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AT6601-AUTOMOTIVE ENGINE COMPONENTS DESIGN
QUESTION BANK
Department Of Automobile Engineering
UNIT I
Part A
1. Define factor of safety.
2. Compare endurance limit for steel and aluminium.
3. State the advantages of cad in auto part design.
4. When do you select the shrink fit?
5. Define endurance limit with SN curve.
6. What do you understand by the nominal size and basic size?
7. What do you mean by surface roughness index?
8. Mention the advantages of the Computer aided drafting.
9. How do you classify engg materials?
10. Why the surface roughness important in assembly?
11. Differentiate between static and variable stress?
12. What are the factors to be considered in deciding the factor of safety?
13. Define the term limits and tolerances.
14. List out the factors to be consider for the selection of engineering materials?
15. Write short notes on stress concentration.
16. What do you mean by fits and tolerance? How they are designated?

(Nov/Dec 2008)
(May/June 2007)
(May/June 2007)
(May/June 2007)
(Nov/Dec 2008)
(Nov/Dec 2008)
(Nov/Dec 2008)
(May/June2010)
(May/June 2010)
(May/June 2012)
(Nov/Dec2010)
(Nov/Dec2010)
(Nov/Dec2010)
(May/June2011)
(May/June2011)
(May/June 2011)

17. Identify the meaning of each representation for the given symbol
(May/June2011)
0.0015

18. What is meant by endurance limit?

(Nov/Dec 2010)
19. What is resilience?
(Nov/Dec 2010)
20. What are the influences of surface finish on interference fits?
(Nov/Dec 2010)
21. Define factor of safety.
(Nov/Dec 2011)
22. What is meant by notch sensitivity?
(Nov/Dec 2011)
23. Give the types of tolerance in the components.
(Nov/Dec 2011)
24. Distinguish between Elasticity and Plasticity.
(May/June, Nov/Dec 2013)
25. Define endurance limit in design.
(Nov/Dec 2013)
26.List the types of forces acting on the push rod of an internal combustion engine.(May/June 2013)
27. State The Importance Of surface roughness((Nov/Dec 2014)
28.Name the various non-metallic materials used in engineering practices. (Nov/Dec 2014)
(april/may 2015).
29. Give any two interference fit (May/June 2014)
30. What is tolerance grade ? (May/June 2014)
31. Give two applications of interference fit. (May/June 2015)
32. What is meant by notch sensitivity? (Nov/Dec 2015)
33. List the design considerations of interference fit. (Nov/Dec 2015)
Part B
1. Discuss the various factor to be considered for the selection of materials for the design of machine
elements
(Nov/Dec 2008)
2. Illustrate the role of computer in designing the machine elements with a aid of case study.
(Nov/Dec 2008)
3. Calculate the tolerances, fundamental deviations and limits of size for hole and shaft in the
following.
(Nov/Dec 2008)
i) 25H8/d9
ii) 60H7/m6.
4. i) Explain the types of tolerance and its fits with suitable example.
ii) Discuss Tetmahers formula in automotive design. Give suitable example.

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5. i) Discuss about endurance limit and notch sensitivity.

(May/June 2012)

ii) Explain how Johnson formula is used for design of push-rods

6 .i. Explain with flow chart about the various phase of computer aided design process.
ii.what are the factors to be considered for the selection of materials for the design of
machine.(Nov/Dec 2010)
7. i) With suitable sketch explain the following
ii. Endurance limit
iii. Notch sensitivity
iv. Explain the principles of design optimization.
(Apr/May 2011)
8. Select the suitable material for the following components an state the reason.
i. Ball bearing
ii. Turbine blade
iii. Cylinder block
iv. Crankshaft
(Apr/May 2011)
9. Write short notes on
i. Optimization techniques
ii. Factor of safety
iii. Endurance limit
(Apr/May 2011)
10. A gear has to be shrunk on a shaft of basic size 120 mm; an interference fit H7/ 6 is being
selected. Determine the minimum and maximum diameter of the shaft and gear. (Apr/May 2011)
11. What do you mean by hole basics and shaft basic system? Which is preferred and why?
(Apr/May 2011)
12. Write short notes on preferred numbers
(Apr/May 2011)
13. Discuss in detailed way about various engineering materials and their physical properties applied
to design.
(Nov/Dec 2010)
14. Discuss the salient features of computer aided drafting.
(Nov/Dec 2010)
15. A circular machine member of ductile material is subjected to a varying axial load from 2,50,000
N compressive to 7,50,000N tensile. Endurance stress for material = 250 MN/m2, tensile yield stress
= 350 MN/m2. Take stress concentration factor of 1.8 and factor of safety = 2.0. Determine the
diameter of member
(Nov/Dec 2010)
16. Explain various types of tolerances and fits.
(Nov/Dec 2010)
17. Discuss about surface finish an surface roughness.
(Nov/Dec 2010)
18. i) Discuss on allowable strength an factor of safety.
ii) What are the advantages of composites in automotive applications?
ii). Discuss the types of composites and its properties highlighting fibre, its size and orientation.
(May/June 2007)
19. i) what is endurance limit?
ii).discuss on Soderberg and Goodman equation applied to fatigue loading.
iii).Discuss on different characteristics (like strength) to be considered in design. (May/June 2007)
20. Discuss the general consideration in the design of engine components.
(Apr/May 2010)
21. Explain the general design procedure for engine components.
(Apr/May 2010)
22. Explain in detail with suitable block diagram, the general procedure in machine design.
(Nov/Dec 2011)
23. Explain the factors to be considered while selecting materials for engineering purposes. Also
explain the important physical an mechanical properties of the materials.
(Nov/Dec 2011)
24. Explain in detail the unilateral and bilateral system of tolerance covering the points of definition,
application, merits and demerits.
(Nov/Dec 2011)
25. A journal of nominal or basic size of 75mm runs in bearing with close running fit. Find the limits
of the shaft and bearing. What is the maximum and minimum clearance?
(Nov/Dec 2011)
26. Explain in detail with suitable block diagram, the general procedure in machine design.
(Nov/Dec 2011)

