Mech Design N6 Q&A Combined

NATIONAL CERTIFICATE
MECHANICAL DRAWING AND DESIGN N6

(8090086)
28 November 2022 (X-paper)

09:00–13:00
OPEN-BOOK EXAMINATION
Nonprogrammable calculators may be used.
This question paper consists of 5 pages and 1 addendum.
255Q1E2228
Copyright reserved Please turn over

(8090086) -2-
DEPARTMENT OF HIGHER EDUCATION AND TRAINING

REPUBLIC OF SOUTH AFRICA
TIME: 4 HOURS
MARKS: 100
INSTRUCTIONS AND INFORMATION
1. Answer all the questions.
2. Read all the questions carefully.
3. Number the answers according to the numbering system used in this

question paper.
4. Start each question on a new page.
5. Use only a black or blue pen.
6. Write neatly and legibly.

(8090086) -3-
QUESTION 1
FIGURE 1
An open flat-belt drive connects two shafts mounted with pulleys with effective diameters
of 400 mm and 250 mm. The idler pulley with an effective diameter of 100 mm is used
to initially remove sag on the belt and results in a normal reaction of 507,142 N as shown
in FIGURE 1. Due to the idler pulley being used, the contact angle improved on each
pulley and the contact angles between the belt and the larger pulley, smaller pulley and
the idler pulley are 208°, 210° and 130° respectively. The coefficient of friction between
the belt and pulleys is 0,3. Neglect any sag in the belt as the driving pulley turns
clockwise at 300 r/min.
Calculate:
1.1 The initial tension in the belt after the idler is used (4)
1.2 The maximum tension in the belt (4)
1.3 The power transmitted by the belt (2)

[10]

(8090086) -4-
QUESTION 2
FIGURE 2
FIGURE 2 shows a driving pinion A made of cast steel that transmits 38 kW when turning
at 900 r/min and mating with gear B made of bronze. Gear B is mounted on shaft 1 and
overhangs the right-hand bearing by 200 mm. A flywheel with a mass of 300 kg is
mounted at the midspan of shaft 1, which is 1 m in length. The pulley overhangs the left
hand bearing by 200 mm.
GEAR INFORMATION
Basic stress for the cast steel and bronze material is 140 MPa and 85 MPa respectively.
The centre distance between the centres of the gears is 228 mm.
The module for the gears is 8 mm.
The gears have an 20° full-depth involute angle.
Pinion A has a PCD of 128 mm.
Pinion A is vertically below gear B.
Pinion A rotates clockwise.
BELT INFORMATION
The mass of the pulley is 100 kg.

The tension on the tight and slag sides is 3 000 N and 1 200 N respectively.
The belt is horizontal and parallel.
SHAFT 1 INFORMATION
▩
The maximum bending and shear stresses are 100 MPa and 45 MPa respectively.
The shock and fatigue faction are gradually applied.
= 1,5 and = 1.
Calculate:
2.1 Using Lewis formula the suitable face width for the gears and check the answer (16)
2.2 Whether there is interference (5)

(8090086) -5-
2.3 The suitable diameter for shaft 1 under bending and shearing, assuming that
shaft 1 bearing is well ventilated, heavy loaded (33)
[54]
▩
QUESTION 3
A cone clutch has to transmit 25 kW at a rotational speed of 1 000 r/min. The coefficient
of friction between the two halves of the cone clutch is 0,25. The allowable mean bearing
pressure is 110 kPa and the mean cone diameter is 120 mm. The cone included angle
is 12,466°.
Calculate:
3.1 The dimensions of the cone clutch (the inner and outer diameters, as well as
the face width of the cone) (13)
3.2 The force required to engage the clutch with no slip (2)
[15]
QUESTION 4
▩
A hollow rectangular column with a length of 3 m is supporting a 2 MN compressive load.
The column is fixed on one end and completely free on the other end. The longer outside
dimension of the hollow rectangular area is twenty-four times the wall thickness and the
shorter is eight times the wall thickness. The crippling stress and the Rankine constant
are 100 MPa and 1/7 500 respectively.
Calculate, using Rankine formula, the suitable dimensions of the hollow rectangular
column. [21]
TOTAL: 100
Copyright reserved
(8090086)
ADDENDUM
FORM FACTORS (y) FOR INVOLUTE TEETH
Number of teeth 14,5° full depth 20° full depth

13 0,071 0,083
14 0,075 0,088
15 0,078 0,092
16 0,081 0,094
17 0,084 0,096
18 0,086 0,098
19 0,088 0,100
20 0,090 0,102
21 0,092 0,104
22 0,093 0,105
23 0,094 0,106
24 0,096 0,107
25 0,097 0,108
26 0,098 0,109
27 0,099 0,111
28 0,100 0,112
29 0,101 0,113
30 0,101 0,114
31 0,101 0,115
32 0,101 0,116
33 0,103 0,117
34 0,104 0,118
35 0,104 0,119
36 0,105 0,120
37 0,105 0,121
38 0,106 0,122
39 0,107 0,123
40 0,107 0,124
50 0,110 0,130
55 0,112 0,132
60 0,113 0,134
65 0,114 0,135
Copyright reserved

(8090086)
12 July 2022 (X-paper)

09:00–13:00
OPEN BOOK EXAMINATION
This question paper consists of 4 pages, 1 diagram sheet and 1 addendum.
253Q1A2212
TIME: 4 HOURS
MARKS: 100
3. Number the answers according to the numbering system used in this question
paper.
4. Use only a blue or a black pen.

QUESTION 1
A cone clutch transmits 11 kW when running at 618,281 r/min. The internal diameter of
the cone is 200 mm. The forces required to engage and maintain the engagement are 2
692,627 N and 107,373 N respectively. The coefficient of friction on the contact surfaces
of the clutch is 0,3. Assume uniform wear theory.
Design the suitable cone clutch dimensions from the given information.
(Hint: The dimensions should be the face width, external diameter and the included
angle for the cone). [18]
💮
QUESTION 2
A solid journal bearing has a diameter of 100 mm and a length of 150 mm and is
subjected to a radial pressure of 2 MPa. The surrounding temperature is 25 °C and SAE
30 oil is used to lubricate the bearing. The bearing temperature is 42,5 °C. The radial
clearance between the shaft and the bearing is 0,0045 mm. The shaft turns at 1 000
r/min. Use McKee's and Lasche's equations and refer to the attached ADDENDUM.
Calculate the heat loss to the surroundings. [16]
QUESTION 3
💮
FIGURE 1 on the DIAGRAM SHEET (attached) shows a shaft supported by a single
bearing. The shaft is driven by pinion A transmitting 50 kW at 1 000 r/min clockwise.
Gear B is mounted 150 mm to the left of the bearing and meshes with pinion A which is
vertically below gear B. The number of teeth for gears A and B are 18 and 28
respectively. The pressure angle of the gears is 20°.
The shaft also supports a pulley with a PCD of 450 mm, 200 mm to the right of the
bearing. The pulley is connected by V-belts that are parallel and at 40° from the vertical.
The density and the cross-sectional area per belt is 920 kg/m3 and 600 mm2 respectively.
The contact angle and the coefficient of friction between the belts and the pulley are
170° and 0,2 respectively. The included angle and maximum stress induced per belt are
40° and 2 MPa respectively.
The stresses in the shaft may not exceed 60 MPa for shear stress and 90 MPa for
bending stress. Neglect shock and fatigue factors on the shaft. Assume that the
maximum bending moment induced in the shaft by the tension from the belts is equal to
that induced by the gears and is at the midpoint of the bearing.
Calculate:
💮
3.1 The number of belts required to transmits 50 kW power (17)
3.2 The suitable shaft diameter which may withstand both bending and twisting (19)
3.3 A suitable gears module (12)

💮 [48]
QUESTION 4
FIGURE 2 on the DIAGRAM SHEET (attached) shows a column with a length of

3 metres and the cross-sectional area is also shown. The allowable stress and the safety
factor for the column are 320 MPa and 4 respectively. The one end of the column is fixed
and the other end is free. Rankine's constant is 1/7500.
Calculate:
💮
4.1 A suitable gap 'x' between the flanges of the I-sections, so that the second
moment of area about x–x is equal to the second moment of area about
y–y (Ixx = Iyy) (12)
4.2 The column buckling load, using Rankine's formula
Properties of the I-profile 💮

h (10-3 m) b (10-3 m) A (10-3 m2) IXX (10-6 m4) IYY (10-6 m4)
203,2 133,4 3,219 23,49 3,09 (6)
[18]
💮 TOTAL: 100
💮
DIAGRAM SHEET
FIGURE 1
FIGURE 2
ADDENDUM
MARKING GUIDELINE
12 July 2022
This marking guideline consists of 9 pages.

QUESTION 1
𝜇
𝐹𝑒𝑛𝑔𝑎𝑔𝑒 = 𝐹𝐴 (1 + )
𝑡𝑎𝑛𝜃
0,3
2 692,627 = 𝐹𝐴 (1 + )✓
𝑡𝑎𝑛𝜃
0,3𝐹𝐴
2 692,627 = 𝐹𝐴 + … … … … … … (1)✓
𝑡𝑎𝑛𝜃
𝜇
𝐹𝑚𝑎𝑖𝑛𝑡𝑎𝑖𝑛 = 𝐹𝐴 (1 − )
𝑡𝑎𝑛𝜃
0,3
107,373 = 𝐹𝐴 (1 − )✓
𝑡𝑎𝑛𝜃
0,3𝐹𝐴
107,373 = 𝐹𝐴 − … … … … … … … (2)✓
𝑡𝑎𝑛𝜃
𝑒𝑞 (1) + 𝑒𝑞 (2)
2 800 = 2𝐹𝐴
𝐹𝐴 = 1 400 𝑁✓
0,3𝐹𝐴
2 692,627 = 𝐹𝐴 +
𝑡𝑎𝑛𝜃
0,3(1 400)
2 692,627 = 1 400 + ✓
𝑡𝑎𝑛𝜃
1 292,627𝑡𝑎𝑛𝜃 = 420
𝜃 = 𝑡𝑎𝑛−1 324,919 × 10−3 ✓
𝜃 = 18°✓
2𝜋𝑁𝑇
𝑃=
60
2𝜋(618,281)𝑇
11 000 = ✓
60
𝑇 = 169,894 𝑁𝑚✓
𝜇𝐹𝐴 𝑅𝑓
𝑇=
𝑠𝑖𝑛𝜃
0,3 × 1 400𝑅𝑓
𝑇= ✓
𝑠𝑖𝑛18
𝑅𝑓 = 125 𝑚𝑚✓
𝑅+𝑟
𝑅𝑓 =
2
𝑅 + 100
125 = ✓
2
𝑅 = 150 𝑚𝑚✓
∴ 𝑑 = 2 × 𝑟 = 2 × 100 = 200 𝑚𝑚✓ 𝑎𝑛𝑑 𝐷 = 2 × 𝑅 = 2 × 150 = 300 𝑚𝑚✓
𝑅−𝑟
𝑠𝑖𝑛𝜃 =
𝑤
150 − 100
𝑤= ✓
𝑠𝑖𝑛18
𝑤 = 161,8 𝑚𝑚✓ [18]
QUESTION 2
∆𝑇 = 𝑇𝐵 − 𝑇𝐴
∆𝑇 = 42,5 − 25
∆𝑇 = 17,5°✓
1
∆𝑇 = 2 (𝑇𝑂 − 𝑇𝐴 )
1
17,5 = (𝑇𝑂 − 25)✓
2
35 = 𝑇𝑂 − 25
𝑇𝑂 = 60°✓
= 0,002✓
(∆𝑇+18°)2 × 𝐿 × 𝐷
𝐻𝑑𝑖𝑠𝑠𝑖𝑝𝑎𝑡𝑒𝑑 =
𝑘
(17,5 + 18°)2 × 0,15 × 0,1

𝐻𝑑𝑖𝑠𝑠𝑖𝑝𝑎𝑡𝑒𝑑 =
0,002
✓
𝐻𝑑𝑖𝑠𝑠𝑖𝑝𝑎𝑡𝑒𝑑 = 9,452 𝑘𝑊✓

𝑊 =𝑃×𝐴
𝑊 = (2 × 106 )(0,15 × 0,1)✓
𝑊 = 30 𝑘𝑁✓
𝜇 = 0,034 𝑘𝑔/𝑚𝑠✓
𝑑𝑖𝑎𝑚𝑒𝑡𝑟𝑎𝑙 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 2 × 𝑟𝑎𝑑𝑖𝑎𝑙 𝑐𝑙𝑒𝑎𝑟𝑒𝑛𝑐𝑒 = 2 × 0,0045 = 0,009 𝑚𝑚✓
𝜇×𝑁 𝐷
𝑓 = 0,326 [ ]× +𝑘
𝑃 𝐶
0,034 × 1 000 100

𝑓 = 0,326 [ 6
]× + 0,002 ✓
2 × 10 0,009
𝑓 = 0,063578 𝑘𝑔/𝑚𝑠✓
𝑓×𝑤×𝜋×𝐷×𝑁
𝐻𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 = 60
(0,063578)(30 × 103 )𝜋× 0,1 × 1 000

𝐻𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 = 60
✓
𝐻𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 = 9,987 𝑘𝑊✓
𝐻𝑙𝑜𝑠𝑠 = 𝐻𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 − 𝐻𝑑𝑖𝑠𝑠𝑖𝑝𝑎𝑡𝑒𝑑
𝐻𝑙𝑜𝑠𝑠 = 9,987 − 9,452✓
𝐻𝑙𝑜𝑠𝑠 = 535 W✓ [16]
QUESTION 3
3.1 𝑁𝐴 × 𝑇𝐴 = 𝑁𝐵 × 𝑇𝐵
1 000 × 18 = 𝑁𝐵 × 28✓
𝑁𝐵 = 642,857 𝑟/𝑚𝑖𝑛✓
2𝑁𝐷
𝑣=
60
2(0,45)(642,857)
𝑣=
60
✓
𝑣 = 15,15 𝑚/𝑠 ✓
𝑇𝐶 = 𝜌𝐴𝑣 2
𝑇𝐶 = (920)(600 × 10−6 )(15,15)2 ✓
𝑇𝐶 = 126,696 𝑁✓
𝑇1
𝜎𝑚𝑎𝑥 = 𝐴
𝑇1 = (600 × 10−6 )(2 × 106 )✓
𝑇1 = 1 200 𝑁✓
𝜇𝜃
𝑇1 −𝑇𝐶
= 𝑒 𝑠𝑖𝑛𝛽
𝑇2 −𝑇𝐶
(0,2)(2,967)
1 200−126,696
𝑇2 −126,696
=𝑒 𝑠𝑖𝑛20 ✓
1 073,304
= 5,669✓
𝑇1 −126,696
1 073,304 = 5,669𝑇2 − 718,24✓
𝑇2 = 316,025✓
𝑃 = (𝑇1 − 𝑇2 )𝑣
𝑃 = (1 200 − 316,025)15,15✓
𝑃 = 13,392 𝑘𝑊✓
𝑃𝑚𝑜𝑡𝑜𝑟
𝑁° 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠 =
𝑃𝑝𝑒𝑟 𝑏𝑒𝑙𝑡
50
𝑁° 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠 =
13,392
✓
𝑁° 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠 = 3,74✓
∴ 𝑁° 𝑜𝑓 𝑏𝑒𝑙𝑡𝑠 = 4✓ (17)
3.2 𝑇ℎ𝑒 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑖𝑠 𝑎𝑡 𝑎 𝑏𝑒𝑎𝑟𝑖𝑛𝑔
𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡(𝑀𝐵 ) = 𝑛°(𝑇1 + 𝑇2 − 2𝑇𝐶 )𝑐𝑜𝑠𝛼 × 𝑙
𝑀𝐵 = 3,74(1 200 + 316,025 − 2 × 126,696)𝑐𝑜𝑠40 × 0,2✓
𝑀𝐵 = 723,49 𝑁𝑚✓
𝐻𝑜𝑟𝑖𝑧𝑜𝑡𝑎𝑙 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡(𝑀𝐵 ) = 𝑛°(𝑇1 + 𝑇2 − 2𝑇𝐶 )𝑠𝑖𝑛𝛼 × 𝑙

𝑀𝐵 = 3,74(1200 + 316,025 − 2 × 126,696)𝑠𝑖𝑛40 × 0,2✓
𝑀𝐵 = 607,08𝑁𝑚✓
𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡(𝑀𝐵 ) = √(𝑀𝐵𝐻 )2 + (𝑀𝐵𝑉 )2
𝑀𝐵 = √(723,49)2 + (607,08)2 ✓
𝑀𝐵 = 944,449 𝑁𝑚✓
2𝜋𝑁𝑇
𝑃=
60
2𝜋(642,857)𝑇
50 × 103 = 60
✓
𝑇 = 742,723 𝑁𝑚✓
𝑇𝑒 = √𝑇 2 + 𝑀2
𝑇𝑒 = √742,7232 + 944,4492 ✓
𝑇𝑒 = 1 201,51 𝑁𝑚✓
𝜋
𝑇𝑒 = 16 𝐷3 𝜏𝑚𝑎𝑥
𝜋
1 201,51 = 16 𝐷3 × 60 × 106 ✓
𝐷3 = 101,987 × 10−6
𝐷 = 46,721 𝑚𝑚✓
∴ 𝐷 = 50 𝑚𝑚✓
1
𝑀𝑒 = 2 (𝑀 + 𝑇𝑒 )
1
𝑀𝑒 = 2 (944,449 + 1 201,51)✓
𝑀𝑒 = 1 071,98 𝑁𝑚✓
𝜋
𝑀𝑒 = 32 𝐷3 𝜎𝐵
𝜋
1 071,98 = 32 𝐷3 (90 × 106 )✓
𝐷3 = 121,436 × 10−6
𝐷 = 49,52 𝑚𝑚✓
∴ 𝐷 = 50 𝑚𝑚✓
𝐵𝑜𝑡ℎ 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟𝑠 𝑎𝑟𝑒 50 𝑚𝑚, ∴ 𝐷 = 50 𝑚𝑚✓ (19)
3.3 𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡 𝑜𝑛 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡 𝑙𝑜𝑎𝑑𝑒𝑑 𝑤𝑖𝑡ℎ 𝑔𝑒𝑎𝑟
𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡(𝑀𝐵 ) = 𝐹𝑅 × 𝑙
𝑀𝐵 = 0,15𝐹𝑅 ✓
𝐻𝑜𝑟𝑖𝑧𝑜𝑡𝑎𝑙 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡(𝑀𝐵 ) = 𝐹𝑡 × 𝑙
𝑀𝐵 = 0,15𝐹𝑡 ✓
𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡(𝑀𝐵 ) = √(𝑀𝐵𝐻 )2 + (𝑀𝐵𝑉 )2
944,449 = √(0,15𝐹𝑅 )2 + (0,15𝐹𝑡 )2 ✓
(944,449)2 = (0,15)2 (𝐹𝑡2 + 𝐹𝑅2 )
39,644 × 106 = 𝐹𝑡2 + 𝐹𝑅2 ✓ … … … … … … (1)

𝐹
𝑅
𝐹𝑡 = 𝑡𝑎𝑛𝜙
𝐹𝑅
𝐹𝑡 = 𝑡𝑎𝑛20
𝐹𝑡 = 2,747𝐹𝑅 ✓ … … … … … … (2)
39,644 × 106 = (2,747𝐹𝑅 )2 + 𝐹𝑅2 ✓
39,644 × 106 = 7,546𝐹𝑅2 + 𝐹𝑅2
𝐹𝑅2 = 4,639 × 106
𝐹𝑅 = 2 153,81 𝑁𝑚✓
𝐹𝑡 = 2,747 × 2 153,81
𝐹𝑡 = 5 916,516 𝑁𝑚✓
2𝑇
𝐹𝑡 =
𝑃𝐶𝐷𝐴
2 × 642,857
5 916,516 =
𝑃𝐶𝐷𝐴
✓
𝑃𝐶𝐷𝐴 = 217,309 𝑚𝑚✓
𝑃𝐶𝐷𝐴
𝑚=
𝑇𝐴
217,309
𝑚=
18
𝑚 = 12,073 𝑚𝑚✓
𝑚 = 13✓ (12)
[48]
QUESTION 4
4.1 𝐵𝐷 3
𝐼𝑥𝑥1 = + 𝐴1 𝑟 2
12
(0,3)(0,015)3
𝐼𝑥𝑥1 = + (0,3 × 0,015)(94,1 × 10−3 )2 ✓
12
𝐼𝑥𝑥1 = 39,931 × 10−6 𝑚4 ✓
𝐼𝑥𝑥2 = 𝐼𝑥𝑥𝐼
𝐼𝑥𝑥2 = 23,49 × 10−6 𝑚4 ✓
𝐼𝑥𝑥𝑇 = 2𝐼𝑥𝑥1 + 2𝐼𝑥𝑥2
𝐼𝑥𝑥𝑇 = 2(39,931 × 10−6 ) + 2(23,49 × 10−6 )✓
𝐼𝑥𝑥𝑇 = 126,842 × 10−6 𝑚4 ✓
𝐷𝐵3
𝐼𝑦𝑦1 = 12
(0,015)(0,3)3
𝐼𝑦𝑦1 = 12
𝐼𝑦𝑦1 = 33,75 × 10−6 𝑚4 ✓
𝐼𝑦𝑦2 = 𝐼𝑦𝑦𝐼 + 𝐴2 𝑟 2
𝐼𝑦𝑦2 = 3,09 × 10−6 + (3,219 × 10−3 )𝑟 2 ✓
𝐼𝑦𝑦𝑇 = 2𝐼𝑦𝑦1 + 2𝐼𝑦𝑦2

𝐼𝑦𝑦𝑇 = 2(33,75 × 10−6 ) + 2[3,09 × 10−6 + (3,219 × 10−3 )𝑟 2 ]✓
𝐼𝑦𝑦𝑇 = 67,5 × 10−6 + 6,18 × 10−6 + (6,438 × 10−3 )𝑟 2
𝐼𝑦𝑦𝑇 = [73,68 × 10−6 + (6,438 × 10−3 )𝑟 2 ]𝑚4 ✓
𝐼𝑥𝑥𝑇 = 𝐼𝑦𝑦𝑇
126,842 × 10−6 = 73,68 × 10−6 + 6,438 × 10−3 𝑟 2 ✓
𝑟 2 = 8,258 × 10−3
𝑟 = 90,871 𝑚𝑚✓
𝑥 𝑏
=𝑟−
2 2
𝑥 133,4
= 90,871 −
2 2
∴ 𝑥 = 48,324 𝑚𝑚✓ (12)
4.2
𝐼 126,842 × 10−6
𝑘=√ =√ = 90,643 𝑚𝑚✓
𝐴𝑇 15,438 × 10−3
𝑙𝑒 = 2𝑙 = 2 × 3 = 6 𝑚✓
𝑙𝑒 6
( )2 = ( )2 = 4 381,577✓
𝑘 90,643 × 10−3
𝜎𝐴
𝐹= 1 𝑙
1 + 𝑎 ( 𝑘𝑒)2
(320 × 106 )(15,438 × 10−3 )

𝐹= 4 381,577 ✓
1+( )
7 500
𝐹 = 7,826 𝑀𝑁✓
𝐹
𝐹𝑠𝑎𝑓𝑒 =
𝑛
7,826 × 106
𝐹𝑠𝑎𝑓𝑒 = = 1,957 𝑀𝑁✓ (6)
4
[18]
TOTAL: 100

(8090086)
15 February 2022 (X-paper)

09:00–13:00
This question paper consists of 4 pages and 1 diagram sheet.
251Q1E2215
(8090086) -2-

TIME: 4 HOURS
MARKS: 100

question paper.

(8090086) -3-
QUESTION 1
An internal combustion engine generates 35 kW at 751,44 r/min to drive the line shaft
shown on the DIAGRAM SHEET (attached). The line shaft drives the generator by
means of a gear drive. The cooling water pump and the cooling fan are both driven by
means of belt drives. The multidisc clutch is introduced between the engine and the line
shaft for a smooth and soft start. Assume no losses on the clutch and the belts due to
◘
slippage.
INFORMATION FOR THE SHAFT
The maximum shear and bending stresses are 55 MPa and 85 MPa respectively.
INFORMATION FOR THE GEARS DRIVING THE GENERATOR
Gear C is mounted on the line shaft 300 mm from the right-hand bearing E and meshes
with gear D vertically below. The PCD for gear D is 240 mm. The gears have a pressure
angle of 20°. Both gears are made of cast steel with a basic stress of 140 MPa. Assume
the form factor for the small gear is 0,112. The centre distance for the gears is 200 mm.
INFORMATION FOR THE CLUTCH

◘
The clutch consists of FOUR discs on the driving shaft and THREE on the driven shaft.
Both sides of the discs are effective. The external diameter of the discs is twice the
internal diameter. The coefficient of friction of the contact surfaces is 0,4. The wearing
on each surface of the disc is 0,9 mm when each disc consists of SIX springs with the
stiffness 16 N/mm. The new axial force after wearing is 728,2 N. Assume uniform wear
theory.
INFORMATION FOR THE BELT DRIVING THE FAN
Pulley F with a mass of 40 kg overhangs the right-hand bearing by 100 mm.

Pulley F drives the fan. The fan is driven at 375 r/min by means of a V-belt with an
included angle of 40° and a cross-sectional area of 300 × 10-6 m2. The coefficient of
friction between the driven pulley with a PCD of 320 mm and the belt is 0,3.
The maximum stress for the belt is 1,2 MPa. The belt is horizontal with a contact angle
of 160°.
◘
INFORMATION FOR THE BELT DRIVING THE PUMP
Pulley B with a mass of 40 kg is mounted 200 mm from the left-hand bearing on the line
shaft. Pulley B drives the pump at a velocity of 5 m/s. The power transmitted by the belts
is 2 kW with a tension ratio of 3:1.
INFORMATION FOR THE ENGINE ◘

The maximum combustion pressure per cylinder is 55 MPa. Each cylinder has a bore
and connecting rod length of 300 mm and 650 mm respectively. The connecting rod is
hinged to the piston on ONE end and to the rotating crank on the other end. Young's
modulus of elasticity for the connecting rod material is 70 GPa. The cross-section of the
connecting rod is an I-profile. The depth is twice the breadth and FIVE times the
thickness.
(8090086) -4-
Calculate the following:
1.1 The internal and external diameters of the discs (14)
1.2 The power required to drive the generator ◘ (10)
1.3 The suitable line shaft diameter which is subjected to twisting and bending
(neglect the shock and fatigue factors) (44)
1.4 The suitable face width for the gear using Lewis formula – check the answer (10)
1.5 Whether there is any interference between TWO meshing gears ◘ (5)
1.6 The suitable cross-section dimensions of the connecting rod using Euler's
theory
◘ (17)
[100]
TOTAL: 100
Copyright reserved
(8090086)
DIAGRAM SHEET
Copyright reserved
MARKING GUIDELINE

15 February 2022

MARKING GUIDELINE -2-
QUESTION 1
1.1 number of contact surfaces wearing on each contact
12 0,9
10,8 mm
F
Spring stiffness
n°
F
16 
10,8 6
1 036,8 N
1 036,8 728,2
1 765 N
2
60
60 35 10

2 751,44
1 765 Nm
0,4 1765 6
150 mm
2
2
150
2
100 mm
2 100 200 mm
200 mm and 400 mm (14)

1.2
, , °

3,515 
1,2 10 
360 N
360 3,515
102,418 N
,

6,283

360 102,418 6,283 1,618 kW
35 1,618 2
31,382 kW (10)
1.3
2 10 3 5
200 N
3 200 600 N
,
31 318 
1 020 Nm

2
8 500 N
Horizontal reaction on the bearings:
Ʃ Ʃ
0,2 0,6 0,5 0,9
800 0,2 0,8 8 500 0,5 462,418 0,9
160 0,8 4 250 416,176
5 632,72 N
Ʃ Ʃ
0,3 0,6 0,1 0,8
8 500 0,3 800 0,6 462,418 0,1 0,8
2 550 480 46,242 0,8 
2 529,698 N
Horizontal bending moments:
2 529,698 0,2 505,94 Nm
2 529,698 0,5 800 0,3 1 504,849 Nm
462,418 0,1 46,242 Nm
Vertical reaction on the bearings:
8500 20°
3 093,745 N

Ʃ Ʃ
0,2 0,8 0,9 0,5
392,4 0,2 0,8 392,4 0,9 3 093,745 0,5
78,48 0,8 353,16 1 546,873
1 394,041 N
Ʃ Ʃ
0,6 0,8 0,1 0,3
392,4 0,6 0,8 392,4 0,1 3 093,745 0,3
235,44 0,8 39,24 928,124
914,904 N
Vertical bending moments:
914,904 0,2 182,981 Nm
914,904 0,5 392,4 0,3 575,172 Nm
392,4 0,1 46,242 Nm
Resultant maximum bending moment for the shaft:
1 504,849 575,172 
1 611,022 Nm
1 611,022 635,4 
1 731,798 kNm
1 731,789 55 10 
1,604 10
54,33 mm ∴ 55 mm

1 611,022 1 731,798 
1 671,41 kN
1 671,41 80 10 
2,128 10
59,7 mm
∴ 60 mm
The suitable shaft size should be 60 mm (44)
1.4
, ,

2,671 
0,529
140 10 0,529 
74,06 MPa
8 500 0,006 0,112 74,06 10 
54,364 mm
∴ 55 mm

Check the limits:
2,5
2,5 6
47,12 mm
4 6
75,4 mm
It is within the limits.  (10)
1.5
2
200
160 mm
2 sin² sin²
120 2 120 80 sin² 20 80 sin² 20 
131,889 mm
130 mm
No interference because is more than . (5)

1.6 0,3 70,686 10 m 
55 10 
,
3,888 kN
Both ends hinged 650 mm.
70 10
3,888 10 
0,65
2,378 10 m 
2,5
2,5 1,5
2 5 2 3
2,5 5
26,042 
12 12
1,5 3
3,375 
12 12
12 12
26,042 3,375
22,667 
2,378 10 22,667
17,997 18 mm
5 2,5
6,51 
12 12

3 1,5
0,844 
12 12
12 12
6,51 0,844
5,666 
2,378 10 5,666
25,45 26 mm
The rod is going to buckle about .
∴ 26 mm
2,5 26 65 mm
5 26 130 mm (17)

[100]
TOTAL: 100
Copyright reserved

(8090086)
11 August 2021 (X-paper)

09:00–13:00
This question paper consists of 5 pages, tables of 5 pages and an addendum

of 3 pages.
259Q1G2111

(8090086) -2-

TIME: 4 HOURS
MARKS: 100

question paper.
5. Use only blue or black pen.

(8090086) -3-
QUESTION 1
A generator running at 804,469 r/min is driven by an electric motor transmitting 23 kW

at 1 440 r/min by means of a wedge belt drive.
The following information is known: 

 The approximate centre distance between the driving and driven shaft is 900 mm.
 A centrifugal clutch is used for a soft start.
 The generator should operate for 18 hours per day.
 The suitable belt section is SPB.
Refer to the TABLES (attached) and determine the following to design a suitable wedge
belt drive:
1.1 The speed ratio (2)
1.2 The service factor

 (1)
1.3 The design power (2)
1.4 The minimum pulley diameter (1)
1.5 The correct centre distance (1)
1.6

The drive and driven pulleys’ pitch diameters (2)
1.7 The belt length (1)
1.8 The correctional factor (1)
1.9 The basic power per belt (1)
1.10 The additional power per belt (1)
1.11 The correctional power per belt

 (2)
1.12 The number of belts to be used for the drive (3)

[18]

(8090086) -4-
QUESTION 2
A centrifugal friction clutch has four blocks which slide radially in a spider keyed to the
driving shaft. The shaft transmits 12 kW at 800 r/min. The internal drum diameter is 300
mm and the center of gravity of each block is 130 mm from the axis of rotation of the
driving shaft. The engagement begins at 65% of the running speed. The coefficient of
friction between the lining of the block and the drum is 0,3.

