MECG1022: Design Project #1

2018-II Due on: November 28, 2018

Design of an Overhanging Countershaft

A countershaft is to be designed to transmit a

power of 105 hp at 2000 rpm. On this shaft, the
overhanging pulley B has a diameter 400 mm at
one end to receive power from a motor
producing belt tensions. Assume V-belt with an
appropriate tension ratio. Due to the constraints
of space and equipment arrangement, this pulley
needs to overhang from the support, as shown in
the figure. The pinion A, having 24 teeth with a
diametral pitch of 10, receives power input from
the shaft to drive gear Q and is installed
between the two bearing supports, as shown in
the figure. The suggested arrangement and
dimensions are shown.

Design consideration and requirements:

(1) Roller bearings are used at all supports; hence, the slope of the countershaft at the
bearings O and R should not exceed 0.06˚ for good bearing life.
(2) An axial load of P=600 N is applied at A due to the arrangement of the system, as
indicated in the figure.
(3) Consider the bending and torsion of the countershaft.
(4) The surface of the shaft is cold-drawn and machined.
(5) The temperature of the room in which this shaft operates can reach as high as 75˚C.
(6) AISI 1018 cold-drawn steel is available for this design. Other low carbon steel
materials in stock sizes are also available for the design.
(7) Fatigue failure must be considered based on the stresses of fluctuating loads, as
discussed in the handouts. Different criteria of fatigue failure can be considered and
compared.
(8) Estimated weight of the overhanging pulley is approximately 7 kg.
(9) The critical rotating speed must be considered for this design.
(10) Use a design factor of safety N =1.85.

Employ the methodology you learned to design for the required diameter(s) of the
countershaft. Clearly state all your assumptions when solving this problem. Discuss if your
design is practical. If yes, present your results; if not, explain how you would change the
parameters so that a more feasible design can be found. Iteration and verification of the
outcomes of the design against your initial assumptions are expected. You must present the
final design which meets all requirements above, as well as the design process and iteration
of design parameters clearly.

A formal written report is required. (See the handout on the Format of Project Reports.) The
grading of your individual report will be based on the rubrics (also see handout).
 MECG1022 Handout: Format of Project Reports
2018-II C.G. Helguero

About the reports of MECG1022 design projects:

All design projects are organized on individual basis. Interactions with the instructor for
directions and design criteria are suggested. Though discussions are encouraged among
peers, report writing is strictly an individual group effort. If two students are found to be
identical, both will receive no credit and will be reported to the appropriate judicial
committee.
A formal written report is due on the date noted in the handout for each project assignment.
The main body of the report should not exceed four pages in a type font no smaller than 11
point. Reports of more than 4 pages (not including the title page, table of content, and
appendices) or with a type font smaller than 11 point will be receive no credit in the
corresponding section of the grading rubrics. It is your responsibility to spell-check the
report. Points will be taken off poorly written and unorganized reports. The details of
derivation and calculation can be arranged in Appendix, which has no page limits. The main
body of the report must be typed; whereas, the appendices can be typed or legibly
handwritten, as appropriate. Your report should include the following:
(i) Title page: name, date, project number, ... etc. (1 page; see the sample)
(ii) Table of contents
(iii) Main body of the report (limited to a total of four pages)
(a) objectives and introduction
(b) design criteria and assumptions
(c) design procedures and descriptions with abridged derivations
(d) results and discussions
(e) conclusions and recommendations
(iv) Appendix (no page limit)
you must include in appendix detailed calculations and derivations of equations or
formulas, and any other necessary information not appropriate in the main body of the
report. Reference the sections or pages of appendix in the main body of the report.

