MEC2020W Design I

Class Test :
Geometric Tolerances, Design Process and
Gears
17 September 2013
Lecturer: Dr. R.A. Govender

This test is closed book. Some useful tables are provided. Unless asked to list items,
please write in full sentences. Neat handwriting and correct grammar are in your own
best interests. Any sketches must be neat and labelled.
Duration 1 hour 10 minutes
Test total 45 marks

MEC2020W Class Test 4 - 2013

Question 1
Figure 1 shows a shelving bracket and how it is used to mount a shelf.

(a) Shelving bracket

(b) Shelf mounted on bracket

Figure 1: Brackets used in shelving application

Make a neat sketch, in 3rd angle orthographic projection, of the bracket. Indicate
geometric tolerances on appropriate features on the sketch. You do not have to state
values for the geometric tolerances, but must follow convention for the feature control
frame including appropriate symbols.
(5)
[5 marks]

Question 2
Your company is designing portable personal music players. You are (partially
responsible) for writing the Product Requirement Specification (PRS). The following
statements are extracted from marketing surveys of previous customers. You must
re-write these statements so that they suitably specific for a PRS. Where applicable,
appropriate units must be stated. If you are uncertain of a reasonable value to apply
to a requirement, you may state it as X m/s or other applicable units. However, more
credit will be given to requirement statements with reasonable values applied.
(i) My first player only stores fifty songs. I want to have more choice of music on my
player.
2

MEC2020W Class Test 4 - 2013

(ii) I charge my player in the morning, and its dead by the evening. I want to listen
for longer.
(iii) I always forget to pack my charger. Cant I charge my player when I plug it into
my PC to load songs?
(iv) I want a music player that fits easily in my pocket and is light so I can carry it
easily when running
(v) My last player could only use the headphones which came with it, which werent
very good. I want to use headphones from different companies
[10 marks]

Question 3
Figure 2 shows pictures of two types of gears. A misguided classmate says Both
pictures show one straight thingy and one circular wheel. These gears do the same job.

(a) Gear pair A

(b) Gear pair B

Figure 2: Pairs of meshing gears

(a) Identify the different types of gears shown in Fig. 2a and 2b respectively.

(2)

(b) Using neat, labelled sketches, explain how these pairs of gears fulfil different
functions.

(7)

[9 marks]

MEC2020W Class Test 4 - 2013

Question 4
A pair of spur gears is used to transmit power from a electric motor running at 1800
rpm clockwise, to a conveyor belt drive which runs at 900 rpm. The gear on the motor
has a pressure angle of 20 , 20 teeth, pitch diameter dp of 50 mm and a face width b of
35 mm. The conveyor belt drive may be considered to experience moderate shock. The
environment in which the drive is installed prevents very accurate mounting, but the
gears are still loaded across the full face. A metallurgist has inspected the gear material,
which is steel and estimated the yield strength Sy to be 400 M P a and the endurance
limit Se to be approximately 150 M P a.
(a) Calculate the number of teeth and pitch diameter of the other gear in the pair.
Calculate the centre-to-centre distance of the gear pair.
(5)
(b) If the gears are loaded such that bending stresses in the teeth are at the endurance
limit, calculate the tangential force exerted at the pitch point (point of contact
between gears on centre-to-centre line).
(7)
(c) Calculate the radial force and make a neat sketch showing all the forces acting on
both gears in the meshing pair.
(3)
(d) Calculate the maximum power which may be transmitted by the gear pair when
loaded up to the endurance limit.
(2)
(e) The motor has a maximum power output of 7 kW . How would you expect this pair
of gears to behave when this power is applied? Comment on the expected life of the
gears.
(4)
[21 marks]

(Potentially) Useful Information

Gears
Pitch diameter dp = mN ,
where m is the module in the plane
perpendicular to the shaft axis, N is the
number of teeth.

Resultant of Ft , Fa

For spur gears of pressure angle :

Radial Force

F0 =

Fr = Ft tan

Fr =

Ft
Cos

Ft T an
Cos

For helical gears of pressure angle and

Tangential Module
helix angle : Axial force
mt =

Fa = Ft T an

Bending stress in spur gear teeth

For moderately precise gears:

Kv =

xx =

Ft
Ko Km Kv
bmJ

mn
Cos

6+V
6

V is the pitch line velocity in m/s

Table 1: Gear Correction Factor - Mounting Km

Support Characteristics

0 to 50

Face width (mm)

50 to 150 150 to 225 225 & above

Accurate mountings, small bearing clearances, minimal deflection, precision gears

1.3

1.4

1.5

1.8

Less rigid mountings, less accurate gears,

contact maintained on full face of gears

1.6

1.7

1.8

2.2

Gears do not contact on full face

2.2

2.2

2.2

2.2

Table 2: Gear Correction Factor - Overload / Impact Ko

Power Source

Uniform

Driven Machinery
Moderate Impact Heavy Impact

Uniform

1.00

1.25

1.75

Moderate Impact

1.25

1.50

2.0

heavy Impact

1.50

1.75

2.25

Figure 3: Spur Gears - J Factor