2.1 The mass of each block (8)
2.2 The stiffness of each spring in N/mm, if the new force required after wearing is
642,4 N and each block worn 4 mm, with no adjustment made
 (6)
2.3 The percentage torque reduction due to 4 mm wear on each block (5)
[19]

QUESTION 3
The FIGURE below shows a line shaft shown supported by two bearings, 1 m apart.
The shaft is driven by a pinion A with a pitch circle diameter (PCD) of 120 mm and
transmits 25 kW at 1 000 r/min clockwise. Gear B is mounted on the line shaft 200 mm
from the left-hand bearing and meshes with pinion A 30° from the vertical. The speed
reduction ratio of the gears is 4:1. The pressure angle of the gears is 20°. The line shaft
is supporting a flywheel with a mass of 400 kg, 500 mm from the left-hand bearing.

The pulley has a mass of 40 kg and a PCD of 300 mm; it overhangs the right-hand
bearing by 250 mm and is mounted with a belt that is parallel at 30° from the vertical.
The belt tension ratio is 2,8:1. The stresses in the shaft may not exceed 55 MPa for
shear or 60 MPa for bending. The shaft is subjected to high shock and fatigue factors
of kB = 3 and kT = 2,5.

FIGURE
Calculate a suitable line shaft diameter that would withstand both twisting and bending
simultaneously.
 [48]
QUESTION 4
A full journal bearing has a diameter of 80 mm and a length of 120 mm. The bearing
supports a radial load of 1,8 MN/m2 of the projected area. A H7g6 fit is used. The
surrounding temperature is to be 25 °C and the oil used has a viscosity of 0,098 kg/m.s
at its operating temperature. The shaft supported by the bearing is turning at 800 r/min.

Assume no heat is dissipated by the surrounds.
Use Mckee's and Lasche's equations, refer to the ADDENDUM (attached) and
determine the bearing temperature. [15]
TOTAL: 100
Copyright reserved
(8090086) -1-
TABLE

(8090086) -2-

(8090086) -3-

(8090086) -4-

(8090086) -5-
Copyright reserved
(8090086) -1-
ADDENDUM

(8090086) -2-

(8090086) -3-
Copyright reserved
MARKING GUIDELINE
11 August 2021

QUESTION 1
1.1 1440
 1,79
804,469 (2)
1.2 1,3 (1)
1.3
23 1,3
29,9  (2)
1.4 140  (1)
1.5 892  (1)
1.6 140  250  (2)
1.7 2400  (1)
1.8 0,9 (1)
1.9 5,73  (1)
1.10 1,06  (1)
1.11
5,73 1,06 0,9
7,401  (2)
1.12
29,9

7,401
4,04
5  (3)
[18]

QUESTION 2
2.1 2
60
2 800
12 10 
60
143,239 
143,239 0,3 , 15 4
636,619 
2 2 800
83,776 / 
60 60
2 2 0,65 800
54,454 / 
60 60
636,619 83,776 54,454 0,13
1,208  (8)
2.2 1,208 83,776 0,13 1102,172 
1,208 54,454 0,13 465,661 
642,5 465,661 
176,839 
176,839
 44,21 / 
4 (6)

2.3 1102,172 642,5 459,672 
0,3 459,672 0,15 4 
82,741 
% 100%
143,239 82,741
100%
143,239
42,24% (5)
[19]
QUESTION 3
25 10 
238,732 
238,732 4 954,928 
,
 3978,867 
,
,
 4234,222 
∅ °
2,8 ……….. 1 
……….. 2
954,928 2,8 0,15
3536,77 
2,8 3536,77 9902,956 
Ʃ Ʃ

0,5 30° 1,25 1 50° 0,2
400 9,81 0,5 40 9,81 9902,956 3536,77 30° 1,2 1

4234,222 50° 0,2
1962 15039,43 648,72
16352,71 
30° 50°
3924 392,4 9902,956 3536,77 30° 4234,222 50° 16352,71
3639,542
3639,542 
0,2 3639,542 0,2 727,908 
0,5 50° 0,3
3639,542 0,5 4234,222 50° 0,3
846,69 
30° 0,25
392,4 9902,956 3536,77 30° 0,25
3007,886 
Ʃ Ʃ
30° 1,25 50° 0,2 1
9902,956 3536,77 30° 1,25 4234,222 50° 0,2 
8399,829 544,341
7855,488 
Ʃ Ʃ
50° 30°

7855,488 4234,222 50° 9902,956 3536,77 30°
3857,33
3857,33 
0,2 3857,33 0,2 771,466 
0,5 50° 0,3
3857,33 0,5 4234,222 50° 0,3
1112,153 
30° 0,25
9902,956 3536,77 30° 0,25
1679,966 
3007,886 1679,966 
3445,238 
3445,238 3 954,928 2,5 
10,608 
10608 55 10 
9,823 10
99,406 
∴ 100 
3445,238 10,608 10  [48]

7027 
7027 60 10 
1,193 10
106,055 
∴ 110 
110 .
QUESTION 4
W P L D 1,8 10 0,12 0,08  17,28 
,
80 .
,
80 ,
80,012 80 ,012 
1,5
0,002
0,326
,
0,326 0,002
, ,
0,0967
, ,

5597,22 

∆ °
∆ ° , ,
5597,22 
,
∆ 18° 1166,09
∆ 16,148°
16,148 25 
57,296° [15]
TOTAL: 100
Copyright reserved

(8090086)
20 April 2021 (X-paper)

09:00–13:00
OPENBOOK EXAMINATION
251Q1A2120
(8090086) -2-

TIME: 4 HOURS
MARKS: 100

question paper.
4. Use g as 9,81 m/s2.

(8090086) -3-
QUESTION 1
The DIAGRAM SHEET (attached) shows a line shaft driven by an electric motor that
transmits 70 kW at 1 500 r/min. The line shaft is driven by a belt drive to allow slip during
operation. A simple gear system with three gears is used for speed reduction from the
line shaft to the screw conveyor.
LINE SHAFT
The line shaft is mounted on two bearings 800 mm apart with the driving gear C mounted
300 mm from the right-hand bearing. Pulley B overhangs the left-hand bearing by
160 mm. The flywheel with a mass of 120 kg is mounted 100 mm from the
right-hand bearing. Maximum bending and shear stresses induced in a shaft may not
exceed 90 MPa and 60 MPa respectively.
GEARS
The gears are made of cast iron. The basic stress for cast iron is 50 MPa.
The pressure angle is 20°. The driving gear has a PCD of 260 mm and 26 teeth.
All meshing gears have a module of 10 mm. The centre distance between shafts 2 and
3 is 320 mm and 450 mm between shafts 3 and 4. Gear D is mounted on shaft 3 and
vertically below gear C. Gear E is mounted on shaft 4 and vertically below gear D.
BELT
An open belt with a rectangular cross-section is used. The width of the belt is three times
its thickness. The maximum stress in the belt may not exceed 2,5 MPa.
The coefficient of friction between the belt and the pulleys is 0,3. The PCD for the driving
pulley A and driven pulley B is 240 mm and 360 mm respectively. The centre distance
between pulleys A and B is 900 mm.
BEARINGS
Both bearings are journal bearings. The coefficient of friction between the bearing and
the shaft is 0,08. Each bearing has a bearing length of 90 mm.
Calculate:
1.1 The actual angle of contact for the belt (3)
1.2 The tensions on the tight and slack sides of the belt (6)
1.3 The suitable thickness, width and length of the belt (6)
1.4 The rotational speeds of shafts 2, 3 and 4 in r/min (10)
1.5 Whether there is any interference taking place between all meshing gears (10)

(8090086) -4-
1.6 A suitable face width using Lewis formula and check if it is within the limits (13)
1.7 The maximum torque transmitted by shaft 2 assuming no overloading (2)
1.8 The maximum bending moment induced on shaft 2 assuming the belts are
vertical and parallel (19)
1.9 The suitable diameter for shaft 2 neglecting the shock and fatigue factors (11)
1.10 The resultant radial load on each bearing (4)
1.11 The frictional power on each bearing (12)
1.12 The bearing pressure induced on each bearing (4)

[100]
TOTAL: 100
Copyright reserved
(8090086)
DIAGRAM SHEET
Copyright reserved
MARKING GUIDELINE

20 April 2021

QUESTION 1
1.1
∝
2
0,36 0,24
∝ 
2 0,9
∝ 3,82°
180° 2∝ 180° 2 3,82° 172,36° (3)
1.2
, ,

2,466 ………… 1 
0,24 1 500
18,85 m/s
60 60
70 10 2,466 18,85
2 533,102 N
2,466 2 533,102 6 246,63 N (6)
1.3
but 3
∴ 
3
6 246,63
2,5 10 
3
28,86 mm ∴ 29 mm
3 3 29 87 mm
²
2
2 4
360 240 ²
360 240 2 900 
2 4 900
2 747 mm (6)

1.4
0,36 1 500 0,24 
1 000 r/min
2
10
320 26 
2
38 teeth
38 1 000 26 
684,21 r/min
2
10
450 38 
2
52 teeth
52 684,21 38 
500 r/min (10)
1.5
10 38 380 mm
10 52 520 mm
Checking interference between gear C and D:
2 4 4
190 2 190 130 20 130 20°
209,42 mm

380 10 10
200 mm
2
is more than thus no interference. 
Checking interference between gear D and E:
2 4 4
260 2 260 190 20 190 20 
288,76 mm
520 10 10
270 mm
2
is more than thus no interference.  (10)
1.6 Should be calculated on smaller gear C:
velocity factor
but
60
0,26 1 000

60
13,614 m/s
6
∴ 
6 13,614
0,3059
working stress
0,3059 50 10 
15,295 MPa
0,912
0,154 form factor
0,912
0,154 
2,6
0,119

face width
5 141,93 0,01 0,119 15,295 10 
89,92 mm
2,5
2,5 10
78,54 mm
4 10
125,66 mm
It is suitable as it is within the limits.  (13)
1.7 2
60
2 1 000
70 10 
60
668,45 Nm (2)
1.8 2
2 66,45
0,26
514,93 N
5 141,93 20°
1 871,51 N
Vertical reactions:
300 120 9,81 700 800 160
5 6145,3 1 177,2 700 800 140 475,12
24,08 N
24,08 62 46,63 2 533,102 1 871,57 1 177,2
11 852,522 N
Bending at left bearing:
6 246,63 2 533,102 0,16
1404,75 Nm
Bending at gear C:
6 246,63 2 533,10 0,46 11 852,522 0,3
482,92 Nm
Bending at flywheel:
24,08 0,1
2,408 Nm
Horizontal reactions:
800 500
800 5 141,93 500
3 213,796 N
3 213,706 5 141,93
1 928,223 N

Bending at gear C:
3 213,706 0,3 964,112 Nm
Maximum bending is vertical and left bearing G:
1 404,757 Nm (19)
1.9
1 404,757 668,45 
1 555,689 Nm
16
1 555,689 60 10 
16
50,92 mm
∴ 55 mm
1
2
1
1 404,757 1 404,757 668,45 
2
1 480,223 Nm
32
1 480,233 90 10 
32
55,127 mm
∴ 60 mm
The suitable diameter is 60 mm.  (11)
1.10 Bearing G:
11 852,522 3 213,706 
12 280,48 N

Bearing H:
24,08 1 928,223 
1 928,373 N (4)
1.11 F μF
0,08 12 280,48 
928,238 N
T F R
928,238 0,03
27,847 Nm
2πNT
P
60
2π 1 000 27,847

60
2,916 kW
F μF
0,08 1 928,373 
154,27 N
T F R
154,27 0,03
4,628 Nm
2πNT
P
60
2π 1 000 4,628

60
484,64 W (12)

1.12
928,238

0,09 0,06
171,896 kPa
154,27

0,09 0,06
28,569 kPa (4)

[100]
TOTAL: 100
Copyright reserved

(8090086)
17 November 2020 (X-paper)

09:00–12:00
This question paper consists of 4 pages, 1 diagram sheet, and 1 information sheet.
121Q1E2017
(8090086) -2-

TIME: 3 HOURS
MARKS: 100
paper.
4. Start each section on a new page.
5. Use g as 9,81 m/s2.

(8090086) -3-
QUESTION 1
A line shaft shown on FIGURE 1 on the DIAGRAM SHEET (attached) is driven by

means of the belt, when the driven pulley transmits 15 kW at 800 r/min anti clock-wise.
INFORMATION ABOUT THE LINE SHAFT 

The line shaft is mounted on two bearings, 600 mm apart. The driving gear, C, is
mounted 300 mm from the left-hand bearing. Pulley A overhangs the left-hand bearing
by 120 mm. Maximum bending and shear stresses induced in a shaft may not exceed
60 MPa and 40 MPa respectively. The line shaft is a hollow shaft and the external
diameter is twice the internal diameter.
INFORMATION ABOUT THE GEARS
The gears are made of cast steel. (Note: basic stress is 140 MPa for cast steel.)
The pressure angle is 20°.
The driving gear, C, has 24 teeth.
All meshing gears have a module of 5 mm.
The centre distances between line shaft, 1, and output shaft, 2, is 190 mm.
Gears mesh at 70°from the vertical.
INFORMATION ABOUT THE BELT AND PULLEY
The pulley has four arms (spokes) with an elliptical cross-section.

The larger axis of ellipse is twice the smaller axis.
The maximum bending stress induced in each arm (spoke) may not exceed 45 MPa.
The initial installation tension on the belt is 2,125 kN.
The belt is parallel and vertical.

The PCD for driven pulley, A, is 360 mm.
INFORMATION ABOUT THE BEARINGS AND LUBRICATION OIL
Both bearings are journal bearings.

The coefficient of friction between the bearings and the shaft is 0,08.
Each bearing has a bearing length of 60 mm.
The radial clearance is 0,06 mm.
The bearing temperature is 32°.
The room temperature is 20°. 
FIGURES 3 and 4 on the INFORMATION SHEET supply further information on the
lubrication oil.
Calculate the following from the given information:
1.1 The tension on the tight and slack sides of the belt (7)
1.2 The internal and external diameter of line shaft 2 (27)
1.3 The suitable dimensions of all parts of a pulley  (9)
1.4 Whether there is any interference between the meshing gears (7)

(8090086) -4-
1.5 The total frictional power loss on the bearings (9)


1.6 The SAE number of the lubricating oil to be used on the right-hand bearing (8)
1.7 A suitable face width using Lewis Formula and check if is within the limits (9)
[76]
QUESTION 2
A machine bracket shown in FIGURE 2 on the DIAGRAM SHEET (attached), supports

a load of 100 kN. AO is a hollow round member of 1,8 m in length and BO is a hollow
rectangular member of 1,5 m in length. Both points O and B are hinged, point A is
fixed. Points A and B are 1,2 m apart. The maximum stress, Rankine constant and
safety factor are 325 MPa, 1/7500 and 5 respectively. 
Use a Rankine formula to calculate the inside and outside diameter of member OA. [24]
TOTAL: 100

(8090086) -5-
DIAGRAM SHEET
120mm 300mm 300mm
A
B C D
F
190mm
FIGURE 1
100kN
B
A
1200mm
FIGURE 2

INFORMATION SHEET
SAE
FIGURE 3
FIGURE 4
Copyright reserved
MARKING GUIDELINE
17 November 2020

QUESTION 1
1.1 1.1
(7)
1.2

(27)
1.3

(9)
1.4
(7)

1.5
(9)

1.6
(8)

1.7
(9)
[76]

QUESTION 2

[24]
TOTAL: 100


(8090086)
15 April 2020 (X-paper)

09:00–13:00
251Q1A2015
(8090086) -2-

TIME: 4 HOURS
MARKS: 100

question paper.
5. Use g as 9,81 m/s2.

(8090086) -3-
QUESTION 1
The DIAGRAM SHEET (attached) shows a hoist system driven by an electric motor
that transmits 40 kW at 1 000 r/min. The electric motor is coupled to the centrifugal
clutch to give the motor a smooth and gradual loading. The gear system is introduced
for speed reduction.
Shaft 2 information:
The shaft is mounted on two bearings 400 mm apart. Gear B is mounted 100 mm from
the left-hand bearing and gear C is 100 mm from the right-hand bearing. The maximum
bending and shear stresses induced in a shaft may not exceed 240 MPa and 180 MPa
respectively. The maximum torque is 20% more than the mean torque. The shaft is
subjected to minor shock and a fatigue factor of KB = 2 and KT = 1,5.
Gear information:
The gears are made of cast steel (basic stress for cast iron is 140 MPa). The pressure
angle is 20°. The number of teeth on gears A, C and E are 20, 18 and 22 respectively.
All meshing gears has a module of 6 mm. The centre distance between shafts 1 and 2
is 168 mm, 174 mm between shafts 2 and 3, and 180 mm between shafts 3 and 4.
Clutch information:
The centrifugal clutch has four shoes which slide radially in a spider, keyed to the
driving motor shaft. The clutch starts engagement at 70% of the maximum speed of the
motor. The drum internal diameter is 340 mm. The centre of gravity of each shoe is
150 mm from the centre of rotation. The coefficient of friction between the drum and
the shoes is 0,3.
Calculate:
1.1 The input torque to the clutch (2)
1.2 The mass of each shoe and the clutch centrifugal and spring forces (12)
1.3 The rotational speed and torque transmitted by each shaft (18)
1.4 If there is any interference taking place between all meshing gears (18)
1.5 A suitable face width for meshing gears A and B by using the Lewis formula
and check if it is within the limits (14)
1.6 The maximum bending moment induced on shaft 2 assuming the belts to be
vertical and parallel (23)
1.7 The maximum torque transmitted by shaft 2 (2)
1.8 The suitable diameter for shaft 2 (11)

[100]
TOTAL: 100
Copyright reserved
(8090086)
DIAGRAM SHEET
100 mm 200 mm 100 mm
Copyright reserved
MARKING GUIDELINE

15 April 2020

QUESTION 1
1.1 2πNT
P
60
2π 1 000 T
40 10 
60
T 381,972 kNm (2)
1.2 2πN
ω
60
2π 1 000
ω 
60
ω 104,72 rad/s
2πN
ω
60
2π 0,7 1 000
ω 
60
ω 73,3 rad/s
F mω r
F m 104,72 0,15 
F 1 645m N
S mω r
S m 73,3 0,15 
S 806,02 rad/s
T μ F S Rn
381,972 0,3 1 645m 806,02m 0,17 4 
m 2,23 kg
F 1 645m 1 645 2,23 3 668,35 N
S 806,02m 806,02 2,23 1 797,45 N (12)

1.3 m
C T T
2
6
168 20 T 
2
T 36 teeth
N T N T
N 36 1 000 20 
N 555,56 r/min
m
C T T
2
6
174 18 T 
2
T 40 teeth
N T N T
N 40 555,56 18 
N 250 r/min
m
C T T
2
6
180 22 T 
2
T 38 teeth
N T N T
N 38 250 22 
N 144,74 r/min
Torque transmitted by shaft 2:
2πNT
P
60
2π 555,56 T
40 10 
60
T 687,54 kNm

2πNT
P
60
2π 250 T
40 10 
60
T 1 527,89 kNm
2πNT
P
60
2π 144,74 T
40 10 
60
T 2 639 kNm (18)
1.4 PCD for each gear:
PCD mT
PCD 6 20
PCD 120 mm
PCD mT
PCD 6 36
PCD 216 mm
PCD mT
PCD 6 18
PCD 108 mm
PCD mT
PCD 6 40
PCD 240 mm
PCD mT
PCD 6 22
PCD 132 mm

PCD mT
PCD 6 38
PCD 228 mm
Checking interference between gears A and B:
R R 2R r sin ψ r sin ψ
R 108 2 108 60 sin 20 60 sin 20 
R 116,624 mm
216 6 6
R 114 mm
2
R is more than R and therefore there is no interference. 
Checking interference between gears C and D:
R 120 2 120 54 sin 20 54 sin 20 
R 127,5 mm
240 6 6
R 126 mm
2
R is more than R and therefore there is no interference. 
Checking interference between gears E and F:
R 114 2 114 66 sin 20 66 sin 20 
R 123 mm
288 6 6
R 120 mm
2
R is more than R and therefore there is no interference.  (18)

1.5 Calculating face width for gears A and B:
πND 2π 1 000 0,12

V 6,28 m/s
60 60
3
C velocity factor
3 v
6
C 
6 6,28
C 0,323
σ C σ working stress
σ 0,323 140 10 
σ 45,22 MPa
0,912
y 0,154 form factor
T
0,912
0,154 
20
0,1084
2T
F tangential force
PCD
2 381,972
F 
0,12
F 6 366,2 N
F π m b y σ face width
6 366,2 π 0,006 b 0,1084 45,22 10 
b 68,9 mm
b 2,5 π m
2,5 π 6
47,12 mm
b 4 π m
4 π 6
75,4 mm
It is suitable and within the limits.  (14)

1.6 Vertical reactions:
F F tanϕ
F 6 366,2 tan20°
F 2 317,1 N
2T
F tangential force
PCD
2 687,54
F 
0,108
F 12 732,2 N
F F tanϕ
F 12 732,2 tan20°
F 4 634,14 N
100 200 100
Σcwm Σacwm
F 100 R 400 F 300
2 317,1 100 R 400 4 634,14 300
R 2 896,33 N down 
ΣFup ΣFdown
R F F F
R 4 634,14 2 317,1 2 896,33
R 579,29 N up 

M R L at gear B
M 579,29 0,1
M 57,93 Nm
M R L at gear C
M 2 896,33 0,1
M 289,63 Nm
Horizontal reactions:
1 2
10 20 10
Σcwm Σacwm
F 100 F 300 R 400
6 366,2 100 12 732,2 300 R 400
R 11 140,7 N up 
ΣFup ΣFdown
R R F F
R 11 140,7 6 366,2 12 732,2
R 7 957,7 N up 
M R L at gear B
M 7 957,7 0,1
M 795,77 Nm
M R L at gear C
M 11 140,7 0,1
M 1 114,07 Nm
The maximum bending is horizontal and at C.
M 1 114,07 Nm (23)

1.7 T 1,2 T
T 1,2 687,54 
T 825,05 Nm (2)
1.8 T M k T k
T 1 114,07 2 825,05 1,5 
T 2 548,76 Nm
π
T D τ
16
π
2 548,76 D 180 10 
16
D 41,46 mm
∴D 45 mm
1
M M k T
2
1
M 1 114,07 2 2 548,76 
2
M 2 388,45 Nm
π
M D σ
32
π
2 388,45 D 240 10 
32
D 46,63 mm
∴D 50 mm
The suitable diameter is 50 mm.  (11)

[100]
TOTAL: 100
Copyright reserved

(8090086)
28 November 2019 (X-Paper)

09:00–13:00
This question paper consists of 6 pages.

(8090086) -2-

TIME: 4 HOURS
MARKS: 100
1. Answer ALL the questions.
2. Read ALL the questions carefully.

question paper.
4. A correct answer is worth only ONE mark.
5. Show ALL the steps to achieve as many marks as possible. An incorrect

answer which has to be carried forward will receive fair consideration.
6. Candidates may use their personal notes.

(8090086) -3-
QUESTION 1
FIGURE 1 shows a gear reduction unit. Pinion A has 22 teeth with a tooth module of
8 mm and delivers 150 kW at 1 200 r/min clockwise. The overall transmission ratio is
approximately 8:1. The centre distances are nearly the same for each step. The
reduction at each step is approximately equal. Assume that all teeth are full depth,
20° involute.

H
A D E
G
C
B F
FIGURE 1
Calculate:
1.1 The approximate reduction at each step (2)
1.2 The number of teeth on gear B  (1)
1.3 The centre distance of A and B (1)
1.4 The number of teeth on gears C and D if the module is 4 mm (3)
1.5 The number of teeth on gears E and F if the module is 6 mm  (2)
1.6 The number of teeth on gears G and H if the module is 5 mm (3)
1.7 The torque on gear H  (5)

[17]

(8090086) -4-
QUESTION 2
A part of a machine mechanism is shown in FIGURE 2. Using Rankine's theory,

calculate the dimensions of the two struts A–C and B-C if a horizontal load of 60 kN is
applied to point C. Strut A–C is 410 mm long and strut B–C is 480 mm in length.
Assume hinged ends for both. The distance A–B is 400 mm and uses a factor of safety
of 4.

If the material to be used has a yield stress of 320 MPa, calculate the material
thickness required if the rods are of an I-section profile with the depth being 7,5 times
the thickness and the width 2,5 times the thickness. Use a Rankine constant
of 1/7 500.


FIGURE 2 [25]

(8090086) -5-
QUESTION 3
In FIGURE 3, driving pinion a has 30 teeth and must transmit 25 kW at 800 revolutions per
minute to the driven gear c, with 40 teeth. Gear b is an idler gear and has 50 teeth. All the
gears are 200 full-depth involute with a 6 mm module.

Calculate the resultant force on the idler gear. Use a basic stress of 80 MPa and determine
the tooth width of gears a and b. Use the Lewis formula. Test the answer for acceptability.
50 teeth/tande 40 teeth/tande
 c
b
m = 6 mm
30 teeth/tande
P = 25 kW a
N = 800 r/min

FIGURE 3 [20]

(8090086) -6-
QUESTION 4
A shaft rotating at 300 r/min with the centrally keyed wheel of a worm drive, is shown in
FIGURE 4. The shaft, which has a diameter of 45 mm, is supported in two journal
bearings and a conical thrust bearing. The assembly is placed in a well-ventilated area
where the ambient temperature is 25 °C and is lubricated with SAE oil. A force of
28 kN acting at an angle of 50° to the horizontal, is present on the wheel. The pressure
on the journal bearing material cannot exceed 1,2 MPa and the temperature of the
bearing surface is limited to 50 °C. Assume that the journal diameter to diametral
clearance ratio (D/C) is 1 000.

FIGURE 4
Calculate:
4.1 The radial load on the journal bearings (1)
4.2 The length of each journal  (1)
4.3 The heat dissipated by each journal bearing (3)
4.4 The coefficient of friction (3)
4.5 The SAE number of the lubricating oil (4)
4.6 The side thrust  (1)
4.7 The inside diameter of the conical thrust bearing to take this side thrust if it is
made of the same material as the journals, but has an outer diameter of
100 mm and a width of 40 mm with a 50° cone angle (3)
4.8 The frictional torque that occurs at the thrust bearing using the uniform
pressure theory (Use the coefficient of friction calculated in QUESTION 4.4.) (2)
4.9 The total power lost in the journals and the thrust bearing  (2)
4.10 The quantity of lubricating oil needed in litres/min if its specific heat capacity is
3,2 kJ/kg °C and its density is 850 kg/m3 (3)
[23]
(8090086) -7-
QUESTION 5
A solid shaft rotating at 450 r/min is seen in FIGURE 5. It is supported by two bearings
650 mm apart. 30 kW is supplied to the shaft through a 400 mm diameter pulley
located 325 mm to the right of the left-hand bearing. The power is transmitted from the
shaft through an 80 mm diameter pinion located 325 mm to the right of the right-hand
bearing. The belt drive is at an angle of 60° below the horizontal and to the right. The
ratio of belt tensions is 4:1 and the pulley has a mass of 6 kg. The gear wheel tooth
form is 20° and it meshes with another gear directly above the shaft. The shaft material
has ultimate shear strength of 400 MPa and a factor of safety of 4 is used.
Design a suitable shaft diameter. 
FIGURE 5
 [15]
TOTAL: 100
Copyright reserved
MARKING GUIDELINE

28 November 2019

QUESTION 1
1.1 The approximate reduction at each step
Total reduction  8:1

Reduction per stage  4
8
 1, 68 (2)
1.2 The number of teeth on gear B
NA  1, 68  N B
TB  1, 68  TA
 1, 68  22
 36,96
 37 (1)
1.3 The centre distance of A and B
m TA  TB 
c 
2
8  22  37 

2
 236 mm (1)
1.4 The number of teeth on gears C and D if the module is 4 mm
TD  1, 68  TC (1)
m TC  TD 
c 
2
4 TC  1, 68TC 
236 
2
TC  44 (1)
TD  1, 68  TC
 1, 68  44
 73,92
 74
(1)

1.5 The number of teeth on gears E and F if the module is 6 mm
TF  1, 68  TE (1)
m TE  TF 
c 
2
6 TE  1, 68TE 
236 
2
TE  29,35
 29
TF  1, 68  TE
 1, 68  29
 48, 72
 49 (1)
1.6 The number of teeth on gears G and H if the module is 5 mm (1)
TH  1, 68  TG
m TG  TH 
c 
2
5 TG  1, 68TG 
236 
2
TG  35, 22 (1)
 35
TH  1, 68  TG
 1, 68  35
 58,8
 59 (1)
1.7 The torque on gear H

2  N T
P 
60
2    1200  T
150000 
60
TA  1193, 7 Nm (1)
TDRIVEN
Gear Ratio 
TDRIVERS
37  74  49  59

22  44  29  35
 8, 06 (2)

TorqueH  8, 06  TA
 8, 06 1193, 7
 9620,9 Nm (2)
[17]
QUESTION 2
(1)
x2 = 4102 -y 2
= 480 2 -  400-y 
2
x2
4102 -y 2 = 4802 -4002 +800y-y 2
4102  4802 +400 2  800y
97700
y 
800
y = 122,125 mm (1)
122,125
Sinz =
410
z = 17,33o
277,875
Sinw =
480
w = 35, 4o (1)
FBCSinw = FACSinz
FBC Sin35, 4 = FAC Sin17,33
FBC  0,5142FAC (1)

60 103 = FBCCosw+ FAC Cosz

= 0,5142  FAC Cos35,4+FAC Cos17,33
60 10 3
= 0, 419  FAC  0,9546FAC
FAC = 43,676 kN
FBC = 22,458 kN (2)
FCRIPPLING AC  43, 676 103  4

 174, 7 kN (1)
FCRIPPLING BC  22, 458 103  4

 89,832 kN (1)
A  B D bd
 7,5t  2,5t  1,5t  5,5t
 10,5t 2 (1)
BD 3  bd 3
I XX 
12
2,5t  (7,5t )3  1,5t  (5,5t )3

12
 67, 094t 4
(1)
B 3 D  b3d 
IYY    Ar 2 
12  12 
(2,5t )3  7,5t   0, 75t   5,5t 
3
   4,125t 2  0, 7656t 2   2
12  12 
 3, 0625t 4 (2)
USE YY
I
kYY 2  YY
A
3, 0625t 4

10,5t 2
 0, 2917t 2 (1)

A
FAC 
a L2
1
n kYY 2
320  106  10,5t 2
174, 7 10 3

1 0, 482
1 
7500 0, 2917t 2
1, 0531104
1  1,9233 10 4 t 2
t2
t  1, 053110 4
2
 1,9233 10 4 t 4
0  19233t 4  t 2  1, 0531 10 4 (2)
Say t2 = x
0  19233 x 2  x  1, 0531104 (2)
t2  1, 0443 104
t  10, 219 mm
 t AC  10 mm (1)
BAC  2,5 10  25 mm

