INTERNATIONAL ISLAMIC UNIVERSITY MALAYSIA

END-OF-SEMESTER EXAMINATION SEMESTER I, 2009/2010 SESSION KULLIYYAH OF ENGINEERING

Programme Time Duration Course Code Course Title : MECHATRONICS ENGINEERING : 2:30 pm 05:30 pm : 3 Hrs : MCT 3214 : Design of Machine Elements Section(s) :1 Level of Study : UG 3 Date : 14 November 2009

This Question Paper Consists of 6 (Six) Printed Pages (Including Cover Page) With 6 (Six) Questions. INSTRUCTION(S) TO CANDIDATES DO NOT OPEN UNTIL YOU ARE ASKED TO DO SO
There are two sections, answer ALL Questions from Section A and ONLY TWO Questions from Section B. Booklets contain necessary equations, tables, and figures will be supplied in examination hall. Assume reasonable value(s) in the case of missing data.

Any form of cheating or attempt to cheat is a serious offence which may lead to dismissal.
Reviewers : Assoc. Prof. Dr. Md. Raisuddin Khan Assit. Prof. Dr. Asan Gani Assoc. Prof. Dr. Wahyudi Martono Head of the Department

Approved by :

Design of Machine Elements SECTION A: Answer ALL QUESTIONS from this Section Q1. [20 marks] (a) i) Sketch and label the typical stress-strain diagrams for both ductile and brittle material. ii) Discuss the difference between these two types of materials with the help of above diagrams. (b) Member A shown in Fig. 1 is a 13-mm-diameter aluminum bar; member B is an 8-mm-diameter steel bar. The lower member is of uniform cross section and is assumed to be rigid. Find the distance x if the lower member is to remain horizontal. Assume that the modulus of elasticity for steel is three times that for aluminum.

MCT 3214

(4 marks) (3 marks)

(7 marks)

Fig. 1 (c) Draw the shear force and bending moment diagrams of the simply supported bar shown in Fig. 2, with w0 = 5 kN/m and l = 15 m. (6 marks)

Fig. 2

Design of Machine Elements Q2. [20 marks] (a) The shaft shown in Fig. 3 rotates at 1000 rpm and transfers 6 kW of power from input gear A to output gears B and C. The spur gears A and C have pressure angles of 200. The helical gear B has a pressure angle of 200 and a helix angle of 300 and transfers 70% of the input power. All important surfaces are ground. All dimensions are in mm. The shaft is made of annealed carbon steel with Sut = 636 MPa and Sy = 365 MPa. (a) Draw the shear and moment diagrams of the shaft. (b) Determine the minimum shaft diameter for a safety factor of 2 and 99% reliability.

MCT 3214

Fig. 3

Q3. [20 marks] (a) Using Mohrs circle, determine the principal planes and the principal stresses for (12marks) the stress state of x = -10 MPa, y = 20 MPa, and xy = 20 MPa. Also find the stress components exerted on the element obtained by rotating the given element counterclockwise through 30 degrees. Sketch all the stress elements. (b) A rectangular-cross-section tube is axially loaded in compression. The tubes outside dimensions are 70 and 90 mm, it is 3 m long with both ends pinned; the wall thickness is 9 mm. The column is made of AISI 1020 steel. Find the critical buckling load. (8 marks)

Design of Machine Elements SECTION B: Answer any TWO QUESTIONS from this Section

MCT 3214

Q4. [20 marks] (a) In Fig. 5 the tension on the slack side of the left pulley is 20% of that on the tight (8 marks) side. The shaft rotates at 720 rpm. Select a pair of roller bearings to support the shaft for 99% reliability and a life of 24,000 hours. All length dimensions are in millimeters.

Fig. 5 (b) Two commercial enclosed gears (Grade 1 with Brinell Hardness of 300HB each, (12 marks) 200 pressure angle) are in contact. The pinion has 12 teeth with a module of 3 mm and the gear has 48 teeth. The pinion speed is 4000 rpm and 2.2 kW is transmitted. The gears are manufactured to a quality standard of Qv=7 and have a face width of 18 mm. The electric power source is uniform, but the machine loading results in occasional light shock. Find the safety factor against failure due to excessive bending stresses. Q5. [20 marks] (a) Two 1 in, 619 plow-steel wire ropes are used to haul mining material to a depth (10marks) of 365 ft at a speed of 25 ft/s and an acceleration of 3 ft/s2. The diameter of the pulley is 32 in. Using a proper safety factor, determine the maximum hauling loads for these ropes.

Design of Machine Elements

MCT 3214

(b) A helical compression spring has 14 active coils, a free length of 1.25 in, and an (10marks) 7 outside diameter of 16 in. The ends of the spring are squared and ground and the end plates are constrained to be parallel. The material is music wire with presetting. The wire diameter is fixed at 0.042 in. For static conditions compute the spring rate, the solid length, and the stress when the spring is compressed to the solid length. Will static yielding occur while the spring is brought to its solid length? . Q6. [20 marks] (a) Two Acme-threaded power screws are to be used to raise a heavy access hatch, as shown in Fig. 6. Select a satisfactory screw from Table 16.2 on the basis of tensile strength, limiting the tensile stress to 10,000 psi. Coefficient of friction is 0.15. i) Compute the lead angle, the torque required to raise the load, the efficiency of the screw, and the torque required to lower the load,. (8 marks) ii) If it is desired to raise the hatch a total of 15 inches in no more than 12 sec. Compute the required rotational speed for the screws and the required power. (4 marks)

Fig. 6

Design of Machine Elements

MCT 3214

(b) The band brake shown in Fig. 7 has wrap angle = 2150 and cylinder radius r = 60 mm. (6 marks) (i) Calculate the brake torque when coefficient of friction = 0.25. 2 (ii) What is the braking time from 1500 rpm if the rotor moment of inertia J = 2 kg-m ? (2 marks)

Fig. 7

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