A
Q
Critical Heat flux q = 1.52  10 6 w/m 2
A
Water is boiled at the rate of 24 kg/h in a polished copper pan, 300 mm in diameter, at
atmospheric pressure. Assuming nucleate boiling conditions calculate the temperature of
the bottom surface of the pan. (13 M) (Dec 2016) BTL4
We know saturation temperature of water is 100C
i.e. Tsat = 100C
Properties of water at 100C

Density l = 961 kg/m3

Kinematic viscosity v = 0.293  10-6 m2 / s
2 Pr andtl number Pr − 1.740
Specific heat Cpl = 4.216 kj/kg K = 4216 j/kg K
Dynamic viscosity l = l  v
= 961 0.293  10-6
L = 281.57  10 −6 Ns/m2
From steam table (R.S. Khumi Steam table Page No.4)
At 100C
Enthalpy of evaporation hfg = 2256.9 kj/kg
hfg = 2256.9  103 j/kg
Specific volume of vapour, Vg = 1.673 m3/kg

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1
v =
vg
1
Density of vapour, (3 M)
1.673
 v = 0.597 kg/m3
For nucleate boiling

3
Q g  ( l −  v ) Cpl  T
Heat flux = l  hfg 
A  Csf  hfgPr1.7
We know transferred Q = m  hfg
Heat transferred Q = m  hfg.
Q mhg
=
A A
Q 6.6  10 −3  2256.9  103

=
A  2
d
4
6.6  10-3  2256.9  103
=
 (5 M)
(.3)2
4
Q
= 210  103 w / m2
A
 = surface tension for liquid vapour interface
At 100C (From HMT data book Page No.147)
 = 58.8  10−3 N/ m
For water – copper – Csf = Surface fluid constant = 013
Csf = .013 (From HMT data book Page No.145)
Q
Substitute, l, hfg, l,  v,  , Cpl, hfg, and Pr values in Equation (1)
A

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(1)  210  103 = 281.57  10 −6  2256.9  103
0.5
9.81 961 − 597
58.8  10 −3
3
4216  T
.013  2256.9  103  (1.74)1.7
4216  T
 = 0.825
75229.7
 T(.56)3 = .825
 T  .056 = 0.937
T - 16.7 (5 M)
We know that
Excess temperature T = Tw − Tsat
16.7 = Tw − 100C.
Tw = 116.7C
Water is boiling on a horizontal tube whose wall temperature is maintained ct 15C

above the saturation temperature of water. Calculate the nucleate boiling heat transfer
coefficient. Assume the water to be at a pressure of 20 atm. And also find the change in
value of heat transfer coefficient when, The temperature difference is increased to 30C
at a pressure of 10 atm, The pressure is raised to 20 atm at  T = 15C (13 M) (Jun ’12)
BTL4
We know that for horizontal surface, heat transfer coefficient
h = 5.56 (T)3 From HMT data book Page No.128

3 h = 5.56 (Tw – Tsat)3
= 5.56 (115 – 100)3
h = 18765 w/m2K (2 M)
Heat transfer coefficient other than atmospheric pressure

hp = hp0.4 From HMT data book Page No.144
= 18765  100.4
Heat transfer coefficient hp = 47.13  103 W / m2K (2 M)

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Case (i)
P = 100 bar T = 30C From HMT data book Page No.144

Heat transfer coefficient
h = 5.56 ( T)3 = 5.56(30)3

(2 M)
h = 150  103 W / m2K

hp = hp0.4
= 150  103 (10)0.4

(3 M)
hp = 377  103 W / m2K
Case (ii)
P = 20 bar; T = 15C
Heat transfer coefficient h = 5.56 (T)3 = 5.56 (15)3
h = 18765 W/m2K

hp = hp0.4
= 18765 (20)0.4
hp = 62.19  103 W/m2K (4 M)
Dry saturated steam at a pressure of 3 bar, condenses on the surface of a vertical tube of
height 1m. The tube surface temperature is kept at 110C. Calculate the following, 1.
Thickness of the condensate film, 2. Local heat transfer coefficient at a distance of 0.25m.
(13 M)BTL4
4
Properties of steam at 3 bar
From steam table R.S. Khurmi steam table Page No.10)
Tsat = 133.5C
hfg = 2163.2 kj/kg = 2163.2  103 j/kg

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Tw + Tsat
We know that Tf =
2
110+133.5
Film temperature =
2
Tf = 121.75C
Properties of saturated water at 121.75C
 = 945 kg/m3
 = 0.247  10-6m2 / s
(4 M)
k = 685  10-3 W/mk
 =   = 945  0.247  10-6
For vertical surfaces,

0.25
 4 K  x  (Tsat − Tw ) 
x =  
 g  h   2
 fg  (2 M)
 = 2.33  10−4 Ns / m2
 4  2.33  10−4  685  10−3  0.25  133.5 − 110 

 
 9.81 2163.2  103  9452  (2 M)
Thickness  x = 1.18  10-4m
k
Local heat transfer coefficient hx =
x
635  10−3
hx =
1.18  10 −4 (5 M)
hx = 5775.2 W/m K 2
A vertical tube of 65 mm outside diameter and 1.5 m long is exposed to steam at

atmospheric pressure. The outer surface of the tube is maintained at a temperature of
5
60C by circulating cold water through the tube. Calculate the following, 1. The rate of
heat transfer to the coolant, 2. The rate of condensation of steam.(13M) BTL4

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Enthalpy of evaporation
hfg = 2256.9 kj/kg = 2256.9  103 j / kg
We know
Tw + Tsat
2
60 + 100
=
2
Tf = 80C
Properties of saturated water at 80C

 - 974 kg/m3
 = 0.364  10-6 m2 / s
k = 668.7  10-3 W / mK (4 M)
 =   = 974  0.364  10 -6
 = 354.53  10-6 Ns/m2
Assuming that the condensate film is laminar

For laminar flow, vertical surface heat transfer coefficient
0.25
 K 3  2hfg 
h = 0943 
 L(T − T ) 
(2 M)
 sat w 

The factor 0.943 may be replaced by 1.13 for more accurate result as suggested by Mc Adams
( )
0.25
 668.7  10−3 3  (974)2  9.81 2256.9  103 
1.13  
 −6
354.53  10  1.5  100 − 60  (2 M)
 
h = 4684 W/m k.2

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Q = hAT
= hA(Tsat − Tw )
= h    D  L  (Tsat − Tw )
= 4.684    .065  1.5  100-60
Q = 57.389 W
ii) The rate of condensation of steam m

We know Heat transfer Q = m hfg
Q
m=
hfg
57,389
m=
2256.9  103
m = 0.0254 kg/s
Let us check the assumption of laminar film condensation. We know
4m
p P = Perimeter = D =  0.0065 = 0.204 m
Where
4  .0254
Re =
0.204  354.53  10−6 (5 M)
Re = 1406.3 < 1800
So our assumption laminar flow is correct.
A vertical flat plate in the form of fin is 500m in height and is exposed to steam at
atmospheric pressure. If surface of the plate is maintained at 60C. calculate the
following.1. The film thickness at the trailing edge,2. Overall heat transfer coefficient, 3.
Heat transfer rate, 4. The condensate mass flow rate.Assume laminar flow conditions and
unit width of the plate. (13 M)(Dec 2019, May 2017, Dec 2016, May 2014)BTL4
6 Answer: Page 3.37-Dr.S.Senthil
Tw + Tsat
2
60 + 100
=
2
Tf = 80C

5/QB+Keys/ Ver1.0
4-68
 - 974 kg/m3
v = 0.364  10−6 m2 / s
k = 668.7  10-3 W/mk

 = p  v= 974  0.364  10-6
 = 354.53  10−6 Ns / m2 (3 M)
1. Film thickness x
We know for vertical plate
Film thickness
0.25
 4K  x  (Tsat − Tw ) 
x =  
 g  hfg   2
 
Where, X = L = 0.5 m
4  354.53  10−6  668.7  10−3  0.5  100 − 60

x =
9.81 2256.9  103  9742 (3 M)
 x = 1.73  10−4 m
2. Average heat transfer coefficient (h)

For vertical surface Laminar flow
0.25
 k 3   2  g  hfg 
h = 0.943  
   L  Tsat − Tw 
The factor 0.943 may be replace by 1.13 for more accurate result as suggested by Mc Adams
0.25
 (668.7  10−3 )3  (974)2  9.81 2256.9  103 
1.13  
 354.53  10−6  1.5  100 − 60  (3 M)
h = 6164.3 W/m k. 2
3. Heat transfer rate Q

We know

5/QB+Keys/ Ver1.0
4-69
Q = hA(Tsat − Tw )
= h  L  W  (Tsat − Tw )
(2 M)
= 6164.3  0.5  1 100-60
Q = 123286 W
4. Condensate mass flow rate m

We know
Q = m  hfg
Q
m=
hfg
(2 M)
1.23.286
m=
2256.9  103
m = 0.054 kg/s
A horizontal tube of outer diameter 2.2 cm is exposed to dry steam at 100C. The pipe
surface is maintained at 62C by circulating water through it. Calculate the rate of
formation of condensate per meter length of the pipe.(13 M) BTL4
Tw + Tsat
Tf =
2
62+100
Film temperature =
2
Tf = 81C = 80C
7
 − 974 kg/m3
 = .364  10-6 m2 / s
k = 668.7  10-3 W/mk (3 M)
 =   = 974  .364  10 -6
 = 354.53  10-6 Ns/m2
For horizontal tubes heat transfer coefficient.

5/QB+Keys/ Ver1.0
4-70
0.25
 K 3  2g hfg 
h = 0.728  
  D(Tsat − Tw ) 

0.25
 (668.7  10-3 )3  (974)2  9.81 2256.9  103 
h = 0.728  
 354.53  10−6  2.2  10−2  (100 − 62)  (4 M)
h = 8783.4 W/m2K
We know
Heat transfer Q
hA (Tsat − Tw )
h   DL  (Tsat − Tw )
= 8783.4    2.2  10 −2  1 (100 - 62) (3 M)
L = 1m
Q = 23.068.5 W
We know , Q = mhfg
Q
m=
hfg
23.0685
m= = 0.010 kg/s (3 M)
2256.9  103
m = 0.010 kg/s
In a counter flow double pipe heat exchanger, oil is cooled from 85C to 55C by water
entering at 25C. The mass flow rate of oil is 9,800 kg/h and specific heat of oil is 2000
j/kg K. the mass flow rate of water is 8,000 kg/h and specific heat of water is 4180 j/kg K.
Determine the heat exchanger area and heat transfer rate for an overall heat transfer
coefficient of 280 W/m2 K. (13 M)(Dec 2016) BTL4.
8
Heat lost by oil Hot fluid = Heat gained by water cold fluid
Qh = Qc

5/QB+Keys/ Ver1.0
4-71
mhCph (T1 − T2 ) = mc Cpc (t 2 − t1 )
2.72  2000 (85-55)=2.22  4180  (t 2 − 25)
163.2  103 = 9279.6 t 2 − 231.9  10 3 (4 M)
t 2 = 42.5C
Exit temperature of water t 2 = 42.5C
Heat transfer Q =mc Cpc (t 2 − t1 ) (or) mhCph (T1 − T2 )

Q = 2.22  4180  (42.5 − 25) (4 M)
Q = 162  10 W 3
Q = UA (T)m........1

For counter flow
(T1 − t1 ) - (T2 − t 2 )
( T)m =
T −t 
In  1 1 
 T2 − t 2 
(2 M)
(85 − 42.5) - (55 − 25)
( T)m =
 85 − 42.5 
In 
 55 − 25 
( T)m = 35.8C
Substitute (T)m U and Q values in Equation (1)
(1)  Q = UA (T)m
 162  103 = 280  A  35.8 (3 M)
 A = 16.16 m2
Water flows at the rate of 65 kg/min through a double pipe counter flow heat exchanger.
Water is heated from 50C to 75C by an oil flowing through the tube. The specific heat
of the oil is 1.780 kj/kg K. The oil enters at 115C and leaves at 70C. The overall heat
9 transfer coefficient is 340 W/m2 K. Calculate the following, 1. Heat exchanger area, 2.
Rate of heat transfer (13 M)BTL4

5/QB+Keys/ Ver1.0
4-72
Heat transfer Q = mc Cpc (t 2 − t1 ) (or)
mhCph (T1 − T2 )
Q = mc Cpc (t 2 − t1 )
(4 M)
Q = 1.08  4186  (75 − 50)
Specific heat of water Cph − 4186 j/kg K
Q = 113  103 W
We know
Heat transfer Q = U  A (T)m (3 M)

From HMT data book Page No., 154
Where
(T)m – Logarithmic Mean Temperature Difference. LMTD

For Counter flow
(T1 − t1 ) − (T2 − t 2 )
( T)m =
T −t 
In  1 1 
 T2 − t 2 
(3 M)
(115 − 75) − (70 − 50)
(T)m =
115 − 75 
In 
 70 − 50 
( T)m = 28.8C
Substitute (T)m Q and U values in Equation (1)
(1)  Q =UA (T)m

 113  103 = 340  A  28.8 (3 M)
 A = 11.54 m2
In a double pipe heat exchanger hot fluid with a specific heat of 2300 J/kg K enters at
380C and leaves at 300C. cold fluid enters at 25C and leaves at 210C. Calculate the
heat exchanger area required for
10
1. Parallel flow 2. Counter flow
Take overall heat transfer coefficient is 750 w/m2 K and mass flow rate of hot fluid is 1
kg/s. (13 M) BTL4

5/QB+Keys/ Ver1.0
4-73
Case (i)
For parallel flow
(T1 − t1 ) − (T2 − t 2 )
( T)m =
T −t 
In  1 1 
 T2 − t 2 
(380 − 25) − (300 − 210)
(T)m =
 380 − 25 
In 
 300 − 210 
( T)m = 193.1C
Heat transfer Q = mc Cpc (t 2 − t1 ) (or)

mhCph (T1 − T2 )
Q = mc Cpc (t 2 − t1 )
= 1 2300  380 − 300
Q = 184  103 W

We know that
Q = U  A (T)m
Heat transfer 184  103 = 750  A  193.1
Area for parallel flow A = 1.27 m2 (3+3 M)

Case (ii)
For counter flow

5/QB+Keys/ Ver1.0
4-74
(T1 − t 2 ) − (T2 − t1 )
( T)m =
T − t 
In  1 2 
 T2 − t1 
(5 M)
(380 − 210) − (300 − 25)
(T)m =
 380 − 210 
In 
 300 − 25 
( T)m = 218.3C
We know that,
Heat transfer Q = UA (T)m
 184  103 = 750  A  218.3

(2 M)
Area for counter flow A = 1.12 m2
Part –C
A nickel wire carrying electric current of 1.5 mm diameter and 50 cm long, is submerged
in a water bath which is open to atmospheric pressure. Calculate the voltage at the burn
out point, if at this point the wire carries a current of 200A. (15 M)(Dec 2016) BTL4
hfg − 2256.9 kj / kg
hfg = 2256.9  103 j/kg
v g = 1.673m3 / kg
1 1
v = = = 0.597 kg/m3
g 1.673
1  = Surface tension for liquid – vapour interface
At 100C
 = 58.8  10−3 N/m (From HMT data book Page No.147)

For nucleate pool boiling critical heat flux (AT burn out)
Q    g  (l -  v)0.25 
= 0.18  hfg   v   − − − −1 (5 M)
A  v2 

5/QB+Keys/ Ver1.0
4-75
Substitute hfg, l,  v,  values in Equation (1)
Q
(1)  = 0.18  2256.9  103  0.597
A
0.25
 58.8  10 −3  9.81 (961 − .597) 
  (5 M)
 .5972 
Q
= 1.52  106 W/m2
A
We know , Heat transferred Q = V  I
Q V I
=
A A
V  200
1.52  106 = A =  dL
 dL (5 M)
V  200
1.52  106 =
  1.5  10-3  .50
V = 17.9 volts
A heating element cladded with metal is 8 mm diameter and of emissivity is 0.92. The
element is horizontally immersed in a water bath. The surface temperature of the metal
is 260C under steady state boiling conditions. Calculate the power dissipation per unit
length for the heater. (15 M)(Dec 2016) BTL4
Answer: Refer class notes
T = Tw − Tsat
Excess temperature,
T = 260 − 100
T= 160C  50C

2
So this is film pool boiling
Tw + Tsat
2
260 + 100
=
2
Tf = 180C
Properties of water vapour at 180C


5/QB+Keys/ Ver1.0
4-76
 v = 5.16 kg/m3
K v = 32.68  10 −3 w/mK
(5 M)
Cpv = 2.709 kj/kgK =2709 j/kg K
 v = 15.10  10-6 Ns/m2
l = 961 kg/m3 (From HMT data book Page No.13)

From steam table At 100C. (R.S. Khurmi Steam
table Page No.4)
hfg = 2256.9  103 j / kg (3 M)
In film pool boiling heat is transferred due to both convection and radiation.
3
Heat transfer coefficient h = hconv + hrad − − − 1
4
(
 K 3v  v  ( v − v )  g  hfg + 0.4 ( Cpv T ) )
0.25

hconv = 0.62  
  vDT 
 
 (32.68  10−3 )  5.16  961 − 5.16  9.81

 
 2256.9  103 + 0.4  2709  160)f 
hconv = 0.62 (3 M)
 15.10  10−6  8  10 −3  160 
 
 
0.25
 4.10  106 
hconv = 0.62  −5 
1.93  10 
hconv = 421.02 W/m2K........2
 Tw − Tsat
4

hrad =  
 Tw − Tsat 
−8  (260 + 273)4 − (100 + 273)4 

hrad = 5.67  10  0.92    (2 M)
 260 + 273 − 100 + 273 

5/QB+Keys/ Ver1.0
4-77
Stefan boltzmann constant
 = 5.67  10−8 W/m2K 4

hrad = 20W / m2K............3
Substitute (2) (3) in (1)
3
1  h = 421.02 + (20)
4
h = 436.02 W/m2K
Heat transferred Q = hA (Tw − Tsat )

= h    D  L (Tw − Tsat )
(3 M)
= 4366.02    8  10-3  1 260 − 100
Q = 1753.34 W/m L = 1m
Or
Power dissipation = 1753.34 W/m. (2 M)
Steam at 0.080 bar is arranged to condense over a 50 cm square vertical plate. The
surface temperature is maintained at 20C. Calculate the following.
a. Film thickness at a distance of 25 cm from the top of the plate.
b. Local heat transfer coefficient at a distance of 25 cm from the top of the plate.
c. Average heat transfer coefficient.
d. Total heat transfer
e. Total steam condensation rate.
f. What would be the heat transfer coefficient if the plate is inclined at 30C with
horizontal plane.(15 M)-BTL4
3 Answer: Refer class notes
Tw + Tsat
2
20+41.53
=
2
Tf = 30.76C
Properties of saturated water at 30.76C = 30C


5/QB+Keys/ Ver1.0
4-78
 − 997 kg/m3
 = 0.83  10-6 m2 / s
k = 612  10-3 W / mK (2 M)
 = p  v = 997  0.83  10 −6
 = 827.51 10 −6 Ns / m2
a. Film thickness
We know for vertical surfaces
0.25
 4 K  x  (Tsat − Tw ) 
x =  
 g  h   2
 fg 
(From HMT data book Page No.150) (2 M)
−6 −3
4  827.51 10  612  10  .25  (41.53 − 20)100
x =
9.81 2403.2  103  997 2
 x = 1.40  104 m
b. Local heat transfer coefficient hx Assuming Laminar flow
k
hx =
x
612  10 −3
hx = (3 M)
1.46  10 −4
hx = 4,191 W/m2K
c. Average heat transfer coefficient h

(Assuming laminar flow)
0.25
 k 3   2  g  hfg 
h = 0.943   (3 M)
   L  Tsat − Tw 
The factor 0.943 may be replaced by 1.13 for more accurate result as suggested by Mcadams
0.25
 k 3  2g hfg 
h = 0.943  
   L  Tsat − Tw 
Where L = 50 cm = .5 m

5/QB+Keys/ Ver1.0
4-79
0.25
(612  10−3 )3  (997)2  9.81 2403.2  103
h = 1.13
827.51 10−6  .5  41.53 − 20 (2 M)
h = 5599.6 W/m2k
d. Heat transfer (Q), We know , Q = hA(Tsat – Tw)
h  A  (Tsat − Tw )
= 5599.6  0.25  (41.53 − 20 (3 M)
Q = 30.139.8 W
The outer surface of a cylindrical vertical drum having 25 cm diameter is exposed to

saturated steam at 1.7 bar for condensation. The surface temperature of the drum is
maintained at 85C. Calculate the following, Length of the drum, Thickness of
condensate layer to condense 65 kg/h steam. (15 M)(Dec 2015)-BTL4
Tw + Tsat
2
85 + 115.2
=
2
Tf = 100.1C

4
 - 961 kg/m3
 - 0.293  10-6 m2 / s
k = 680.4  10 −3 W / mK
 =   =961 0.293  10-6
 = 281.57  10 −6 Ns / m2
For vertical surfaces (Assuming Laminar flow)

Average heat transfer coefficient
0.25
 k 3  2g  hfg 
h = 0.943 
 L(T − T ) 
(5 M)
 sat w 

5/QB+Keys/ Ver1.0
4-80
0.25
 k 3  2g  hfg 
h − 1.13 
 L(T − T ) 
 sat w 
0.25
 (680.4  10−3 )3 (961)2  9.81 2215.8  103 
h = 1.13  
 281.57  10−6  l  (115.2 − 85)  (2 M)
h = 5900L-0.25 ........1
Heat transfer Q
m  hfg
= 0.0180 kg/s  2215.8  103 j/kg
= 39.8  103 j/s
Q = 39.8  103 W
We know that ,
Q = hA(Tsat − Tw )
39.8  103 = h   DL  (Tsat − Tw ) (3 M)
39.8  103 = h    .25  L (115.2 − 85)
Substitute h value
39.8  103 = (5900L−0.25 )    .25  L  (115.2 − 85)

0.278 = L0.75  (115.8 − 85)
L = 0.18m
Length of the drum L = 0.18 m
2. Film thickness
0.25
 4 Kx(Tsat − Tw ) 
x = 
 g  h   2 
 fg 
x = L = 0.18 m
Let us check the assumption of laminar flow

4m
We know that , Reynolds Number Re =
p
Where , P = Perimeter =  D =   .25 = 0.785

5/QB+Keys/ Ver1.0
4-81
4  .0180
Re =
0.785  281.57  10−6 (5 M)
Re = 325.7 < 1800
So our assumption laminar flow is correct.
In a refrigerating plant water is cooled from 20C to 7C by brine solution entering at -
2C and leaving at 3C. The design heat load is 5500 W and the overall heat transfer
coefficient is 800 W/m2 K. What area required when using a shell and tube heat
exchanger with the water making one shell pass and the brine making two tube
passes.(15 M)-BTL4
Answer: Page 3.112, Dr.S.Senthil
Shell and tube heat exchanger – one shell pass and two tube passes
For shell and tube heat exchanger or cross heat exchanger.
Q = F U A (T)m (Counter flow)

(From HMT data book Page No.154) (3 M)
For counter flow
( T)m =
(T1 − t 2 ) − (T2 − t1)
T − t 
In  1 2 
5  T2 − t1 
(20-3)-(7 +2)
=
 20-3 
In 
 7+2 
(5 M)
(T)m = 12.57C
To find correction factor F refer HMT data book Page No.161

One shell pass and two tube passes
From graph
t 2 − t1 3+2 5
Xaxis Value P = = =
T1 − t1 20 + 2 22
P = 0.22
(5 M)
T −T 20 − 7 13
Curve value = R= 1 2 = =
t 2 − t1 3+2 5
R = 2.6

5/QB+Keys/ Ver1.0
4-82
Xaxis value is 0.22 curve value is 2.6 corresponding Yaxis value is 0.94
Substitute (T)m Q, U and F value is Equation (1)
1  Q = F U A (T)m
5500 = 0.94  800  A  12.57 (2 M)
A = 0.58 m2

5/QB+Keys/ Ver1.0
4-83
UNIT IV RADIATION
Black Body Radiation – Grey body radiation - Shape Factor – Electrical Analogy – Radiation Shields.
Radiation through gases.
PART * A
Q.No. Questions
Define Radiation. BTL1

1 The heat transfer from one body to another without any transmitting medium is known as
radiation. It is an electromagnetic wave phenomenon.
Define emissive power [E].(Nov 2018, Dec 2016, May 2013)BTL1

2
The emissive power is defined as the total amount of radiation emitted by a body per unit time
and unit area. It is expressed in W/m2.
Define monochromatic emissive power. [Eb] BTL1

3 The energy emitted by the surface at a given length per unit time per unit area in all directions
is known as monochromatic emissive power.
What is meant by absorptivity? BTL2

Absorptivity is defined as the ratio between radiation absorbed and incident radiation.
4
Radiation absorbed
Absorptivity  =
Incident radiation
What is meant by reflectivity? BTL2
Reflectivity is defined as the ratio of radiation reflected to the incident radiation.
5
Radiation reflected
Reflectivity  =
Incident radiation
What is meant by Transmissivity? BTL2
6 Transmissivity is defined as the ratio of radiation transmitted to the incident radiation.
Radiation transmitted
Transmissivity  =
Incident radiation
What is black body? [April.97, April 99] BTL2
7 Black body is an ideal surface having the following properties.
1. A black body absorbs all incident radiation, regardless of wave length and direction.

5/QB+Keys/ Ver1.0
4-84
2. For a prescribed temperature and wave length, no surface can emit more energy than
black body.
State Planck’s distribution law. (Dec 2019, May 2017, Dec 2016, May 2014)BTL2
The relationship between the monochromatic emissive power of a black body and wave length
of a radiation at a particular temperature is given by the following expression, by Planck.
C1 −5
Eb =
 C2 
8  
e   T  −1
Where Eb = Monochromatic emissive power W/m2
 = Wave length – m
c1 = 0.374  10-15 W m2
c2 = 14.4  10-3mK
State Wien’s displacement law. BTL2
The Wien’s law gives the relationship between temperature and wave length corresponding to
the maximum spectral emissive power of the black body at that temperature.
9
 T = c3
mas
Where c3 = 2.9  10-3 [Radiation constant]
  mas T = 2.9  10-3 mK

State Stefan – Boltzmann law. [April 2002] BTL2
The emissive power of a black body is proportional to the fourth power of absolute
temperature.
Eb  T4
10 Eb =  T4
Where Eb = Emissive power, w/m2
 = Stefan. Boltzmann constant
= 5.67  10-8 W/m2 K 4
T = Temperature, K
Define Emissivity. [Oct. 2000, April 2002] BTL1
11 It is defined as the ability of the surface of a body to radiate heat. It is also defined as
the ratio of emissive power of any body to the emissive power of a black body of equal
temperature.

