MECH 3003.

Gear design and mechanical stress analysis

1. Produce a hand-written report. Systematic and numerically accurate solutions is expected.

2. Approach the tutor and discuss your solutions.

3. The report must be submitted on Ilearn as a record of your attendance.

1. Analyse the force in the members of the following truss system. Design a suitable cross
section of the members based on the general dimensions of the frame and suggest an appropriate
material suitable for the structure. Suggest and describe a suitable method to connect the
members.

2. Analyse the force in the members of the following truss system. Set F = 800j. Design a
suitable cross section of the members based on the general dimensions of the frame and suggest
an appropriate material suitable for the structure.
3. A gearbox is needed to provide an exact 28:1 increase in speed, while minimizing the
overall gearbox size. The input and output shafts should be in-line. Specify appropriate teeth
numbers.

4. Determine the absolute maximum bending stress in the tubular shaft if di = 160 mm and
do = 200 mm.
MECH 3003.
Shaft design
1. Produce a hand-written report. Systematic and numerically accurate solutions is
expected.

2. Approach the tutor and discuss about your solutions.

3. The report must be submitted on Ilearn as a record of your attendance.

The figure below shows a steel shaft (800mm long). A pulley (15kg) is attached at the
centre of the shaft. The shaft is supported by two bearings located at 100mm away
from the ends of the shaft. The belt tension is 50N and it is acting in the z- direction.
Assume Sut (steel) = 50 GPa.

a.) Design a suitable shaft for this application. Specify the steps clearly and show how
you determine the diameters of the shaft. Make assumptions of the modification
factors whenever appropriate and optimise the design of your shaft.

b.) Produce a manufacturing drawing of the shaft. Consider the appropriateness of the
shoulders and mechanisms to prevent the components from falling off the shaft. Make
sure that the mechanisms that you implement enables ease of assembly.

Bearing Bearing

600 mm 100 mm
100 mm
MECH 3003
Belt drive system
1. Produce a hand-written report. Systematic and numerically accurate solutions is
expected.

2. Approach the tutor and discuss your solutions.

3. The report must be submitted on Ilearn as a record of your attendance.

A belt drive is required to transmit power and achieve a speed reduction ratio of
3:1. The input power to the belt system is 7 kW, and the belt drive is known to be
subjected to light shock load. The motor that supplies power to the belt drive has
normal torque characteristics and is running at 800rpm. The minimum centre distance
between the belt drive must be greater than 400mm but less than 1000mm. You are
required to manufacture one of the pulleys.

i) Design a suitable belt drive system suitable for the application stating clearly the size
of pulleys, number of belts and belt type. Optimise your design using the excel
spreadsheet which you have developed during your lecture.

ii) Design (and analyse) the mechanisms to attach the pulleys to rotating shafts and
suggest appropriate material for them. Provide detailed calculation and explanation
for your design.

iii) Present a detailed manufacturing drawing of your driven pulley. Consider the
mechanisms to lock the pulley on the shaft.
MECH 3003.
Chain Drive system
1. Produce a hand-written report. Systematic and numerically accurate solutions is
expected.

2. Approach the tutor and discuss about your solutions.

3. The report must be submitted on Ilearn as a record of your attendance.

The chain drive system is to transmit power over a distance (centre distance between
sprockets) of less than 1 m and to achieve a speed reduction ratio of 1:3. The input
power for the chain drive is supplied by a motor that produces 30 kW of power and
turns at a revolution of 1200 rpm.

a.) Design a suitable chain drive system suitable for the application stating clearly all
the important design parameters. Optimise the design using the Excel
spreadsheet which you generated during the lecture.

b.) Design a chain guard for the system and produce a manufacturing drawing for it.
Dimensions of your chain guard can be approximated from the centre to centre
distance of the chain sprockets and layout of the chain drive system as shown in
the figure below. All components in the figure are to be secured on a wooden table.
Plan out your design carefully and consider ease of assembly and maintenance.

Chain drive system

Motor Machine Machine

MECH 3003.
Bearing selection and design
1. Produce a hand-written report. Systematic and numerically accurate solutions is
expected.

2. Approach the tutor and discuss about your solutions.

3. The report must be submitted on Ilearn as a record of your attendance.

The figure below shows a steel shaft (800mm long). A pulley (15kg) is attached at
the centre of the shaft. The shaft is supported by two bearings located at 100mm
away from the ends of the shaft. The belt tension is 50N and it is acting in the z-
direction. Assume Sut (steel) = 50 GPa.

a.) Design and select a suitable pair of bearings for this application. Specify the
steps clearly and show how you choose the bearings. The inner ring of the bearing
needs to run for at least 3000 million cycles.

b.) Design a suitable housing for the bearings and proposed a suitable place where it
can be mounted. Produce a manufacturing drawing for the bearing housing.
Consider carefully how the bearing is to be installed and other detailed design
features of the bearing housing such as seals, and features to enable maintenance
including lubrication of the bearings.

Bearing Bearing

600 mm 100 mm
100 mm

Marking rubrics
Grade Bearing calculations and Manufacturing drawing
analysis
HD Demonstrate systematic Perfect manufacturing
and accurate analysis of drawings based on
bearing parameters industrial standards.
requirements
CR 1 or more calculation error 1 - 2 errors spotted in
but design outcome is still manufacturing drawings.
feasible.
P Design calculations 3 or more errors spotted in
resulting in borderline manufacturing drawings.
feasibility of bearings
selected from catalogue.