27. Define with suitable sketches the following terminologies used in the limit systems used in design.
(i) Nominal size (ii) Limits of sizes (iii) Tolerance Zone (iv) Clearance fit (v) Interference fit
(May/June 2013) (Nov/Dec 2011)
28. (i) Explain normal stress theory (Rankines Theory) (4)
(ii) A mild steel shaft of 50 mm diameter is subjected to a bending moment of 2500 N-m and a
torque of T. If the yield point of the steel is 200 MPa,find the maximum value of this torque without

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causing yielding of this shaft according to Rankines theory.
(Nov/Dec 2013)

(May/June

2013)

29.(i) determine the diameter of the pushrod which made of mild steel of an ic engine if the maximum
force exerted by th push rod is 1500N the length of the pushrod is 0.5m take the factor of safety as 2.5
and the end fixing coefficient as 2
(ii).explian the design procedure of vale push rods (Nov/Dec 2014)
30(i).explian the different types of fits (May/June 2015)
(ii). Explain the terms limits and tolerance with suitable sketch(Nov/Dec 2014) (May/June 2015)
31. (a) A medium force fit on a 50mmshaft requires a hole tolerance of 0.025mm and a shaft tolerance
of 0.016mm. the maximum interference is to be 0.042mm. how will you dimension the hole and the
shaft, if hole deviation is H?(MAY/JUNE2014)
32. The maximum load on a petrol engine push rod 300mm long is 1400N. It is hollow having the
outer diameter 1.25 times the inner diameter.spherical seated bearings are used for the push rod . the
modulus of elasticity for the materials of the push rod is 210kn/mm^2.find a suitable size for the push
rod ,taking a factor of safety of 2.5(MAY/JUNE2014) (MAY/JUNE2015)
33.Derive the Johnsons formulae for short columns (Nov/Dec 2015)
UNIT II
Part A
1.Calculate the radial thickness of piston ring for a piston of 100mm dia. Permissible wall pr is
0.03N/m2 and bending strength is 90 N/m2
(May/June 2007)
2. Why piston pin is normally lapped or super finished?
(May/June 2007)
3. What are the criteria for selection of material for con rods?
(May/June 2007)
4. Define piston slap.
(Nov/Dec 2008) (May/June 2010) (Nov/Dec 2011)
5. Differentiate under square and over square engines.
(May/June 2010)
6. Give the types of rings used in automobile engines?
(Nov/Dec 2011)
7. State the need for compression ring and oil scrapper ring.
(Nov/Dec 2008)
8. List out the forces should be considered for connecting rod design. (Dec 2008) (May 2010)
9. Write about the forces experienced by the connecting rod.
(May/June 2012)
10. Why lubrication of piston is necessary? What are the methods adopted for lubricating the piston?
(May/June 2012)
11. What are the factors to be considered in designing small end of the connecting rod?
(May/June 2012)
12. Briefly explain the term piston slap and piston seizure?
(May/June2011)
13. Why different clearance is provided at top, middle and at open end of a piston? (May/June2011)
14. Why I Section is chosen for connecting rod used in high speed engines? (May/June2011)
15. Write the formula used for the calculation of piston skirt length?
(Nov/Dec 2010)
16. Under what conditions the piston pins are designed? Write empirical relations for it.
(Nov/Dec 2010)
17. Why the connecting rod shank portion is made of I section?
(Nov/Dec 2010)
18. Briefly enumerate the types of failure, the piston of a spark ignition engine undergoes.
(May/June 2013, Nov/Dec 2013)
19. List out some important aspects of a connecting rod used in automobiles. (Nov/Dec 2013)
20. What are the types of loads acting on the crankshaft of a multicylinder automobile?
( May/June 2013)
21. what are the main function of the cylinder liner ?(NOV/DEC2014)
22. how is the wear of the piston rings prevented ?(NOV/DEC2014)
23.under what force the big end bolts and caps are designed?(MAY/JUNE2014)
24.specify the reason for the use of tapered skirt for pistons? (MAY/JUNE2014)
25. What are the desirable properties of cylinder block materials? (May/June 2015)
26. Why is emi-skirt pistons used? (May/June 2015)
Part B