5/QB+Keys/ Ver1.0
4-85
E
Emissivity  =
Eb
What is meant by gray body? [April, 2000, 2002] BTL2
12 If a body absorbs a definite percentage of incident radiation irrespective of their wave length,
the body is known as gray body. The emissive power of a gray body is always less than that of
the black body.
State Kirchoff’s law of radiation. [April 2001] BTL2

This law states that the ratio of total emissive power to the absorbtivity is constant for all
surfaces which are in thermal equilibrium with the surroundings. This can be written as
E1 E2 E3
13 = = ,
1 2 3
It also states that the emissivity of the body is always equal to its absorptivity when the body
remains in thermal equilibrium with its surroundings.
1 = E1; 2 = E2 and so on.
Define intensity of radiation (Ib). [Nov. 96, Oct. 98, 99] BTL1
It is defined as the rate of energy leaving a space in a given direction per unit solid angle per
14 unit area of the emitting surface normal to the mean direction in space.
Eb
In =

State Lambert’s cosine law. BTL1
It states that the total emissive power Eb from a radiating plane surface in any direction
15
proportional to the cosine of the angle of emission
Ebcos
What is the purpose of radiation shield? [Apr. 2012,Apr.2013] BTL2

16 Radiation shields constructed from low emissivity (high reflective) materials. It is used to
reduce the net radiation transfer between two surfaces.
Define irradiation (G) [Nov. 17] BTL1

17 It is defined as the total radiation incident upon a surface per unit time per unit area. It is
expressed in W/m2.
What is radiosity (J)? [April 2016] BTL2

18
It is used to indicate the total radiation leaving a surface per unit time per unit area. It is

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expressed in W/m2.
What is meant by shape factor? (Dec 2016, May 2015)BTL2

The shape factor is defined as the fraction of the radiative energy that is diffused from on
19 surface element and strikes the other surface directly with no intervening reflections. It is
represented by Fij. Other names for radiation shape factor are view factor, angle factor and
configuration factor.
What are the assumptions made to calculate radiation exchange between the surfaces?
BTL2
20 1. All surfaces are considered to be either black or gray
2. Radiation and reflection process are assumed to be diffuse.
3. The absorptivity of a surface is taken equal to its emissivity and independent of
temperature of the source of the incident radiation.
Part*B
A black body at 3000 K emits radiation. Calculate the following:
i) Monochromatic emissive power at 7 m wave length.

ii) Wave length at which emission is maximum.
iii) Maximum emissive power.
iv) Total emissive power,
Calculate the total emissive of the furnace if it is assumed as a real surface having
emissivity equal to 0.85. (Nov 2018, Dec 2016, May 2013)(13 M)BTL4

1. Monochromatic Emissive Power :
From Planck’s distribution law, we know
C1 −5
Eb =
 C2 
 
e   T  −1
[From HMT data book, Page No.71]

Where
c1 = 0.374  10-15 W m2
c2 = 14.4  10-3mK
 = 1  10-6 m [Given]

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0.374  10 −15 [1 10 −6 ]−5
 Eb =
 144  10−3 
1 10−6  3000  (3 M)
  −1
Eb = 3.10  1012 W/m2
2. Maximum wave length (max)
From Wien’s law, we know

max T = 2.9  10 −3 mK
2.9  10 −3
 max = (3 M)
3000
max = 0.966  10-6m
3. Maximum emissive power (Eb) max:
Maximum emissive power

(Eb)max = 1.307  10-5 T5
= 1.307  10-5 (3000)5
(Eb)max = 3.17  1012 W/m2 (2 M)
4. Total emissive power (Eb):
From Stefan – Boltzmann law, we know that

Eb =  T4
Where  = Stefan – Boltzmann constant
= 5.67  10-8 W/m2K4
Eb = (5.67  10-8) (3000)4
Eb = 4.59  106 W/m2 (2 M)
5. Total emissive power of a real surface:
(Eb)real =  T4
Where  = Emissivity = 0.85
(Eb)real = 0.85  5.67  10−8  (3000)4
(Eb )real = 3.90  106 W / m2 (3 M)

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A black body of 1200 cm2 emits radiation at 1000 K. Calculate the following:
1. Total rate of energy emission
2. Intensity of normal radiation
3. Wave length of maximum monochromatic emissive power.
4. Intensity of radiation along a direction at 60 to the normal. (13 M)BTL4
1. Energy emission Eb =  T4
Eb = 5.67  10−8  (1000)4
Eb = 5.67  103 W/m2
Here Area = 1200  10-4 m2,
Eb = 5.67103 1200  10-4

Eb = 6804 W (3 M)
1
2. Intensity of normal radiation
Eb
In =

56.7  103 W / m2
= (5 M)

In = 18,048 W/m2
3. From Wien’s law, we know that
max T = 2.9  10-3 mK
2.9  10-3
 max =
3000
max = 2.9  10-6 m (5 M)
max = 2.9  [ 1 = 10 -6 m]
Assuming sun to be black body emitting radiation at 6000 K at a mean distance of 12 

1010 m from the earth. The diameter of the sun is 1.5  109 m and that of the earth is 13.2
2  106 m. Calculation the following. (i) Total energy emitted by the sun, (ii) The emission
received per m2 just outside the earth’s atmosphere, (iii) The total energy received by the
earth if no radiation is blocked by the earth’s atmosphere, (iv) The energy received by a

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2  2 m solar collector whose normal is inclined at 45 to the sun. The energy loss
through the atmosphere is 50% and the diffuse radiation is 20% of direct radiation.(13
M) (Dec 2019, May 2017, Dec 2016, May 2014)BTL4
1. Energy emitted by sun Eb =  T4
 Eb = 5.67  10-8  (6000)4

[  = Stefan - Boltzmann constant
= 5.67  10-8 W / m2 K 4 ]
Eb = 73.4  10 6 W/m2
Area of sun A 1 = 4 R12
2
 1.5  109 
= 4   
 2 
A1 = 7  1018 m2
 Energy emitted by the sun

Eb = 73.4  106  7  1018 (3 M)
Eb = 5.14  1026 W
2. The emission received per m2 just outside the earth’s atmosphere:

The distance between earth and sun
R = 12  1010 m
Area, A = 4 R2
= 4    (12  1010 )2
A = 1.80  1023 m2
 The radiation received outside the earth atmosphere per
m2 (3 M)
Eb
=
A
5.14  1026
=
1.80  1023
= 2855.5 W/m2
3. Energy received by the earth:

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4-90

Earth area = (D2 )2
4

=  [13.2  10 6 ]2
4
Earth area = 1.36  10 4m2
Energy received by the earth
= 2855.5  1.36  104

(3 M)
= 3.88  1017 W
4. The energy received by a 2  2 m solar collector;

Energy loss through the atmosphere is 50%. So energy reaching the earth.
= 100 - 50 = 50%
= 0.50
Energy received by the earth
= 0.50  2855.5
= 1427.7 W/m2 ......(1)
Diffuse radiation is 20%
 0.20  1427.7 = 285.5 W/m2

(2 M)
Diffuse radiation = 285.5 W/m2 .........(2)
Total radiation reaching the collection

= 142.7 + 285.5
= 1713.2 W/m2
Plate area = A  cos 

= 2  2  cos 45
= 2.82 m2
Energy received by the collector
= 2.82  1713.2
(2 M)
= 4831.2 W
A large enclosure is maintained at a uniform temperature of 3000 K. Calculate the
3 following, (i) Emissive power, (ii) The wave length 1 below which 20 percent of the
emission is concentrated and the wave length 2 above which 20 percent of the emission is

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concentrated, (iii) The maximum wave length, (iv) Spectral emissive power, (v) The
irradiation incident.(13 M)BTL4
1. Emissive power Eb=  T4
= 5.67  10−8  (3000)4
Eb = 4.59  106 W/m2 (3 M)
2. The wave length 1 corresponds to the upper limit, containing 20% of emitted radiation.
Eb(0-1T)
 = 0.20 , corresponding
 T4
1T = 2666 K
 1T = 2666 K
2666
 1 =
3000
 1 = 0.88
The wave length 2 corresponds to the lower limit, containing 20% of emitted
radiation.
Eb(0-1T)
 = (1 − 0.20)
 T4
Eb(0-1T)
 = 0.80, corresponding
 T4
2T = 6888 K (3 M)
6888
 2 =
3000
2 = 2.2 
3. Maximum wave length (max):
max T = 2.9  10-3mK

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2.9  10-3
max =
3000
= 9.6  10-7m (2 M)
max = 0.96  10−6 m
4. Spectral Emissive Power:

From Planck’s distribution law, we know
C1max −5
Eb = [From HMT data book, Page No.71]
 C2 
 
e   T  −1
where C1 = 0.374  10 −15 W m2

C2 = 14.4  10−3 mK
( 0.374  10 )  (0.96  10 )
−5
−15 −6
 Eb =
 14.4  10 −3 
 −6  (3 M)
e
0.96  10  3000 −1
 Eb = 3.1  1012 W/m2
5. Irradiation:
The irradiation incident on a small object placed within the enclosure may be treated as
equal to emission from a black body at the enclosure surface temperature.
So, G = Eb= 4.59  106 W/m2 . (2 M)
A furnace wall emits radiation at 2000 K. Treating it as black body radiation, calculate,
(i) Monochromatic radiant flux density at 1m wave length, (ii) Wave length at which
emission is maximum and the corresponding emissive power., (iii) Total emissive power
(13 M)BTL4
4
1. Monochromatic emissive power (Eb):
c1 −5
Eb = [From HMT data book, Page No.71]
 C2 
 
e   T  −1

5/QB+Keys/ Ver1.0
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where C1 = 0.374  10 −15 W m 2
C2 = 14.4  10 −3 mK
 = 1 m = 1 10-6 m [Given] (4 M)
−15 −6 −5
0.374  10  (1 10 )
 Eb =
 14.4  10 −3 
 
e
1 10−6  2000 −1
Eb = 2.79  1011 W / m2
2. Maximum Wave Length (max):

From Wien’s Law, we know that
max T = 2.9  10−3 mK
2.9  10−3
max =
T
2.9  10−3
= = 1.45  10 −6 m
2000
max = 1.45 
Corresponding emissive power
c1max −5
Eb =
 C2 
 
 T
e  max  −1
−5
0.374  10−15  1.45  10−6 
=
 14.4  10−3  (4 M)
 −6 
e
1.45  10  2000 −1
= 4.09  1011 W / m2
3. Total emissive power (Eb):
From Stefan – Boltzmann law, we know
Eb =  T4
Where  - Stefan – Boltzmann constant

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= 5.67  10−8 W / m2 K 4
Eb = 5.67  10-8  (2000)4 (5 M)
Eb = 907.2  103 W/m2
The temperature of a black surface 0.25 m2 of area is 650C. Calculate, (i) 1. The total
rate of energy emission, (ii) 2. The intensity of normal radiation, (iii) The wavelength of
maximum monochromatic emissive power. (13 M)BTL4
1. We know
Emissive power Eb =  T4
= 5.67  10−8  (923)4

Eb = 41151.8 W/m2
Here Area = 0.25 m2
 Eb = 41151.8 W/m2  0.25 m2
5 Eb = 10.28  103 Watts (5 M)
2. We know
Eb
Intensity = In =

10.28  103
= (3 M)

In = 3274.7 W
3. From Wien’s law,
max T = 2.9  10−3 m

2.9  10-3
max = (5 M)
923
max = 3.13  10−6 m
Calculate the heat exchange by radiation between the surfaces of two long cylinders
having radii 120mm and 60mm respectively. The axis of the cylinder are parallel to each
6
other. The inner cylinder is maintained at a temperature of 130C and emissivity of 0.6.
Outer cylinder is maintained at a temperature of 30C and emissivity of 0.5.(13 M)BTL4

5/QB+Keys/ Ver1.0
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Q =   A T14 − T2 4  .....(1)
[From equation No.27]
1
where  =
1 A1  1 
+  − 1
1 A 2   2 
1
 = [ A =  DL]
1  D1L 2  1 
+ −1
0.6  D2L 2  0.5 
1
= [ L1 = L 2 = 1]
1 0.12  1 
+ −1
0.6 0.24  0.5 
 = 0.46
(1) 
Q12 = 0.46  5.67  10 −8    D1  L  (403)4 − (303)4 
= 0.46  5.67  10 −8    0.12  1 (403)4 − (303)4 
(13 M)
Q12 = 176.47 W
Emissivities of two large parallel plates maintained at 800C and 300C are 0.5
respectively. Find net radiant hat exchange per square metre for these plates. Find the
percentage reduction in heat transfer when a polished aluminium radiation shield of
emissivity 0.06 is placed between them. Also find the temperature of the shield. (13 M)
(Jun ’12) BTL4
7
Answer: Page 4.60-Dr. S. Senthil
Heat exchange between two large parallel plates without radiation shield is given by
Q12 =   A T14 − T24 

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(1)  Q12 = 0.230    A  [T14 − T2 4 ]
= 0.230  5.67  10−8  A  (1073)4 − (573)4 
Q12
= 15,879.9 W/m2 (3 M)
A
Heat transfer square metre without radiation shield
Q12
= 15.87 k W/m2 ......(1)
A
Heat exchange between plate 1 and radiation shield 3 is given by
(1)  Q13 =  A [T14 − T2 4 ]

1
=
1 1
+ −1
1 3
  A [T14 − T3 4 ]
 Q13 = .....(A)
1 1
+ −1
1 3
Heat exchange between radiation shield 3 and plate 2 is given by
Q32 =  A [T3 4 − T2 4 ]
1
Where =
1 1
+ −1
3 2
  A T3 4 − T2 4 
 Q32 = .....(B)
1 1
+ −1
3 2
We know Q13 = Q32
 T3 4 = 0.926 (1073)4 − 0.926  (T3 )4  + (573)4

(T3 )4 + 0.926 (T3 4 ) = 1.33  1012
(1.926) (T3 )4 = 1.33  1012

(T3 )4 = 6.90  1011 (5 M)
T3 = 911.5 K
Radiation shield temperature T3 = 911.5 K

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Substituting T3 value in equation (A) (or) equation (B), Heat transfer with radiation shield
5.67  10−8  A  (1073)4 − (911.5)4 

 Q13 =
1 1
+ −1
0.3 0.06
Q13
= 1895.76 W/m2
A
Heat transfer with radiation shield
Q13
 = 1.89kW / m2 ......(2)
A
Reduction in heat loss due to radiation shield
Qwithout shield − Q with shield Q12 − Q13

= =
Qwithout shield Q12
15.87 - 1.89
= (5 M)
15.87
= 0.88 = 88%
Find the relative heat transfer between two large plane at temperature 1000 K and 500 K
when they are 1. Black bodies 2. Gray bodies with emissivities of each surface is 0.7. (13
M)BTL4
Case 1: Heat exchange between two large parallel plate is given by
Q =  A  T14 − T2 4 
8 For black bodies,  = 1

Q = A  T14 − T2 4 
Q
= 5.67  10−8 (1000)4 − (500)4 
A
(5 M)
Q
= 53.15  103 W / m2
A
Case 2: Q =  A  T14 − T24 

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1
=
1 1
+ −1
1 2
1
 =
1 1
+ −1
0.7 0.7
 = 0.538 (8 M)
 Q = 0.538  A  5.67  10 −8 (1000)4 − (500)4 
Q
= 28.6  103 W / m2
A
Two parallel plates of size 3 m  2 m are placed parallel to each other at a distance of 1
m. One plate is maintained at a temperature of 550C and the other at 250C and the
emissivities are 0.35 and 0.55 respectively. The plates are located in a large room whose
walls are at 35C. If the plates located exchange heat with each other and with the room,
calculate. (i) Heat lost by the plates, (ii) Heat received by the room. (13 M)BTL4
Answer: Page 4.121Dr.S.Senthil
Area A1 = 3  2 = 6 m2
A1 = A 2 = 6m2
Since the room is large A 3 = 

9
From electrical network diagram.
1 − 1 1 − 0.35
= = 0.309
1A1 0.35  6
1 −  2 1 − 0.55
= = 0.136 (2 M)
 2 A 2 0.55  6
1− 3
=0 [ A 3 = ]
3 A3
1− 3 1-1 1− 2
Apply = 0, = 0.309, = 0.136 values in electrical network diagram.
3 A3 1A1 2A2
To find shape factor F12 refer HMT data book, Page No.78.

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b 3
X= = =3
c 1 (3 M)
a 2
Y = = =2
c 1
X value is 3, Y value is 2, corresponding shape factor
[From table]
F12 = 0.47
F12 = 0.47
We know that,
F11 + F12 + F13 = 1
But, F11 = 0
 F13 = 1 − F12
 F13 = 1 − 0.47 (2 M)
F13 = 0.53
Similarly, F21 + F22 + F23 = 1

We know F22 = 0
 F23 = 1 − F21
 F23 = 1 − F12
(2 M)
F13 = 1 - 0.47
F23 = 0.53
From electrical network diagram,
1 1
= = 0.314 ....(1)
A1F13 6  0.53
1 1
= = 0.314 ....(2) (2 M)
A 2F23 6  0.53
1 1
= = 0.354 ....(3)
A1F12 6  0.47
From Stefan – Boltzmann law, we know

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Eb =  T 4
Eb1 =  T14
= 5.67  10 -8 823 
4
Eb1 = 26.01 103 W / m2 .....(4)
Eb2 =  T2 4
= 5.67  10 -8 823 
4
Eb2 = 4.24  103 W / m2 .....(5)

Eb3 =  T3 4
= 5.67  10 -8 308 
4
Eb3 = J3 = 510.25 W / m2 .....(6)
At Node J1:
Eb1 − J1 J2 − J1 Eb3 − J1
+ + =0
0.309 1 1
A1F12 A1F13
[From diagram]
At node j2
J1 − J2 Eb3 − J2 Eb2 − J2
+ + =0
1 1 0.136
A1F12 A 2F23
 -9.24J1 + 2.82J2 = −85.79  103 .....(7)

 2.82J1 − 13.3J2 = −32.8  103 .....(8) (2 M)
__________________________
J2 = 4.73  103 W / m2
J1 = 10.73  103 W / m2
A furnace of 25 m2 area and 12 m2 volume is maintained at a temperature of 925C over

is entire volume. The total pressure of the combustion gases is 3 atm, the partial pressure
10
of water vapour is 0.1 atm and that of CO2 is 0.25 atm.Calculate the emissivity of the
gaseous mixture. (13 M)BTL4

5/QB+Keys/ Ver1.0
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V
Lm = 3.6 
A
12
= 3.6 
25
Lm = 1.72 m
To find emissivity of CO2
PCO2  Lm = 0.25  1.72

PCO2  Lm = 0.43 m-atm.
From HMT data book, Page No.90, we can find emissivity of CO2.
 CO  CCO = 0.18
2 2
From graph, Emissivity of CO2 = 0.15 ,  CO = 0.15

2
(3 M)
To find correction factor for CO2: Total pressure P = 3 atm.
PCO2 Lm = 0.43 m-atm
From HMT data book, Page No.91, we can find correction factor for CO2.
From graph, we find CCO2 = 1.2
CCO2 = 1.2
  CO2  CCO2 = 0.15  1.72 .....(1) (3 M)
To find emissivity of H2O:
PH2O  Lm = 0.1 1.72 , PH2O  Lm = 0.172
From HMT data book, Page No.92, we can find emissivity of H2O.
From graph, Emissivity of H2O = 0.15
H O = 0.15
2
(3 M)
To find correction factor for H2O:

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4-102
PH2O + P 0.1 + 3 PH O + P
= = 1.55 2 = 1.55,PH2O Lm = 0.172.
2 2 2
From HMT data book, Page No.94, we can find correction factor for H2O.
PCO2 Lm + PH2O Lm = 0.602
From graph, we find
CH2O = 1.58
CH2O = 1.58
 H2O  CH2O = 0.15  1.58
 H O  CH O = 0.237 ........(2)
2 2
Correction Factor for mixture of CO2 and H2O:
PH2O 0.1
= = 0.285
PH2O + PCO2 0.1 + 0.25
PH2O
= 0.285
PH2O + PCO2
PCO2  Lm + PH2O  Lm = 0.25  1.72 + 0.1 1.72 (3 M)
= 0.602.
From HMT data book, Page No.95 we can find correction factor for mixture of CO2
and H2O.
From graph, we find  = 0.045.
 = 0.045 ..........(3)
Total emissivity of the gaseous mixture is
 mix =  CO CCO + H O CH O − 
2 2 2 2
 mix = 0.18 + 0.237 − 0.045

(1 M)
[From equation (1), (2) and (3)]
 mix = 0.372
Part*C
1 The sun emits maximum radiation at  = 0.52. Assuming the sun to be a black body,
5/QB+Keys/ Ver1.0
4-103
calculate the surface temperature of the sun. Also calculate the monochromatic emissive
power of the sun’s surface. (Dec 2016, May 2015)(15 M)BTL4
1. From Wien’s law, we know
max T = 2.9  10−3 mK

2.9  10-3 (5 M)
 T=
0.52  10−6
T = 5576 K
2. Monochromatic emissive power (Eb):

From Planck’s law, we know
c1 −5
Eb =
 C2 
 
e   T  −1
where C1 = 0.374  10 −15 W m 2

C2 = 14.4  10 −3 mK
 = 0.52  10-6 m (5 M)
−15 −6 −5
0.374  10  (0.52  10 )
 Eb  =
 14.4  10 −3 
 −6 
e
0.52  10  5576 −1
Eb = 6.9  1013 W / m2
(5 M)
Two concentric spheres 30 cm and 40 cm in diameter with the space between them
evacuated are used to store liquid air at - 130C in a room at 25C. The surfaces of the
spheres are flushed with aluminium of emissivity  = 0.05. Calculate the rate of
evaporation of liquid air if the latent heat of vaporization of liquid air is 220 kJ/kg.(15
2
M)(Dec 2019, May 2017, Dec 2016, May 2014)BTL4

Solution: This is heat exchange between large concentric sphere problems.

5/QB+Keys/ Ver1.0
4-104
Heat transfer Q12 =   A1 [T14 − T24 ] ......(1) (5 M)
1
Where  =
1 A1  1 
+  − 1
1 A 2   2 
1
=
1 4 r12  1 
+ 2 
− 1
0.05 4 r2  0.05 
[ 1 =  2 = 0.05;A = 4 r 2 ]
(5 M)
1
=
1 (0.15)2  1 
+ 2 
− 1
0.05 (0.20)  0.05 
 = 0.032
(5 M)
Emissivities of two large parallel plates maintained at T1 K and T2 K are 0.6 and 0.6
respectively. Heat transfer is reduced 75 times when a polished aluminium radiation
shields of emissivity 0.04 are placed in between them. Calculate the number of shields
required.(15 M)BTL4
A [T14 − T2 4 ]
Qin = .......(1)
1 1  2n 
+   − (n − 1)
1  2   s 
Heat transfer without shield, i.e., n=0 (5 M)
3
A [T − T2 ]
4 4
(1)  Q12 = 1
.......(2)
1 1
+ −1
1 2
Heat transfer is reduced 75 times
Qwithout shield
 = 75
Qwith shield
(5 M)
Q12
 = 75
Q13

5/QB+Keys/ Ver1.0
4-105
A [T14 − T2 4 ]
1 1
+ −1
(2) 1  2
 = 75
(1) A [T14 − T2 4 ]
1 1 2n
+ − (n + 1)
1 2 s
1 1 2n
+ − (n + 1)
1 2 s
 = 75
1 1
+ −1
1 2
1 1 2n
+ − (n + 1)
 0.6 0.6 0.04 = 75
1 1
+ −1
0.6 0.6
3.33 + 50n − (n − 1)
 = 75
2.33
 50n n-1 = 171.67
49n - 1 = 171.67 (5 M)
49n = 172.67
n = 3.52  4
n=4
The inner sphere of liquid oxygen container is 40 cm diameter and outer sphere is 50 cm
diameter. Both have emissivities 0.05. Determine the rate at which the liquid oxygen
would evaporate at -183C when the outer sphere at 20C. Latent heat of oxygen is 210
kJ/kg.(15 M) May 2BTL4
This is heat exchange between two large concentric spheres problem.
4 Heat transfer Q =   A1 T14 − T24  ......(1)
[From equation No.27]
1
where  = (5 M)
1 A1  1 
+  − 1
1 A 2   2 

5/QB+Keys/ Ver1.0
4-106
1
= [ A = 4 r 2 ]
1 4 r12  1 
+ −1
0.05 4 r2 2  0.05 
1
=
1 r  1
2

+  1
− 1 (5 M)
0.05 r  0.05 
2
2
1
=
1 (0.20)2  1 
+ 2 
− 1
0.05 (0.25)  0.05 
 = 0.031
(1)  Q12 = 0.031 5.67  10−8  4   (90)4 − (293)4 

Q12 = 6.45 W
[Negative sign indicates heat is transferred from outer surface to inner surface.]
Heat transfer
Rate of evaporation =
Latent heat
6.45 W
=
210  103 J/kg
6.45 J/s
=
210  103 J / kg
Rate of evaporation = 3.07  10-5kg/ s (5 M)
Emissivities of two large parallel plates maintained at 800C and 300C are 0.3 and 0.5
respectively. Find the net radiant heat exchange per square meter of the plates. If a
polished aluminium shield ( = 0.05) is placed between them. Find the percentage of
reduction in heat transfer. (15 M) (May 17) BTL4
Case 1 : Heat transfer without radiation shield:
5
Heat exchange between two large parallel plats without radiation shield is given by
Q12 =   A T14 − T24 
1
=
1 1
+ −1
1 2

5/QB+Keys/ Ver1.0
4-107
1
=
1 1
+ −1
0.3 0.5
 = 0.230
 Q12 = 0.230  5.67  10−8  A  (1073)4 − (573)4 

Q12
Heat transfer = 15.8  103 W / m2
A
Case 2: Heat transfer with radiation shield:

Heat exchange between plate 1 and radiation shield 3 is given by
Q13 =  A [T14 − T2 4 ]
1
where = (5 M)
1 1
+ −1
1 3
 A [T − T3 4 ]
4
 Q13 = 1
.....(A)
1 1
+ −1
1 3
Heat exchange between radiation shield 3 and plate 2 is given by
Q32 =  A [T3 4 − T24 ]
1
Where  =
1 1
+ −1
3 2
 A T3 4 − T2 4 
 Q32 = .....(B)
1 1
+ −1
3 2
We know Q13 = Q32

5/QB+Keys/ Ver1.0
4-108
 A [T14 − T3 4 ]  A [T3 4 − T2 4 ]
 = =
1 1 1 1
+ −1 + −1
1 3 3 2
(1073)4 - (T3 4 ) (T3 4 ) − (573)4 ]
 = =
1 1 1 1
+ −1 + −1
0.3 0.05 0.3 0.05 (5 M)
(1073)4 − (T3 4 ) (T3 4 ) − (573)4
 =
22.3 21
 2.78  10 − 21T3 = 22.3T3 4 − 2.4  1013
13 4
 3.02  1013 = 43.3T3 4

Shield temperature  T3 = 913.8 K
Substitute T3 value in equation (A) or (B).

Substituting T3 value in equation (A) (or) equation (B),
−8
 A  (1073) − (913.8) 
4 4
5.67  10
Heat transfer with   
Q =
radiation shield  13 1 1
+ −1
0.3 0.05
Q13
= 1594.6 W / m2 ......(2)
A
Re duction in heat loss  Q without shield − Q with shield

=
due to radiation shield  Q without shield
Q − Q13
= 12
Q12 (5 M)
15.8  103 - 1594.6
=
15.8  103
= 0.899 = 89.9%

5/QB+Keys/ Ver1.0
4-109
UNIT V MASS TRANSFER
Basic Concepts – Diffusion Mass Transfer – Fick‟s Law of Diffusion – Steady state Molecular Diffusion –
Convective Mass Transfer – Momentum, Heat and Mass Transfer Analogy –Convective Mass Transfer
Correlations.
PART * A
Q.No. Questions
What is mass transfer? BTL2

1 The process of transfer of mass as a result of the species concentration difference in a mixture is
known as mass transfer.
Give the examples of mass transfer. BTL3

Some examples of mass transfer.
2
1. Humidification of air in cooling tower
2. Evaporation of petrol in the carburetor of an IC engine.
3. The transfer of water vapour into dry air.
What are the modes of mass transfer? BTL2
3 There are basically two modes of mass transfer,

1. Diffusion mass transfer
2. Convective mass transfer
What is molecular diffusion? (Jun ’13) BTL2
4 The transport of water on a microscopic level as a result of diffusion from a region of higher
concentration to a region of lower concentration in a mixture of liquids or gases is known as
molecular diffusion.
What is Eddy diffusion? BTL2

5
When one of the diffusion fluids is in turbulent motion, eddy diffusion takes place.
What is convective mass transfer? BTL2

6 Convective mass transfer is a process of mass transfer that will occur between surface and a fluid
medium when they are at different concentration.
State Fick’s law of diffusion. (AU June 06, May’05).BTL2

7 The diffusion rate is given by the Fick’s law, which states that molar flux of an element per unit area
is directly proportional to concentration gradient.

