Mechanical Engineering Department

ME-312 Machine Design (3-0)

Major Exam 01
Semester Spring 2017

Exam time: 39 hours

Exam Instructions:

1. Answer all questions to the best of your ability.

2. You can consult any book, manual, library or the internet.
3. You cannot consult any person (including your colleagues or teachers).
4. The exam will be start at 12:00 am (Sunday 26/02/17) and end at 9:00 am (Monday
28/02/17).
5. There will be no extension in time.
6. Exams should be handed either to me personally, or my office assistant. No other
submissions will be accepted.
7. I want you to use your thinking and design abilities in this exam. You may receive
maximum marks even if your numerical answer is wrong for some reason, as long as
your method is correct.
8. Answer sheets must be correctly stapled together. Do not expect me to be to do it for
you.
Question 1

In a diesel engine the gas pressure is 2 MPa and the cylinder diameter is
250 mm. The contact surfaces of the head and cylinder made of cast
iron are ground and no packing is required. Choose any factor of safety
between 1.5 and 2.0. Make a program in Excel which:

1) Calculates the size and minimum number of bolts required for

different bolt grades
2) For chosen bolts, also designs the flange diameters so that there
is half a bolt space between bolt edge and cylinder outer circle.
3) What should be the flange thickness? How is it chosen. Tricky
question, but you can do it.
4) Find the price of bolts and nuts and calculate the price of each
solution, considering welding of flange and its material as well.
5) Which is the best bolting solution in terms of cost?

Question 2
Look at the figure below.
a) Identify all potential ultimate failure modes of concern.
b) Explain how you would assess those failure modes and obtain
corresponding allowable stresses.
c) For P=2000 lb, design the array of bolts shown. Consider all
materials to be made of steel