FINAL Test Engineering - Design - 80 Points in total-which count for 40% of your grade!

Instructor: Prof. Dr.-Ing. Karl H GROTE

Name:
Student number:

PART I - estimated time needed to answer all questions: 60 Minutes

( 2 Points for each correct answer = 50 points)

1. The following design of a pipe for hot water needs improvement – why and what do you suggest
as improvement?

2. The following design of a shaft hub connection needs a design change? What do you suggest?

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3. The following bolted joint has the “standard” nut – with all the imperfections. How do you improve
the design for a better carrying capacity?

4. What is the disadvantage of the following self - helping solution of a pipe end?

5. The engineer used two different bearings in the following design – for what reason?

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6. Why did the engineer use hollow shafts on this very heavy duty transmission – support your
answer with one single equation?

7. Improve the design of this V-belt

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8. Why can this rim (and most rims today) be used with tubeless tires, as in this figure?

9. The following figure shows a multiple V-belt arrangement. Is this design good? Support your
answer with reason(s).

10. The engineer had good intentions, selecting this solution for a shaft-hub connection. Why did it
turn into a bad design?

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11. The following figure shows a bearing arrangement. Why would you improve what?

12. The following combined axial / radial needle/ball bearing carries axial and radial load. What makes
it a design, open for improvement?

13. The following rotor blade attachment for a helicopter is a thorough and good design, capable to
carry the applied loads. Which loads carry the machine elements Z and B and what is the major
equation for each, which supports the selected solution?

14. The drive shaft of a crane drive is o.k. – why would you improve it and how?

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15. The bracket (2) is brazed or glued to the wall (1) – resulting is an uneven stress distribution in the
adhesive or the filler material. What is the easy fix using the same attachment method ?

16. u. 17. The figure shows two designs of flexible couplings. Both have an overload protection,
included in the design. How does that work for design a, and design b, based on what kind of
stress?

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18. The following bolted joint is used in an environment, exposed to rather high temperatures, which
causes the bolt to fail. Why does it fail and how can you prevent a failure with an improvement of
the design ?

19. A high-pressure vessel has a riveted cap one end and a bolted cap on the other. Indicate where you
would place the bolts and rivets, and explain your rationale.

D > 200 mm

pressure p = 50 bar
max

20. The following figure shows four designs, two proposed solutions each ( left and right), which are
cast. Would you select the design on the left or on the right for your application? (Cross out the
wrong design!)

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21. The following figure shows components, which are made by bending out of sheet metal. Again,
would you select the design on the right side or the one on the left side as favorable for the
manufacturing process? (Cross out the wrong designs!)

22. What is the difference between a fastener and a power (lead) screw? (0.5 points)

23. Would you weld, braze or glue the following pipes together for maximal carrying capacity? [0.5 points]

Copper
Zinc

24. Sketch the stress distribution in the given shaft for a stress- concentration factor of 2.
Try to sketch to scale!

F= constant F= constant

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25. Complete the following:

a) Indicate in the given diagram the

1. elastic limit
2. yield point
3. ultimate strength
4. rupture point

σ
stress

strain ε

c) In a single diagram, sketch the stress-strain curves for

a. ductile steel
b. brittle steel
c. plastics

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PART II - estimated time to answer all questions: 20 Minutes
1 points for each correct answer = 10 points in total

Part II is multiple choice. There may be 0, 1, or more correct answer(s) to each.

1. A fastener has a helix angle of

a) less than 3 degrees
b) more than 3 degrees
c) exact 3 degrees

2. A power screw has a helix angle of

a) more than 15 degrees
b) less than 15 degrees
c) exactly 15 degrees

3. A bolt quality of 5.6 means:

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a) Yield point is 300 N/mm
2
b) Yield point is 500 N/mm
2
c) Yield point is 600 N/mm

4. The best approach to locking a bolt in place (and prevent loss of preload) is:
a) A high preload
b) A split washer
c) A low preload
d) A lock – pin

5. How can you increase the resilience of a bolt?

a) increase the length
b) increase the elastic modulus (Young’s modulus)
c) increase the cross section
d) can not be done at all

6. By increasing the resilience of a bolt

a) the fatigue limit is enhanced
b) the fatigue limit is reduced
c) the fatigue limit stays constant

7. Is it useful for the fatigue life of the bolt to change any of the following, assuming that nothing else is
changed about the design?
a) increase the stiffness of the flange (parts)
b) decrease the stiffness of the flange (parts)
c) does not matter

8. If you machine a standard bolt down to get a necked down bolt for a bolted joint you will:
a) decrease the stress in the bolt with the same load
b) increase the fatigue life of the bolt for the same load
c) nothing will change with the same load

9. A bolted joint carries the radial load (e.g. from a torque) in a pre-loaded joint by:
a) friction force in the parting line of the joint
b) the cross section of the bolt, subject to shear stress (shear bolt)
c) normal stress in the bolt
d) shearing stress in the bolt

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10. The most exact method to tighten a bolt is:
a) yield point controlled tightening process
b) torque controlled tightening process
c) just by hand with a wrench
d) by hand with a torque wrench

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PART III : Estimated time to answer all questions: 40 Minutes (20 points in total plus 10 EXTRA!)
SOVLE PROBELM 3 OR 4 , OR BOTH for extra points to make up deficiencies in other problems!

1. ( 5 points) The sketch below shows a resilient coupling, with a rubber spring as dampener and a
connector.
- Where is the maximum stress in/on the rubber for an input torque Mt?
- How do you calculate this stress?
- Qualitatively redesign the shape of the rubber spring so that there is constant stress across it.

2. ( 5 points) In the sketch below, the bottom member is of uniform cross section and can be assumed to
be rigid. In order for the bottom member to be horizontal, what must the diameter of the steel rod be?

Aluminum rod steel rod

diameter d=10 mm diameter = ?
l = 5000 mm

500 mm
100 mm

rigid bottom member W

1000 mm

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3. (10 points) A flywheel with a mass of 30 kg is supported by on each side by a bearing block. Due to
poor manufacturing tolerances, the flywheel is not balanced and its center of gravity S is located 4 mm
from the center of the shaft that it is mounted to. The speed of the shaft is n = 1200 rev/min and the
friction coefficient between frame and bearing block is µ = 0.2. The imbalance is distributed equally
over the four fasteners of the two bearing blocks. ( alpha = turn angle!)

Calculate:
• The bolt preload necessary to keep the bearing blocks
from moving radially, as may happen when the shaft is
misaligned. Consider a safety factor against motion of SF
= 1.5. Assume that motion may occur at alpha = 90° and
alpha = 270°.
• The clamping force FR (or FK) needed to prevent the
bearing blocks from lifting off or moving. Assume that the
resilience of the flange is 1/5 of the resilience of the bolt.
(Resilience = 1/ stiffness!!, ) That is, the flange is 5 times
as stiff as the bolt. Again, assume alpha = 90° and
alpha = 270°.
• Make a sketch of the bolt-triangle and include the centrifugal force as external load .
•

Flywheel of
α mass m= 30 kg.

S
S

µ = 0.2
µ = 0.2

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4. (10 Points) Compare the service life of the ball bearings of a friction drive and a gear drive at both the
input and output shafts. In both cases, the power transmitted is P = 20 kW, the input speed is n1 = 1000
rev/min and the output speed is n2 = 500 rev/min. Use standard-sized gears with a = 20° (pressure
angle). The friction coefficient is m = 0.5. Neglect the forces due to weight, and assume the same
dimensions and layout (e.g. center distance of the shafts) for both transmissions.

d = 50 mm
1

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