DAC  7,5 10  75 mm
(1)
A
FBC 
a L2
1
n kYY 2
320 106 10,5t 2
89,832  103 
1 0, 412
1 
7500 0, 2917t 2
7, 68 105
1  3, 7403  104 t 2
t2
t 2  7, 68 105  3, 7403 104 t 4
0  37403t 4  t 2  7, 68 10 5 (2)
Say t2 = x
0  37403x 2  x  7, 68 105 (2)
t2  6, 0612 105
t  7,8 mm
 t BC  8 mm (1)
BBC  2,5  8  20 mm
DBC  7,5  8  60 mm (1)
[25]
QUESTION 3
2 N T
P =
60
2    800  T
25  103 =
60
T = 298,42 Nm (1)
PCDa  mt
 6  30
 180 mm (1)
T  FT  R
298,42  FT  0,18
2
FT  3315,7N (1)
FR = FT  Tan20
= 3315,7  Tan20
= 1206,8 N (1)
FR
FT
FN
FN
FR
FT
b c
b
(5)
FVTOTAL = 3315,7  1206,8

= 4522,5 N (2)
FHTOTAL = 3315,7  1206,8

= 4522,5 N (1)
2 2
FRESULT = 4522,5  4522,5
= 6395,8 N (2)

TOOTH WIDTHS
GEAR A IS THE WEAKEST
  PCD  N
V 
60
  0,18  800

60
 7,54 m / s (1)
3
CV 
3 V
3

3  7,54
 0, 2846 (1)
y30  0,114 (1)

FT    m  b    y  CV
3315, 7    0, 006  b  80 106  0,114  0, 2846
 67,8 mm
 68 mm (2)
bMIN  2,5    6
 47,12 mm
bMAX  4  6
 75, 4 mm (1)
[20]
QUESTION 4
4.1 FR = 28 103  Sin50

= 21,45 kN (1)
4.2 FR = PA
21450
= 2 106  0, 045  L
2
= 0,119 m
L = 120 mm for each (1)

4.3 T = TB -TA
= 50-25
= 25o C (1)
 25+18
2
 0,12  0, 045
HD =
0, 273
= 36, 6 J/s (2)
4.4   D N
HG = f  FR 
60
  0,045  300
36, 6  2 = f  21450 
60
f = 0,00483 (3)
4.5 N D
f = 0,325   +k
P C
  300  0,045  2  0,12
0,00483 = 0,325  1000+0,002
21450
 = 0,058 kg/m.s. (1)
2 O A 
T = T -T1
25  2 = TO -25
TO = 75O C (1)
0,8
0,6
0,4
0,3
0,2
0,15
0,1
0,08
0,06
ABSOLUTE 0,04
VISCOSITY 0,03
0,02 70
60
0,015 50 SAE
0,01 NUMBER
40
0,008
30
0,006
20
0,004 o 10
o o o o
20 40 60 80 100
o
TEMPERATURE C
Use SAE 70. (2)
4.6 FST = 28 103  Cos50

= 17998 N (1)
4.7 17998
FN 
Cos 25
 19859 N (1)
FN
P =
A
FN
1,2 106 =
2    RMEAN  w
19859
1,2 106 =
2     R  r   0, 04
Rr = 0, 0659 (1)
Rr  65,9
50  r  65,9
r  15,9
Say r  16 mm
d  32 mm (1)
4.8 2   R 3 -r 3 
RF =
3   R 2 -r 2 
2  0,053 -0,0163 
=
3  0, 052 -0,0162 
RF = 0,0359 m (1)
T = f  FN  R F
FA
= f  RF
cos25
17998
= 0,00483   0, 0359
Cos 25
T  3, 45 Nm (1)
4.9 2    300  3, 45
P =
60
= 108,24 W (1)
PTOTAL = 108, 24+2  36, 6

= 181,44 W (1)

4.10 H LOST = H GAINED

181,44 = m  3200  25
m = 0,002268 kg/s (1)
0,002268  60
Q =
0,85
= 0,16 l/min
(2)
[23]
QUESTION 5
PULLEY
  D N
V 
60
  0, 4  350

60
 9,42 m/s
P  T1  T2  V
30 10 3
  4T2  T2  9, 42
T2  1061, 6 N
T1  3  T2
 4  1061, 6
T1  4246,3 N (1)
T1  T2  4246,3  1061, 6
T1  T2  5307,9 N (1)
T1  T2  Sin60  4596,8 N

T1  T2  Cos60  2653,9 N
(1)
W  m g
 6  9,81
W  58,86 N (1)

(1)
GEAR
  D N
V 
60
  0, 08  450

60
 1,885 m/s
P  FT  v
30  10 3
 FT 1,885
FT  15915 N (1)
FR
FT 
Tan 20
FR  15915  Tan 20
FR  5792, 6 N (1)
(1)
VERTICAL REACTIONS
0, 65  RL  4655, 66  0,325  5792, 6  0,325

RL  568, 47 N
0, 65  RR  4655, 66  0,325  5792, 6  0,975

RR  11016, 73 N (1)
VERTICAL BENDING MOMENTS
BM PULLEY  568, 47  0,325

 184, 75 Nm
BM RH BEARING  5792, 6  0,325

 1882, 6 Nm (1)
HORIZONTAL REACTIONS
0, 65  RL  2653,9  0,325  15915  0,325

RL  9284, 45 N
0, 65  RR  15915  0,975  2653,9  0,325

RR  22545,55 N (1)
HORIZONTAL BENDING MOMENTS
BM PULLEY  9284, 45  0,325

 3017,5 Nm
BM RH BEARING  15915  0,325

 5172, 4 Nm (1)
RESULTANT BENDING MOMENTS
BM PULLEY  184, 752  3017,52

 3023, 2 Nm
BM RH BEARING  1882, 62  5172, 42

 5504, 4 Nm
2  N T
P 
60
2    450  T
30  103 
60
T  636, 62 Nm (1)
TE  T2 M2
 636, 622  5504, 42
TE  5541,1 Nm (1)
TE    d 3 
16
400  106
5541,1   d3 
16 4
d  65, 6 mm.
d  66 mm
(1)
[15]
TOTAL: 100
Copyright reserved
(8090086) -1-
T1090(E)(A8)T

(8090086)
8 August 2019 (X-Paper)

09:00–13:00

(8090086) -2

TIME: 4 HOURS
MARKS: 100
paper.
4. A correct answer is worth only one mark. Show ALL the steps to achieve as
many marks as possible. (An incorrect answer which must be carried forward
will receive fair consideration.)
5. All work you do not want to be marked must be clearly crossed out.
6. Candidates may use personal notes.

(8090086) -3
QUESTION 1
In FIGURE 1 below, (A), is a flywheel with a mass of 150 kg. (B) is a driven gear. (D) is
the driving pinion which transmits 30 kW from a motor rotating at 2 100 r/min. Pinion
(D) has a PCD of 180 mm. The gear ratio is 3:1. (C) is a V-belt pulley, mounted on the
overhanging part of the shaft and drives a machine situated below it. The PCD of the
pulley is 480 mm and T1/T2 is 4:1.

FIGURE 1
Calculate the diameters of the hollow shaft if D = 2 d. The safe tensile stress is 60 MPa
and the safe shear stress is 50 MPa. Use the following steps:
1.1 Calculate the flywheel, gear and V-pulley forces acting on the shaft. (14)

1.2 Calculate the values and then draw the bending moment diagrams for vertical
and for horizontal loading. (20)
1.3 Calculate the maximum combined bending moment. (2)
1.4 Calculate the shaft torsion. (1)
1.5 Calculate the shaft diameters using (TE) and (ME). (5)
1.6 Calculate the number of teeth on gears B and D if the module is 4 mm. (1)
1.7 Calculate the face width of gears B and D assuming a basic stress of
110 MPa for cast steel (gear B) and a basic stress of 120 MPa for alloy steel
(gear D). (10)

1.8 Calculate the elliptical spoke sizes for the large gear with a ratio of 2:1. The
bending stress is 30 MPa. (8)
[61]

(8090086) -4
QUESTION 2
A cone clutch shown in FIGURE 2 transmits 28 kW at 1 400 r/min. The large diameter
of the cone is 250 mm and the enclosed cone angle is 12°.
The friction face width is 65 mm and the coefficient of friction between the faces is 0,2.
FIGURE 2
2.1 Axial force required to transmit the power (6)
2.2 Axial force required to engage the clutch, assuming that there is no relative
movement between the faces during engagement (2)

2.3 Average normal pressure on the contact surfaces for maximum power (2)
2.4 Maximum normal pressure assuming uniform wear condition (1)
2.5 Dimensions of the operating lever to keep the clutch engaged

The allowable stress in the rectangular arms (ratio 2:1) is 30 MPa. (6)
2.6 Stress induced in the lever during engagement (2)

[19]

QUESTION 3
A hollow cast-iron column has a square cross section with an outside length of 250 mm
and the column length is 4 500 mm. The column carries an axial load of 600 kN.
Calculate the thickness of the metal required for the column by using the Rankine
formula with 1 6400 as the constant.
A safety factor of 8 is allowed on a stress of 500 MPa. [20]
TOTAL: 100

MARKING GUIDELINE
8 AUGUST 2019

QUESTION 1
1.1 FORCES ON FLYWHEEL

WFLYWHEEL  m  g
 150  9,81
WFLYWHEEL  1471,5N (1)
FORCES ON BELT PULLEY

  PCD  N
VPulley 
60
  0,48  2100
 3
60
 17,59 m/s (1)
P   T1  T2  v
30  10 3
  T1  T2 19,98
17,59
 T1  T2   1705,2 N (1)
T1
 4
T2
T1  4  T2 (1)
 T1  T2   1705,2
 4T2  T2   1705,2
3T2  1705,2
T2  568,41N (1)
T1  4  T2
 4  568,41
T1  2273,6 N (1)
T1  T2  2273,6+568,41
 2842,1N
(1)

(1)
FH   T1  T2  sin 30
 2842,1  0,5
 1421N (1)
FV   T1  T2  Cos30
 2842,1  0,866
 2461,22N (1)
FORCES ON THE GEARS
  PCD  N
VPINION 
60
  0,18  2100

60
 19,79 m/s (1)
Power  FT  v
30000  FT  19,79
FT  1515,8 N (1)
FR  Tan20  FT
 Tan20  1515,8
FR  551,69 N (1)

(1)
1.2 BENDING MOMENTS

VERTICAL REACTIONS
(2)
1  RL  2461,22  1,2  551,69  0,75  1471,5  0,25

RL  3735,11 N (1)
1  R R  2461,22  0,2  551,69  0,25  1471,5  0,75

(1)
RR  749,3 N
Check
F  F
749,3  3735,11  2461,22  551,69  1471,5
4484,41  4484,41 (1)

BML  2461,22  0,2
 492,24
-492,24Nm
Nm (1)

BMB  749,3  0,75  1471,5  0,5

 -173,78 Nm (1)
BM A  749,3  0,25
 187,31 Nm (1)
(2)
1  RL  1421  1,2  1515,8  0,75
RL  568,35 N (1)
1  RR  1421  0,2  1515,8  0,25

(1)
RR  663,15 N
Check
F  F
1515,8  568,35  1421  663,15
(1)
2084,15  2084,15

BML  1421  0,2
 -284,2 Nm (1)
BMB  663,15  0,75

(1)
 -497,36 Nm
BM A  663,15  0,25
 -165,79 Nm (1)

492,24
(4)
1.3 MAXIMUM RESULTANT BENDING MOMENTS
BML  492,242  284,22

 568,4 Nm (1)
BML  497,362  173,782

 526,8 Nm
USE 568,4 Nm (1)
1.4 TORQUE ON SHAFT

2 N  T
P =
60
2    2100 3  T
30  103 =
60
T = 409,26 Nm (1)

1.5 SHAFT DIAMETERS
TE  M 2  T2
 568,4 2  409,262
 700,41 Nm (1)
TE   
D 4
 d4 
16 D
700,41   
 2d   d 
4 4
 50  10 6
16 2d
d  0,0211
 21mm
(1)
D  42mm
ME  0,5  M  M2  T2 
 
 0,5 568,4  700,41
(1)
 634,4 Nm
ME   
D 4
 d4  
32 D
634,4   
2d  d   60 10
4 4
6
32 2d
d  0,0243
 24 mm
(1)
D  48 mm
USE 48 mm and 24 mm (1)
1.6 GEAR TEETH

PCD  m  T
180  4  TA
TD  45
TB  3  TD
TB  135 (1)

1.7 FACE WIDTH

 DN
V 
60
  0,18  2100

60
 19,79 m/s (1)
6
CV 
6V
6

6  19,79
(1)
 0,23
T  FT  R
409,26  FT  0,18
3 2
FT  1515,78 N (1)
 0,912 
yD  0,154   
 T 
 0,912 
 0,154   
 45 
 0,134 (1)
 0,912 
yB  0,154   
 T 
 0,912 
 0,154   
 135 
 0,147 (1)

To find which gears govern the design i.e. the weaker gear:
GearD  O  CV  y
 120  106  0,23  0,134
 3,6984  106 (1)
GearB  O  C V  y
 110  106  0,23  0,147
 3,7197  106 (1)
bMIN  2,5    m
 2,5    4
 31,4 mm (1)
bMAX  4 m
 4 4
 50,3 mm (1)
FT   bm y
1515,8    4  103  b  3,6984  106
b  32,615 mm Say 33 mm (1)
1.8 PULLEY ARMS

PCDB  3 180
 540 mm
No arms  5 ( from tables) (1)
d BOSS  2  d SHAFT
 2  48
 96 mm (1)
PCD d BOSS
LBENDING  
2 2
540  96

2
 222 mm (1)
FT  L
M 
arms
1515,8  0, 222

5
 67,3 Nm (1)

M   Z
67,3  30 106  Z
Z  2, 2434 106 m3 (1)

Z  a3
64

2, 2434  10 6  a3
64
a  35, 7 mm
Say 36 mm (2)
a  36 mm
b  18 mm (1)
[61]
QUESTION 2
2.1 Rr
Sin 
w
125  r
Sin 6 
65
r  118, 21 mm (1)
Rr
RF 
2
125  118, 21

2
 121, 6 mm (1)
2  N T
Power 
60
2    1400  T
28  103 
60
 190,99 Nm (1)
Torque  FT  RF
190,99  FT  0,1216
FT  1570, 6 N (1)
FT    FN
1570, 6  0, 2  FN
FN  7853 N
(1)

FA
FN 
Sin
FA
7853 
Sin 6
FA  820,87 N (1)
2.2 FENG  FN  Sin  Cos 

 7853  Sin6  0, 2Cos 6 
 2382,87 N (2)
2.3 Area  2    RMEAN  width

 2    0,1216  0, 065
 0, 04966 m 2 (1)
FN
P 
Area
7853

0, 04966
 158,128 kPa (1)
2.4 FA
Pr essureMAX 
2  R  r  r
820,87

2  0,125  0,11821 0,11821
 162, 768 kPa (1)
2.5 M  0
F  0, 21  820,87  0,12
F  469,1 N (1)
b  d2
Z 
6
b  22  b2

6
 4 6 b3 (1)
M  F  dis tan ce
 469,1 0, 21
 98,5 Nm (1)

M   Z
98,5  30 106  Z
Z  3, 2835 106 m3 (1)
4  b3  3, 2835 106
6
b  17 mm (1)
d  2  17
b  34 mm (1)
2.6 M  F  dis tan ce

 2382,87  0, 21
(1)
 500, 4 Nm
M   Z
500, 4    4  0, 0173
6
  152, 78 MPa (1)
[19]
QUESTION 3
A
F  2
aL
1  
n k 
500 106  A
600 103  8
2
1  4,5 
1  
6400  k 
0, 003164
1  104,17 A
k2
k 2  0, 003164  104,17  A  k 2 (5)
BD 3  bd 3
k 2

12  BD  bd 
B 4  b4


12 B 2  b 2 

B 2
 b2  B 2
 b2 

12 B  b 2 2

k 2

B 2
 b2 
12 (2)

A  B 2  b2 (1)
k 2  0, 003164  104,17  A  k 2
B 2
 b2   0, 003164  B 2
 b2
12

 104,17  B  b
2
 122

 2

B  b 2  0, 037968  104,17   B  b  B  b 
2 2 2 2
 0, 25 2

 b 2  0, 037968  104,17   0, 25  b  4 4
0,1  b 2  0, 41  104,17b 4
104,17b 4  b 2  0,31  0 (5)
Say b2 = x (1)
b  b 2  4ac

2a
1  12  4(104,17)( 0,31)

2(104,17)
 0, 0499 (3)
b2  0, 0499
b  223,5 mm
(1)
250  223
t 
2
b  13,5 mm (2)
[20]
TOTAL: 100
Copyright reserved
T1090(E)(A10)T

(8090086)
10 April 2019 (X-Paper)

09:00–13:00

(8090086) -2-

TIME: 4 HOURS
MARKS: 100
paper.
4. ALL calculations must have at least THREE steps, namely the formula,
substitution and answer.
5. Use g = 9,81 m/s2.

(8090086) -3-
QUESTION 1
A cam with a radial flat-face follower is fitted with a spring as shown in FIGURE 1 on
the DIAGRAM SHEET (attached). The cam is mounted on a solid shaft and overhang
the journal bearing by 200 mm.
CAM INFORMATION

The spring force is 1 200 N.
The frictional force between the guide and the follower is 180 N.
The coefficient of friction between the cam and the follower is 0,12.
The rise is uniform at a rotation of 60° and the follower moves 10 mm.
BELT INFORMATION
The coefficient of friction between the belts and the pulley is 0,45.
The pulley effective diameter is 400 mm.
The angle of contact between the belts and the pulley is 160°.
The mass of the pulley is 40 kg.
JOURNAL BEARING INFORMATION
The coefficient of friction between the bearing and the shaft is 0,08.
The rotational frequency of the shaft is 1 000 r/min.
The bearing pressure is 39,166 kPa. 
The specific heat capacity of the cooling oil is 3,187 kJ/kg.°C.
The rise in temperature of the cooling water is 8 °C.
The rate of flow of the cooling oil is 0,064 ℓ.
BEARING INFORMATION
Both bearings are journal bearings.

The coefficient of friction between the bearing and the shaft is 0,08.
CLUTCH INFORMATION 
The centrifugal clutch has FOUR shoes which slide radially on a spider key to the
driving shaft.
The coefficient of friction between the shoes and the clutch drum is 0,25.
The clutch engages at 400 r/min.
The mass of each shoe is 3,2 kg.
Calculate from the given information the:
1.1 Frictional force between the follower and the cam (2)
1.2 Torque provided by the cam shaft

 (11)
1.3 Maximum bending on the shaft induced by the cam (4)

(8090086) -4-
1.4 Safe diameter of the cam shaft if the maximum bending and shear stresses
are 50 MPa and 45 MPa respectively (9)
1.5 Tension in the slack and tight side (5)
1.6 Length of the shaft supporting the pulley from the centre bearing (assume that
the shaft has a maximum bending moment at the centre of the bearing and is
also in a state of equilibrium)
 (5)
1.7 Resultant reaction on the bearing (4)
1.8 Journal bearing length (6)
1.9 Specific gravity of cooling liquid on the journal bearing (8)

[54]
QUESTION 2
FIGURE 2 on the DIAGRAM SHEET (attached) shows a four-speed gearbox for a

motor vehicle. The pinion A transmits 55 kW at 1 500 r/min. The number of teeth for
gears A, B, D, E and H is 31, 64, 53, 37 and 67 respectively. ALL gears have the same
module and are made of cast steel with a basic stress of 140 MPa. The pressure angle
for ALL gears is 20°.

2.1 Calculate:
2.1.1 The FOUR different output speeds of the gearbox (15)
2.1.2 If there is no interference between gears G and H (7)
2.1.3 The face width for gears E and F (15)
2.2 If a gearbox is coupled to a single-plate clutch to give the gearbox a smooth

gear change, the clutch is fitted between the engine and the gearbox.
The inside diameter of the clutch plate is two-thirds of the outside diameter.
The uniform pressure on the contact surface is 200 kPa. The coefficient of
friction 0,45.

Assume uniform pressure and calculate the inside and outside diameters of
the clutch plate. (9)
[46]
TOTAL: 100
Copyright reserved
(8090086)
DIAGRAM SHEET
FIGURE 1
FIGURE 2
Copyright reserved
MARKING GUIDELINE
10 APRIL 2019

QUESTION 1
1.1 𝐹𝑓 = 𝜇𝑁𝑅
= 0,12(1 200 + 180)
= 165,6 N (2)
1.2 𝜋
𝜃 = 60° × = 1,047 rad
180°
= (1,047)(0,03)
= 31,42 mm
𝑊𝐷 = 𝐹 × 𝑆 (to overcome friction)
= (165,5)(31,42 × 10−3 )
= 5,2 J
𝑊𝐷 = 𝐹𝑆 (to move the follower)
= (1 380)(0,01)
= 13,8 J
𝑊𝐷𝑇𝑂𝑇𝐴𝐿 = 13,8 + 5,2
= 19 J
𝑊𝐷𝑇𝑂𝑇𝐴𝐿 19
𝑇𝑞 = =  = 18,147 Nm
𝜃 1,047 (11)
1.3 Resultant force acting on cam:

𝐹𝑅 = √𝐹𝑓 2 + 𝑁𝑅 2
= √(165,6)2 + (1 380)2 
= 1 389,9 N
Bending moment in the shaft:

𝑀𝑀𝐴𝑋 = 𝑊ℓ
= (1 389,9)(0,2)
= 277,98 Nm (4)
1.4
𝑇𝑒 = √𝑇𝑀𝐴𝑋 2 + 𝑀𝑀𝐴𝑋 2
𝑇𝑒 = √(18,147)2 + (277,98)2 
𝑇𝑒 = 278,572 Nm
𝜋 3
𝑇𝑒 = 𝐷 𝜏𝑀𝐴𝑋
16
𝜋 3
278,572 = 𝐷 (45 × 106 )
16
𝐷 = 31,59 mm
∴ 𝐷 = 32 mm
1
𝑀𝑒 = 2 [𝑀𝑀𝐴𝑋 + 𝑇𝑒 ]
1
= 2 [277,98 + 278,572]
= 278,272 Nm

𝜋
𝑀𝑒 = 32 𝐷3 𝜎𝑛
𝜋
278,276 = 32 𝐷3 (60 × 106 )
𝐷 = 36,15 mm
∴ 𝐷 = 37 mm
∴ Safe diameter 𝐷 = 37 mm (9)
1.5 𝑇1
= 𝑒 𝜇𝜃
𝑇2
𝑇1
= 𝑒 (0,45)(2,793) 
𝑇2
𝑇1 = 3,514𝑇2 
𝑇𝑞 = (𝑇1 − 𝑇2 )𝑅
18,147 = (3,514𝑇2 − 𝑇2 )0,4
𝑇2 = 17,854 N
𝑇1 = 62,74 N (5)
1.6 𝑀𝑀𝐴𝑋 = 277,98

𝑊𝑃 = 𝑚𝑔 = 40 × 9,81 = 392,4 N
𝑀𝑀𝐴𝑋 = (𝑊𝑝 + 𝑇1 + 𝑇2 )𝐿
277,98 = (392,4 + 62,74 + 17,854)𝐿
𝐿 = 588 mm (5)
1.7 𝐹𝑉 = 392,4 + 62,74 + 17,854 + 1 380 = 1 852,994 N

𝐹𝐻 = 165,6 N
𝐹𝑅 = √𝐹𝐻 2 + 𝐹𝑉 2
𝐹𝑅 = √(165,6)2 + (1 852,994)2 
𝐹𝑅 = 1 860,379 N (4)
1.8 𝐹𝑇 = 𝜇𝐹𝑅
= (0,08)(1 860,379)
= 148,83 N
𝐹𝑇
𝑃=
𝐴
148,83
39 166 = 
𝐴
𝐴 = 3,8 × 10−3 m2 
𝐴 = 𝐷𝐿
3,8 × 10−3 = (0,037)𝐿
𝐿 = 100 mm (6)

1.9 Frictional torque and power:

𝑇𝑓 = 𝐹𝑇 × 𝑅𝑆𝐻𝐴𝐹𝑇
𝑇𝑓 = (148,83)(18,5 × 10−3 )
𝑇𝑓 = 2,753 Nm
2𝜋𝑁𝑇𝑓
𝑃𝑓 =
60
2𝜋(1 000)(2,753)
𝑃𝑓 = 
60
𝑃𝑓 = 288,331 W
𝐻𝑒𝑎𝑡𝑔 = 𝐻𝑒𝑎𝑡𝐿
ṁ𝑐∆𝑡 = 𝑃𝑜𝑤𝑒𝑟𝐿
ṁ(3,187)(8) = 288,331
ṁ = 0,0113 kg/s
ṁ
𝑄=
𝛿𝑅𝐸𝐿
0,0113
0,064 = 
𝛿𝑅𝐸𝐿
𝛿𝑅𝐸𝐿 = 0,177 (8)
[54]
QUESTION 2
2.1 2.1.1 𝑚
𝐶= (𝑇 + 𝑇𝐵 )
6 𝐴
𝑚
285 = (31 + 64)
2
𝑚 = 6 mm
𝑚
𝐶 = (𝑇𝐶 + 𝑇𝐷 )
2
6
285 = (𝑇𝐶 + 53)
2
𝑇𝐶 = 42 teeth
𝑚
𝐶 = (𝑇𝐸 + 𝑇𝐹 )
2
6
285 = (37 + 𝑇𝐹 )
2
𝑇𝐹 = 58 teeth
𝑚
𝐶 = (𝑇𝐺 + 𝑇𝐻 )
2
6
285 = (𝑇𝐺 + 67)
2

𝑇𝐺 = 28 teeth
𝑁𝐻 𝑇𝐴 × 𝑇𝐺
=
𝑁𝐴 𝑇𝐵 × 𝑇𝐻
𝑁𝐻 31 × 28
= 
1 500 64 × 67
𝑁𝐻 = 303,738 r/min
𝑁𝐹 𝑇𝐴 × 𝑇𝐸
=
𝑁𝐴 𝑇𝐹 × 𝑇𝐵
𝑁𝐹 31 × 37
= 
1 500 58 × 64
𝑁𝐹 = 463,497 r/min
𝑁𝐷 𝑇𝐴 × 𝑇𝐶
=
𝑁𝐴 𝑇𝐵 × 𝑇𝐷
𝑁𝐷 31 × 42
= 
1 500 64 × 53
𝑁𝐷 = 575,767 r/min
𝑁𝑂𝑈𝑇 = 1 500 r/min (15)
2.1.2 𝑃𝐶𝐷𝐺
𝑚=
𝑇𝐺
𝑃𝐶𝐷𝐺
6=
28
𝑃𝐶𝐷𝐺 = 168 mm
𝑃𝐶𝐷𝐻
𝑚=
𝑇𝐻
𝑃𝐶𝐷𝐻
6=
67
𝑃𝐶𝐷𝐻 = 402 mm
𝑅𝑀𝐴𝑋 = √𝑅 2 + 2𝑅𝑟 sin² 𝜑 + 𝑟 2 sin² 𝜑
= √(201)2 + 2(201)(84) sin ²20 + (84)2 sin² 20 
= 212,547 mm
outside diameter
𝑅𝐴𝐶𝑇𝑈𝐴𝐿 =
2
402+2×6
= 
2
= 207 mm
No interference 𝑅𝑀𝐴𝑋 > 𝑅𝐴𝐶𝑇𝑈𝐴𝐿  (7)

2.1.3 𝑃𝐶𝐷𝐹
𝑚=
𝑇𝐹
𝑃𝐶𝐷𝐹
6= 
58
𝑃𝐶𝐷𝐹 = 348 mm
𝜋𝑁𝐷
𝑉=
60
𝜋(463,497)(0,348)
= 
60
= 8,445 m/s
Velocity factor:
3
𝐶𝑉 =
3+𝑉
3
𝐶𝑉 = 
3 + 8,445
𝐶𝑉 = 0,262
Working stress:
𝜃 = 𝜃𝑜 × 𝐶𝑉
= (140 × 106 )(0,262)
= 36,68 MPa
Tangental force:
𝑃
𝐹𝑇 =
𝑉
55 × 103
= 
8,445
= 6,51 kN
Form factor:
0,912
𝑦 = 0,154 − ( )
𝑇
0,912
= 0,154 − 
37
= 0,129
Face width:
𝐹𝑇 = 𝜋 × 𝑚 × 𝑏 × 𝑦 × 𝜃
6 513 = 𝜋(0,006)𝑏(0,129)(36,68 × 106 )
𝑏 = 73 mm
𝑏𝑚𝑖𝑛 = 2,5 × 𝜋 × 𝑚
= 2,5 × 𝜋 × 6
= 47,12
𝑏𝑚𝑎𝑥 = 4 × 𝜋 × 𝑚
=4×𝜋×6
= 75,4 (15)

2.2 Pressure:
𝐹𝑛
𝑃=
𝐴
𝐹𝑛
200 × 103 = 
𝜋(𝑅 2
− 𝑟 2)
𝐹𝑛 = 628 319(𝑅 2 − 𝑟 2 )𝑁
Power:
2𝜋𝑁𝑇
𝑝=
60
2𝜋(1 500)𝑇
55 × 103 = 
60
𝑇 = 350,141 Nm
𝑇 = 𝜇 × 𝐹𝑛 × 𝑅𝑚
2 𝑅3 − 𝑟 3
350,141 = 0,45(628 319)(𝑅 2 − 𝑟 2 ) [ ( 2 )] 
3 𝑅 − 𝑟2
1,858 × 10−3 = 𝑅 3 − 𝑟 3
2
1,858 × 10−3 = 𝑅 3 − ( 𝑅)3 
3
𝑅 3 = 2,64 × 10−3 
𝑅 = 138,214 ≈ 139 mm
2 2
𝑟 = 𝑅 = (139) = 93 mm (9)
3 3
[46]
TOTAL: 100
Copyright reserved
T1090(E)(N27)T

(8090086)

09:00–13:00

(8090086) -2- T1090(E)(N27)T

TIME: 4 HOURS
MARKS: 100
paper.
4. Use g = 9,81 m/s2.

