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The University of Nottingham
DEPARTMENT OF MECHANICAL, MATERIALS AND MANUFACTURING ENGINEERING
A LEVEL 1 MODULE, SPRING SEMESTER 2012-2013
DESIGN AND MANUFACTURE 1
Time allowed ONE Hour THIRTY Minutes
Candidates may complete the front cover of their answer book and sign their desk card but
must NOT write anything else until the start of the examination period is announced
Answer ONE question from each Section
Only silent, self contained calculators with a Single-Line Display or Dual-Line Display are
permitted in this examination.
Dictionaries are not allowed with one exception. Those whose first language is not English
may use a standard translation dictionary to translate between that language and English
provided that neither language is the subject of this examination. Subject specific translation
dictionaries are not permitted.
No electronic devices capable of storing and retrieving text, including electronic dictionaries,
may be used.
DO NOT turn examination paper over until instructed to do so
ADDITIONAL MATERIAL: None
INFORMATION FOR INVIGILATORS: None
Turn Over
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Section A
1.
(a) The following types of lubrication types are available:
Boundary
Dry
Hydrodynamic
Hydrostatic
None
For each application below (i-v), choose the most suitable lubrication type.
i) A car wheel
[2 marks]
Answer
Boundary
ii) A car crankshaft
[2 marks]
Answer
Hydrodynamic
iii) A barrel lock in a door
[2 marks]
Answer
Dry
iv) A toddlers bike wheel (A steel axle running in a polymeric bearing)
[2 marks]
Answer
None
v) A slowly rotating shaft which experiences a high radial load
[2 marks]
Answer
Hydrostatic
(b) Explain why a cylindrical roller bearing can support a greater radial load than a
ball bearing.
[5 marks]
Answer
The cylindrical roller distributes the load across a line contact rather than a point
contact.
(c) Sketch a deep groove ball bearing mounted on a shaft with a fixed inner race
and a floating outer race.
[10 marks]
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Answer
(d) A shaft of 20mm running in a plain bearing rotates at 100 RPM in a journal that
is 30mm long. A radial load of 500N is carried by the bearing. Calculate the
limiting PV value for the bearing.
[25 marks]
Answer
The Pressure is calculated as

=


= 833,333

(10 marks)
The operating Velocity is calculated as

2

(10 marks)
The limiting PV is calculated as

(5 marks if units are correct else 2 marks )
(e) A pulley (75 mm) on a crankshaft is used to drive an alternator pulley (30
mm) using a vee belt. The distance between the pulley centres is 500 mm. The
crankshaft rotates at 3000 RPM. The vee belt has a cross sectional area of
1.44x10
-4
m
2
and the maximum permissible strength of the belt is 12 MPa. The
coefficient of friction between the belt and the pulleys is 0.8.
You may find the following equations useful:
Belt length

+
1
2
(

)
Angle of contact on smaller pulley

Angle of contact on larger pulley

Eytleweins Formula
e
F
F
2
1

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i.) Determine the speed of the alternator pulley in RPM.
[5 marks]
Answer

= 3000
75/2
30/2
= 7500
ii.) Determine the maximum power that can be transmitted from the crankshaft to
the alternator assuming no belt slippage
[35 marks]
Answer
The tight side load in the belt is limited by the maximum permissible strength of the
belt.

= 1210

1.4410

= 1728
(5 marks)
To transfer the power, no slippage can occur, so Eytleweins formula must be satisfied
e
F
F
2
1

Where slippage is likely to occur on the smallest pulley as it has the least contact area,
so
= (

) = 2 sin

2
= 2 sin

0.075 0.030
2 0.500


180
= 3.052
(10 marks)
The Eytleweins formula can be solved for the slack side force, F
2

=
1728

..
= 150
(10 marks)
The belt speed is calculated as
=

2
= 3000

1
60

2
1

0.075
2
= 11.781 /
(5 marks)
So the maximum power transmitted is
= (

) = (1728 150) 11.781 = 18,590

(5 marks)
iii.) Determine the torque produced at the crankshaft
[10 marks]
Answer

= (

= (1728 150)
0.075
2
= 59
2.
(a) If you wanted to prevent axial and rotational movement of a gear on a shaft
would you make the connection with a roll pin or a plain key?
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[2 marks]
Answer
Roll pin
(b) Name 2 advantages and 2 disadvantages of keys for attaching elements to
shafts.
[8 marks]
Answer
Advantages
1. Inexpensive
2. Provide positive drive
Disadvantages
1. Shafts requires a keyway to be machined
2. The keyway gives rise to a stress concentration in the shaft
(2 marks/answer)
(c) Name 5 ways of achieving an interference fit between the hub of a gear and a
shaft
[10 marks]
Answer
1. Cool the shaft prior to assembly
2. Heat the hub prior to assembly
3. Use a combination of 1 and 2 above
4. Press the hub onto the shaft
5. Expand the hub using high pressure oil
(2 marks/answer)
(d) A hub is secured onto a shaft using an interference fit. Pressure, P, is developed
between the hub and shaft which keeps the hub from slipping on the shaft when
a torque is applied. Show that the expression for the maximum torque capacity
of this hub to shaft connection is

