FACULTY OF ENGINEERING, THE BUILT ENVIRONMENT AND IT

Department of Mechatronics

TEST 1
SUBJECT: MACHINE DESIGN 3 SUBJECT CODE: MMD3111:
DATE: 24 MARCH 2009 TIME ALLOWED: 2.5 HOURS
TOTAL MARKS: 100

LECTURER______ MODERATOR_________________
IA GORLACH B ROBERTS

INSTRUCTIONS: Answer all the questions

You may use only Shigley’s book
Show all steps

QUESTION 1

A shaft is subjected to a fully reversed cyclic bending moment of 150 Nm and a constant
torque of 125 Nm at the bearing seat (journal) having a diameter of 30 mm (d). The D/d ratio
is 1,1. The shaft is fitted with a Single-Row 02 Series Deep groove bearing. The shaft material
is cold rolled G100300 steel.

1.1 Find the safety factor using the DE-elliptic criterion. Select all the data as required. (8)
1.2 Draw the fatigue-failure diagram. (6)
1.3 What is the most probable cause of shaft failure? Explain. (2)
[16]
Use:
Kt K ts
kf k fs
2. K t 1 . 139 2 . K ts 1 . 139
1 1
K t . r . σ ult K ts . r . σ ult

QUESTION 2

A double-reduction gear train shown below consists of two spur gear sets having modules of 6
and 10 mm for the first and second stage respectively. The gear sets have a 200 pressure angle.
The input shaft rotates anticlockwise at 1200 rpm and transmits 37 kW of power. Ignore all
loses in the transmission. The safety factor is 2.
2.1 What is the revolutionary speed and direction of the output shaft? (2)
2.2 What is the torque of the output shaft? (2)
2.3 What is the distance between the intermediate and the output shaft? (2)
2.4 Determine the maximum bending moment in the input shaft. (4)
2.5 Determine the minimum uniform diameter of the input shaft using the Distortion-Energy
criterion and the safety factor. (4)
2.6 If the slope at the journals is limited to 0.001 rad, what is the minimum uniform diameter
of the input shaft? (4)

[18]
Figure 1. Diagram for Question 2

QUESTION 3

A commercial enclosed helical gear transmission has a reduction ratio of 5 transmitting 3.5 kW of
power. A pinion rotates at 1500 rpm and has 30 teeth, a 200 pressure angle, a helix angle of 250, a
module of 1.5 mm and a face width of 45 mm. The pinion and gear material is through-hardened steel
of Grade 1 with HB 200, a modulus of elasticity of E = 200 GPa and Poisson's ratio of 0.30. The
gear teeth are uncrowned, and manufactured to a No.6 quality standard. The overload factor is 1.
Assume a pinion life of 108 cycles and a reliability of 0.90, use Y N =1.3558 N-0.0178 and
Z N = 1.4488 N-0.023.

3.1 Determine the AGMA bending and contact stresses for the gear. (11)
3.2 Determine the AGMA bending and contact strengths for the gear. (11)
3.3 Determine the safety factors for bending and contact loadings for the gear. (2)
[24]
QUESTION 4

A right-hand worm with a single tooth made of hardened steel rotates anticlockwise around Z-
axis at 600 rpm and transmits 2 kW of power (output on the gear). The worm has an axial
pitch of 25mm, a pitch diameter of 100 a face width of 100 mm. The cast-iron gear has 48
teeth and a face width of 50 mm.

Figure 2. Diagram for Question 4

4.1 Draw a fee-body diagram of the worm. (3)

4.2 Determine all the forces in the gear-set. (12)
4.2 Determine the reactions of the supports A and B using preferably Vector Algebra. (8)
4.3 Which of the supports should have a thrust bearing? (1)
4.4 Determine the efficiency of the gear-set. (1)
[25]

QUESTION 5

The following data was obtained from a series of specimens tested for Normalised steel:
Ultimate Tensile Stress (σ uts ) =750 MPa
Yield Stress (σ y ) = 702 MPa

Fatigue data:
Fatigue Stress (σ f ) MPa Number of cycles (AVE of 8 specimens)
100 109 run out
100 108
300 106
450 105
500 104
600 103
700 102
 Construct an approximate but well labelled SN curve and indicate the following:
i) Endurance limit
ii) Finite life section (8)

QUESTION 6

Figure 3 shows a planetary system consisting of the Sun (Gear 2), the Planets (Gears 3, 4 and
6), the Arm 5 and the Ring (Gear 7). Shaft B is attached to Arm 5 and goes through Gear 7.
Gear 7 (Ring) is fixed.

Find the gear ratio of the transmission and interpret/comment on the answer.
[9]

Figure 3. Diagram for Question 6

Total: 100