(8090086) -3- T1090(E)(N27)T
QUESTION 1
The electric motor shown on the DIAGRAM SHEET (attached) transmits 15 kW at

900 r/min to drive a screw conveyor. The transmission of the power from the motor has
to go through reduction gears to increase the output torque drive and through belts to
avoid overloading of the motor.
REDUCTION GEAR INFORMATION
There are FOUR reduction gears. Gear A is mounted on shaft 1, gears B and C are
both mounted on shaft 2 and gear D is mounted on shaft 3. ALL FOUR gears are gear
wheels, each with FOUR elliptical spokes. The smaller dimension of the elliptical shape
is two-thirds of the larger dimension. Gear A has a PCD of 108 mm and 18 teeth.
Gear C has 28 teeth. The centre distance between shaft 1 and shaft 2 is 243 mm and
between shaft 2 and shaft 3 255 mm. The bending stress on each spoke may not
exceed 50 MPa.
SHAFT INFORMATION
ALL THREE shafts mounted with gears are solid shafts. The diameter of shaft 1,
shaft 2 and shaft 3 is 35 mm, 45 mm and 50 mm respectively. Shaft 3 is supported by
TWO bearings that are one meter apart. Gear D is mounted 250 mm from the left-hand
bearing.
BELT INFORMATION
Pulley E, with a PCD of 180 mm, is overhanging the right-hand bearing by 200 mm on
shaft 3. Pulley F, with a PCD of 400 mm, is mounted vertically above pulley E on
shaft 4. Assume belts to be vertical and parallel. The tension ratio on the belts is 3,5:1.
Calculate:
1.1 The speed of the screw conveyor (12)
1.2 The dimension of the spokes and the boss for each gear wheel in order to
design ALL FOUR suitable gear wheels (42)
1.3 The maximum torque on shaft 3 assuming that the maximum torque is 12%
more than the mean torque (3)
1.4 The maximum bending on shaft 3 (19)
1.5 The output torque required to drive the screw conveyor (2)
[78]

(8090086) -4- T1090(E)(N27)T
QUESTION 2
A four-stroke internal-combustion engine has a cylinder diameter of 400 mm and a

stroke-connecting rod of 400 mm. The connecting rod is made of mild steel and has a
cross-sectional area of an H-profile that is uniform for full length. The height of the
profile is equal to the breadth. The thickness of the web is equal to the thickness of the
flanges and the breadth of the flange is THREE times the thickness. The connecting
rod is hinged on both ends to the piston and the crank. The crippling stress for mild
1
steel is 325 MPa and the Rankin constant is .
7
Design a suitable mild-steel H-profile for the connecting rod if the maximum
internal-combustion pressure is 2 MPa and the factor of safety 5. [22]
TOTAL: 100
Copyright reserved
(8090086) T1090(E)(N27)T
DIAGRAM SHEET
200mm
750mm
C
250mm
Copyright reserved
MARKING GUIDELINE
27 NOVEMBER 2018

MARKING GUIDELINE -2- T1090(E)(N27)T
QUESTION 1
1.1 PCD 180

m  6 mm
T 30
m
C T T
2
6
177 18 T 
2
T 41 teeth
m
C T T
2
6
255 28 T 
2
T 57 teeth
N T N T
900 18 N 41 
N 395,122 r/min
N T N T
395,122 28 N 57 
N 194,095 r/min
N T N T
194,095 0,18 0,4 D 
D 87,343 r/min (12)

1.2 V
5,089 m/s
P F V
15 10 F 5,089 
F 2 947,534 N
d 2 35 70 mm
PCD d
L
2
108 70
2
19 mm
Fℓ
M
N
2 947,534 0,019

4
14 Nm
M
Z
σ
14
50 10
280 10 
π
Z a b
32
π 2
280 10 a a 
32 3
a 4,278 10
a 16,233 17 mm
2
b 17 11,333 11 mm
3

PCD mT OR PCD N PCD N
6 41 108 900 PCD 395,122
246 mm
d 45 2 90
PCD D
L
2
246 90
2
78 mm
F ℓ
M
N
2 947,534 0,078

4
57,477N m
M 57,477
Z 1,15 10 m 
σ 50 10
π
Z ba
32
π 2
1,15 10 a a 
32 3
a 17,571 10
a 26 mm
2
b 26 17,333
3
b 18 mm
PCD m T
6 28
168 mm

PCD D
L
2
168 90
2
39 mm
πND
V
60
π 395,122 168

60
3,476 m/s
P F V
15 10
F 
3,476
4 315,305 N
F ℓ
M
N
4 315,305 0,039

4
42,074 Nm
M
Z
σ
42,074
50 10
841,484 10 m 
π
Z ba
32
π 2
841,484 10 a a 
32 3
a 12,857 10
a 23,427 24 mm
2
b 24 16 mm
3

PCD mT
6 57
342 mm
d 50 2 100 mm
PCD D
L
2
342 100
2
121 mm
F ℓ
M
N
4 315,305 0,121

4
130,54 Nm
M 130,54
Z 2,611 10 
σ 50 10
π
Z ba
32
π 2
2,611 10 a a 
32 3
a 39,893 10
a 34,269 35 mm
2
b 35 23,33 23 mm
3 (42)
1.3 2πNT
P
60
2π 194,095 T
15 10 
60
T 737,986 Nm
T 1, xT
1,12 737,986
826,544 Nm (3)

1.4 T T T R
737,986 3,5T T 0,09
T 3 279,938 N
T 11 479,783 N
F F tan ∅
4 315,305 tan 20°
1 570,643 N
Vertical reactions:
Take moments about R :
ƩCWM ƩACWM
F 0,25 T T 0,95 R 1
1 570,643 0,25 11 479,783 3 279,938 1,2 R 1
R 18 104,326 N
ƩCWM ƩACWM
R 1 T T 0,2 F 0,75
R 1 11 479,783 3 279,938 0,2 1 570,6 3 0,75
R 1 773,962 N
M R 0,25
1 773,962 0,25 443,491 Nm
M T T 0,2
11 479,283 3 279,938 0,2 2 951,944 Nm

Horizontal reaction:
Take moment about R :
ƩCWM ƩACWM
F 0,25 R 1
4 315,305 0,25 R 
R 1 078,826 N
ƩCWM ƩACWM
R 1 F 0,75
R 4 315,305 0,75
R 3 236,479 N
M R 0,25
3 236,479 0,25
809,12 Nm
Resultant maximum bending moment on the right bearing:
M 2 951,944 Nm (19)
1.5 Torque required to drive the conveyor:
60P
T
2πN
60 15 10

2π 87,343
1,64 KNm (2)

[78]

QUESTION 2
π
A D
4
π
0,4
4
125,664 10 m 
F PA
2 10 125,664 10
251,327 KN
F 251,327 10 5
1,257 MN
A Bh bh
3t 3t 2t t 
7t m 
BD bd
I
12 12
3t 3t 2t t

12 12
6,75t 0,167t
6,583t m 
I
K
A
6,583t
7t
940,429 10 t 

σA
F
1
325 10 7t
1,257 10 , 
1
,
1
1 1 809,865t 
44 082,609t
44 082,609t 1 79,784 10 t
79,784 10 t 44 082,609t 1 0
b √b 4ac
t
2a
44 082,609 44 082,609 4 79,784 10 1

t 
2 79,784 10
t 574,347 10 
t 23,966 mm 24 mm
B H 3t 3 24 72 mm
DB db
I
12 12
3t 3t t 2t

12 12
6,75t 0,667t
6,083t 
I
K
A
6,083t
7t
0,869t 

σA
F
1
325 10 7t
1,257 10 ,

1
,
1
1 1 809,865t 
40 734,375t
40 734,375t 1 73,724 10 t
73,724 10 t 40 734,375t 1 0
b √b 4ac
t
2a
40 734,375 40 734,375 4 73,724 10 1

t 
2 73,724 10
t 576,071 10
t 24 mm
B H 3t 3 24 72 mm
∴B 72 mm, H 72 mm and t 24 mm about xx or yy axis is the same. [22]
TOTAL: 100
Copyright reserved
T1090(E)(A3)T

(8090086)

09:00–13:00

(8090086) -2- T1090(E)(A3)T

TIME: 4 HOURS
MARKS: 100
paper.
4. ALL calculations must have at least THREE steps, e.g. formula, substitution
and answer.
5. Use g = 9,81 m/s2.

(8090086) -3- T1090(E)(A3)T
QUESTION 1
The FIGURE on the DIAGRAM SHEET (attached) shows a line shaft driven by an
electric motor directly beneath and a driver by means of a gear drive and transmits
80 kW at 900 r/min. A centrifugal clutch is introduced between the motor and the gears
for a smooth movement, to reduce drive-related vibrations and allow the motor to reach
enough torque to drive before engagement.
Driven shaft information:
The driven solid shaft is mounted on TWO bearings 1 metre apart. The driven gear is
mounted 250 mm from the right-hand bearing. A pulley with a PCD of 400 mm is
mounted 300 mm from the left-hand bearing. The flywheel, with a mass of 120 kg, is
mounted at the midspan of the two bearings. The maximum bending and shear
stresses induced in the shaft is 100 MPa and 60 MPa respectively.
Gear information:
The gears are made of cast steel. The basic stress for cast steel is 140 MPa.
The pressure angle is 20°. The driving pinion A has a PCD of 120 mm and
20 teeth. The centre distance between the gears is 273 mm.
Belt information:
The belts are at an angle of 30° and parallel. The coefficient of friction between the belt
and the pulley is 0,25. The angle of contact between the belt and pulley is 180°.
Bearing information:
Both bearings are journal bearings. The coefficient of friction between the bearing and
the shaft is 0,08.
Clutch information:
The centrifugal clutch has FOUR shoes which slide radially on a spider key to the
driving shaft. The coefficient of friction between the shoes and the clutch drum is 0,25.
The clutch engages at 400 r/min. The mass of each shoe is 3,2 kg.
Calculate from the given information:
1.1 The number of teeth and the PCD of driven gear B (6)
1.2 Whether there is no interference between the gears (4)
1.3 The suitable face width using Lewis formula and check if it is within the limits (15)
1.4 The maximum torque on the driven shaft (assume 15% overloading) (4)
1.5 The maximum bending moment on the driven shaft (36)

(8090086) -4- T1090(E)(A3)T
1.6 The suitable driven shaft diameter (neglect the shock and fatigue factors) (10)
1.7 The resultant radial load on both bearings (4)
1.8 The frictional force, frictional toque and frictional power (12)
1.9 The suitable internal diameter for the centrifugal clutch drum (9)
[100]
TOTAL: 100
Copyright reserved
(8090086) T1090(E)(A3)T
DIAGRAM SHEET
300 mm 200 mm 250 mm 250 mm
Flywheel
Gear B
Motor
Pinion A
Clutch
30°
FIGURE
Copyright reserved
MARKING GUIDELINE
3 AUGUST 2018

MARKING GUIDELINE -2- T1090(E)(A3)T
QUESTION 1
1.1 m
C T T
2
PCD 120
m 
T 20
m 6 mm
6
273 20 T 
2
T 71 teeth
PCD
m
T
PCD
6 
71
PCD 426 mm (6)
1.2
R R 2 R r sin² φ r sin² φ
213 2 213 120 sin² 20° r sin² 20° 
230,29 mm
426 6 6
R
2
219 mm
There is no interference R R  (4)
1.3 :
V OR V
, , ,
 
5,655 m/s 5,655 m/s

3
CV
3 V
3

3 5,655
0,347
δ CV δ
0,347 140 10 
48,58 MPa
P F V
80 10 F 5,655 
F 14,147 kN
0,912
y 0,154
T
0,912
0,154 
20
108,4 10 
F π m b y θ
14,147 π 600 10 b 0,1084 48,58 10 
b 142,52 mm
b 2,5 π m b 4π m
2,5 π 6 4π 6
47,12 mm 75,4 mm
Outside limits (15)

1.4 N D N D
900 120
N  253,521
426
60P
T 1, x
2πN
60 80 10
1,15 
2π 253,521
3 465,325 Nm (4)
1.5 P OR T
,
,
80 10 T 
,
T 848,826 Nm T 3 013,335 Nm
T N T N
848,826 900 T 253,521
T 3 031,335 Nm
T
e
T
T ,
e 
T
T 2,193T 
T T T R
3 013,335 2,193T T 0,2
T 12 629 N
T 2,193 T
T 27 695 N
F T T sin 30°

27 695 12 629 sin 30° 
20 162 N
ƩCWM ƩACWM
F 0,3 F 0,75 R 1
20 162 0,3 14 147 0,74 R 1
R 16 658,85 N
ƩCWM ƩACWM
R 1 F 0,25 F 0,7
R 1 14 147 0,25 20 162 0,7
R 17 650,15 N
M R 0,3 17 650,15 0,3 5 295,045 Nm
M R 0,5 F 0,2
17 650,15 0,5 20 162 0,2
4 792,675 Nm
M R 0,25 16 658,85 0,25 4 164,713 Nm
F T T cos 30°
27 695 12 629 cos 30° 
34 922 N
W mg
120 9,81

1 177,2 N
F F tan ∅
14 147 tan 20° 
5 149,087 N
ƩCWM ƩACWM
F 0,3 W 0,5 F 0,75 R 1
34 922 0,3 1 177,2 0,5 5 149,087 0,75 R 1
R 7 203,385 N
ƩCWM ƩACWM
R 1 F 0,25 F 0,7 W 0,5
R 1 5 149,087 0,25 34 922 0,7 1 177,2 0,5
R 23 746,728 N
M R 0,3 23 746,728 0,3 7 124,018 Nm
M R 0,5 F 0,2
23 746,728 0,5 34 922 0,2
4 888,964 Nm
M R 0,25 7 203,385 0,25 1 800,846 Nm
∴ The maximum bending moment is at a pulley.
M F F
5 295,045 7 124,018 
8 876,324 Nm (36)

1.6 T M T 8 876,324 3 465,325  9 528,778 Nm
π
T D τ
16
π
9 528,778 D 60 10 
16
D 93,17 mm
1
M M T
2
1
M 8 876,324 9 528,778 
2
M 9 209,551 Nm
π
M D σ
32
π
9 202,551 D 100 10 
32
D 97,87 mm
∴ The suitable D 97,87 mm
∴D 100 mm (10)
1.7 :
R R R
17 650,15 23 746,728 
29,588 kN
R R R
16 658,85 7 203,385 
18,150 kN (4)

1.8 :
F μF
F 0,08 29 588 
F 2,367 kN
T F R
T 2 367 0,0475 
T 112,433 Nm
2πNT
P
60
2π 253,521 112,433
P 
60
P 2,985 kW
F μF
F 0,08 18 150 
F 1,452 kN
T F R
T 1 452 0,0475 
T 68,97 Nm
2πNT
P
60
2π 253,521 68,97
P 
60
P 1,831 kW (12)

1.9 2πN 2π 900

w 94,248 rad/s
60 69
F mw R
3,2 94,248 ²R
28,425 10 R N
2πN 2π 400
w 41,888rad/s
60 60
S mw R
3,2 41,888 ²R
5,615 10 R N
T μ F S R n
848,826 0,25 28 425R 5 615R R 4
R 106,88 mm
D 2R
2 196,88 
394 mm (9)

[100]
TOTAL: 100
Copyright reserved
T1090(E)(A10)T

(8090086)

09:00–13:00
Calculators, personal notes and textbooks may be used.

(8090086) -2- T1090(E)(A10)T

TIME: 4 HOURS
MARKS: 100
paper.
4. Show ALL steps to achieve as many marks as possible. An incorrect answer

which must be carried forward will receive fair consideration.

(8090086) -3- T1090(E)(A10)T
QUESTION 1
Consider FIGURE 1. F is a flywheel with a mass of 200 kg. B is a driven gear. A is the
driving pinion which transmits 40 kW from a motor rotating at 2 200 r/min. Pinion A has a
PCD of 240 mm. The gear ratio is 2 : 1. C is a flat-belt pulley mounted at the extreme left
end of the shaft and drives a machine situated below it. The PCD of the pulley is
500 mm and the angle of contact of the belt is 210°. The coefficient of friction between
the belt and the pulley is 0,3. ALL distances are in mm.
A ``
A
F
C
F
C
30°
200 400 500 300
6400
FIGURE 1
1.1 Calculate the number of teeth on both gears A and C if the module is 5 mm. (1)
1.2 Calculate the torque on the shaft. (1)
1.3 Calculate the face width of gears A and B assuming a basic stress of
112 MPa for cast steel (gear A) and a basic stress of 120 MPa for alloy steel
(gear B). (10)
1.4 Calculate the forces of the flywheel, gear and flat pulley acting on the shaft. (14)
1.5 Calculate the values for the bending moments and draw the bending moment
diagrams for the vertical and horizontal loading. (20)
1.7 Calculate the diameters of the hollow shaft using (TE) and (ME) if D = 2 d.
The safe tensile stress is 50 MPa and the safe shear stress is 40 MPa. (5)
1.8 Calculate the rectangular spoke sizes for the large gear with a ratio of 2 : 1.
The bending stress is 40 MPa. (7)
[61]

(8090086) -4- T1090(E)(A10)T
QUESTION 2
FIGURE 2 shows a cast-iron compression member. The 50 mm diameter pins each

have a bearing surface length of 40 mm and when the member is in compression the
bearing pressure in the eye portion is 95 MPa.
Regard the member as a column with the end fixation conditions as follows:
a) Relative to the x-x axis the end may be regarded as pivoted (hinged)
b) Relative to the y-y axis the end may be regarded as fixed
Ø50
Ø50.0000
60
600
FIGURE 2
Use the Rankine formula with appropriate constants 1/1 600 and determine the
stresses induced in the material for the conditions a) and b) respectively. [19]

(8090086) -5- T1090(E)(A10)T
QUESTION 3
The conical pivot shown in FIGURE 3 has an included angle of 120° and rests on a
bearing surface having an outer diameter to inner diameter ratio of 3 : 1. The pivot
supports an axial load of 35 kN while rotating at 350 r/min. The coefficient of friction of
the material is 0,09 and the bearing pressure is 450 kPa. The temperatures of cooling
oil entering and leaving the bearing are 20 °C and 85 °C respectively. The specific heat
capacity of the oil is 3,14 kJ/kg.°C and the density is 0,85 kg/litre.
FA
D
120°
FN
FIGURE 3
Calculate:
3.1 The normal force between the surfaces (3)
3.2 The inner diameter of the bearing assuming pressure wear (6)
3.3 The outer diameter of the bearing assuming uniform wear (2)
3.4 The power lost to friction assuming uniform pressure theory (4)
3.5 The quantity of cooling oil required in litres/min to the bearing surface (5)
[20]
TOTAL: 100
Copyright reserved
MARKING GUIDELINE
10 APRIL 2018

QUESTION 1
1.1 Gear teeth
PCD m T
240 5 T
T 48
T 2 48
T 96 (1)
1.2 Torques on shaft
2 π N T
P
60
2 3,142 1 100 T
40 10
60
40 10 60
T
2 3,142 1 100
T 347,2 Nm (1)
1.3 Face width
π PCD N
V
60
π 024 2 200
V
60
V 27,65 m/s (1)
5,6
C
5,6 V
5,6
C
5,6 27,65
C 0,1684 (1)
P F v
40 10 F 27,65
40 10
F
27,65
40 10
F
27,65
F 1 446,67 N (1)

Form factor
0,912
y 0,154
T
0,912
y 0,154
48
y 0,154 0,019
y 0,135 (1)
0,912
y 0,154
T
0,912
y 0,154
96
y 0,154 0,0095
y 0,145 (1)
Working stress for gear A
σ σ C y
σ 112 10 0,1684 0,135
σ 2,546 MPa (1)
Working stress for gear B

σ σ C y
σ 120 10 0,1684 0,145
σ 2,93 MPa
(1)
F π m b σ y
1 446,67 π 5 10 b 2,546 10
1 446,67
b
π 5 2,546 10
b 36,17 mm (1)
b 2,5 π m
2,5 π 5
b 39,3 mm (1)
b 4 π m
4 π 5
b 62,8 mm (1)
1.4 Force on flywheel
W m g
200 9,81
1 962 N
(1)
N 2
N 1
N 2 200
N
2 2
N 1 100 r/min (1)
Forces on belt pulley
π PCD N
V
60
π 0,5 1 100
V
60
V 28,80 r/min (1)
P T T V
T
e
T
T ,
,
e
T
T 3T (1)
40 10 T T 28,80
40 10 3T T 28,80
40 10 2T 28,80
40 10
T
28,80 2
(1)
T 694,44 N
T 3 694,44
T 2 083,32 N
(1)
T T 2 083,32 694,44
T T 2 777,76 N (1)

2 777,76 sin30 0
°
30
°
2 777,76 2 777,76 cos30
(1)
Vertical and horizontal forces on pulley

F T T cos30
2 777,76 0,866
2 405,61 N (1)
F T T sin30
2 777,76 0,5
1 388,88 N (1)
Determination of forces on the gear

2 Nπ T
P
60
60 P
T
2 π N (1)
Torque on pinion
60 40 000
T
2 π 2 200
T 173,60 Nm (1)
torque 2
F
PCD
173,60 2
F
0,24
(1)
F 1 446,67 N
F tan20 1 446,67
0,364 1 446,67
(1)
F 526,59 N

1.5
``
A
1 446,67 N
526,59 N
(2)
2 405,61 505,48 1 962

`
Q R S T
P
R1 R2
200 250 500 250
6400
(1)
Sum of forces in one direction = the sum of forces in the opposite direction
R R 2 405,61 526,59 1 962

R R 4 894,2 N
(1)
Taking moment about Q
1,2 R 2 405,61 0,2 526,59 0,4 1 962 0,9 (1)
1,2 R 481,12 210,64 1 765,8

1,2 R 2 457,56
R 2 047,97 N
(1)
R 4 894,2 2 047,97
R 2 846,23 N (1)

Vertical bending moments

BM 2 405,61 0,2
481,12 Nm (1)
2405,61 0,6 2846,23 0,4

1443,37 1138,49
304,88
2047,97 0,3
614,39 (1)
Horizontal reactions on shaft
1 388,88 Ft = 1 446,67
Q R S T
`
P
R3 R4
200 250 500 250
(1)
6400
R R F 1 388,88
R R 1 388,88 F
R R 1 388,88 1 446,67
R R 57,79
(1)

Taking moment about Q

1,2 R F 0,4 1 388,88 0,2
1,2 R 1 388,88 0,2 1 446,67 0,2
1,2 R 277,78 289,33 (1)
1,2 R 11,55
11,55
R
1,2
R 9,63 N (1)
R 57,79
R 57,79 R (1)
R 57,79 9,63
48,16 N (1)
Horizontal bending moments

BM 1 388,88 0,2
277,78 Nm
BM 1 388,88 0,6 48,16 0,4
852,59 Nm
BM 9,63 0,3
2,89 Nm
(1)
614,39
P R S
Q Vertical bending moment
T
304,88
481,12
640
0
P Q R S T Horizontal bending moment
2,89
277,78
852,59
640
0
(4)

1.6 Maximum resultant bending moments

BM 481,12 277,78
231 476,45 77 161,73

555,55 Nm
(1)
BM 304,88 852,59
BM 92 951,81 726 909,71

BM 905,46 Nm
(1)
BM 614,39 2,89
BM 614,4 Nm
Use 905,46 Nm (1)
1.7 Shaft diameter
T M T
T 905,46 347,2
T 819 857,81 120 547,84

T 969,75 Nm
(1)
π D d
T τ
16 D
π 2d d
T τ
16 2d
π
T 15d τ
32
π
969,75 15d 40 10
32
969,75 32
d
40 10 π 15
d 16,46 10
d 0,0406 m
d 41 mm
D 82 mm (1)

1
M M T M
2
1
M 905,46 969,75
2
M 937,61 Nm (1)
π D d
M σ
16 D (1)
π 2d d
M σ
16 2d
π
937,61 15d 50 10
32
937,61 32
d
50 10 π 15
d 12,73 10
d 0,0357 m
d 35,7 mm
Say d 36 mm
D 72 mm (1)
1.8 The gear arms

PCD 2 240
480 mm (1)
No arms 4 from tables
d 41 mm
D 82 mm
d 2 d
d 2 82
164 mm (1)
PCD d
L
2 2
480 164
2 2
L 158 mm
(1)

F L
arm
1 446,67 0,158
M
4
57,1 Nm (1)
M σ Z
57,1 40 10 Z
57,1
Z
40 10
Z 1,428 10 m
d
Z
12 (1)
d 1,428 10 12
d 1,428 10 12
d 4,14 10 m
d 41,4 mm
(1)
41,4
b mm
2
b 20,7 mm
(1)
[61]

QUESTION 2
Surface area of bearing

A d L
A 0,05 0,04
A 0,002 m (1)
F
P
A
F
95 10
0,002
F 190 kN (1)
Surface area of a section through the column

π
A a b
4
π (1)
0,06 0,03
4
0,0014 m (1)
π b a
I
64
(1)
π 0,03 0,06
I
64
3,18 10 m (1)
I
k
A
3,18 10
k
0,0014
2,27 10 m
(1)
π b a
I
64
π 0,03 0,06 (1)
I
64
7,9 10 m
(1)
I
k
A
7,9 10
k
0,0014 (1)
5,64 10 m
σ A
F
1
σ 0,0014 (3)
190 000 ,
1 (1)
,
σ 270,23 MPa
σ A
F
1
0,6
L
2 (1)
0,3
σ 0,0014
190 000 , (3)
1
,
(1)
σ 169,55 MPa
[19]
QUESTION 3
3.1 θ 120 (1)

θ 120
α
2 2
θ 60
35 10 (1)
F
sin60
35 10
F
0,866
F 40,41 kN (1)

3.2 Inner diameter of bearing

R r
sin60
w
R r
w
sin60 (1)
R r
R
2
F P A
F P 2 π w
R r R r
40 410 450 10 2 π
2 sin60 (1)
D 3
d 1
D 3d (1)
R 3r
0,02475 3r r 3r r
(1)
0,02475 9r r
0,02475 8r
0,02475
r
8
(1)
r 0,05562
r 56 mm
d 112 mm (1)
3.3 Outer diameter of the bearing

D 3 112
(1)
D 336 mm (1)

3.4 Power lost by friction
T μ F R
2 R r
R
3 R r
2 0,168 0,056
R
3 0,168 0,056 (1)
R 0,121 m (1)
T 0,09 40 410 0,121

T 440,06 Nm (1)
2 π N T
P
60
2 π 350 440,06
P
60
P 16,13 kW
(1)
3.5 Quantity of cooling water

Heat lost = Heat gained
H H
16,13 10 m S. H. C ∆T
16,13 10 m 3,14 10 85 20 (1)
16,13 10
m
65 3,14 10
(1)
m 0,079 kg/s
0,079
Q (1)
0,85
Q 0,0929 lit/s
(1)
Q 0,0929 60 lit/s
Q 5,574 lit/min (1)
[20]
TOTAL: 100
Copyright reserved
T1090(E)(N28)T

(8090086)
28 NOVEMBER 2017 (X-Paper)

09:00–13:00
Copyright reserved Please turnover

(8090086) -2- T1090(E)(N28)T

TIME: 4 HOURS
MARKS: 100
paper.
4. A correct answer is worth only one mark. Show all the steps to achieve as
many marks as possible. (An incorrect answer which has to be carried
forward will receive fair consideration.)
5. ALL work you do not want to be marked must be clearly crossed out.

(8090086) -3- T1090(E)(N28)T
QUESTION 1
An overhung pulley transmits 35 kW at 240 r/min. The belt drive is vertical and the
angle of wrap is 180°. The distance of the pulley centre line from the nearest bearing is
350 mm. The coefficient of friction between the pulley and the belt material is 0,25. The
density of the pulley material is 7 200 kg/m3. The section of the arm is elliptical. The
major axis is twice the minor axis.
The following stresses may be taken for design purposes:
Shaft tension and compression 80 MPa

Key shear 50 MPa
Belt tension 2,5 MPa
Pulley rim tension 4,5 MPa
Pulley arms tension 15 MPa
Determine:
1.1 Diameter of the pulley (3)
1.2 Width of the belt assuming a thickness of 10 mm (7)
1.3 Diameter of the shaft (7)
1.4 Dimensions of the key for securing the pulley to the shaft (3)
1.5 Size of the six arms (6)

[26]

(8090086) -4- T1090(E)(N28)T
QUESTION 2
The figure below shows the cross section of a built up steel column, 8 m long and with
ends firmly fixed. The properties of the I-section are:
Area = 9 300 mm2

Ixx = 3 × 106 m4
Iyy = 8,4 × 106 mm4
Young's modulus of elasticity = 2 × 105 N/mm2
Factor of safety = 3,5
Ultimate crushing load for the column = 330 N/mm2
Rankine's constant = 1/7 500
All the dimensions are in mm
2.1 Determine the safe axial load the above column can carry using:
2.1.1 Euler's formula (7)
2.1.2 Rankine's formula (5)
2.2 Determine the length of the column for which both formulae give the same
crippling load. (4)
2.3 Determine the length of the column for which the Euler's formula ceases to
apply. (4)
[20]

(8090086) -5- T1090(E)(N28)T
QUESTION 3
A solid steel shaft is supported on two bearings 1,8 m apart and rotates at 250 r/min.
A 20° involute gear D with a 300 mm diameter is keyed to the shaft at a distance of
150 mm to the left on the right-hand bearing. Two pulleys B and C are located on the
shaft at distances of 600 mm and 1 350 mm respectively to the right of the left-hand
bearing.
The diameters of pulleys B and C are 750 mm and 600 mm respectively. 30 kW is

supplied to the gear, out of which 18,75 kW is taken off at the pulley C and 11,25 kW
from pulley B. The drive from B is vertically downward while from C the drive is
downward at an angle of 60° to the horizontal. In both cases the belt tension ratio is
2 and the angle of lap is 180°. The combined fatigue and shock factors for torsion and
bending may be taken as 1,5 and 2 respectively.
Design a suitable shaft taking working stress to be 42 N/mm2 in shear and 84 N/mm2 in
tension. [45]
QUESTION 4
A plate clutch with a single driving plate with contact surfaces on each side, has to
transmit 110 kW at 1 250 r/min. The outer diameter of the contact surfaces is 300 mm.
The coefficient of friction is 0,4. Assume a uniform pressure of 0,17 N/mm2.
Determine the inner diameter of the friction surfaces. [9]
TOTAL: 100
Copyright reserved
MARKING GUIDELINE
28 NOVEMBER 2017

QUESTION 1
1.1


(3)
1.2

Cross-sectional area of the belt
10
10 10
10
Mass of the belt per metre length
10
1 1000 0.01 /
10


Select a standard belt width of 140 mm. (7)

1.3

M 1 923 Nm 
NOTE: 1 MPa = 1 N/mm2
d 62.3mm 
Select d = 65 mm standard diameter (7)
1.4 The standard dimensions of the key of the 65 mm diameter shaft are:
w = 20 mm
t = 12 mm
l = length of the key
Considering shearing of the key.

65 102  (3)

1.5 b minor axis

b major axis 2b

42,8
45 
 (6)
[26]
QUESTION 2
2.1 2.1.1


 (7)
2.1.2

 (5)
2.2
 
 (4)

2.3
 (4)
[20]
QUESTION 3
For gear D
1146 

Vertical component of WD

Horizontal component of WD

For pulley C
Let TC1 and TC2 = Tensions in the tight side and slack side of the belt for pulley C

Vertical component of WC

Horizontal component of WC

For pulley B
Let TB1 and TB2 be tensions in the tight side and slack side of the belt for pulley B.


Total load acting on pulley B

Considering vertical loading on the shaft
Let RPV and RQV be the reactions at bearings P and Q respectively for vertical loading

Taking moments about P, we get:




Considering the bending moments at P, B, C and D respectively



Let RPH and RQH be the reactions at the bearings P and Q respectively for horizontal
loading

Taking moments about P

It is known that B.M. at P and Q = 0

The resultant bending moments for the points B, C and D are:

The maximum resultant bending moment is at C.
3790 
T = Torque corresponding to 30 kW = TD = 1 146 Nm
d = diameter of the shaft in mm.
Equivalent twisting moment Te
Equivalent bending moment Me


Choose the larger of the two diameters, hence d = 98 mm. 

Select d = 100 mm. [45]

QUESTION 4
As the intensity of pressure is maximum at the inner radius (r2)
For uniform wear conditions
0.1 / 
Axial load acting on the friction surface
2 – 2 0.1 1.25 – 
0,157 
/ 1,25
The torque transmitted T
Outer diameter of frictional surface
2 2 120 240 
Inner diameter of frictional surface
2 2 96 192 mm  [9]
TOTAL: 100
Copyright reserved
T1020(E)(A4)T

(8090086)

09:00–13:00

(8090086) -2- T1020(E)(A4)T

TIME: 4 HOURS
MARKS: 100
paper.
5. Show ALL steps. (An incorrect answer that must be carried forward will
receive fair consideration.)