2

Where
= coefficient of friction between shaft and hub
l = hub length in contact with the shaft
D = shaft diameter
[30 marks]
Answer
The interface pressure, P, sets up a frictional force, N, between the hub and shaft surface
which acts tangentially to the surface and along the contacting length of the shaft, l. When
this frictional force is overcome, the hub will slip on the shaft, therefore the maximum torque
at the point of slip can be defined as

(5 marks)
The normal force, N acts everywhere normal to the interface surface, A which is related to the
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interface pressure as
=
(5 marks)
Where the interface surface is defined as
= 2

2

(5 marks)
So
= = 2

2

(5 marks)
Substituting for the normal force and simplifying

2
=

2

(10 marks)
(e) Estimate the fastener pre-load, F, required in the tapered hub-shaft connection shown
below to achieve a maximum torque capacity, T
max
, of 500 Nm, assuming a friction
coefficient of 0.2 on all surfaces. An M24 thread is employed. The taper angle is 12,
the shaft end diameter, D
1
is 30 mm and the hub length is 45 mm. Include the torque
capacity associated with the hexagonal nut having a major thread diameter of 24 mm
and a distance across its flats of 36 mm.
(f)
Recall that the maximum torque carrying capacity for the tapered region only is
expressed as

Where
=coefficient of friction between the shaft and hub as well as between the nut
and hub
l = hub length
D
t
= mean shaft diameter along the taper
[50 marks]
Answer
As stated, the maximum torque capacity generated in the tapered region is given by the
=12
45 mm
D
1
D
2
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expression

The additional torque capacity resulting from the nut is

2

(15 marks)
The total torque capacity is

+
+
(10 marks)
Solving for the pre-load force
=
2

+
+
(5 marks)
Where

2
(5 marks)
And

= 2 (0.045 12) +

= 2 (0.045 12) +0.030 = 0.049

=
0.030 +0.049
2
= 0.040
(5 marks)
Also the average of the major nut thread diameter and the distance across the flats is
=
0.024 +0.036
2
= 0.030
(5 marks)
Finally
=
2

