Section A: Answer the Following Question Question 1 (30%): June 2009 A bracket as shown in Figure 1 is to carry a load of 45 kN.

Determine: 1 (a) The diameter of the rivet if the maximum shear stress is 40 MPa assuming rivets of the same size. 2 (b) The bracket thickness if the maximum bending stress is 120 MPa and bearing stress is 200 MPa.

Figure 1: Riveted bracket Section B: Answer TWO of the Following Questions Question 2 (35%): June 2009 Power of 60 kW at 750 rpm is to be transmitted from an electric motor to compressor shaft at 300 rpm by V-belts. The approximate larger pulley diameter is 1500 mm. The approximate centre distance is 1650 mm, and overload factor is to be taken as 1.5. A belt with cross sectional area of 350 mm2 and density of 1000 kg/m3 and having an allowable tensile strength of 2 MPa is available for use. The coefficient of friction between the belt and the pulley may be taken as 0.28. The driven pulley is overhung to the extent of 300 mm from the nearest bearing and is mounted on a shaft having a permissible shear stress of 40 MPa with the help of a key. Determine: 1 (a) The number of belts and the belt length assuming a groove angle of 35o 2 (b) The shaft diameter 3 (c) The key dimensions, assuming a rectangular key with allowable shear stress of 40 MPa and bearing stress of 120 MPa.

Final 2009 Petroleum Assume any missing data and state your assumptions clearly Please attempt Five of the following questions. 7 questions were given and students were asked to attempt 5 1.Gears, 2.Threads, 3.Gears, 4.Shafts, 5.Pressure vessels, 6.Screw Jack-threads, 7. Fatigue failure Question 1 [20 Marks] Final 2009-Petroleum A conveyor drive involving heavy shock torsional loading is to be operated by an electric motor turning at a speed of 1600 rpm, as shown in Figure 1. The speed ratio of the spur gears connecting the motor and the conveyor or speed reducer is to be 1:2. Determine the maximum horsepower that the gear set can transmit, based on bending strength and applying the AGMA formulas. Both gears are made from Carburized and hardened steel Grade 1(Sall = 55 ksi), and have a face width of 1.5 in. The pinion has a diameteral pitch of 10 in-1 and 18 teeth.

Figure 1 Question 4 [20 Marks] Final 2009 Petroleum The gears in the shaft assembly shown in Figure 4 transmit 100 kW of power and rotate at 3600 rpm. Gear wheel 1 is loaded against another gear such that the force P1 acts in a 45o direction at a radius of 80 mm from the shaft centre. The force P2 acts vertically downward at a radius of 110 mm from the shaft centre. The distance from bearing A to gear 1 is 100 mm, that from gear 1 to gear 2 is 85 mm, and that from gear 2 to bearing B is 50 mm. Perform the following: a) Find values of force components as well as the resultant force at locations A and B. b) Find the transmitted torque. c) Draw a bending moment diagram in the x-y and x-z planes along with a torque diagram; also, indicate the maximum bending moment and the maximum torque. d) Find the safety factor according to the distortion-energy theory (DET) if the shaft has a diameter of 35 mm and is made of AISI 1080.

Figure 4 Question 7 [20 Marks] Final 2009 Petroleum Figure 7 shows the input shaft of the crane gear box, supported in the gear box by bearings A and B and driven by electric motor. Determine: 1 a) The factor of safety n guarding against fatigue failure of the shaft. For a hollow shaft, replace in the shaft design equations. 433 by 1dDdD 2 b) The stresses in the shaft key. The geometry and dimensions of the hollow shaft and square shaft key are: Ft = 206N, Fr = 75 N, T = 2.06 Nm, a = 66mm, b = 84mm, L = 150Nm, D = 12mm, d = 6 mm, dp = 20 mm, w = 2.4 mm, Lk = 25 mm, The shaft and shaft key are made of 1030 CD steel with machined surfaces: Sut = 520 MPa, Sy = 440 MPa. At the keyway, Kf = 2. The shaft rotates and carries steady loading at normal temperature with a survival rate of 99.9%. The factor of safety against shear of shaft key is n = 3.