(8090086) -3- T1020(E)(A4)T
QUESTION 1
The following data refers to a square mild steel strut with a side of 80 mm and a wall
thickness of 5 mm:
 Factor of safety 6
 End conditions Fixed ends
 Young's modulus of elasticity 210 GPa
 Crippling stress 0,2 GPa
 Constant 1/3 000
 Actual length 2m
Determine the working load using the following formulae:
1.1 Euler (6)
1.2 Rankine (4)
1.3 Straight line (4)

[14]
QUESTION 2
A shaft is supported by two bearings placed 1 m apart. A pulley with a diameter of

600 mm is mounted at a distance of 300 mm to the right of a left-hand bearing that
drives a pulley directly below it with the help of a belt with a maximum tension of
2,25 kN. Another pulley with a diameter of 400 mm is placed 200 mm to the left of a
right-hand bearing and is driven with the help of an electric motor and belt placed
horizontally to the right. The angle of contact for both pulleys is 180˚ and μ = 0,24.
Determine the suitable diameter for a solid shaft, allowing working stress of 63 MPa in
tension and 42 MPa in shear for the material of the shaft. Assume that the torque on
one pulley is equal to that on the other pulley. [44]

(8090086) -4- T1020(E)(A4)T
QUESTION 3
Design a single-plate automobile clutch to transmit a maximum torque of 250 Nm at

2 000 r/min. The outside diameter of the clutch is 250 mm and the clutch is engaged at
55 km/h.
The following additional data is available:
 Engine torque during engagement 100 Nm

 Mass of the automobile 1 500 kg
 Diameter of the automobile wheel 0,7 m
 Moment of inertia of combined engine rotating parts,
flywheel and input side of the clutch 1 kgm2
 Gear reduction ratio at differential 5
 Torque at rear wheels available for accelerating
automobile 175 Nm
 Coefficient of friction for clutch material 0,3
 Permissible pressure 0,13 N/mm2
Calculate:
3.1 The number of revolutions of the clutch slip during engagement (18)
3.2 The heat to be dissipated by the clutch for each engagement (2)
[20]
QUESTION 4
A 350 mm pulley rotating at 900 r/min has to transmit 42 kW by means of a flat belt to
a second pulley 750 mm in diameter. The pulley centres are 1,5 m apart. The belt,
18 mm thick, has a mass of 0,8 kg/m and may be loaded to a maximum value of
30 N/mm belt width.
Assume that the friction coefficient is 0,4 and calculate the following:
4.1 Belt width (8)
4.2 Belt length (1)

[9]
QUESTION 5
An 80 mm long journal bearing supports a load of 2 800 N on a shaft 50 mm in

diameter. The bearing has a radial clearance of 0,05 mm and the viscosity of the oil is
0,021 kg/ms at operating temperature.
Determine the maximum safe speed if the bearing is capable of dissipating 80 J/s. [13]
TOTAL: 100
Copyright reserved
T1110(E)(A7)T

(8090086)

09:00–13:00
Candidates may use personal notes.

(8090086) -2- T1110(E)(A7)T

TIME: 4 HOURS
MARKS: 100
paper.
4. A correct answer is worth only ONE mark. Show ALL the steps to achieve as

(8090086) -3- T1110(E)(A7)T
QUESTION 1
A belt bucket elevator is used to raise crushed aluminium sulphate through a vertical
height of 30 m from charge to discharge. Each bucket has a volume of 3 litres and there
are 45 loaded buckets at any one time. The density of the aluminium sulphate is
1 850 kg/m3. The head pulley has a diameter 300 mm and rotates at 250 r/min. The
motor rotates at 900 r/min. The coefficient of friction between the belt and head pulley is
0,3 and the angle of contact is 180°.
The gears driving the head pulley have a module of 4 mm and the small gear has
25 teeth. The two gears are vertically above one another with the pinion A at the top as
shown in FIGURE 1 below. The return of the buckets is not shown.
FIGURE 1
1.1 Assume that each bucket is always full when calculating the diameter of the
shaft required on the head pulley. The shear stress in the shaft may not exceed
120 MPa and the tensile stress is limited to 140 MPa. Use shock factors of 3 for
both bending and torsion. (30)
1.2 The width of the gears using the Lewis equation. The pinion (A) is made of steel
with a basic stress of 80 MPa and the cast-iron gear (B) has a basic stress of
50 MPa. (8)

(8090086) -4- T1110(E)(A7)T
1.3 Assume the head pulley uses arms with an H-profile with a constant metal
thickness and the ratio of height to thickness is 3 : 1 and determine the profile
dimensions. The bending stress in the arms is limited to 20 MPa. There are
identical arms at either end of the head pulley. (10)
[48]
QUESTION 2
A centrifugal clutch has a driving member consisting of a cruciform spider carrying four
shoes which can slide radially in grooves in the spider. This movement is resisted by
springs in each shoe until the increase of centrifugal force during rotation will overcome
the spring resistance and the shoe will make contact with the inside of the driven drum
and will then, by virtue of frictional resistance, transmit power. Assume the drum has
an outside diameter of 370 mm and a rim thickness of 10 mm. 8 kW must be
transmitted at an operating speed of 800 r/min. Initially, until rotation commences,
there will be a clear space of 5 mm between the driven drum inside diameter and the
shoe contact surface. Engagement is to commence at 500 r/min. The thickness of the
friction lining when new is 6 mm.
Determine the following:
2.1 The radial distance from the centre of shoe mass to the shaft centre when the
clutch is in operation. The shoe is shown in FIGURE 2 below. Ignore the
curved area (A) and the thickness of the friction lining. (8)
FIGURE 2
2.2 The mass of each shoe if the coefficient of friction is 0,3 (6)
2.3 The shoe depth if the density of the shoe material is 7 700 kg/m3 (3)

(8090086) -5- T1110(E)(A7)T
2.4 Whether the maximum pressure of 3 kg/cm2 the lining can withstand is not
exceeded (3)
[20]
QUESTION 3
A 60 mm diameter shaft is supported by means of a journal bearing 100 mm long. The

shaft rotates at 500 r/min and the reaction on the bearing is 4 kN. The temperature of
the bearing is limited to 60 °C whilst the ambient temperature is 30 °C.
3.1 The SAE number of the oil required to lubricate the bearing assuming it
operates in still air (the radial clearance of the bearing is 0,08 mm) (8)
3.2 The quantity of oil in litres per minute required if its density is 780 kg/m3 (the
specific heat capacity of the oil is 3 140 J/kg.K) (4)
[12]
QUESTION 4
Prove when the band brake shown in FIGURE 3 below is self-locking for clockwise
rotation.


P
T2
T1 y
x
FIGURE 3 [4]

(8090086) -6- T1110(E)(A7)T
QUESTION 5
FIGURE 4 below shows a motor vehicle gearbox connected to a differential with a gear
ratio of 4 : 1. The wheels have a diameter of 0,7 m and the centre distance between
shafts 1 and 2 and between 2 and 3 are equal. Gears A and D have 20 teeth and
45 teeth respectively.
C
B
A C
1 3
Engine
H
H
2
G
G
E F
20 teeth  0,7 m
4:1
= =
45 teeth
FIGURE 4
5.1 The number of teeth on gears C and F for first gear if the engine rotates at
approximately 2 000 r/min and the wheels have a velocity of 25 km/h (6)
5.2 The number of teeth on gears B and E for second gear if the engine rotates at
approximately 3 500 r/min and the wheels have a velocity of 60 km/h (6)
5.3 The number of teeth on gears C, G and H for reverse gear if the engine
rotates at approximately 1 400 r/min and the wheels have a velocity of
10 km/h. There is no reduction between gears G and H. Note that gears
G and H mesh with gear C to give reverse gear. (4)
[16]
TOTAL: 100
Copyright reserved
MARKING GUIDELINE
7 APRIL 2017

QUESTION 1
1.1 Diameter of the shaft:
mass
=
vol
3
m  1850 
1000
 5,55 kg / bucket (1)
W=5,55  45  g
 2450 N (1)
T1 
=e
T2
2450
 e0,3
T2
T2  954, 688 N (1)
T=  T1  T2   R HEAD PULLEY
0,3
  2450  954, 688  
2
T  224,304 Nm (1)
N A TA =N BTB
900  25  250  TB
TB  90 (1)
PCD B =m  T
 4  90
 360 mm (1)
PCD
T=FT 
2
0,36
224,304  FT 
2
FT  1246,133 N (1)
FR =FT  Tan20
 1246,133  Tan20
FR  453,56 N (1)

(1)
T1 +T2 =2450  954, 688

 3404, 688 N (1)
Vertical loading:
L  0, 68=3404,688  0,3  453,56  0,58

L  1888,93 N (1)
R  0, 68=3404, 688  0,38  453,56  0,1

R  1969,32 N (1)
Check
1888,93  1969,32=3404, 688  453,56
3858, 25  3858, 25 (1)
BM GEAR =1888,93  0,1

 188,893 Nm (1)
BM HEAD PULLEY =1969,32  0,3

 590, 796 Nm (1)

Horizontal loading:
L  0, 68=1246,133  0,58
L  1062,88 N (1)
R  0, 68=1246,133  0,1
R  183, 255 N (1)
Check
1062,88  183, 255=1246,133
1246,133 1246,133 (1)
BM GEAR =1062,88  0,1

 106, 288 Nm (1)
BM HEAD PULLEY =183, 255  0,3

 54,9765 Nm (1)
Resultant bending moments:
BM GEAR = 106, 2882  188,8932

 216, 743 Nm (1)
BM HEAD PULLEY = 54,97652  590, 7962

 593,35 Nm (1)
 KB  M    KT  T 
2 2
TE =
 3  593,35   3  224,304 
2 2
=
 1902,99 Nm (2)
TE =   d3  
16
1902,99=   d3 120 106
16
 0,043
 43mm (2)
M E =0, 5  K B  M   TE 
=0,5 3  593,35  1902, 99 
 1841,52 Nm (2)

ME =   d 3  T
32
1841,52=   d 3 140 106
32
 0,51
d  55mm (2)
1.2 Width of the gears:
 PCD B  N B
v=
60
 0,36  250

60
 4, 7124 m / s (1)
y25 =0,108 (1)
 0,912 
y90 =0,154   
 90 
 0,144 (1)
3
CV =
3 V
3
=
3  4, 7124
 0,39 (1)
 A =80  106  0,108  0,39

= 3,3696 MPa (1)
 B =50  106  0,144  0,39

= 2,808 MPa (1)
FT B = m  b    y
1246,133=  0, 004  b  2,808  106
 35,3mm
 36 mm (1)
b MIN =2,5   m
 2, 5   4
 31, 4 mm

b MAX =4   m
 4   4
 50,3mm (1)
1.3 Arm dimensions:
d BOSS =2  d SHAFT
 2  55
 110 mm (1)
D=300 mm
 4 arms (1)
300  110
LE =
2
 95 mm (1)
BM=
 T1  T2   LE
2  No arms

 2450  954, 688  0, 095
2 4
17, 76 Nm (3)
t  d2
Z=
3
t   3t 
2

3
 3t 3
(2)
M= Z
17, 76  20 106  3t 3
t  0, 00666 mm
 8 mm
d  24 mm (2)
[48]

QUESTION 2
2.1 The radial distance from the centre of shoe mass to the shaft centre when the
clutch is in operation.
AREA B =98  23
 2254 mm 2
AREA C =98  23
 2254 mm 2 (1)
AREA D =40 12

 480 mm2 (1)
AREA E =40  30
 1200 mm 2 (1)
AREA TOTAL =2254  2  480  1200

 6188 mm2 (1)
2  A C  49  A D  42  A E  83=A TOTAL  y
2  2254  49  480  42  1200  83  6188  y
y  55, 05 mm (2)
370  20
R DRUM =
2
 175 mm (1)

R G =175  6  102  55, 05
 122, 05 mm (1)
2.2 The mass of each shoe if the coefficient of friction is 0,3:
2   N  T
P=
60
2   800  T
8 103 =
60
T=95,493 Nm (1)
95,493
T=
4
 23,873 Nm (1)
T=FT  R DRUM
23,873  FT  0,175
FT  136, 419 N (1)
FT =  FNETT
136, 419  0,3  FNETT
FNETT  454, 728 N (1)
FNETT =FCMAX  FCENG

 m  2  R G  m  2  R G
 2 
2
454, 728  m  0,12205     8002  5002 

 60 
m  0,871kg (2)
2.3 The shoe depth if the density of the shoe material is 7 700 kg/m3:
m
=
Vol
0,871
7700 
6188 106  d
d  18, 283mm
 20 mm (3)
2.4 The pressure that the shoe exerts on the drum:

FNETT
P=
Area
454, 728

0, 02  0, 086
d  264,377 kPa
 OKAY (3)
[20]
QUESTION 3
3.1 The SAE oil required to lubricate the bearing:
T=TB  TA
 60  30
 300 C (1)
 T  18
2
HD =  L D
K
 30  18
2
  0,1 0, 06
0, 484
 28,562 W (1)
 d  N
H G =f  W 
60
 0, 06  500
 f  4 103 
60
 2000   f (1)
H D =H G
28,562  2000   f
f  4,546 103 (1)
W
P=
 d  L
4  103

 0, 06  0,1
 212206 Pa (1)

0,326    N D
f=  k
P C
0,326    500 60
0, 004546    0, 002
212206 0, 08
  4, 419 103 kg / m.s (1)
T=0,5  TO  TA 
30  0,5  TO  30 
TO  900 C (1)
From table use SAE 10. (1)
3.2 The quantity of oil in litres per second required if its density is 780 kg/m3:
H G =m  SHC  T
28,562  m  3140  30
m  0, 000303kg / s (2)
m
=
Q
0, 000303
780 
Q
Q  388, 698 109 m3 / s
 388, 698 109 103  60
 0, 0233l / min (2)
[12]
QUESTION 4
P  y  T1  z=T2  x
T2  x  T1  z
P
y (1)
T1 
=e
T2
T1  T2  e (1)
T2  x  T1  z
P
y
T2  x  T2  e  z

y
T

P  2 x  e  z
y

(1)
When e  z  x then the brake is self locking (1)

[4]
QUESTION 5
5.1 The number of teeth on gears C and F:
 D  N
v=
60
25  0, 7  N

3, 6 60
N WHEEL  189, 47 r / min (1)
N C  189, 47  4
 757,88 r / min (1)
N A TC  TD

N C TA  TF
2000 T  45
 C
757,88 20  TF
TC  1,1728TF ....................1 (1)

CAD  CCF
m  TA  TD  m  TC  TF 

2 2
20  45  TC  TF
TC  TF  65.........................2 (1)
1,1728TF  TF  65
TF  29,9
 30 teeth (1)
TC  TF  65
TC  65  30
 35 teeth (1)
5.2 The number of teeth on gears B and E:
 D  N
v=
60
60  0, 7  N

3, 6 60
N WHEEL  454, 728 r / min (1)
N B  454, 728  4
 1818,913r / min (1)
N A TB  TD

N C TA  TE
3500 T  45
 B
1818,913 20  TE
TB  0,8552TE ....................1 (1)
CAD  CBE
m  TA  TD  m  TB  TE 

2 2
20  45  TC  TF
TB  TE  65.........................2 (1)

0,8552TE  TE  65
TE  35, 036
 35 teeth (1)
TB  TE  65
TB  65  35
 30 teeth (1)
5.3 The number of teeth on gears C, G and H:
TG  TH
 D  N
v=
60
10  0, 7  N

3, 6 60
N WHEEL  75, 788 r / min (1)
N C  75, 788  4
 303,1523r / min (1)
N A TC  TD

N C TA  TG
1400 35  45

303,1523 20  TE
TG  17 teeth (1)
TG  TH
TH  17teeth (1)
[16]
TOTAL: 100
Copyright reserved
T950(E)(N16)T
NOVEMBER EXAMINATION

(8090086)

09:00–13:00

(8090086) -2- T950(E)(N16)T

TIME: 4 HOURS
MARKS: 100
paper.
many marks as possible. (An incorrect answer which must be carried

(8090086) -3- T950(E)(N16)T
QUESTION 1
A motor car clutch is required to transmit 120 kW at 6 500 r/min. It is of a single plate
with both sides effective. The average axial pressure is 140 kPa and the external
diameter is 1,75 times the internal diameter. The coefficient of friction between the
contact surfaces is 0,3.
FIGURE 1
1.1 Determine the following:
1.1.1 The internal and external diameters assuming uniform wear theory (8)
1.1.2 The diameter (d) of the pins if the clutch is engaged by means of
the forked lever as shown in FIGURE 1 and the shear stress is
limited to 30 MPa (6)
1.1.3 The dimensions of the fork at A-A if it is of square cross-section

and the bending stress is 40 MPa (6)
1.1.4 The thickness of the steel driving disc (where the Ferodo is riveted)
if the shear stress in the steel may not exceed 40 MPa (Assume
that the disc joins the hub at a diameter of 50 mm.) (5)
1.2 If a clamping force of 125 N/mm is provided by each of the six springs when
they are compressed 8 mm, how much can the friction material wear before
the clutch will slip? (5)
[30]

(8090086) -4- T950(E)(N16)T
QUESTION 2
A solid shaft is mounted between two bearings 0,7 m apart and is driven by a 100 kW
power source rotating at 200 r/min. A gear with a 20° pressure angle and a pitch-circle
diameter of 250 mm is situated between the two bearings and 300 mm from the
right-hand bearing. The shaft is subjected to high shock and fatigue factors of K b = 3
and Kt = 2,5. The shear stress in the shaft cannot exceed 100 MPa and the maximum
tensile stress must not exceed 80 MPa.
Determine a suitable shaft diameter (consider bending and twisting). [17]
QUESTION 3
FIGURE 2 shows a reduction unit between a motor that rotates at 1 720 r/min and a
conveyor drive that rotates at 860 r/min. Both 20° full-depth involute gears are 41 mm
wide and have a module of 5 mm. The pinion (A) has 18 teeth and is made of steel
with a basic stress of 186 MPa. The cast-iron gear (B) has a basic stress of 138 MPa.
Only use the tables for the form factor.
FIGURE 2
3.1 The teeth on gear B (1)
3.2 The pitch-circle diameters of both gears (2)

(8090086) -5- T950(E)(N16)T
3.3 The velocity of each gear (1)
3.4 The power that can be safely transmitted (12)

[16]
QUESTION 4
FIGURE 3 shows a hollow cast-iron column 4 m long and carrying a load of

1
500 kN. The stress is 520 MPa. Assume a Rankine constant of (end fixation
7 500
not taken into account) and determine the dimensions of the elliptical column as well
as the thickness of the material. A = 2B and B = 1,2 b.
FIGURE 3 [21]
QUESTION 5
A conical pivot has an included angle of 130° and rests on a bearing surface having an
outer diameter to inner diameter ratio of 4 : 1. The pivot supports an axial load of
20 kN while rotating at 300 r/min.
Given a coefficient of friction of 0,05 and a bearing pressure of 300 kPa for the lining
material, calculate the following:
5.2 The inner diameter of the bearing assuming uniform wear (5)
5.4 The power lost to friction assuming uniform pressure (4)
5.5 The quantity of cooling water needed in litres/min to keep the bearing surface
temperature constant at 60 °C if the water enters at 21 °C. The specific heat
capacity of water is 4,2 kJ/kg.K (5)
[16]
TOTAL: 100
Copyright reserved
MARKING GUIDELINE
16 NOVEMBER 2016

QUESTION 1
1.1 2   N  T
P =
60
2   6500  T
120 103 =
60
T = 176,295 Nm (2)
T = 88,147 Nm
R+r
Rf 
2
FT    FA

FA  P   R 2 -r 2 
T  FT  R f
 R+r 
 
88,1,47  0,3  140  103   R 2 -r 2  
 2 

1, 75r 2 -r 2  1, 75r  r   1,336  103

 
2, 063r 2 1,85r  1,336 103
3,816r 3  1,336  103
r  70, 484 mm
d  140,968
 141mm
D  246, 75
 247 mm (6)
1.2 
FA  P   R 2 -r 2
 140 103    0,1235 -0,0705 
2 2
FA  4522 N(FPIN )
FPIN
A

4522
2    d2 
4 30 106
d  9,78 mm
 10 mm (6)

1.3 4522
BM=  0,15
2
=339,15 Nm (1)
M= Z
339,15=40 106  Z
Z=8, 479 10-6 m3 (1)
bd 2
Z=
6
6 d3
8, 479  10 =
6
d  37,053 mm
=38 mm (4)
1.4 T=FT  R
176, 295  FT  0, 025
FT  7052 N (2)
FT =A  
  d  t  
7052   0, 05  t  30 106
t  1, 496 mm
 1,5 mm (3)

1.5 R+r
RF 
2
123,5+70,5

2
 97 mm (1)
4522
FA =
6
 753, 667 N (1)
753, 667
L=
160
 4, 71mm (2)
Wear=8  4, 71
 3, 29 mm (1)
[30]
QUESTION 2
2   N  T
P=
60
2   200  T
100 103 =
60
T=4774,65 Nm (1)
T=FT  R
0, 25
4774,65=FT 
2
FT =38197,2 N (1)
FT
FN =
Cos20
38197,2
=
Cos20 (1)
FN = 40648, 6 N
0,7  R L =40648, 6  0,3

R L =17420,8N (1)

0,7  R R =40648, 6  0, 4
R R =23228N
17420,8  23228=40648, 6
BM=17420,8  0, 4
= 6968 Nm (1)
 KB  M    KT  T 
2 2
TE =
 3  6968   2,5  4774, 65

2 2
=
(3)
 24 kNm
TE =   d3  
16
24000=   d 3 100 106
16
 0,107
 110 mm (2)
M E =0,5  K B  M   TE 

=0,5 3  6968  24 103 
(3)
 22, 452 kNm
ME =   d 3  T
32
22452=   d 3  80 106
32
 0,1419
d  145 mm (3)
[17]

QUESTION 3
3.1 N A  TA =N B  TB
1720 18= 860  TB
TB  36 (1)
3.2 PCDA =m  TA
= 5 18
 90 mm
PCDB =m  TA
= 5  36
 180 mm (2)
3.3  PCD A  N A
VA =
60
 0, 09 1720
=
60
 8,105 m / s (1)
3.4 y A =0, 098

0,122-0,118 y B  0,118
=
38  34 36  34
yB = 0,12
3
CV =
3 V
3
=
3  8,105
 0, 27015
A =186 106  0, 27015
= 50, 247 MPa
B =138 106  0, 27015
= 37, 28 MPa
FT A = m  b   y
=  0, 005  0, 041 0,1033  50, 247 106
 3343,8 N
FT B = m  b   y
=  0, 005  0, 041 0,1286  37, 28 106
 3087, 6 N
P=FT B  v
 3087, 6  8,105
 25 kW (12)
[16]
QUESTION 4
L E =0,5  L
 0,5  4
 2m (1)
I YY =  B3  A   b3  a
64 64
   B  2B  b  2b3 
3
64
   2B4  2b 4 
64
   B4  b 4 
32 (2)
A=  B  A   b  a
4 4
   B  2B  b  2b 
4
   2B2  2b 2 
4
2
  B2  b 2  (1)
I
k2 =
A


32 
B4  b 4 
 B2  b 2
2  


B2  b 2 B2  b 2  
16 B2  b 2 

B 2
 b2 
16 (2)
C  A
FC =
L 2 
1  a  E2 
 k 
500 10  3
520 106  
2 B 2
 b2 
 
 
 22 
1 1


7500  B2  b 2  

 16 
8,533 103
1 
 B2  b 2  520   

B b
2 2

B 2

 b 2  8,533 103  B4  b 4  520    (4)

B 2
  
 b 2  8,533 103  B4  b 4  520  
1, 2b  b   8,533 10  1, 2b  b   520  

2 2 3 4 4
2, 44b 2  8,533 103  1, 074  b 4  520  

2, 44b 2  8,533 103  1754  b 4
b 2  3, 497 103  718, 796  b 4 (4)
Say b 2  x (1)
0  718, 796x 2  x  3, 497  103 (2)
b  54,849 mm
 55 mm
B  1, 2  55
 66 mm
A  2  66
 132 mm
66  55
t
2
 5,5 mm (4)
[21]
QUESTION 5
5.1 20  103
FN 
Sin65
 22068 N (1)
5.2 Rr
Sin 
w
R r
w (1)
Sin65
Rr
R MEAN  (1)
2
FN  P  A
 P  2   R MEAN  w
22068  300 103  2  

R  r  R  r
2 Sin65
21, 221 10   4r  r  4r  r 
3
21, 221 103  15r 2

r  0, 03761m
 38 mm
d  76 mm (3)

5.3 D  304 mm (1)
5.4 T    FN  R F
2 0,1523  0, 0383
 0, 05  22068  
3 0,1522  0, 0382
 117, 404 Nm (2)
2   N  T
P=
60
2   300 117,404

60
 3688 W (2)
5.4 H LOST =H GAINED

3688  m  SHC  T
 m  4200   60  21
m  22,501103 kg / s (3)
Q=22,501L / s
 1,351L / min (2)
[16]
TOTAL: 100
Copyright reserved
T1030(E)(M29)T
APRIL EXAMINATION

(8090086)
29 March 2016 (Y-Paper)

13:00–17:00
This question paper consists of 5 pages and 2 diagram sheets.

(8090086) -2- T1030(E)(M29)T

TIME: 4 HOURS
MARKS: 100
paper.
4. Show ALL the steps to achieve as many marks as possible. (An incorrect
answer which must be carried forward will receive fair consideration.)
7. Work neatly.

(8090086) -3- T1030(E)(M29)T
QUESTION 1
FIGURE 1, DIAGRAM SHEET 1 (attached) shows a line shaft on which two gears B
and D and a V-belt pulley C are mounted. Gear A receives 40 kW at 1 100 r/min from
a motor as shown. Gear D delivers 25 kW to another gear E and the pulley C delivers
15 kW. All gears are 20° full-depth involute.
Pinion A has a PCD of 132 mm. The gear transmission ratio for gears A–B is 3 : 1 with
a module of 6 mm.
C is a V-belt pulley mounted on the shaft, and drives a machine using 15 kW. The
PCD of the pulley is 300 mm and T1/T2 is 4 : 1.
The gear transmission ratio for gears D–E is 4 : 1 and 20° involute form. Gear D has
20 teeth with a module of 8 mm.
The shaft is supported by two bearings, F and G.
Calculate the diameter of the shaft for combined stresses (bending and twisting).
Use the following stresses:
 Tensile stress 50 MPa

 Shear stress 60 MPa
It is recommended that the following steps be followed in the working:
1.1 Determine the gear and V-belt forces acting on the shaft. (25)
1.2 Calculate the values and draw separate bending moment diagrams for the
vertical and horizontal planes respectively. (17)
1.3 Determine the maximum resultant bending moment using the combined
bending moment diagrams. (3)
1.4 Determine the shaft diameter for both equivalent bending and equivalent
torque. (9)
[54]

(8090086) -4- T1030(E)(M29)T
QUESTION 2
A single-plate clutch has an inside and an outside diameter of 90 mm and 200 mm

respectively. The friction material provides a coefficient of friction of 0,4 when in
contact with the flywheel. The maximum engine torque is 150 Nm. A clamping force of
800 N is provided by each of the eight springs when the springs are compressed
10 mm.
Calculate how much the friction material can wear before the clutch will slip. [10]
QUESTION 3
A single-reduction gearbox is to be used to drive a machine that requires 20 kW.

