Mechanical Design

1st Test Year 2017/2018 27/01/2018

Notes: 1) Answer in separate sets of sheets for each of the Problems.
2) If answering in square-lined sheets write in every other line.
3) Failure to readability and clarity of the calculations and the justifications may lead to penalty in the quotation.
4) Identify all sheets with your name and number (unidentified sheets will not be considered).
5) Respect the coordinate systems of figures and nomenclature of loads indicated therein.
6) Duly justify your answers.

Problem I
A 20 hp (15 kW) gear reducer is directly coupled to a shaft and runs at 63.0 rpm. There are two gears, one at
point B and another at point C, where each draws 7.5 kW, as shown in figure 1. The material of the shaft is
AISI 1030 hot-rolled steel. The shaft is supported by two bearings, one in A and another in D. The safety
factor of this design is 2.0.
y

x
z

Figure 1 (mm)
a) Represent the free body diagram, the efforts diagrams, in the shaft, together with their main values.
[1.5 points]
b) Identify the potential critical section of the shaft and determine the loading on that section. [1.0 point]
c) Considering the values of My = 1.0 kN.m and Mz = 0.7 kN.m, determine the rod diameter to buy using
the Tresca criterion. Neglect the shear effort. [1.5 points]
d) Considering the referential (x;y;z) and a diameter of 52.0 mm in the critical section, make a 3D sketch of a
2.0 mm crack length in this section. Still in the scope of MFLE, what alternatives would you consider if there
is risk of failure for the shaft? [1.0 point]

Problem II
Consider that the shaft of Figure 1 has a diameter of d= 52.0 mm in the critical section, a fatigue stress-
concentration factor in bending of 1.3 and in torsion of 1.1 in that section, and a design safety factor n = 1.5.
Neglect the shear effort and consider a maximum bending moment of M = 400 N.m applied in the critical
section.
a) Determine the shaft reliability knowing that the fatigue endurance limit is 141.53 MPa. [1.5 points]

b) Determine the maximum allowable torque to apply in the shaft regarding infinite life and respecting the
project requirements. [2.0 points]

c) Neglect now the torque applied in the shaft. Determine the maximum loading that could be applied to the
shaft for a life of 80,000 cycles under the project requirements. Represent the current loading on the
Goodman diagram. [1.5 points]