DELFT UNIVERSITY OF TECHNOLOGY Faculty 3ME

OWS2 wb3201 - Open book exam

April 8, 2014 from 14.00 - 17.00 h

Problem 3, 6, 9, 10, 12 and 14 are graded with 2 points, the rest with 1 point.

Always choose the single best answer!

1. A batch of shafts and pulleys needs to be assembled using an interference fit. It is

important that the torque T that can be transmitted by the assemblies will have the
smallest coefficient of variation CV, where CV=(T50 -Tmin)/T50. T50 is the torque that can be
transmitted by 50% of the assemblies, Tmin is the torque that can be transmitted by the
combination with the smallest interference. If linear elastic deformation can be assumed
for all interference fits, which interference fit would you recommend?

a) 16H7/r6 16r6: tolerance field between +23 and +34 m

b) 16H7/p6 16p6: tolerance field between +18 and +29 m
c) 16H7/s6 16s6: tolerance field between +28 and +39 m
d) 16H7/p5 16p5: tolerance field between +18 and +26 m

The tolerance field for 16H7 is limited between 0 and +18 m

2. The torque T that can be transmitted by a tapered shaft-hub connection is proportional to

the clamping force, which is a result of the bolt/nut preload Fi. It is assumed that the bolt
preload Fi is, with given tightening torque, proportional to 1/, where is the coefficient of
friction in the screw assembly. The coefficient of friction is managed by using a proper
thread lubricant and varies between 0.12 and 0.16. Calculate the coefficient of variation
CV=(T50 -Tmin) /T50 of the torque that can be transmitted via the tapered shaft hub
connection (Note, T = c / where c is a known constant).

a) CV <= 5%
b) 5 < CV <= 10%
c) 10 < CV <= 20%
d) CV > 20%

3. The mean value of the fatigue life of a drive shaft (motor shaft) at a given load is 3 105 load
cycles with a standard deviation of =0.2. Calculate the operating reliability of this drive
shaft for a service life Ln = 2 105 load cycles.

a) Rj (2 105) 75%
b) Rj (2 105) 80%
c) Rj (2 105) 90%
d) Rj (2 105) 95%

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4. Calculate the effective contact radius R of the cam roller support shown in the figure
below. Consider a radius of the support of r1=10 mm and a curved cam with r2=20 mm
and r3 =1.05 r1.

a) R 5 mm
b) 5 < R 10 mm
c) 10 < R 15 mm
d) R > 15 mm

5. The position accuracy of a linear axis is measured 5 times. The intended position was
xtarget = 40 mm. The measured positions are: 40.12, 40.07, 39.98 39.95 40.02 mm.
Calculate the achieved accuracy defined by the Root Mean Square Error.

a) RMSE 0.03
b) 0.03 < RMSE 0.045
c) 0.045 < RMSE 0.06
d) RMSE > 0.06

6. Consider a grooved shaft in rotary bending. The diameter of the shaft d = d1 = 16 mm, the
diameter of the groove dk = 15.2 mm. The stress concentration factor Kt = 4.5. Calculate
how much weight can be saved when this shaft is replaced by an un-grooved shaft of
smaller diameter d2 with the same endurance strength.

Calculate the percentage [%] of weight saving (m1-m2)/m1 where m1 is the mass of the
grooved shaft and m2 is the mass of the un-grooved shaft.

a) 33%
b) 43%
c) 57%
d) 67%

7. Consider two possible configurations for the mounting of a bearing housing. Both
configurations are realized with M10 bolts sufficiently preloaded. The clamping length of
the configuration 1 and 2 are Lm.1=0.8d and Lm.2=2d. Calculate P2/P1, where P1 and P2 are
the maximum load fluctuations on the bearings of configuration 1 and 2 respectively.

a) P2/P1 = 0.69
b) P2/P1 = 1.44
c) P2/P1 = 0.74
d) P2/P1 = 1.35

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8. Calculate the stress concentration factor in the threaded section of an M10-8.8 bolt. The
endurance strength of the threaded part e = 52.5 MPa. The endurance strength of
smooth un-notched steel when loaded in axial tension is e =0.4Rm.

a) Kf 3
b) 3 < Kf 4
c) 4 < Kf 6
d) Kf > 6

9. Stretch bolts are used by car manufacturers for several reasons; to accommodate LCF
thermal expansion (thermo-mechanical Cycling TMC), to withstand HCF load and finally
they can be prestressed accurately.

Calculate the minimal diameter of the shank, if the same fatigue strength [N] is asked for
the shank and the threaded section. The stress concentration in the fillet on both ends of
the shank is Kt =1.8. The strength reduction factors in the
shank are Csurf Creliab = 0.8. Consider the same bolt from
problem 8.

a) d 5 mm
b) 5 < d 6 mm
c) 6 < d 7 mm
d) d > 7 mm

10. Two hot rolled steel sections of S235 (Rp0.2 =235 MPa) are connected by welding. The
fatigue strength of the welded zone is characterised HCF (N=107) = 30 MPa (SN-diagram
shown below).

