MM1DM1-E1

The University of Nottingham

Malaysia Campus
DEPARTMENT OF MECHANICAL, MATERIALS AND MANUFACTURING ENGINEERING
A LEVEL 1 MODULE, SPRING SEMESTER 2010-2011
DESIGN AND MANUFACTURE 1
Time allowed ONE Hour THIRTY Minutes

Candidates may complete the front cover of their answer book and sign their desk card but
must NOT write anything else until the start of the examination period is announced
Answer THREE question, ONE from each of Section A, B and C
Only silent, self contained calculators with a Single-Line Display or Dual-Line Display
are permitted in this examination.
Dictionaries are not allowed with one exception. Those whose first language is not English
may use a standard translation dictionary to translate between that language and English
provided that neither language is the subject of this examination. Subject specific translation
dictionaries are not permitted.
No electronic devices capable of storing and retrieving text, including electronic dictionaries,
may be used.
DO NOT turn examination paper over until instructed to do so
ADDITIONAL MATERIAL:
Table for single-row deep groove ball bearing ratings
bs4500a data sheet: selected iso fitshole basis
INFORMATION FOR INVIGILATORS:

None

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2
SECTION A Machine Elements
1.

(a)

In the application of a threaded fastener based on a bolt, nut and washer, explain
with the aid of schematic diagram a suitable joining mechanism for the two lapjoints shown in Figure 1(a-1) and 1(a-2), respectively.

(a-1)

(a-2)
Figure 1
[8 marks]

(b)

A square power screw shown in Figure 1(b) has a major diameter of 36 mm and a
pitch of 4 mm, and it is to be used to drive a load of 8 kN.

Figure 1(b)
Assume that the coefficient of friction between the screw and nut () and the
coefficient of friction in the thrust collar (c) both equal 0.05 and mean diameter of
thrust collar, dc = 44 mm. Find
i)
ii)
iii)
iv)
v)

Pitch diameter
Minor diameter
Lead
Total torque required to raise the load
Comment on the amount of torque required to rotate the screw against the
load
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For an ISO thread, the total torque required to lift a load F is given as

Where

2 = included angle of thread

dm = pitch or effective diameter

= thread helix angle and

tan

Pitch
dm
[10 marks]

(c)

A metric steel bolt is denoted as M8 1.0 6g, 6.8 to BS 3692. What is the tensile
strength and yield stress (in kgf/mm2) of the bolt concerned?
[2 marks]

(d)

Explain why is it important to apply pre-tensioning to fastened components?

[2 marks]

(e)

Name three methods of applying pre-tension to fastened components.

[3 marks]

2.

(a)

Under what condition should a chain drive be used instead of belt drive and vice
versa? Give the advantages and disadvantages of chain drives.
[4 marks]

(b)

Name the differences between frictional and positive belt drives

(c)

List and describe (using sketches if necessary) three different types of frictional belt
drives and their applications.
[5 marks]

(d)

Keys offer a means of making positive shaft-hub connections. Describe with the aid
of sketches four different variants of keys. Discuss their advantages and
disadvantages in each case.
[6 marks]

(e)

Describe the differences between the basic dynamic load rating and the basic static
load rating in rolling contact bearings.
[2 marks]

[4 marks]

Continued on the next page

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4
(f)

MM1DM1-E1

For two groups of apparently identical rolling contact bearings tested under loads F1
and F2, the respective lives L1 and L2 are related by

L1 F2

L2 F1

Where
k is a constant which is equal to 3 for ball bearings and 3.33 for roller bearings
The life of a bearing with a basic dynamic load rating C and load P may be
calculated as:
k

C
L million revolutions
P

i)

What would be the expected L10 life of a 6405 single row deep groove ball
bearing if it were subjected to 4 kN.

ii)

Determine the life in hours that this corresponds to if the speed of rotation is
3000 rpm.
[4 marks]

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5
SECTION B Machining
3.

