AT- 6601 AUTOMOTIVE ENGINE COMPONENT DESIGN

TWO MARKS QUESTION BANK

UNIT 1 INTRODUCTION

1. What is mean by fatigue?

When a material is subjected to repeated stress, it fails at below the yield point; such type
failure of the material is called fatigue.

2. What are the factors does fatigues depends on?

Size of the component.
Static load.
Fluctuating load
No. of load reversal

3. Define endurance limit.

It is the limiting stress below which the infinite number of cycles time, the stress acting on
the material without failure. It is also called as safe maximum stress.

4. What is meant by stress concentration?

Whenever a machine component changes the shape of it cross section, the stress
distribution is irregular or discontinuity. The irregular stress distribution is caused by abrupt
changes of form, size is called stress concentration.

5. Define stress concentration.

It is defined as the ration of maximum stress to nominal stress

Kt =

6. What are the methods of reducing stress concentration?

Avoid stress like hole and notches
Free from corrosion
Good surface finish
Making additional holes
Gradual rise of size in the components

7. Define notch sensitivity

It is the degree of stress concentration reached in the material due to stress rises.

=

8. What is meant by tolerance?
It is defined as permissible variation in the dimension of the component.
Two types (i) Unilateral (ii) Bilateral

9. Define fits.
When two parts are to be assembled the relationship resulting from the difference between
their sizes before assembly is called fit.

Types of fits (i) Clearance fit (ii) Interference fit (iii) transition fit

10. What is meant by fluctuating stress?

When a machine member subjected to completely reversed stress, the maximum value of
compressive stress is not equal to maximum value of tensile stress. The variation in stress is
known as fluctuating stress.

11. Define Resilience.

It is ability of the material to absorb shocks or energy within elastic range.

12. Draw the stress-strain curve.

13. Define Factor of Safety (F.O.S).

It is the ratio of failure stress to allowable stress

N=

14. Define Toughness.
It is the ability to absorb energy within elastic and plastic range.

15. How do you select materials for design?

Mechanical properties are the significant importance in the selection of material. The
material should be able to withstand stresses and also cost and availability.

Some of the Mechanical properties

(i) Strength (ii) elasticity (iii) stiffness (iv) toughness (v) resilience (vi) brittleness (vii)
hardness

16. What is use of selective assembly and its necessity?

It is a process of sorting the manufactures components into different groups according
to their sizes and then assembling the components of one group to the corresponding components
of matching group. In this method, larger shafts are assembled with large holes and smaller shaft
with smaller holes.

17. Why hole basis system is mostly preferred in tolerance?

Holes are machined by standard drills or reamers having fixed dimension whereas,
shafts can be turned or ground to any dimension. Due to this reason hole basis system preferred.

18. What is the role of surface roughness in interference fit?

Roughness surfaces have a reduced contact area in interference fits, which reduces the
holding capacity of the joints.

19. Define fatigue life.

It is defined as the number of stress cycles that the standard specimen can complete during
the test before the appearance of the first fatigue crack.

20. Difference between failure due to static load and fatigue failure.

Sl Failure due to static load Fatigue Failure

no.
1. Failure due to static load are gradual Fatigue failure is sudden
2. There is a sufficient plastic Fatigue cracks are not visible till they reach
deformation prior to failure, which the surface of the component and by that time
gives a warning in advance failure has already taken place

21. Define fracture mechanics.

It is the science of predicting the influence of cracks and crack like deflect on the brittle
fracture of component.
22. What is meant by stress intensity factor and fracture toughness?
It specifies the stress intensity at the tip of the crack is known as stress intensity factor.
=
It is the critical value of stress intensity at which crack extension occurs is known as
fracture toughness.

23. Define Clearance fit.

It is a fit which always provides a positive clearance between the hole and the shaft over
the entire range of tolerance.

24. What you meant by interference fit and transition fit?

It is a fit which always provides a positive interference over the whole range of tolerance
is called as Interference fit.
It is a fit which may provides either a clearance or interference, depending upon the actual
values of the individual tolerance of the mating components is called as Transition fit.

25. What are the factors in selection of interference fit?

Materials and diameter
Surface finish and machining method

It is also necessary to calculate the maximum and minimum interference in each case
 UNIT II DESIGN OF CYLINDER, PISTON AND CONNECTING ROD
1. What is the function of cylinder?
To retain the working fluid.
To guide the piston.

2. What are the desirable properties of materials for cylinder?

It should be strong enough to withstand gas pressure.
It should be strong enough to resist wear due to piston movement.
It should be corrosion resistance.