Grading is based on the attached “Grading Rubrics” and the score of your report will be the
sum of all categories in the rubrics. Read it thoroughly and write your report accordingly.
(Sample of Title Page)

MECG1022 Design Project Report

Title of the Design Project

Date: Month Day, Year

Name: Name
Design Project No.: n
Instructor: Professor Carlos Gabriel Helguero

Mechanical Engineering Faculty

ESPOL
 Design Project Report Grading Rubric
The Grading Rubrics for the Written Report of the MEC410 Design Projects
! Excellent
Organization The required Title page, Table of
(Weight: 4.0) contents, Main body of the report, and
Appendix are arranged in a logical
order to help readers locate
information. The “Main body of the
report” does not exceed four pages.
The Appendix is organized and
referenced in the main text.
5 4
Objectives The objectives provide a concise
and description of the design project. The
Introduction introduction provides complete details
(Weight: 1.0) on the design project. The reader is left
with a clear, complete, and thorough
understanding of the objectives.
5 4
Design The criteria used in design are clearly
Criteria & presented, with reasonable assumptions
Assumptions accompanied by explanation. Limitations
(Weight: 2.0) of the assumption and design criteria are
discussed, as appropriate.
5 4
Design The design procedures are clearly
Procedures presented in logical steps with clarify.
and The design criteria are explained clearly
descriptions in each step of the procedures. The reader
with is left with a clear, complete, and
abridged thorough understanding of the design,
derivations including the derivation and/or
(Weight: 6.0) application of equations employed in the
design procedures. Details of algebra and
calculations are organized in the
Appendix, as appropriate, with reference.
5 4
! 1!
Good
The required sections are generally in
place, but certain information is
missing. Furthermore, there are issues
with the organization of information
that will result in some confusion for
the reader.
3 2
The objectives are present, and contain
a partial introduction of the design
project, but necessary details are
missing or only vaguely addressed. The
objectives of the design tend to be very
general, lacking development.
3 2
The criteria used in design are
presented, but some details are missing
or lack clarity. The assumptions are
not reasonable, and are not explained.
3 2
The design procedures are presented,
but are not easy to follow with some
details missing or lacking clarity. The
design criteria are explained, but not
clear enough in each step of the
procedures. Only some details of
calculation are provided in the
Appendix. The readers have to search
to obtain information. Some equations
used are incorrect without justification.
3 2
Needs Improvement Possible Score
The “Main body of the report” 20 !
exceeds four pages. Report is poorly
organized, with information very
difficult to locate for the readers.
1 0
The objectives are not effective, are 5 !
incomplete, or lack content. There is
no real introduction or the
introduction is ineffective and/or
incomplete to the point of being
devoid of significant content.
1 0
No statement of the design criteria is 10 !
provided. No assumption pertaining
to the design, with explanation, is
provided.
1 0
No procedure of the design is 30 !
provided, neither is the description of
the design. The reader is left with
confusion and bewilderment of the
design. Equations and methodology
employed for the design are incorrect,
and poorly organized. No detail of
calculation is provided in the
Appendix, as appropriate, with
reference.
1 0
 Results and The results of the design are summarized The results of the design are not The results of the design are not 15 !
Discussions with discussion providing a clearly summarized. The discussion is summarized. The discussion is
With mathematical justification of the results. provided, but lacks sufficient details, lacking, without explanations of the
Conclusions The conclusions are clear, concise, and without a mathematical justification. results. Conclusions are not clear,
and effectively summarize the results of the The conclusions are clear and and do not effectively summarize
recommen- experiment. Proper recommendations are concise, but miss key points. the results. Recommendations are
dations also provided with explanation, as Recommendation are made, but not not provided, or are not well
(Weight: 3.0) appropriate. always well developed. thought out.
5 4 3 2 1 0
Citation and All appropriate external resources (e.g., Most external resources (e.g., the Attempt was made at citation, but 20 !
Reference the textbook or instructor’s handouts, textbook or instructor’s handouts, external resources (e.g., the textbook
& books, journals, etc.) are cited as books, journals, etc.) are cited as or instructor’s handouts, books,
Appendix reference using a professional and reference, but a professional and journals, etc.) are not cited
(Weight: 4.0) complete format (MLA, ASME, ETC.). complete format is not used effectively. No Appendix for the
All information needed to find the consistently. All information needed to details of calculations leaves the
reference is included in Appendix, and find the reference is included in reader with no trace of information
is easy to find and reference. The areas Appendix, but not in a clear manner and calculations of the report.
in the text attributed to relevant which makes location of the source
reference are clearly marked as such. straightforward.
5 4 3 2 1 0
Total 100 !
Note: if no citations and no attempt at citations are made, the design project report
grade will be automatically set to 0. This supersedes all the grading criteria in this
rubrics. Failure to submit a written report results in an automatic grade of zero.
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