Total No. of Questions : 10] SEAT No.
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P3745 [Total No. of Pages : 4
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B.E. (Mechanical )
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MACHANICAL SYSTEM DESIGN
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(2012 Course) (402048) (Semester-II)
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Time : 3 Hours] [Max. Marks : 70
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Instructions to the candidates:
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1) Answer Q1 or Q2, Q3 or Q4, Q5 or Q6, Q7 or Q8, Q9 or Q10.
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2) Neat diagrams must be drawn whenever necessary.
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3) Figures to the right side indicate full marks.
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4) Assume suitable data, if necessary.
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Q1) a) A machine tool requires six speed gear box. Which having a 160 rpm
minimum and 1000 rpm maximum speed, when the motor shaft is
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1440 rpm. Draw the speed diagram for the following structural formula.
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i) 2 (3) 3 (1) ii) 2 (1) 3 (2). 13 [6]
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b) Give formula for calculating Mean and Standard deviation of resultant
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Population if two individual populations are to be added and multiplied.[4]
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OR
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Q2) a) Draw the structure diagram and identify the optimum structural formula
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out of them. i) 2 (1) 3 (2) ii) 2 (3) 3 (1) iii) 3 (2) 2 (1) [6] sta
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b) Define design tolerance (DT) and natural tolerance (NT) in statistical
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design. State what happens when NT=DT, NT>DT and DT>NT. [4]
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Q3) a) Explain the concepts of Unit Load and Containerzation. [4]
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b) A three idler, troughed belt, horizontal conveyor is to be used for
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transporting 500 ton of iron per hour having mass density of iron ore is
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1700 kg/m3. If the belt speed is 2m/sec, determine the required belt
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width. Take surcharge factor = 0.1. [6]
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Q4) a) State the appropriate guidelines for selection of material handling system.
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b) A flat horizontal belt conveyor is to be used for transporting material
with mass density of 3 ton/m3. The belt is 750 mm wide and has speed
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of 2.75 m/s Determine capacity of vonveyor if surcharge angle is 25°
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(k = 2.35 * 10-4). [6]
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Q5) a) Derive an expression for the thickness of a thick cylinder subjected to
internal pressure by using maximum shear stress theory. [8]
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b) A seamless cylinder with a storage capacity of 0.025 m3 is subjected to
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an internal pressure of 20 MPa. The length of the cylinder is twice its
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internal diameter. The cylinder is made of plain carbon steel 20C8
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( Sut = 390 N/mm2) and the factor of safety is 2.5. Determine the
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dimensions of the cylinder. [10]
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Q6) The following data refers to single acting hydraulic cylinder. [18]
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Pressure of hydraulic fluid = 10 MPa
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Operating force available at the piston rod. = 10KN sta
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Friction due to piston ring and stuffing box = 10% of operating force
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Thickness of cylinder flange = 10 mm
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Thickness of cylinder head = 8 mm
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Cylinder and, cylinder head material = FG200
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Modulus of elasticity for FG200 = 100 GPa
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Thickness of Zinc gasket = 3 mm
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Modulus of elasticity for zinc = 83 GPa
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Number of bolts =4
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Preload in each bolt = 2.8 KN
Bolt material = FeE400
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Modulus of elasticity for FeE400 = 207 GPa
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Factor of safety for cylinder =5
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Factor of safety for bolts =6
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Standard diameter of cylinder
1 = 20, 30, 40, 50, 60 mm
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Standard Thickness of cylinder = 2, 4, 5, 6, 7, 8, 10 mm
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Standard diameter of bolts = 8, 10, 12, 14, 16, 18, 20, 22 mm
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Determine :
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i) Inner diameter of cylinder
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ii) Thickness of cylinder
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iii) Diameter of bolts
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Q7) a) What is the difference between centre and overhung crankshafts? [6]
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b) The bore of a cylinder of the four stroke diesel engine is 120 mm. The
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maximum gas pressure inside the cylinder is limited to 4 MPa. The cylinder
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head is made of cast iron and the allowable tensile stress is 40 N/mm2.
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Determine the thickness of the cylinder head. The studs which are made
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of steel have allowable stress as 50 N/mm2. Calculate i) Number of studs,
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ii) Nominal diameter, and iii) Pitch of studs. K = 0.162 [10]
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Q8) The following data is given for a four- stroke diesel engine : [16]
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Cylinder bore = 250 mm, Length of stroke = 300 mm, speed = 600 rpm
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Indicated mean effective pressure = 0.6 MPa., Mechanical efficiency = 80 %
Maximum gas pressure = 4 MPa
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Fuel consumption = 0.25 kg per BP per hr.
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Higher calorific value of fuel = 44000 KJ/kg
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Assume that 5% of total heat developed in the cylinder is transmitted by the
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piston. The piston is made of gray C.I FG 200 (Sut = 200N/mm2 and
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K = 46.6 W/m/°C) and the factor of safety is 5. The temperature difference
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between the center and the edge of the piston head is 220°C.
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i) Determine the thickness of piston head by strength consideration and
thermal consideration.
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ii) State whether the ribs are required, If so calculate the number and
thickness of ribs.
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iii) State whether a cup is required in the top of piston head, If so calculate
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the radius of the cup.
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Q9) a)
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Write a short note on design for manufacturing and assembly.
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b) A tensile bar of length 300 mm is subjected to constant tensile force of
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4 KN. If the factor of safety is 1.5, design the bar diameter, using
Johnson’s method with the objective of minimizing material weight using
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optimum material from the list given below. [10]
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Material Density( ) kg/m3 Cost(c)Rs/Kg Syt N/mm2
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Steel 7800 34 400
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Aluminum alloy 2800 160 150
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Titanium alloy 4500 2400 800
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Q10)a) A tensile bar of length 400 mm is subjected to the tensile force of
4.5 KN. Assume Factor of Safety 2. Design the bar with the objective of
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minimizing the material cost, out of the following materials: [10]
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Material Mass Density Material cost Yield Strengthsta
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kg/m3 per Unit Mass Syt N/mm2
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c,Rs./kg
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Plain Carbon Steel 7500 16 130
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Aluminum Alloy 3000 32 50
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Titanium Alloy 4800 480 90
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Magnesium Alloy 2100 32 20
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b) Explain design consideration in design for forgings. [6]
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