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1. Discuss the step by step design procedure of an IC Engine Piston
(Nov/Dec 2008)
2. A four stroke IC engine has the following specifications. Brake power = 7.5 kW. Speed =1000rpm;
indicated mean effective pressure = 0.035 MPa; maximum gas pressure =3.5MPa; Mechanical
efficiency=80% determine
(Nov/Dec 2008)
i) The dimension of the cylinder; if the length of stroke is 1.4 Times the bore of the cylinder.
ii) Wall thickness of the cylinder, if the hoop stress is 35MPa
3. Design a connecting rod for a petrol engine from the following data. Diameter of piston weight of
reciprocating part = 2kg length of the connecting rod =300 mm stroke length = 140mm; speed =
2000rpm; max explosion pressure = 2.25MPa.
(Nov/Dec 2008)
4. i) Explain the types piston failure in IC Engines with suitable remedies.
(May/June 2012)
ii) Determine the piston pin size for four stroke single cylinder Diesel engine Developing 10kW of
power running at a maximum speed of 6000rpm. The capacity of engine is 200cc with stroke length
of 150mm, water cooled. Assume suitable data
5. i)Discuss about the materials selected for the construction of cylinder and piston.
ii) A petrol engine running with four stroke is to develop 5kW of power at 7000 rpm with 500cc
capacity. Determine the minimum length of the piston rod, if the torque developed at 3000 rpm is
10Nm and with a stroke length of 100mm. Assume suitable data. (May/June 2012)
6. Design a cast iron piston for a single acting four stroke engine for the following data:
Cylinder bore = 100mm, stroke = 125 mm, Maximum gas pressure = 5 N/mm2 indicated mean
effective pressure = 0.75 N/mm2. Mechanical efficiency = 80%, fuel consumption = 0.5kg per brake
power per hour: Higher calorific value of the fuel = 42 x 103 kJ/kg, speed = 200 rpm. Any other data
require for the design may be assumed.
(Nov/Dec 2010)
7. Design a mild steel connecting rod with an I section for a single cylinder IC engine from the
following data:
Diameter of the piston = 0.104m
Weight of the reciprocating Parts = 18.0N
Length of the connecting Rod-centre to centre = 0.314m
Stroke length = 0.14mm
Speed of the engine = 1500rpm
Maximum explosion pressure = 2.28MPa
Assume that the maximum thrust takes place at TDC during the explosion stroke. Assume also any
missing data and sketch the connecting rod.
(Nov/Dec 2010)
8. Discuss in detail the various forces acting on a typical connecting rod.
9. Design a cast iron piston for a single acting four stroke engine for the following data;
Cylinder bore = 100mm;
Stroke = 125mm
Maximum gas pressure = 5 MPa; Indicated Mean Effective Pressure = 0.35MPa
Mechanical Efficiency = 80%
SFC = 0.15kg per brake power per hour; Higher calorific value of fuel = 42 x 103 kJ/kg; Speed =
2000rpm;
(Apr/May 2011)
10. A four stroke IC engine has the following specifications: Brake power = 10kW
Speed = 1000rpm;
Indicated Mean Effective Pressure = 0.35 MPa;
Maximum gas pressure = 3.5 N/mm2
Mechanical Efficiency = 80%
Determine Dimension of the cylinder, if length of the stroke is 1.4 times the bore of the cylinder. Wall
thickness of the cylinder, if hoop stress is 35 MPa Thickness of the cylinder head and the size of the
studs when permissible stress for the cylinder head and stud material is 45MPa and 65MPa
respectively.
(Apr/May 2011)
11. What are the various design procedure you will adopt in designing a piston? (Nov/Dec 2010)
12. Discuss the factors that are considered in selection of material for piston and cylinder
(Nov/Dec 2010)
13. Explain the design details of piston pin
(Nov/Dec 2010)
14. Design a connecting rod for four stroke petrol engine with the following data:
Diameter of piston
= 8.8cm
Stroke
= 12.5cm
Weight of reciprocating parts = 1.6kg
Length of connecting rod, centre to centre = 30cm
R.P.M
= 2200 with possible over speed of 3000
Compression ratio
= 6.8: 1
Probable maximum explosion pressure = 350 N/cm2
(Nov/Dec 2010)
15. i).What materials are used for connecting rods?
(May/June 2007)