The machine pulley must rotate at 400 r/min. The driving pinion inside the gearbox
must be replaced.
The following information is available for the 20° full-depth involute cast-iron driven
wheel in the gearbox:
 Gear width = 70 mm
 Teeth = 60
 Basic stress = 40 MPa
The pinion is mounted on an electric motor that rotates at 1 200 r/min.
Use a module of 6 mm and determine the velocity factor as well as the required basic
stress of the pinion material. [9]
QUESTION 4
FIGURE 2, DIAGRAM SHEET 2 (attached) shows a conical pivot with an included

angle of 140° which rests on a bearing surface having an outer diameter to inner
diameter ratio of 3 : 1. The pivot supports an axial load of 15 kN while rotating at
400 r/min.
Given: A coefficient of friction of 0,04 and a bearing pressure of 200 kPa for the lining
material
4.2 The inner diameter of the bearing assuming uniform wear (6)
Copyright reserved
(8090086) -5- T1030(E)(M29)T
4.4 The power lost to friction assuming uniform pressure (4)
4.5 The quantity of cooling water needed in litres/min to keep the bearing surface
temperature constant at 50 °C if the water enters at 20 °C. The specific heat
capacity of water is 4,2 kj/kg.K (2)
[14]
QUESTION 5
A four-stroke internal combustion engine has a cylinder diameter of 75 mm and a

maximum combustion pressure of 1,2 MPa. The length of the connecting rod is
250 mm and it has an I-profile of uniform metal thickness across the full length.
The height of the I-profile is 5 times the metal thickness and the width of the flanges of
the I-profile is 3 times the metal thickness.
Use the Rankine formula with a safety factor of 5 and a crippling stress of 300 MPa
and determine the suitable profile dimensions for the connecting rod. Use a Rankine
constant of 1/7 500 for pin-jointed ends about the X–X axis and a Rankine constant of
1/30 000 (end fixation already taken into account) for both ends rigidly fixed about the
Y–Y axis. [13]
TOTAL: 100
Copyright reserved
400mm 300mm 300mm 200mm
(8090086)
Copyright reserved
E
DIAGRAM SHEET 1
B C D
F G
-1-
A E
A
P = 40 kW
FIGURE 1
NA = 1100r/min
m = 6mm D
NA=3NB B
0 P = 25 kW
60
m = 8 mm
A-A T = 20 teeth/tande
D
0
45 ND = 4 NE
C
PCD/SSD A
PCD/SSD
132mm 300mm
0
30 T1=4T2
A-A P = 15 kW
A-A
Please turn over

T1030(E)(M29)T
(8090086) -2- T1030(E)(M29)T
DIAGRAM SHEET 2
15kN
D
0
140
=0,04
FIGURE 2
Copyright reserved
MARKING GUIDELINE
APRIL EXAMINATION
MECHANICAL DRAWING AND DRAWING N6
29 March 2016

MARKING GUIDELINE -2- T1030(E)(M29)T
QUESTION 1
1.1 1100
NB 
3
 366, 67 r / min (1)
  D N
VA 
60
  0,132 1100

60
 7, 6 m / s (1)
P  FT  V
40000  FT  7, 6
FT  5263, 2 N (1)
Torque  FT  R
0,132
 5263, 2 
2
 347,37 Nm (1)
TorqueB  347,37  3
 1042,1 Nm (1)
TorqueCDTOTAL  1042,1 Nm (1)
PC  15 kW (1)
  D N
VC 
60
  0,3  366, 67

60
 5, 76 m / s (1)
P  T1  T 2  v
15000   3T2   5, 76
T2  868, 06 N
T1  4  868, 06
T1  3472, 24 N (1)
Copyright reserved
T1  T2  3472, 24  868, 06
 4340, 3N (1)
T  T1  T2   R
 2604, 2  0,15
 390, 63 Nm (1)
TD  1042,1  390, 63
 651, 47 Nm
TD  TCSHAFT (1)
GEAR FORCES A–B

B FN B
200 FH
FV
0 0
FN
30 10
A
A
(1)
FT
FN 
Cos 20
5263, 2

Cos 20
FN  5600,981 N (1)
FH  5600,981 Cos10
 5515,89 N (1)
FV  5600,981 Sin10
 972, 6 N (1)
GEAR FORCES D–E
E
FN
FV
0
40
D
20
0
D FH
600
FN (1)
Copyright reserved
PCDD  m  TD
 8  20
 160 mm (1)
Torque  FT  R
0,16
651, 47  FT 
2
FT  8143,375 N (1)
FT
FN 
Cos 20
8143,375

Cos 20
FN  8666 N (1)
FH  8666  Cos 40
 6638,54 N (1)
FV  8666  Sin 40
 5570, 4 N (1)
BELT DRIVE
T1+T2
FV
0
C 45
FH
(1)
FV  T1  T2  Sin45
 4340,3  Sin 45
 3069, 06 N (1)
FH  T1  T2  Cos 45
 4340,3  Cos 45
 3069, 06 N (1)
Copyright reserved
1.2 Shaft loading

Horizontal
5515,89N 3068,99N 6638,54N

400 300 300 200
B F C G D
(1)
RF  0, 6  6638,54  0, 2  5515,89  1  3069, 06  0,3

RF  8514,83 N (1)
RG  0, 6  5515,89  0, 4  6638,54  0,8  3069, 06  0,3

RG  6708, 66 N (1)
5515,89  3069, 06  6638,54  8514,83  6708, 66

15223, 49  15223, 49 (1)
Bending moments
@F  5515,89  0, 4
 2206,356 Nm (1)
@G  6638,54  0, 2
 1327, 71 Nm (1)
@C  5515,89  0, 7  8514,83  0,3

 1306, 67 Nm (1)
Vertical
972,6N
400 300 300 200
B F C G D
3068,99N 5570,4N
RF  0, 6  3069, 06  0,3  5570, 4  0, 2  972, 6  1

RF  1943, 27 N (1)
Copyright reserved
RG  0, 6  5570, 4  0,8  972, 6  0, 4  3069, 06  0,3

RG  9610,13 N (1)
972, 6  9610,13  1943, 27  3069, 06  5570, 4

10582, 73  10582, 73 (1)
Bending moments
@ F  972, 6  0, 4
 389 Nm (1)
@G  5570, 4  0, 2
 1114,1 Nm (1)
@C  972, 6  0, 7  1943, 27  0,3

 97,84 Nm (1)
2206,4
1306,7 1327,71
HORIZONTAL
1114,1
389 97,83
VERTICAL (4)
1.3 @F  389 2  2206,3562

 2240, 4 Nm (1)
@G  1114,1 2  1327, 712

 1733, 2 Nm (1)
@C  97,842  1306, 67 2
 1310, 3Nm (1)
Copyright reserved
1.4 TE @ F  M 2  T2
 2240,4 2  1042,12
 2470,9 Nm (1)
2 2
TE @ G  M T
 1733,22  1042,12
 2022,36 Nm (1)
2 2
TE @ C  M T
 1310, 32  651,472
 1463,3 Nm (1)

M E @ F  0,5 M  M2  T2 
 0,5  2240,4  2470,9 
 2355,65 Nm (1)
ME @ G  0,5 M  M2  T2  
 0,5 1733,2  2022,36 
 1877,78 Nm (1)

M E @ C  0,5 M  M  T 2 2

 0,5 1310, 3  1463, 3 
 1386,8 Nm (1)
D d  4 4
TE   
16  D 
 1,5d 4  d 4 
2470,9       60  106
16  1,5d 
 
d  0,0426
 42,6mm (1)
D d  4 4
ME   
32  D  T
 1,5d 4  d 4 
2355,65       50  106
32  1,5d 
 
d  0,0562
 56,2mm (1)
Say d = 60 mm standard shaft (1)
[54]
Copyright reserved
QUESTION 2
Rr
RF 
2
100  45

2
 72,5 mm (1)
T  FT  R F  N o
150  FT  0, 0725  2
FT  1034, 48N (1)
FT    FA
1034, 48  0, 4  FA
FA  2586, 2N (1)
2586, 2
FA 
8
 323, 28N / spring (2)
FS  800
10
 80N / mm (2)
323, 28
L 
80
 4mm (2)
Wear  10  4
 6mm (1)
[10]
Copyright reserved
QUESTION 3
N A  TA  N B  TB
1200  TA  400  60
TA  20 (1)
y 20  0,102(tables)
y 60  0,134(tables) (2)
PCD  m  T
 6  20
 120mm (1)
 PCD  N
v
60
 0,12  1200

60
 7,54m / s (1)
3
CV 
3 v
3

3  7,54
 0, 285 (1)
FT PINION  FT GEAR
  m  b  o  CV  y    m  b  o  C V  y
o  0,102  40 106  0,134
o  52,549 MPa (3)
[9]
Copyright reserved
QUESTION 4
4.1 FT
FN 
Sin70
15  103

Sin70
 15962, 67N (1)
4.2 Rr
Sin70 
w
Rr
w
Sin70 (1)
Rr
R MEAN 
2 (1)
FN  P  A
15962, 67  200  103  A
A  0, 0798m 2 (1)
A  2   R MEAN  w
R r R r
 2   
2 Sin70
3r  r 3r  r
0, 0798  2   
2 Sin70
0, 02387  4r  2r
 8r 2
r  54, 6
r  55mm
d  110mm (3)
4.3 D  3 110
 330mm (1)
2  R 3  r3 
RF   
3  R 2  r2 
2  1653  553 
  
3  1652  552 
 119,17 mm (1)
Copyright reserved
T    FN  R F
 0, 04 15962, 67  0,11917
 76Nm (2)
2   N  T
P
60
2   400  76

60
 3183, 48W (1)
4.5 H GAINED  H LOST

 m  C  T
m  C  T  3183, 48
m  4200   50  20   3183, 48
m  0, 0253kg / s
 1,52 litres / min (2)
[14]
QUESTION 5
F  PA
 1, 2  106    0, 0752
4
 5301, 44 N (1)
FULT  F  FoS
 5301, 44  5
 26507,19N (1)
A  2  3t  t  3t  t
 9t 2 (1)
BD3 bd 3
I XX  
12 12
3t   5t   2t  3t 
3 3

12
375t  54t 4
4

12
 26, 75t 4 (1)
Copyright reserved
B3 D b3d
I YY  
12 12
 3t 
3
 5t t 3  3t 
  2  3t  t  t 2 
12  12 
 11, 25t  6,5t
4 4
 4, 75t 4 (1)
I XX
k XX 2 
A
26, 75t 4

9t 2
 2,97t 2 (1)
I YY
k YY 2 
A
4, 75t 4

9t 2
 0,53t 2 (1)
 ULT  A
FULT 
L2
1 a  2
k
300 106  9t 2
26507,19 
0, 252
1 a  2
k
2
0, 25
1  a  2  101,859  103  t 2
k (1)
For X–X axis

0, 252
1  a  2  101,859  103  t 2
k
1 0, 252
1   101,859  103  t 2 (t 2 )
7500 2,97  t 2
t 2  2,8058  10 6  101,859 103  t 4 (1)
0  101,859 103  t 4  t 2  2,8058 106
Copyright reserved
b  b 2  4ac
t2 
2a
  1   1  4 101,859  103  2,8058  106 
2

2 101,859 103
2, 4639

203718
t  1, 20949 105
2
t  0, 00347 m
t  3, 5 mm (1)
For Y–Y axis

0, 252
1  a  2  101,859 103  t 2
k
1 0, 252
1   101,859 103  t 2 (t 2 )
30000 0,53  t 2
t 2  3,93  106  101,859 103  t 4 (1)
0  101,859 103  t 4  t 2  3,93 106
b  b 2  4ac
t2 
2a
  1   1  4 101,859  103  3,93 106 
2

2 101,859 103
2, 613

203718
t  1, 283 105
2
t  0, 00358 m
t  3, 6 mm (1)
t  4 mm STD PLATE (1)

[13]
TOTAL: 100
Copyright reserved
T950(E)(J27)T
AUGUST EXAMINATION
(8090086)
27 July 2016 (X-Paper)

09:00–13:00
This question paper consists of 5 pages and 2 diagram sheets.

(8090086) -2- T950(E)(J27T

TIME: 4 HOURS
MARKS: 100
paper.
5. Show ALL the steps to achieve as many marks as possible. An incorrect

answer which must be carried forward will receive fair consideration.
6. Candidates may use their own notes.

(8090086) -3- T950(E)(J27T
QUESTION 1
FIGURE 1 on DIAGRAM SHEET 1 (attached) shows a 10-gear system with the

corresponding table shown below. Gears F, G and I are all keyed to shaft 4. The input
power is 30 kW and machine M needs 10 kW whilst machine N requires 20 kW.
Assume that all teeth are full depth, 20° involute.
Member No of Module PCD Speed Centre Basic

Teeth (mm) (mm) r/min distance stress
(mm) (MPa)
A 75 3600
100
B 5
C 20
D 4 1080
E 20 60
F 50
G 125 60
150
H 6 50
I 4
J 40 216
TABLE (FIGURE 1)
1.1 The number of teeth, speed, module, centre distance and pitch-circle
diameter of all the gears (22)
1.2 The diameter of shaft 5 for combined bending and twisting
Use the following stresses:
 Tensile stress = 120 MPa

 Shear stress = 80 MPa
 Tension ratio T1/T2 of the belt drive = 4 : 1. (28)
1.3 The width of gears G and H using the Lewis formula
Use the following basic stresses:
 Gear G = 60 MPa
 Gear H = 50 MPa
Check the answers. (13)

(8090086) -4- T950(E)(J27)T
1.4 A centrifugal friction clutch is placed between the motor and gear A as a soft
start. The clutch has a driving member consisting of a spider carrying three
shoes which can slide radially in grooves in the spider. This movement is
resisted by a flat spring in each shoe until the increase of centrifugal force on
the shoes during rotation overcomes the resistance of the springs.
Engagement commences at approximately 3 000 r/min.
The inside diameter of the drum is 250 mm. The coefficient of friction
is 0,3. The centre of gravity of each shoe from the shaft axis is 90 mm when
the shoes make contact with the drum. The flat spring in each shoe has a
stiffness of 100 kN/m.
Determine the speed in r/min at which engagement would commence as well

as the power that could be transmitted at 3 600 r/min if each shoe has worn
down by 3 mm. (15)
[78]
QUESTION 2
A shaft rotating at 400 r/min with the centrally keyed worm of a worm drive is shown in
FIGURE 2 on DIAGRAM SHEET 2 (attached). The shaft which has a diameter of
40 mm is supported in two journal bearings and a thrust bearing.
The assembly, lubricated with SAE oil, is placed in a well-ventilated area where the
ambient temperature is 25 °C. A force of 15 kN acting at an angle of 30° to the
horizontal is present on the worm. The pressure on the journal bearing material cannot
exceed 1,2 MPa and the temperature of the bearing surface is limited to 50 °C.
Assume that the journal diameter to diametral clearance ratio (D/C) is 1 000 and
calculate the following:
2.1 The radial load on the journal bearings (1)
2.2 The length of each journal (1)
2.3 The heat dissipated by each journal bearing (3)
2.5 The SAE number of the lubricating oil (7)
2.6 The side thrust (1)

(8090086) -5- T950(E)(J27)T
2.7 The inside diameter of the thrust bearing to take this side thrust if the
pressure of the material cannot exceed 2,5 MPa and has an outer diameter of
90 mm (1)
2.8 The frictional torque that occurs at the thrust bearing using uniform pressure
theory using a coefficient of friction of 0,08 (2)
2.9 The total power lost in the journals and the thrust bearings (2)
2.10 The quantity of lubricating oil needed in litres/min if its specific heat capacity is
3,2 kJ/kg °C and its density is 850 kg/m3 (2)
[22]
TOTAL: 100
Copyright reserved
(8090086) -1- T950(E)(J27)T
DIAGRAM SHEET 1
FIGURE 1
(8090086) -2- T950(E)(J27)T
DIAGRAM SHEET 2
FIGURE 2
Copyright reserved
higher education
& training
Department:
Higher Education and Training
rri-rf rin E-nr) 0
MARKING GUIDELINE
AUGUST EXAMINATION
27 JULY 2016
M,
IM ,01
1M- kiit/throz opv K

c-6-Yr) rn cin;

MARKING GUIDELINE -2- T950(E)(J27)T
QUESTION 1
1.1 A—B
PCDA =mx TA
75 =5x TA
TA =15 (1)
m (T +T )
C= A B
2
5(T +T )
100 = A B
2
TA -F TB = 40
TB =40-15
=25
PCDB = M X TB
=5x25
(1)
=125 mm
NA X TA = NB X TB
3600x15 = NB x25
NB = 2160r / min (1)
C—D
Nc =NB = 2160r/ min
Nc xTc = ND X TD
2160x 20 = 1080XTD
(1)
TD = 40
PCDc = m x TO
= 4x 20
(1)
= 80mm
PCDD =mx TD
= 4x 40
=160 mm (1)
Copyright reserved Please turn ofer

m (Tc +TD )
C=
2
4(20+40)
2 (1)
=120 mm
E-F
NE =ND =1080r/ min
PCDE = M X TE
60 = m x 20
m =3mm (1)
N E xTE =N F xTF
1080 x 20 = N F X50
N F = 432 r/ min (1)
PCDE = M X TE
= 3x 50
=150 mm (1)
m(TE +TF )
2
3(20+50)
2
(1)
=105 mm
G-H
NG = NF = 432 r / min
m(TG+TH)
C=
2
6(T +T )
150= 0 H
2
TG TH = 50 (1)
PCDG = M X TG
125= 6x TG
TG = 20,8
=21 (1)
Copyright reserved
OA
Please turn er
1\1\
TH =50-21
= 29
(1)
PCDH = m x TH
= 6x 29
=174mm (1)
NI0 x T0 = NH X TH
432x 21=1\1H x29
NH = 312,83 r/min (1)
I-J
N/ =NF = 432 r / min
1\11 xT1 =1\1,xT,

432xTi = 216x 40
T, = 20 (1)
PCD1 = m x 'I',
=4x20
=80mm (1)
PCD, = m x 'I',
=4x40
=160mm (1)
m(T/ +TJ )
C=
2
4(20+40)
2
=120 mm (1)
99
1.2 Shaft 5
P= 2 xnxNxT
60
2 x7rx 216 xT
20x1o3 ,
60
T = 884,19Nm (1)
For gear
(2)
T= Fr xR
884,19= FT X 0, 0 8
FT =11052,43N (1)
FR = FT x Tan 20
= 11052, 43 x Tan20
FR = 4022, 75 N (1)
For belt
T = (T1 — T2 )x R
884,19 = (4T, — T2 ) x 0,07
T, =4210,43N
(1)
T1 =4x4210,42
=16841,7N (1)
T1 +T2 =16841,7+ 4210,42

=21052,13N (1)

(T, +T2 )Cos30 =18231,68N
(T, +T2 )Sin30 =10526,1N
Horizontal Loading
18231,68 4021,75
150 300
R
150
J
BM L =18231,68x0,15
= 2734, 75 Nm
BM R =4022,75x0,15
= 603,4 Nm
Vertical loading
10526,1
150 300 150 ,1

L R 11052,43
BM L =10526,1x0,15
=1578,915Nm
BM R =11052,43x0,15
= 1657, 86 Nm
Copyright reserved Please turn ove
/41
Maximum resultant bending moment
BMR L =V2734,752 +1578,9152

= 3157, 8 Nm
BMRR =V603,42 +1657,862

= 1764, 25 Nm
Guest
TE = VM2 ± T2
=V3157,82 + 884,192
(2)
=3279,25 Nm
TE =~6 x d3 xt
3279,25 =TC16 x c13 x 80 x106

(2)
= 59,3 mm
Rankine
ME = 0,5(M +VM2 +T2 )
=0,5(3157,8+3279,25)
=3218, 53 Nm (2)
ME = 7Y32 Xd3 X6T
3218,53 =7X2 xd3 x120x106

= 64,88mm
Use 65 mm standard diameter shaft

1.3 P= 2 xrcx NxT

60
2x 7C X 312.83 xT
10x103 =
60 (1)
T= 305, 255 Nm
T= FT R
0.174
305,255 = F x
T 2
(1)
FT = 3508,68N
nxPCDxN
v=
60
nx 0.174 x312.83
60
(1)
= 2,85m /s
3
Cv =
3+v
3
3+2,85
(1)
=0.513
y,, = 0,104(Tables)
y29 = 0,113(Tables)
FT =7TxmxbxyxC v xcro
3508,68=71x 0,006xbx 0,104x 0,513x 60x106

b= 58,15 mm
(2)
FT =TCXMxbxyXCv xao
3508.68 = rcx 0,006 x bx 0,113x 0.513x 50x106

b= 64.22mm
Use 65 mm
= 2,5 x Trx m
=2,5x iC x6
=47,13 mm (1)
bmAx = 4x Trx m
= 4><Tux 6 144
= 75,4 mm
,,f)/
1.4 P = 2x7txNxT
60
30000 2xitx3600xT
3 60
T= 26, 53 Nm (1)
T = FT X RDRUM
26,53 = FT X 0,125
(1)
FT =212,24N
FT = X FNE/T
212,24=0,3XFNETT
(1)
F = 707,47N
FNErr = mxcomAx X RG — M X (DENG2 X R0

= m x (a/MAX2 (DENG2 ) X RG
mx [( 2 x
60mAx )2 (2x 6X0N ENG 2 X 0, 09
707.47=
J
J
7860,78 = mx(
26012 x(NmAx2 —NENG2
716817.18 = m x (36002 —30002 )

(2)
m= 0,181kg
FC ENG =mxco2 xRG

181x (2xnx 300012 x0,09
60
=1607,76N
AFs =Fs x wear

=100x103 x 0,003
=300N
FC ENG NEW FC ENG + AFs x wear

=1607,76+300
=1907,76N (1)
Copyright reserved Please turn ove

FCENG M X W ENG2 X RG
(2X7EXNENG )2 G
=m x xR
60
2
2x
1907,76 = 0,181x( x0,093
60
N „G =3214,78r/min (2)
Fc.mAx = m x c mAx2 x Ro
2
( 2 xicxNmAx ) xRe
=MX
60
= 0,181x r 2 MI 360012
0 x0,093
60
(1)
= 2392,344N
= FcmAx — FCENG
FCNETT
= 2392,344-1907,76
= 484,58N (1)
FT = X FNETT
= 0,3x 484,58
FT = 145,38 N (1)
T= FT X RDRum
=145,38x0,125
FT =18,17Nm (1)
P=2 xlcx NxT

60
2 xnx 3600 x18,17 x3
60
P = 20,55kW (1)
[78]
fiti f'
Copyright reserved Please
MliL
Please -rn ov
ti
i
/)11
QUESTION 2
2.1 FRADIAL =15 x 103 x S in30

= 7500N (1)
2.2 FRADIAL = Px A
7500 = 2 x1,2x106 x 0,04xL
L = 78mm (1)
2.3 AT = TB - TA
=50-25
= 25°C
[AT + 1 8f xLxD
14 0 =
K
[25 +1812 x 0,078x 0,04
0,273
=21,13J /s per bearing (2)
2.4 7ExDxN
HG f x FRADIAL x
60
0 04x 400
21,13 = fx3750x '
60
f = 0,0067 (2)
Copyright reserved Please turn o L r

2.5 L/ 78
/D — 40
(1)
=1,95
0,015
0,010
k
0,005
_----------
0 05 1,0 1,5 20 25 30
(1)
YD
la x N
f =0,326( D +k
C
0,0067 = 0,326 ( p. x 400 \ 1000+0,0026

1,2x106 ,
}i= 0, 0377 kg / ms (2)
AT = 12 (ToIL —TAmBIENT )
25 = .(To,L —25)
(1)
TOIL =75°C
0,8
0,6
0,4
0,3
0,'0,26
■ ■
0,1 \
0,08
0,06
0,04
Absolut e 0,03
viscosity IA
kg/ ms
0,02 700
0,015 50
0,0 40
SAE
0,008 30
0,006 20
0,00420°C -0
40°C 60°C 80°C 130°C
Temperat ure
Use SAE 50
Copyright reserved Plea er

r MARKING GUIDELINE -13- T950(E)(J27)T
2.6 FTHRLsr = 15 x103 x Cos30

=12990,38N (1)
2.7 P = FTHRUST
A
6 12990,38
2,5 x10 =
4 (0,092 —d2 )
d=38,5mm
= 38mm (1)
2.8 2 x [R 3 — r']
RF =
3X[R 2 —r2 ]
2 x [45' —193 ]
3x[452 —192 ]
(1)
=33,76mm
T = It X FTHRusT x R
= 0,08 x 12990,38 x 0,03376
= 35 Nm (1)
2.9 2x7cxNxT
P
60
2x TC x 400 x 35
60
=1466.1W
PTOTAL = THRUST PBEARINGS
=1466,1+2x21,13
=1508,34W
2.10 H Los,- — HGAINED

1508,34 = rTaxSHCx
1508,34 =rTi x 3200 x 25
eh= 0,01886kg/s
0 01886
Q= '
0,85
= 0, 022 Litres / s
=1,331/min (2)
[22]
TOTAL: _ 100
P/I1L
Copyright reserved
//a
T1020(E)(N23)T

(8090086)
09:00–13:00

(8090086) -2- T1020(E)(N23)H

TIME: 4 HOURS
MARKS: 100
paper.
4. Sketches must be done FREEHAND and in good proportion in the ANSWER

BOOK.
will receive fair consideration).
8. Work neatly.

(8090086) -3- T1020(E)(N23)H
QUESTION 1
Two pulleys are connected by a belt (FIGURE 1) with the centres of the shafts
500 mm apart. The diameter of the large pulley is 260 mm and that of the smaller
pulley is 130 mm. The frictional coefficient is 0,3. The electric motor and stand have a
total mass of 80 kg.
FIGURE 1
1.1 The belt tensions (11)
1.2 The torque that can be transmitted (2)

[13]

(8090086) -4- T1020(E)(N23)H
QUESTION 2
A steel pinion with 21 teeth drives a 50-tooth phosphor bronze gear mounted on a solid
shaft between two bearings 0,5 m apart. The gear is situated between the two
bearings, 300 mm from the right-hand bearing. The 20° full depth phosphor bronze
gear rotates at 400 r/min and has a 5 mm module. The ultimate stress of the pinion is
620 MPa and that of the gear 420 MPa. The power transmitted between the two gears
is 20 kW.
2.1 Use a safety factor of 4 and determine the required face width of the teeth. (18)
2.2 Check for interference. (3)
2.3 Determine the diameter shaft needed to transmit the required torque.
Use a shaft shear stress of 60 MPa. The shaft is subjected to high shock and
fatigue factors of Kb = 3 and Kt = 2,5. (9)
[30]
QUESTION 3
A cone clutch must transmit 23 kW of power at 1 098 r/min. The included cone angle
is 12,5°, the outside diameter is 350 mm and the width of the lining is 65 mm. The
coefficient of friction is 0,2.
3.1 The inside diameter (3)
3.2 The normal pressure between the surfaces (5)
3.3 The axial force required to transmit the power (1)
3.4 The maximum pressure between the surfaces (2)
3.5 The engagement force required so that no relative motion occurs between the
surfaces (2)
[13]

(8090086) -5- T1020(E)(N23)H
QUESTION 4
The load on a shaft journal is 7 kN and the shaft transmits a torque of 80 Nm. The
maximum shearing stress induced in the shaft may not exceed 50 MPa and the
maximum pressure on the projected area of the journal is 7 MPa. Assume the length
of the journal is 1,9 times its diameter.
4.1 Calculate a suitable journal diameter as well as its length. (4)
4.2 If the journal in QUESTION 4.1 rotates at 700 r/min and the diametrical
clearance is 0,03 mm, determine a suitable oil viscosity (SAE) if the
temperature of the bearing surface is limited to 90 °C and the ambient
temperature is 20 °C (FIGURE 2 and FIGURE 3).
0,015
0,010
k
0,005
0 0,5 1,0 1,5 2,0 2,5 3,0
L
D
FIGURE 2

(8090086) -6- T1020(E)(N23)H
1
0 ,8
0 ,6
0 ,4
0 ,3
0 ,2
0 ,15
0,1
0 ,0 8
0,06
0,0 4
Absolute
Absolute
0,03
viscosity/
viscosity
absolute
µ 0 ,0 2 70
kg/ms
viskositeit 60
m 0,0 15
50
kg/ms SAE
0 ,0 1
40
0 ,00 8
30
0 ,00 6
20
0 ,0 04 10
200C 4 0 0C 600C 8 0 0C 10 0 0 C
Temperature
Temperature/temperatuur
FIGURE 3 (7)
[11]

(8090086) -7- T1020(E)(N23)H
QUESTION 5
A cam gives the following movement to a roller follower which moves vertically up and
down directly in line with the centre line of the cam:
Lift of 20 mm with SHM for 90° of cam rotation followed by a further 10 mm lift with a
constant velocity for 45° of cam rotation. Fall of 10 mm with constant velocity for 45° of
cam rotation followed by a fall-back to the basic radius for 90° of cam rotation with
SHM. Dwell for the following 90° of cam rotation. The speed of the cam is 1 800 r/min.
Sketch the curves with all the values for displacement, velocity and acceleration. [12]
QUESTION 6
A gantry must raise a mass of 8 000 kg.
Design the strut which has a length of 2,5 m.
The material to be used has a yield stress of 325 MPa. Use a safety factor of 2 and
calculate the material thickness required if the strut is of an 'I' section profile with the
depth being 7 times the thickness and the width 3 times the thickness.
Assume both ends to be hinged on the X–X axis as shown in FIGURE 4, and fixed
along the Y-–Y axis.
Use a RANKINE constant of 1/7 500 for hinged ends.
FIGURE 4 [21]
TOTAL: 100
Copyright reserved
T1030(E)(A5)T
AUGUST EXAMINATION
(8090086)
5 AUGUST 2015 (Y-Paper)

13:00–16:00
This question paper consists of 4 pages and a table of 3 pages.

(8090086) -2- T1030(E)(A5)T

TIME: 4 HOURS
MARKS: 100
3. One mark is one per cent.
paper.
6. All work you do not want to be marked, must be clearly crossed out.

(8090086) -3- T1030(E)(A5)T
QUESTION 1
100mm
Clutch/ Bearing/Laer
Koppelaar
Motor
1 A
248mm
100mm 80mm
m=8mm
A
B 2 C
200mm
B
m=5mm
C 100mm
80mm
D 3
D Pinion/Kleinrat
5kN
v=6m/s
Rack/tandstang
FIGURE 1
Gear A, in figure 1, is mounted on shaft 1. It meshes with gear B on shaft 2 which also
supports gear C. Shafts 1 and 2 are 248 mm apart. On shaft 3 is a gear D which
meshes with a gear rack. The speed of the rack must be 6 m/s. The centre distance
between shafts 2 and 3 is 200 mm.
Use a module of 8 mm for gears A and B and a module of 5 mm for gears C and D.
The overall transmission ratio is approximately 4,3:1. The reduction at each step is
approximately equal. Assume that all teeth are full depth, 20 0 involute and that all
gears engage vertically. The ultimate stress of the gear A is 40 MPa and that of the
pinion is 180 MPa.
Safe tensile stress = 60 MPa and the safe shear stress = 80 MPa for all shafts
It is recommended that the following steps be followed in the working:
1.1 A suitable face width for gears C-D and A-B. Use the Lewis formula. (28)
1.2 Calculate the bending moment for the vertical and horizontal planes
respectively for shaft 2. (14)

(8090086) -4- T1030(E)(A5)T
1.3 Determine the maximum resultant bending moments using the combined
bending moment for shaft 2. (1)
1.4 Determine drive shaft (2) diameters for both ME and TE. (8)
1.5 Determine drive shaft (1) diameter for both ME and TE. (10)
1.6 Determine drive shaft (3) diameter for both ME and TE. (9)
A centrifugal clutch is to be incorporated so as to allow the motor to gain speed before

any torque is transmitted. The internal diameter of the drum is 300 mm, and the four
shoes must transmit the power. Assume that engagement takes place at 600 r/min,
and that the centre of gravity of each shoe is 30 mm from the contact surface when
engaged. The co-efficient of friction is to be 0,4.
Calculate:
1.7 The mass of each shoe. (5)
1.8 If the depth of each shoe is 30 mm and the maximum pressure that the
friction lining material can withstand is 150 kPa, calculate the length of
the lining of each shoe. (2)
1.9 The segmental arc of each shoe in degrees. (1)
The journal bearings (shaft 2 only) are provided with a H8 - g6 fit. The surrounding air
temperature is 30O C and the oil used has an absolute viscosity of 0,01 kg/ms.
The pressure on the journal bearing material cannot exceed 1,5 MPa and the
temperature of the bearing surface is limited to 60oC.
The specific heat capacity of oil is 3,2 kJ/kg.0C. and the specific gravity of oil is 0,82.
Calculate:
1.10 The SAE number of the lubricating oil. (4)
1.11 The maximum radial load on the journal bearings of shaft 2 (3)
1.12 The length of each journal of shaft 2 (2)
1.13 The minimum diametral clearance between the journal and the bearing
(tables are supplied). (3)
1.15 The quantity of cooling oil required in litres per minute to cool both bearings (5)
TOTAL: 100
Copyright reserved
(8090086) -1- T1030(E)(A5)T
0,015
0,010
k
0,005
0 0,5 1,0 1,5 2,0 2,5 3,0
L
D
1
0,8
0,6
0,4
0,3
0,2
0,15
0,1
0,08
0,06
0,04
Absolute
viscosity/ 0,03
absolute 0,02 70
viskositeit 60
 0,015
50
kg/ms SAE
0,01
40
0,008
30
0,006
20
0,004 10
0 0 0 0
20 0C 40 C 60 C 80 C 100 C
Temperature/temperatuur

(8090086) -2- T1030(E)(A5)T
LIMITS OF TOLERANCE FOR SELECTED HOLES

LIMIETE VAN TOLERANSIE VIR GEKOSE GATE
ES = Upper deviation/boonsteafwwyking
EI = Lower deviation/ondersteafwyking
Unit/eenheid = 0,001 mm
Nominal
sizesNominale H7 H8 H9 H11
groottes
Over/ Up to and ES EI ES EI ES EI ES EI
Bo including/ + + + +
Tot by
mm mm
0 3 10 0 14 0 25 0 60 0
3 6 12 0 18 0 30 0 75 0
6 10 15 0 22 0 36 0 90 0
10 18 18 0 27 0 43 0 110 0
18 30 21 0 33 0 52 0 130 0
30 50 25 0 39 0 62 0 160 0
50 80 30 0 46 0 74 0 190 0
80 120 35 0 54 0 87 0 220 0
120 180 40 0 63 0 100 0 250 0
180 250 46 0 72 0 115 0 290 0
250 315 52 0 81 0 130 0 320 0
315 400 57 0 89 0 140 0 360 0
400 500 63 0 97 0 155 0 400 0

