Question 1 [5 marks]

a) Describe with the aid of simple sketches in your answer booklet, what 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 (other shafts may exist inside the gearbox).
b) Calculate the gear ratio associated with each gearbox.

spur/helical 100/40 = 2.5

i) spur/helical ii)
100/60 = 1.67

ωi = 100 RPM ωi = 100 RPM

ωo = 60 RPM ωo = 40 RPM

iii) 100/100 = 1 iv) Bevel Gears

bevel
100/100 = 1

ωo = 100 RPM ωi = 100 RPM

ωi = 100 RPM
ωo = 100 RPM

v) spur vi) bevel

1200/100 =12
100/48 = 2.08

ωo = 100 RPM
ωi = 100
RPM

ωi = 1200 RPM ωo = 4RPM

 Question 2 [12 marks]
BEARING DESIGN
a) What is the probability of survival (i.e. percentage of non-failed bearings) for a L10 life?
The L-10 life is defined as 90% probability of survival when subjected to the boundary conditions
b) What is a separable bearing?
The bearing of which sub component can be separated.
c) Briefly explain why a bearing with a cylindrical roller generally has a greater load bearing
capacity than a bearing with a ball rolling element.
cylindrical roller include thrust collars, parallel or tapered bore and lubrication holes and grooves. This type of bearings feature high
radial load capacity as the rollers and raceway are in linear contaclow-friction
d) In a hydrodynamically lubricated bearing what is meant by the term embedability?
ability to “capture” contaminant materials to avoid damage
BELT/CHAIN DESIGN
The following questions are based on a belt selection chart (below) presented in lectures based on
Australian Standards 2784.

e) Arrow “A” indicates that for increasing transmitted power the belt size should generally
increase; why does the belt size generally increase as power increases?

f) Arrow “B” indicates that for increasing shaft speed the belt size should generally decrease;
why does the belt size generally decrease as shaft speed increases?

MOTOR SELECTION
g) What is the meaning of locked rotor torque?
is the torque an electrical motor develops when starting at zero speed
h) Provide an example of a design scenario that is suited to a NEMA D electric motor.
suited for equipment with very high inertia starts - like cranes, hoists etc.
CLUTCH / BRAKE DESIGN
i) What is the technical difference between a clutch and a brake?
A brake decelerates a system by transferring power from it. A clutch both accelerates and decelerates a system by transferring
power to/from it
j) Is an assumption of constant pressure, or constant wear more appropriate for a brand new
(unused) clutch.
Constant wear is more realistic
SHAFT DESIGN
k) AS 1403 provides design equations for calculating shaft diameter; are these equations
based on Von-Mises or Tresca failure criteria?
Von-Mises, to check whether the design will withstand a given load condition
l) AS 1403 requires that steel be used and does not allow the use of aluminium. What property of
aluminium makes it undesirable for shaft design?
Because of its endurance limit
m) Table 2 from AS 1403 is provided below. What is the meaning of the term FS in Table 2?
endurance limit
n) Table 2 from AS 1403 is provided below. From Table 2, which of the Formulas use Yield
Strength (rather than endurance limit) as the failure criterion?
Formula no 1

GEAR DESIGN
o) Fill in the blanks in the following statement of the law of gearing.

“The common normal to the tooth profiles at the point of contact must always pass
through ___________________
a fixed point (the pitch point) on the line of _______.”
centers

p) In the following image showing the terminology used for tooth definition, four terms
(A,B,C and D) are hidden. What are the terms A, B, C and D?

top land

face

flank

bottom land
DE-MOUNTABLE CONNECTOR DESIGN
q) What is the name given to describe a joint where the screws clamp the plates together so firmly
that load is transferred without any direct shear being applied to the screws?
tensile joint force
r) A spline is often used to allow shaft translation. What is the failure mode of such a spline (i.e.
what design rule do we use to ensure the spline functions correctly)?
need to be to avoid failure by shear
s) Name one advantage and one disadvantage of connecting two shafts with a flexible coupling.
To provide for misalignment of the shafts or to introduce mechanical flexibility.
To reduce the transmission of shock loads from one shaft to another.
To introduce protection against overloads.

Speed limited due to difficulties in maintaining balancing requirements

Requires lubrication
Limited allowable axial displacement
 Question 3 [9 marks]

The initial stages of a gear design are complete with the following data given:
Npinion = 17 teeth
Ngear = 68 teeth
ωpinion = 1750 RPM
m = 6 mm
Tpinion = 75Nm
Km = 2.2
Ko = 1.75

Pd = m*Np With reference to the design charts and tables below answer the following questions
= 6*17 a). Does the design provide a hunting tooth ratio? yes because they don't have the common prime factorial to
= 102mm b). What is the pitch diameter of the pinion? their tooth counts.

Kv = 1.8 c). What is the approximate worst-case value of the velocity factor Kv for the pinion if the pinion is
“Precision, shaved and ground”?
J = 0.29 d). What is the (AGMA) geometry factor, J, for the pinion for 20 degree full depth teeth?
p= Ft*r e). What is the value of Ft?
= 1470.5N f). A reasonable estimate of the bending strength (St) of a high carbon nickel chromium vanadium
steel (such as 4130) is 700MPa. If we make the pinion from 4130 steel what minimum face width b
do we require to avoid fatigue failure due to bending?

BENDING STRESS
700000000 = (1470.5/b*0.006*0.29) = 2.2*1.75
b= 4.6mm
Question 4 [9 marks] IF YOU COMPLETE THIS QUESTION, YOU SHOULD NOT
COMPLETE QUESTION 5.

A 600mm radius brake drum contacts a short shoe, as shown below, and sustains a braking torque
of 550Nm. For a co-efficient of friction of 0.25 determine:

(a) The total normal force, N, on the shoe required to achieve the braking torque.
T=N*f*R 550 = 0.25 * N * 0.2 N = 3666.7 N
(b) The force required, W, to apply the brake when the rotation is in the clockwise direction?
(N * 0.8 )=(2.2*w)+(f*N * 0.08) (3666.7*0.8)=(2.2w)+(916.6*0.08) w= 1300N
(c) The required force, W, to apply the brake when the rotation is in the counter-clockwise
direction?
(2.2*w) =(N * 0.8 )+(f*N * 0.08)=0 (2.2w)=(3666.7*0.8)+(916.6*0.08) w=1366.67 N
(d) A revised dimension “x” required to make the brake self-locking, assuming all other
dimensions remain as shown. In which rotational direction of the drum is self-locking achievable,
i.e. W = 0 ?
self locking is advisable on clockwise direction.therefor when w=0
(N * 0.8 )=(2.2*w)+(f*N * x)
(3666.7*0.8)=(0)+(916.6*x)
x=3.2 m

W
Question 5 [9 marks] IF YOU COMPLETE THIS QUESTION, YOU SHOULD NOT
COMPLETE QUESTION 4.

Four M12 (i.e 12mm diameter) bolts secure the flanges of a rigid coupling to each other. The bolts
are on a pitch circle of 100 mm diameter. The threaded portion of the bolts does not traverse the
interface between the flanges.

a) Determine the maximum torque the coupling may transmit if the maximum permitted value
of shear stress in the bolt material is 80 MPa.
Tr
For bolt groups experiencing torsional shear loading  2
(A r )
b) Discuss with the aid of sketches at least four failure modes that a designer should consider
when determining the necessary proportions of the bolts and flange geometry.