SHIVAJI UNIVERSITY, KOLHAPUR,

Final Year B.Tech (Mechanical Engineering)

CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

Chapter 1:- Aesthetic and Ergonomic Consideration in

Design
1. Explain relationship between man, machine and environment.
2. Explain following w.r.to aesthetic design
i) Form ii) Symmetry and Balance
iii) Color iv) Style
3. Explain aspects of Aesthetic design with suitable examples.
4. Ergonomic considerations in design of displays and controls.
5. Explain basic types of product forms with suitable examples.
6. Discuss ergonomic design considerations in displays and control panels.
7. With the help of suitable examples, explain the importance of aesthetic consideration in
the product design.
8. Explain the ergonomic design consideration involved in the dashboard panel of car. With
suitable example, explain effect of appearance, shape, color and quality in aesthetic
design.
9. Explain the Ergonomic consideration in the following items:
i) Control knob ii) Hand wheel
10. What are different types of displays? Explain the ergonomic considerations in the design
of displays.
11. Explain the ergonomic design consideration involved in the Executive Chair. With
suitable example, explain effect of appearance, shape, color and quality in aesthetic
design.
12. Explain the ergonomic design consideration involved in the Ladies Bi-Cycle. With
suitable example, explain effect of appearance, shape, color and quality in aesthetic
design.
13. With suitable example explain the creativity concept in the product design.
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

14. Explain the various steps involved in Creativity in Design.

15. List objectives of optimum design
16. Explain with suitable example adequate design and optimum design

Chapter 2 Pressure Vessel Design

1) Derive Clavarino’s and Brinie’s equations for pressure vessel
2) Explain with neat sketches types of end closures of pressure vessel.
3) Explain with neat sketches types of pressure vessel support.
4) Explain classification of pressure vessels as per IS 2825-1969.
5) Differentiate thin and thick cylinders.
6) Discuss the design considerations of skirt support for vertical pressure vessels.
7) What are the objectives of pre-stressing the high pressure cylinders? Describe the various
methods of pre-stressing such cylinders.
8) The piston rod of a hydraulic cylinder exerts an operating force of 10 kN. The friction
due to piston packing and stuffing box is equivalent to 10% of the operating force. The
pressure in the cylinder is 10 MPa. The cylinder is made of cast iron FG 200 and the
factor of safety is 5. Determine the diameter and the thickness of the cylinder.

9) The inner diameter of a cylindrical tank for liquefied gas is 250 mm. The gas pressure is
limited to 15 MPa. The tank is made of plain carbon steel 10C4 (Sut = 340 N/mm2 and m
= 0.27) and the factor of safety is 5. Calculate the cylinder wall thickness.
10) A high pressure cylinder consists of a steel tube with inner and outer diameters of 20 mm
and 40 mm respectively. It is jacketed by an outer steel tube, having an outer diameter of
60 mm. The tubes are assembled by shrinking process in such a way that maximum
principal stress induced in any tube is limited to 100 N/mm2. Calculate the shrinkage
pressure and original dimensions of the tubes (E = 207 kN/mm2).
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

11) An air receiver consists of a cylinder closed by hemispherical ends as shown in Figure 3a.
It has a storage capacity of 0.25 m3 and operating internal pressure of 5 MPa. It is made
of plain carbon steel 10 C4 (Sut = 340 N/mm2) and the factor of safety is 4. Neglecting
effect of welded joints determine dimensions of the receiver.

12) A compound cylinder consists of an inner steel tube with inner and outer diameters of 40
mm and 60 mm respectively. It is reinforced by shrinking a steel jacket of outer diameter
80 mm. The compound cylinder is subjected to an internal pressure of 60 MPa The
shrinkage allowance is such that the maximum circumferential stresses in inner tube and
jacket are same.
Calculate:
i) The interferential pressure and
ii) The original dimensions of inner tube and jacket.
Assume E = 207000 N/mm2.
13) A pressure vessel consists of a cylindrical shell with an inside diameter of 1650 mm,
which is closed by torispherical heads with a crown radius of 1300 mm. The operating
pressure inside the vessel is 1.5 MPa. The yield strength of the material used for the shell
and head is 255 N/mm2 and the weld joint efficiency may be assumed to be 0.8. The
corrosion allowance is 2 mm. Determine the thickness of the cylindrical shell and the
torispherical head.
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