The stress spectrum in the welded zone is simplified to 10 times and 10 times 2 every
hour, where =80 MPa.

Calculate the fatigue life L50

with 50% probability of the
welded connection expressed
in hours.

a) L50 1000 hr
b) 1000 < L50 2000 hr
c) 2000 < L50 5000 hr
d) L50 > 5000 hr

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11. One of the options in a morphological matrix to fulfil the actuator function in a linear
motion drive system is a pneumatic cylinder. The friction between the piston seals and the
cylinder typically results in a friction as modelled in Figure 5.24 page 183.

The seal friction is highest in

the static position of the
piston and falls down to a
very low level by elasto-
hydrodynamic lubrication
when the piston moves.

Consider a pneumatic cylinder - spring system. The static friction between the piston and
cylinder wall can be expressed as a percentage of the piston force Fstat = 10% Fpiston. The
piston is actuated by air pressure. The air pressure is increased until the piston starts to
move. When the piston starts to move the friction falls down to approximate zero level.
The piston will make a step forward. This process is repeated.

Calculate the smallest possible step size x in a step by step movement of the piston. Start
from a position in which there is equilibrium between the air pressure and the spring force
(zero friction). In this position F0 = 500 N. Next the air pressure is increased until the piston
starts to move etc. The spring stiffness k =10 N/mm.

a) x 1 mm
b) 1 < x 3 mm
c) 3 < x 6 mm
d) x > 6 mm

12. Many work lamps use friction joints, so you can easily direct the light where you want it.
Consider a lamp arm with two legs in the position as illustrated. The friction joints should
maintain a fixed clamping for a load up to F=10 N and will slip when the lamp arm is
loaded with a higher load. Calculate the hysteresis of this mechanism (virtual play,
bidirectional).

Consider: Arm lengths L1=0.4 m and L2=0.4

m. The arms are made of hollow steel pipes
E=210 GPa, D=10 mm and d=8 mm.

a) sv 10 mm
b) 10 < sv 15 mm
c) 15 < sv 25 mm
d) sv > 25 mm

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13. Consider a polymer bearing with a PV-value of PV = 0.2 MPa m/s. The shaft diameter
d=20 mm, the bearing width L=d, rotational speed n=477 rpm. Calculate the power loss in
this bearing at the moment of failure, assuming a coefficient of friction =0.2

a) P = 16 W
b) P = 25 W
c) P = 32 W
d) P = 50 W

14. A linear guides travel smoothness and tolerance variations are key concerns for machine
designers. But, the most important design factor is how well the guide resists deflection.
Linear support rails in combination with open design bearings are best suited to sustain
heavy loads and to provide high stiffness.

Linear plain bearings are the better choice compared to linear ball bearings when the
bearing arrangement is subjected to heavy shock loads, vibrations or high accelerations in
the unloaded state however, increased friction must be expected.

Calculate over what sliding distance s [km] the bearing will wear down over h=0.1 mm.
Consider a mean value of the contact pressure of p = 3 MPa and the specific wear rate of
k=10-15 m2/N. Consider good conformity
between the plain bearing and the linear
support.

a) s 5 km
b) 5 < s 10 km
c) 10 < s 20 km
d) s > 20 km

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15. Which statement is untrue?

a) Three body abrasive wear refers to erosion, which is the predominant wear
mechanism in sand-slurry pumps.
b) Lapping is based on three body abrasion.
c) Burnishing is the plastic deformation (smearing) of a surface generally using a rolling
contact, and makes the surface shinier.
d) Accumulation of work piece material on the cutting edge of a tool can be characterized
by galling, a severe form of adhesion.

16. Which statement is untrue?

a) Scuffing is a type of adhesive wear that typically occurs in dry sliding.

b) When lapping a hardened steel surface using a pearlitic cast iron disc and diamond
powder in a mixture of petrol and oil, the relative soft cast iron disc doesn't suffer from
wear while the hard steel surface becomes finished to a high polish.
c) The wear rate of metals subjected to abrasive wear is in a large range of operating
conditions by approximation inversely proportional to their hardness.
d) The main difference between surface grinding and super finishing techniques like
polishing, lapping and honing is that super finishing is limited to the smoothening of
roughness summits.

17. Which statement is untrue?

a) Coulombs friction law, that says that the friction in a dry sliding contact is independent
of the visible area, do not apply to polymers.
b) Coulomb's friction law - if the load is doubled the friction is doubled - can be explained
by the elastic deformation in the micro contacts, i.e. in the real contact area.
c) The real contact area is formed by the micro contacts between roughness peaks of the
surfaces. Friction in a boundary lubricated contact is a result of ploughing and
adhesion forces in these micro contacts.
d) Friction in a hydrodynamic lubricated contact is a result of viscous shearing.

18. Which statement is untrue?

a) Metallurgical compatible materials are sensitive to adhesion.

b) The adhesion component of friction can be decreased by applying a soft coating.
c) The backlash is defined as the geometric play that a mechanical structure exhibit when
actuated by reversed loading.
d) The coefficient of friction in polymer metal contacts increases with the contact
pressure.