5/QB+Keys/ Ver1.0
4-110
ma dCa
= −Dab
A dx
where,
ma kg -mole
− Molar flux,
A s-m2
Dab Diffusion coefficient of species a and b, m2 / s
dCa
− concentration gradient, kg/m3
dx
What is free convective mass transfer? BTL2

If the fluid motion is produced due to change in density resulting from concentration gradients, the
8
mode of mass transfer is said to be free or natural convective mass transfer.
Example : Evaporation of alcohol.
Define forced convective mass transfer. BTL1

If the fluid motion is artificially created by means of an external force like a blower or fan, that type
9
of mass transfer is known as convective mass transfer.
Example: The evaluation if water from an ocean when air blows over it.
Define Schmidt Number. BTL1

It is defined as the ratio of the molecular diffusivity of momentum to the molecular diffusivity of
10 mass.
Molecular diffusivity of momentum

Sc =
Molecular diffusivity of mass
Define Scherwood Number. BTL1

It is defined as the ratio of concentration gradients at the boundary.
hm x
Sc =
11 Dab
hm − Mass transfer coefficient, m/s
Dab − Diffusion coefficient, m2 / s
x − Length, m
Give two examples of convective mass transfer. BTL3.

12
Evaporation of alcohol, Evaporation of water from an ocean when air blows over it.
13 Define Mass concentration and molar concentration. BTL 1

5/QB+Keys/ Ver1.0
4-111
Mass Concentration = Mass of component/Unit volume of mixture
Molar Concentration = Number of moles of component/ Unit volume of mixture.
Define mass fraction and molar fraction. BTL 1

14 Mass fraction=Mass concentration of a species/ Total mass density
Molar fraction = Mole concentration of a species/ Total molar concentration.
Part * B
Explain steady diffusion through a plane membrane.(13 M)(Dec 2016) BTL2

Answer: Page::5.4-Dr.S.Senthil
Consider a plane membrane of thickness L, containing fluid ‘a’. The concentrations of the fluid at
the opposite wall faces are Ca1 and Ca2 respectively.
d2Ca
=0
dx 2
Integrating above equation
(3 M)
dCa
= C1
dx
 Ca = C1x + C2 ..........(2)
Apply boundary condition

At, x = L
1
Ca1 = C2
Ca2 = C1L + C2
Ca2 = C1L + Ca1
 C − Ca1 
 C1 =  a2 
 L 
Substituting C1,C2 values in equation (2) (3 M)
Ca2 − Ca1
(2)  Ca1 = x + Ca1
L
From Fick’s law we know
ma dCa
Molar flux, = −Dab (3 M)
A DX

5/QB+Keys/ Ver1.0
4-112
Ma d   Ca2 − Ca1  
 = −Dab  x + C 
dx    a1
A L  
m kg-mole
where, a − Molar Flux -
A s-m2
 m2 
Dab − diffusion coefficient -  2 
S 
kg-mole
Ca1 − Concentrations at inner side -
m3
L – Thickness, For cylinders.
L = r2 − r1
2 L(r2 − r1 )
A (2 M)
 r2 
In  
 r1 
A = 4 r1r2
where,
for sphere,L = r2 – r1, r1 = Inner radius - m (2 M)
r2 = Outer radius - m
L = Length - m
Helium diffuses through a plane membrane of 2 mm thick. At the inner side the concentration
of helium is 0.25 kg mole/m3. At the outer side the concentration of helium is 0.007 kg mole/m3.
What is the diffusion flux of helium through the membrane. Assume diffusion coefficient of
helium with respect to plastic is 1  10-9 m2/s. (Nov 2018, Dec 2016, May 2013)(8 M)BTL4
Answer: Page: 5.13-Dr.S.Senthil

We know, for plane membrane
2
mo Dab
A
=
L
Ca1 − Ca2  [From equation 3] (4 M)
ma 1 10−9
Molar flux, = [.025 − .007]
A .002 (4 M)
ma −9 kg − mole
= 9  10
A s − m2
Gaseous hydrogen is stored in a rectangular container. The walls of the container are of steel
3 having 25 mm thickness. At the inner surface of the container, the molar concentration of
hydrogen in the steel is 1.2 kg mole/m3 while at the outer surface of the container the molar
concentration is zero, calculate the molar diffusion flux for hydrogen through the steel. Take
5/QB+Keys/ Ver1.0
4-113
diffusion coefficient for hydrogen in steel is 0.24  10-12 m2/s. (5 M)BTL4
ma Dab
A
=
L
Ca1 − Ca2 
0.24  10-12
Molar Flux, = [1.2 − 0] (5 M)
25
ma kg-mole
= 1.15  10-11
A s-m2
Oxygen at 25C and pressure of 2 bar is flowing through a rubber pipe of inside diameter 25
mm and wall thickness 2.5 mm. The diffusivity of O2 through rubber is 0.21  10-9 m2/s and
kg − mole
the solubility of O2 in rubber is 3.12  10-3 3 . Find the loss of O2 by diffusion per
m − bar
metre length of pipe. (13 M)BTL4
We know,
ma Dab Ca1 − Ca2 

=
A L
4 2 L (r2 − r1 ) (5 M)
For cylinders, L = r2 − r1; A =
r 
In  2 
 r1 
ma D C − Ca2 
Molar flux, (1)  = ab a1
2 L(r2 − r1 ) (r2 − r1 )
2 L.Dab Ca1 − Ca2 
 ma = [ Length = 1m) (8 M)
r
In 2
r1
kg − mole
ma = 4.51 10-11 .
s
Co2 and air experience equimolar counter diffusion in a circular tube whose length and
diameter are 1.2 m, d is 60 mm respectively. The system is at a total pressure of 1 atm and a
temperature of 273 k. The ends of the tube are connected to large chambers. Partial pressure
5 of CO2at one end is 200 mm og Hg while at the other end is 90mm of Hg. Calculate the
following.1. Mass transfer rate of Co2 and2. Mass transfer rate of air. (13 M)BTL4

5/QB+Keys/ Ver1.0
4-114
200
Pa1 = 200 mm of Hg = bar
760
Pa1 = 0.263 bar [  1 bar = 760 mm of Hg]
 Pa1 = 0.263  105 N/ m2 [ 1 bar = 105N/ m2 ]
Partial pressure of CO2 at other end
90
Pa2 = 90 mm of Hg = bar
760
Pa2 = 0.118 bar
 Pa2 = 0.118  105 N/ m2 (3 M)
ma Dab  Pa1 − Pa2 

We know, for equimolar counter diffusion, Molar flux, =   ....(1)
A GT  x 2 − x1 
Where, Dab – Diffusion coefficient – m2s

The diffusion coefficient – m2/s
 Dab = 4.28  10-3 m2 / h

−3
42.8  10
 Dab = m2 / s
3600
 Dab = 1.18  10-5m2 / s

J
G - Universal gas constant = 8314
kg-mole-k

5/QB+Keys/ Ver1.0
4-115
ma 1.18  10 −5  0.263  105 − 0.118  105 
(1)  =  
A 8314  273  1.2 
ma kg − mole
Molar flux, 6.28  10 −8 (5 M)
A m2 − s
m kg − mole
Molar flux of CO2 , a = 6.28  10 −8
A m2 − s
 
we know, Area, A = d2 =  (0.060)2 ,
4 4
A = 2.82  10 −3 m2
ma
 = 6.28  10 −8
A
ma = 6.28  10 −8  2.82  10 −3
kg − mole
ma = 1.77  10 −10
s
We know,
Mass transfer rate = Molar transfer  Molecular weight of CO2
= 1.77  10−10  44
[ Molecular weight of CO2 = 44, refer HMT data book, Page: No.187]
Mass transfer rate of CO2 = 7.78  10−9 kg/ s
We know,
Molar transfer rate of air, mb =
kg − mole
−1.77  10−10 [ ma = mb ]
s
Mass transfer rate = Molar transfer  Molecular weight
of air of air of air
(5 M)
= 1.77  10-10  29
Mass transfer rate of air = -5.13  10-9kg / s.
Two large tanks, maintained at the same temperature and pressure are connected by a
6 circular 0.15 m diameter direct, which is 3 k in length. One tank contains a uniform mixture of
60 mole % ammonia and 40 mole % air and the other tank contains a uniform mixture of 20
mole % air and the other tank contains a uniform mixture of 20 mole % ammonia and 80
5/QB+Keys/ Ver1.0
4-116
mole % air. The system is at 273 K and 1.013  105 pa. Determine the rate of ammonia
transfer between the two tanks. Assuming a steady state mass transfer. (13 M)BTL4
We know, for equimolar counter diffusion,
ma D ab  Pa1 − Pa2 
Molar flux, =  
A GT  x 2 − x1 
Where,
J
G – Universal gas constant = 8314 (4 M)
kg − mole − k
 
Area, A = d2 =  (0.15)2
4 4
Dab = Diffusion coefficient of ammonia with air = 77.8 10-3 m2/h [From HMT data book,
Page: No.185]
77.8  10−3 m2
 Dab =
3600s (4 M)
−5
 Dab = 2.16  10 2
m /s
ma 2.16  10−5  0.6  105 − 0.2  105 

(1)  =  
0.017 8314  273  3 
kg − mole
Molar transfer rate of ammonia, m a = 2.15  10−9
s
Mass transfer = Molar transfer rate  Molecular of

rate of ammonia of ammonia ammonia weight
(5 M)
= 2.15  10-9  17
Mass transfer rate of ammonia = 3.66  10-8kg / s
Determine the diffusion rate of water from the bottom of a test tube of 25 mm diameter and 35
mm long into dry air at 25C. Take diffusion coefficient of water in air is 0.28  10-4 m2/s. (13
M)(Nov 2018, Dec 2016, May 2013)BTL4
7
We know, for isothermal evaporation.

5/QB+Keys/ Ver1.0
4-117
ma Dab P  P − Pw 2 
Molar flux, = in   ....(1)
A GT (x 2 − x1 )  P − Pw1 
[From equation (9)]
Where,
J
G - Universal gas constant - 8314
kg -mole-k
P − Totalpressure = 1 bar = 1 105 N / m2 (5 M)
Pw1 − Partial pressure at the bottom of the test tube
Corresponding to saturation temperature 25C
At 25C
Pw1 = 0.03166 bar
Pw1 = 0.03166  105 N / m2
Pw2 – Partial pressure at the top of the test tube, that is zero
 
Area, A = d2 =  (0.025)2
4 4
−4
A = 4.90  10 m 2
ma
Area A = (1) 
4.90  10−4
0.28  10-4 1 105  1 105 − 0 
=  In  5
(5 M)
8314  298 0.035 1 10 − 0.03166  10 
5
kg − mole
Molar rate of water vapour ma = 5.09  10 −10 .
s
Mass rate of = Molar rate of  Molecular weight of

water vapour water vapour water vapour
We know that, (3 M)
[  Molecular weight of steam = 18 - Refer HMT data book]
Mass transfer rate of water = 9.162  10-9kg / s.
Estimate the rate of diffusion of water vapour from a pool of water at the bottom of a well
which is 6.2 m deep and 2.2 m diameter to dry ambient air over the top of the well. The entire
system may be assumed at 30C and one atmospheric pressure. The diffusion coefficient is
8 0.24  10-4 m2/s. (13 M)BTL4
We know, for isothermal evaporation,

5/QB+Keys/ Ver1.0
4-118
= in   ....(1)
A GT (x 2 − x1 )  P − Pw1 
Molar flux, where,
(5 M)
 
Area, A = d =
2
 (2.2) 2
4 4
A = 3.80 m2
J
G – Universal gas constant – 8314
kg − mole − k
Pw1 – Partial pressure at the bottom of the test tube corresponding to saturation temperature 30C
At 30C
Pw1 = 0.04241 bar
Pw1 = 0.04241 105 N/ m2
Pw2 = 0
(1)  ma / 3.80 =
0.24  10-4 1 105  1 105 − 0 
 in  5
8314  303 6.2 1 10 − 0.04241 10 
5
kg − mole (5 M)
 ma = 2.53  10 −8
s
kg − mole
Molar rate of water = 2.53  10-8
s
We know,
Mass rate of = Molar rate of  Molecular weight
water vapour water vapour of steam
−7
= 2.53  10  18 = 4.55  10 kg / s
-8
Diffusion rate of water = 4.55  10-7kg/ s. (3 M)
An open pan 210 mm in diameter and 75 mm deep contains water at 25C and is exposed to
dry atmospheric air. Calculate the diffusion coefficient of water in air. Take the rate of
9 diffusion of water vapour is 8.52  10-4 kg/h.(13 M) BTL4

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=  in  
A GT ( x 2 − x1 )  P − Pw1 
Dab  A P  P − Pw 2 
ma =  in  
GT ( x 2 − x1 )  P − Pw1 
We know that,
Dab  A P  P − Pw 2 
2.36  10-7 =   in   18....(1)
GT ( x 2 − x1 )  P − Pw1 
where,
 2 
A − Area = d =  (0.210)2 = 0.0346 m2
4 4 (8 M)
1
G − Universal gas constant = 8314
kg-mole-k
P − total pressure = 1 bar = 1  105 N/ m2
corresponding to saturation temperature 25C
At 25C
Pw1 = 0.03166 bar

Pw1 = 0.03166  105 N/m2
Pw 2 = Partial pressure at the top of the pan, that is zero
Pw2 = 0
(1)  2.36  10−7
Dab  .0346 1 105  1 105 − 0 

=   In  5
 18
8314  298 0.075 1 10 − 0.03166  10 
5
(5 M)
Dab = 2.18  10-5 m2 / s.
Estimate the diffusion rate of water from the bottom of a test tube 10mm in diameter and
15cm long into dry atmospheric air at 25C. Diffusion coefficient of water into air is 0.255 
10-4 m2/s., (13 M) BTL4
10
We know that for isothermal evaporation.

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ma Dab  P − Pw 2 
Molar flux, − In   .....(1)
A GT  P − Pw1 
 
A − Area = d2 =  (.010)2 = 7.85  10 −5 m2
4 4 (5 M)
J
G − Universal gas cons tan t = 8314
kg − mole − k
P - Total pressure = 1 bar = 1  105 N/m2
Pw1 – Partial pressure at the bottom of the test tube corresponding to saturation temperature 25C
At 25C,
Pw1 = 0.03166 bar
Pw1 = 0.03166  105N/m2

Pw2 = Partial pressure at the top of the test tube that is zero.
Pw2 = 0
ma
(1) 
7.85  10 −5
0.255  10-4 1 105  1 105 − 0 
=   In  5
(5 M)
8314  298 0.15 1 10 − 0.03166  10 
5
kg − mole
Molar rate of water vapour, ma = 1.73  10 −11
s
We know that,
Water vapour water vapour of steam
= 1.73  10  18
-11
[ Molecular weight of steam = 18. Refer HMT data book]

(3 M)
Mass rate of water vapour = 3.11 10-10kg / s.
Part*C
Explain FICK’s Law of Diffusion. (15 M)BTL2

1
Consider a system shown in figure.
A partition separates the two gases a and b. When the partition is removed, the two gases

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diffuses through one other until the equilibrium is established throughout the system. (5 M)
The diffusion rate is given by the Fick’s law, which states that molar flux of an element per
unit area is directly proportional to concentration gradient.
ma dc a

A dx
ma dc
= −Dab a (5 M)
A dx
m dc
Na a − Dab a
A dx
where,
ma kg-mole
Na = − Molar flux Unit is
A s-m2
(or)
kg
Mass flux unit is
s-m2
m2
Dab − Diffusion coefficient of species a and b - (5 M)
s
dc a
− Concentration gradient
dx
Hydrogen gases at 3 bar and 1 bar are separated by a plastic membrane having thickness 0.25
mm. the binary diffusion coefficient of hydrogen in the plastic is 9.1  10-3 m2/s. The solubility
kg − mole
of hydrogen in the membrane is 2.1  10-3 . An uniform temperature condition of 20
m3 bar
is assumed.(15 M)BTL4
1. Molar concentration on inner side,
2
Ca1 = Solubility  inner pressure
Ca2 = 2.1  10-3 3
kg - mole
Ca1 = 6.3  10-3
m3
Molar concentration on outer side
Ca1 = solubility  Outer pressure

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Ca2 = 2.1  10-3 1
kg - mole
Ca2 = 2.1  10-3 (5 M)
m3
2. We know
mo Dab
A
=
L
Ca1 − Ca2 
9.1 (6.3  10−3 − 2.1 10−3 )

Molar flux, = −
.25  10−3
1.2 − 0
(5 M)
ma −6 kg-mole
= 1.52  10
A s-m2
3. Mass flux = Molar flux  Molecular weight
kg − mole
= 1.52  10 −6  2 mole
s − m2
[ Molecular weight of H2 is 2] (5 M)
kg
Mass flux = 3.04  10-6 .
s − m2
Explain steady state Equimolar counter diffusion.(15 M)BTL2

Consider two large chambers a and b connected by a passage as shown in figure.
Na and Nb are the steady state molar diffusion rates of components a and b respectively.
Equimolar diffusion is defined as each molecule of ‘a’ is replaced by each molecule of ‘b’
and vice versa. The total pressure P = Pa + Pb is uniform throughout the system.
3
P = Pa + Pb
Differentiating with respect to x
dp dpa dph
= +
dx dx dx
Since the total pressure of the system remains constant under steady state conditions.

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dp dpa dph
= + =0
dx dx dx
(5 M)
dpa dp
 =− h
dx dx
Under steady state conditions, the total molar flux is zero.
 Na + Nb = 0
Na = - Nb
A dpa A dpa
 -Dab = Dab .........(5)
GT dx GT dx
From Fick’s law,
A dpa
Na = −Dab
GT dx
A dpb
Nb = Dba
GT dx
We know
dpb dpa
−
dx dx (5 M)
substitute in Equation (5)
A dpa A dpa
(5)  -Dab = −Dba
GT dx GT dx
 Dab = Dba = D
We know,
A dpa
Na = -Dab
GT dx
int eresting
ma Dab 2 dpa
A GT 1 dx
Na = =

Molar flux, Na = =   .....(6)
A GT  x 2 − x1 
similarly,
mb Dab  Pb1 − Pb2 

Molar flux, Nb = =   ......(7) (5 M)
A GT  x 2 − x1 

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Solved Problems on Equimolar Counter Diffusion
Ammonia and air in equimolar counter diffusion in a cylindrical tube of 2.5 mm diameter and
15m length. The total pressure is 1 atmosphere and the temperature is 25C. One end of the
tube is connected to a large reservoir of ammonia and the other end of the tube is open to
atmosphere. If the mass diffusivity for the mixture is 0.28  10-4 m2/s. Calculate the following,
a) Mass rate of ammonia in kg/h, b) Mass rate of air in kg/h(15 M)BTL4
Total pressure P = Pa1 + Pa2
1 bar = Pa1+ 0 [ open to atmosphere. So, Pa2 = 0]
 Pa1 = 1 bar
 Pa1 = 1 105 N / m2
Pa2 = 0
For equimolar counter diffusion

Molar flux, =   [From equation 6] ...(1) (5 M)
A GT  x 2 − x1 
4
J
Where, G – Universal gas constant = 8314
kg − mole − k

A − Area = d2
4

= (2.5  10 −3 )2
4
A = 4.90  10 −6 m2 (5 M)
ma 0.28  10 1 10 − 0 
−4 5
(1)  = x 
4.90  10 -6
8314  298  15 
kg − mole
Molar transfer rate of ammonia, ma = 3.69  10 −13 .
s
We know,
Mass transfer rate = Molar transfer rate  Molecular of
of ammonia of ammonia weight of ammonia
Mass transfer rate of ammonia = 3.69  10-13 17

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Molecular weight of ammonia = 17,
[refer HMT data, Page: No.187]
Mass transfer rate of ammonia = 6.27  10-12kg/ s
kg
Mass transfer rate of ammonia = 6.27  10-12
// 3600h (2 M)
Mass transfer rate of ammonia = 2.25  10-8kg / h
We know,
kg − mole
Molar transfer rate of air, mb = −3.69  10 −13
s
[Due to equimolar diffusion, ma = −mb ]
Mass transfe rate = Molar transfer rate  Molecular weight
of air of air of air
= 3.69  10−13  29
Mass transfer rate of air = −1.07  10−11kg/ s
kg
= −1.07  10−11
1/ 3600h (3 M)
Mass transfer rate of air = -3.85  10 kg / h
-8
An open pan of 150 mm diameter and 75 mm deep contains water at 25C and is exposed to
atmospheric air at 25C and 50% R.H. Calculate the evaporation rate of water in grams per
hour. (15 M)(Dec 2019, May 2017, Dec 2016, May 2014)BTL4
Diffusion coefficient (Dab) [water + air] at 25C

5
= 93  10−3 m2 / h
93  10−3 2
 Dab = m /s
3600 (5 M)
Dab = 2.58  10−5 m2 / s .
Atmospheric air 50% RH (2)

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We know that, for isothermal evaporation,
Molar flux, At 25C, Pw1 = 0.03166 bar ,Pw1 = 0.03166  105 N/m2
Pw2 = Partial pressure at the top of the test pan corresponding to 25C and 50% relative humidity.
= In   ......(1)
A GT ( x 2 − x1 )  P − Pw1 
where,
 
A - Area = d2 =  (.150)2
4 4
 Area = 0.0176 m 
2
(5 M)
J
kg-mole-K
P − Total pressure = 1 bar = 1 105 N/m2
= In   ......(1)
A GT ( x 2 − x1 )  P − Pw1 
where,
 
A - Area = d2 =  (.150)2
4 4
At 25C  Area = 0.0176 m 
2
J
kg-mole-K
P − Total pressure = 1 bar = 1 105 N/m2
Pw 2 = 0.03166 bar = 0.03166  105  0.50

Pw 2 = 0.03166  105  0.50
Pw 2 = 1583 N/ m2
a
(1) 
0.0176

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2.58  10−5 1 105  1 105 − 1583 

=   In  5
8314  298 0.075 1 10 − 0.03166  10 
5
kg − mole
Molar rate of water vapour, ma = 3.96  10 −9
s
= 3.96  10  18
-9
(5 M)
Mass rate of water vapour = 7.13  10 kg/s. -8
1000g
= 7.13  10-8 
1
3600h
Mass rate of water vapour = 0.256 g/h
Air at 10C with a velocity of 3 m/s flows over a flat plate. The plate is 0.3 m long. Calculate
the mass transfer coefficient.(May 2019, Dec 2015)(15 M)BTL4
Properties of air at 10C [From HMT data book, Page: No.22]
Kinematic viscosity. V = 14.16  10-6 m2/s

We know that,
Ux
Reynolds Number, Re =

3  0.3
= (5 M)
14.16  10-6
6
Re = 0.63  105  5  105
Since, Re < 5  105 , flow is laminar
For Laminar flow, flat plate,

Sherwood Number (Sh) = 0.664 (Re)0.5 (Sc)0.333 ….(1)
[From HMT data book, Page: No.179]
Where,

Sc – Schmidt Number = ......(2)
Dab
Dab – Diffusion coefficient (water+Air) at 10C = 8C

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m2
= 74.1 10−3
3600s (5 M)
−5
Dab = 2.50  10 m / s.
2
14.16  10−6
(2)  Sc =
2.05  10−5
Sc = 0.637
Substitute Sc, Re values in equation (1)
(1)  Sh = 0.664 (0.63  105 )0.5 (0.687)0.333

Sh = 147
We know that,
hm x
Sherwood Number, Sh = (5 M)
Dab
hm  0.3
 147 =
2.05  10 −5
Mass transfer coefficient, hm = .01 m / s.

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ME8694 HYDRAULICS AND PNEUMATICS LTPC
3003
OBJECTIVES:
➢ To provide student with knowledge on the application of fluid power in process, construction and
manufacturing Industries.
➢ To provide students with an understanding of the fluids and components utilized in modern industrial fluid
power system.
➢ To develop a measurable degree of competence in the design, construction and operation of fluid power
circuits.
UNIT I FLUID POWER PRINICIPLES AND HYDRAULIC PUMPS 9

Introduction to Fluid power – Advantages and Applications – Fluid power systems – Types of fluids - Properties of
fluids and selection – Basics of Hydraulics – Pascal’s Law – Principles of flow - Friction loss – Work, Power and
Torque Problems, Sources of Hydraulic power : Pumping Theory – Pump Classification – Construction, Working,
Design, Advantages, Disadvantages, Performance, Selection criteria of Linear and Rotary – Fixed and Variable
displacement pumps – Problems.
UNIT II HYDRAULIC ACTUATORS AND CONTROL COMPONENTS 9

Hydraulic Actuators: Cylinders – Types and construction, Application, Hydraulic cushioning – Hydraulic motors -
Control Components : Direction Control, Flow control and pressure control valves – Types, Construction and
Operation – Servo and Proportional valves – Applications – Accessories : Reservoirs, Pressure Switches –
Applications – Fluid Power ANSI Symbols – Problems.
UNIT III HYDRAULIC CIRCUITS AND SYSTEMS 9

Accumulators, Intensifiers, Industrial hydraulic circuits – Regenerative, Pump Unloading, Double- Pump, Pressure
Intensifier, Air-over oil, Sequence, Reciprocation, Synchronization, Fail-Safe, Speed Control, Hydrostatic
transmission, Electro hydraulic circuits, Mechanical hydraulic servo systems.
UNIT IV PNEUMATIC AND ELECTRO PNEUMATIC SYSTEMS 9

Properties of air – Perfect Gas Laws – Compressor – Filters, Regulator, Lubricator, Muffler, Air control Valves,
Quick Exhaust Valves, Pneumatic actuators, Design of Pneumatic circuit – Cascade method – Electro Pneumatic
System – Elements – Ladder diagram – Problems, Introduction to fluidics and pneumatic logic circuits.
UNIT V TROUBLE SHOOTING AND APPLICATIONS 9

Installation, Selection, Maintenance, Trouble Shooting and Remedies in Hydraulic and Pneumatic systems, Design
of hydraulic circuits for Drilling, Planning, Shaping, Surface grinding, Press and Forklift applications. Design of
Pneumatic circuits for Pick and Place applications and tool handling in CNC Machine tools – Low cost Automation
– Hydraulic and Pneumatic power packs.
TOTAL:45 PERIODS
TEXT BOOKS:
1. Anthony Esposito, “Fluid Power with Applications”, Pearson Education 2005.
2. Majumdar S.R., “Oil Hydraulics Systems- Principles and Maintenance”, Tata McGraw-Hill, 2001.
REFERENCES:
1. Anthony Lal, “Oil hydraulics in the service of industry”, Allied publishers, 1982.
2. Dudelyt, A. Pease and John T. Pippenger, “Basic Fluid Power”, Prentice Hall, 1987.
3. Majumdar S.R., “Pneumatic systems – Principles and maintenance”, Tata McGraw Hill, 1995
4. Michael J, Prinches and Ashby J. G, “Power Hydraulics”, Prentice Hall, 1989.
5. Shanmugasundaram.K, “Hydraulic and Pneumatic controls”, Chand & Co, 2006.
JIT-JEPPIAAR/MECH/Mr.S.ARUN & Mr.S.KANNAN/IIIrdYr/SEM 06 /ME8694/HYDRAULICS AND PNEUMATICS/UNIT 1-

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Subject Name: Hydraulics and Pneumatics Subject Handler: Mr.S.Arun & Mr.S.Kannan
UNIT I – FLUID POWER PRINCIPLES AND HYDRAULIC PUMPS
Introduction to Fluid power – Advantages and Applications – Fluid power systems – Types of fluids -
Properties of fluids and selection – Basics of Hydraulics – Pascal’s Law – Principles of flow - Friction
loss – Work, Power and Torque Problems, Sources of Hydraulic power : Pumping Theory – Pump
Classification – Construction, Working, Design, Advantages, Disadvantages, Performance, Selection
criteria of Linear and Rotary – Fixed and Variable displacement pumps – Problems.
PART * A
Q.No. Questions
1 Define the term fluid power. BTL1