3. What are the materials used for cylinder and formula to find thickness of cylinder
liner?
Grey cast iron
Nickel cast iron
Nickel chromium cast iron
Cast steel and aluminum alloys.

Thickness of Cylinder liner t = 0.03 D to 0.035D, D = Diameter

4. What is the stress acting in cylinder wall?

Longitudinal Stress
Circumferential stress

5. What is the function of the piston?

It reciprocates within the cylinder
It dissipates the large amount of heat from the combustion chamber to cylinder wall.
It compress the gas during the compression stroke
It transit the force due to gas pressure inside the cylinder to the crankshaft through
the connecting road
6. Define oil scraper ring and piston skirt.
It prevents the leakage of lubricating oil post the piston into the combustion chamber is
called as oil scraper ring.
It is the lower part of the piston below the piston rings which acts as bearing surface for the
side thrust exerted by the connecting rod is called as piston skirt.

7. What are the materials for the piston and stress acting on piston?
Materials: Cast iron, Cast aluminum, Forged Aluminum, Forged steel and Cast Steel
Stress : Bending stress and Thermal stress
8. Why the piston clearance necessary? What is its range.
It is necessary because if clearance is in sufficient, piston seizure occur. When clearance is
excessive, Piston Slap occurs resulting in piston running with excessive noise. Piston
clearance varies from 0.0375 to 0.1875

9. Define Slenderness ratio.

It is the ratio of length of the column to the least radius of gyration

10. What is the function of piston ribs and cap?

Ribs strengthen the piston head against the gas pressure and prevent distortion of piston
head. Ribs transmit large portion of combustion heat from piston head to the piston rings.
Cap provides additional space for combustion of fuel

11. Why more number of thin piston rings are preferred that a small number of thick
rings?
Thin rings reduce the frictional loss and wear surface.
More number of thin rings have better sealing action
Thin rings occupy less piston length

12. Why the piston made light weight and give the two design consideration of piston pin?
Piston is made light weight to reduce the inertia force due to reciprocating parts of motion
There are two design consideration of piston pin are (i) Bearing consideration (ii) Bending
failure.

13. State the reason for piston failure.

Ring might not have been compressed during installation
Detonation or pre-ignition
Leakage of water into cylinder
Improper and insufficient lubrication of cylinder walls

14. Define Piston Slap.

It is characteristic sound of a seriously worn piston in a cylinder. When the rings on the
piston are little undersized and until heat is built in cylinder a slapping noise occurs and when
heat expands the ring the slapping goes away. Slapping is piston slap.

15. What are forces acting on connecting rod?

Forces on the piston due to gas pressure and inertia of reciprocating parts
Forces due to inertia of connecting rod
Forces due to friction of the piston pin
Forces due to friction of the piston rings and the piston
16. What are materials used for connecting rod and lubrication used?
Mild carbon steel
Alloy steel
Carbon steel
Lubrication : Splash lubrication and pressure feed system

17. What are material selection criteria for piston?

It is should withstand high pressure, temperature and stress
It is should be non-corrosive
Light weight

18. What is the function of connecting rod?

Transmit the push and pull forces from the piston pin to the crank pin
Transmit the reciprocating motion of the piston to the rotary motion of the crank
shaft
Transfers lubrication oil from the crank pin to the piston pin

19. Why connecting rods made of I- Section?

Connecting rods are made of I section because it reduces the weight and inertia forces. It is
also easy for forging.

20. What is the force acting on bolt of big end of connecting rod?
Inertia force is the force acting on bolts of big eng of connecting rod. Inertia force acting on
the bolts is given by
cos 2
= 2 [cos + ]

21. State the failure reason for connecting rod.

Piston pin seizure
Fatigue
Hydro lock is a deformation of the connecting rod caused when water gets into
piston chamber
Over revving is the main cause of connecting rod

22. Why piston pin is circular in cross section ?

Stress is evenly distributed
Circular piston have no weak points which lead to crack
Circular cross section provides tremendous strength
23. State the design consideration of piston.
It should have enormous strength to with stand pressure
Should form effective sealing
Should have sufficient support to piston pin
Should dissipate heat quickly

24. What are the important parameters in design of studs for cylinder?
No of studs
Nominal diameter
Pitch of studs and various other

Parameter is stiffness of gasket, flanges and initial preload on stud.

 UNIT III DESIGN OF CRANKSHAFT
1. What is the function of flywheel?
The crankshaft is used to convert the reciprocating motion of the piston into rotary
motion.