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ii). Design a connecting rod for high speed IC engine. The diameter of the piston is 100mm, mass
of reciprocating parts 1.5Kg, length of the connecting rod centre to distance is 355mm, stroke
40mm, speed 2200 rpm, maximum explosion pressure is 3N/mm2 3 after dead centre. Suitable
assumption may make with proper justification.
(May/June 2007)
16. i). Discuss the design parameter considered in designing cylinder for a two wheeler petrol engine
and four wheeler diesel engine highlighting weight saving?
ii). Calculate the piston diameter for an engine with the cylinder bore of 50mm and gas pressure of
6.2N/m2. Permissible bearing pressure is 25N/m2.
(May/June 2007)
17. i). Discuss on piston failures How are they minimize?
ii).Design a suitable piston head thickness for a piston of diameter 100mm and stroke 120mm.
Maximum gas pressure is 6.N/m2. Break mean effective pressure is 0.75 N/m2, fuel consumption is
0.22kh/kw/hr, speed 2800rpm. Suitable assumption may made with proper justification
(May/June 2007)
18. A four stroke over square engine has the following specifications: BHP = 10, rpm = 1400, IMEP =
3.5kg/cm2, maximum gas pressure = 35kg/cm2. Mechanical efficiency = 0.8, an Poissons ratio =
Determine the dimensions of cylinder it is made of cast iron. Also determine the thickness of cylinder
wall and stress induced in it.
(Apr/May 2010)
19. Explain the design procedure for cost iron piston assembly. Discuss about the various piston
materials and their requirements.
(Apr/May 2010)
20. A connecting rod is to be designed for a high speed I.C. engine. The data available are
Diameter of piston = 90mm
Mass of reciprocating parts = 1.5kg
Length of connecting rod centre to centre = 350mm
Stroke = 140mm, Rpm = 2200
When developing 55kW, possible over speed is 3000rpm, compression ration is 6.8:1.
Possible maximum explosion pressure after 3 from dead centre is 3 N/mm2.
(Apr/May 2010)
21. Determine the diameter and length of the piston pin of a crankpin. Take the following data.
Horizontal reaction = 157.1KN: Distance between the bearings = 800mm: Allowable bending stress =
75MPa; Piston gas load = 34.2KN; permissible bearing pressure = 100 N/mm2
(Nov/Dec 2011)
22. A four stoke diesel engine has the following specifications; Brake power = 4.5kW; speed =
1150rpm; indicated mean effective pressure = 0.35N/mm2; mechanical efficiency = 83%. Determine
cylinder design parameters like
a) Bore and length
b) Thickness of the cylinder head
c) Size of studs for the cylinder head.
(Nov/Dec 2011)
23. Design piston rings for a cylinder bore of 10mm pressure on the cylinder wall = 0.035N/mm 2.
Allowable bending stress 90MPa; number of rings = 4 thickness of the cylinder head = 6 mm. Assume
any other relevant data and highlight the dimensions with a neat sketch.
(Nov/Dec 2011)
24. Derive an expression for the force acting on the connecting rod due to gas pressure an inertia of
reciprocating parts.
(Nov/Dec 2011)
25. Design a cast iron piston for a single acting four stroke engine for the following data:
Cylinder bore = 90 mm
Cylinder stroke =90 mm
Maximum gas pressure =70 bar
Mechanical Efficiency = 80 %
Fuel consumption 0.14 kg/brake power per hour
HCV of fuel = 42000 KJ/kg
Speed= 2500 rpm
Any other required data may be assumed or referred from Design Data book. (May/June
2013 ) (Nov/Dec 2013)
26. The connecting rod of a petrol engine at 2000 rpm and developing a maximum pressure of 35 bar.
The diameter of the piston is 100 mm. Mass of the reciprocating parts per cylinder is 2.3 kg.Length of
the connecting rod = 150 mm. Stroke of the engine is 110 mm. Compression ratio of the engine is
7.5.Take the factor of safety as 4.Take the length to diameter ratio for the big end bearing as 1.3 and
the small end bearing as 2 and the corresponding bearing pressures as 10 N/mm2 and 15 N/mm2.The
density of the material of the rod may be taken as 8000 kg/m3.Design the connecting rod for the I
Section alone. Mark your designed dimensions in sketch.
(May/June 2013)
(Nov/Dec
2013)

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27.a, the following projected data refer to a four-cylinder petrol engine of a car to be designed.
Piston diameter = 68mm
Stroke length =75mm
Maximum pressure =2.5 MN/m3
Connecting rod length =175mm
Brake power =32KW at 5000rpm
Bsfc =0.33kg/kW- hr
b. Design a suitable connecting rod for an ic engine with the following data
piston diameter =68mm
stroke length = 80mm
connecting rod length =160mm
maximum pressure = 3.5N/mm
weight of the reciprocating part =2.5kg
speed =4000rpm
compression ratio =8.1 (May/June 2014)
12a, design a connecting rod for an (engine from the following data)
Piston diameter =125mm
Stroke =150mm
Length of connecting rod =300mm
Maximum gas pressure at 5% of stroke =5N/mm
Speed of engine =1200rpm
Mass of reciprocating parts=2kg
Factor of safety =5
Material steel = 35Ni cr 60
b, a four stroke diesel engine has the following specification
brake power =5kw
speed =200rpm
indicated mean effective pressure =0.3N/mm
mechanical efficiency =80%
determine
(i)
Bore and length of the cylinder
(ii)
Thickness of the cylinder head; and
(iii)
Size of studs for the cylinder head (May/June 2014)
UNIT III
Part -A
1. What are the failure modes of crank shaft?
(Apr/May 2007)
2. What do you mean by firing order? Mention its significance
(Nov/Dec 2008)
3. Which value is bigger in size? Justify
(Nov/Dec 2008)
4. Why balancing of IC Engine is important?
(May/June2012)
5. A single cylinder reciprocating engine has speed of 300 rpm, stroke of 100mm. Mass of the
reciprocating parts is 5kg; mass of revolving parts at 75 mm radius of 200mm, if 2/3 of the
reciprocating parts and all the revolving parts and all the revolving parts are to be balanced.
(May/June 2012)
6. Name the few materials used for crankshaft?
(Apr/May 2010)
7. What do you mean by the term simple torsion?
(Nov/Dec2010)
8. What is the function of crank shaft?
(Nov/Dec2010)
9. What are the stresses set up in IC Engine?
(Nov/Dec2010)
10. State the importance of firing order mention the firing order for four and six cylinder engine.
(Apr/May2011)
11. Brief about various types of crank shaft.
(Nov/Dec 2010)
12. Under what force the big end bolts and caps are designed?
(Nov/Dec 2010)
13. Mention the various forces acting on a crank shaft.
(Nov/Dec 2010)
14. What are the significance of the firing order?
(Nov/Dec 2011)
15. Why balancing is necessary in I C Engines?
(Nov/Dec 2011)
16. What are the types of loads on the crankshaft of a multi cylinder automobile? (Nov/Dec 2013)