Fluid power may be defined as the technology that deals with the generation, control and transmission
of power using pressurized fluids.
2 Compare hydraulic and pneumatic system. BTL2
S.No Hydraulic System Pneumatic System
1. It employs a pressurized liquid as It. employs a compressed gas usually air as
a fluid. a fluid.
2. Generally, Hydraulic systems are Pneumatic systems are usually designed as
designed as closed system. open system.
3. System get slow down if leakage Leakage does not affect the system much
3 What are the functions of hydraulic fluid? BTL2
➢ To transmit fluid power efficiently to perform useful work.
➢ To lubricate the moving parts to minimize wear and friction.
➢ To absorb, carry and dissipate the heat generated within the system
4 Write the importance of viscosity and what happens if viscosity is too high (or) too low. BTL2
Viscosity is the most important property of a hydraulic fluid, as it determines the ability of a fluid to
be pumped and transmitted through the system.
Too high viscosities (Heavy weight fluids) have the following effects.
➢ High resistance to flow, which causes sluggish operation (Difficult to flow).
➢ Increases power consumption.
Too low viscosities (Light weight fluids) have the following effects.
➢ Less precision control and slower responses.
➢ Increases Leakage losses past seals.
5 List any four applications of fluid power system. BTL2
➢ Agriculture : Hydraulically driven farm equipments.
➢ Automobile : Fluid power steering and braking systems.
➢ Defence : Missile Launch Systems, navigation controls.
➢ Transportation : Hydraulically powered overhead sky tram.
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6 List the advantages and disadvantages of hydraulic system. BTL2
Advantages of Hydraulic system
➢ Large load capacity with almost high accuracy and precision.
➢ Smooth movement.
➢ Disadvantages of Hydraulic system
➢ Hydraulic Elements needs to be machined to a high degree of precision.
➢ Leakage of Hydraulic oil poses problems to hydraulic operators.
7 List the advantages and disadvantages of pneumatic systems. BTL2
Advantages of Pneumatic system
➢ Low inertia effect of pneumatic components due to light density of air.
➢ System is light in weight.
Disadvantages of Pneumatic systems
➢ Suitable only for light loads or small loads.
➢ Availability of the assembly components is doubtful.
8 What is the function of compressor in pneumatic system? BTL2
It is use to compress the incoming atmosphere air above 5 bar which is used as medium in pneumatic
system.
9 Name three basic methods of transmitting power. BTL2
➢ Electrical power transmission,
➢ Mechanical power transmission, and
➢ Fluid power transmission, Hydraulic power transmission, and Pneumatic power transmission
10 In comparison with hydraulic systems, why are pneumatic systems are suitable only for low
load and low power applications? BTL4
Since pneumatic pressures are quite low due to the compressor design, the pneumatic systems are
suitable only for low load and low power applications.
11 What are the basic components that are required for a hydraulic system? BTL2
The six basic components of a hydraulic system are :
➢ Reservoir (or tank),
➢ Pump,
➢ Prime mover
➢ Valves,
➢ Actuator, and
➢ Fluid-transfer piping
12 What is demulsibility? Write its significance. BTL2
The property of a hydraulic fluid to separate rapidly and completely from moisture and to resist
emulsification is known as demulsibility. Significance: This property is significant because the
operation of many hydraulic systems are conducive to the forming of moisture or of stable water-in-
oil emulsions.
13 What is oxidation stability? BTL2
Oxidation stability is defined as the ability of a liquid to resist reaction with oxygen or oxygen-
containing compounds.
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14 List few required properties of a good hydraulic fluid. BTL2
➢ Stable viscosity characteristics.
➢ Good lubricity.
➢ Compatibility with system materials.
➢ Stable physical and chemical properties.
15 State the law that govern the fluid power system. BTL1
Pascal's law states that the pressure generated at any point in a confined fluid acts equally in all
directions.
16 Differentiate between laminar and turbulent flow. BTL2
A laminar flow is one in which paths taken by the individual particles do not cross one another and
moves along well-defined paths. The laminar flow is characterized by the fluid flowing in smooth
layers of lamina. A turbulent flow is that flow in which fluid particles move in a zig-zag way. The
turbulent flow is characterized by continuous small fluctuations in the magnitude and direction of the
velocity of the fluid particles.
17 List out the various energy losses when liquid flows through a pipe. BTL2
➢ Major energy losses: This is due to friction
➢ Minor energy losses: These losses are due to Losses in valves and pipe fittings. Sudden
enlargement/Contraction of pipe, Bend in pipe, etc.
18 Name any four hydraulic fluids that are commonly used. BTL2
➢ Petroleum oils.
➢ Water-in-oil and oil-in-water emulsions.
➢ Glycols.
➢ Phosphate esters.
19 Pump do not pump pressure. Justify the statement. BTL4
In pump, fluid flow in the inlet line always takes place at negative pressure and hence a relatively low
flow velocity is needed here. This causes the fluid to the pushed up \ and creates it to lift. Due to the
resistance offered by the system to fluid flow, the pressure get raises to the required level. So, pumps
do not pump pressure, but, they /produce fluid to flow.
20 List the advantages of hydrostatic pumps over hydrodynamic pumps. BTL2
➢ They are capable of generate high pressure (over 690 bar).
➢ They are relatively small and compact in size.
➢ High volumetric efficiency due to less leakages.
21 Classify different types of pumps used in fluid power system. BTL2
Based on the construction, Hydrostatic pumps are classified as
i) Gear pumps (Fixed displacement only)
➢ External Gear pump
➢ Internal Gear pump
➢ Lobe pump
➢ Screw pump
➢ Gerotor pump
ii) Vane pump (Fixed or variable displacement)
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➢ Balanced vane pump
➢ Unbalanced vane pump
iii) Piston pump (Fixed or variable displacement)
➢ Axial design
➢ Radial design
22 How the vane pump / piston pump can be made as variable displacement unit? BTL2
Variable displacement units can be made by either varying the eccentricity of rotor with respect to
cam ring, in case of vane pumps or by varying the offset angle, in case of piston pumps.
23 Why are positive displacement pumps universally used in fluid power industries? BTL2
Positive displacement pumps are primarily used where pressure development is the prime
requirement. This type of pumps is capable of delivering high pressure fluid, so it is universally used
in fluid power systems.
24 What are piston pumps? Name the two basic types of piston pumps. BTL2
In piston pumps, the pumping action is affected by a piston that moves in a reciprocating cycle
through a cylinder. Types: 1. Axial piston pumps, and 2. Radial piston pumps.
25 How can you vary the displacement in an axial piston pump? BTL2
The variable displacement in an axial piston pump can be achieved by altering the angle of the swash
plate (or offset angle). Because in axial pumps, this swing angle determines the piston stroke and
hence the pump displacement.
26 What are the advantages of screw pumps than other gear pumps? BTL2
➢ Screws are continuous, most reliable.
➢ No pressure pulsation will occur.
➢ High speed operation is possible with less noise.
➢ No pump turbulence and oil churning.
PART * B
1 What are the desirable properties of hydraulic fluids? Discuss them in detail. BTL2
➢ Viscosity: (2M)
It is a measure of the fluid’s internal resistance offered to flow. If the viscosity of the hydraulic
oil is higher than recommended then, the viscous oil may not be able to pass through the pipes.
The working temperature will increases because there will be internal friction.
➢ Oxidation stability: (2M)
It is caused by a chemical reaction between the oxygen of the dissolved air and the oil. The
oxidation of the oil creates impurities like sludge, insoluble gum and soluble acidic products
which cause corrosion and make the operation sluggish.
➢ Demulsibility: (2M)
➢ It's an ability of a hydraulic fluid to separate rapidly from moisture and successfully resist
emulsification. If oil emulsifies with water the emulsion will promote the destruction of
lubricating value and sealant properties.
➢ Lubricity: (2M)
➢ Wear results in increase clearance which leads to all sorts of operational difficulties including fall
of efficiency. Selecting a hydraulic oil care must be taken to select one which will be able to
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lubricate the moving parts efficiently.
➢ Flash point & Fire point: (3M)
➢ Flash point is the temperature at which a liquid gives off vapour in sufficient quantity to ignite
momentarily or flash when a flame is applied. The minimum temperature at which the hydraulic
fluid will catch fire and continue burning is called fire point.
➢ Compressibility: (2M)
➢ All fluids are compressible to some extent. Compressibility of a liquid causes the liquid to act
much like a stiff spring. The coefficient of compressibility is the fractional change in a unit
volume of liquid per unit change of pressure.
2 With neat sketch explain the working of lobe pump and gerotor pump with advantages and
disadvantages. BTL2
Lobe Pump:
Working: (3M)
Gears replaced by lobes - lobes are driven independently and they do not have actual contact with
each other - contact is prevented by external timing gears - lobes come out of mesh, they create
expanding volume on the inlet side of the pump - flows into the cavity and is trapped by the lobes
rotation -.liquid travels around interior of casing in pockets b/w lobes and casing - meshing of the
lobes forces liquid through the outlet port under pressure.
Diagram: (3M)
Gerotor pump:
Working: (3M)
Inner gerotor (driver) - outer gerotor (follower) - housing - outer gerotor has one more teeth than
inner gerotor - both rotates in same direction - have different centre of rotation - when teeth
disengage space b/w them increases - partial vacuum sucks oil inside the chamber - chamber
reaches maximum volume suction stops - space diminishes with meshing teeth forces oil to
discharge.
Diagram: (4M)

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3 With neat sketch explain the hydraulic and pneumatic fluid power systems. BTL2
Hydraulic system: (6M)
Reservoir - Pump - motor (prime mover) - Filter - Pressure relief valve - direction control valve -
hydraulic cylinder (actuator)
Pneumatic system: (7M)

Motor (prime mover) - Compressor - Filter - Direction control valve - Pneumatic cylinder
actuator)
4 a. How to calculate frictional losses in common valves and fittings (8M) BTL5
𝑉2
𝐻𝐿 = 𝐾 (2𝑔) (2M)
Where, K = Constant of proportionality called the K-factor.
𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝, ∆𝑃 = 𝐻𝐿 × 𝑤𝑜𝑖𝑙 (2M)
Where, woil = Weight density of oil flowing through valves and fittings.
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K-factors of common valves and fittings (4M)
b. Differentiate between laminar and turbulent fluid flow. (5M) BTL2
Laminar Flow Turbulent Flow
Laminar flow is one in which paths taken by Turbulent flow is that flow in which fluid
the individual particles do not cross one particles move in zig-zag way. The turbulent
another and move along well defined paths. flow is characterised by continuous small
The laminar flow is characterised by the fluid fluctuations in the magnitude and direction of
flowing in smooth layers of laminae. the velocity of the fluid particles.
5 Explain the construction and working of a gear pump. BTL2

Working: (4M)
Two mating gear (driver and follower) - closely fitted casing - driver shaft coupled with prime
mover - inlet and outlet are directly opposite to each other - larger straight ports are preferred for
better performance - vacuum formed in the cavity b/w the teeth as they unmesh - pressure rise in
pump produced by sequencing action on the fluid.
Diagram: (6M)
Analysis of volumetric displacement and theoretical flow rate: (3M)

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6 a. A gear pump has a 80 mm outside diameter, a 55 mm inside diameter and a 25 mm
width. If the actual pump flow at 1600 rpm and rated pressure is 95 Lpm, what is the
volumetric efficiency? (6M) BTL5
Solution:
Actual Discharge, QA = 95 Lpm = 95 x 10-3 m3/min
𝜋 10−5 𝑚3
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑑𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡, 𝑉𝐷 = 4 (𝐷𝑜2 − 𝐷𝑖2 )𝐿 = 6.627 × (2M)
𝑟𝑒𝑣
3
Theoretical Discharge, QT = VD x N = 0.106 m /min (2M)
𝑄𝐴
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑒, 𝜂𝑣𝑜𝑙 = × 100 = 89.62 % (2M)
𝑄𝑇
b. Explain the radial piston with advantages and disadvantages of piston pump. (7M)
number of radial pistons in a cylinder block revolves around stationary eccentric cam - piston
move perpendicularly to shaft centerline - eccentric cam causes in and out or pumping motion of
the pistons.
7 With neat sketch explain the working of screw pump and internal gear pump with
advantages and disadvantages. BTL2
Screw pump: (7M)
Axial flow positive displacement gear pump - two rotor screw with helical gears - meshing
screws - sealed chamber - connected by timing gear - liquid moves forward along the axis with
rotation of screw.
Internal gear pump: (6M)

Internal spur gear - outside ring gear - crescent shaped spacer - external housing - internal gear
drives the external gear - cavity volume increases and suction occurs - oil trapped b/w internal
and external gear teeth .
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8 With a neat sketch explain the principle and working of unbalanced vane pump and derive
the expression for the output of vane pump. BTL2
Diagram: (5M)
Working: (4M)
Rotor mounted off center - rectangular vanes free to move in radial slots - vanes thrown outwards
by centrifugal force - eccentricity of revolving rotor produces vacuum at suction side causing
inflow of liquid.
Expression: (4M)
𝜋
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑑𝑖𝑠𝑝𝑙𝑎𝑐𝑒𝑚𝑒𝑛𝑡, 𝑉𝐷 = (𝐷𝐶 + 𝐷𝑅 )𝑒𝐿
2
where,
VD = Volumetric displacement in m3
DC = Diameter of cam ring in m
DR = Diameter of rotor in m
(𝐷𝐶 + 𝐷𝑅 )
𝐸𝑐𝑐𝑒𝑛𝑡𝑟𝑖𝑐𝑖𝑡𝑦, 𝑒 =
2
L = Width of rotor in mIf N = Rotor speed in rpm, then
QT = VD x N
9 a) A pump has a displacement of 80cm3. It delivers 1.25 Lps at 1200rpm and 75 bar. If the
prime mover input torque is 110N-m. Calculate i) overall efficiency ii) theoretical torque
required to operate the pump. (8M) BTL5
Solution:
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VD = 80 cm ; QA = 1.25 x 10 m /s; N = 1200 rpm; P = 75 x 10 N/m2; T = 90 N-m
3 -3 3 5
2𝜋𝑁 𝑟𝑎𝑑
𝜔= = 125.66 (2M)
60 𝑠
P×QA
𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦, 𝜂0 = T × 100 = 82.89% (3M)
A ×ω
𝑉𝐷 ×𝑃
𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑇𝑜𝑟𝑞𝑢𝑒, 𝑇𝑇 = = 95.49 𝑁 − 𝑚 (3M)
2𝜋
b) Calculate the actual flow rate in units of Lps of a radial piston pump for the following
specifications:
Number of pistons = 9; Diameter of piston = 25 mm; Maximum eccentricity = 10 mm;
Speed of rotor = 1800 rpm; Volumetric efficiency = 95%. (5M) BTL5
Solution:
Y = 9; d = 25 mm; e = 10 mm; N = 1800 rpm; η = 95%
𝑚3
𝑄𝑇 = 0.5𝑒𝑌𝜋𝑑2 𝑁 = 0.159 𝑚𝑖𝑛 (3M)
𝑚3 0.151×103
𝑄𝐴 = 𝑄𝑇 × 𝜂𝑣𝑜𝑙 = 0.151 𝑚𝑖𝑛 = = 2.516 𝐿𝑝𝑠 (2M)
60
PART * C
1 What types of fluids are available for hydraulic system? Explain each of them. BTL2
Petroleum Oils: (3M)
➢ These are the most common among the hydraulic fluids which are used in a wide range of
hydraulic applications.
➢ The characteristic of petroleum based hydraulic oils are controlled by the type of crude oil
used.
➢ Naphthenic oils have low viscosity index so it is unsuitable where the oil temperatures
vary too widely.
➢ The aromatics have a higher presence of benzene and they are more compatible with
moderate temperature variation.
➢ Paraffinic oils have a high viscosity index and they are more suitable for the system where
the temperature varies greatly.
Water glycols: (3M)
➢ These are solutions contains 35 to 55% water, glycol and water soluble thickener to
improve viscosity.
➢ Additives are also added to improve anticorrosion, anti wear and lubricity properties.
Water oil emulsions: (3M)
➢ These are water-oil mixtures.
➢ They are of two types oil-in-water emulsions or water-in-oil emulsions.
➢ The oil-in-water emulsion has water as the continuous base and the oil is present in lesser
amounts as the dispersed media.
➢ In the water-in-oil emulsion, the oil is in continuous phase and water is the dispersed
media.
Phosphate Ester: (3M)
➢ It results from the incorporation of phosphorus into organic molecules.

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➢ They have high thermal stability.
➢ They serve as an excellent detergent and prevent building up of sludge.
Water: (3M)
➢ The least expensive hydraulic fluid is water.
➢ Water is treated with chemicals before being used in a fluid power system. This treatment
removes undesirable contaminates.
2 a. State and explain Pascal’s law and With neat sketch, explain the hydraulic jack. (7M)
BTL1
Pascal Law: (2M)
It states that the pressure generated at any point in a confined fluid acts equally in all directions.
Hydraulic jack: (5M)
b. List the advantages and disadvantages of fluid power system. (8M) BTL2
Advantages: (4M)
➢ No breakage as in mechanical transmission.
➢ Self lubricated with the hydraulic liquid itself.
➢ Overloads can easily controlled by using relief valves.
➢ Simplicity and compactness
Disadvantages: (4M)
➢ Leakage of oil or compressed air
➢ Busting of oil lines, air tanks
➢ More noise in operation.
3 Explain the working of bent axis and swash plate design of piston pump with advantages
and disadvantages. BTL2
Bent axis piston pump: (8M)
Cylindrical block rotating with drive shaft - offset angle relative to centerline - pistons and
cylinders arranged along a circle - ball and socket joints connect piston rods with drive shaft -
distance b/w drive shaft flange and cylinder block changes - piston moves in and out of cylinder.

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Swash plate piston pump: (7M)

Variable displacement capability - altering the angle of swash plate - angle of tilt determines
piston stoke - increase swash plate angle will increase piston stoke - when swash plate is vertical
no displacement.
4 Compare between hydraulic, pneumatic and electromechanical power system. BTL4

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UNIT II – HYDRAULIC ACTUATORS AND CONTROL COMPONENTS
Hydraulic Actuators: Cylinders – Types and construction, Application, Hydraulic cushioning – Hydraulic
motors - Control Components : Direction Control, Flow control and pressure control valves – Types,
Construction and Operation – Servo and Proportional valves – Applications – Accessories : Reservoirs,
Pressure Switches – Applications – Fluid Power ANSI Symbols – Problems.
PART * A
Q.No. Questions
1 Define fluid power Actuator. Classify its types. BTL2

Fluid power actuators are devices that perform useful work by extracting energy from the fluid
and convert it to mechanical energy. Actuators transmits and controls the fluid power efficiently
to provide correct force and speed for any job ranging from simplex to complex. Fluid power
actuators may be either linear type or rotary type. There are two types of fluid power actuators.
They are (1) Linear actuators (2) Rotary actuators. Linear actuators provide linear motion while
rotary actuators provide rotary mechanical motion.
2 Name different types of hydraulic cylinders. BT2
➢ Single acting cylinders,
➢ Double acting cylinders,
➢ Telescoping cylinders,
➢ Tandem cylinder and
➢ Through rod cylinders.
3 By what means, single-acting cylinders are retracted? BTL2
The single-acting cylinders are retracted using gravity or by the inclusion of compression spring
at the rod end of the cylinders.
4 What is meant by cylinder cushioning? BTL2
When the pressurised fluid is allowed to enter inside the cylinder, the piston accelerates and
travels in the cylinder barrel. If the piston is allowed to travel at the same speed till the end of the
stroke, it will hit the end cap with a great impact. To avoid this impact, the piston needs to
decelerate at the end of the travel. The arrangement made at the end caps to achieve the same is
called 'cylinder cushion'.
5 What do you mean by double-rod cylinder? BTL2
A double-rod cylinder, also known as through-rod cylinder has piston rods extending from both
ends of the cylinder. These cylinders produce equal force and speed on both sides of the cylinder.
6 Why are double-acting cylinders known as differential cylinders? BTL2
Since the piston rod is attached at one side only, the cylinder exerts greater force when extending
[F = P x Apiston] than when retraction [F = P x (Apiston - Arod)]. This results in different pressure
levels on either side of the piston and that's why double-acting cylinders are also called as
differential cylinders.
7 What do you mean by a limited rotation hydraulic motor? BTL2
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The limited-rotation motors provide rotary output motion over a finite angle. Usually rotation of
the shaft of these motors is 90°, 180°, or 270°.
8 Name the basic types of rotary actuators. BTL2
➢ Continuous rotary actuator, and (a) Gear motor, (b) Vane motors, and (c) Piston motors.
➢ Limited rotation hydraulic motors. (a) Vane type, and (b) Piston type.
9 List any four types of pressure control valves. BTL2
➢ Pressure-compensated valves
➢ Unloading valves
➢ Pressure relief valve
➢ Sequence valves
➢ Counterbalance valves
➢ Pressure reducing valve
10 What are fluid power symbols? BTL2
Fluid power symbols are used to represent individual components in fluid power circuit diagrams,
which identify components and their functions uniquely.
11 What are actuation devices and list them? BTL2
Actuation devices are components used in hydraulics/pneumatic circuits that are used for shifting
the valve spool from one position to another. The types of actuation devices are:
➢ Manual actuation devices
➢ Mechanical actuation devices
➢ Pilot operated actuation devices
➢ Solenoid operated actuation devices
12 What is two-way valve? BTL2
This particular valve has two ports, labeled P and A. P is connected to the pump line and A is the
outlet to the system.
13 What is shuttle valve? BTL2
A valve that has two inlets and one outlet is known as shuttle valve. The outlet receives the flow
from the inlet whichever is at a higher pressure.
14 Classify the control valves. BTL2
Based on the function, control valves are classified into three types.
➢ Direction control valves
➢ Pressure control valves
➢ Flow control valves
15 What are the functions of control valves? BTL2
The main functions of control valves are
➢ To regulate the pressure through a system
➢ To control and limit flow to the actuator
➢ To maintain contact pressure ratio between output and input to actuator.
16 Distinguish between pressure reducing valve and pressure relief valve. BTL2
Pressure reducing valve Pressure relief valve

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It is type of hydraulic pressure control It is a type of pressure control valve that
valve that controls the maximum pressure limits the maximum pressure in a hydraulic
in a branch of a circuit. or pneumatic circuit.
The reducing valve reads the pressure The relief valve reads the pressure upstream.
downstream.
The pressure reducing valve has an The pressure relief valve does not have an
external drain. external drain.
17 What are the three types of control valves based on their configuration? BTL2
➢ Poppet (or seat) valves
➢ Sliding spool valve and
➢ Rotary spool valves
18 Name various types of pressure control valves. BTL2
➢ Pressure limiting (or relief) valves,
➢ Pressure reducing valves,
➢ Sequence valves,
➢ Counter balance valves, and
➢ Unloading valves.
19 What is the use of a pressure relief valve in a hydraulic system? BTL3
The pressure relief valve protects a system from excessive fluid pressure over and above the
design pressure limit.
20 What is the use of sequence valve? BTL2
It is a type of hydraulic pressure control valve that is used to force two actuator to be operated in
a pre- determined sequence.
21 What is the purpose of a pressure reducing valve? BTL2
A pressure reducing valve is used to supply a prescribed reduced outlet pressure in a circuit and
to maintain it at a constant value.
22 What are flow control valves? Why are they referred as speed-control valves? BTL2
Flow control valves, also known as volume-control valves, are used to regulate the rate of fluid
flow to different parts of a hydraulic system. Since control of flow rate is a means by which the
speed of hydraulic machine elements is governed, therefore flow control valves are also referred as
speed-control valves.
23 What are sequence valves? BTL2
The sequence valves are used to control the fluid flow to ensure several operations in a particular
order of priority in the system.
24 What is the function of servo system? BTL2
Generally, hydraulic direction control valves are working with many actuating devices, especially
solenoids. Solenoids can be operated under two states: shifted and not shifted. So, solenoid valve
can be shifted open to allow flow or closed to block flow. But servo systems are able to precisely
position the valve spool between the open and closed positions. This allows the flow to be
throttled (metered) through the valve and provides precise flow control as well as direction
control. Simply, servo systems are integration of DCV with FCV.
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25 What are proportional control valves? BTL2
It is an infinite variable position valves. They use a variable force direct current solenoid to
control the output from the main spool.
PART * B
1 How cylinder cushioning takes place in cylinders? Explain with diagram. BTL2
When the pressurised fluid is allowed to enter inside the cylinder, the piston accelerates and
travels in the cylinder barrel. If the piston is allowed to travel at the same speed till the end of the
stroke, it will hit the end cap with great impact. To avoid this impact, the piston needs to
decelerate at the end of the travel. the arrangement made at the end caps to achieve the same is
called cylinder cushion. (3M)
Operation: (5M)
➢ Exhaust flow passes freely out of cylinder until the plunger enter the end cap port.
➢ Plunger enters cap and blocks the free flow
➢ Now the restricted flow path decelerates the piston
➢ Needle valve controls the rate of deceleration
➢ check valve allows free flow on the return stroke
Diagram: (5M)
2 With neat sketches explain the working of simple check valve and pilot operated check
valve. BTL2
Simple Check Valve: (6M)
Flow - normal direction - pressure acts against spring tension. Pressure overcomes spring force -
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valve allows free flow.
Flow - opposite direction - spring force pushes poppet in closed position - no flow permitted.
Pilot operated Check valve: (7M)

Free flow - Port A to Port B.
Reverse flow - poppet in closed position - no flow.
Reverse flow - Port B to Port A - pilot pressure applied through pilot pressure port.
Applications: hydraulic jack (hydraulically lock the cylinder)
3 In detail write the working of pressure reducing valve and sequence valve with neat
sketches. BTL2
Pressure reducing valve: (6M)
Spring loaded spool to control downstream pressure - valve setting pressure - free flow - outlet
pressure increases - spool moves left - partly blocks outlet port - drain passage provided to drain

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fluid to tank.
Sequence valve: (7M)
These valves are used to control the fluid flow to ensure several operations in a particular order
of priority in the system.
Preset valve pressure - allows fluid from primary port to operate first phase - when pressure
exceeds - spool moves up - flow diverted to secondary port to operate the second phase.
4 Explain in detail the different types of FCV. BTL2

Globe valve: (6M)
Disk type globe valve is also called butterfly valve consists of a large disc which is rotated inside
the pipe, the angle determining the flow rate.
Plug type globe valve has a tapered plug that control the flow rate by varying the vertical plug
position.
Ball type globe valve has a ball with a through hole which is rotated inside a machined seat.

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Needle valve: (2M)
Adjusted manually to control the flow rate of fluid through valve.
Have smaller flow area and high pressure drop then the globe valve.
Pressure compensated flow control valve: (5M)

Spool controls the size of inlet orifice - maintains constant pressure drop across the throttle valve.
Inlet pressure increase - spool closes the inlet passage - permits fluid flow for which throttle is
set.
5 Explain with neat sketches of simple pressure relief valve and compound relief valve. BTL2
Simple pressure relief valve: (6M)
Inlet pressure overcomes force exerted by spring - valve opens - fluid directed to sump.
Adjusting screw to adjust screw pressure.
Types: Ball, poppet, sliding pool
Compound pressure relief valve: (7M)

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Stage 1: Movable poppet allows fluid to escape to reservoir when system pressure exceeds.
Stage 2: Pilot valve poppet - pressure limit adjustment screw - fluid passes from inlet to control
chamber - pressurised fluid escapes through centrally drilled drain hole.
PART * C
1 How position valves can be classified? Explain each of them. BTL2
2/2 Direction Control Valve: (3M)
Position 1: When the push button is in normal position, spring and fluid pressure force the ball
up, therefore flow is blocked.
Position 2: When the pressure of the push button pushes the ball off its seat, then the flow is
permitted.

