QUESTION 1 (30 marks) Figure 1 shows a structure made of AISI 1050 Normalized steel subject to horizontal forces. F1=500N and F2=200N. = i. Draw the free body diagram (EBD) for the entire structure showing all the forces, moment and torque acting on it. (15 marks) ii. Ifthe vertical round bar is to be made of solid AIS! 1050 Normalized steel, what is the minimum diameter d based on static strength factor of safety n = 2.0. Use Distortion Energy Theory in your calculation. (15 marks) Figure 1 Powered by (3 CamScanner Scanned with CamScannerQUESTION 2 (40 marks) ‘A 2-blade propeller (Figure 2) with adjustable blade angle rotates at a speed of 750 (pm The blade angle can be manually adjusted to create 8 ‘variable axial force of 0 to QeNPe ‘The mass of each blade is 1.2 kg and center of gravity of each blade is 10cm from center. Due to an accident, one of the blades broke, causing imbalance to the propeller. If the gravity can be ignored, answer the following questions. i. Calculate the endurance limit of th alized steel. (10 marks) used by the centrifugal force of e shaft machined from an AISI 1050 norm ii, Calculate the bending stress.at the middle bearing cal The unbalanced propeller (you should refer to “Appendix D2 — Simply supported beam). Determine whether itis static or fatigue stress. (5 marks) ii, Find the stress concentration factor of the shoulder ‘and groove at the middle bearing. ee (8 marks) iv, Calculate the mean and alternating stresses at the middle bearing. (8 marks) v. Using graph, draw the Modified Goodman Line according to scale and tag all the important values of reference. (4 marks) .g at the middle bearing on the graph and Vi. Show the mean and alternating stresses st has infinite life. determine the safety factor and state whether the shat Centrifugal forcdlp = ace) cenlass of the blade,r — distance of CG of the blade to the center 0 \f propeller (6 marks) 7 2b2be le) = 2-AK3 = 23.54) Figure 2 Powered by € CamScanner — Scanned with CamScannerQUESTION 3 (30 marks) ~—Table 1 shows Honda Civic FD 5-speed manual transmission gear ratios. The numbers represent the ratio of engine (input gears) shaft revolution, engine 10 gearbox output (output gears) shaft revolution, nourpue- The input and output gears are illustrated in Figure 3. Mathematically, gear ratio for automotive gearbox is defined as, (1) ‘gear ratio The output shaft of the gearbox is connected to the wheel by a pair of mating gears. The mating gears ratio is defined as the final drive ratio. The final drive ratio is the ratio of gearbox output shaft revolution, mouepue to wheel revolution, nyheei- For example, final drive Tatio of 4.30 indicates that when the gearbox output shaft rotates 4.30 revolutions, the Wheel would have rotated only once. Mathematically, the final drive ratio is defined as, Rourpue (2) final drive ratio = aokest Table 1: Honda Civic FD Gear Ratio Gear transmission Ratio | 3.143 1.871 1.244 O94 | 0.733 Final drive |" 4.30 a] a) || tetiGean nd eda St) Reverse Road wheels ap Teput oars Figure 3: Honda Civic FD Gearbox Illustration (not to scale) Powered by CamScanner Scanned with CamScannerTina Honda Civic FD 1.8-lter engine is capable of delivering a maximum torque of 173.5 Nem ‘at 4300 rpm and a maximum power output of 104.4 kW at 67, rpm which is the maximum rpiTral the engine can withstand without damage. The caf weighs 1200 N and itis fitted with P205/55 R16 89H tires. The tire has a circumference of 1985.2 mm and an outer diameter of 631.9 mm. For the gearbox, all gear pressure angle @ is 20°, module mis 1.25 mm, and their pitch diameters@pre listed in Table 2. e SHn Table 2: Pitch diameters for input and output gears (see Figure 3) La Gear pitch ae Fo er Gear » | diameter (in transmission mm) Finns = GE.4W 5 Loutput | Mba 1 82.50 | 26.25 a 2 72.50 | 38.75 3 63.75 | 51.25, 4 60.00 | 63.75 5 41.25 | 66.25 Final drive 25.00 | 107.5 | +. Honda claims that the maximum speed can be achieved is at he 4” gear. What isthe eevimum ear speed that can be achieved at 4 gear in km/h without damaging the engine? What is the corresponding wheel revolution in rpm? (8 marks) ji, To achieve a good fuel consumption, Honda recommends driving using the highest gear whenever possible because atthe highest gear, the same car speed is achieved at lower engine rpm, thus saving fuel J. Ifa driver drives at 110 km/h using the 5" gear, what is the rpm of the engine? Prove that the engine rpm at the 5" gear is lower than at 4" gear when iii, Ifthe car is driven at the maxi force at the wheel that moves than the weight of the car so that it ean move] Why does the engine feel ‘stronger’ when dri fs the 1* gear instead of using the 5° proof. peed is 110 km/h. Is Honda's fuel saving recommendation true? (10 marks) imum torque using the 1* gear, what is the value of he the car forward? (hint: the force should be much greater (7 marks) iving up a steep hill using low gear such gear? Please explain and give engineering (5 marks) Powered by CamScanner Scanned with CamScanner