University of Al-Qadisiyah Class: 4th

Subject: Machine Design

College of Engineering
Examiner: Ass. Prof. Dr. Kareem Dakhil
Mechanical Engineering Department Time: 2 Hours
Final Examination 2016-2017 Date: / / 2017
Open notes
Q-1 (25 marks )
It is required to design a rigid type of flange coupling to connect two shafts. The input
shaft transmits 37.5 KW power at 180 rpm to the output shaft through the coupling.
The service factor for the application is 1.5, i.e., the design torque is 1.5 times of the
rated torque. Design the coupling and specify the dimensions of its components.
Selection of materials
Components Materials fs
2
Shafts 40C8(Syt=380 N/mm ) 2.5 Ssy = 0.5 Syt
2
Keys and bolts 30C8 (Syt=400 N/mm ) 2.5 Ssy = 0.5 Syt Syc=1.5 Syt
2
Flanges FG 200 (Sut=200 N/mm ) 6 Ssu= 0.5 Sut

Q-2. (25 marks )

A pair of straight bevel gears, mounted on shafts, which are intersecting at right
angles, consists of a 24 teeth pinion meshing with a 32 teeth gear. The pinion shaft is
connected to an electric motor developing 12.5 KW rated power at 1440 rpm. The
starting torque of the motor is 150% of the rated torque. The pressure angle is 20°.
Both gear are made of case hardened steel (Sut =750 N/mm2). The teeth on gears are
generated and finished by grinding and lapping processes to meet the requirements of
Class-3 Grade. The factor of safety in the preliminary stages of gear design is 2.
A-In the initial stages of gear design, assume that velocity factor accounts for the
dynamic load and that the pitch line velocity is 7.5 m/s. Estimate the module based on
beam strength.
B-Select the first preference value of the module and calculate main dimensions of the
gear.
C-Determine the dynamic load using Buckingham's equation and find out the effective
load for the above dimensions. What is the correct factor of safety for bending?
D-Specify the surface hardness for the gears assuming a factor of safety of 2 for wear
consideration .

Q-3 ANSWER TWO BRANCHES ONLY (30 marks )

A-A pair of worm and wheel is designated as 3/60/10/6 The worm is transmitting 5
kw power at 1440 rpm to the worm wheel. The coefficient of friction is 0.1 and the
normal pressure angle is 20o . Determine the components of the gear tooth force acting
on the worm and the worm wheel.
B- A multi-disk clutch consists of steel and bronze plates. It transmits 15 kw power at
1400 rpm .The inner and outer diameters of the contacting surfaces are 100 and 200
mm respectively. The coefficient of friction is 0.15 and the permissible intensity of
pressure is 0.5 N/mm2 . Assuming uniform wear theory, Calculate the number of steel
and bronze disks.
C- A four-wheeled automobile car has a total mass of 1000 kg. The moment of inertia
of each wheel about a transverse axis through its center of gravity is 0.5 kg m2. The
rolling radius of the wheel is 0.35 m. The rotating and reciprocating parts of the engine
and the transmission system are equivalent to a moment of inertia of 2.5 kg m2 , which
rotates at five times the road-wheel speed. The car is traveling at a speed of 100 km/h
on a plane road. When the brakes are applied, the car decelerates at 0.5 g. There are
brakes on all four wheels. Calculate: the energy absorbed by each brake, and torque
capacity of each brake.

Q-4 (20 marks )

o
The following data is given for a 360 hydrodynamic bearing: radial load 2 KN,
journal diameter 50mm, bearing length 50mm,viscosity of oil 20 m Pa s. Specify radial
clearance that need be provided so that when the journal is rotating at 2800 rpm the
minimum film thickness is 30 microns. Evaluate the corresponding coefficient of
friction.