Figure 7

Question 4 May2010 Mechanical In a horizontal belt drive for a centrifugal blower, the blower is belt driven at 600 rpm by a 15 kW, 1750 rpm electric motor. The centre distance is twice the diameter of the larger pulley. The density of the belt material is 1500 kg/m3; maximum allowable stress equals 4 MPa; friction coefficients between the belt and the motor pulley and the belt and the blower pulley are 0.5 and 0.4 respectively; and the peripheral velocity of the belt is 20 m/s. Determine the following: 1 (a) Pulley diameters and belt length, [8 Marks] 2 (b) Cross sectional area of the belt, [8 Marks] 3 (c) Minimum initial tension for operation without slip, [8 Marks] 4 (d) Resultant force in the plane of the blower when operating with an initial tension 50% greater than the minimum value, [6 Marks]

Figure 4

Question 1 Final 2007-2008 Petroleum The shaft shown in the figure below is supported on two bearings A and B, and rotates at 1150 rpm. The shaft carries a bending load of 44500 N. Identify the likely mode of failure and its location when d = 64 mm assuming the shaft is to be ground after machining and is to have 80000 cycles of life corresponding to 90 % reliability. The steel used has the following properties Sut= 827 MPa, and Sy= 620 MPa. Select suitable bearings to be used at A and B.

[20 marks]

Question 2 Final 2007-2008 Petroleum The shaft shown in the figure below supports two gears. The shaft is made from high carbon steel (AISI 1080), and is to be designed with a safety factor of 2.0. The gears transmit a constant torque caused by PA=2000 N acting vertically as shown. The shaft has a constant machined cross section. (a) What is the reaction force on Gear C (b) Where is the critical location in the shaft? Determine it using both shear force and bending moment diagrams. (c) Obtain the required shaft diameter assuming all endurance limit modification factors equal to 1.0 except for the surface finish factor. (d) Select suitable bearings to be used at 0 and B.

[20 marks]

Question 4 Fianl_Exam-package-2009-2010 Petroleum A 10x50 mm AISI 1080 cantilever bar supports a static load of 1.4 kN as shown in Figure 4. The bar is secured using two bolts size M12x1.75 grade 5.8. Determine: (a) The shear stress acting on each bolt and hence the safety factor guarding against bolts failure. [9 Marks] (b) The maximum bending stresses in the cantilever and its safety factor. [5 Marks] (c) The maximum bearing stresses in the cantilever and the corresponding safety factor if the allowable bearing stress is 380 MPa. [4 Marks] (d) Explain without calculations how to achieve the same shear stress in both bolts. [2 Marks]

Figure 4: Cantilever bar supports a static load. All dimensions in mm [Total 20 Marks]

Question 5 Fianl_Exam-package-2009-2010 Petroleum The shaft shown in Figure 5 supports two gears. The shaft is made from high carbon steel (AISI 1080), and is to be designed with a safety factor of 2.0. The gears transmit a constant torque caused by PA=2000 N acting vertically as shown. The shaft has a constant machined cross section. (a) What is the reaction force PC on Gear C [2 Marks] (b) Using both shear force and bending moment diagrams, determine the critical location on the shaft? [12 Marks] (c) Obtain the required shaft diameter assuming static loads and using both the distortion energy theory (DET) and maximum shear stress theory (MSST). [6 Marks]

Figure 5 [Total 20 Marks] Question 6 Fianl_Exam-package-2009-2010 Petroleum The tensile link shown in Figure 6 has a thickness of 15 mm and is made of steel with ultimate tensile strength of 700 MPa and yield strength of 500 MPa. Both fillets are 16 mm in radius and their surfaces are ground. Determine: (a) The maximum load Pmax that will cause static yielding. [5 Marks] (b) If the applied load fluctuates between Pmin = 90 kN and Pmax = 210 kN, determine the safety factor for infinite life. [10 Marks] (c) If the fillets surfaces were machines and not ground, what are the maximum forces for part (a) and the new safety factor for part (b)? [5 Marks]

Figure 6

[Total 20 Marks]