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17. What are the unbalanced forces acting in an internal combustion engine? (May/June 2013,
Nov/Dec 2013)
18. List out some important aspects of a connecting rod used in automobiles. (May/June 2013)
19. enumerate the design consideration for crankpin. (May/June 2014)
20.What is the net forcew acting on the crankshaft of an engine ? (May/June 2014)
21.list out the types of crank shafts commonly used in the engine ? (Nov/Dec 2014)
Part B
1. Discuss the step by step design procedure of an IC Engine crank shaft
i) Discuss about the firing order and its effect in IC Engine.

(Nov/Dec 2008)
(May/June 2012)

ii) Explain the short and long crank arms with suitable example.
2. i) A single cylinder reciprocating engine has speed of 300rpm, stroke 250mm, mass of
reciprocating parts 70kg, mass of revolving parts at 150mm radius 50kg. If 2/3 of the reciprocating
parts an all the revolving parts are to be balanced, find the balancing mass required at radius of
500mm and the residual unbalanced force when the crank has rotated 600 from the TDC
ii) Discuss about the material used for crankshaft.
(May/June 2012)
3. Design a center crank for an IC engine with bore of 150mm and stroke of 200mm. Length of the
connecting rod is 400mm. Maximum gas pressure is 300N/cm2. The maximum torque at 35 of the
crank angle when the gas pressure is 1 Mpa. Design stress is 60 N/mm2. Distance between the main
bearings of the crank is 400mm.
(Nov/Dec 2010)
4. Design a plain carbon steel centre crankshaft for a single acting four stroke single cylinder engine
for the following data:
Cylinder bore = 400mm: stroke = 600mm; speed = 200mm; Mean effective Pressure = 0.5MPa
Maximum gas pressure = 2.5 MPa ; Weight of the flywheel used as a pulley = 50kN;
Total belt pull = 6.5kN
When the crank has turned through 35 from top dead centre, the pressure on the piston is 1MPa and
the torque on the crank is maximum. The ratio of the connecting rod length to the crank radius is 5.
(Apr/May 2011)
5. Describe the design details of crankshaft for a four cylinder four stroke C.I. engine.
(Nov/Dec 2010)
i). what are the design requirements of crankshafts?
ii). Design a centre crank shaft for IC engine for the following data. Stroke 275mm, cylinder bore
225mm, length of the connecting rod 4.5 times crank radius. Maximum gas pressure 2.3N/mm2, gas
pressure when the torque is maximum is 1.4 N/mm2 and crank angle is 35. Suitable assumptions may
made with proper justification.
(Apr/May 2007)
6. Explain the design procedure for engine crankshaft of overhung type.
(Apr/May 2010)
7. A mild steel shaft transmits 23kW at 200 rpm. It a central load of 900 N and is simply supported
between the bearings 2.5 meters apart. Determine the size of the shaft, if the allowable shear stress is
42 N/mm2 and the maximum tensile or compressive stress is not 56N/mm2. What
(Apr/May 2010)
8. An internal combustion engine has a bore and stroke of 100 mm and 110 mm respectively. The
engine speed is 3000 rpm. Mean effective pressure is 0.15 N/mm2. The maximum combustion
pressure is 5 N/mm2.The mass of the flywheel is 70 kg. When the crank has turned 20 from TDC the
pressure on the piston is 0.08 N/mm2.and the on the crank is maximum. The ratio of connecting rod
length to crank radius is 1.8.Design the crankshaft when the crank at the dead centre for
(i) crank pin (ii) crank webs.
(May/June 2013) (Nov/Dec 2013)
9. A mild steel shaft transmits 20 kW at 2000 rpm. It carries a central load of 900 N and it is simple
supported between the bearings 2.5 m apart. Determine the size of the shaft if the allowable shear
stress is 42 MPa and the maximum tensile or compressive stress is not to exceed 56 MPa. What size
of the shaft will be required if it is subjected to gradually applied loads.
(May/June 2013) (Nov/Dec 2013)
10 .
(A)design a side crank shaft for an ic engine as per the following specification
Bore =150mm
Stroke length =190mm
Connecting rod length =380mm
Maximum pressure = 320N/mm

