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AIN SHAMS UI{IVERSITY
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FACI]LTY OF ENGINEERING
DESIGN & PRODUCTION ENGIN EE RI.NG DEPARTIVIENT
Third Year Mechanicnl. Production Section
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2003-2004 13 June 2004 Ti me: 4.00 Hrs
MACHINE DESIGI\
The Ersrn Consistr of Two Ouestions in Three Pa
Any missing data may be reasonably asamed
Questi on
L
An assembly line is driven by a speed reducer through a 3000 RPM motor (the motor is
pl aced on the top of the worm). TIre speed reducer consi sts of two gear reducti ons (a
side worm drive and n straight spun gear drive). A third reduction system is also used
in the form of a V-belt drive. The sketch shows a plan view for the uniL
In your design consider the follorving:
Do not ellow for any overloading.
Yt i Y
( , f
Speed ofthe conveyor belt 0.98 m/s
Convevor drum diameter 220 mn
Con
Worm Drive
Spur Gcar s
Assembly line
(Conveyor Belt)
Conveyor Pulley
220 mm
Worm Gear Dri ve
Module
8mm
Helix angle
17. 5"
Worm starts
1
Ngnt@I
!tg"4rt9e!h 35
Effective
ceer tooth width 48 nm
Coefficient of friction between threads 0.05
Worm material Nist 250 BHN
Velocitv factor 0. 5
Modified form factor 0. 371
Pt et Ks=
o* b* l t r * Kv* KY
=t any/ t an( y* p'
=
ut
*
cos 61n
(crn
=
20
* HP=330* A* AT
Thlrd Ycrr, Mpclranlcat ?roductlon t*ctlort
MAtRtNt 9eb{(lN
You are required
to
onl
ower
The
+
(l .pqr
Drl ve
(Consi der
stati c
condi ttons
Mndr r l e
4mm
Number of teeth
40/60
Tooth width
50 mm
Pinion material
(vield) at t t OO
(9. 6kg/ sqmnD
Velocitv factor
0. 68
Modified form factor atz: 40
0.389
P1
*Ks
=
o*b*m*Kv*KY
--?1
Mrh
=
10 ks/"t**L
V-Belt Drive
ral fc
qro
sol ocfod co as to carrY the safg maxl n rut t t uossl bl e
Number of belts
J
Belt size, Smaller
pulley diameter
(25
*
16)
*
2!9 -m
Centre dlstance
1200 mm
belts and
Pulleys
a. 25
V-belt cross-sectional angle
34"
Young's modulus
2UUU . cm
I P f rrnsrrifted ner belt for belt slze
=
25
*
16 urm, (v n tr/s
v 0.5 I 1. 5
2
4 6 10 16 20 30
IIP/belt 0. 4 0. 9 L,Z 1. 5
J 4.4 6. 9 9.8 10.7
I
1
(rsrl nrrl crfp
the effi ei encv of the worm-gear drtve
Ft".t fh" t-""imnm \iforklns bending StreSS On the Wofrn-geaf
teeth'
2
3
4 Calculate the rubbing velocity between the worn and wolrn-wneel
teeth.
Tcii.-nf. tho
.,*r.,,rLi,' ,J"ctnr
of safetv on the ninion spur teeth.
5
6 Fincl the minimum angle of contact between the V-belt anO tne
putteY'
ormal tensiie stress on the V-belt cross-
I
section
(consider the V-belt cross-section
as a rectangle).
7
B Comment on the above design'by one of the followtng:
uncl er-desi gned
or nortnal l y-desi gned
or. o\/er-desi gned
Present u .o*pl.t" .o*tt*tion drawing for the worm gear unit
including the #aight spur gears and the V-belt pulley. On your
drawing show the details of the shafts,
gears, rolling bearings and
casins. At least TWO viervs should be used'
9
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Question
2
Use brief answers and clear sketches to explain the following:
1
Why should the design of r,vorm drives be checked on heat
dissipation?
)
What is the main advantase of double-helical sears over sinsle-
helical ones?
3
What is the function of
pullev
crowning in belt drives?
' 4
Why do we multiply
tangential load on
eouation?
by a factor of
bevel gears
(l-b/L) when we calculate the
as estimated by the Lewis's
5
Draw a sketch to explain the function of a
jaw
clutch.
6
Why it is preferable to use V-belts and not flat ones with short
centre-distance drives ?
7
How can cvlindrical roller bearinss carrv axiai loads?
8
Drarv a positive clutch.which can transmit torque in one sense of
rotation oniv.
9
Give one example for a rubbing and a non-rubbing seal used with
rolline bearings.
10
What is meant by an idler
pullev
and what is its fi.urction?
11
When should helical
gears
be
rrreferred
over straieht spur
gears?
72
Draw a rolling roller bearing that can never carry a thrust load.
13
What is the difference between the permissible error and the
probable
one in
gears?
74
Is there any difference between a self-aligning ball bearing and a
spherical roller self-aliming one?
15
What is the diflerence between slin and creeD in belts?
16
What is the main difference between single and double thrust ball
bearinss?
t 7
Draw a tapered rolling bearing and show how it can be located.
1B
What is the difference between "Speed
Range" and
"Speed
Ratio"
in a variable speed drive unit?
19
In estimating the
which is correct to
of the sear?
limiting load for
use. the diameter
wear in straight spur gears,
of the pinion or the diameter
20
What is the difference beti,veen the equivalent d1'namic bearing
load and the resultant force on a rolling bearing?