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Ministry of Science and Technology

Department of Technical and Vocational Education
Promotion Examination for B.Tech Second Year
Machine Design (ME 04031)
(Mechanical)
Date: 23-10-06 Time: 12:30 - 15:30
Part A (Attempt any Two questions)
1. A 600 mm pulley driven by a horizontal belt transmits power through a solid
steel shaft to a 250 mm pinion which drives a mating gear. The pulley weighs
1000 N to provide some flywheel effect. The arrangement of elements, the belt
tension, and the components of the gear reaction on the pinion are as shown in
figure below. (All dimensions are given in millimeter)
(a) Sketch in order the following: vertical loading, vertical bending moment,
horizontal loading, horizontal bending moment, and combined bending
moment.
(b) Determine the necessary shaft diameter using ASME stress values for
commercial shafting and fatigue factors of Kb = 2.0 and Kt = 1.5.

1500N

3000N

8400N

250 500 200 5000N

1000N

2. (a) A bare steel shaft of diameter D shows a first critical speed of 1200 rev/min.
If the shaft were bored to make it hollow, with and inside diameter of ¾ D, what
would be the critical speed.
(b) It has been determined for the shaft shown in figure that the static deflections
due to shaft bending are 1 = 0.02 mm, 2 = 0.08 mm, 3 = 0.03 mm. The bearing
supports have a flexibility in the vertical direction equivalent to a spring constant
= 315 MN/m. In the horizontal direction the supports are essentially rigid.
Investigate the first mode critical speed (or speeds)

930N
400N
530N

1 2
3
200 300 350 250
3. Two shafts at right angles are to be connected with a pair of bevel gears having
20 full depth teeth. The velocity ratio is to be 4½ to 1. The pinion is to be made
of steel (s0 = 100 MN/m2) and the gear is to be made of semi-steel (s 0 = 85
MN/m2). The pinion is to transmit 4 kW at 900 rev/min. Determine the
minimum diameters, module and face width that should be used based on
strength only. Then using the AGMA durability equation estimate the minimum
diameter that would be required for wear, assuming a material factor of 0.4.
(Take modulus of elasticity for steel = 200 x 109 N/m2 wherever necessary)

Part B (Attempt any Three questions)

4. Describe the organization of the drawing office. What are the relationship
between the drawing office and other department?

5. How are the various possible solution found?

6. Define accuracy and repeatability. Which items affect positioning accuracy and
repeatability? Which technical features are used to specify robot.

7. How can define robot? Why robot should be used in manufacturing and in which
applications robot could perform in industry?

******************************
 Answers (KZ – 535), 97 marks

No.1(a) Solution
1500N

3000N

8400N

250 500 200 5000N

1000N

1000N R2
Vertical loading diagram
R1 8400N

M2
M1

Vertical bending moment diagram

1500+5000
3000N
Horizontal loading diagram
R3 R4
M3

Horizontal bending moment diagram

M4

Mb2
Mb1

Combined bending moment diagram

No.1(b) T1 +T2 = 1500 + 5000 = 6500 N

Mt = (T1 - T2)D/2 = 5000 – 1500  (0.6/2) = 1050 N-m
Vertical loading diagram
M   0
R1 x 0.75 – 1000 x 0.5 – 8400 x 0.2 = 0
R1 = 2906 N-m
 F y 0

1000 + R2 = R1 + 8400
R2 = 2906 + 8400 -1000 = 10306 N-m

Vertical bending moment diagram

M1 = R1 x 0.25 = 726.5N-m
M2 = 8400 x 0.2 = 1680 N-m

Horizontal loading diagram

M 0
R3 x 0.75 – 6500 x 0.5 + 3000 x 0.2 = 0
R3 = 3533.33 N
F y 0
R3 + R4 = 6500 +3000
R4 = 5966.67 N

Horizontal bending moment diagram

M3 = R3 x 0.25 = 3533.33 x 0.25 = 883.3325 N-m
M4 = 3000 x 0.2 = 600 N-m

Combine bending moment diagram

M b1  M12  M 32  (786.5)2  (883.3325)2  1143.71 Nm
M b2  M 22  M 24  (1680)2  (600)2  1783.928 Nm
The maximum bending moment is 1783.928 at occur bearing without keyway.
Ss = 55 MN/m2
Kb = 2, Kt = 1.5

ASME CODE Equation

16
d3   KbMb  2   KtMt  2
πSs
16
  2 1783.928 2  1.5 1050 2
π  55  10 6
d  0.0712m
 71.2mm

The standard shaft diameter = 73.2 mm.