Spool position 1: Flow from Port P to Port A - Port R remains closed.
Spool position 2: Port P closed, flow from Port A to Port R

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Spool position 1: Flow from Port P to Port A & Port B to Port T
Spool position 2: Flow from Port P to Port B & Port A to Port T

Spool position 1: Flow from Port P to Port A & Port B to Port T
Spool position 2: Flow from Port P to Port T, Port A & B closed
Spool position 3: Flow from Port P to Port B & Port A to Port T

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2 A hydraulic motor has a displacement of 150 cm3 and operates with a pressure of 85 bar
and a speed of 1800rpm. The actual flow rate consumed by the motor is 5 Lps and actual
torque delivered by the motor is 185 N-m. Find (i) Volumetric efficiency (ii) Mechanical
efficiency (iii) Overall efficiency (iv) Power delivered by the motor. BTL5
3 A pump supplies oil 1.5 Lps to a 50 mm diameter double acting hydraulic cylinder. If the
load is 4300N (extending and retracting) and the rod diameter is 25 mm, find: BTL5
(i) Hydraulic pressure during the extending stroke
(ii) Piston velocity during the extending stroke
(iii) Cylinder kW power during the extending stroke
(iv) Hydraulic pressure during the retracting stroke
(v) Piston velocity during the retracting stroke
(vi) Cylinder kW power during the retracting stroke

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4 List and sketch the fluid power ANSI symbol for the five basic classifications. BTL1

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UNIT III – HYDRAULIC CIRCUITS AND SYSTEMS
Accumulators, Intensifiers, Industrial hydraulic circuits – Regenerative, Pump Unloading, Double-

Pump, Pressure Intensifier, Air-over oil, Sequence, Reciprocation, Synchronization, Fail-Safe, Speed
Control, Hydrostatic transmission, Electro hydraulic circuits, Mechanical hydraulic servo systems.
PART * A
Q.No. Questions
1 What is the function of accumulator? BTL2

Accumulators are temporary storage devices that stores the potential energy of a hydraulic fluid
under pressure and acts as a secondary source as demanded by the system.
2 What are the types of accumulator? BTL2
Based on the source of dynamic force to maintain pressure, the accumulators are classified as
➢ Weight or gravity-loaded accumulator
➢ Spring-loaded accumulator
➢ Gas-loaded accumulator
The first two are categorized as mechanical accumulators and third one as hydro-pneumatic
accumulator.
3 What is electromechanical relay? BTL2
A relay is a electrically actuated switch which open or close when its corresponding coil is
energized. These relays are commonly used for energizing and de-energizing the solenoids as
they require high current to operate.
4 What is the use of intensifier? Mention its applications. BTL2
A pressure intensifier or booster is a device which generates pressures to a greater value than the
pump discharge pressure by using fluid power.
Intensifier finds many applications of which, important are listed below.
➢ Burst testing machines
➢ High pressure clamping devices
➢ Moulding machines
➢ Spot-welding machines
➢ Riveting machines
5 What type of gas is used in gas loaded accumulators and why oxygen not used for this
purpose? BTL2
Inert gas is used in gas loaded accumulators and oxygen is not used for this purpose because it
catches fire and cause explosion.
6 What is the use of air-to-hydraulic pressure booster? BTL2
The air-to-hydraulic pressure booster is a device used for converting compressed air into the
higher hydraulic pressure, which is required for operating hydraulic cylinders.
7 What are the basic requirements for parallel cylinder synchronizing system? BTL2
Two cylinders must be identical, but no cylinders are really identical, as manufacturing tolerances
may vary.
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Load should be divided equally for both cylinders to extend in exact synchronization.
8 What are the constituents of hydraulic power pack? BTL2
➢ Cylinder,
➢ Hydraulic pump,
➢ Hydraulic oil,
➢ Reservoir
9 What is air-oil intensifier? BTL2
An air-oil intensifier circuit, which drives a cylinder over a large distance at low pressure and
then over a small distance at high pressure
10 What is hydraulic fuse? BTL2
Hydraulic fuse is a device used in hydraulic systems to prevent hydraulic pressure from
exceeding an allowable value in order to protect circuit components from damage.
11 What is the function of bleed-off circuit? BTL2
Bleed off circuits control the fluid flow rate by bleeding off the excess flow back to the tank. This
is accomplished by providing a additional line parallel to the system pressure line. To slow down
the actuator, some of the flow is bled off through this line, thereby reducing the flow to the
actuator. It may be noted that, opening a bleed off FCV, slows down the actuator, whereas,
opening a meter in or meter out FCV increases the actuator speed.
In this system the flow control valve is placed in the line loading to the inlet port of the cylinder.
12 What is the difference between meter-in circuit and meter-out circuit? BTL2
Meter - in Circuit Meter - out Circuit
In this system the flow control valve is In this system the flow control valve is
placed in the line leading to the inlet port placed in the outlet line of the hydraulic
of the hydraulic system. system.
It controls the oil flow rate into the It controls the oil flow rate out of the
cylinder. cylinder.
Less pressure is developed in the rod end Excessive pressure is developed in the
of the cylinder while it is extending rod end of the cylinder while it is
If meter-in is desired point the arrow If meter-out is desired point the arrow
toward the cylinder port. away from the cylinder port.
13 What is the use of a regenerative circuit? BTL2
A regenerative circuit is used to speed up the extending speed of the double-acting cylinder.
14 What is the purpose of a fail-safe circuit? BTL2
Fail safe circuit is designed to safeguard the operator, the machine, and the workpiece. It prevents
any possible injury to the operator or damage to the machine and the workpiece.
15 What is meant by an air-over-oil system? BTL2
The air-over-oil system was both air and oil to obtain the advantages of each medium. By the use
of these two media, the quick action of air and the smooth high-pressure action of oil can be
blended.

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16 What are hydropneumatic circuits? BTL2
In some applications, the hydraulic and pneumatic circuits are coupled to get best use of the
advantages of both oil and air mediums. These combination circuits are known as
hydropneumatic or pneumohydraulic circuits.
17 Name the three ways of applying flow control valves in a fluid power circuit. BTL2
➢ Meter-in circuit,
➢ Meter-out circuit and
➢ Bleed-off circuit.
18 Why is extension stroke faster than retraction stroke in a regenerative circuit? BTL4
This is because oil flow from the rod end regenerates with the pump flow to provide a total flow
rater, which is greater than the pump flow rate to the blank end of the cylinder.
19 What do you mean by sequencing of cylinders? Name some applications where it would
be desirable to have sequencing of two cylinders. BTL2
In many applications, the operation of two hydraulic cylinders is required to be performed in
sequence one after the another. This is known as sequencing of cylinders.
Applications : (i) In a drilling machine, clamping and drilling operations should be performed in a
sequence. ii) In a punching machine, clamping and punching operations should be performed in a
sequence.
20 What do you mean by synchronization of cylinders? Name some applications where it
would be desirable to have two cylinders synchronized in movement. BTL2
Synchronization of cylinders is the process of making cylinders to perform identical task at same
rate. Application: The application of synchronizing of two cylinders can be found in material
handling equipment to push heavy components. Also they are widely used in packing industries.
21 List any two advantages of employing hydro pneumatic circuits. BTL2
➢ Using the combination circuit, the quick action of air and smooth, high pressure action of
oil can be blended.
➢ These circuits increase the performance of the equipment.
22 List the applications of an intensifier. BTL2
➢ Burst testing machines,
➢ High pressure clamping devices,
➢ Moulding machines,
➢ Spot-welding machines,
➢ Riveting machines,
➢ Hydraulic pressing and
➢ Punching machines etc.,
23 What is an intensifier? BTL2
Intensifer is an ancillary part used in hydraulic system to increase the pressure of hydraulic liquid.
24 What are the advantages of electrohydraulic servo systems over hydromechanical servo
systems? BTL2
➢ The electrohydraulic servo system can easily achieve the precision remote control of
position, force, and speed of actuator.
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➢ They guarantee the higher flexibility of operation.
➢ They ensure better control of fluid compressiblity, system stiffness and dynamic
behaviour of load.
➢ They also ensure correct ratio of force and speed that leads to higher energy conversion.
25 Define the terms 'lap' and 'null' with respect to servo valves. BTL1
Lap is the length relationship between the metering lands to the spool and the port openings in
the sleeve or body.
Null is the relational condition between the spool and valve port where the vale supplies no
control flow at zero load pressure drop.
PART * B
1 With neat sketch, write the different types of accumulator with advantages and
disadvantages that are used in hydraulic system. BTL2
Weight loaded Accumulator: (5M)
Idle periods of driven machine - fluid supplied till ram move to uppermost end - maximum
preesure is accumulated - working stroke - accumulated energy discharged.
Spring loaded Accumulator: (4M)
Hydraulic fluid is forced into accumulator cylinder - spring compressed - pressure depend on

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preloading and size of spring - fluid discharged from accumulator - spring expands and
approaches its free length.
Gas loaded Accumulator: (4M)
Pressurisation achieved by introducing pressurizing gas into container - when pressure increases
oil enters into oil port - reduction of volume of gas increases its pressure - limit switches actuated
by oil to limit the pressure.
2 Explain with suitable circuit, how an accumulator can be used as leakage compensator and
as emergency power source. BTL2
Accumulator as leakage compensator: (7M)
When maximum pressure is reached, the pressure switch stops the pump motor. The leakage of
oil is replaced by the volume of the accumulator and the rate of leakage in the cylinder
Accumulator as emergency power source: (6M)

In some hydraulic applications, it is necessary to retract the pistons of cylinder to their starting
position; even there may be an electrical power failure. In such applications, the accumulator can
be used as an emergency power source to retract the piston of the cylinder.

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3 How air over oil circuit can be used to have the advantages of air and oil. BTL2
Extension: (3M)
4/2DC valve shifted to left mode - air forces the oil to blind end through bottom of intensifier.
Retraction: (3M)
4/2DC valve shifted to right mode - air flow is blocked - air from top of intensifier vented to
atmosphere - completes the high pressure portion of cycle.
Circuit: (7M)
4 Explain the working of a pressure intensifier with advantages and applications. BTL2
A hydraulic intensifier is a device which converts a large volume, low pressure fluid supply into
a proportionately small volume high pressure fluid outlet. (2M)
Applications: (2M)
Punching presses, riverting machines, spot welder, tubing fixtures, high pressure holding fixtures,
pressure testing machines.
Advantages: (2M)
Eliminates need of expensive, high pressure pumps - compact and simple - low power input -
small volume of oil, heat generated is minimum - kW power requirements remain constant.
Construction: (3M)
Two pistons (low pressure and high pressure) - common piston rod - larger piston exposed from
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low pressure pump - neglecting losses due to friction - small end piston exerts force on fluid.
Diagram: (4M)
5 Explain the two handed safety circuit. BTL2

Fail safe circuit - safeguard operator, machine and workpiece - prevent any possible injury or
damage. (1M)
Construction: (1M)
Filter - unidirectional fixed displacement pump - pressure relief valve - pilot operated spring
offset 4/3 DC valve - push button operated 4/2 pilot control valve - check valve - double acting
cylinder.
Working: (3M)
Extension of cylinder takes place only when the operator depresses both the push buttons.
Retraction of cylinder takes place when the operator releases both the push buttons.
Circuit: (8M)
6 Explain the automatic cylinder reciprocation circuit. BTL2

Construction: (1M)
Filter - unidirectional fixed displacement pump - pressure relief valve - pilot operated spring
centered 4/3 DC valve - sequencing valves - check valves - double acting cylinder.
Retraction: (2M)
4/3 DC valve shifted to left - oil flows from pump to rod end - retraction of cylinder - check
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valve 1 prevent shifting DC valve - end of stroke pressure build up - sequence valve 1 opens -
pilot pressure signal shifts DC valve to right.
Extension: (2M)
4/3 DC valve in right mode - oil flows from pump to blind end - extension of cylinder - check
valve 2 prevents shifting DC valve - end of stroke pressure builds up - sequence valve 2 opens -
pilot pressure signal shifts DC valve to left.
Circuit: (8M)
7 How synchronizing of cylinder is possible in series piping? BTL2

There are many industrial applications require nearly perfect synchronization of movement of
two or more cylinders in order to complete some phase of operation. to accomplish the identical
task from the cylinders at the same rate, synchronization circuits are employed. (1M)
Circuit: (8M)
Filter - unidirectional fixed displacement pump - pressure relief valve - solenoid operated spring
offset 4/3 DC valve - double acting cylinders.
Extension of cylinder 1 and 2: (2M)

4/3 DC valve shifted to left - oil flows from pump to blind end of cylinder 1 - piston 1 extends -
oil from rod of cylinder 1 flows to blind end of cylinder 2 - piston 2 extends.

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Retraction of cylinder 1 and 2: (2M)
4/3 DC valve shifted to right - oil flows from pump to rod end of cylinder 2 - piston 2 retracts -
oil from blind of cylinder 2 flows to rod end of cylinder 1 - piston 2 retracts.
8 Explain the speed control circuit of hydraulic system. BTL2
Construction: (1M)
Filter - unidirectional fixed displacement pump - pressure relief valve - manually operated 4/2
DC valve - pressure compensated flow control valve - double acting cylinder - pressure gauges.
Meter in circuit: (6M)
Pressure compensated flow control valve connected to blind end of the cylinder - extension is
controlled - retraction at full speed
Meter out circuit: (6M)

Pressure compensated flow control valve connected to rod end of the cylinder - retraction is
controlled - extension at full speed
PART * C
1 With an example how electro hydraulic servo system works. BTL2
Operation: (7M)
Feedback device attached to actuator - actuator position or speed - electric signal to servo valve.
Feedback signal comparison with electrical input - not intended - electronic summer - error
signal.
Accurate control relative to position, speed, pressure and load.
Diagram: (8M)

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2 Discuss the construction and working of a Mechanical hydraulic servo system with a
diagram. BTL2
Diagram: (8M)
Operation: (7M)
Input - turning of steering wheel - command signal - servo system.
Valve sleeve - steering cylinder - valve spool attached to linkage - cuts off oil flow to cylinder -
motion of output wheel - desired position - feedback line.
3 Develop a circuit for punch- press application. BTL3
Intensifier circuit in punching press application:
Construction: (2M)
Filter - unidirectional fixed displacement pump - pressure relief valve - lever operated spring
return 4/3 DC valve - check valve - intensifier - double acting cylinder.
Working: (5M)
4/2 valve shifted to right side position - oil flow to blind end - sequence valve opens and supplies
flow to intensifier - low pressure input to high pressure output - pilot check valve allows to blind
end.
4/2 valve shifted to left side position - oil flow to rod end - pilot signal opens check valve -
cylinder retract to starting position.
Circuit: (8M)

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UNIT IV – PNEUMATIC AND ELECTRO PNEUMATIC SYSTEMS
Properties of air – Perfect Gas Laws – Compressor – Filters, Regulator, Lubricator, Muffler, Air control
Valves, Quick Exhaust Valves, Pneumatic actuators, Design of Pneumatic circuit – Cascade method –
Electro Pneumatic System – Elements – Ladder diagram – Problems, Introduction to fluidics and
pneumatic logic circuits.
PART * A
Q.No. Questions
What is a quick exhaust valve? BTL2

Quick exhaust valve is a special purpose three way pneumatic valve that increases the cylinder
rod speed by dumping the exhaust air directly to the atmosphere from the cylinder. Use of quick
1
exhaust valves, permits increased cylinder velocities and needs smaller, less expensive DCV.
This eliminates the need for exhaust air to travel from the cylinder to the main control valve
through long restricted pipe lines.
Name the factors to be considered for designing fluid power circuits. BTL2
Any circuit design should involve the three major considerations
2 ➢ Safety of system/operation
➢ System performance of function/operation.
➢ Efficiency of system/operation.
What is the purpose of fluid conditioners? BTL2
3 The purpose of fluid conditioners is to make the compressed air more acceptable and suitable
fluid medium for the pneumatic system components as well as for operating personnel.
How do pneumatic actuators differ from hydraulic actuators? BTL2
Generally pneumatic actuators are of lighter construction and of lesser weight when compared to
4
that of hydraulic actuators. This is because the pneumatic actuators are used mostly for low or
medium pressure applications only.
What is a FRL unit? BTL2
5
The combination of filter, regulator, and lubricator is often labelled as FRL unit or service unit
What is the purpose of a shuttle valve in a pneumatic circuit? BTL2
Shuttle valves are used when control is required from more than one power source. They are
6
generally used to shift the fluid flow from the second and back up source, when the main source
becomes inoperative
What is fluidics? BTL1
7 Fluidics is the technology that utilizes fluid flow phenomena in components and circuits to
perform a wide variety of control functions.
What advantages does fluidics offer? BTL2
➢ Fluidic devices offer exceptional thermal and physical stability and ruggedness.
8
➢ They are completely insensitive to radiation, even of extremely high loads.
➢ They are not affected by severe vibration and shock.
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➢ They are not susceptible to wear and tear.
Where are fluidic control systems preferred than other control systems? BTL2
9 Fluidic control systems are preferred over other control systems in areas subject to nuclear
radiation, magnetic flux, temperature extremes, vibration, and mechanical shock.
State the Coanda effect. BTL1
10 "When a stream of fluid meets other stream, the effect is to change its direction of flow and effect
is the fluid sticks to the wall."
Name four fluidic devices. BTL2
➢ Bistable flip-flop,
11 ➢ Flip-flop with start-up preference,
➢ SRT flip-flop,
➢ OR/NOR gate.
What is a bistable flip-flop? BTL2
12 A bistable flip-flop provides controlled assurance as to which of the two output ports will deliver
the power stream. It is normally used as a memory device.
What is a monostable device? BTL2
A monostable device is required to perform monostable function which is analogous to spring
13
return function. In this device, when the control signal is removed, the device will switch back to
the favoured output.
When do you use a flip-flop with start-up preference? BTL2
14 A flip-flop with start-up preference is used in applications where a specific output is required
when the power supply is first turned ON and all controls are OFF.
What is the use of truth table in logic devices? BTL2
15
A truth table helps to describe the functioning of that particular logic device.
Give the symbol and truth table for fluidic OR/NOR gate. BTL1
Truth Table
16 Inputs Output
A B OR NOR
0 0 0 1
0 1 1 0
1 0 1 0
1 1 0 0
What is Boolean algebra? Write its two functions relative to fluid power systems. BTL2
Boolean algebra is’algebra of logic'. This is the algebra of proportions where only two
17 possibilities - true or false - are allowed. Boolean algebra provides the following two functions:
It provides a means by which a logic circuit can be reduced to its simplest form.
It allows for the quick synthesis of a circuit that is to perform desired logic operations.
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Name four fluid sensors that are used in fluid power systems. BTL2
➢ Back-pressure sensor.
18 ➢ Cone-jet Proximity sensor,
➢ Interruptible-jet sensor, and
➢ Contact sensing.
Define Ladder diagram. BTL1
It is a special standard schematic representation of the physical components arrangement and its
19
way of connections made between them. It is so called because the circuit devices are connected
in parallel across the AC line form something looks like a ladder.
What is a PLC? BTL2
A programmable logic controller (PLC) is a user-friendly electronic computer designed to
20
perform logic functions such as AND, OR, or NOT for controlling the operation of industrial
equipment and processes.
List any four advantages that PLCs provide over electromechanical relay control
systems. BTL2
➢ PLCs are more reliable and faster in operation.
21
➢ They are smaller in size and can be more readily expanded.
➢ They require less electrical power.
➢ They have very few hardware failures when compared to electromechanical relays.
What is a solenoid? BTL2
It is electromechanical electromagnets that convert the electrical power into mechanical force to
22 operate fluid power valves remotely. It consists of a coil wrapped removable iron core
(Armature). When the solenoid is energized, the magnetic created causes the armature to shift the
valve spool.
Define relay. BTL1
Relay is an electrically actuated switch which open or close when its corresponding coil is
23
energized. These relays are commonly used for energizing and de-energizing the solenoids as
they require high current to operate.
Write few applications of electrohydraulic servo valve. BTL2
24 It is employed in more sophisticated control systems such as on tape controlled machine tools,
high speed printing presses, press brakes etc.
What is cascade method in pneumatics? BTL2
25 It involves dividing the sequence into groups with each group’s manifold (power or main pressure
line) being supplied with pneumatic power (pressure) one at a time and in sequence.
PART * B
Explain the FRL trio unit in pneumatic system. BTL2
Description: (6M)
Compressor:
1
Pressure vessel with stored compressed air
Emulsion made of lubricating oil and condensate.
Polluted compressed air, oil, water, solid matter.
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Filter: Clean, dehydrated, compressed air with pressure variations.
Regulator: Clean, dehydrated, compressed air regulated at desired pressure for spray guns, food
packing, etc.
Lubricator: Clean, dehydrated, regulated, lubricated compressed air for cylinders, valves, tools,
motors etc.
Diagram: (7M)
Design a system in which cylinder A is used to clamp the workpiece, cylinder B is used for
punching and cylinder C removes the workpiece from the station using cascade method.
BTL4
Circuit: (8M)
Working: (5M)
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+ + - - + -
Step 1: Sequence: A B B A C C
Step 2: No. of groups: 2
Step 3: No. of pressure lines: 2
Step 4: No. of pilot operated 4/2 DC valve = No. cylinders = 3
No. of limit valves = 6.
No. of cascade valves = 1
How the control of air cylinder using preferenced flip-flop is made? BTL2
Circuit: (7M)
Construction: (6M)
1 & 2 - Back pressure sensors, 3 - preferenced flip flops, 4 & 5 - pilot operated 3/2 control
valves, 6 - shuttle valves, 7 - normally closed limit switch, 8 - double acting air cylinder, 0.5 bar
represents pressure of the fluidic (pilot) air, 7 bar represents pressure f main air supply.
Explain the fluidic sequence control of two pneumatic cylinders. BTL2
Circuit: (7M)
Construction: (6M)
1 - Back pressure sensor, 2 - preferenced flip flop, 3 - OR/NOR gate, 4 & 5 - pilot operated 4/2
control valve, 6 & 7 - normally closed limit switches, 8 & 9 - double acting pneumatic cylinders,
0.5 bar represents pressure of the fluidic air, 7 bar represents pressure of the main air supply.
How the continuous reciprocation of a hydraulic cylinder using fluidic controls is made?
5 BTL2
Circuit: (7M)

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Construction: (6M)
1 - selector switch, 2 - preferenced flip flop, 3 & 4 - NOR gate, 5 - pilot operated 4/3 interface
valve, 6 & 7 - interruptible jet sensor, 8 - hydraulic cylinder
Explain the elements of PLC with neat diagram. BTL2
Diagram: (5M)
Description: (8M)
6
Central processing unit:
i) receives input data from various sensing elements
ii) executes the stored program
iii) delivers corresponding output signal to various load control devices.
Programmer/monitor:
Allows user to enter desired programme into RAM - relay logic determines sequence of
operation of system controlled.
Input/output module:
Transforms signals received from or sent to the fluid power interface devices - push button,
switches, pressure switches, limit switches, solenoid coils, motor relay coils, indicator lights.
PART * C
Define Coanda effect. Discuss how this effect useful to develop a monostable and bistable-
flip flop device. BTL1
1 Coanda effect: (3M)
When a stream of fluid meets other stream, the effect is to change its direction of flow and effect
is the fluid sticks to the wall.

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Monosatble flip flop: (6M)
Bistable filp flop: (6M)
Explain the PLC ladder programs for logic functions. BTL2

2 Descriptions: (3M)
The logic functions (such as AND, OR, NOR, etc) can be obtained by comibinations of switches
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(such as limit switches, solenoids coils, etc). The following sections show how PLC ladder
programs for such combinations.
OR Logic: (3M)
NOR Logic: (3M)
AND Logic: (3M)
NAND Logic: (3M)
Develop an electropneumatic circuit by cascade method for the following sequence:

A+B+B-A- where A and B stand for cylinders, (+) indicates extension and (-) retraction of
cylinders. BTL4
Working: (5M)
3 Step 1: Sequence: A+B+B-A-
Step 2: No. of groups: 2
Step 3: No. of pressure lines: 2
Step 4: No. of pilot operated 4/2 DC valve = No. cylinders = 2
No. of limit valves = 4.
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No. of cascade valves = 1
Circuit: (10M)

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UNIT V – TROUBLE SHOOTING AND APPLICATIONS
Installation, Selection, Maintenance, Trouble Shooting and Remedies in Hydraulic and Pneumatic
systems, Design of hydraulic circuits for Drilling, Planning, Shaping, Surface grinding, Press and
Forklift applications. Design of Pneumatic circuits for Pick and Place applications and tool handling in
CNC Machine tools – Low cost Automation – Hydraulic and Pneumatic power packs.
PART * A
Q.No. Questions
What is trouble shooting in hydraulic system? BTL2

1 Finding the faults in various components of hydraulic system like pump, strainer, valve, cylinder
and taking remedies to work in proper condition.
Define Drilling operation. BTL1
2 Drilling is the operation of producing a cylindrical hole of required diameter and depth by
removing metal by the rotating edge of a cutting tool called drill.
Mention the selection criteria of pneumatic systems. BTL2
➢ The force or Load required to work must be light or medium and suitable for light weight
3 applications.
➢ If the application requires speed, a medium amount of pressure, and only a fairly accurate
feed, then an air pneumatic system can be used.
Name any two faults that can be found in hydraulic systems. BTL2
4 Usage of low capacity pump and leakage in the hydraulic cylinder can lead to hazardous cause of
breakdown of hydraulic system.
What is a tree-branching chart? BTL2
Tree-branching chart is a chart used to simplify the troubleshooting process. This chart asks a
5 question which has only two possible answers-Yes or No. The answer determines the next step to
be taken in fault analysis. This chart helps to develop a logical and rapid approach to fault
diagnosis.
List any two selection criteria of hydraulic systems. BTL2
Pressure or force produced at the output should be high and the usage of hydraulic system
occupies more floor space. It also depends on
➢ Purpose
➢ Stroke requirement
6
➢ Thrust
➢ Speed
➢ Acceleration and deceleration
➢ Cylinder mountings
➢ Special seal requirement.
Define a low cost automation. BTL1
7
Low cost automation is a technology that creates some degree of automation around the existing
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equipment, tools, methods, people etc. using mostly standard component. A wide range of
activities such as loading, feeding, clamping, machining, welding, forming and packing can be
subjected to low cost automation.
What are the benefits of low cost automation? BTL2
➢ Reduce manual controls without changing the basic set up.
➢ Low investment
8
➢ Increased labor productivity
➢ Consistent quality
➢ Better utilization of material.
Define a power pack. BTL1
Power pack consists of a pump, electric motor, reservoir and associated valve assembled to one
9
unit to supply pressurized fluid. They are relatively small in size and provide functions of
pressure, direction and flow control within the basic package.
List three causes for low or erratic pressure in a hydraulic system. BTL2
➢ Very low relief valve setting
10
➢ Leakage of pump delivery within the system
➢ Pump slipping its entire volume.
List five things that can cause a noisy pump. BTL2
➢ Misalignment of pump and prime mover
➢ Air remains in pump casing
11
➢ Pump bolts very loose
➢ Very high viscosity of oil
➢ Pump running too fast.
If a pneumatic cylinder has erratic motion, name the causes. BTL4
12 ➢ Valve sticking or binding
➢ Cylinder sticking or binding.
List four basic requirements on which the life of the fluid power systems depend. BTL2
➢ Properly installed equipments
13 ➢ Properly trained personnel
➢ Planned preventive maintenance
➢ Efficient troubleshooting.
If an air cylinder produces erratic cylinder action, identify the probable causes and also
give remedies for them. BTL4
Probable Causes Remedies
Valve sticking or binding Check for dirt or gummy deposits
14
Check for worn parts
Cylinder sticking or binding Check for over tightened packing on rod seal
or piston.
Check for misalignment or worn parts.
List any two types of faults that can be found in each of the components of a FRL unit.
15
BTL4
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Faults in filter:
➢ Excessive pressure drop through filter
➢ Contaminants carried through the filter.
Faults in a regulator:
➢ Air often escaping from vent hole
➢ Chatter and vibration
Faults in a lubricator:
➢ Oil not delivered from the lubricator
➢ Delayed oil delivery.
If a pump is delivering insufficient or no oil, what are all the possible causes and also give
remedies for them. BTL4
Probable Causes Remedies
Wrong direction of shaft Must be reserved immediately to prevent
seizure.
16 Pump shaft turning too slowly to prime itself. Check minimum speed recommendation and
momentarily increase rpm, to rectify.
Clogged strainer or suction pipeline. Clean strainer or suction pipeline. Remove
foreign matter.
Air leak in suction line. Add oil and check oil level in reservoir. Check
for leaks and repair.
Illustrate the fault find using troubleshooting chart for pneumatic system. BTL1
17
Illustrate the fault find using troubleshooting chart hydraulic system. BTL1
18

