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Examination for the Degree of Bachelor of Engineering Semester 1, 2007 MECHENG 2018 DESIGN PRACTICE

Official Reading Time: 10 mins Writing Time: 180 mins Total Duration: 190 mins Questions Answer all three questions Marks 20 marks each 60 Total

Instructions for Candidates Answer all THREE questions. Begin each answer on a new page. Examination materials must not be removed from the examination room.

Permitted Materials Open-book Notes and textbooks permitted Calculator without remote communications capability permitted Graphics calculator permitted

DO NOT COMMENCE WRITING UNTIL INSTRUCTED TO DO SO

Course ID: MECH ENG 2018

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Q.1. a) Briefly explain how reactive torque tensioning works in a flat belt drive. (3 Marks) b) A band brake operates on a drum 610 mm in diameter running at steady speed of 240 rpm. The wrap angle of the brake band on the drum is 270. Under these conditions the brake must be able to stop the system of a three-phase 15 kW motor driving an average inertia generator. The band friction material has a friction coefficient of 0.3 under operating conditions. The maximum allowable contact pressure of the friction material is 345 kPa, and the value of pV power rating must not exceed 2.84 MPa m/s. i) Calculate required braking torque. (3 marks) ii) Calculate maximum tension in the band. (8 marks) iii) Determine a suitable width for the friction lining on the brake band and check if power rating of the brake is within limits. (6 marks)

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Course ID: MECH ENG 2018 Q.2. a)

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Explain why, and under what circumstances, the bearing angular length () of a hydrodynamically lubricated bearing can be less than 360. (3 marks) A 28 tooth spur gear pinion mounted on a shaft has a module of 3 mm and a tooth pressure angle of 20. The pinion shaft is driven by a directcoupled 1440 rpm electric motor delivering a power of 10 kW. The pinion shaft is supported in two oil film bearings located 50 mm and 150 mm respectively from the pinion (see Figure 1). i) ii) Calculate bearing loads. (8 marks) Select appropriate minimum diameters, length and diametral clearances for the two bearings. (6 marks) iii) There is a need to limit the range of bearing sizes required to be held as spares, and a need to minimise shaft deflection under loading. Select final bearing dimensions to take into account these requirements. (3 Marks)

b)

Figure 1. Gear shaft schematic layout (dimensions in mm).

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Course ID: MECH ENG 2018 Q.3.

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Figure 2 shows the general layout of the shaft for a large circular saw in a wood mill. The shaft is driven by a flat belt and pulley (at the right hand end of the drawing) and the saw blade is mounted between clamping discs on the opposite end of the shaft. The input power to the shaft is 20 kW and the shaft speed is 6000 rev/min. The shaft diameter at the pulley is 45 mm and at the saw blade is 40 mm. The maximum shaft diameter is to be 60 mm. The minimum inside diameter of the housing is 80 mm. Bearing radial loads are not high; at bearing location A the load is about 2 kN, and at bearing location B it is about 0.6 kN a) Deep groove ball bearings have been selected for this application at both locations A and B. Is it a good choice? Provide brief explanation. (6 Marks) b) Show how you would locate these bearings on the shaft and in the housing (provide a sketch of the complete assembly). (8 Marks) (Note: Figure 2 shows the nominal shaft and housing sizes. You may machine these components to suit your design. Your design should include features to react the loads from the blade clamping discs and pulley clamping plate.) c) Specify a suitable form of lubrication and method for sealing. (6 Marks)

Figure 2. Shaft for circular saw.

END OF EXAMINATION PAPER