(a)

List and explain three independent variables in a cutting process that affects the
temperature rise in a workpiece.
[9 marks]

(b)

Which is the preferable chip during machining; continuous chips or discontinuous

chips? Explain the reason by comparing the formation of the chips and their affect
on part quality and the operational hazard.
[6 marks]

(c)

Assume that in orthogonal cutting the rake angle is 20 and the coefficient of
friction is 0.75. Determine the percentage increase in chip thickness when friction is
doubled.
Use the following formulas:
= tan ,

= 450 + /2 /2,
r = to / tc = sin

/ cos( )
[10 marks]

4.

(a)

Using the Taylors equation for tool life and letting n = 0.5 and C = 120, calculate
the percentage increase in tool life when the cutting speed is reduced by 50%.
[10 marks]

(b)

Although tool steel is harder than high speed steel, high speed steel is still
preferred as a cutting tool material. Explain the reason?
[5 marks]

(c)

List the uses of the cutting fluid in the manufacturing process.

[10 marks]

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SECTION C Metrology & Tolerancing

5.

(a)

All measurements consist of the following elements below except for one. Indicate
which one it is and state the reason for your choice.
i)
ii)
iii)
iv)

An unknown
A reference standard
A mean of comparing an unknown and a reference
A person to operate the equipment
[5 marks]

(b)

A circuit board manufacturer wants to verify that all the components are inserted
on the 3000 boards they manufacture each day. The manufacturer was given four
possible choices of inspection systems as below:
i)
ii)
iii)
iv)

Machine vision gaging

Automated weighing system
Hi-pot testers
Trained quality inspectors

Indicate and explain possibly with the aid of a sketch the most effective inspection
system the manufacturer would choose.
[10 marks]

6.

(c)

List the guidelines that have to be followed before using any measuring instrument
in the measurement process.
[10 marks]

(a)

A shaft with nominal diameter of 50 mm has to be connected to a hole with the

same diameter. Using the BS4500A Data Sheet, calculate the maximum and
minimum clearances required to produce:
i)

H7p6 interference fit

ii)

H7k6 transition fit

[12 marks]

(b)

The design of a square part with dimensional tolerance of 6.4 mm 0.025 mm has
a hub at the centre of the square with tolerance of 0.025 mm. With the aid of a
figure, show how geometrical dimensioning and tolerance (GD&T) can be used to
add geometrical tolerances to the design. You can use reasonable tolerance values
in the figure.
[9 marks]

(c)

Explain the advantages and disadvantages of using a limit gauge for inspection.
[4 marks]
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MM1DM1-E1
Table for Single-row Deep Groove Ball Bearing Ratings

MM1DM1-E1

1.
(a)

[2]

Ensure that the load is applied axially and that bending is not induced in the thread
as bending can greatly increase the stresses taper washer should be used to
ensure a flat seating [2]
Maximise force that can be taken by a bolt joint face should lie across the plain
shank of the bolt, never across the threads,
  
     . Comment
on cross-sectional area in threaded vs. shank region. E.g. threaded region using
average of pitch and minor diameter; shank region using the major diameter [2]
Ensure full engagement at least two threads should show beyond the nut when
tighten [2]

(b)

