AUTOMOBILE COMPONENT DESIGN II (PRACTICAL QUESTIONS)

1. A helical coil compression spring is needed for food service machinery. The load varies from a minimum of
20 N to a maximum of 90 N. The spring rate k is to be 1660 N/m. The outside diameter of the spring cannot
exceed 62 mm. The springmaker has available suitable dies for drawing 2-, 2.3-, 2.6- and 3- diameter wire.
Using a fatigue design factor nf of 1.5, and the Gerber-Zimmerli fatigue-failure criterion, design a suitable
spring.

2. A screw clamp similar to the one shown in the figure 1 has a handle with diameter of 10 mm made of cold-
drawn AISI 1006 steel. The overall length is 108 mm, but the force will be applied to the handle at a radius
of 90 mm from the screw centerline. The screw is M20 X 2.5 mm acme thread and 203 mm long, overall.
Distance A is 75 mm. The clamp will accommodate parts up to 150 mm high. [Take E=207 GPa.]
(a) What screw torque will cause the handle to bend permanently?
(b) What clamping force will the answer to part (a) cause if the collar friction is neglected and if the thread
friction is 0.15?
(c) What clamping force will cause the screw to buckle?
(d) Are there any other stresses or possible failures to be checked?
3. The shoes on the brake depicted in the figure 2 subtend a 90° arc on the drum of this external pivoted-shoe
brake. The actuation force P is applied to the lever. The rotation direction of the drum is counterclockwise,
and the coefficient of friction is 0.30.
a) What should the dimension e be?
b) Draw the free-body diagrams of the handle lever and both shoe levers, with forces expressed in
terms of the actuation force P.
c) Does the direction of rotation of the drum affect the braking torque?
d) If a rigid molded non-asbestos lining (coefficient of friction, f = 0.33 and maximum pressure, pmax =
0.7 MPa) is used dry in the brake on a cast iron drum. The shoes are 190 mm wide and subtend a 90°
arc. Find the maximum allowable actuation force and the braking torque.

All dimensions are in mm.

Figure 1 Figure 2
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