problem 1)a) A gun metal bush of internal diameter 30mm, outer diameter 36mm, and length 45mm is used to support a shaft at one end. Prepare the production drawing of bush showing tolerance on dimension, geometrical tolerance and surface finish

b) Mention the type of fit and the respective surface roughness grade number for the following applications.

i) Assembly of cylinder liner in block

ii) Assembly of connecting rod bolt

iii) Mounting of gear wheel on shaft

iv) Assembly of IC engine exhaust valve in guide

c) Briefly describe TAGUCHI concept with appropriate ex

problem 2) Describe reliability and design for reliability

b) With the help of flow diagram and appropriate ex describe Failure Mode & Effects Analysis (FMEA)

problem 3)a) A two speed gearbox is to transmit 30 kW. The driver shaft runs at 1500 rpm and driven at 2 different speeds of 600 rpm and 350 rpm. A ±4% variation in the specified speed is accepted. Design the gears and compute the centre distance. Prepare a sketch of two speed gearbox with dimension.

b) Describe the following terms with neat sketch with respect to

Casting design

i) Ribs

ii) Significance of fillets at juncture

Forging design

iv) Draft angles

v) Parting line