No.3 Solution
 = 20 full depth
TR = 4 ½ to 1
Sop = 100 MN/m2
Sog = 85 MN/m2
P = 4 kW
rpmp = 900 rpm
Dp = ?, Dg = ?
M = ?, b = ?
AGMA  Dp = ?, Cm = 0.4
Different material
TR = 4.5/1 = Ng/Np = 72/16
Np
Nf p  N 2p  N g2
Ng
16
 16 2  72 2  16.39
75
Nfp = 16.39   = 20 full depth  yfp =0.09478

Ng
Nf g  N 2p  N g2
Np
72
 16 2  72 2  331.9
16
Nfp = 331.9   = 20 full depth  yfp =0.154
(Soy)p = 100  0.09478 = 9.478106 N/m2
(Soy)g = 85  0.154 = 13.09 MN/m2
Pinion is weaker.
Design base on pinion.
Unknown diameter case
2M t  1 
Sin d   
m 2 byπy  L  b 
9550kW 9550  4
Mt    42.44Nm
rpm p 900
L 3
Assume 
L-b 2
Npm
1   V.R 
2
L
2
16  m
 1  4.5 2  36.878m
2
L 36.878
b   12.2927m
3 3
2  42.44 3 2.174
Sin d  3  
m 12.2927  0.09478  π 16 2 m3
S 100
Sin d  0 
2 2
2.174
 50  10 6
m3
m  3.516mm
Standard module series
2.5, 3, 3.5, 4, 4.5
Try m = 3.5 mm
Dp = Npm = 16 x 3.5 x 10-3 = 56 mm
 πD p rpm p π  56  10 3  900
V   2.6389m/s
60 60
6
Sall  S0 
6V
6
 100 106   69.45MN/m 2
6  2.6389
2.174 2.174
Sin d    50.706MN/m 2
m 3
3.5 10 
 3 3

Sin d Sall :
 Design is not satisfied.
Choose , m= 3.5 mm
Dp = 56 mm
T.R = Dg/Dp = 4.5, Dg = 4. 5x 5 6= 252 mm
b = 12.2927 m = 12.2927 x 3.5 = 43.02 mm
L = 36.878 m = 36.878 x 3.5 = 129.073 mm
Use b = 45 mm
AGMA Standard for wear (durability)
Power = 0.8 CmCBb
D1.5
p (rpm) p  5.6 
CB   
0.032  5.6  V 
p  900 
D1.5 5.6 
    21800.9D1.5
p
0.032  5.6  2.6389 
1.5
4 = 0.8 x 0.4 x 21800.9 D p x 45 x 10-3
Dp = 0.05456 m
= 54.55 mm
= 55 mm

Dp = 56 mm
Dg = 252 mm
m = 3.5 mm
b = 45 mm
AGMA  Dp = 55 mm

No.4 Solution
 Organization of the drawing office

Technical Director

Chief Engineer

Department Manager

Engineer in Charge

Deputy Engineer in Charge

Section leader

Detail Designer

Assistant Designer

Designer Draughtmen

The Organization of personal drawing office

The term design engineer are engaged on design and an excellent knowledge of
mathematic, physics and engineering which are qualified in the best sense to undertake
untirely independent of the product.
Chief designer (who may also called director), Head of department, Chief
engineer, duputy chief engineer also have to carry a measure of large responsibilities.
Head of section should also have capacity to problem without existing design to copy.
Detail designer need only ordinary standard of profession training.
A engineering draughtmen and trainee designer are usually ambious juniers
which have been transferred from the shop to the drawing offices for training which
carried out there and by attentanced at techanical college.

Relationship between the drawing office and other departmet

The two principles area of the creative design activities are design and
production. The importance of the creative work of the designer is apparent from single
fact that he is responsibility for patting the engineering products in the most economical
manufacture way. Design and production are closely interrelated.
There are also reciprocal relationship between the other department of a factory
and the drawing officies. Result in the test department can often be lead to major
improvements. The relationship between the engineering department of designer or his
department goes without saying. From the sales engineers, too, the designer can often
hear the importance paint of view.

Test Plant
engineer engineer

Depelopment Design Production

engineer engineer engineer

Sales Customer
engineer

Regulation
Rules

Relationship between the drawing office and other department

N0.6 Solution
Accuracy of the robot refers to capability to position is the wrist end to give a
target point within its work volume. Positioning accuracy is defined as the
difference between position desired and position actually achieved. Accuracy of
the robot would be one-half the distance between two adjancent resolution points.
Accuracy may be important when using adaptive program.
Repeatability of the robot refers to ability to position it’s the wrist end back to a
point in space that was previously taught. It is a measure the position between
successive moments in the same commanded assembly. Repeatability errors
form random variable. Repeatability can be extremely importance in small
assembly operation. Repeatability will better (less) than accuracy.

There are seven items effect positioning accuracy and repeatability.

1. Gravitational forces due to the arm members and loads of the robot cause the
deflection of the arm and support system.
2. Acceleration forces may act in any direction due to acceleration motions.
 3. Slack of drive gear and belt can cause backlash errors.
4. Thermal effect can cause expand and contract the links of the robot arm.
5. Bearing can cause contributes the errors.
6. Leakage of hydraulic fluids can cause the positioning errors.
7. Wind up can be important when long rotary members in the drive system and
twist under load.

Technical features
1. Work volume or work evelope
2. Precision of movement
3. Speed of movement
4. Weight carrying capacity
5. Type of drive system

No.7 Solution
Robot can be defined as reprogamable, multifunctional manipulators designed to
move material and parts or other specialized devices through the variable
program motions for the performance of the variety of tasks.

Applications of the robot

Robots are employed in a wide assortments of production in industry. Material
handling, mechanical loading and unloading is applications of the robots’
functions that it is atteancted the end of the robot’s wrist end. Spot welding is
welding, Spray painting and other operations is processing application which
enable the robot could perform a particular jobs in the most economical
manufactured.
Robot should be used in manufacturing. The following resons.
1. Increasing productivity
2. Quality improvement
3. Improvement of working environment
4. Better cost effectiveness
5. Fexibility to change.