(8090086) -3- T1030(E)(A5)T
LIMITS OF TOLERANCE FOR SELECTED SHAFTS

LIMIETE VAN TOLERANSIE VIR GEKOSE ASSE
es = Upper deviation/boonsteafwwyking
ei = Lower deviation/ondersteafwyking
Unit/eenheid = 0,001 mm
Nominal c11 d10 e9 f7 g6 h6
sizes
Nominale
groottes
Over/ To/ es ei es ei es ei es ei es ei es ei
Bo Tot - - - - - - - - - - - -
mm by
mm
- 3 60 120 20 60 14 39 6 16 2 8 0 6
3 6 70 145 30 78 20 50 10 22 4 12 0 8
6 10 80 170 40 98 25 61 13 28 5 14 0 9
10 18 95 205 50 120 32 75 16 34 6 17 0 11
18 30 110 240 65 149 40 92 20 41 7 20 0 13
30 40 120 280 80 180 50 112 25 50 9 25 0 16
40 50 130 290 80 180 50 112 25 50 9 25 0 16
50 65 140 330 100 220 60 134 30 60 10 29 0 19
65 80 150 340 100 220 60 134 30 60 10 29 0 19
80 100 170 390 120 260 72 159 36 71 12 34 0 22
100 120 180 400 120 260 72 159 36 71 12 34 0 22
120 140 200 450 145 305 85 185 43 83 14 39 0 25
140 160 210 460 145 305 85 185 43 83 14 39 0 25
160 180 230 480 145 305 85 185 43 83 14 39 0 25
180 200 240 530 170 355 100 215 50 96 15 44 0 29
200 225 260 550 170 355 100 215 50 96 15 44 0 29
225 250 280 570 170 355 100 215 50 96 15 44 0 29
250 280 300 620 190 400 110 240 56 108 17 49 0 32
280 315 330 650 190 400 110 240 56 108 17 49 0 32
315 355 360 720 210 440 125 265 62 119 18 54 0 36
355 400 400 760 210 440 125 265 62 119 18 54 0 36
400 450 440 840 230 480 135 290 68 131 20 60 0 40
450 500 480 880 230 480 135 290 68 131 20 60 0 40
Copyright reserved
MARKING GUIDELINE
AUGUST EXAMINATION
5 AUGUST 2015

QUESTION 1
1.1 GENERAL
GRSTEP  4,3
 2,07
(1)
TB  2,07TA
(1)
TD  2,07TC
(1)
GEARS C-D
m TC  TD 
C 
2
200  2
TC  TD 
5
TC  2,07TC  80
TC  26
(1)
TD  2,07  26
 53,8
 54
(1)
PCDC  m  TC
 5  26
 130 mm
(1)
PCDD  m  TD
 5  54
 270 mm
(1)
  D N
VD 
60
  0, 27  N
6 
60
ND  424, 4 r / min (1)
NC  TC  N D  TD
NC  26  424, 4  54
NC  881, 446 r / min (1)

3
CV 
3 V
3

3 6 (1
 0,333
0,912
y26  0,154   0,119 or y26  0,109 (tables)
26 (1)
FT    m  b  y  
5000    0,005  b 180 106  0,333  0,119
b  44,63 mm Say 46 mm (2)
or
FT    m  b  y  
5000    0,005  b 180 106  0,333  0,109
b  48,72 mm Say 50 mm
bMIN  2,5    m
 2,5    5
 39,3 mm
bMAX  4   m
 4   5
 62,8 mm
(1)
GEARS A-B
NB  881,446 r / min (1)
m TA  TB 
C 
2
248  2
TA  TB 
8
TA  2,07TA  62
TA  20,195
 20
TB  62  20
 42 (1)

PCDA  m  TA
 8  20
 160 mm (1)
PCDB  m  TD
 8  42
 336 mm (1)
N A  20  881, 446  42
N A  1851r / min (1)
  D N
VA 
60
  0,16 1851

60
VA  15,51m / s (2)
6
CV 
6 V
6

6  15,51
(1)
 0, 279
0,912
y20  0,154   0,108 or y20  0,102 (tables) (1)
20
PCD  FT V
 5000  6
 30 kW (1)
PAB  FT V
30000  FT 15,51
FT  1934, 2 N
(1)
FT    m  b  y  
1934, 2    0,008  b  40 106  0, 279  0,108
b  63,85 mm Say 64 mm
or

FT    m  b  y  
1934, 2    0,008  b  40 106  0, 279  0,102
b  67,61 mm Say 68 mm (2)
bMIN  2,5    m
 2,5    8
 62,8 mm
bMAX  4   m
 4   8
 100,5 mm (1)
1.2 SHAFTS
FN
B FR C
FT 200
FR 200 FT
FN
(2)
FRCD  FTCD  Tan20

 5000  0,364
 1819,9 N (1)
FRAB  FTAB  Tan20

 1934, 2  0,364
 703,99 N (1)

HORIZONTAL LOADING
1934,2N 5000N
80mm 100mm 80mm
RL RR
L  0, 26  5000  0,08  1934, 2  0,18
748,156

0, 26
L  2877,52 N
(1)
R  0, 26  5000  0,18  1934, 2  0,08
1054,736

0, 26
R  4056,68 N
(1)
1934, 2  5000  2877,52  4056,68
6934, 2  6934, 2
(1)
Bending moments
@ B  2877,52  0,08
(1)
 230, 2 Nm
@ C  4056,68  0,08
 324,53 Nm (1)

VERTICAL LOADING
RL 703,99N RR
80mm 100mm 80mm
1819,9N
L  0, 26  703,99  0,18  1819,9  0,08

18,87

0, 26
L  72,59 N (1)
R  0, 26  703,99  0,08  1819,9  0,18

271, 26

0, 26
R  1043,3 N (1)
72,59  703,99  1043,32  1819,9

1819,9  1819,9 (1)
Bending moments
@ B  72,59  0, 08
 5, 81 Nm
@ C  1043,32  0,08
 83, 47 Nm (1)
BM RESULTC  324,53 2  83, 472

 335,1Nm (1)
1.4 SHAFT 2 DIAMETER

TorqueBC  FTBC  RC
0,13
 5000 
2
 325 Nm (1)

TE  M2  T2
 335,12  3252
 466,82 Nm (1)
TE    d3  
16
466,82    d3  80 106
16
d  0,03097
 30,97mm (1)
ME  1 M  M 2  T 2 
2 
 1 2 335,1  466,82
 400,96 Nm (2)
ME   32  d 3   T
400,96   32  d 3  60 106
d  40,83 mm (2)
FT
FN 
Cos 20
1934, 2

Cos 20
 2058,33 N (1)
2058,33
BM   0,05 WL 2058,33  0,1
2 or BM    51, 46 Nm
4 4
 51, 46 Nm
(1)
TorqueA  FTA  RA
0,16
 1934, 2 
2
 154,736 Nm (1)

TE  M2  T2
 51,462  154,7362
 163,1 Nm (1)
TE    d3  
16
163,1    d3  80 106
16
d  0,0218
 21,8mm (1)
ME  1 M  M 2  T 2 
2 
 1 2 51, 46  163,1
 107, 28 Nm (1)
ME   32  d 3   T
107, 28   32  d 3  60 106
d  26,3 mm (2)
FT
FN 
Cos 20
5000

Cos 20
 5320,9 N (1)
5320,9
BM   0,05 WL 5320,9  0,1
2 or BM    133 Nm
4 4
 133 Nm
(1)
TorqueD  FTD  RD
0, 27
 5000 
2
 675Nm (1)

TE  M2  T2
 1332  6752
 687,98 Nm (1)
TE    d3  
16
687,98    d3  80 106
16
d  0,0352
 35,2mm (2)
ME  1 M  M 2  T 2 
2 
 1 2 133  687,98
 410, 49 Nm (1)
ME   32  d 3   T
410, 49   32  d 3  60 106
d  41,15 mm (1)
1.7 CENTRIFUGAL CLUTCH
Mass of each shoe
T  FT  RDRUM
154,736
 FT  0,15
4
FT  257,9 N (1)
FT    FNETT
257,9  0, 4  FNETT
FNETT  644,75 N (1)
300
RG   30
2
 150  30
 120 mm (1)

FNETT  m  MAX 2  Rg  m  ENG 2  Rg

 2  
2
644,75  m  0,12     18512  6002 

 60 
m  0,159 kg (2)
1.8 Length of the lining
FNETT
P 
Area
644,75
150000 
dL
dL  4, 2983 103
4, 2983 103
L 
0,03
L  143, 28 Say 144 mm (2)
1.9 Angle subtended by each shoe
L   R
144   150
  0,96 radians
180
  0,96 

  55o (1)
1.10 BEARINGS ON SHAFT 2
SAE NUMBER
T  TB  TA
 60  30
 300 C (1)
T  1 2 TO  TA 
30  1 2 TO  30
TO  900 C (1)
USE SAE 30 from tables (2)

1.11 Resultant Reaction @ L

LRESULT  2877,522  72,592
 2878, 44 N (1)
RRESULT  4056,682  1043, 32

 4188,69 N (1)
Use 4188,69 N (1)
1.12 LENGTH OF EACH JOURNAL
F
P 
A
4188,69
A 
1,5 106
 2,792 103 m2 (1)
A  l  d SHAFT
3
2,792 10  l  0,042
 66, 48
lBEARING  68mm (1)
1.13 DIAMETERAL CLEARANCE
H8 – g6 fit
0,039
DBEARING  42 0000
0,009
DSHAFT  42 0,025
(2)
Min clearance  42,00-41,991

 0,009 mm (1)
1.14 46
L
D 
42
 1
kPINION  0,002 from table (1)

 N  D
f  0,326  k
 P  C
 0,01 881, 46  0,046  0,042  42
 0,326   0,009  0,002
 4188,69 
 0,0082 (1)
1.15 QUANTITY OF COOLING OIL
 d  N
HGENERATED  f W 
60
  0,042  881, 446
 0,0082  4188,69 
60
 66,58 J/s (1)
HGENERATED  HOIL
 m  SHC  T
66,58  m  3200  30
m  0,00069 kg/s
 0,00069  60
 0,042 kg/min per bearing (3)
m
Q 

0,042

0,82
 0,0512 l/min per bearing (1)
TOTAL: 100
Copyright reserved
T1030(E)(M30)T
APRIL EXAMINATION
(8090086)
30 March 2015 (Y-Paper)

13:00–17:00
This question paper consists of 7 pages and a table of 2 pages.

(8090086) -2- T1030(E)(M30)T

TIME: 4 HOURS
MARKS: 100
paper.
4. A correct answer is worth only ONE mark. Show ALL the steps to achieve as

(8090086) -3- T1030(E)(M30)T
QUESTION 1
FIGURE 1 below, shows a salvaged gear which is to be used in a pulveriser at

400 r/min. No details are available from the manufacturer for the gear. The following
information is available for the cast iron gear:
Number of teeth = 75
Width of teeth = 60 mm
Profile of teeth 20 degrees involute
PCD = 375 mm
Basic stress for cast iron = 60 MPa
For the 40 mm diameter shaft:
 (shear stress) = 40 MPa
Gear wheel arms:
Allowable stress in the material of 40 MPa (elliptical ratio 2 : 1)
Key:
Shear stress = 30 MPa
Determine whether the gear and shaft are capable of transmitting 15 kW.
FIGURE 1 [25]

(8090086) -4- T1030(E)(M30)T
QUESTION 2
A 40 mm diameter journal bearing, 20 mm long, supports a load of 7 000 N.

The shaft speed is 800 r/min and an H8- g6 fit is used. The surrounding air
temperature is 20° C and the oil used has an absolute viscosity of 0,018 kg/ms at its
normal operating temperature of 90° C.
2.1 The minimum diametral clearance between the journal and the bearing
(tables are supplied) (5)
2.2 The approximate amount of heat generated. (Use the McKee equation with
an appropriate constant) (7)
2.3 The approximate amount of heat dissipated by the oil. (Assume still air and
use the Lasche equation) (3)
2.4 The approximate amount of heat to be dissipated by an external cooling

system (1)
[16]
QUESTION 3
A capstan is used in a mine to haul 4 loaded trucks up an incline of 1 : 60. The capstan
rotates at 120 r/min. The operator is capable of exerting a force of 100 N to the free
end of the rope. Each truck has a mass of 4 tonne and has a resistance to motion of
800 N.
3.1 The pull on the trucks
3.2 The number of turns the rope must make around the capstan if the coefficient
of friction is 0,2
3.3 The power that the capstan must supply if the diameter of the capstan is
350 m
(3 x 3) [9]

(8090086) -5- T1030(E)(M30)T
QUESTION 4
When in use the motor and flywheel of a press must run continuously. A compressed-
air-actuated, multi-disc clutch connects the flywheel to the countershaft each time the
press is to punch a hole. The clutch torque required is 1 300 Nm. Alternative moulded
and cast-iron discs are to be used. For design purposes 75% of the maximum average
value of the coefficient of friction , and 0,3 of the maximum average value of the
pressure P given in the table is to be used.
Friction material properties when operating dry

Material Dynamic coefficient of Pressure
friction  kPa
Moulded 0,25–0,45 1 030–2 070
Woven 0,25–0,45 345–690
Sintered metal 0,15–0,45 1 030–2 070
Cast-iron, steel 0,15–0,25 690–1 720
A factor of safety of 2 is to be used with respect to torque capacity. The outside

diameter of a disc is 350 mm. Assume that the inside diameter is 0,6 times the outside
diameter.
4.1 The minimum number of discs required to transmit the given torque (12)
4.2 The minimum area of compressed-air-actuating surface that must be provided

if the air pressure is 0,65 MPa (5)
[17]

(8090086) -6- T1030(E)(M30)T
QUESTION 5
The cam shown in FIGURE 2 below, causes the follower to move vertically.
For the position shown, the spring force is 800 N. In addition, for this position it has
been determined that a rotation of 1 radian corresponds to a follower motion of 10 mm.
A frictional force of 300 N occurs between the follower and the guide. In addition there
is a frictional force between the cam and follower where the coefficient is 0,3.
(The cam is in contact with the follower for a distance of 50 mm). Assume the torque
remains constant through the rotation.
FIGURE 2
5.1 The frictional force between the cam and follower (2)
5.2 The work done to overcome the frictional force in 1 when the cam moves
through an angle of 1 radian (4)
5.3 The total work done (4)
5.4 The torque provided by the camshaft (2)

[12]

(8090086) -7- T1030(E)(M30)T
QUESTION 6
FIGURE 3 below, shows a part of a gear-reduction unit. The pinion has 21 teeth with a
tooth module of 10 mm and delivers 170 kW power at 2 000 r/min. The transmission
ratio is 4 : 1. The spur gear has a mass of 90 kg and is mounted on a hollow shaft with
an inside diameter six-tenths of the outside diameter (d = 0,6 D).
Calculate the shaft diameters for combined stresses. Use the following stresses:
Tensile stress 70 MPa

Shear stress 40 MPa
Consider a temporary overload of 50% when determining the hollow shaft torque.
FIGURE 3 [21]
TOTAL: 100
Copyright reserved
(8090086) -1- T1030(E)(M30)T
TABLE 1
LIMITS OF TOLERANCE FOR SELECTED HOLES

ES = Upper deviation
EI = Lower deviation Unit = 0,001 mm
Nominal sizes H7 H8 H9 H11
Over Up to and ES EI ES EI ES EI ES EI
including + + + +
mm mm
0 3 10 0 14 0 25 0 60 0
3 6 12 0 18 0 30 0 75 0
6 10 15 0 22 0 36 0 90 0
10 18 18 0 27 0 43 0 110 0
18 30 21 0 33 0 52 0 130 0
30 50 25 0 39 0 62 0 160 0
50 80 30 0 46 0 74 0 190 0
80 120 35 0 54 0 87 0 220 0
120 180 40 0 63 0 100 0 250 0
180 250 46 0 72 0 115 0 290 0
250 315 52 0 81 0 130 0 320 0
315 400 57 0 89 0 140 0 360 0
400 500 63 0 97 0 155 0 400 0

(8090086) -2- T1030(E)(M30)T
TABLE 2
LIMITS OF TOLERANCE FOR SELECTED SHAFTS

es = Upper deviation ei = Lower deviation Unit = 0,001 mm
Nominal sizes c11 d10 e9 f7 g6 h6
Over To es ei es ei es ei es ei es ei es ei
- - - - - - - - - - - -
- 3 60 120 20 60 14 39 6 16 2 8 0 6
3 6 70 145 30 78 20 50 10 22 4 12 0 8
6 10 80 170 40 98 25 61 13 28 5 14 0 9
10 18 95 205 50 120 32 75 16 34 6 17 0 11
18 30 110 240 65 149 40 92 20 41 7 20 0 13
30 40 120 280 80 180 50 112 25 50 9 25 0 16
40 50 130 290 80 180 50 112 25 50 9 25 0 16
50 65 140 330 100 220 60 134 30 60 10 29 0 19
65 80 150 340 100 220 60 134 30 60 10 29 0 19
80 100 170 390 120 260 72 159 36 71 12 34 0 22
100 120 180 400 120 260 72 159 36 71 12 34 0 22
120 140 200 450 145 305 85 185 43 83 14 39 0 25
140 160 210 460 145 305 85 185 43 83 14 39 0 25
160 180 230 480 145 305 85 185 43 83 14 39 0 25
180 200 240 530 170 355 100 215 50 96 15 44 0 29
200 225 260 550 170 355 100 215 50 96 15 44 0 29
225 250 280 570 170 355 100 215 50 96 15 44 0 29
250 280 300 620 190 400 110 240 56 108 17 49 0 32
280 315 330 650 190 400 110 240 56 108 17 49 0 32
315 355 360 720 210 440 125 265 62 119 18 54 0 36
355 400 400 760 210 440 125 265 62 119 18 54 0 36
400 450 440 840 230 480 135 290 68 131 20 60 0 40
450 500 480 880 230 480 135 290 68 131 20 60 0 40
Copyright reserved
MARKING GUIDELINE
APRIL EXAMINATION
30 MARCH 2015

QUESTION 1
Gear
bMIN  2,5    m
 2,5    5
(1)
= 39,3 mm
bMAX  4 m
 4 5
(1)
= 62,8 mm
OK
PCD  m  T
375  m  75
m  5 mm (1)
  PCD  N
V 
60
  0,375  400

60
 7,854 m / s (1)
y75  0,138
3
CV 
3 V
3

3  7,854
 0,276 (1)
FT    m  b    Cv  y
   0,005  0,06  60  106  0,276  0,138
(1)
 2153,8N
P  FT  V
 2153,8  7,854
(1)
 16,9 kW
OK (1)

Shaft
TE    d3  
16
   0,043  40  106
16 (1)
 502,65Nm
FT
FN 
Cos20
 1,0642  FT
(1)
BM  FN  0,15
 0,15FN 
2
M2 
 0,15 1,0642FT 
2

(1)
 0,02548FT2
 FT  R 
2
T2 
2
 0,375 
  FT 
 2 
 0,03516FT2 (1)
TE  M2  T2
M 2  T2  502,652
0,02548FT2  0,03516FT2  502,652
0,06064FT2  502,652
(1)
FT  2041,2N
T  FT  R
0,375
 2041,2 
2
 382,73Nm (1)
2 N  T
P 
60
2    400  382,73
 (1)
60
 16 kW
OK

Arms
DBOSS  2d
 2  40
(1)
 80mm

Z   a3
64

  0,043
64
 3,1  10 6 m3 (1)
M  Z
 40  106  3,1  106 (1)
 124 Nm
PCD DBOSS
LE  
2 2
375 80
 
2 2 (1)
 147,5mm
BM  FT  L E
124  4  FT  0,1475
FT  3362,7N (1)
P  FT  V
 3362,7  7,854
(1)
 26,4 kW
OK
Key
t KEY  8mm
wKEY  12mm (1)
l KEY  1,5  40
 60mm (1)

TKEY  FR
DSHAFT
  A 
2
D
   w  l  SHAFT
2
6
30  10  0,012  0,08  0,04

2
 576Nm (1)
2 N  T
P 
60
2    400  576

60
 24,1kW (1)
OK
[25]
QUESTION 2
0,039
2.1
DBEARING  40 0,00 (2)
0,025
DSHAFT  40 0,00
(2)
C  40, 009  40, 000

 0, 009 mm
(1)
2.2 20
L  (1)
D 40
 0,5
(1)
k0,5  0, 005
 N  D
f  0,326    k
 P  C
 0, 018  800  0, 04  0, 02  32
 0,326     0, 05
 7000  0, 009
 0, 0519 (3)

f W    D  N
HG 
60
0, 0519  7000    0, 04  800

60
 608,8W (2)
2.3 T  0,5 TO  TA 

 0,5  90  20 
(1)
 35O C
 T  18
2
 L D
HD 
K
 35  18
2
 0, 02  0, 04

0, 484
 4, 643W (2)
2.4 H  HG  H D
 608,8  4, 643
 604,16W (1)
[16]
QUESTION 3
3.1 T1
TR+TG
m g
TG 
Gradient
4000  g  4

60
 2616 N (1)
1
TR  800  4
(1)
 3200 N
1
T1  TR  TG
 3200  2616
 5816 N (1)

3.2 T1
 e 
T2
5816
 e0,2
100
lin 58,16  0, 2
  20,316 rad
20,316
N O turns 
2
 3,3 (3)
3.3   D N
v 
60
  0,35 120
 (1)
60
 2,199 m / s
P  T1  v
 5816  2,199
(2)
 12, 79 kW
[9]
QUESTION 4
4.1 0, 25  0, 45
 AVE 
2
 0,35  0, 75
(2)
 0, 2625
2070  1720
PAVE 
2
 1895  0,3
(2)
 568,5 kPa
T  1300  2
 2600 Nm (1)
d  0, 6  D
 0, 6  350
 210 mm (1)

FA
PMAX 
2  R  r  r
FA
568,5 103 
2    0,175  0,105  0,105
FA  26254 N (2)
 R3  r 3 
RF  2  2 2
3 R r
 
 1753  1053 
 2 
3 1752  1052 
 
 142,92 mm (1)
T  FT  RF
  FA  RF
 0, 2625  26254  0,14292
 984,9 Nm (2)
2600
NO 
984,9
 2, 6
 4 (1)
4.2 Rr
RMEAN 
2
175  105

2 (1)
 140 mm
T  FT  RF
984,9   FA  RF
 0, 2625  FA  0,14
FA  26800 N (2)
FAIR
P 
Area
26800
650 103 
A
A  4,123 102 m 2 (2)
[17]

QUESTION 5
5.1 F  F
 0, 2  800  300 
 330 N (2)
5.2 S   r
 1 0, 05
 0, 05 m (2)
WD  F  S
 330  0, 05
 16,5 J (2)
5.3 WD  F  
 1100  0, 2
 220 J (2)
WDTOTAL  220  16,5

 236,5 J (2)
5.4 WDTOTAL  T 
236,5  T 1
T  236,5 Nm (2)
[12]

QUESTION 6
2  N T
P 
60
2    2000  T
170000 
60 (1)
T  811, 69 Nm
TMAX  1,1 T
 1,5  811, 69
(1)
= 1217,5 Nm
TMAX GEAR  4 1217,5

 4870,1 Nm (1)
PCDGEAR  m T  4
 10  21 4
 840 mm (1)
T  FT  R
0,84
4870,1  FT 
2
FT  11595, 476 N (1)
FT
Cos 20 
FN
11595, 476
FN 
Cos 20
 12339, 648 N (1)
(2)
FH  FN  Cos5
 12339, 648  Cos5
(1)
 12292, 692 N
FV  FN  Sin5  m  g
 12339, 648  Sin5  90  g
 1075, 47  882,9
 1958,37 N (1)
FRESULTANT  12292, 6922  1958,37 2

 12447, 71 N (1)
BM  12447, 71 0,18

 2240, 6 Nm
(1)
 M   T 
2 2
TE 
 2240, 6    4870,1
2 2

 5360,8 Nm
(2)
ME  0,5  M  TE 
 0,5  2240, 6  5360,8
 3800, 7 Nm
(2)
 D d 4 4
TE   
16 D
 D    0, 6 D   40 106
4 4
5360,8   
16 D
D  92, 2 mm
(2)
 D4  d 4
ME   
32 D
 D    0, 6 D   70 106
4 4
3800, 7   
32 D
D  85,97 mm (2)
Say D = 95 mm
and d = 0,6  95
d = 57 mm (1)
[21]
TOTAL: 100
MARKING GUIDELINE
13 NOVEMBER 2014

QUESTION 1
1.1 2    N A  TA
PA 
60
2    420  TA
25  103  
60
TA  568, 41 Nm (2)
2    N B  TB
PB 
60
2    420  TB
8  103  
60
TB  181,89 Nm (1)
2    N C  TC
PC 
60
2    420  TC
17 103  
60
TC  386,52 Nm (1)
TA  FTA  RA

0, 45
568, 41  FT  
2
FTA  2526,3 N (2)
FR A  Tan20  FTA
 Tan20  2526,3 
FR A  919,49 N  (2)

TC  FTC  RC
0,3
386,52  FT  
2
FTC  2576,8 N
(1)
FTC
FN C 
Cos 20
2576,8 

Cos 20 
FNC  2742,17 N (2)
FH C  FNC  Cos10 
 2742,17  Cos10 
FHC  2700,5 N (2)
FV C  FNC  Sin10
 2742,17  Sin10 
FVC  476,17 N (1)
FHB  P  S in 45
 1200  0,707 
 848,53N (1)

FVB  P  Cos45
 1200  0,707 
 848,53N (1)

2,3  R E  476,17  2,1  848,53  0,3  919,49  0,2
RE  625,397 N
(2)
2,3  R D  476,17  0,2  848,53  2  919,49  2,5

RD  220,2 N
(1)
CHECK
F  F
625,39  919,49  476,17  848,53  220,2 
1544,88  1544,88 (1)

(1)

(1)


 (2)
 
2,3  R E  2700,5  2,1  848,53  0,3  2526,3  0,2
RE  2796 N (2)
2,3  R D  2526,3  2,5  848,53  2  2700,5  0,2

RD  1773,3 N 
(1)
CHECK
F  F
2796  2526,3  2700,5  848,53  1773,3
5322,38  5322,38  (1)
 (1)
 (1)
 
(2)

(3)
(3)
Resultant bending moment at B. Use this as the maximum torque also occurs
here.

(2)
Torque entering at B is 568,41 Nm
(1)

 (1)


 (2)



 (2)
Say d = 60 mm std shaft  (1)


1.3  
 
 (3)
1.4 
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
 (2)

(2)

(1)
1.5
(1)
 (1)
No interference  (1)
(1)
 (1)
No interference (1)

1.6
(1)
(1)
(2)
(1)
(1)
(1)
(1)
(2)
1.7
(2)
(2)

1.8
(1)
(1)
(2)
(2)
(1)
0,015
0,010
0,005
0 0,5 1,0 1,5 2,0 2,5 3,0

L
D
(1)
0,002
0,0672
(2)

(1)
1
0,8
0,6
0,4
0,3
0,2
0,15
0,1
0,08
0,06
0,04
Absolut e
0,03
viscosit y 
0,02 70
kg/ms 60
0,015
50
0,01 SAE
40
0,008
30
0,006
20
0,004 10
20 0 C 40 0 C 60 0 C 80 0 C 100 0 C
Temperat ure
USE SAE 70 (1)
1.9
(1)
min (3)
TOTAL: 100

T1010(E)(J23)T
AUGUST 2014
(8090086)
23 July (Y-Paper)
13:00–17:00
Candidates may use personal notes.

(80900086) -2- T1010(E)(J23)T

TIME: 4 HOURS
MARKS: 100
paper.
4. Show ALL the steps to achieve as many marks as possible. (An incorrect
answer which must be carried forward will receive fair consideration.)