(c)
Tensile strength = 6 10 = 60 kgf/mm2 [1]
Yield stress = 6 8 = 48 kgf/mm2 [1]
(d)
Two main objectives:
- Pre-tensioning is essential to prevent the fastened components from moving apart when under
load [1]
- Pre-tensioning reduces the magnitude of stress fluctuations in the bolt when the loads on the
component fluctuate and this reduces the effects of failure, e.g. in the cylinder head bolts of an
internal combustion engine [1]
(e)
Three methods of applying pre-tension to fastened components (any three):
Measuring the bolt extension
Use of load indicating washers
Turning the nut a prescribed number of turns
Applying tension externally (e.g. 'Tangye' system)
Measuring the applied torque with the aid of a torque wrench
2.
(a)
Chain drives are most commonly used in low speed high torque applications, especially where space
is limited whereas belt drives are in general used for higher speed applications where the torques
are lower. [2]
Chain drives have the advantage of having longer lives than belts but they need good lubrication and
generally run noisier at high speed compared to belt drives. [2]
An alternative chain form is the inverted tooth. This is quieter than the roller chain and may be run
at higher speed.
The most common type of chain is roller chain (as on a bicycle). For high load applications two or
more rollers can be placed side by side. Roller chains are described in BS 228 and BS 2947.
(b)
Frictional belt drives [2]
- Operate based on friction between belt and pulley
- May slip if the torque is too high
- Potential creep of the belt on the pulleys even under normal operation (up to 4% of belt
speed, due to slight change in length of belt as tension changes around pulleys). This means
that exact speed ratios cannot be achieved
Positove belt drives: [2]
- Teeth on belt engage positively in grooves on pulley and exact speed ratios can be achieved
- Required lower belt tensions compared to frictional belt drives
(c) [5]
Vee belts: These are the most common form of belt.

vee shape enhances friction

several belts side by side for heavy loads
flexing of belt around pulley and wedging of belt in
into
to vee generates heat - hence losses - low
efficiency.
vee and cogged vee belts have higher efficiency.
Poly-vee
Flat belts: These were once very common and made from leather or woven cotton. They are now
making a comeback made from reinforced polymeric mate
materials.
quieter than vee belts
higher efficiency than vee belts ( up to 98%) - thinner cross section is more flexible hence
lower losses.
barrelled pulleys prevent belt slipping off
require higher belt tension than vee belts
Linked belts: These are made of small sections of vee belt joined together by pins, which enable the
belt to be split.
they
hey are of use where a shaft would have to be dismantled to fit a continuous belt.
(d) [6]
Keys

Keys make a positive shaft coupling and can be used to transmit loads of all type.
Plain keys do not provide any axial restraint to the hub. The key may be held in position
either by fitting in a profiled keyway or by set screws.
Taper keys provide some axial restraint due to friction; the radial force between the shaft
and hub allows some of the torque to be transmitted by friction between shaft and hub.
A gib head taper key may be used to assist removal.
Woodruff keys are easy to make and locate but can only be used for light loads.
Only taper keys provide ax
axial
ial restraint and then only by friction. Where large axial forces
may occur, it is common practice to use a more positive restraint such as a shoulder on the
shaft, a circlip, a retaining nut or sleeve. Good alignment between the hub and shaft
depends upon a close tolerance between the hub and shaft. Standard sizes for keys may be
found
und in the following standards: BS 46 (Imperial) ; BS 4235 (Metric).

(e) [2]
The basic dynamic load rating, C, is the constant radial load which a ball bearing can withstand for
fo
6
10 (1 million) revolutions.

The basic static load rating is the load the bearing can withstand without permanent deformation of
any component exceeding this load causes indentation of the rolling elements, called brinelling.
(f) [4]
i.
Dynamic load rating for single row deep groove ball bearing code 6405, C = 36 000 N,
Pd = 4 000 N,
L = 106 (L10 life at load C),
k = 3 (ball).
Hence,
3

36000
L = 10

4000
= 729 10 6 (= L10 life at 4 000 N)
6

ii.
If the rotational speed is 3000 rpm, L = 729 106 / (3000 60) = 4 050 hours. Approximately 168
days.
This isnt very long and highlights the need to use a bearing with a higher basic dynamic load rating
or use a suitable roller bearing.

3.

4.
a.

5 marks

c.

5.
a.

b.

c.

6.
a.
Nominal diameter = 50 mm
(i) Interference fit H7p6
0.025
7 
0
50.025
7 
50.000
(ii) Transition fit H7k6
0.025
7 
0
50.025
7 
50.000

0.042
0.026
50.042
6 
50.026

6 

0.018
0.002
50.018
6
50.002

6 

b.

c.