025 SABARAGAMUWA UNIVERSITY OF SRI LANKA FACULTY OF TECHNOLOGY DEPARTMENT OF ENGINEERING TECHNOLOGY BACHELOR OF ENGINEERING TECHNOLOGY HONORS DEGREE PROGRAMME ‘YEAR II SEMESTER I EXAMINATION-MARCH /APRIL 2021 ET 21023 DESIGN OF MACHINE ELEMENTS Time allowed: Three (03) Hours INSTRUCTIONS TO CANDIDATES: This paper consists of 07 questions in 07 pages. Answer any 05 questions. The marks given in brackets are indicative of the weight given to each part of the question. Write your Index No clearly in all places where appropriate. Write clearly in English and use blue or black ink. Write the question number clearly in the allocated space and begin the answer to each question on a new page. Complete the front page of the answer booklet with the required information and write the numbers of the questions you answer in the order attempted in the allocated space. Non-programmable calculators are ALLOWED in this examination. No clarifications will be provided on the given questions. Strike a line through all unused pages in the answer booklet/sheets. No part of this question paper shall be removed from the Examination Hall without permission from the examination supervisor. Cross out all scratch paper and hand in at the time of collection. Page 1 of 7v a. “Designing is an innovative and highly iterative process” Explain. What are “general purpose machine elements’ and “special purpose machine elements”? Briefly explain with examples. What is ergonomics? Express your idea and give two examples where we can find ergonomic considerations in practical designs. Engineering failures occur due to fatigue. Explain with proper sketches how a rotating shaft might subject to fatigue failure due to an undesirable continuous vibration. ; Draw a simple clear sketch of the fracture surface after fatigue failure and indicate the necessary regions. In welding, when two ends of two plates are connected, it is called a “butt joint” To get different strength properties we can prepare the two end faces of the metal plates. Accordingly depending on the type of end face preparation, name and sketch four (04) different types of Butt joints. A gas tank consists of a cylindrical shell of 2 m inner diameter. It is enclosed by hemispherical shells by means of butt welded joint as shown in Figure 1. The thickness of the cylindrical shell as well as the hemispherical cover is 14 mm. Assume efficiency of the welded joint as 0.8. Determine the allowable internal pressure to which the tank may be subjected, if the permissible tensile stress in the weld is 80 N/mm, (Hint: take the length of the weld joint as, inner circumference of the cylindrical shell) Figure 1 Page 2 0f7 (4 marks) (4 marks) (4 marks) (4 marks) (6 marks) (14 marks)2 Briefly explain about the function ofa “washer” in nut & bolt assembly. (2 marks) b. An electric motor weighing 10 KN is lifted by means of 4 (9 marks) Nos of eye bolts. One of the eye bolts is as shown in Figure 2. The eye bolt is screwed into the frame of the motor. The eye bolt has coarse threads. It is made of plain carbon steel 30C8 (Syt = 400 N/mm?) and the factor of safety is 6. Determine the size of the bolt. (use Table 1 to select a proper bolt) Syt = Yield Tensile Stress of the bolt = 400 N/mm? de =O08xd d:: Core diameter of the bolt 4: Nominal/Major diameter of the bolt Table 1 \ Row dimrcors br IS mets nee teal eure ere) PEEESESEUSERG SESE: EEEEECEGERRERSES EE) z L nee c. Two plates are fastened by means of two bolts as shown in Figure 3. The bolts are made of plain carbon steel 30C8 (Syt = 400 N/mm?) and the factor of safety is 6. < i. Determine the failure mode of this bolt. (2 marks) ii. Determine the size of the bolts if the force applied is 10 KN. (Use the (7 marks) Table 01) Assume Syt = 2 x Sys Syt = Yield Tensile Stress Sys = Yield Shear Stress Page 3 0f7Figure 3 ‘- Two flat plates subjected toa tensile force P are connected together by means of double strap butt joint as shown in below Figure 4. Force P is 250 kN and the width of the plate w is 200 mm. The rivets and the plates are made of the same steel and the permissible stresses in tension, compression and shear are 70, 100 and 60 N/mm? respectively. Calculate: i The diameter of the rivets i SY ii, The thickness of the plates a) iti, The dimensions of the seam p (pitch), p, (transverse pitch) and m loa (module iv. The efficiency of the joint (6 marks) Take m (module) = 1.5d and py (transverse pitch) = 0,6P r Figure 4 5. a For the selection of machine elements, most ofthe time, we deal with standard (2 marks) sizes and shapes. What are the advantages of having standard sizes and shapes of machine elements in the industry? 3 vag) Page 4 of 7b. : Distinguish the Usage of Coarse series thread, Fine series thread and Extra fine (3 marks) Series thread with applications. ©. Write down brief explanations as guided by each questions given below, (15 marks) i Explain the axis arrangement of straight bevel gear and worm gear using 3 masks proper sketches. each i, Describe the advantages of straight bevel gears with a suitable sketch by giving applications in the industry. me machines are having miter gears instead straight bevel gears”. Justify this statement iv. Explain the reason of using tapered roller bearing than ball bearings in the following application shown in Figure 5. Figure 5 Briefly describe the main usage of cams & followers, gears systems and belt driven systems using an application for each. 6. a. When you are designing a product or a device using a modelling software, it is (8 marks) important to consider the method of manufacturing. Manufacturing processes are Casting Technology, Forming Technology and Machining Technology. “Design considerations are totally rely on the method of manufacturing”. Justify this statement by using following factors, i. — Capital cost in terms of manufacturing method ii, Precision of dimensions iii, Cost of production iv. Surface Quality v. Product Strength vi Volume of Production Page 5 of 7Write any three (03) advantages and disadvantages of casting technology. (3 marks) Write down the manufacturing processes followed for the parts mentioned in (5 marks) A, B and C in Figure 6 and briefly explain the main advantage of forging technology by providing sufficient applications from the industry. Figure 6 c Explain the involvement & benefits of “Computer Aided Design (CAD)” inthe (4 marks) design stage of the product life cycle. Avoiding concentration of metal at a junction in casting is an important task. (6 marks) Explain two ways of avoiding following casting defect as shown in Figure 7 by using proper sketches Page 6 of 7b. : Some of the products are having a draft in exterior and interior of the product (4 marks) as shown in Figure 8. Briefly describe the usage of having a draft with applications of different manufacturing processes. Y KGS Wi. Figure 8 What is meant by “Design for Manufacturing and Assembly (DFMA)” and (4 marks) what are the guidelines to be followed in order to achieve the main objectives of the DFMA. What is meant by “Tolerance” in machining and briefly describe following (6 marks) types of fits in tolerance in terms of hole basis system by providing suitable sketches. i Clearance Fit ii, Transition Fit iii, Interference Fit Page 7 of 7