DESIGN PROBLEM

1. Design a pogo stick for a child who weighs up to 50 Kg, including the spring design, structural design,
and the size of tubes for the leg. Estimate the performance characteristics of this design, including the
amount of compression in the spring and the height to which the pogo stick would jump.

2. Design the rear coil suspension spring for Hero Splender Bike take a curb weight of the motorcycle
120 Kg along with the rider and pillion weight (200 Kg). Assume the suspension spring can deflect a
maximum up to 30 mm.

3. Design a helical Compression Spring to apply force and control motion using Cam & Follower in the
feed mechanism of automatic lathe machines. Assume the maximum deflection of the spring will not
exceed 40 mm.
4. For the truck use the following constraints:
a. Each of the axles on the truck body will share one-quarter of the trailer part of the truck, which has
a total weight of 20,000 Kg.
b. The spring should deflect approximately 4 inches under the static load.
c. Under some road conditions, such as hitting a pothole, the maximum load on the spring increases
to double the static load.
Design a spring for these conditions and include diameter, wire pitch, and material. Verify that the stress
in the spring is suitable under solid conditions and that buckling is not a concern. Multiple coil springs
could be used for each wheel assembly.

5. The truck needs a transmission. The motor creates 350 hp of power at 2400 rpm and requires a
selectable gear ratio of 4:1, 3:1, and 2:1 for the first step in the reduction. Design three sets of spur gears.

6. Design a spur gear for a compressor drive train as shown in the figure below. The required gear ratio is
a 2.5:1 reduction in velocity from the input to the output shaft. The output shaft velocity is 1500
rpm.AGMA standard full–depth teeth will be used. Set Both pinion and gear will be through hardened
steel.
7. Design the rear coil suspension spring for Dirt Bike having a curb weight of the motorcycle of 100 Kg
along with the rider and pillion weight (70 Kg). Assume the suspension spring can deflect a maximum
up to 70 mm.

8. A stepped transmission shaft is supported by the ball bearings at A and C where the shaft diameter is
d₂ The shaft transmits a power of 2 HP at 1260 rpm to a gear that is mounted at B where the diameter
is d1 and a sheave that is mounted at D over diameter d3. Design the transmission shaft for a minimum
design safety factor of 2.
9. Design a Shaft for a bicycle near to pedal region to transmit power from chain drive to the rear wheel
as shown in the figure. Assume the force applied through pedaling varies from 50 N to 300 N.

10. Design a spur gear for the transmission box of a two-wheeler Yamaha FZ motorbike to transmit 20
KW of power at 1500 rpm, the speed reduction is 2.5, Take a pressure angle of 20o.

11. A multi-plate clutch is to be designed to transmit a power of 80 kW at 600 rpm for Fork Lift. Assuming
suitable materials and data, determine the main dimensions of the friction lining used in that clutch.
12. Design a Belt drive for the given system as shown in the figure. Before the belts can start turning, they
must be tensioned and, in this case, the tensions are the same on both sides of each belt (i.e. they are
acting as ideal pulleys). If point D acts as a thrust bearing and point A is a regular journal bearing, what
are the reactions at A and D? You may assume that F= 3,000N and P = 2, 000N. The distances, X1,
X2, and X3 are 500 mm, 300 mm, and 200 mm, respectively. The drive at B has a pulley diameter of
100 mm and the drive at C has a pulley diameter of 220 mm.

13. Design a chain drive for a bicycle mounted on a pedaling shaft to transmit power from the bigger chain
sprocket to the rear chain sprocket wheel as shown in the figure. Assume the force applied through
pedaling varies from 50 N to 300 N.
14. Design the frame for a racing bicycle that should have a higher strength to low weight ratio. Assume
the material for the frame is carbon fiber epoxy reinforced composite whose yield strength and ultimate
strength are 2000 Mpa and 2800 Mpa respectively. Take a maximum load of rider 750 N.

15. Design the rear coil suspension spring for KTM Bike take a curb weight of the motorcycle 150 Kg
along with the rider and pillion weight (180 Kg). Assume the suspension spring can deflect a maximum
up to 40 mm.

16. Select Roller chain which is used in Camshaft of an Internal Combustion engine .Both shaft rotate at
350 rpm. The centre distance between their axes should be fixed i.e 550mm. and number of teeth on
each sprocket wheel is 19. Determine unknown parameter for design.
17. Design a protected type CI flange coupling for a steel shaft transmitting 30 kW at 350 rpm. The
allowable shear stress in the shaft and key material should consider accordingly. The maximum torque
transmitted is to be 20% greater than the mean torque. The allowable shear stress in the bolt is 60 MPa
and allowable shear stress in CI flange is 40 MPa.

18. Determine the dimensions of flange coupling that connects a motor and a pump shaft. The power is
transmitted a 2 kW at a shaft speed of 960 rpm. Select suitable materials for the parts of the coupling
and list the dimensions.

19. The Schematic diagram in Fig. illustrates part of a tape dispenser mechanism for an industrial
packaging system.Which consists of shaft ABCD driven by a torque”T” acting at point A.As per the
given system find the suitable bearing and key and shaft design.
20. The shaft of a hand operated wire rope hoist on the bearing A and B as shown in Fig. As per the given
condition design which key, shaft and bearing is suitable.

21. A hollow circular shaft of outer and inner diameters of d0 and di respectively is subjected to a torsional
moment of Mt over a length l. The permissible angle of twist is q degrees. Derive the Expression of
shaft diameter. Where di/do. Also Justify by taking proper value of G (Modulus of rigidity) and its
effect.
22. A transmission system comprises a bevel gear derive arrangement as shown in Fig, the bevel gear at B
is positioned at mid span of the shaft ABC of 1.2 m long and transmits 15 kW at 600 rpm. Design the
shaft, key and bearing as per the given condition, by considering suitable FOS=3

23. Design a spur gear for the transmission box of a two-wheeler KTM motorbike to transmit 30 bhp power
at 2000 rpm, the speed reduction is 2.5, Take a pressure angle of 20o.

24. A propeller shaft is required to transmit 50 kW power at 600 rpm. It is a hollow shaft, having an inside
diameter 0.8 times of the outside diameter. if factor of safety is 4. Calculate the inside and outside
diameters of the shaft and Select suitable material for Shaft, which fulfil the requirement.
25. Design a Belt drive for the given system as shown in the figure. Before the belts can start turning, they
must be tensioned and, in this case, the tensions are the same on both sides of each belt (i.e. they are
acting as ideal pulleys). If point D acts as a thrust bearing and point A is a regular journal bearing, what
are the reactions at A and D? You may assume that F= 2,000N and P = 3, 000N. The distances, X1,
X2, and X3 are 400 mm, 200 mm, and 100 mm, respectively. The drive at B has a pulley diameter of
100 mm and the drive at C has a pulley diameter of 220 mm.

26. Design a spur gear reduction gearbox to reduce an input speed of 3600 rpm to 180 rpm from 5-hp
motor. Select gear, shafts and bearings to accomplish this. A complete stress analysis of all gears,
shafting, and loads on the bearings should be included.

27. A semi-elliptic spring used for automobile suspension, consists of two extra full-length leaves and eight
graduated-length leaves, including the master leaf. The centre-to-centre distance between the two eyes
is 1 m. Select the material of leaves which can withstand maximum load and consider the factor of
safety is 2. The maximum spring load is 30 kN. The leaves are pre-stressed so as to equalize stresses in
all leaves under maximum load. Determine the dimensions of the cross-section of the leaves and the
deflection at the end of the spring.