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Speed =600rpm
Brake mean effective pressure =70N/mm
Design stress for the crank shaft =30N/mm(Nov/Dec 2014)
(B) design a plain carbon steel centre crankshaft for a single acting, four stroke , single cylinder
engine for the following data;
Piston diameter
=250mm
Stroke length
=400mm
Maximum combustion pressure =2.5N/mm^2
Weight of the flywheel
=16kN
Total belt pull
=3N
Connecting rod length
=950mm
When the crank has turned through 30degree from top dead centre, the pressure on the piston is 1
N/mm^2 and the torque on the crank is maximum (Nov/Dec 2014)
11. (a) Design a single-throw, double-view crank shaft made of forged steel for a single
cylinder,vertical IC engine having cylinder diameter of 120mm and stroke length of 160mm. The
engine develops 10KW at 300 mm. The explosion pressure is 2.5 N/mm^2gauge. The maximum
tirque is developed when the crank shaft turns through 25degree from the TDC position during the
expansion stroke. The burnt gas pressure at that moment is 2.0N/mm^2.the crank shall main bearings
are 320mm apart.(MAY/JUNE2014)
(B) Design an overhang crank shaft with-two main bearings for an IC engines with the following data:
Cylinder bore =250mm
Stroke length =300mm
Flywheel weight =27KN
Max. Pressure =2.5N/mm^2
Max.torque at crank rotation 30 degree the pressure at that instant 1.7 N/mm^2. .(MAY/JUNE2014)
UNIT IV
Part -A
1. Define co efficient of fluctuation of energy.
2. What is meant by co-efficient of speed?
3. What are stresses experienced by the rim of the flywheel?
4. How the function of the flywheel does differ from governor?
5. List out the various functions of a flywheel.
6. What are the factors to be considered while deciding flywheel capacity?
7. Why a slant cut is provided on the ring gear teeth?
8. List the material used for flywheel.

(Nov/Dec 2008)
(May/June 2012)
(May/June 2012)
(Nov/Dec 2010)
(Apr/May 2011)
(Nov/Dec 2010)
(Apr/May 2010)
(Nov/Dec 2011)

9. Mention the stresses induced in a taper key used in a flywheel-shaft interface.

(May/June 2013) (Nov/Dec 2013)
10. Draw the turning moment of the diagram of a flywheel with respect to crank angle for suction,
compression, power and exhaust of an internal combustion engine.
(Nov/Dec 2013)
11. Define endurance limit in design. (May/June 2013)
12.State the role of fly wheel.(NOV/DEC2014)
13.List the factor on which the valve of coefficient of speed fluctuation depends. .(NOV/DEC2014)
14.Define coefficient of fluctuation of speed. . (MAY/JUNE2014)
15.state the type of stresses induced in a rim flywheel.(MAY/JUNE2014) S
Part B
1. The intercepted areas between the output torque curve and the mean resistance line of a turning
moment diagram for a multi cylinder engine, taken in order from one end are as follows : -35, +410, 285 +325, -335, +260,-365, +285, -260 mm2 . The diagram has been drawn to a scale of 1mm = 70Nm and 1mm = 4.5. The engine speed is 900 rpm and the fluctuation in speed is not to exceed 2% of

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the mean speed. Find the mass and cross section of the flywheel rim having 650mm mean diameter.
The density of the material of the fly wheel may be taken as 7200 kg/mm3. The rim is rectangular
with the width is 2 times the thickness.
(Nov/Dec 2008)
2. i ) The mass of fly wheel of an engine is 0.25 tonnes and the radius of gyration is 0.8 meters. It is
found from the turning moment diagram that the fluctuation of energy is 25KN-m. If the mean speed
of the engine is 120 rpm, determine the maximum and minimum speeds.
(May/June 2012)
ii) Discuss about the stress on the rim of the flywheel.

(May/June 2012)

3. The turning moment diagram of a four stroke engine is represented by a four triangles, the areas of
which from the zero pressure are as follows; suction stroke = 0.45 10-3m2; compression stroke =
1.7 10-3m2; Expansion stroke = 6.85 10-3m2 Exhaust stroke = 0.65 10-3m2. Each m2 of area
represents 3MN-m of energy. Assuming resisting torque to be uniform, find the mass of the rim of
the flywheel required to keep the speed between 200 and 19 rpm. The mean radius of the rim is 0.4m
(May/June 2012)
4. A single cylinder, single acting four stroke oil engine develops 20 kW indicated power at 300 rpm.
The work done by the gases during the expansion stroke is 2.3 times the work done on the gases
during the compression stroke and work done during the suction and exhaust strokes is negligible, if
the speed is to be maintained within 1% of the mean speed, fine the flywheel effect
(May/June 2013) (Nov/Dec 2010)
5. Discuss in detail the step by step procedure to design a flywheel used in an IC Engine.
(Apr/May 2011)
6. Explain in detailed way about the design of flywheel for a four stroke six cylinder petrol engine.
(Nov/Dec 2010)
7. Design a cast iron flywheel for a 4 stroke engine developing 60kW at 3200 rpm. The work done
during power stroke is 1.2 times the average work done during full cycle. The mean diameter of the
flywheel is 0.4m.The total fluctuating speed is limited to 5% of the mean speed.
(Apr/May 2007)
8. Describe the design details of engine flywheel.
(Apr/May 2010)
i).Explain the procedure for determining the cross sectional dimensions of arms of a flywheel.
ii). Explain the various types of stresses induced in a flywheel rim
(Nov/Dec 2011)
9. A single cylinder acting four stroke oil engine develops 20 kW at 300 rpm. The work done by the
gases during the expansion stroke is 2.3 times the work done on the during compression stroke. The
work done during suction and exhaust a stroke is negligible. The speed is maintained within plus or
minus 1%. Determine the Mass Moment of Inertia of the flywheel.
(Nov/Dec 2013)

