Question 1 [9 marks] a) Briefly describe with the aid of simple sketches in your answer booklet, what you think

are the most likely types of gearing inside each of the gearboxes shown below (i) to (vi). Only those shafts that emerge from the gearbox have been shown. In some cases other shafts may exist inside the gearbox.

(i)

(ii)

i = 1000 RPM

i = 1000 RPM

o = 340 RPM

o = 340 RPM

(iii)

(iv)

i =
1000 RPM

o =
1000 RPM

i =
1000 RPM

o =
500 RPM

(v)

(vi)

o =
100 RPM

i =
1000 RPM

i = 1500 RPM

o = 20 RPM

b)

(i) The Lewis equation and modern refinements of it are based on the determination of a particular stress in gear teeth. Explain with a sketch the location and nature of this stress. (ii) What damaging stress condition is not covered by the Lewis equation and those equations derived from it? (i) In your answer booklet complete the following statement of the kinematic law of gearing, which is missing approximately 12 words: "If the line drawn normal to the contacting surfaces of two rotating bodies ..., the angular velocity ratio of the two bodies will remain constant." (ii) Name two possible shapes of gear teeth that satisfy the law of gearing. What are two important operational advantages of helical gearing compared to spur gearing? What are herringbone gears, and what special attribute do they offer the designer? Use a sketch to explain.

c)

d)

e)

Question 2 [ 5 marks ] a) b) Make an isometric (3D) sketch of a Hooke's joint. Label the principal elements. What problems occur if a single Hooke's joint is used but which can be eliminated if a pair of them is used appropriately? For the shaft system shown schematically below, which runs between two parallel shafts with a given offset, sketch in your answer booklet an appropriate arrangement incorporating two Hooke's joints and an intermediate shaft.

c)

___________Y d) Explain in what circumstance it would be necessary to fit a sliding spline joint in the situation described in part c).

Question 3 [5 marks ] The horizontal shaft of a winch drum, which has a brake drum attached to it, is supported by two spherical roller bearings mounted in plummer blocks (also known as pillow blocks). These plummer blocks are bolted to a welded steel frame. The left hand bearing is fully located; the other is axially floating on its outer race. (a) Sketch a cross-section of one of the bearings and its plummer block. Label the: inner race outer race spherical rollers plummer block housing

(b) Sketch a simplified schematic of the mounting system showing both bearings, and with heavy dots indicating the restraints, for the locations where they are used, for each of the inner and outer races. (d) Give two reasons why this mounting system is appropriate for this application.

Question 4 [ 8 marks ] The short shoe brake shown in the figure below is applied by the spring and released by a hydraulic cylinder (not shown). (a) Determine, with the aid of appropriate free body diagrams, the spring force required to produce a braking torque of 175 Nm given that the co-efficient of friction is 0.35. (b) A shoe brake may be self actuating to some extent. Is this the case for either of the caliper arms shown? Explain your answer by reference to your free body diagrams. (c) For the most heavily loaded shoe, determine the minimum possible width of shoe (i.e. measured normal to the page) if the average pressure on the projected area of the shoe is not to exceed 500 kPa.

Question 5 [8 marks] DO THIS QUESTION OR QUESTION 6 (a) The figure below shows the hub of an idler gear into which plain bearing bushes have been pressed. When the hub is assembled and mounted on the shaft the permitted minimum and maximum values of axial clearance C are 0.15 and 1.05mm respectively. Determine the upper and lower limits of size the hub length H may have given that the distance between shoulders S is 150.00 0.15mm, and bush face-thickness B is 9.00 0.08mm.

(b)

In the operation of oil lubricated plain bearings we distinguish between two main regimes of lubrication. State what they are and describe the function of the lubricant in each. Use sketches to facilitate your explanation. Two important properties of the materials used in plain bearings are compressive strength and embeddability. Discuss what is meant by these terms; why they are important; and what conflict, if any, exists between them. On earth scooping machinery the pin joints on the linkage working the scoop obviously need bearings of some sort. Given that shock loadings occur would you use plain bearings or deep groove ball bearings in this application? Explain why.

(c)

(d)

Question 6 [8 marks] DO THIS QUESTION OR QUESTION 5 (a) Referring to the figure below, the load is applied to the flat bracket via a pin in the hole. Discuss with the aid of sketches the various modes of failure that a designer should consider when determining the necessary proportions of the pin and the plate near the hole.

(b)

The flat bracket is to be attached to a vertical surface using a pattern weld run as shown in Figure 3. The weld metal will be laid as an equal legged fillet weld. (i) Determine the location and magnitude of the maximum load on the weld (in N/mm of weld run). (ii) Suggest a size of the weld leg based on your findings assuming that the allowable resultant stress on the throat of the weld is 0.33 x the ultimate strength of the weld material, and that the weld material has an ultimate strength of 375 MPa.

91,000 N

320 mm

160mm

300 mm

The following formulas are provided, as are geometry factors for weld analysis on page 5: Loading type Direct Shear Force per mm run of weld
V Shear Force = L Aw V Normal Force = L Aw V T. r = L Jw V = L M Zw

Normal Force

Torque

Bending Moment

Weld dimensions

Bending

Torsion

Weld geometry factors. Source: Robert L Mott Machine Elements in Mechanical Design