CurtinUniversityofTechnology

DepartmentofMechanicalEngineering

MIDSEMESTERTEST

UNIT:

DURATION:

TOTALMARKS:

308803MechanicalDesign337
Hours
100(for25%)

INSTRUCTIONS

Togainfullmarksforanyquestion,oranypartofaquestion,thecorrect
unitsmustbestated,allnecessaryworkingmustbeshown,andwhere
necessarytosupportyouranswer,clear,neatsketchesshouldbeprovided.

ATTEMPTALLQUESTIONS

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OneA4sheetofhandwrittennotes(singlesideonly)isallowed.

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NAME:___________________________________

RETURNTHISQUESTIONPAPERANDTHEFORMULASHEETWITHYOUR
ANSWERBOOK.

Q1

(a)

Describe LCA. Draw a schematic to illustrate the relationship between

differentphasesofLCA.

(6)

(b)

DifferentiatebetweenFactorofSafetyandMarginofSafety?

(4)

(c)

Marks

A speed reducer is required to provide an exact ratio of 648:1, while

minimising the overall gearbox size. Use 20 fulldepth teeth with a
moduleof5mmtocomputethefollowing:

(15)

I. Appropriatenumberofteethoneachgear.
II. A sketch of the gearbox indicate gear sizes and directions of
rotationoneachgear.
III. Centredistances,wholedepth,workingdepth,andtooththickness.
IV. Trainvalue
Q2

(a)

Listdown:

(9)

1).Sixmethodsusedtotransfertorquefromgearstoshafts.
2).Threemethodsusedtosecureaxiallocationofgearsandbearingsonshafts

(b)

Draw sketches to differentiate between fully reversed, repeated, and

fluctuatingstressesinshafts.

(3)

(c)

Two meshing 20 spur gears have a module of 5 mm. The pinion has 35
teethandthecentredistanceis400mm.Towhatvalueshouldthecentre
distancebeincreasedinorderfortheactualpressureangletobecome24?

(13)

Q3

(a)

Draw a sketch to compare the following theories of failure: Maximum

shear stress theory, maximumnormal stress theory and maximum
distortion energy theory. Comment on their suitability for ductile
materials.

(5)

(b)

A ductile hotrolled steel bar has minimum yield strength in tension and
compressionof390MPa.Usingthedistortionenergyandmaximumshearstress
theoriesdeterminethefactorofsafetyforthefollowingplanestresses:

(10)

x=160MPa,xy=100MPa
(c)

Bolts,eachofwhichhasameantwistingoffstrengthof25Nmwithastandard
deviation of 1.5 Nm are tightened with automatic wrenches on a production
line. If the automatic wrenches have a standard deviation of 2 Nm, calculate
mean value of wrench torque setting that results in an estimated 1 bolt in 400
twistingoffduringassembly.

(10)

Q4

Marks

(a)

Definebacklash.Whatarethemethodsusedtocreatebacklash?

(5)

(c)

Figure below shows the countershaft for a doublereduction, spur geartype

speedreducer.Theshaftisapartofthedriveforalargeblowersystemsupplying
airtoafurnace.GearAreceives150KWfromgearP.GearCdeliversthepower
togearQ.TheshaftcarryinggearsAandCrotatesat62.8rad/s.

(20)

a) Determinethepitchlinevelocities.
b) Determinethetorquecarriedbytheshaft
c) Determine the radial loads applied to bearings B and D, and sketch the
countershaftasafreebodyinequilibrium.

ENDOFEXAMINATION

Figure6.20:Generalisednormaldistributioncurve

PARTIALSOLUTIONS

QUESTION1(c):
PART(I)
Requirednumberofstages =3
Numberofteethoneachgear
N1
N3
N5

=18,
=18,
=18,

N2
N4
N6

=162
=162
=144

PART(II)

PART(III)
C1
=450mm
C2
=450mm
C3
=405mm

Workingdepth
Wholedepth
Clearance

Tooththickness

=10mm
=11.25mm,
=1.25mm
=7.854mm

PART(III)
Overalltrainratio

=648:1

QUESTION2(c):
C=411.451mm

QUESTION3(b):
MaximumShearStressTheory
max

=128MPa
1.52

MaximumDistortionEnergyTheory
e

=235.8MPa
1.65

QUESTION3(c):

=2.81

=2.5N.m

=7.025N

Meanvalueoftorquewrench18Nm

QUESTION4(c):
Part(a):PitchlineVelocities

15.95m/sec
7.98m/sec

Part(b):Torquecarriedbytheshaft
T=2388.54Nm

Part(c):RadialLoadsonBearings
Freebodydiagram

9403.7N
.

18807.4N
.
DH=5476.3N
BH=2053.7N
DV=7523N
BV=20688N
Br 20789.8 N
Dr 9305N