10. An Otto cycle engine develops 50 kW at 150 rpm with 75 Explosions/minute. The change of
speed from the commencement to the end of power stroke must not exceed 0.5 % of the mean on
either side. Design a suitable rim section having width four times the flywheel stores 16/15 times to
energy stored by the rim and that the work done during the power stroke is 1.4 times the work done
during the rest of the cycle. Density of the rim material is 7200 kg/m3. (May/June2013) (Nov/Dec
2013)
11.(A) the turing moment diagram for a multi cylinder engine has been drawn to a scale of
1mm=1000N-m and 1mm=6degree. The areas above and below the mean turning moment line taken
in order are 530, 330, 380, 470, 180, 360, 350 qnd 280 sq.mm. For the engine find the diameter of the
flywheel. Ther mean rpm, is 150 and the total fluctuation of speed must not exceed 3.5% of the mean.
Detemine a suitable cross-sectional area of the rim of the flywheel assuming the total energy of the
flywheel to be 15/14 that of the rim. The peripheral velocity of the flywheel is 15m/s. (May/June
2014)
(B) Design a flywheel for a single cylinder , four stroke vertical cylinder diesel engine developing
4KW at 1500rpm. Asuume coefficient of speed fluctuation Cs=0.01(May/June 2014)
12.(a) A four stroke, four cylinder IC engine, which develops 38KW at 750rpm is used to drive an AC
generator. Design and sketch the flywheel. Assume it is supported on a shaft of 60mm dia. (NOV/
DEC2014)
(b) A single cylinder, four stroke gas engine develops 30KW at 300rpm. The work done by the gases
during the expansion stroke is 3 times the work done on the gasesduring the compression stroke. The
work during suction and exhaust strokes may be neglected. If total fluctuation of speed is 2% of
mean speed, Design a suitable flywheel. (NOV/ DEC2014)

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UNIT V
Part -A
1. What are the types of cam followers according to the surface in contact? (May/June 2012)
2. Why the area of the inlet valve port is made larger than the area of exhaust valve port?
(Nov/Dec2010) (Apr/May2011)
3. What are the limiting values for D/d ratio in spring design?
(Nov/Dec 2010)
4. Define the term spring index.
(Apr/May 2010)
5. What is the function of rocker arm?
(Nov/Dec 2010)
6. What are the design criteria for the inlet and exhaust valve?
(Apr/May 2007)
7. What are the design requirements of intake manifold?
(Apr/May2007)
8. What are the advantages and disadvantages of helical springs?
(Nov/Dec 2011)
9. Give the necessity of tappet clearance.
(Nov/Dec 2011)
10. List the types of forces acting on the push rod of an internal combustion engine.(Nov/Dec 2013)
11. Define hysteresis of springs.
(May/June 2013, Nov/Dec 2013)
12. Draw the turning moment diagram of a flywheel with respect to crank angle for suction,
compression, power and exhaust of an internal combustion engine.
(May/June 2013)
13.why the area of the inlet valve port is made larger than the area of exhaust valve
port?(MAY/JUNE2014)
14.what are the methods and materials used in the manufacture of cam shafts? (MAY/JUNE2014)
15.list the materials commonly used for IC engine valves?(NOV/DEC2014)
16.what is the significance of pressure angle in cam design? (NOV/DEC2014)
Part B
1. Design a close coiled helical compression spring for a service load ranging from 2250N to 2750N.
The axial deflection of the spring for the load range is 6mm. Assume a spring index of 5.Their
permissible shear stress intensity is 420MPa and modulus of rigidity as84kn/mm2
(Nov/Dec 2008)
2. Design and draw a valve spring of a petrol engine for the following operating conditions:
(Nov/Dec 2008)
Spring load when the valve is open
= 400N
Spring load when the valve is closed
= 250N
Maximum inside diameter of the spring
= 25mm
Length of the spring when the valve is open
= 40mm
Length of the spring when the valve is closed
= 50mm
Maximum permissible stress
= 400 Mpa
3. A cam is to give the following motion to a knife edged follower; out stroke during 60 o of cam
rotation; dwell for next 30o of cam rotation; return stroke during next 60o of cam rotation and; dwell
for the remaining 210o of cam rotation. The stroke of the follower is 40mm and the minimum radius
of the cam is 50mm. The follower moves with uniform velocity during both the outstroke and return
stroke. Draw the profile of the cam when
i) The axis of the follower passes through the axis of the cam shaft, and
ii) The axis of the follower is offset by 20mm from the axis of the cam shaft.
(May/June 2012)
4. A single cylinder diesel engine develops 15kW of power with stroke length of 300 mm. The engine
is expected to run at 750rpm with the maximum gas pressure of 5N/mm2. The valve opens and closes
at constant acceleration and deceleration for each half of the lift. The length of rocker arm on either
side of the fulcrum is 100 mm with the included angle of 130o. The mass of the valve is 0.5 kg.
Design the components of the valve mechanism.
(May/June 2012)
5. The conical valve of an IC engine is 70mm in diameter and is subjected to a maximum gas pressure
of 5 N/mm2. The valve is made of steel for which K =0.42. The angle at which the valve disc seat is
tapered is 25 Determine
1. Thickness of the valve head
2. Stem diameter and
3. Maximum lifts of the valve.
(Nov/Dec 2010)
6. Design and draw a valve spring of a petrol engine for the following operating conditions.
Spring load when valve is open = 400N
Spring load when valve is closed = 250N
Maximum inside diameter of the spring = 25mm
Length of the spring when the valve is close = 40mm