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List any two types of faults that can be found in each of the follwing hydraulic valve:
(i) Directional control valve, and (ii) Flow control valve. BTL2
Faults in a DC valve may be:
➢ Faulty or incomplete shifting, or
19
➢ Cylinder creeping or drifting.
Faults in a flow control valve may be:
➢ Variation in feed, or
➢ External leakage.
Mention any two roles of pneumatic systems in low cost automation. BTL2
20 Pneumatic systems are popularly used for low cost automation (LCA) applications due to their
low cost, ease of fabrication, and safe operation.
PART * B
Explain in detail how trouble shooting of hydraulic and pneumatic system are done. BTL2
Trouble shooting refers to an organised and systematic study of the problem and a logical
approach to the difficulty faced in a system. (1M)
Hydraulic system: (6M)
Pneumatic system: (6M)

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Explain how drilling circuit can be designed for any drilling operation. BTL4
Construction: (5M)
Filter, pump, motor, pressure relief valve, double acting cylinder, 4/3 lever operated spring return
DCV.
Circuit: (8M)
How surface grinding can be used by hydraulic circuit. BTL4

Construction: (5M)
Filter, pump, motor, pressure relief valve, double rod double acting cylinder, 4/2 pilot operated
3
DCV, pilot valve.
Circuit: (8M)

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Design a hydraulic circuit for planning machine operation. BTL4

Construction: (5M)
Filter, pump, motor, pressure relief valve, double acting cylinder, 4/3 lever operated DCV, flow
control valve, limit switch, deceleration valve.
Circuit: (8M)
Describe the basic concepts of low cost automation with suitable example. BTL2
➢ Low cost automation is a technology that creates some degree of automation around the
existing equipment, tools, methods, people etc. using mostly standard component
available in the market.
➢ A wide range of activities such as loading, feeding, clamping, machining, welding,
5
forming and packing can be subjected to low cost automation
➢ Low cost automation is very useful for process industries, manufacturing, chemical, oil or
pharmaceuticals. Many operations in food processing can also be done by low cost
automation system.
Methodology:

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Benefits:
➢ Reduce manual controls without changing the basic set up.
➢ Low investment
➢ Increased labor productivity
➢ Consistent quality
➢ Better utilization of material.
PART * C
Design and draw a circuit using the hydraulic components for the Shaping operation. BTL4
Construction: (5M)
1 Double rod cylinder, flow control valves, limit switches, 4/2 solenoid operated DCV, filter,
pump, pressure relief valve, motor.
Circuit: (10M)

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Design a circuit using the hydraulic components for the Punching & press operation. BTL4
Construction: (5M)
1 - Line to reservoir, 2 - filter strainer, 3- unidirectional fixed displacement pump, 4 - pressure
relief valve, 5 - manually operated spring centered 4/3 DC valve, 6 & 7 - sequence valve, 8 & 9 -
check valve, 10 & 11 - double acting cylinders.
Circuit: (10M)
Explain in detail about various faults in pneumatic components. BTL2

Compressor: unusual noise, inadequate performance.
Filters: excessive pressure drop, contaminants carried through filter, moisture in downstream air,
3 plastic blow crazed and breaking.
Regulators: regulator cannot reach high set point, set point becomes too high, air often escaping
from vent hole, pressure too low when air is flowing, chatter and vibration, delay or lack of
reverse flow.

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Lubricators: oil not delivered from the lubricator, oil delivery is delayed, too much oil delivery,
poor component performance even with oil delivery, reservoir bowl crazed.
Air cylinder: cylinder fails to move load when valve is actuated, erratic cylinder action, cylinder
body seal leak, rod gland leak, excessive piston seal wear.
Valves: valve blows to exhaust, poppet chatters, spool valve action is sluggish, air flow is normal
only in actuated position, solenoid buzzes, solenoid burns out, sequence valve gives erratic
timing, flow control valve does not respond to adjustment.
Explain in detail about various faults in hydraulic components. BTL2
Pump: delivering insufficient or no oil, developing unstable or zero pressure, making noise,
pump oil over heated, internal leakage around pump, excessive wear, breakage of parts inside
pump housing.
Relief valve: Erratic pressure, no or low pressure, excessive noise or chatter.
Direction control valves: Faulty or incomplete shifting, cylinder creeping or drifting.
Hydraulic cylinders: Piston packing failing too often, reduced speed, insufficient force available
4
or no movement at all.
Hydraulic motor: Motor turning in wrong direction, absence of proper speed and torque,
external oil leakage from fluid motor, times of operation longer than specified.
Accumulator: Sudden drop of pressure when position of selector valve is changed, no pressure
available after pump is stopped, sluggish response.
Sequencing valves: Premature movement of secondary operation, no movement or slow
secondary operation.

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ME8091 AUTOMOBILE ENGINEERING LTPC
3003
OBJECTIVES:
• To understand the construction and working principle of various parts of an automobile.
• To have the practice for assembling and dismantling of engine parts and transmission system
UNIT I VEHICLE STRUCTURE AND ENGINES 9

Types of automobiles, vehicle construction and different layouts, chassis, frame and body, Vehicle
aerodynamics (various resistances and moments involved), IC engines –component, function sand
materials, variable valve timing (VVT).
UNIT II ENGINE AUXILIARY SYSTEMS 9
Electronically controlled gasoline injection system for SI engines, Electronically controlled diesel
injection system (Unit injector system, Rotary distributor type and common rail direct injection system),
Electronic ignition system (Transistorized coil ignition system, capacitive discharge ignition system),
Turbo chargers (WGT, VGT), Engine emission control by three way catalytic converter system, Emission
norms (Euro and BS).
UNIT III TRANSMISSION SYSTEMS 9
Clutch-types and construction, gear boxes- manual and automatic, gear shift mechanisms, Over drive,
transfer box, fluid flywheel, torque converter, propeller shaft, slip joints, universal joints ,Differential
and rear axle, Hotchkiss Drive and Torque Tube Drive.
UNIT IV STEERING, BRAKES AND SUSPENSION SYSTEMS 9
Steering geometry and types of steering gear box-Power Steering, Types of Front Axle,Types of
Suspension Systems, Pneumatic and Hydraulic Braking Systems, Antilock Braking System(ABS),
electronic brake force distribution (EBD) and Traction Control.
UNIT V ALTERNATIVE ENERGY SOURCES 9
Use of Natural Gas, Liquefied Petroleum Gas, Bio-diesel, Bio-ethanol, Gasohol and Hydrogen in
Automobiles- Engine modifications required –Performance, Combustion and Emission Characteristics of
SI and CI engines with these alternate fuels - Electric and Hybrid Vehicles, Fuel Cell
Note: Practical Training in dismantling and assembling of Engine parts and Transmission Systems
should be given to the students.
TOTAL: 45 PERIODS
OUTCOMES:
• Upon completion of this course, the students will be able to identify the different components in
automobile engineering.
• Have clear understanding on different auxiliary and transmission systems usual.

TEXT BOOKS:
1. Kirpal Singh, “Automobile Engineering”, Vol 1 & 2, Seventh Edition, Standard Publishers, New Delhi,
1997.
2. Jain K.K. and Asthana .R.B, “Automobile Engineering” Tata McGraw Hill Publishers, NewDelhi,
2002.
JIT-JEPPIAAR/MECH/ Mr.M.Kalaimani & Mr.D.Arunkumar/IIIrdYr/SEM 06/ME8091/AUTOMOBILE ENGINEERING/UNIT 1-

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REFERENCES:
1. Newton ,Steeds and Garet, “Motor Vehicles”, Butterworth Publishers,1989.
2. Joseph Heitner, “Automotive Mechanics,” Second Edition, East-West Press, 1999.
3. Martin W, Stockel and Martin T Stockle , “Automotive Mechanics Fundamentals,” The Goodheart –
Will Cox Company Inc, USA ,1978.
4. Heinz Heisler, “Advanced Engine Technology,” SAE International Publications USA, 1998.
5. Ganesan V. “Internal Combustion Engines”, Third Edition, Tata McGraw-Hill, 2007.

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Subject Name:Automobile Engineering
Subject Handler: Mr.M.Kalaimani & Mr.D.Arunkumar
UNIT I - VEHICLE STRUCTURE AND ENGINES
Types of automobiles, vehicle construction and different layouts, chassis, frame and body, Vehicle
aerodynamics (various resistances and moments involved), IC engines –component, functions and
materials, variable valve timing (VVT).
PART * A
Q.No. Questions
What are the classification of automobile based on transmission

system?(MAY/JUNE2016)(BTL1)
• Manual type
1. • Semi-Automatic
• Fully Automatic
• Continuously Variable
• Automated Manual
What are the advantages of tubeless tyre over tubes tyre?(MAY/JUNE2016) (BTL1)
• Lower Tire Pressure
2 • More Comfortable for Hire Speed
• Easily puncture repair
• Doesn’t Puncture easily
What are the advantages of diesel engine in cars?(MAY/JUNE2014) (BTL1)
• Diesel engines offer significantly higher efficiency than current gasoline spark-ignition
3 engines
• Although the modern diesel engine is very clean
• Fuel cost is low compared to petrol.
How automobiles are classified based on capacity? Give example.(MAY/JUNE2014) (BTL1)
4 • Heavy Transport Vehicle – Trucks, Lorry
• Light Transport vehicle – Car, Jeep
Name the resistance to vehicle motion(APR/MAY 2015) (BTL1)
5 • Air Resistance
• Gradient Resistance
• Rolling Resistance
6 Name the components of engine(APR/MAY 2015) (BTL1)
i) Cylinder ii) Piston iii) Crank case iv) Connecting rod
7 What are the types of cross section frames used in automobile? (MAY/JUNE 2016) (BTL1)
(a)channel section,(b) tubular section (c)box section (d) hat section (e) double channel or I section
8 What are the forces acting on running vehicle?(MAY/JUNE 2016)
i) Lift Force ii) Drag Force & iii) Cross wind force
What is frameless construction? (APR/MAY 2017) (BTL2)
9 This type of construction has heavy side members used in conventional construction are
eliminated and floor is strengthen by cross members and the body, all welded together. In some
cases sub frames also used along with this type of construction.

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State the function of pushrod and rocker arm(APR/MAY 2017) (BTL1)
10 The push rod and rocker arm actuates valves according to engine stroke by the cams.
List the classification of chassis name according to its control method. (NOV/DEC2016)
11 (BTL1)
(a) Conventional control chassis (b)Semi formal Chassis (c) Full forward control Chassis
Why a Gear box required in an automobile? (NOV/DEC2015) (BTL1)
• The main purpose of a gear box is to multiply the torque available in the driving wheels so
that a wide range of torque is available in the same.
12
• Gear box is basically used to shift gears.
• The need for gearbox is simple that is you have a control over the reduction ratio
• Transmit power from engine to wheels
What is meant by dumb iron in frame work? (NOV/DEC2013) (BTL2)
A Dumb iron is a curved side piece of a chassis to which the front springs are attached, at the
13 front of the car dumb irons project forward, providing a location to attach the front of the leaf
springs.
State any four function of lubricants(NOV/DEC2013) (BTL1)

14 • To avoid friction between moving parts
• To reduce excess heat produced
What are the types of engine valve? (NOV/DEC2012) (BTL2)
The valves are usually made of stainless steel. The valves used in modern passenger car engines
15
are termed as poppet and mushroom valves.
Write down the firing order of 4 and 6 cylinder engine. (BTL2)

16 i) For 4 cylinders engine, the firing order is 1-3-4-2 or 1-4-3-2
ii) For six cylinder engine, the firing order is 1-5-3-6-2-4 or 1-4-2-6-3-5
List out the forces acting on a chassis frame (MAY/JUNE2013) (BTL1)
• Reactions from ground acting on tires and transmitting through suspensions.
• Weight of different components like engine, transmission, passengers, fuel tank, seats,
exhaust, etc acting at mounting points
17
• Centrifugal force acting on the CG during turning.
• Aerodynamic forces at considerable speed.
• Bending moment and torsion moment along the longitudinal axis
• Impact load when the vehicle passes over a hump or a pot hole
What are the major functions of the chassis frame?[NOV/DEC 14] (BTL1)
• To carry load of passenger or goods carried in the body.
18 • To support the load of the body, engine, gear box, steering system, Propeller or shaft etc.
• To withstand the forces causes due to sudden breaking or acceleration and withstand the
load cause due to bad road condition.
• To withstand the centrifugal force by cornering
Give any two advantages of frameless construction over the conventional framed
construction.(MAY/JUNE2012) (BTL1)
19 • Reduce weight and consequent saving in fuel consumption
• Lower manufacturing cost
• Increase stability of automobile.
20 Name the sources of automobile pollutants.(MAY/JUNE2012) (BTL2)
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Hydrocarbons, Carbon monoxide, Nitrogen oxides, Particulate matter, Sulphur oxide
PART * B
(i)What is the effect of weight of vehicle and passenger on the frame side member?
Explain(MAY/JUNE2016) (7 M)(BTL5)
• Vertical bending,
• Longitudinal torsion,
• Lateral bending,
• Horizontal lozenging.7M
1 (ii)Write note on different types of material used for chassis frame(MAY/JUNE2016) (6 M)
(BTL5)
• Steel
• Aluminium
• Magnesium
• Carbon-fibre epoxy composite
• Glass-fibre composites 6M
(i)Explain the term rolling resistance with the help of neat sketch. (MAY/JUNE 2016)
2
(7 M)(BTL5)
Rolling resistance, sometimes called rolling friction or rolling drag, is the force resisting
the motion when a body (such as a ball, tire, or wheel) rolls on a surface. It is mainly caused
by non-elastic effects; that is, not all the energy needed for deformation (or movement) of the
wheel, roadbed, etc. is recovered when the pressure is removed. Two forms of this
are hysteresis losses (see below), and permanent (plastic) deformation of the object or the surface.
2M
2M
The "rolling resistance coefficient" F = CrrN
F is the rolling resistance force
Crr is the dimensionless rolling resistance coefficient or coefficient of rolling friction (CRF)
Nis the normal force, the force perpendicular to the surface on which the wheel is rolling. 3M

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(ii)Draw a neat labelled diagram of rear engine wheel drive type of vehicle layout
(MAY/JUNE 2016)(6 M)(BTL5)
Answer: Page
6M
3 (i)Give reasons for using single cylinder four stroke petrol engines on two wheelers
(MAY/JUNE2014) (6 M)(BTL4)
Single-cylinder engines are simple and compact, and will often deliver the
maximum power possible within a given envelope. Cooling is simpler than with multiple
cylinders, potentially saving further weight, especially if air cooling is used. 2M
Single-cylinder engines require more flywheel than multi-cylinder engines, and the rotating mass
is relatively large, restricting acceleration and sharp changes of speed. In the basic arrangement
they are prone to vibration - though in some cases it may be possible to control this with balance
shafts. 2M
A variation known as the split-single makes use of two pistons which share a single combustion
chamber. 2M
(ii)Give reasons for using multi cylinder diesel engines in commercial vehicles.
(MAY/JUNE2014) (7 M)(BTL3)
A multicylinder engine develops more power. A commercial vehicle needs greater force to propel
the vehicle because it carries greater loads. 2M
A diesel engine runs at a higher compression ratio and at this compression ratio the thermal
efficiency of a multi-cylinder engine is higher than an Otto cycle petrol engine. This means that a
diesel engine gives better fuel economy per kilometer. 2M
A multi cylinder engine has a greater swept volume and also its surface volume ratio is increased.
This results in greater engine output and also better cooling which is essential for the protection
of the engine parts like cylinder head, cylinder liner, piston, etc. The lubricating oil is also
prevented from partial oxidation. 2M
In a multi-cylinder engine, vibrations are decreased due to balancing of the crank. 1M
4 (i)Write short notes on following engine parts, Piston, Cylinder Head, Piston Ring, Gudgeon
Pin, Flywheel, Exhaust Valve, Lubrication Pump (MAY/JUNE 2016) (8 M)(BLT4)
Engine parts, 1M
Piston,1M
Cylinder Head, 1M

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Piston Ring, 1M
Gudgeon Pin, 1M
Flywheel, 1M
Exhaust Valve, 1M
Lubrication Pump 1M
(ii) Draw the layout of automobile chassis and explain its significance (MAY/JUNE 2016)(5
M)(BLT4)
Answer: Page 528-R.S KHURMI
2M
The internal framework of an artificial object, which supports the object in its construction and
use. An example of a chassis is a vehicle frame, the underpart of a motor vehicle, on which the
body is mounted; if the running gear such as wheels and transmission, and sometimes even the
driver's seat, are included, then the assembly is described as a rolling chassis. 3M
With neat diagram explain components and drive system in an automobile chassis
5 (APR/MAY2017) (13 M)(BTL4)

Diagram
5M
PartsPower plant, Transmission System, Axles, Wheels and Tyres, Suspension,
Controlling Systems like Braking, Steering 8M
6 List IC engine parts its materials and functions.(APR/MAY2017) (13 M) (BTL3)

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3M
Parts 3M
Materials 3M
Functions 4M
Explain the construction of various chassis frames used in automobile with neat figure.
7 (NOV/DEC2016) (13 M) (BTL4)
3M
1. According to Fitting of Engine:

• Full forward Chassis
• Semi forward Chassis
• Bus Chassis
• Engine at back Chassis (Eg. Volvo Bus, Tata nano)
• Engine at Centre Chassis (Eg. Royal tiger master bus) 5M
2. According to No of wheels fitted into vehicle:

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• 4 x 2 Drive Chassis [has 4 wheels with 2 driving wheels]
• 4 x 4 Drive Chassis [ has 4 wheels with 4 driving wheels]
• 6 x 2 Drive Chassis [ has 6 wheels with 2 driving wheels]
• 6 x 4 Drive Chassis [ has 6 wheels with 4 driving wheels]5M
Explain with suitable sketches and valve timing diagram, the working of a variable valve
8 timing (VVT) system used in automobiles. (NOV/DEC2016)(13 M) (BLT4)

Variable valve timingIn internal combustion engines, variable valve timing (VVT) is the process
of altering the timing of a valve lift event, and is often used to improve performance, fuel
economy or emissions. It is increasingly being used in combination with variable valve
lift systems. There are many ways in which this can be achieved, ranging from mechanical
devices to electro-hydraulic and camless systems. Increasingly strict emissions regulations are
causing[citation needed] many automotive manufacturers to use VVT systems.
5M
3M
Typical effect of timing adjustments
Late intake valve closing (LIVC)
Early intake valve closing (EIVC)
Early intake valve opening
Early/late exhaust valve closing 5M
Draw the layout of an automobile and indicate its various components(NOV/DEC2015) (13
9 M) (BLT4)

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3M
In automotive design, the automobile layout describes where on the vehicle the engine and drive
wheels are found. Many different combinations of engine location and driven wheels are found in
practice, and the location of each is dependent on the application for which the vehicle will be
used. Factors influencing the design choice include cost, complexity, reliability, packaging
(location and size of the passenger compartment and boot), weight distribution, and the vehicle's
intendedhandling characteristics. 4M
Front-wheel-drive layouts 3M
Rear-wheel-drive layouts 3M
PART * C
1 Discuss the various resistance encountered by an automobile.(15 M)(BTL4)

• Aerodynamic drag 5M
• Gradient resistance 5M
• Rolling resistance 5M
Explain the frameless construction type vehicles with neat sketch and example.
2
(15 M)(BTL4)

ADVANTAGE OF FRAMELESS CONSTRUCTURE
* light in weight and hence fuel efficient.
* manufacturing cost is less.
* safe for the passenger during collision , since the body crumbles thereby absorbing the shock
due to impact.
* more stable automobile can be made because of the lower body construction.

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DISADVANTAGE OF FRAME LESS CONSTRUCTION

* less strength and durability.
* cost of repair is height.
* economical only if adopted in mass production.
* car without roof are difficult to design.
APPLICATION OF FRAME LESS CONSTRUCTION
it is possible only in case of closed car, since the roof, screen pillars,door pillars and rear panel
are essential load taking parts of the structure.
A third type of body construction is the space frame. it is made by steel stamping welded together
this is similar to tube chassis and roll cage in a race car plastic panels fasten to the space frame to
complete the body.
Explain why automobile engine causes vibration when it started and stands idle. Discuss the
3 effect. (15 M) (BTL3)
Sometimes the vibration depends on certain speeds, not by deceleration and acceleration.
Sometime when driving and braking, the steering wheel shakes heavily, and the most
common reason for that is the brake rotors. Out of round brake rotors sometimes can be
the reason for the car engine shaking. 5M
Causes for automobile engine vibration
• The Crankshaft Damper
• Faulty Engine Mount
• Spark Plug Issues
• Extreme Weather
• Car Axle 5M
solution for automobile engine vibration
• Step 1: Spot The Problem Source
• Step 2: Analyze The Problem
• Step 3: Replace Damaged Car Parts 5M

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UNIT II -ENGINE AUXILIARY SYSTEMS
Electronically controlled gasoline injection system for SI engines, Electronically controlled diesel injection system
(Unit injector system, Rotary distributor type and common rail direct injection system), Electronic ignition system
(Transistorized coil ignition system, capacitive discharge ignition system), Turbo chargers (WGT, VGT), Engine
emission control by three way catalytic converter system, Emission norms (Euro and BS).
PART * A
Q.No. Questions
1. Enumerate the factors which affect battery life. [NOV/DEC 13] (BTL1)
1. Driving style 2. Extreme temperatures 3. Dirt 4. Low driving
What is CRDI? [NOV/DEC 12] (BTL2)
Common rail direct fuel injection is a direct fuel injection system for diesel engines. On diesel
2 engines, it features a high-pressure (over 1,000 bar or 100 MPa or 15,000 psi) fuel rail feeding
individual solenoid valves, as opposed to a low-pressure fuel pump feeding unit injectors (or
pump nozzles).
What are the components of battery? [NOV/DEC 12] (BTL2)
There are three main components of a battery: two terminals made of different
3 chemicals (typically metals), the anode and the cathode; and the electrolyte, which separates these
terminals. The electrolyte is a chemical medium that allows the flow of electrical charge between
the cathode and anode.
Write any two benefits of CRDI system. [MAY/JUN 13] (BTL1)
• Fuel can be supplied and discharged into the cylinder at a very high pressure
4 • Finer atomization of fuel
• Produce better combustion,
• Lower soot production
• Multiple smaller injections per stroke
Name the drawbacks of Carburetor in multi-cylinder engine. [MAY/JUN 13] (BTL1)
• At a very low speed, the mixture supplied by a carburetor is so weak that it will not ignite
properly and for its enrichment, at such conditions some arrangement in the carburetor is
5 required
• The working of carburetor is affected by changes of atmospheric pressure.
• It gives the proper mixture at only one engine speed and load, therefore, suitable only for
engines running at constant speed increase or decrease
What is exhaust gas recirculation? [MAY/JUN 13] (BTL2)
6 The process of re-circulating about 10% of the inert gas back into the intake manifold to reduce
the combustion temperature when peak combustion temperature exceeds 19500C. It is done to
avoid the formation of excessive nitrogen oxides (NO2) formation.
7 Write the two methods of lead acid battery charging. [MAY/JUN 12] (BTL1)
Constant Current Charging, Constant Voltage Charging
List out the major components in an electronic fuel injection system. [NOV/DEC 14]
8 (BTL1)
(1)Pumping element (2)Metering Element (3) Mixing Element (4) Metering Control (5) Mixture
Control (6) Distributing Element (7) Timing Element (8) Ambient Control
9 What is the role of regulator unit in electrical systems? [NOV/DEC 14] (BTL2)
Faster the vehicle moves more voltage goes into the car's electrical system. If this weren't
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controlled the generator would damage the battery and burn out the car's lights. Also, if the
generator weren't cut out from the car's circuitry when not running, the battery would discharge
through its case. To avoid above two mistake a voltage regulator is used.
10 List out the emissions that are common for both SI and CI engines. [NOV/DEC 16] (BTL1)
(a) HC (b) CO (c) NOx (d)Particulate matters
What is the need of altering the ignition timing with respect to engine speed and
load?(MAY/JUNE 2016) (BTL2)
• The ignition timing will need to become increasingly advanced (relative to TDC) as the
engine speed increases so that the air-fuel mixture has the correct amount of time to fully
11 burn. As the engine speed (RPM) increases, the time available to burn the mixture
decreases but the burning itself proceeds at the same speed, it needs to be started
increasingly earlier to complete in time.
• The ignition timing is also dependent on the load of the engine with more load (larger
throttle opening and therefore air: fuel ratio) requiring less advance (the mixture burns
faster).
12 What are the factors that affect the life of spark plug?(MAY/JUNE2016) (BTL1)
(a)Overheating Damage (b)Oil Contamination (c)Carbon
Enlist the limitation of turbo charging(MAY/JUNE2014) (BTL2)
13 The main limitation of turbo charging is Turbo Lag. Turbo lag is the time it takes for a
turbocharger to “light up” or produce positive manifold pressure drastically changing the power
output of a motor.
Write the main requirements of an injector nozzle(MAY/JUNE2014) (BTL1)
• To inject fuel at a sufficiently high – pressure so that the fuel enters the cylinder with a
14 high velocity.
• The penetration should not be high.
• The fuel supply and cut off should be rapid.
What is gasoline injection system(APR/MAY2015) (BTL2)
The gasoline is highly pressurized, and injected via a common rail fuel line directly into the
15 combustion chamber of each cylinder, as opposed to conventional multipoint fuel injection that
injects fuel into the intake tract or cylinder port. Directly injecting fuel into the combustion
chamber requires high-pressure injection, whereas low pressure is used injecting into the intake
tract or cylinder port.
What are the function of turbocharger(APR/MAY2015) (BTL2)
The function of a turbocharger is to improve an engine's volumetric efficiency by increasing
16 density of the intake gas (usually air) allowing more power per engine cycle. The turbocharger's
compressor draws in ambient air and compresses it before it enters into the intake manifold at
increased pressure.
Define continuous injection of petrol engine(MAY/JUNE2016) (BTL2)
In a continuous injection system, fuel flows at all times from the fuel injectors, but at a variable
17 flow rate. This is in contrast to most fuel injection systems, which provide fuel during short
pulses of varying duration, with a constant rate of flow during each pulse. Continuous injection
systems can be multi-point or single-point, but not direct.
Which is most commonly used supercharger in automobile? why petrol engines are rarely
supercharged?(APR/MAY2017) (BTL2)
18 Commonly used supercharger is Positive Displacement supercharger. There are two main types
of superchargers defined according to the method of gas transfer positive displacement and
dynamic compressors. Positive displacement blowers and compressors deliver an almost constant
level of pressure increase at all engine speeds (RPM). Dynamic compressors do not deliver
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pressure at low speeds; above a threshold speed, pressure increases with engine speed
Give short note on unit injector system. (APR/MAY2017) (BTL1)
Unit injector is an integrated direct fuel injection system for diesel engines, combining the
19 injectornozzle and the injection pump in a single component. The plunger pump used is usually
driven by a shared camshaft. In a unit injector, the device is usually lubricated and cooled by the
fuel itself.
Define intermittent injection of petrol engine(NOV/DEC2016) (BTL2)
20 Intermittent fuel injection systems provide fuel during short pulses of varying duration, with a
constant rate of flow during each pulse.
PART * B
What are primary and secondary batteries? Give the details about the major components,
Working principles and energy storage in secondary battery. [NOV/DEC 14]
(13 M) (BTL4)
A flashlight battery, or dry cell, is constructed with a zinc shell that serves as the anode; a
graphite rod which serves as the cathode; and a moist mixture of ammonium chloride {NH4Cl},
zinc chloride {ZnCl2}, and manganese dioxide {MnO2}. A schematic representation of a dry cell
is shown on the right. The half-reaction that occurs on the anode when the battery delivers current
is the oxidation of zinc atoms:
Zn(s, shell) Zn2+(aq) + 2e–
The half-reaction that occurs simultaneously on the cathode is the reduction of ammonium ions:
2 e– + 2 NH4+(aq, moist paste) 2 NH3(g) + H2(g)
A porous graphite electrode is embedded in the moist paste and readily conducts electrons from
the external circuit to the aqueous ammonium ions. Take another look at the products of the
reduction that occurs at the graphitic cathode. Two gases are being produced in a sealed
container! Not to fear, our battery will not explode as additional reactions essentially fix the two
gases:

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+2 2+
2 NH3(g) + Zn (aq) [Zn(NH3)2] (aq)
In this reaction, zinc ion, primarily from ZnCl2, is acting as a Lewis acid; the complex formed
solubilizes the gas.
2 (i)Explain electronic spark timing control with a circuit diagram. [MAY/JUN 16] (BTL3)
The spark-Optimizer is a closed-loop type electronic control device that continuously corrects the
ignition timing; in effect it re-tunes the engine some ten times every second. In contrast to the
better known pre-programmed controls, the Optimizer is an adaptive type system, in which the
output influences the input. By providing the correct spark timing all the time, the Optimizer
reduces fuel consumption considerably.
(ii)Discuss the various methods to reduce the level of pollutants in the exhaust gases.
[MAY/JUN 16](13 M)(BTL4)
Humid Air Method

Exhaust Gas Re circulation (EGR)
Water Injection and Water emulsion
High Scavenge Pressure and Compression Ratio
Selective Catalytic Reduction
Two Stage Turbocharger
Engine Component Modification
(i)Discuss about CRDI system[APR/MAY2015] (BTL4)
3

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The System is divided into 3 basic circuits

1. High Pressure Delivery Circuit
2. Low Pressure Supply Circuit
3. Fuel Leak back and return
(ii)Discuss the construction and working principle of rotary distributor type diesel injection
system[APR/MAY2015](13 M) (BTL4)
The main components of a fuel injection system

(i) Fuel tank.
(ii) Fuel feed pump to supply the fuel from the main fuel tank to the injection pump.
(iii) Fuel filters to prevent dust and abrasive particles from entering the pump and injectors.
(iv) Injection pumps to meter and pressurize the fuel for injection.
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(v) Governor to ensure that the amount of fuel is in accordance with variation in load.
(vi) Fuel piping and injectors to take the fuel from the pump and distribute it in the combination
chamber by atomizing it in fine droplets. (vii) Fuel atomizer or injector to inject the fuel
(i)What are the advantages of transistorized coil ignition (TCI) System? [MAY/JUN 16]
4
(BTL4)
• A CDI system has a short charging time, a fast voltage rise (between 3 ~ 10 kV/μs)
compared to typical inductive systems (300 ~ 500 V/μs) and a short spark duration
limited to about 50-80 µs. The fast voltage rise makes CDI systems insensitive to shunt
resistance, but the limited spark duration can for some applications be too short to
provide reliable ignition. The insensitivity to shunt resistance and the ability to fire
multiple sparks can provide improved cold starting ability.
• Since the CDI system only provides a short spark, it's also possible to combine this
ignition system with ionization measurement. This is done by connecting a low voltage
(about 80 V) to the spark plug, except when fired. The current flow over the spark plug
can then be used to calculate the temperature and pressure inside the cylinder.
(ii)Sketch and explain the capacitive discharge ignition system[MAY/JUN 16](13 M) (BLT4)
Most ignition systems used in cars are inductive discharge ignition (IDI) systems, which are
solely relying on the electric inductance at the coil to produce high-voltageelectricity to
the spark plugs as the magnetic field collapses when the current to the primary coil winding is
disconnected (disruptive discharge). In a CDI system, a charging circuit charges a high
voltage capacitor, and at the instant of ignition the system stops charging the capacitor, allowing
the capacitor to discharge its output to the ignition coil before reaching the spark plug.

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Advantages and Disadvantages of CDI

• A CDI system has a short charging time, a fast voltage rise (between 3 ~ 10 kV/μs)
compared to typical inductive systems (300 ~ 500 V/μs) and a short spark duration
limited to about 50-80 µs. The fast voltage rise makes CDI systems insensitive to shunt
resistance, but the limited spark duration can for some applications be too short to
provide reliable ignition. The insensitivity to shunt resistance and the ability to fire
multiple sparks can provide improved cold starting ability.
• Since the CDI system only provides a short spark, it's also possible to combine this
ignition system with ionization measurement. This is done by connecting a low voltage
(about 80 V) to the spark plug, except when fired. The current flow over the spark plug
can then be used to calculate the temperature and pressure inside the cylinder.
With neat sketch explain the working of turbocharger and state how it differs from
5 supercharger[APR/MAY2017] [NOV/DEC2015](13 M) (BTL4)
An Engine may not produce same power output when it is operated at different location and
altitudes. Super charging & turbo charging is used to overcome this effect. Super charging is
the process of supplying the fuel (or air-fuel mixture) above the atmospheric pressure by
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boosting the pressure. When the supercharger is driven by gas turbine which derives gas from
engine exhaust, it is called TURBO CHARGER. The turbocharger is bolted to the exhaust
manifold of the engine. The exhaust from the cylinders spins the turbine, which works like
agas turbine engine. The turbine is connected by a shaft to the compressor, which is located
between the air filter and the intake manifold. The compressor pressurizes the air going into
the pistons.
6 What are the main function of ECU?[NOV/DEC2016] (13 M)(BTL4)
ELECTRONIC CONTROL UNIT:

• Electronic Control Unit acts as a Central Processing Unit which
• receives the signals from various sensors and automatically
• monitors and regulates the system. Various parts controlled by ECU are represented in
picture
• In modern vehicles, which uses fuel injection for petrol engine operates in the sequence as
shown below. Vehicle which uses direct fuel injection are
• MAZDA, AUDI, VOLKSWAGEN, BMW, ALFA
Describe the construction details of distributor type diesel fuel injection pump with sketch.
7 [NOV/DEC2016] [MAY/JUN 16](13 M) (BTL4)

Each injector operates in the following manner. fuel under pressure enters the injector through the
injector's filter cap and filter element. From the filter element the fuel travels down into the
supply chamber (that area between the plunger bushing and the spill deflector). The plunger
operates up and down in the bushing, the bore of which is open to the fuel supply in the supply
chamber by two funnel-shaped ports in the plunger bushing.
he motion of the injector rocker arm (not shown) is transmitted to the plunger by the injector
follower which bears against the follower spring. As the plunger moves downward under pressure
of the injector rocker arm, a portion of the fuel trapped under the plunger is displaced into the
supply chamber through the lower port until the port is closed off by the lower end of the plunger.
The fuel trapped below the plunger is then forced up through the central bore of the plunger and
back out the upper port until the upper port is closed off by the downward motion of the plunger.
With the upper and lower ports both closed off, the remaining fuel under the plunger is subjected
to an increase in pressure by the downward motion of the plunger.
When sufficient pressure has built up, the injector valve is lifted off its seat and the fuel is forced
through small orifices in the spray tip and atomized into the combustion chamber. A check valve,
mounted in the spray tip, prevents air in the combustion chamber from flowing back into the fuel
injector. The plunger is then returned back to its original position by the injector follower spring.
On the return upward movement of the plunger, the high pressure cylinder within the bushing is
again filled with fresh fuel oil through the ports. The constant circulation of fresh, cool fuel
through the injector renews the fuel supply in the chamber and helps cool the injector. The fuel
flow also effectively removes all traces of air that might otherwise accumulate in the system.

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The fuel injector outlet opening, through which the excess fuel returns to the fuel return manifold
and then back to the fuel tank, is adjacent to the inlet opening and contains a filter element exactly
the same as the one on the fuel inlet side
8 (i)What are the types of electronic ignition system used in S I engine? [NOV/DEC2016]
(BLT4)
• Capacitance Discharge Ignition system
• Transistorized system
• Piezo-electric Ignition system
• The Texaco Ignition system

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(ii)Draw and explain the circuit diagram of electronic ignition system using a magnetic pick
up method. [NOV/DEC2016](13 M) (BLT5)

▪ To understand the working of the electronic ignition system let’s consider above figure in which
all the components mentioned above are connected in their working order.
▪
▪ When the driver switch ON the ignition switch in order to start a vehicle the current starts flowing
from the battery through the ignition switch to the coil primary winding, which in turn starts the
armature pickup coil to receives and send the voltage signals from the armature to the ignition
module.
▪
▪ When the tooth of the rotating reluctor comes in front of the pickup coil as shown in the fig the
voltage signal from pickup coil is sent to the electronic module which in turn senses the signal
and stops the current to flow from primary coil.
▪
▪ When the tooth of the rotating reluctor goes away from the pickup coil, the change in voltage
signal is sent by pickup coil to the ignition module and a timing circuit inside ignition module
turns ON the current flow.
▪
▪ A magnetic field is generated in the ignition coil due to this continuous make and break of the
circuit which induced an EMF in secondary winding which increases the voltage upto 50000
Volts.
▪
▪ This high voltage is then sent to distributor,which has the rotating rotor and distributor points
which is set according to the ignition timing.
▪
▪ When the rotor comes in front of any of those distributor points the jumping of voltage through
the air gap from the rotor to the distributor point takes place which is then sent to the adjacent
spark plug terminal through the high tension cable and a voltage difference is generated between
the central electrode and ground electrode which is responsible for generating a spark at the tip of
the spark plug and finally the combustion takes place.

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PART * C
1 Draw a sketch of three way catalytic converter and explain its principle of operation.
[NOV/DEC2015] [APR/MAY2015] (15 M)(BTL4)
• The Catalytic Convertor Converts the toxic gases like HC, CO, NOx into harmless gases.
• It contains ceramic or metallic base with active coating incorporating alumina and other
oxides with combination of precious metals like platinum, palladium and rhodium.
• Inside the passage way of catalytic convertor is a honey comb set passage way or
ceramic bead coated with catalyst. It makes chemical reaction without being part of the
reaction.
• Convertors may TWO WAY or THREE WAY Catalytic convertor.

• Two Way convertors are Oxidation catalytic convertor.
• Three ways Convertor are Oxidation as well as Reduction Catalytic Convertor.
• In 3 Way Convertors, 3 refer to emission control of CO, HC and Volatile Organic
Compounds (VOC).
• It uses 2 types of Catalyst >> Oxidation Catalyst & Reduction Catalyst both structure
coated with a catalyst such as Platinum, Rhodium & Palladium.
• REDUCTION CATALYST is the first stage of catalytic convertor which uses platinum
& rhodium to help reduce NOx emissions.
2 Compare BS Standard and Euro Standard emission norms for a diesel engine and petrol
engine vehicle.(15 M) (BTL4)
Bharat stage emission standards (BSES) are emission standards instituted by the Government of
India to regulate the output of air pollutants from internal combustion enginesand Spark-ignition
engines equipment, including motor vehicles. The standards and the timeline for implementation
are set by the Central Pollution Control Board under the Ministry of Environment & Forests and
climate change
European emission standards define the acceptable limits for exhaust emissions of new vehicles
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sold in the European Union and EEAmember states. The emission standards are defined in a
series of European Union directives staging the progressive introduction of increasingly stringent
standards.
3 What is the purpose of WGT & VGT and explain its working principle in detail.(15 M)
(BTL3)
wastegate turbochargers (WGTs)
• A wastegate is a valve that diverts exhaust gases away from the turbine wheel in
a turbocharged engine system.
• Diversion of exhaust gases regulates the turbine speed, which in turn regulates the
rotating speed of the compressor. The primary function of the wastegate is to regulate the
maximum boost pressure in turbocharger systems, to protect the engine and the
turbocharger. One advantage of installing a remote mount wastegate to a free-float (or
non-WG) turbo includes allowance for a smaller A/R turbine housing, resulting in less
lag time before the turbo begins to spool and create boost.
Variable-geometry turbochargers (VGTs)
• Variable-geometry turbochargers (VGTs), (also known as variable nozzle

turbines/VNTs), are a family ofturbochargers, usually designed to allow the
effective aspect ratio (A:R) of the turbo to be altered as conditions change. This is done
because optimum aspect ratio at low engine speeds is very different from that at high
engine speeds. If the aspect ratio is too large, the turbo will fail to create boost at low
speeds; if the aspect ratio is too small, the turbo will choke the engine at high speeds,
leading to high exhaust manifold pressures, high pumping losses, and ultimately lower
power output. By altering the geometry of the turbine housing as the engine accelerates,
the turbo's aspect ratio can be maintained at its optimum. Because of this, VGTs have a
minimal amount of lag, have a low boost threshold, and are very efficient at higher
engine speeds. VGTs do not require a waste gate.

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UNIT III -TRANSMISSION SYSTEMS
types and construction, gear boxes- manual and automatic, gear shift mechanisms, Over drive,
transfer box, fluid flywheel, torque converter, propeller shaft, slip joints, universal joints ,Differential
and rear axle, Hotchkiss Drive and Torque Tube Drive
PART * A
Q.No. Questions
Differentiate between live and a dead axle. [NOV/DEC 13] (BTL2)

LIVE AXLE DEAD AXLE
An axle that is driven by the engine or prime A dead axle, also called a lazy axle, is not
1. mover is called a drive axle. part of the drive train, but is instead free-
Modern front-wheel drive cars typically rotating. The rear axle of a front-wheel drive
combine the transmission (gearbox and car is usually a dead axle.
differential) and front axle into a single unit
called a transaxle.
How is drive from propeller shaft turned at right angle? [NOV/DEC 13] (BTL1)
2 Slip joint and Universal joint used at end of propeller shaft is reason for converting te drive at
right angle.
State the functions of a clutch. [NOV/DEC 12] (BTL2)
3 To engage or disengage the rest of the transmission as required.
To transmit the engine power to rear wheels without shock.
To enable the gear to get engaged when the vehicle is in motion.
What is synchromesh Device? [NOV/DEC 12] (BTL2)
This type of gear box is similar to the constant mesh type. The provision of synchromesh device
4 avoids the necessity of double declutching. The parts which ultimately are to be engaged are first
brought into frictional contact which equalizes their speed, after which these may be engaged
smoothly.
5 List the disadvantages of floor mounted gear shifting mechanism. [MAY/JUN 13] (BTL1)
(a) Complexity (b) Shifting Speed (c) Ease of Use (d) Stopping on hills
Define the term 'double declutching' used in sliding mesh gear box. [MAY/JUN 13] (BTL2)
The clutch pedal is used twice during a gear change, therefore disengaging the transmission
twice- hence the name.
6 1. Clutch pedal depressed and accelerator released, gear stick shifted to neutral position.
2. Using the throttle, the engine speed is matched as closely as possible to the gear speed.
3. The clutch pedal is depressed again and the required gear is selected and throttle pedal is used
to accelerate the vehicle.
Name the possible causes for the propeller shaft to develop noise while running[MAY/JUN
12] (BTL1)
7 Grinding and squeaking from the drive shaft is frequently caused by worn universal joints.
A clunking sound, when going from acceleration to deceleration or deceleration to acceleration,
may be caused by slip yoke problems.
A whining sound from the drive shaft is sometimes caused by a dry, worn center

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support bearing.
Where and why do we use the multiple clutch system? [NOV/DEC 14] (BTL1)
8 A multi-plate clutch has more than one driven plate. Multi-plate type of clutch finds a use in
automatic gearboxes. In these gearboxes, a number of clutches hold the various gear elements,
and as the clutch diameter in these units is limited, a multi-plate clutch is suitable.
Distinguish between transfer box and over drive. [NOV/DEC 14] (BTL2)
TRANSFER BOX OVERDRIVE
Transfer case is a part of four wheel drive Gear in a motor vehicle providing a gear ratio
9
system used in four wheel drive and all wheel higher than that of direct drive (the usual top
drive vehicles which provides a two speed gear), so that the engine speed can be reduced
transmission to obtain low gear and direct at high road speeds to lessen fuel
gear in vehicles. consumption or to allow further acceleration.
Why do we provide slip joint in the propeller shaft? [NOV/DEC 16] (R08,R13)
10 (APR/MAY2015) (BTL1)
Slip joint serves to adjust the length of the propeller shaft when demanded by the rear
axle movements.
What is the function of differential? [NOV/DEC 16] (MAY/JUNE2016) (BTL1)
11 A vehicle with two drive wheels has the problem that when it turns a corner the drive wheels
must rotate at different speeds to maintain traction. The automotive differential is designed to
drive a pair of wheels while allowing them to rotate at different speeds.
State the function of main shaft and lay shaft of a gear box?(MAY/JUNE2016) (BTL2)
MAIN SHAFT
It is the shaft which runs at the vehicle speed. It carries power form the counter shaft by use of
12 gears and according to the gear ratio, it runs at different speed and torque compares to counter
shaft. One end of this shaft is connects with the universal shaft
LAY SHAFT
A lay shaft is an intermediate shaft within a gearbox that carries gears, but does not transfer the
primary drive of the gearbox either in or out of the gearbox
What do you meant by overdrive?(MAY/JUNE2016) (BTL1)
13 Gear in a motor vehicle providing a gear ratio higher than that of direct drive (the usual top gear),
so that the engine speed can be reduced at high road speeds to lessen fuel consumption or to allow
further acceleration.
What is known as one way clutch?(MAY/JUNE2014) (BTL2)
14 One way Clutch is also called as freewheel, it transmit torque in one direction and disengages or
freewheels in another direction.
Mention few important causes of axle failure(MAY/JUNE2014) (BTL2)
Any of the two half shaft may be broken
15 Splines on the axle shaft may be stripped
The teeth of some gear in the rear axle drive may be stripped
The taper key at the hub be fracture.
Name the types of clutches(APR/MAY2015) (NOV/DEC2016) (NOV/DEC2015) (BTL1)
16 i)Wet clutch ii)Dry clutch iii)Cone clutch
iv)Centrifugal clutch v)Positive clutch vi)Vacuum clutch
What are the functions of gear box?(MAY/JUNE2016) (BTL1)
17 A gearbox converts the rotational energy of the engine to a rotational speed appropriate for the
wheels. Mechanical gearboxes do so with simple gears. Automatic gearboxes use more
complicated planetary gear sets
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What is a free wheel? What is the importance of the free wheel in the transmission of an
automobile?(APR/MAY2017) (BTL2)
Free wheel is a device which is installed between propeller shaft and the gear box. (Also there is
18 overdrive between propeller shaft and gearbox.) Free wheel makes the wheel to rotate wheel
freely when propeller shaft is disengaged from the engine or gear box.
To reduce the wear on transmission system
To reduce the fuel consumption on sloping downward
Using this, at low speed gear changing is simplified
Write short note on panhard rod(APR/MAY2017) (BTL1)
19 A Panhard rod (also called Panhard bar or track bar) is a suspension link that provides lateral
location of the axle.
Define Tractive Force (BTL1)
20 The torque available on the wheel produces a driving force which is parallel to road known as
tractive effort.
PART * B
Explain the working of a torque converter with neat sketch.[NOV/DEC 13] [MAY/JUN 13]
(13 M) (BTL3)
The parts of a torque converter (left to right): turbine, stator, pump
The pump section of the torque converter is attached to the housing.
The torque converter turbine: Note the spline in the middle. This is where it connects to the
transmission.
The stator sends the fluid returning from the turbine to the pump. This improves the efficiency of
the torque converter. Note the spline, which is connected to a one-way clutch inside the stator.
2 With a neat sketch, explain the working of simple floor mounted gear shifting
mechanism.[MAY/JUN 13] [MAY/JUN 12] (MAY/JUNE2016)(13 M) (BTL5)
The mechanism that transmits engine four to the rear wheel (in case of rear wheel drive vehicle)
or to the front wheel. (In front wheel drive vehicle) or to all the four wheel (in four wheel drive
vehicles) is known as a transmission system.

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The gear box and its associated units perform the following function on
A gear box assists in variation of torque (or tractates effort) produced

by the engine in accordance with the driving conditions.
A large torque is required at the start of the vehicle and a low torque at higher speeds. oIt
helps in smooth running of the vehicle at different speed since variation a torque induces.
Answer: Page
What is the need of clutch system in automotive vehicle? Classify the types of clutch.
3 Explain the working of centrifugal clutch with neat schematic[NOV/DEC 14]
(MAY/JUNE2016)(13 M) (BTL5)
Clutch is a machine member used to connect the driving shaft to a driven shaft, so that the
driven shaft may be started or stopped at will, without stopping the driving shaft. A clutch thus
provides an interruptible connection between two rotating shafts. Clutches allow a high inertia
load to be stated with a small power.
Clutches are used whenever the ability to limit the transmission of power or motion needs to be
controlled either in amount or over time (e.g. electric screwdrivers limit how much torque is
transmitted through use of a clutch; clutches control whether automobiles transmit engine power
to the wheels).
Types of clutch
Single plate clutch
Multi plate clutch
Cone clutch
Centrifugal clutch
Centrifugal Clutch
It consists of two members one is fitted to the driving shaft and other to the driven member. It is
a drum which encloses the driving member. The driving member consists of a spider, shoes
having friction linings at outer end. The springs exert a radially inward force.

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Explain the construction details of Hotchkiss and torque tube drive rear axle drive
4
system.[NOV/DEC 14] [NOV/DEC 12] [APR/MAY2017] [MAY/JUNE2016](13 M) (BLT4)
Hotchkiss Drive
It consists of two longitudinal leaf spring and propeller shaft. The propeller shaft has slip joint.
* The front end of the leaf springs is hinged to the frame and the rear end is connected with the
frame by swinging shackles.
* The driving force is transferred from the axle casing to the front end of the spring and then to
the frame. Hence, both rear end torque and driving thrust are opposed by the springs.
TORQUE TUBE DRIVE

It is similar to Hotch kiss drive but uses a hollow tube which encloses the propeller shaft. The
tube is rigidly connected to the differential housing at one end. The other end of the tube is
connected to the gearbox casing by a flexible ball and socket arrangement. The driving thrust
and rear end torque are carried by a hollow tube.
5 With the help of neat sketch, explain the construction and operation of a sliding mesh gear
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box.[NOV/DEC 16] (13 M)(BTL4)
1st Gear:
When driver wand’s to move the vehicle he engage the 1st dog to the with the help of gear
shifting levees as the dog slides on engage to the 1st gear it starts rotate with 1st gear and tends
to rotate the main shaft like 1st gear operates.
6 Explain types of gear boxes in detail with neat sketches(MAY/JUNE2016)(13 M)(BTL4)

MANUALGEARBOX
1) Sliding mesh gearbox.
2) Constant mesh gearbox.
3) Synchromesh gearbox.

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4) Synchromesh gear box with over drive.
SEMI- AUTOMATIC GEARBOX
1)Electric controlled with a avid drive.
2) Electric controlled with over drive.
3) Fluid – torque drive.

AUTOMATIC GEARBOX
1) Hydromantic drive.
2) Torque converter drive.
7 (i)Discuss about the working principle of single plate clutch[APR/MAY2015] (BTL4)
It is when drivers want to shift the gear or to stop the vehicle. He depress clutch pedal so that the
fork pushed the forward and pushes the clutch bearing and finger. The finger are pivoted so that
they pulls the pressure plate back hence the clutch plate will get free so the flywheel radiate
but the clutch plate will not get rotate. This is the disengage position on clutch.
(ii)Discuss about the working principle of differential with neat diagram

[APR/MAY2015](13 M)(BTL4)
When the car is on a straight road, the ring gear, differential case, differential pinion gears, and
two differential side gears all turn 38 a unit. The two differential pinion gears do not rotate on

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the pinion shaft. This is because they exert equal force on the two differential gears. As a result,
the side gears turn at the same speed as the ring gear, which causes both drive wheels to turn at
the same speed also. However, when the car begins to round a curve, the differential pinion
gears rotate on the pinion shaft. This permits the outer wheel to turn faster than the inner wheel.
8
(i)What are the types of rear axle casing?[MAY/JUNE2016] (BLT3)
Following are the three different types of axles
• Rear Axles
• Front Axle
• Stub Axle
(ii)What are the rear axle drive? and explain with neat sketch[MAY/JUNE2016]
(13 M) (BLT5)
Rear Axle
In between the differential and the driving wheels is the rear axle to transmit power from the
differential to the driving wheels. It is clear from the construction of the differential, that the rear
axle is not a single piece, but it is in two halves connected by the differential, one part is known
as the half shaft.
The inner end of the half shaft is connected to the sun gear of the differential. and the outer end of
the driving wheel. In rear-wheel-drive vehicles, the rear wheels are the driving wheels. Whereas,
in front-wheel drive vehicles, the front wheels are the driving wheels. Almost all rear axles on
modern passenger cars are live axles, that is, they revolve with the wheels.
Dead axles simply remain stationary, do not move with the wheels. A housing completely
encloses the rear axles and the differential, protecting them from water, dust and injury, in
addition to mounting their inner bearings and providing a container of the lubricant.
9
(i)Explain construction and working principle of constant mesh gear box with neat
sketch.[APR/MAY2017] (BLT3)

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This type of gears is fixed to their positions. They are meshed. It is a type of manual
transmission. It is this gear box that we use in today’s automobiles, right? Synchromesh is
absent here. It shows a simple constant mesh gear box though from it you will not be able to
understand its simulation. I would suggest that you try to analyze how the power is
transmitted through main shaft to the wheels through clutch and gear system. We use various
gear ratios to control the vehicle speed. It is that gear box in which sliding synchronizing
units are provided in place of sliding Clutches as in case of constant mesh gear box. With the
help of synchronizing unit, the speed of both the driving and driven shafts is synchronized
before they are clutched together through train gears. The arrangement of power flow for
the various gears remains the same as in the constant mesh gear box.
(ii)Describe the line diagram of synchromesh unit and mention the component (spring with
ball type system)[NOV/DEC2016](13 M) (BLT5)
Synchromesh gear devices work on the principle that two gears to be engaged are first
Brought into frictional contact which equalizes their speed after which they are engaged
readily and smoothly.
Advantages

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The synchromesh type of transmission has the big advantage of allowing smooth type and quick
shifting of gears without danger of damaging the gears and without necessity for double
clutching. The synchromesh gear box is considered the most advanced and has been adopted in
most cars.
PART * C
1
(i)What are the functions of transmission systems? [NOV/DEC2016]
(ii)Sketch and explain the working method of fluid flywheel [NOV/DEC2016] (15 M)(BTL4)
• The fluid flywheel is used in cars with automatic transmission.

• It consists of two members; the driving member is attached to the engine flywheel and the
driven member to the transmission shaft.
• There is no direct contact between the two members. The two rotors are always filled with
fluid of suitable viscosity.
• A simplified diagram representing the fluid flywheel is shown. At start tube X is rotating
say at N rpm and Y tube is stationary.
• With the movement of fluid in X and Y, Y also starts rotating but at a lower speed.
• The speed goes on increasing till the speed equals to N rpm, then the coupling is fully
engaged.