2. What are the types of crankshaft?

There are two types of crank shaft,
Side or over hung crankshaft
Center crankshaft

3. What are the materials used for crank shaft?

Materials: Carbon steel, Manganese steel, special steel, Nickel Chromium steel and
special cast iron

4. What is the stress acting on crank shaft?

The stress is
Bending stress
Shear stress due to torsional movement on the shaft

5. State the main parts of cranks shaft.

Shaft part or journal which revolves in the main bearing.
Crank pin with which the big end of connecting is linked.
Crank web which unites crank pin with the journal.

6. What you meant by balancing of cranks shaft?

Dynamic balancing of crankshaft is where the weight of the piston, connecting rod and
shells are balanced against the counter balance weight and the flywheel of the crank shaft.

7. How the material selected for crank shaft?

Should have high strength and stiffness
Low cost

8. What is meant by failure mode of crank shaft?

Improper balancing
Misalignment during installation
Improper grinding of crank shaft
Absence of nitrated layer in the fillet region reduces fatigue strength and cause
crank which leads to failure
 UNIT IV DESIGN OF FLYWHEELS
1. What is flywheel?
It is a heavy disc type, thick sized member usually employed in I.C engine in order to
store extra energy during power stroke.

2. What is the purpose of flywheel?

During power stroke extra energy is stored and release the stored energy during
remaining stroke such us suction, compression and exhaust and thus the energy supplied
to crank shaft remains constant and also the vibration of the engine can be reduced.

3. What are the types of flywheel?

There are different types of flywheel
i. Solid piece type (a) Web type (b) Rim & hub type.
ii. Split type rim & hub type.
iii. Rim type with riveted flywheel.

4. Difference between flywheel and governor.

Flywheel is used to store extra energy produced during power strokes and release the
stored energy during other strokes and hence jerking of the engine is avoided whereas the
governor controls the supply of fuel and thus maintain the speed constant.

5. What are the constructional parts of flywheel?

The constructional parts are
Rim
Web
Hub
Arms

6. Define fluctuation of speed.

Difference between the maximum and minimum speed of the flywheel (N2 N1)

7. Define coefficient of fluctuation of speed.

It is the ratio of fluctuation speed to average speed
(N2 N1)
=
s
8. What is purpose of turning moment diagram?
It is used to calculate kinetic energy stored in the flywheel.
How torque varies depending on crank angle.
9. Name few materials used for flywheel.
Materials: Cat iron for low speed velocity.
Steel for high velocity.

10. Define co-efficient of fluctuation of energy.

It is the ration of fluctuation of energy to the work done per cycle.

11. State design criteria of flywheel.

Energy storing capacity of flywheel
Materials of which flywheel is made
Size and shape of flywheel
Amount of stress induced in operation.
 UNIT V - DESIGN OF VALVES AND VALVE TRAIN
1. What are the types of valve used in general?
Poppet or mushroom valves
Sleeve valve

2. Name some of material used for valves.

Materials : Inlet valve- Nickel chromium silicon
Exhaust valve heat resistant silicon, Chromium silicon.

3. What are materials used for valve should have following characteristics?
Should be heat resistance
Should have good thermal conductivity
Should be corrosive resistance
Should have shock resistance.

4. Why the inlet port larger than exhaust port?

Inlet ports are 20 % to 40 % larger than exhaust port for better cylinder charging and
scavenging.

5. What is the function of rocker arm?

The basic function of rocker arm is to open or close the inlet or exhaust valve with respect to
motion of the cam and follower

6. Name the materials of rocker arm.

Materials: Grey cast iron, malleable cast iron and cast steel

7. What is the force acting on rocker arm?

Gas pressure on the valve when its open
Inertia force
Cast steel

8. What is the force acting on Valve spring?

Initial spring force
Force required to lift the valve

9. What is the purpose of valve spring?

To exert a force on the rocker arm in order to maintain contact between the follower and
cam at the other end
10. State the assumption in design of valve spring
Spring is made of oil hardened and tempered valve spring
Stiffness of the spring is 10 N/mm
Spring has square & ground ends
Spring index D/d should be 8

11. Define Cam.

Cam is a rotating machine element which gives reciprocating motion to another element
known as follower. Cams are usually rotated at uniform speed by means of crankshaft but
the follower motion is predetermined and will be according to the shape of cap

12. What are the types of follower

Knife edge follower
Roller follower
Flat faced follower

13. Define valve gear mechanism.

It is a sub assembly of the I.C engine and its function is to open and close the inlet &
exhaust valve at proper time with respect to the position of the piston of the piston &
crankshaft.