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Maximum permissible shear stress = 400MPa
(Apr /May2011)
7. Design the various components of a valve gear mechanism for a horizontal diesel engine for the
following specifications.
Brake power = 10kW
Bore = 140mm
Speed = 600 rpm
Maximum gas pressure = 3.5 N/mm2: The valve opens 30 before TDC and closes 20 after BDC. It
opens and closes with constant acceleration and deceleration for each half of the lift. The length of the
rocker arm on either side of the fulcrum is 150mm and the included angle is 135. The mass of the
valve is 0.3kg.
(Apr/May 2011)
8. Design a suitable inlet and exhaust valves for a single cylinder engine of 90mm diameter.
Maximum gas pressure acting is 8MPa. Assume that the spring compression load and spring preload
are equal and it is 60N. The maximum acceleration and retardation is 235m/s2. Safe operating stress
for the valve is 80MPa.
(Nov/Dec 2010)
9. A spring with following specifications is designed to fire a 50N projectile into air:
Coil diameter = 150mm
Wire diameter = 20mm
Free length = 650mm
No. Of coils = 24
Ends
= squared and ground
Shear elastic limit = 5.5 x 108 N/m2
G = 8 x 1010 N/m2
The spring is compressed 200mm when loaded or set. Determine the height to which the projectile
will be fired. Also determine the factor of safety for spring
(Nov/Dec 2010)
10. Discuss on the design aspects of inlet and exhaust valves.
(Apr/May 2007)
11. Design a helical spring for an engine valve. Length of spring when valve open is 60mm and when
closed is 80mm. spring load is 420 N when valve open and it is 320N when valve is closed. Maximum
internal diameter is 28mm. Allowable shear stress is 400MPa and modulus of rigidity is 0.8 x 10 5MPa
(Apr/May 2007)
12. Design a close coiled helical compression spring for a service load ranging from 2250N. The axial
deflection of the spring for a load range is 6mm. Assume a spring index of 5. The permissible shear
stress intensity is 420 N/mm2 and modulus of rigidity, G = 84kN/mm2 neglect the effect of stress
concentration.
(Apr/May 2010)
13. Describe the materials and design details of engine inlet and exhaust valves.
(Apr/May 2010)
14. Determine the diameter of the valve port, maximum lift of the valve, thickness of the valve head
and valve stem diameter for a value used in diesel engine having a bore of 140 mm, stroke of 270 mm
operating at 475rpm. Take maximum gas pressure = 3.5 N/mm2, bending stress = 56MPa.
(Nov/Dec 2011)
15. (i) Enumerate the importance of a proper intake port design for a multi cylinder SI engine.
(ii) With suitable sketches discuss the design aspects for optimum performance of the engine for
(1) Tangential port
(2) Directed port
(3) Helical port
(May/June 2013)(Nov/Dec 2013)
16. Design a suitable springs for the exhaust valve of a petrol engine .The spring should be capable of
exerting a net force of 400 N when the valve is open and 240 N when the valve is closed. The
maximum inside diameter of the spring is 25mm. The compression in spring is 8mm.
(May/June 2013, Nov/Dec 2013)
17. (a) Design a suitable spring for the exhaust valve of a petrol engine. The spring should be capable
of exerting a net force of 360N when the valve is open and 200N when it is closed. The maximum
inside diameter of the spring is 25mm. The compression in spring is 8mm. (NOV/DEC2014)
(b) The following data refer to a cam operating the suction valve of a 4-stroke petrol
Engine;
Least radius
=18mm
Lift
=10mm
Nose radius
=3mm
Crank angle when the suction valve opens before TDC = 4o
Crank angle when the suction valve closes after BDC =50o
Cam shaft speed =80rpm
The cam is of circular type with circular nose and flanks. It integral with the cam shaft and operates a
flat faced follower. Calculate :

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(i)
(ii)

The maximum acceleration and retardation of the valve

The maximum force to be exerted by the spring to overcome inertia of valve parts whose
mass is 250gram. Also calculate the angles of cam rotation during the acceleration and
retardation of the follower. (NOV/DEC2014)

18.(a) Design a rocker arm of I section made of cast steel for operating an exhaust valve of a gas
engine. The effective lenth of the rocker arm is 250mm and angle between the arm is 135o. The
exhaust valve is 80mm in diameter and the gas pressure when the valve begins to open is 0.4N/mm2.
The greatest suction pressure is 0.03N/mm2 below atmospheric. The initial load may be assumed as
0.05N/mm2 of valve area and the valve inertia and friction losses as 120N. The ultimate strength of
cast steel is 750 Mpa. The allowable bearing pressure is 8N/mm2 and the permissible stress in the
material is 72Mpa.(MAY/JUNE 2014)

(b) Thefollowing data refer to a circular arc cam which operats flat faced followers
Least radius = 50mm; Total fit 25mm ; Flank radius 50mm ; Angle of lift 70 degrees; calculate the
principal dimensions of the cam and draw the cam profile. (MAY/JUNE 2014)

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