Chapter 3:- Design of Braking and Clutch System

A) Brakes
1. Write short notes on :
i) Band brake
ii) Auto frottage
2. Explain Thermal consideration and rating of brakes.
3. What is the energy consideration in the design of brakes?
4. Explain briefly various types of materials used for brakes?
5. Describe energy consideration in the design of braking system in hoist and car.
6. An automotive type internal expanding brake (double-shoe) is as shown in Fig. 4a.
The face width of the friction lining is 40 mm and the maximum intensity of pressure
is limited to 1 N/mm2. The coefficient of friction is 0.32. The angle 61 can be
assumed to be zero, calculate :
i) The actuating force P, and
ii) The torque-absorbing capacity of the brake

All dimensions are in mm. Automotive double shoe brake

 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

7. An automotive vehicle weighing l0 kN and moving on the level road at a speed of

100 Km/hr is brought to the rest in 4 seconds by applying the brakes on all four
wheels. The mass moment of inertia of each wheel about the axis of rotation is 0.75
Kg-m2. The rolling radius of the wheel is 0.175m. The rotating and reciprocating
parts of the engine and transmission system are equivalent to a mass moment of
inertia of 2.5 kg-m2 at 4000 rpm. The mass of each brake drum assembly is 10 Kg.
The specific heat of the brake drum is 500 J/kg°C.
Calculate:
i) The temperature rise of the brake drum assembly and
ii) The braking torque capacity of each brake.
8. A flywheel of 100 kg mass and 350 mm radius of gyration is rotating at 500 rpm. It is
brought to rest by means of a brake. The mass of the brake drum assembly is 5 kg.
The brake drum is made of cast-iron FG260(c = 460 J/kg°C ). Assuming that the total
heat generated is absorbed by the brake drum only, calculate the temperature rise.

B) Clutches
1. Compare :
i) Single plate and multiplate clutches
ii) Dry and wet clutches.
2. Derive an expression for torque transmission capacity of plate clutch based on
uniform pressure theory (p=C). Discuss uniform pressure and uniform wear theory in
relation to clutch design.
3. Derive an expression for torque transmission capacity of plate clutch assuming
uniform wear theory (p*r = C).
4. Discuss the considerations used in design of centrifugal clutch.
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

5. A centrifugal clutch, transmitting 20 KW at 750 rpm consists of four shoes. The

clutch is to be engaged at 500 rpm. The inner radius of the drum is 165 mm. The
radius of the centre of gravity of the shoes is 140 mm when the clutch is engaged. The
coefficient of friction is 0.3 mm, while the permissible pressure on friction lining is
0.1 N/mm2. Calculate: (i) Mass of each shoe (ii) Dimensions of friction lining.
6. A plate clutch consists of one pair of contacting surfaces. The inner and outer
diameters of the friction discs are 100 mm and 200 mm respectively. The coefficient
of friction is 0.2 and permissible intensity of pressure is 1 N/mm2. Assuming uniform
wear theory calculates power transmitting capacity of the clutch at 750 r.p.m.
7. A cone clutch with asbestos friction lining is used to transmit 35 KW power at 2000
rpm. The coefficient of friction between the contacting surfaces is 0.15, while the
permissible intensity of pressure is 0.3 N/mm2. The cone angle is 24°. The face width
of the cone is not to exceed one third of the mean radius. Assuming the uniform wear
condition, determine:
i) The dimensions of friction surfaces
ii) The axial force required to engage the clutch:
iii) The axial force required to disengage the clutch
8. A centrifugal clutch transmitting 20KW at 800 rpm consists of four shoes. The clutch
is to be engaged at 500 rpm. The inner radius of the drum is 165 mm while the radius
to the center of gravity the shoes in engaged position is 140 mm. The coefficient of
friction is 0.3. Calculate the mass of each shoe.
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

