This project is computer based.

You are to use the computer program EXCEL to perform

as many calculations as possible. It is iterative as you attempt to arrive at safety factors
close to the minimum allowable as this will reduce cost. The project will be accepted on
the basis of completeness of design, accuracy of design, achieving the objectives of the
design, and on organization and presentation.

PART A: REPORT (TO BE TURNED ELECTRONICALLY AS A .PDF FILE)

Page 1: This cover page Pages 2-3: Detailed 2-D technical shop drawing of your shaft
designs (both of them on separate sheets) like the one I attached that shows all of the
dimensions, locations of bearings, keyways, shoulders, radii, etc. This must be done using
a CAD program and set-up/labeled as you would for any company. .

Pages 4-6: Type written report: 3 pages. 12 pt Times New Roman Font with double
spacing and 1.0 margins all around. (Use of tables is encouraged to summarize your
design). The following sections must be included:

a. Executive Summary

b. Problem Statement

c. Problem Solution w/assumptions

d. Design Summary: summarize all components of your design

e. Conclusions and Recommendations

Pages 7-end: Appendix of Design Equations: This is where you write out your
diagrams, free-body diagrams and solution equations and state your assumptions for each
part of your design. You will use these equations in Excel. It is as long as you need it to
be.

PART B: EXCEL DESIGN (TO BE TURNED IN ELECTRONICALLY AS AN

EXCEL FILE)

One worksheet should be input parameters. A second worksheet should be intermediate

calculations/results and a third worksheet should be the output of your design.
XYZ CONSULTING ENGINEERS -- HEAT EXCHANGER SHELL DESIGN

XYZ Consulting Engineers, LLC

You are a design engineer for XYZ Consulting Engineers Company. It is your
responsibility to design and specify rotating machines and drivetrains for a variety of
applications. A customer is proposing to manufacture a lightweight airboat as shown in
Attachment 1. The customer has sized and completely specified the propeller, which
rotates at 2400 rpm, producing 68 lb of thrust and weighing 17.0 lbs, as indicated in
Attachment 1. Additionally, the propeller produces 9.4 ft-lb of resistance torque due to
frictional wind resistance at 2400 rpm. The customer receives large discounts from an
engine manufacturer for 900 rpm engines at various power levels. The table below
summarizes the engine choices, as prescribed by the customer.

Table 1: Engine Alternatives

All engines, independent of HP, are mounted on the same size baseplate and have
roughly the same height. Further, these engines are supplied with a stub shaft on which a
coupling is keyed using a parallel rectangular key. The dimensions of the engine with
stub shaft and coupling are shown below:

XYZ CONSULTING ENGINEERS -- HEAT EXCHANGER SHELL DESIGN

For safety reasons, the complete propeller and drivetrain must be enclosed by a safety
cage. Therefore, it must fit within the geometric envelope indicated by the dashed line in
Attachment 1, and having the overall dimensions of 4.5 feet high, 5.0 feet long (plus the
propeller overhang), and 5.0 feet wide (equal to the boat width). In addition to the safety
cage constraints, the propeller centerline must be 18 inches below the top of the safety
cage. The engine however, can be located anywhere in the cage, at the designers
discretion.

The customer must decide whether to go into production of the airboat design. The
deciding factor will be cost, therefore, standard materials of construction must be used (ie
- steels for most parts) for the drivetrain, and the drivetrain must be designed to minimize
overall weight but use standard sizes where feasible.
XYZ Company records indicate a policy for drivetrain design, which you must adhere to
for liability reasons. The policy takes the form of recommended saftey factors and
reliability information. The recommended minimum safety factors, reliabilities and other
data are:

Your job is to:

Completely specify the drivetrain and drivetrain components for the system, including (at
a minimum) bearing types and sizes, shaft materials and sizes, a V-belt drive with
pulleys, keyway and key dimensions (where appropriate) for the coupling hub and the V-
belt pulleys, and interference fits for the inner diameter of the ball bearings, as well as
retaining rings for the inner and outer diameters of the bearings as appropriate. (This is an
open ended design project and you are encouraged to examine any and all issues related
to the design.)