KOLEJ KEJURUTERAAN

SEMESTER KEDUA
TAHUN AKADEMIK 2007/2008

PROGRAM : Bachelor in Mechanical Engineering

PROGRAM

MATAPELAJARAN : Machine Design

SUBJECT

KOD MATAPELAJARAN : MEMB 333

SUBJECT CODE

TARIKH :
DATE

MASA : 3 Hours
TIME

Instructions to candidates:

1. Answer all questions.

2. All answers and rough work must be done on the exam booklet.
3. Useful equations will be provided during the exam.
4. Candidates are not allowed to bring any unauthorized materials into
the examination hall.

DO NOT OPEN THIS QUESTION PAPER UNTIL YOU ARE INSTRUCTED TO DO

SO

KERTAS SOALAN INI MENGANDUNGI 4 MUKA SURAT BERCETAK

TERMASUK MUKA SURAT INI.

THIS QUESTION PAPER CONSISTS OF 4 PRINTED PAGES INCLUDING THIS

PAGE.
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1). a. Give an explanation of the following tests for finding certain mechanical
properties of materials to be considered for application in machine components
design : [ 6 marks]
i). Tensile test.
ii). Impact test.
b. Give an explanation with a drawing of graph of force or load versus time of static
loading on a machine component [3 marks]
c. A steel specimen has a strength of 414 MPa at its elastic limit and the strain at
that point is 0.002. The test specimen is 12.5 mm diameter and has a 50 mm
gauge length. Determine : [6 marks]

i). Modulus of elasticity of the steel specimen.

ii). Strain energy of the steel specimen at the elastic limit.

2). a. An overhung diving board is shown in Figure 1. The dimensions of the

board are 2 m length, 0.3 m width, and 0.03 m thickness. Find the largest
principal stress in the board when a 120 kg person (P) is standing at the free
end of the board. What is the static safety factor if the material of the board is a
brittle fiberglass with Sut = 140 MPa in the longitudinal direction ?.
Give suggestion on how to increase the static safety factor. [10 marks]

Figure 1

b. Give definition of a shaft. [2 marks]

c. Give definition of a key. [2 marks]
d. List two types of key. [1 mark]
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3). a. Give a definition of a bearing. [2 marks]

b. Find the minimum film thickness for a long bearing with: 45-mm dia., 200 mm
long, eccentricity ratio = 0.55, clearance ratio = 0.001, speed = 2500 rpm, and ISO
VG 46 oil at 150oF.
Why finding of the minimum film thickness is very important in bearing design ?
Explain. [5 marks]
c. Give an explanation of a gear train . [2 marks]
d. An epicyclic spur gear train as shown in Figure 2 has a sun gear of 33 teeth and a
planet gear of 21 teeth. Find the required number of teeth in the ring gear
and determine the ratio between the arm and sun gear if the ring gear is held
stationary. Hint : Consider the arm to rotate at 1rpm. [6 marks]

Figure 2

4). a. Find the ultimate tensile strength, the ultimate shear strength, and the torsional
yield strength of a 1.8 mm diameter, A229 oil-tempered steel wire spring .
[ 5 marks]
b. A 1.25 in major diameter and 5 threads per inch (1.25-5) Acme single thread
power screw with radial angle of thread α = 14.50 is used to lift a 1000 lb
load. The mean collar diameter is 1.75 in. The coefficient of friction for both
the screw and collar is 0.15. Find the torque to lift the load and the
efficiency of both screw and collar ?. [5 marks]
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c. Give a brief explanation on clutches and brakes [4 marks]

d. List two types of brakes [1 marks]

5). This is an open ended design problem. You are allowed to make relevant assumptions
if deem necessary.
You are required to design a speed reducer (gear box) for an industrial saw that is
used to cut bar stock. The saw will be driven by motor rotating at 1,600 rpm. The
drive shaft for the saw should rotate at approximately 400 rpm. Flexible couplings
may be used to connect the motor shaft to the input shaft of the reducer and to connect
the output shaft directly to the shaft of the main drive wheel for the band saw. The
saw is a band saw and generally operates in a smooth manner, but moderate shock
may be encountered as the saw blade engages the stock or if there is any binding of
the blade in the cut. The constant input torque to the saw should be 3500 in-lb. The
saw is expected to operate 16 hours per day, 5 days per week, with a design life of 5
years. The factory environment will have a temperature range from 50oF to 100oF.
For this design, you are required to :
i) Size the input and output steel shaft diameters of the gear box with a factor of
safety of 2.
ii) Discuss and verify whether the chosen gear design as given below is
appropriate and is safe to be used for the need operation life.
iii) Design suitable ball bearings needed to support both the input and output
shafts. If the output and input shafts of the gear needs to be co-axial, what
needs to be done to the gear box design? Explain
Note:
1 hp = 6600 in-lb/sec, Csize = 0.8, CH =1.0
Gear design:
Pinion diameter is 4 in and gear diameter is 16 in, pressure angle 20oF with a face
width of 2.0 in. Assume no stress concentrations exist.
[40 marks]