Chapter 4:- Design of Gear boxes for machine tool

applications
1. What are considerations in design of multi-speed gear boxes? Explain.
2. Compare structure diagram and speed diagram.
3. What is structure diagram? Explain the procedure to construct a structure diagram for
a multispeed drive.
4. Explain method of constructing structure diagrams and steps involved in selection of
optimum structure diagram.
5. Why geometric progression is used for estimating spindle speeds in machine tools
drives? Explain.
6. Discuss the need of multispeed gearbox in machine tool.
7. A three-stage, twelve speed gear box is to be designed for spindle speeds varying
between 60 r.p.m. and 2880 r.p.m. The second stage consists of 3 speed steps. If the
gear box is driven by 5 kW, 1440 r.p.m. electric motor.
i) Draw ray diagram I
ii) Draw gearing diagram
iii) Determine No. of teeth on gears for 1st stage
8. A multi speed gearbox is to be designed for a head stock of a turret lathe for a nine
spindle speeds ranging from 30 rpm to 1000 rpm. If the gear box is driven by 5 kW,
720 rpm electric motor through drive.
i) Draw speed ray diagram
ii) Draw gearing diagram
iii) Calculate no. of stages
iv) Spindle speeds.
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

9. A multi speed gear box is to be designed for a headstock of a turret lathe for nine
spindle speeds ranging from 30 rpm to 1000 rpm. If the gear box is driven by 5KW,
720 rpm electric motor through the belt drive; Assume same module for all gears.
i) Draw the speed ray diagram
ii) Draw the gearing diagram
iii) Select the diameters of pulleys tor belt drives.
The standard pulley diameters are: 80, 90, 100, 112, 125, 140, 160,180,200, 224, 250,
280, 290, 300, 310, 355, 375, 400, 450, 500 rpm.
10. A six speed gear box is to be designed for a m/c tool drive. The spindle speeds range
between 150 rpm to 1000 r.p.m., driven by an electric motor of 5 KW with 1000 rpm
through belt drive (i) Draw speed diagram (ii) Draw gearing diagram (iii) Number of
stages (iv) Dimension of pulleys.
11. A three stage, twelve-speed gear box is to be used in machine tool for spindle speeds
ranging between 25 rpm and 1500 rpm. The second stage of gear box consists of three
speed steps. If gear box is driven by 3.7 KW, 750 rpm electric motor through the belt
drives:
i. Draw the ray diagram
ii. Select the diameter of pulleys for belt drive and,
iii. Determine the maximum torque acting on all shafts.
The standard pulley diameters are: 80, 90, 100, 112, 125, 140, 160, 180, 200, 224,
250, 280, 290, 300, 3l0, 355, 375, 400, 450, 500 mm
12. A six speed gear box is to be designed for a machine tool drive. The spindle speed
ranges between 150 rpm and 1000 rpm. If the gear box is driven by 5 kW, 1000 rpm.
Electric motor through the drive;
i) Draw the speed diagram.
ii) Draw the gearing diagram.
iii) Determine the number of teeth on gear.
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

iv) Select the diameters of the pulleys for the belt drives.
The standard pulley diameters are: 80, 90, 100, 112, 125, 140, 160, 180, 200, 224,
250, 280, 290, 300,310, 355,375,400, 450, 500 rpm. Assume same module for all
gears.
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

Chapter 5:- Design of I. C. Engine components

1. Explain step by step procedure for finding out the dimensions of the I-sections of the
connecting rod.
2. Explain briefly stresses in cylinder wall.
3. Explain desirable properties of materials for cylinders and cylinder liners.
4. Explain briefly Guidelines for design of piston Rings.
5. Explain design considerations of piston barrel and piston skirt with neat
sketch.
6. The cylinder of a four stroke diesel engine as the following specifications
Brake power = 3.75 kW.
Speed = 1000 rpm.
Indicated Mean Effect Pressure = 0.35 Mpa.
Mechanical Efficiency = 80%
Determine the bore and length of the cylinder liner.
7. Determine the dimensions of cross section of the connecting rod for a diesel engine
with the following data.
Cylinder bore=100 mm
Length of connecting rod = 350 mm.
Maximum gas pressure = 4 Mpa.
Factor of safety = 6.