(80900086) -3- T1010(E)(J23)T
QUESTION 1
FIGURE 1 below, shows a kick start mechanism of a motor cycle. The maximum force
on the pedal is 1 600 N.
1600 N
A
E
FIGURE 1
1.1 The shaft diameter for both (Me) and (Te). The allowable tensile stress for
the shaft is 80 MPa and the allowable shear stress is 50 MPa. The shaft is
subjected to high shock and fatigue factors of = K b = 2,5 and
Kt = 2,5. (13)
1.2 The width of the gear (b), module of 10 mm, treating it as a cantilever
(assume total tangential force acts on the tooth tip) where the following ratios
apply and the stress is 100 MPa. Tooth height = 2,25 × module.
PCD = 200 mm. (9)
1.3 The dimensions of the key (E) if the key material has a maximum shear stress
of 45 MPa. (2)
1.4 The diameter (d) of the shear pin in double shear. The shear stress is
50 MPa. (2)
[26]

(80900086) -4- T1010(E)(J23)T
QUESTION 2
Two journals of a shaft 80 mm diameter carry a flywheel with a weight 4 kN which is

positioned 400 mm from the centre line of the left hand bearing. The centre distance
between the two bearing (journals) is 1 metre. If the friction coefficient is 0,3 when the
shaft rotates at 1 200 r/min.
2.1 The power loss due to friction. (2)
2.2 The bending stress induced in the shaft (4)
2.3 The quantity of cooling oil in litres per minute that flows through the bearing to
absorb the heat generated.
 Specific heat capacity of oil is 3,14 kJ/kg °C.
 Specific weight is 0,8 kg/litre
 The oil enters at 20 °C and leaves the bearing at 60 °C. (4)
2.4 Determine each journal length. Bearing pressure is 200 kPa. (6)
[16]
QUESTION 3
An hydraulic lifting apparatus is shown in FIGURE 2 below. Determine a suitable ram

rod diameter (one end free, one fixed). The rod is made of mild steel with an ultimate
stress of 300 MPa. Use a safety factor of 4 and a Rankine constant of 1 7500 for
hinged ends.
FIGURE 2 [20]

(80900086) -5- T1010(E)(J23)T
QUESTION 4
A disc clutch fitted between an electric motor and a machine has a single-driving plate
with contact surfaces on both sides. The clutch is required to transmit 240 kW at a
speed of 4 000 r/min. The outside diameter of the contact surfaces are 320 mm and
the coefficient of friction is 0,4.
4.1 Calculate the inside diameter of the driving plate. Assume a constant uniform
surface pressure of 220 kPa. (Use uniform pressure theory for clutch
dimensions) (8)
4.2 Use the calculated plate dimensions in QUESTION 4.1 and calculate the
power transmitted by the clutch if the uniform wear theory is used. (4)
4.3 In order to compensate for the difference in power between QUESTION 4.1
and QUESTION 4.2 the speed of the assembly needs to be altered.
Determine the new speed. (4)
4.4 The clutch in QUESTION 4.1 must be replaced with a multi-plate clutch
having discs with outside and inside diameters of 180 mm and 130 mm
respectively.
Calculate the number of plates required to transmit 240 kW at 4 000 rpm if the
pressure is 220 kPa. (Use uniform wear theory) (4)
[20]
QUESTION 5
A gearbox is shown schematically in FIGURE 3 (below). The parallel shaft centres are
300 mm apart. Assume ALL teeth to be 20° full depth involute.
The input power drive shaft rotates at 1 200 r/min and carries TWO gears (A) and (C).
FIGURE 3
(80900086) -6- T1010(E)(J23)T
The output power driven shaft carries two sliding gears (B) and (D). (B) engages with
(A) to give the driven shaft a speed of approximately 700 r/min. (D) engages with (C) to
give the driven shaft a speed of approximately 300 r/min.
All the gear teeth are module 6 and widths of teeth are 3 times the circular pitch.
Use a basic stress of 100 MPa for all teeth and assume one pair of teeth to make
contact.
5.1 Calculate the number of teeth on each gear. (8)
5.2 The speed at each step. (1)
5.3 Use the Lewis formula to determine the power that the gearbox can transmit. (9)
[18]
TOTAL: 100

MARKING GUIDELINE
AUGUST EXAMINATION
23 JULY 2014

QUESTION 1
1.1 T  FR
 1600  0,3
 480Nm (2)
BM  F  Dis tan ce
 1600  0,22
 352Nm (2)
Kb  M  Kt  T
2 2
TE 
 2,5  352    2,5  480 

2 2

 1488 Nm (2)
TE    d3  
16
1488    d 3  50  106
16
d  0,0533
 54 mm (2)
2
ME  1 M  TE 
2 
 1 2,5  352   1488 
 1928 Nm (2)
ME    d3  
32
1928  
 d 3  80  106
32
d  0,0626 m (2)
 Use/gebruik d=65 mm STD (1)
1.2 T  FT  PCD
2
480  FT  0,1
FT  4800 N (2)
BM  FT  h
 4800  2,25  0,01
 108Nm (2)

M  Z
108
Z 
100  106
 1,08  10 6 (1)
m
t 
2
  0,01

2
 0,0157 m (2)
b  t2
Z 
6
b  0,01572
1,08  10 6 
6
t  26,2mm
 27 mm (2)
1.3 w  18 mm
t  11mm
T  l  wR
0,065
480  45  106  l  0,018 
2
l  18,23mm
 20mm (2)
1.4 T      d2  R  2
4
0,065
480  50  106    d 2  2
4 2
d  13,7 mm
 14 mm (2)
[26]

QUESTION 2
2.1  W    D  N
P 
60
0,3  4000    0, 08 1200

60
 6031,86 W (2)
2.2 RL  1  4000  0, 6
RL  2400 N (1)
BM  2400  0, 4
 960 Nm (1)

Z  d3
32

  0, 083
32
 5, 03  105 m3 (1)
M   Z
960

5, 03 105
  19,1 MPa (1)
2.3 P  m  SHC  T
6031,86  m  3140   60  20 
m  0, 048 kg / s (2)
m
 
Q
0, 048
800 
Q
Q  6 105 m3 / s
 0, 06 l / s × 60 = 3,6 /min (2)

2.4 W
P 
d  LTOTAL
4000
200 103 
0,1 LTOTAL
LTOTAL  200 mm
600
LLEFT  200 
1000
 120 mm
400
LRIGHT  200 
1000
 80 mm (6)
[16]
QUESTION 3
(4)
Adj
Cos 
Hyp
Y
Cos 16 
160
Y  153,8 mm (2)
F  dist  F  dist
4000  0,38  F  0,1538
F  9882,96 N (2)
FCRIPPLING  F  FoS
 9882,96  4
 39531,86 N (2)

A =   d2
4
I
k2 =
A
  d4
= 64
  d2
4
2
d
k2 =
16 (2)
LE = 2 L
 2  450
 900 mm (2)
A
F 
a L2
1
n k XX 2
300 106   d 2
9882,96  4
1 0,92
1  2
7500 d
16
0, 001728
1  2,3841104 d 2
d2
d 2  0, 001728  2,384110 4 d 4
0  2,3841104 x 2  x  0, 001728
b  b 2  4ac
0 =
2a
d  2,9101 104
2
d  17,059 mm
 18 mm (6)
[20]

QUESTION 4
4.1 2  N T
P 
60
2    4000  T
240000 
60
T  572,96 Nm (1)
 R3  r 3 
Rf  2  2 2
3 R r
 
FA
P 
Area
FA  P  R 2  r 2 
T    FA  R f  N
 R3  r 3 
572,96  
 0, 4  P   R 2  r 2  2  2 2   2
3 R r
 
3

 0, 4  220 10    2 R  r  2
3
3

3
R 3
 r3   1,5544 103 (4)
R  r 
3 3
 1,5544 103
 0,16  r 
3 3
 1,5544 103
r  0,13647 m
r  137 mm
d  274 mm (3)
4.2 T    FA  R f  N
Rr

   P   R2  r 2   
 N
 2 
 0,16  0,137 

 0, 4  220 103    0,162  0,137 2  

 2 2

 560,88 Nm (3)
2  N T
P 
60
2    4000  560,88

60
 234,94 kW (1)

4.3 240  234,94

%  100
240
 2,1%
4000 102,1
N2 
100
N2  4084,3 r / min (4)
T    FA  R f  N
Rr
 
   P   R2  r 2    N
 2 
 0, 09  0, 065 

572,96  0, 4  220 103    0, 092  0, 0652  

 2  N

N  6,9
 8 pairs (4)
[20]
QUESTION 5
5.1 m TA  TB 
C 
2
6 TA  TB 
300 
2
TA  TB  100 (1)
1200  TA  700  TB
TA  7 TB (1)
12
TA  TB  100
7 TB  TB  100
12
TB  63,15
 63 (1)
TA  TB  100
TA  63  100
TA  37 (1)

m TC  TD 
C 
2
6 TC  TD 
300 
2
TC  TD  100 (1)
NC  TC  N D  TD
1200  TC  300  TD
TC  3 T
(1)
12 D
TC  TD  100
3 T T  100
12 D D
TD  80 (1)
TC  TD  100
TC  80  100
TC  20 (1)
5.2 N A  TA  N B  TB
1200  37  N B  63
NB  704, 76 r / min
N C  TC  N D  TD
1200  20  N D  80
ND  300 r / min (1)
5.3 b  3  m
 3  6
 56,55 mm
 57 mm (1)
PCDA  m  TA
 6  37
 222 mm
PCDC  m  TC
 6  20
 120 mm (1)

  PCD  N
VA 
60
  0, 222 1200

60
 13,95 m / s
  PCD  N
VA 
60
  0,12 1200

60
 7,54 m / s (1)
6
CVA 
6 V
6

6  13,95
 0,3
3
CVC 
3 V
3

3  7,54
 0, 285 (1)
yA  0,121
yC  0,102 (1)
FTAB    m  b    y  CV
   6 103  0, 057 100 106  0,121 0,3
FTAB  3900, 2 N (1)
FTC D    m  b    y  CV
   6 103  0, 057 100 106  0,102  0, 285
FTC D  3123, 4 N (1)

PCDA
TA  FTA 
2
0, 222
 3900, 2 
2
 432,9 Nm
PCDC
TC  FTC 
2
0,12
 3123, 4 
2
 187, 4 Nm (1)
2  N T
PC 
60
2   1200 187, 4

60
 23,549 kW (1)
[18]
TOTAL: 100

T1010(E)(M26)T
APRIL EXAMINATION

(8090086)
26 MARCH 2014 (Y-Paper)

13:00–17:00

(8090086) -2- T1010(E)(M26)T

TIME: 4 HOURS
MARKS: 100
3. A correct answer is worth only one mark. Show all the steps to achieve as many
marks as possible. (An incorrect answer which must be carried forward will
receive fair consideration.)
paper.

(8090086) -3- T1010(E)(M26)T
QUESTION 1
Referring to FIGURE 1 below, (A) is a flywheel with a mass of 150 kg. (B) is a driven
gear. (D) is the driving pinion which transmits 30 kW from a motor rotating at 2 100
r/min. Pinion (D) has a PCD of 180 mm. The gear ratio is 3 : 1. (C) is a V-belt pulley,
mounted on the overhanging part of the shaft, and drives a machine situated below it.
The PCD of the pulley is 480 mm and T1/T2 is 4 : 1.
FIGURE 1
Calculate the diameters of the hollow shaft if D = 2 d. The safe tensile stress is 60 MPa
and the safe shear stress is 50 MPa. Use the following steps:
1.1 Calculate the flywheel, gear and V-pulley forces acting on the shaft. (14)
1.2 Calculate the values and then draw the bending moment diagrams for vertical
and for horizontal loading. (20)
1.4 Calculate the shaft torsion. (1)
1.5 Calculate the shaft diameters using (TE) and (ME). (5)
1.6 Calculate the number of teeth on gears B and D if the module is 4 mm. (1)
1.7 Calculate the face width of gears B and D assuming a basic stress of 110
MPa for cast steel (gear B) and a basic stress of 120 MPa for alloy steel
(gear D). (10)
1.8 Calculate the elliptical spoke sizes for the large gear with a ratio of 2 : 1. The
bending stress is 30 MPa. (8)
[61]

(8090086) -4- T1010(E)(M26)T
QUESTION 2
A cone clutch (FIGURE 2 below) is to transmit 28 kW at 1 400 r/min. The large

diameter of the cone is 250 mm and the enclosed cone angle is 12°.
The friction face width is 65 mm and the coefficient of friction between the faces is 0,2.
FIGURE 2
2.1 The axial force required to transmit the power. (6)
2.2 The axial force required to engage the clutch, assuming that there is no
relative movement between the faces during engagement. (2)
2.3 The average normal pressure on the contact surfaces for maximum power. (2)
2.4 The maximum normal pressure assuming uniform wear condition. (1)
2.5 The dimensions of the operating lever to keep the clutch engaged. The
allowable stress in the rectangular (ratio 2 : 1) arms is to be 30 MPa. (6)
2.6 The stress induced in the lever during engagement. (2)

[19]

(8090086) -5- T1010(E)(M26)T
QUESTION 3
A hollow cast-iron column has a square cross section with an outside length of side of
250 mm and the column length is 4 500 mm. The column carries an axial load of
600 kN.
Calculate the thickness of the metal required for the column by using the Rankine
formula with 1 6400 as the constant.
A factor of safety of 8 is to be allowed on a stress of 500 MPa. [20]
TOTAL: 100

MARKING GUIDELINE
APRIL EXAMINATION
26 MARCH 2014

QUESTION 1
1.1 FORCES ON FLYWHEEL

WFLYWHEEL  mg
 150  9,81
WFLYWHEEL  1471,5N (1)
FORCES ON BELT PULLEY

  PCD  N
VPulley 
60
  0,48  2100
 3
60
 17,59 m/s (1)
P   T1  T2  v
30  103   T1  T2 19,98
17,59
 T1  T2   1705,2 N (1)
T1
 4
T2
T1  4  T2 (1)
 T1  T2   1705,2
 4T2  T2   1705,2
3T2  1705,2
T2  568,41N
(1)
T1  4  T2
 4  568,41
T1  2273,6N (1)
T1  T2  2273,6+568,41
 2842,1N
(1)

(1)
FH   T1  T2  sin 30
 2842,1  0,5
 1421N (1)
FV   T1  T2  Cos30
 2842,1  0,866
 2461,22N (1)
FORCES ON THE GEARS
  PCD  N
VPINION 
60
  0,18  2100

60
 19,79 m/s (1)
Power  FT  v
30000  FT  19,79
FT  1515,8 N (1)
FR  Tan20  FT
 Tan20  1515,8
FR  551,69 N (1)

(1)
1.2 BENDING MOMENTS

VERTICAL REACTIONS
(2)
1  RL  2461,22  1,2  551,69  0,75  1471,5  0,25

(1)
RL  3735,11 N
1  R R  2461,22  0,2  551,69  0,25  1471,5  0,75

RR  749,3 N
(1)
Check
F  F
749,3  3735,11  2461,22  551,69  1471,5
4484,41  4484,41 (1)

BML  2461,22  0,2
 492,24
492,24Nm
Nm (1)

BMB  749,3  0,75  1471,5  0,5

 -173,78 Nm (1)
BM A  749,3  0,25
 187,31 Nm (1)
(2)
1  RL  1421  1,2  1515,8  0,75
RL  568,35 N (1)
1  RR  1421  0,2  1515,8  0,25

(1)
RR  663,15 N
Check
F  F
1515,8  568,35  1421  663,15
(1)
2084,15  2084,15

BML  1421  0,2
 -284,2 Nm (1)
BMB  663,15  0,75

 -497,36 Nm (1)
BM A  663,15  0,25
 -165,79 Nm (1)

492,24
(4)
BML  492,242  284,22

 568,4 Nm (1)
BML  497,362  173,782

 526,8 Nm
USE 568,4 Nm (1)
1.4 TORQUE ON SHAFT

2 N  T
P =
60
2    2100 3  T
30  103 =
60
T = 409,26 Nm (1)

1.5 SHAFT DIAMETER
TE  M2  T2
 568,42  409,262
 700,41 Nm (1)
TE   
D 4
 d4 
16 D
700,41   
 2d   d 
4 4
 50  10 6
16 2d
d  0,0211
 21mm
D  42mm (1)
ME  0,5  M  M2  T2 
 
 0,5 568,4  700,41
(1)
 634,4 Nm
ME   
D4
 d4  
32 D
634,4   
2d  d   60 10
4 4
6
32 2d
d  0,0243
 24 mm
D  48mm (1)
USE 48mm and 24mm (1)
1.6 GEAR TEETH

PCD  m  T
180  4  TA
TD  45
TB  3  TD
TB  135 (1)

1.7 FACE WIDTH

 DN
V 
60
  0,18  2100

60
 19,79 m/s (1)
6
CV 
6V
6

6  19,79
 0,23 (1)
T  FT  R
409,26  FT  0,18
3 2
FT  1515,78 N
(1)
 0,912 
yD  0,154   
 T 
 0,912 
 0,154   
 45 
 0,134 (1)
 0,912 
yB  0,154   
 T 
 0,912 
 0,154   
 135 
 0,147 (1)
To find which gears govern the design i.e. the weaker gear.
GearD  O  CV  y
 120  106  0,23  0,134
 3,6984  106 (1)

GearB  O  C V  y
 110  106  0,23  0,147
 3,7197  106 (1)
bMIN  2,5    m
 2,5    4
 31,4 mm
(1)
bMAX  4 m
 4 4
 50,3 mm
(1)
FT    b  m    y
1515,8    4  103  b  3,6984  106
b  32,615 mm Say 33 mm (1)
1.8 PULLEY ARMS

PCDB  3  180
 540 mm
No arms  5 ( from tables)
(1)
d BOSS  2  d SHAFT
 2  48
 96 mm
(1)
PCD d BOSS
LBENDING  
2 2
540  96

2
 222 mm (1)
FT  L
M 
arms
1515,8  0, 222

5
 67,3 Nm (1)
M   Z
67,3  30 106  Z
Z  2, 2434 106 m3 (1)


Z  a3
64

2, 2434  106  a3
64
a  35, 7 mm
Say 36 mm (2)
a  36 mm
b  18 mm (1)
[61]
QUESTION 2
2.1 Rr
Sin 
w
125  r
Sin 6 
65
r  118, 21 mm (1)
Rr
RF 
2
125  118, 21

2
 121, 6 mm (1)
2  N T
Power 
60
2    1400  T
28  103 
60
 190,99 Nm (1)
Torque  FT  RF
190,99  FT  0,1216
FT  1570, 6 N
(1)
FT    FN
1570, 6  0, 2  FN
FN  7853 N
(1)
FA
FN 
Sin
FA
7853 
Sin 6
FA  820,87 N (1)

2.2
FENG  FN  Sin   Cos 
 7853  Sin6  0, 2Cos6 
 2382,87 N (2)
2.3 Area  2    RMEAN  width

 2    0,1216  0, 065
 0, 04966 m2 (1)
FN
P 
Area
7853

0, 04966
 158,128 kPa (1)
2.4 FA
Pr essureMAX 
2  R  r  r
820,87

2  0,125  0,11821 0,11821
 162, 768 kPa (1)
2.5 M  0
F  0, 21  820,87  0,12
F  469,1 N (1)
b  d2
Z 
6
b  22  b2

6
 4
6b
3
(1)
M  F  dis tan ce
 469,1 0, 21
 98,5 Nm (1)
M   Z
98,5  30 106  Z
Z  3, 2835 106 m3 (1)

4  b3  3, 2835 106
6
b  17 mm (1)
d  2 17
b  34 mm (1)
2.6 M  F  dis tan ce

 2382,87  0, 21
 500, 4 Nm (1)
M   Z
500, 4    4  0, 0173
6 (1)
  152, 78 MPa [19]
QUESTION 3
A
F  2
aL
1  
nk 
500  106  A
600 10 3
 8
2
1  4,5 
1  
6400  k 
0, 003164
1  104,17 A
k2
k 2  0, 003164  104,17  A  k 2 (5)
BD 3  bd 3
k2 
12  BD  bd 
B 4  b4


12 B 2  b 2 

B 2
 b2  B 2
 b2 

12 B  b 2 2

k 2

B 2
 b2 
12 (2)

A  B 2  b2 (1)
k 2  0, 003164  104,17  A  k 2
B 2
 b2   0, 003164  B 2
 b2
12

 104,17  B  b2
 122

 2

B  b 2  0, 037968  104,17   B  b B  b 
2 2 2 2
 0, 25 2

 b 2  0, 037968  104,17   0, 25  b  4 4
0,1  b 2  0, 41  104,17b 4
104,17b 4  b 2  0,31  0 (5)
Say b2 = x (1)
b  b 2  4ac

2a
1  12  4(104,17)(0,31)

2(104,17)
 0, 0499 (3)
b2  0, 0499
b  223,5 mm
(1)
250  223
t 
2
b  13,5 mm (2)
[20]
TOTAL: 100

T1150(E)(N14)T
NOVEMBER 2012

(8090086)
14 November (X-Paper)
09:00 – 13:00
OPEN-BOOK EXAMINATION.
Copyright reserved NOV 2012 Please turn over

(8090086) -2- T1150(E)(N14)T

TIME: 4 HOURS
MARKS: 100
________________________________________________________________________
paper.
3. ALL work you do NOT want to be marked must be clearly crossed out.
4. A correct answer is worth only ONE mark. Show ALL the steps to obtain as
many marks as possible. (An incorrect answer which must be carried
5. One mark = 1%.

(8090086) -3- T1150(E)(N14)T
QUESTION 1
The diagram shows a part of a gear reduction unit. The pinion has 25 teeth with a
tooth module of 8 mm, rotates at 1 000 r/min and delivers 150 kW. The transmission
ratio is 5:1. The spur gear has a mass of 40 kg and is mounted on a hollow shaft with
an inside diameter four-tenths of the outside diameter (d = 0,4 D).
Consider a temporary overload of 10% when determining the hollow shaft torque.
1.1 The hollow shaft diameters for combined stresses. Use the following
stresses:
Tensile stress : 60 MPa

Shear stress : 50 MPa (24)
1.2 The tooth width for the gear pair. Use the Lewis formula for the gear width
calculations. Check the answers.
The spur gear has a basic stress of 250 MPa and the pinion has a basic
stress of 320 MPa. (12)
1.3 ALL the required gear wheel dimensions including the boss, key, outside
diameter and spoke sizes.
Gear wheel spokes : 4

Ratio of axis of elliptical spokes : 2:1
Allowable bending stress in arms : 16 MPa (12)
[48]

(8090086) -4- T1150(E)(N14)T
QUESTION 2
Collar bearings are used to support a shaft with an axial load of 150 kN. The shaft
rotates at 400 r/min. The outside diameter of the collar bearings is 250 mm and the
inside diameter is 80 mm. The average permissible intensity of normal pressure on the
collars is 250 kPa and the coefficient of friction is 0,03.
2.1 The number of collars required (2)
2.2 The actual intensity of normal pressure on the collars (2)
2.3 The torque required to overcome friction in the bearings (4)
2.4 The heat generated in J/s at the bearings (3)
2.5 The amount of cooling oil which must be circulated through the bearings in
litres per minute to absorb the heat generated if the specific heat capacity of
the oil is 1,8 kJ/kg oC. The density of the oil is 800 kg/m3. The difference in
oil temperature between exit and entrance is 30 oC. (4)
[15]
QUESTION 3
A single-plate clutch has inside and outside diameters of 160 mm and 300 mm
respectively. The friction material provides a coefficient of friction of 0,4 when in
contact with the flywheel. The maximum engine torque is 245 Nm. A clamping force
of 1 200 N is provided by each of the EIGHT springs when the springs are compressed
to 6 mm.
3.1 The factor of safety with respect to slippage when the clutch is new (uniform
pressure) (6)
3.2 The factor of safety with respect to slippage after initial wear has taken place
(uniform wear) (4)
3.3 How much can the friction material wear before the clutch will slip? (4)
3.4 The power transmitted at 900 r/min (uniform wear) (1)

[15]

(8090086) -5- T1150(E)(N14)T
QUESTION 4
The diagram shows a mild steel compression member.

The 50 mm diameter pins each has a bearing surface length of 40 mm and when the
member is in compression the bearing pressure in the eye portion is 8 MPa.
Regard the member as a column with the end fixation conditions as follows:
4.1 Relative to the X-X axis the ends may be regarded as pivoted (hinged)
4.2 Relative to the Y-Y axis the ends may be regarded as fixed.
Use the Rankine formula with appropriate constants and determine the stresses
induced in the material for the above conditions in 4.1 and 4.2.
[13]
QUESTION 5
A 350 mm pulley rotating at 900 r/min has to transmit 42 kW by means of a flat belt to
a second pulley 750 mm in diameter, the pulley centres being 1,5 m apart. The belt,
18 mm thick, has a mass of 0,8 kg/m and may be loaded to a maximum value of
30 N/mm belt width. Assume the friction coefficient as 0,4 and calculate the following:
5.1 Belt width (8)
5.2 Belt length (1)

[9]
TOTAL: 100

MARKING GUIDELINE
14 NOVEMBER 2012

MARKING GUIDELINE -2- N1150(E)(N14)H
QUESTION 1
SHAFT
PCDPINION  m T
 8  25
 200 mm (1)
2  N T
P 
60
2    1000  T
150000 
60
T  1432, 4 Nm (1)
TMAX  1, 2  T
 1,11432, 4
= 1575, 6 Nm (1)
TMAX GEAR  5 1575, 6

 7878 Nm (1)
T  FT  R
0,1
1575, 6  FT 
2
FT  31513 N (1)
FT
Cos 20 
FN
31513
FN 
Cos 20
 33535 N (1)
(2)

FH
Cos 45 
33535
FH  23712,83 N (1)
FV
Sin45 
33535
FV  23712,83 N (1)
WGEAR  m g
 40  g
 392,4 N (1)
FGEARVERTICAL = 23712,83+392,4
= 24105,23 N (1)
FRESULTANT  23712,832  24105, 232

 33813, 6 N (2)
BM  33813, 6  0,3
 10144,1 Nm (1)
 M   T 
2 2
TE 
10144,1   7878
2 2

 12843,88 Nm (2)
ME  0,5  M  TE 
 0,5 10144,1  12843,88
 11493,98 Nm (2)
 D4  d 4
TE   
16 D
 D    0, 4 D 
4 4
12843,88     50 106
16 D
D  110,32 mm (2)
 D4  d 4
ME   
32 D
 D    0, 4 D 
4 4
11493,98     60 106
32 D
D  126 mm (2)

Say D = 130 mm
and d = 0,4 130
d = 52 mm (1)
GEAR WIDTH
  PCD  N
V 
60
  0, 2 1000

60
 10,47 m/s (1)
6
CV 
6 V
6

6  10, 47
 0,364 (1)
yPINION  0,108 from tables (1)
 0,912 
yGEAR  0,154   
 T 
 0,912 
 0,154   
 125 
 0,147 (1)
 GEAR yGEAR  CV  250  106  0,147  0,364

 13,377 MPa (1)
Pinion is weaker and governs design (1)
FT    m  b   y
31513    0, 008  b 12,58 106
b  99, 7 mm (1)
bMIN  2,5    m bMAX  4  m

 2,5    8  4 8
= 62,83 mm = 100,5 mm (3)
Say b = 100 mm (1)

GEAR WHEEL ARMS (1)
DBOSS  2 130  260 mm

L BOSS  1,5  130=195 mm (2)
wKEY  25 mm
t KEY  14 mm
LKEY  LBOSS
 195 mm (3)
PCDGEAR  m  Teeth
 8  25  5
 1000 mm (1)
PCD DBOSS
LE  
2 2
1  0, 26

2
 0,37 m (1)
BM  FT  LE
31513  0,37

4
 2914,95 Nm (1)
a  b3
Z  64 
b
2
 
32  0,5  b
3
  b3
64 (1)
M   Z
2914,95  16 106    b3
64
b  0,15483 m
Say b  156 mm
a  0,5 156
a  78 mm (2)
DBLANK  PCD  2  m
 1000  2  8
DBLANK  1016 mm (1)
[48]

QUESTION 2
FA
P 
A
150  103
P 
 0, 252  0, 082 
4  
P  3, 4  106
PTOTAL
No of collars 
PSINGLE COLLAR
3, 4 106

350 103
 9, 7
 10 (2)
P  A  No  FA
P   0, 252  0, 082  10  150 103
4
P  3, 4044 105 Pa (2)
 R3  r 3 
Rf  2  2 2
3 R r
 
 1253  403 
 2
3 1252  402 
 
 89,8mm (1)
T    FA  R f
 0, 03 150 103  0, 0898
 404,1 Nm (3)
2  N T
HG 
60
2    400  404,1

60
 16926,9J/s (3)
HG  HD
 m  SHC  T
16926,9  m 1,8 103  30
m  0,3135 kg / s

m
 
Q
0,3135
800 
Q
Q  3,92  104 m3 / s
 3,92  104  1000  60
 23,5 l / min (4)
[15]
QUESTION 3
 R3  r 3 
Rf  2  2 2
3 R r
 
 1503  803 
 2
3 1502  80 2 
 
 118,55 mm
T    FA  R f  N 0
 0, 4  8  1200  0, 011855  2
 910, 47 Nm
910, 47
F .O.S 
245
 3, 72 (6)
Rr
Rf 
2
150  80

2
 115 mm
T    FA  R f  N 0
 0, 4  8  1200  0,115  2
 883, 2 Nm
883, 2
F .O.S 
245
 3, 6 (4)

1200
Spring force 
8
 150 N / mm
T    FA  R f  N 0
245  0, 4  8  FA  0,115  2
FA  332,88 N
332,88
L 
150
 2, 219 mm
Wear  6  2, 219
 3, 78 mm (4)
2  N T
P 
60
2    900  883, 2

60
 83, 24 kW (1)
[15]
QUESTION 4
A  dL
 0, 05  0, 04
 0, 002 m 2 (1)
F
P 
A
F
8 106 
0, 002
F  16 kN (1)
A  bd
 0, 05  0, 03
 0, 0015 m 2 (1)

bd3
I XX 
12
0, 03  0, 053

12
 3  10 7 m 4 (2)
d  b3
IYY 
12
0, 033  0, 05

12
 1, 0  10 7 m 4 (2)
I XX
k XX 2 
A
3 107

0, 0015
 2 104 m 2 (1)
IYY
kYY 2 
A
1, 0 107

0, 0015
 7,5 105 m 2 (1)
A
F  2
L 
1 a  E 
 k 
  0, 0015
16000 
 0, 252 
1 1
7500  2 104 
  11,111 MPa (2)
A
F  2
L 
1 a  E 
 k 
  0, 0015
16000 
 0,1252 
1 1
7500  7,5 105 
  10,9 MPa (2)
[13]

QUESTION 5
DE  750  18
 768 mm
dE  350  18
 368 mm (1)
  D N
V 
60
  0,368  900

60
 17,34 m/s (1)
DE  d E
Sin 
2C
0, 768  0,368

2  1,5
  7, 660 (1)
 SMALL PULLEY  180  2

 180  2  7, 66
 164, 680

 = 164, 68
180
= 2,874 radians (1)
Tc = m  v2
= 0,8 17,342
= 240,58 N (1)
P  T1  T2  v
42  103  T1  T2 17,34
T1  T2   2421,9 N
T1  2421,9  T2 (1)

T1  TC
 e 
T2  TC
 e0,42,874
 3,157
T1  240,58
 3,157
T2  240,58
T1  240,58  T2  240,58   3,157
2421,9  T2  240,58  3,157T2  759, 49
2421,9  240,58  759, 49  3,157T2  T2
T2  1363, 4 N (1)
T1  2421,9  T2
 2421,9  1363, 4
 3785,3N
T1  TMax  w
3785,3
w 
30
 126,2 mm
 127 mm (1)
 D  de 
2

L   De  de   e  2C
2 4C
0, 768  0,368
2

 0, 768  0,368   2 1,5
2 4 1,5
 4,81 m (1)
[9]
TOTAL: 100

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NATIONAL CERTIFICATE

MECHANICAL DRAWING AND DESIGN N6

28 November 2022 (X-paper)

Nonprogrammable calculators may be used.

This question paper consists of 5 pages and 1 addendum.

Copyright reserved Please turn over

DEPARTMENT OF HIGHER EDUCATION AND TRAINING

INSTRUCTIONS AND INFORMATION

1. Answer all the questions.

2. Read all the questions carefully.

3. Number the answers according to the numbering system used in this

4. Start each question on a new page.

5. Use only a black or blue pen.

6. Write neatly and legibly.

Copyright reserved Please turn over

1.2 The maximum tension in the belt (4)

1.3 The power transmitted by the belt (2)

Copyright reserved Please turn over

The mass of the pulley is 100 kg.

2.2 Whether there is interference (5)

Copyright reserved Please turn over

FORM FACTORS (y) FOR INVOLUTE TEETH

Number of teeth 14,5° full depth 20° full depth

MECHANICAL DRAWING AND DESIGN N6

12 July 2022 (X-paper)

OPEN BOOK EXAMINATION

Nonprogrammable calculators may be used.

This question paper consists of 4 pages, 1 diagram sheet and 1 addendum.

INSTRUCTIONS AND INFORMATION

1. Answer all the questions.

2. Read all the questions carefully.

4. Use only a blue or a black pen.

5. Write neatly and legibly.

3.3 A suitable gears module (12)

FIGURE 2 on the DIAGRAM SHEET (attached) shows a column with a length of

4.2 The column buckling load, using Rankine's formula

Properties of the I-profile 💮

MECHANICAL DRAWING AND DESIGN N6

This marking guideline consists of 9 pages.

𝜃 = 𝑡𝑎𝑛−1 324,919 × 10−3 ✓

∴ 𝑑 = 2 × 𝑟 = 2 × 100 = 200 𝑚𝑚✓ 𝑎𝑛𝑑 𝐷 = 2 × 𝑅 = 2 × 150 = 300 𝑚𝑚✓

𝑤 = 161,8 𝑚𝑚✓ [18]

(17,5 + 18°)2 × 0,15 × 0,1

𝐻𝑑𝑖𝑠𝑠𝑖𝑝𝑎𝑡𝑒𝑑 = 9,452 𝑘𝑊✓

𝑊 = (2 × 106 )(0,15 × 0,1)✓

𝑑𝑖𝑎𝑚𝑒𝑡𝑟𝑎𝑙 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 2 × 𝑟𝑎𝑑𝑖𝑎𝑙 𝑐𝑙𝑒𝑎𝑟𝑒𝑛𝑐𝑒 = 2 × 0,0045 = 0,009 𝑚𝑚✓

0,034 × 1 000 100

(0,063578)(30 × 103 )𝜋× 0,1 × 1 000

𝐻𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 = 9,987 𝑘𝑊✓

𝐻𝑙𝑜𝑠𝑠 = 𝐻𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 − 𝐻𝑑𝑖𝑠𝑠𝑖𝑝𝑎𝑡𝑒𝑑

𝐻𝑙𝑜𝑠𝑠 = 9,987 − 9,452✓

𝐻𝑙𝑜𝑠𝑠 = 535 W✓ [16]

𝑇𝐶 = (920)(600 × 10−6 )(15,15)2 ✓

𝑇1 = (600 × 10−6 )(2 × 106 )✓

1 073,304 = 5,669𝑇2 − 718,24✓

3.2 𝑇ℎ𝑒 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑖𝑠 𝑎𝑡 𝑎 𝑏𝑒𝑎𝑟𝑖𝑛𝑔

𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡(𝑀𝐵 ) = 𝑛°(𝑇1 + 𝑇2 − 2𝑇𝐶 )𝑐𝑜𝑠𝛼 × 𝑙

𝑀𝐵 = 3,74(1 200 + 316,025 − 2 × 126,696)𝑐𝑜𝑠40 × 0,2✓

𝐻𝑜𝑟𝑖𝑧𝑜𝑡𝑎𝑙 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡(𝑀𝐵 ) = 𝑛°(𝑇1 + 𝑇2 − 2𝑇𝐶 )𝑠𝑖𝑛𝛼 × 𝑙

Mech Design N6 Q&A Combined

Mech Design N6 Q&A Combined

Mech Design N6 Q&A Combined