+
+
=
2 500
0.2
0.040
0.2 12 +12
+0.030
= 38,723
(5 marks)
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Section B
3.
(a) Using a detailed figure in each case, demonstrate how 3 forms of milling tool
wear occur. Your answer should also include some commentary on the defects
to the machined surface which may result from this.
[30 marks]
Answer
Any three figures and discussion with three comments relating to
surface properties of the workpiece.
(b) Modern machine tools which are used to mill complex geometries are
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capable of 5-axis machining. Using a fully labelled diagram discuss the
principal features of such a machine tool.
[30 marks]
Answer
Discussion of principle features (6 features for 5 marks each).
Candidates may also choose to discuss trunion type arrangements and
horizontal machine tools
(c) Discuss the typical stages involved in developing a CNC program for a machine tool
using generic CAD/CAM software. Your answer should go on to make mention of the
stages involved in setting up a job on a modern machining centre.
[40 marks]
Answer
Import of CAD data
Perhaps some mention of CAD formats and method of importing into the CAD package
Placing the part inside a stock block
Selection of tool type and profile
Defining cutting conditions (feed and spindle speeds)
Post processing to translate to the machine dialect
G-Code created in readable format
Typical commands may include: spindle ON (M05), Spindle speed (S4000) for 4000rpm
or M00 for all stop. Accept any sensible suggestion with meaning.
Set up of job (may include figure with datum acquisition, fixturing and tooling).
4.
(a) With the aid of a diagram discuss briefly the process of laser cutting. Your
answer should include some comment about the interaction of the laser with the
workpiece.
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[30marks]
Answer
Answer should include some commentary on the conversion of incident radiation to
heat within the substrate, formation of dross and evaporation.
(b) With the aid of a labelled diagram explain the process of electrochemical
machining. You should also discuss a typical application for this process in your
answer.
[30 marks]
Answer
Answers should give a sensible application for this process, most likely finishing of
aero/biomedical components.
(c) The purchase of any machine tool and its incorporation into a manufacturing process
presents a significant challenge to manufacturing companies. Discuss, with the aid of
diagrams the typical stages and considerations involved when selecting and
commissioning a new machine tool.
[40 marks]
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Answer
Some discussion around key points such as (but not limited to):
Cost
Capability/performance
Quality
Environmental
Availability
Flexibility
The outlay associated with machine tools is significant (10K- 1000sK)
Good decisions must be made, SME large multinational. To expand or replace legacy
equipment
Development of business plan/case for investment
Technical justification
Consideration of product life time.
Scientific metrics must often be devised and applied to facilitate these decisions.
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Section C
5.
(a) Describe the process of calibration.
[40 marks]
Answer
[8 marks for each of the steps described below]
1. A second instrument or standard of known accuracy is required for calibration.
2. The value of the quantity being measured is varied over the range of interest.
3. All other parameters (e.g. temperature, pressure, noise) kept constant as far as possible.
4. Readings of both instruments are recorded
a. X - output of the known instrument/standard
b. M - output of the instrument being calibrated.
5. These are plotted on a Calibration Graph as follows, a regression analysis is performed to
create an equation that give X in terms of M
(b) The Vernier callipers listed in Table 1 below are available to measure a steel shaft of
diameter 65 mm 0.2 mm, to ensure the manufacturing process is well controlled the
measurements must be accurate to 10% of the tolerance for the shaft.
i) Select the most appropriate Vernier calliper from those available (A to D) as shown in
Table 1.
[30 marks]
ii) Of the four Vernier callipers state which one appears to be making an unreasonable
claim with respect to accuracy.
[10 marks]
Table 1
Answer
For part (i) there are three steps required as follows
[15 marks] step 1
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From the table first calculate the absolute accuracy of each Vernier:
Absolute accuracy = ( % of range accuracy / 100 ) * Range
[10 marks] step 2
Then calculate 10% of the tolerance for the shaft = 0.2 / 10 = 0.02
[5 marks] step 3
Based on this only Verniers C and D are candidates but Vernier C has a range that is too
small.
Therefore select Vernier D.
For part (ii) [10 marks]
The absolute accuracy calculated in part (i) for each sensor must be compared to the stated
resolution. As the resolution for Vernier A is greater than the stated accuracy this brings into
question the accuracy of the instrument as it would not be possible to resolve measurements
to the stated accuracy.
(c) Based on Taylors Gauge Theory state the difference between a Go Gauge and a
Not-Go Gauge, then describe the benefits of using Go and Not-Go gauges as
compared to taking instrument measurements.
[20 marks]
Answer
[5 marks for each of the following]
The GO gauge checks the maximum material condition and should check as many
dimensions as possible.
The NOT-GO gauge checks the minimum material condition and should check one
dimension.
[5 marks for each of the following statements about the benefits of using Go and Not-Go
gauges]
Limit gauging is faster than direct measurement for giving conformance data
Skill requirement and opportunity for human error is minimised
6.
(a) Describe the meaning of each of the five symbols that may be used on an engineering
drawing as part of the geometric tolerance definition for orientation and location. You
may support your description with sketches to illustrate the description of each symbol.
[40 marks]
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Answer
[4 marks each] for correctly naming the symbol
[4 marks each] for the description which may include an associated sketch as shown below.
(b) Describe the working principle of a stylus based surface texture instrument used to
measure surface form and roughness; you may use a diagram to support your answer.
[30 marks]
Answer
A stylus based surface measurement instrument consists of:
[5 marks for each bullet points below, that are included as a description of the stylus
instrument]
a skid that makes contact with the specimen to be measured
protruding from the skid is a pointed stylus that rests on the surface of the specimen
a.
b.
c.
d.
e.
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It is connected to a pivot point and is allowed to move up and down in response to the
local height of the specimen.
The vertical position is measured using a position transducer which converts displacement
into a voltage signal
The voltage is converted to a digital signal using and A/D converter
The digital signal is passed to a computer for analysis and display
(c) A cylindrical shaft must be manufactured with a diameter of 8.5mm 0.03mm. Large
volumes of components are to be manufactured so for speed it is to be inspected using
GO and NOT-GO gauges.
i) Calculate the ideal gauge size required
[10marks]
ii) Calculate the maximum and minimum gauge sizes if the wear limit of the gauge is
0.002 mm, and the gauges can be manufactured with a tolerance of 0.005 mm
[20 marks]
Answer
i) Ideal size for GO gauge : shaft size + tolerance = 8.5 + 0.03 = 8.53
[5 marks]
Ideal size for NOT-GO gauge: shaft size - tolerance = 8.5 - 0.03 = 8.47
[5marks]
ii)
GO maximum: Ideal gauge size gauge wear limit = 8.53 0.002 = 8.528 mm
[5 marks]
GO minimum: Ideal gauge size gauge wear limit gauge tolerance = 8.53 0.002
0.005 = 8.523
[5 marks]
NOT-GO minimum: is the ideal not-go minimum size = 8.47 mm
[5 marks]
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NOT-GO maximum: ideal minimum size + the gauge tolerance = 8.47 + 0.005 = 8.475
mm
[5 marks]
END