8. Determine the small and the big end bearings of the connecting rod for a diesel
engine with the following data:

(i)Cylinder Bore = 100mm

(ii)Maximum gas pressure = 4 Mpa
(l/d) ratio for piston pin bearings = 2
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

(l/d) ratio for crank pin bearing =1.3

Allowable bearing pressure for piston pin bearing = 12 Mpa
Allowable bearing pressure for crank pin bearing = 7.5 Mpa

9. The following data is given for a connecting rod:

Engine speed =1800rpm.
Length of connecting rod =350mm.
Length of stroke = 175mm.
Density of material =7800 kg/m3
Thickness of web or flanges = 8 mm
Assume the cross-section of the connecting rod as shown in figure below for which
Area of cross section (A) =11t2 , Ixx=(𝟒𝟏𝟗
𝟏𝟐
)t4 and y = ( 𝟓𝒕𝟐 )
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

10. The following data is given for a connecting rod:

Engine speed = 1800 rpm
Length of connecting rod = 350 mm
Length of stroke = 175 mm
Density of material = 7800 kg/m3
Thickness of web or flanges = 8 mm
Assume the cross-section illustrated in the figure “I” section above. For this cross-
section, Area of cross section (A) =11t2 , Ixx=(𝟒𝟏𝟗
𝟏𝟐
)t4 and y = ( 𝟓𝒕𝟐 )
Calculate whipping stress in the connecting rod.

11. The cylinder of a four-stroke diesel engine has the following specifi cations:
Brake power = 7.5 kW
Speed = 1400 rpm
Indicated mean effective pressure = 0.35 MPa
Mechanical efficiency = 80%
Maximum gas pressure = 3.5 MPa
The cylinder liner and head are made of grey cast iron FG 260 (Sut = 260 N/mm2 and m =
0.25). The studs are made of plain-carbon steel 40C8 (Syt = 380 N/mm2). The factor of
safety for all parts is 6.
Calculate: (i) bore and length of the cylinder liner (ii) thickness of the cylinder liner.
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank

Chapter 6:- Design of Material handling Equipments

1. Classification of Material Handling Systems.

2. Explain Objectives of Material Handling System.
3. Guidelines during selection of Material Handling System (MHS).
4. Explain briefly Conveyors and its types.
5. Explain the work of Belt take up (Tension take up) devices.
6. A horizontal flat belt conveyor is used to transporting bulk material having mass
density 800kg/m3.The surcharge factor ‘C’ for the flat belt is 0.075 while the belt
width is 500mm the belt speed is 0.9m/sec. Determine the Capacity of Conveyor.
7. A three idler, troughed belt, horizontal conveyor used for transporting 110x103 kg /hr
mineral ore having weight density of 12,000N/m3.The surcharge factor ‘C’ for the
troughed belt is 0.15. If the belt speed is 66m/min, select the standard belt width and
conveyor belt. Available standard belt width are 400,450,500,600,650,750,800,900,
1000, 1200, 1400, 1600, 1800, 2000 in mm
8. A horizontal flat belt conveyor is used to transporting bulk material having mass
density 1000kg/m3.The surcharge factor ‘C’ for the flat belt is 0.075 while the belt
width is 600mm the belt speed is 0.75m/sec. Determine the Capacity of Conveyor.
9. An inclined belt conveyor is used for loading the mineral ore in a ship. The belt
inclination is 300 for which the flow ability factor ‘k’ is 2.2x10-4.the belt width is 750
mm while belt speed is 1.75 m/sec .if the specific weight of the mineral ore is
16000N/m3, determine the capacity of conveyor.
10. An inclined belt conveyor is used for loading the mineral ore in a ship. The belt
inclination is 300 for which the flow ability factor ‘k’ is 2.0x10-4.the belt width is
1000 mm while belt speed is 2.5 m/sec .if the specific weight of the mineral ore is
14000N/m3, determine the capacity of conveyor.
 SHIVAJI UNIVERSITY, KOLHAPUR,
Final Year B.Tech (Mechanical Engineering)
CBCS PATTERN Semester VII
Subject:-Mechanical System Design
Subject Code: 83713
Chapter wise Question Bank