2 Compare the applications of sliding mesh, constant mesh and synchromesh gear box.
(15 M) (BTL4)
Sliding Mesh

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Constant Mesh
synchromesh gear box
3 Explain EPICYCLIC GEARBOX and AUTOMATIC GEAR BOX. (15 M) (BTL5)

EPICYCLIC GEARBOX:
In epicyclic gear box at least one of the gear not only rotates about its own axis but also
revolves bodily about the some other axis. Here speed can be changed automatically by
tightening the band (mechatronic control).

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AUTOMATIC GEAR BOX
It consists of a set of epicyclic gears with fluid flywheel & changes the speed automatically
(hydraulic control).

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UNIT IV -STEERING, BRAKES AND SUSPENSION SYSTEMS
Steering geometry and types of steering gear box-Power Steering, Types of Front Axle,Types of Suspension
Systems, Pneumatic and Hydraulic Braking Systems, Antilock Braking System(ABS), electronic brake force
distribution (EBD) and Traction Control.
PART * A
Q.No. Questions
Define the term 'braking efficiency'. [NOV/DEC 2013] (BTL12)

1. The brake efficiency, which is expressed as a percentage, calculates how effective your brakes are
when you lightly and heavily tap on them. The brakes efficiency is dependent on the weight of
your vehicle and the force of your brakes.
State functions of steering gears. [NOV/DEC 2013] (BTL2)
2 A function of steering wheel, the rotary motion of the steering wheel is converted into straight
line motion of the linkage by the steering gears. The gear which is used for steering arrangement
is worm gear. Steering gear is the device used for controlling the direction of a vehicle.
What is steering geometry? [NOV/DEC 2012] (BTL1)
3 Steering geometry is a geometric arrangement of linkages in the steering of a car or other vehicle
designed to solve the problem of wheels on the inside and outside of a turn needing to trace out
circles of different radii.
What is the use of stub axle? [NOV/DEC 2012] (BTL2)
4 A stub axle is one of the two front axles that carry a wheel in a rear wheel drivevehicle. The axle
is capable of limited angular movement about the kingpin for steering the vehicle. The stub axle
consists of wheel bearings which support the wheel hub.
Define 'camber' and 'castor'. [MAY/JUN 2013] (BTL2)
Camber angle is the angle made by the wheels of a vehicle; specifically, it is the angle between
the vertical axis of the wheels used for steering and the vertical axis of the vehicle when viewed
5 from the front or rear
Caster angle or Castor angle is the angular displacement of the steering axis from the vertical axis
of a steered wheel in a car, motorcycle, bicycle or other vehicle, measured in the longitudinal
direction
Define 'King pin inclination'. [MAY/JUN 2012] (BTL2)
6 The kingpin angle is set relative to the true vertical line, as viewed from the front or back of the
vehicle.
Write the functions of automobile suspension system. [MAY/JUN 2012] (BTL1)
To safeguard the passengers and goods against road shocks.
7 To pressure the stability of the vehicles while in motion.
To maintain proper steering geometry.
To bear the torque and braking reaction.
What is bleeding of hydraulic brakes? [NOV/DEC 2014] (BTL2)
Brake bleeding is the procedure performed on hydraulic brake systems whereby the brake lines
8 (the pipes and hoses containing the brake fluid) are purged of any air bubbles. This is necessary
because, while the brake fluid is an incompressibleliquid, air bubbles are compressiblegas and
their presence in the brake system greatly reduces the hydraulic pressure that can be developed
within the system.

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What do you mean by telescopic steering wheel? [NOV/DEC 2016] (BTL2)
9 Between the wheel and the dash on the steering column is found a metal tab that is the adjusting
collar. This collar is attached to a threaded insert that when loosened screws out away from a
metal rod that actuates the locking device. It is a fairly simple device.
What is self-energizing brake?(MAY/JUNE2016) (BTL1)
10 Self – Energizing brake uses the force (typically torque) generated by friction to increase the
clamping force of the brake shoes.
Why synchronizer is required in the automotive transmission system?(MAY/JUNE2016)
11 (BTL1)
Synchronizer is required in the automotive transmission system is to avoid double clutching and
smooth engagement of gears.
What is the advantage of having rigid axle suspension?(MAY/JUNE2014) (BTL2)
Simplicity
12 Space efficient, durable in high load environment
Cheap to manufacture
Better vehicle articulation
With regard to steering what is Toe-in and Toe-out?(MAY/JUNE2014) (BTL2)
Toe-in
The front wheels are usually turned in slightly in front so that the distance between the front ends
13 A is slightly less than the distance between the back ends B, when viewed from the top. The
difference between these distances is called toe-in. The amount of toe-in is usually 3 to 5 mm.
Toe-out
The inner front wheel turns a larger angle than the outer while turning. So the wheels are made
toe-out on turns due to the difference in their turning angles and thereby avoiding tyre scrub.
14 Name the types of front axles.(APR/MAY2015) (BTL1)
i) Live front axle ii) Dead front axle
What is meant by traction control(APR/MAY2015) (BTL2)
15 Traction control is an active vehicle safety feature designed to help vehicles make effective use of
all the traction available on the road when accelerating on low-friction road surfaces.
What is the function of the tension spring in the clutch plate?(MAY/JUNE2016) (BTL2)
Clutch springs can be found in use on most motorcycle clutch assemblies. The function of these
16 short coil springs is to continuously hold the friction and driven plates together through spring
tension, preventing slippage except when the clutch lever is engaged. Most often, five or more
clutch springs are used per motorcycle clutch assembly.
17 Name the classification brake system(MAY/JUNE2016) (BTL1)
(a) Mechanical brakes (b) Hydraulic brakes (c) Air brakes (d) Vacuum brakes (e) Electric brakes.
Give types of stub axle(APR/MAY2017) (BTL2)
18 i) Elliot type stub axle ii) Reversed Elliot stub axle iii) Lamoine stub axle iii) Reversed Lamoine
stub axle
19 Name any four types of suspension spring(NOV/DEC2016) (BTL2)
(a)Leaf Spring (b)Semi Elliptical Spring (c)Torsion Beam (d)Coil Spring
List down any two types of steering gear.(NOV/DEC2015) (BTL1)
20 (a)Worm and Sector Steering Gear (b)Worm and roller Steering Gear (c)Cam and double lever
steering gear (d)Worm and Ball bearing nut steering gear (e)Cam and roller steering gear (f)Cam
and peg steering gear (g)Rack and pinion steering gear
PART * B
1 Discuss the working of diagonal braking system with a layout. Also explain the working of
master cylinder in a hydraulic brakes.[MAY/JUN 2013]
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(13 M) (BTL5)
• In this system the brake is operated with the help of oil pressure in this system master
cylinder and wheel cylinder is most important part.
• This system is very popular on four wheeler vehicle basically light and medium vehicle.
2 Explain the various types of suspension and types offered for automobile with neat
schematic.[NOV/DEC 2014](BTL5)
Answer: Page
Suspension system is responsible for smoothing out the ride and keeping the car in control.
Specifically, the suspension system maximizes the friction between the tires and the road to
provide steering stability and good handling. The suspension system also provides comfort for
passengers to limiting the impact of particular road conditions to not only the car, but the
passengers riding inside.
The suspension system is made up of several components, including the chassis, which holds the
cab of the car. The springs support the vehicle weight and absorb and reduce excess energy from
road shocks, along with the shock absorbers and struts. Finally, the anti-sway bar shifts the
movement of the wheels and stabilizes the car.
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Your car's suspension system must be in good condition. Worn suspension components may
reduce the stability of the vehicle and reduce driver control, as well as accelerate wear on other
suspension system components. Replacing worn or inadequate shocks and struts will help
maintain good ride control, as they:
• Control spring and suspension movement

• Provide consistent handling and braking
• Prevent premature tire wear
• Help keep the tires in contact with the road
• Maintain dynamic wheel alignment
• Control vehicle bounce, roll, sway, drive, and acceleration squat
• Reduce wear on other vehicle systems
• Promote even and balanced tire and brake wear
3 (i)Write short notes on power steering.[NOV/DEC 2016] [NOV/DEC2015] (BTL5)

The increased use of large section low-pressure balloon tyres has aggravated the
steering problem due to the greater contact area between the tyre and ground. The driver
requires a greater force to be exe11ed on the steering wheel for steering the heavy vehicle or
heavily loaded commercial vehicle, especially when the vehicle has to take a sharp turn.
Power steering makes it easier to turn sharp corners. It is fitted not only to heavy commercial
vehicles but also to heavy and medium weight cars. It is usually arranged to be operative
when the effort at the steering wheel exceeds a pre-determined value. When this effort is
excluded, a valve directs the working fluid to the appropriate side of the power cylinder, and
this result in the steered wheels being turned in the desired direction. The working fluid
is high quality lubricating oil having a viscosity rating equivalent to ASE low for normal

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conditions. The actual amount of assistance given depends upon the resistance offered to
movement of the road wheels.
Types of power steering systems:
1. Integral power steering, in which the power operating assembly is part of the steering
gear.
2. Linkage power steering, in which the power opening assembly is part of the linkage.
(ii)What is the 'Under steering' and Over steering'?[NOV/DEC 2013] (13 M)(BTL5)
(i)With neat sketch explain the construction and operation of a shock
4 absorber[MAY/JUNE2016] (BTL4)|
A shock absorber (in reality, a shock "damper") is a mechanical or hydraulic device designed to
absorb and damp shock impulses. It does this by converting the kinetic energy of the shock into
another form of energy (typically heat) which is then dissipated. Most shock absorbers are a form
of dashpot (a damper which resists motion via viscous friction).
(ii)What are the requirements of good braking system?[NOV/DEC2015](13 M) (BLT5)
The brake must be strong enough to stop the vehicle within minimum distance. It is inversely
proportional to brake efficiency and proportional to square of speed.
Provide good control over vehicle during emergency braking and vehicle must not skid
After prolonged period of application of brakes, the coefficient of friction drops and property of
brake material changes which leads to less braking effect. This is called Brake Fade and hence
brakes must have antifade characteristics.
Cooling of the brakes must be very efficient
The maximum retarding force F applied by the brakes at the wheels must be close to F=μN
The brake torque depends upon effective axle height and braking force between road surface and
tyre. Hence anchor pin supporting brake shoes must have enough strength to withstand high
braking load.
Explain any one of the front independent suspension system with neat
5 diagram[APR/MAY2017] (13 M) (BTL5)
Independent suspension is any automobile suspension system that allows each wheel on the
same axle to move vertically (i.e. reacting to a bump in the road) independently of the others.
This is contrasted with a beam axle or deDion axle system in which the wheels are linked –
movement on one side affects the wheel on the other side. "Independent" refers to the motion or
path of movement of the wheels or suspension. It is common for the left and right sides of the
suspension to be connected with anti-roll bars or other such mechanisms. The anti-roll bar ties the
left and right suspension spring rates together but does not tie their motion together.
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Types
• Double wishbone suspension

• Multi-link suspension
• MacPherson strut
• Transverse leaf-spring
Transverse leaf-spring
Draw the schematic diagram of pneumatic braking system and explain it.
6 [MAY/JUNE2016] [APR/MAY2015] (13 M) (BTL5)
An pneumatic brake system or a compressed air brake system is a type of friction brake for
vehicles in which compressed air pressing on a piston is used to apply the pressure to
the brake pad needed to stop the vehicle.
With the aid of neat sketch explain the working principle of antilock braking
7
system[APR/MAY2015] [MAY/JUNE2016] [NOV/DEC2015] (13 M) (BLT5)

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Parts
Working
principle
Explain the steering principle, its need, functions in detail with proper sketches and
8 mention the parts of steering system.[MAY/JUNE2014] [MAY/JUNE2016]
[APR/MAY2017](13 M) (BLT5)
Parts
Working principle
PART * C
Compare the suspension system of four wheeler and two wheeler.

1 (15 M) (BTL5)
A motorcycle's suspension serves a dual purpose: contributing to the vehicle's handling and
braking, and providing safety and comfort by keeping the vehicle's passengers comfortably
isolated from road noise, bumps and vibrations.

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The typical motorcycle has a pair of fork tubes for the front suspension, and a swingarm with one
or two shock absorbers for the rear suspension.
Suspension is the system of tires, tire air, springs, shock absorbers and linkages that connects
a vehicle to its wheels and allows relative motion between the two. Suspension systems must
support both roadholding/handling and ride quality, which are at odds with each other. The tuning
of suspensions involves finding the right compromise. It is important for the suspension to keep
the road wheel in contact with the road surface as much as possible, because all the road or
ground forces acting on the vehicle do so through the contact patches of the tires. The suspension
also protects the vehicle itself and any cargo or luggage from damage and wear. The design of
front and rear suspension of a car may be different.
2 (i)Distinguish between independent suspension and conventional suspension system.

[MAY/JUNE2016] [MAY/JUNE2014] (BTL5)
Independent suspension is any automobile suspension system that allows each wheel on the
same axle to move vertically (i.e. reacting to a bump in the road) independently of the others.
This is contrasted with a beam axle or deDion axle system in which the wheels are linked –
movement on one side affects the wheel on the other side. "Independent" refers to the motion or
path of movement of the wheels or suspension. It is common for the left and right sides of the
suspension to be connected with anti-roll bars or other such mechanisms. The anti-roll bar ties the
left and right suspension spring rates together but does not tie their motion together.
The suspension system of an automobile helps to support the car body, engine and passengers,
and at the same time absorbs shocks received from the ground while vehicle moves on rough
roads.
(ii)List the types of suspension spring used in automobile [MAY/JUNE2016] (15 M) (BTL5)
• Leaf Spring: Semi elliptic leaf springs are used in almost all commercial vehicles. ...
• Helical Spring or Coil Spring: We all have seen coil springs many times. ...
• Torsion Bar: It is simply a rod which acting under the torsion and taking shear stresses. ...
• Rubber Springs:The rubber springs are also used in suspension because it store greater energy per
unit weight than the steel. So it is more compact than other springs. It has also excellent vibration
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damping property. One more advantage of using rubber is that it is not suddenly fail like steel so
there is less risk.
Derive an expression for condition of correct steering.
3
(15 M) (BTL5)
The steering gear mechanism is used to change the direction of two or more of the wheel axle’s
with reference to the chassis, so as to move the automobile in the desired path. The steering is
done by front wheels and back wheels remain straight and do not turn.
The condition for correct steering is that all the four wheels must rotate about the same
instantaneous centre which lies on the axis of the back wheels.
Let the axis of the inner wheels makes a larger angle θ than the angle φ subtended by the axis of
outer wheel.
Let a = wheel track, b = wheel base
c= distance between the pivots A and B of the front axle
From triangle IBP
From triangle IAP
This is the fundamental equation for correct steering.

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UNIT V - ALTERNATIVE ENERGY SOURCES

Use of Natural Gas, Liquefied Petroleum Gas, Bio-diesel, Bio-ethanol, Gasohol and Hydrogen in Automobiles-
Engine modifications required –Performance, Combustion and Emission Characteristics of SI and CI engines with
these alternate fuels - Electric and Hybrid Vehicles, Fuel Cell
Note: Practical Training in dismantling and assembling of Engine parts and Transmission Systems
should be given to the students.
PART * A
Q.No. Questions
Mention the various methods of storing hydrogen. [NOV/DEC 2013](BTL2)

1. (a)Compressed storage (b)Liquid Storage (c)Solid State Storage
Write down the parts of a fuel cell. [NOV/DEC 2013] (BTL2)
2
Oxidizer.
State the advantages of natural gas. [NOV/DEC 2012](BTL3)
Low engine emission. Less aldehyde than withmethanol
3
Natural Gas is abundant worldwide. It can be made from coal.
Octane number is 110 and make suitable for SI engine fuel.
What is fuel cell? [NOV/DEC 2012] (BTL1)
4 A fuel cell is electrochemical energy conversion device that continuously converts chemical
energy of a conventional fuel is converted directly and efficiently into electrical energy.
What is meant by reformulated and oxygenated gasoline? (BTL1)
Reformulated gasoline is gasoline blended to burn more clearly than conventional gasoline and to
5 reduce smog-forming and toxic pollutants in the air. Gasoline additives are added to increase
oxygen content in the fuel in order to reduce carbon monoxide and soot produced during burning
of fuel.
Define the term 'Esterification'. [MAY/JUN 2012] (BTL2)
6 Esterification is the process of converting Carboxylic acids to ester using acid and alcohol.
How a fuel cell differs from lead acid battery? [NOV/DEC 2014] (BTL1)
The biggest difference between the two is that a battery stores energy, while a fuel cell generates
7
energy by converting available fuel. A fuel cell can have a battery as a system component to store
the electricity its generating.
State functions of stabilizers. [NOV/DEC 2014] (BTL3)
The main function of stabilizer is to make the output voltage that fees the equipment connected to
8 it as much as possible equivalent to the ideal electrical power supply, ensuring that the oscillation
in electrical power are offset, and its output maintain a stable value, preventing them from being
experienced by equipment and thereby avoiding their damage.
What are the advantages of Hybrid vehicle? [NOV/DEC 2016] (BTL3)
Environmental Friendly
It runs cleaner and better mileage
9 Regenerative braking system.
Less dependent of fossil fuels
Built from lighter material
Higher resale value.

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Mention the advantages of LPG usage in automobiles. [NOV/DEC 2016] (BTL3)
Higher heating value
10
Does not contain sulphur, so burnt cleaner.
Releases only 70% of Carbon dioxide
What is the need to switch over to alternate source of
energy?(MAY/JUNE2016) (BTL3)
To reduce pollution
11 To protect against Global warming
To save money & can be produced frequently.
Write the reaction takes place during discharging and charging of nickel
metal hydride cell(MAY/JUNE2016) (BTL1)
When NiMH cell is discharged, the chemical reaction is the reverse of what occurs
12 when charged. Hydrogen stored in the metal alloy of the negative electrodes is
release into the electrolyte to form water. This water the releases a hydrogen ion
that is absorbed into the positive electrode to form nickel hydroxide.
Define energy intensity(MAY/JUNE2014) (BTL1)
13 consumption per work unit, often is used.
Why is hydrogen called as secondary energy source?(MAY/JUNE2014) (BTL1)

Hydrogen is called as secondary energy source commonly referred to as energy
14 carrier. Energy carrier are used to move store and deliver energy in the form that
can be easily used.
Define Hybrid Vehicle. (NOV/DEC2016) (BTL1)
The vehicle which is using more than one source of energy to run is called hybrid
15 vehicle. Hybrid means something that is mixed together from to things.
Write short notes on LPG(MAY/JUNE2016) (BTL2)

It is the by product of fractional distillation of petrol, consisting mainly of butane
16 and propane and used as engine fuel. It is formed naturally, interspersed with
deposits of petroleum and natural gas.
Why alcohol is an alternate fuel for S I engine?(MAY/JUNE2016) (BTL1)
Alcohol has good calorific value, good volatility, not much higher ignition energy,
17 average autoignition temperature; Viscosity also not much higher, easy burning,
easy availability and easy storing makes it suitable as alternate fuel for SI engine.
What are the merits and demerits of supercritical methanol (SCM)
transesterification process?(APR/MAY2017) (BTL1)
Super critical methanol is any substance at a temperature and pressure above its
18 critical point, where distinct liquid and gas phase do not exist. It can effuse through
solids like gas and dissolve materials like liquids.
Mention any four types of fuel cells(APR/MAY2017) (BTL2)
1. Alkaline fuel cells 2. Solid oxide fuel cells 3. Molten carbonate fuel cells
19 4. Direct methanol fuel cells.
List down any two types of steering gear.(NOV/DEC2015) (BTL2)

(a)Worm and Sector Steering Gear (b)Worm and roller Steering Gear (c)Cam and
20 double lever steering gear (d)Worm and Ball bearing nut steering gear (e)Cam and
roller steering gear (f)Cam and peg steering gear (g)Rack and pinion steering gear
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PART * B
Explain the various properties of alternative fuels. (13M) [MAY/JUNE2016]
(BTL3)
1
Measuring a fuel's relative potential energy can easily be done by defining that
fuel's Btu content. A Btu is defined as the amount of heat necessary to raise one (1)
pound of water, one (1) degree Fahrenheit.Gasoline and LPG are derived from oil
or from natural gas production while CNG comes fromnatural gas. Both oil and
natural gas are fossil fuels. The finite reserves of oil are far less than those of
natural gas. Farm crops and waste-by-products are the usual sources for methanol
and ethanol. The primary CNG component, methane, also may be produced from
these sources.
From an environmental standpoint, the sulphur content affects the level of tailpipe
acids produced as an exhaust by-product. These acids significantly contribute to
"acid rain." Acid rain affects plant life, animals, and humans. Environmentalists are
deeply concerned over increased exposure and concentrations of automobile-
produced, exhaust-oriented, tailpipe emissions.
An engine fuel's "antiknock" or octane rating is important to an engine's performance and to the
power yield curve. Gasoline has a relatively low octane number, thus compression ratios must
be moderated resulting in a lower power yield per cubic inch displacement. Gasoline may be
refined to higher octane levels; however, more fuel stocks are needed. Greater waste by-
products result as a part of this refining process. Other additives such as tetraethyl lead,
phosphorus, and boron were formally used to raise octane ratings. They are no longer used as
they damage catalytic converters and are environmentally detrimental. Additionally, exhaust
by-products that contain lead are thought to cause some forms of retardation in small children.
Tailpipe emissions produced from gasoline yield significant amounts of benzene, a known
carcinogen. Other additives, such as MTBE, are being studied to determine if they are
carcinogenic. (13M)
Explain LPG is an alternate fuel for petrol engine with diagram. Also explain
its performance and emission characteristics. (13 M) [APR/MAY2017] BTL3
An alternative fuel vehicle is a vehicle that runs on a fuel other than traditional petroleum
fuels (petrol or Diesel fuel); and also refers to any technology of powering an engine that does
not involve solely petroleum (e.g. electric car, hybrid electric vehicles, solar powered).
Because of a combination of factors, such as environmental concerns, high oil prices and the
potential for peak oil, development of cleaner alternative fuels and advanced power systems
for vehicles has become a high priority for many governments and vehicle manufacturers
around the world.
2 The mixture of liquefied hydrocarbon gases C3-C4 (propane and butane), called colloquially
liquefied gas or LPG, is a particular energy carrier, counted among the group of alternative
fuels. LPG has more than 1000 different uses, including applications in industry, civil
engineering, communal economy, agriculture, households, and transport. Because of simplified
logistics of transport ensuring supply diversification, availability of sources, and most of all
environmental
aspects, LPG exhibits high dynamics of production and consumption; the global
production of this fuel comes close to 280 million tonnes. (13M)

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Explain construction and working principle of hybrid vehicle with neat
sketch. (13M) [APR/MAY2017] [APR/MAY2015] (BLT3)
Temperature fuel cell to be used to drive a gas turbine. Initially the researchers are
developing small systems ranging from 250 kW to 1 MW, for use by business and
light industry for co- generation. (2M)
3 Explain construction and working principle of hybrid vehicle with neat sketch. (13M)
[APR/MAY2017] [APR/MAY2015] BLT3
Temperature fuel cell to be used to drive a gas turbine. Initially the researchers are developing
small systems ranging from 250 kW to 1 MW, for use by business and light industry for co-
generation. (2M)
the word hybrid refers to anything that has a combination of two different ideas. When a car uses
two different ideas to move, it is called a hybrid car. Usually our cars run on petrol, diesel or gas.
But their inefficiency, as explained earlier, led to the invention of electric cars. But, since electric
cars also had disadvantages of frequent battery charging and inefficient long drives, there evolved a
combination of both. When gas and electricity were used in the combined mode, a better solution
was made to the inefficiency and mileage.
A user of a car always asks for some minimum requirements while using a car. They are
• For long distances, the car must run for at least 450 kilometres before refuelling.
• The drive should be smooth and easy.
• The car should maintain a good speed so as to cope up with other cars in traffic.
• Easy and fast refuelling of cars.
• A good mileage
• Less pollution
Though most of the conventional cars can provide the first four requirements correctly, they are
very much backwards in the case of mileage and pollution. Electric cars, on the other hand can
provide a very good mileage and very less pollution. But, the first four requirements will be let
down. A combined use of both electric and gas energy will clearly find all these requirements
satisfactory.
As Hybrid cars use two energy sources, a lot of energy consumption was reduced for travel (As
both the gas and electricity share their energy.) As explained in my article about electric cars, there
would not be a disadvantage of recharging the battery frequently. They will be spontaneously
charged, while the car is running. Apart from the mileage, the car has also proved to give a
performance almost adequate to a conventional car. Due to its improved mileage and reduced
pollution, the governments in most countries have been pleased and have helped in its promotion.

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Parts Of a Hybrid Car
There are mainly 5 essentials for a hybrid car. They are
1. Conventional car engine – It can be a gasoline engine or also petrol or diesel respectively. But
whatever engine is used, will be more advanced than the usual ones, as they have to work together
with the electrical system. They will be smaller with greater efficiency and lesser emissions.
2. Fuel Tank – For storing the fuel needed to rum the car engine.
3. Batteries – Batteries are needed to store and release energy as required by the car. The energy from
the battery is taken by the motor.
4. Electric Motor and generator – Though motors can act as generators, both of them are needed for
this car. A motor will be needed to take energy from the batteries and accelerate the car. Generators,
on the other hand, are needed to produce the electrical power.
5. Transmission System – The entire transmissions that were performed in a conventional car will be
done here as well, but in the hybrid manner.

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JEPPIAAR INSTITUTE OF TECHNOLOGY

Self Belief | Self Discipline | Self Respect

ACADEMIC YEAR : 2019-2020

III YEAR – 06th SEMESTER

➢ To produce competent and disciplined high quality professionals with the

➢ To improve the quality of education through excellence in teaching and

➢ To provide excellent infrastructure, serene and stimulating environment

To be the most sought-after Department in the field of Mechanical Engineering for

• To provide innovative solutions for industrial problems which helps in

Engineering Graduates will be able to:

➢ BTL 2 – Understand - The learner embraces the meaning of the information by

➢ BTL 5 – Evaluate - The learner makes decisions based on in-depth reflection,

ME8651 – Design of Transmission Systems

ME8651 DESIGN OF TRANSMISSION SYSTEMS L TPC

UNIT I DESIGN OF FLEXIBLE ELEMENTS 9

UNIT II SPUR GEARS AND PARALLEL AXIS HELICAL GEARS 9

UNIT III BEVEL, WORM AND CROSS HELICAL GEARS 9

UNIT IV GEAR BOXES 9

UNIT V CAMS, CLUTCHES AND BRAKES 9

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

Subject Code:ME8651 Year/Semester: III /06

UNIT I –DESIGN OF FLEXIBLE ELEMENTS

1 Give an expression for ratio of tensions in a flat belt drive. BTL3

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

𝑇𝑜𝑡𝑎𝑙 𝑝𝑜𝑤𝑒𝑟 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

UNIT II–SPUR GEARS AND PARALLEL AXIS HELICAL GEARS

1 Specify the conditions based on which gear cutters are selected.BTL4

Dynamic Load, Fd:(1M)

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

Dynamic Load, Fd:(1M)

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

UNIT III–BEVEL, WORM AND CROSS HELICAL GEARS

Minimum value is selected.

Dynamic Load, Fd:(1M)

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

Revision of centre distance, a:(1M)

𝜎𝑐 = 146.2 × 106 𝑁/𝑚2

Basic dimensions of pinion and wheel:(1M)

0.72 (𝑖 2 + 1)3 𝐸[𝑀𝑡 ]

Dynamic Load, Fd:(1M)

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

Dynamic Load Fd:(1M)

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

UNIT IV–GEAR BOXES

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

14 What are preferred numbers? (Apr/May 2011,2013, Nov/Dec 2014)BTL2

18 What is a speed reducer?BTL1

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

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JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS

JIT-JEPPIAAR/MECH/Mr.S.KANNAN & Mr.S.VIGNESH/IIIrdYr/SEM 06 /ME8651/DESIGN OF TRANSMISSION SYSTEMS