INME 4011 Term Project Guideline

• Each team consists of four students (maximum).

• The projects are described in the attached document.
• First part of the project includes the calculation of the shaft diameter using static concepts
with stress concentration and static failure theories.
• The second part of the project includes the calculation of the shaft diameters using dynamic
concepts with dynamic stress concentration.
• A minimum of three diameters must be calculated in your shaft.
• Each group must select a project from the sample projects given.
• Each group has to deliver a different design.
• Each group must select its project by September 28th, 2010.
• Only four groups per project are available in the first come first serve basis.

Important Deadlines:
1. The next class after the first partial exam. A preliminary design must be presented and a report
(max 8 pages) must be handled-in. All calculations and formulas must be explicitly detailed.
Calculations must be performed using Excel or any other software.
2. The next class after the second partial exam. A final project report is due (16 pages maximum).
Calculations must be performed using Excel or any other software.

Design Resources:

The document "Practical Guidelines for Mechanical Design and Manufacture", which can be
found below provides some useful general information.
http://www-mdp.eng.cam.ac.uk/resources/enginfo/mechanical/practical_guidelines.pdf
www.freestudy.co.uk, a free web site for Engineers aspiring to take the examinations of the
Engineering Council, provides a range of self-study materials on Solid Mechanics including
statics and dynamics.
Introduction to the Design Process
http://www-mdp.eng.cam.ac.uk/nagty/resources/enginfo/design/design_process.pdf
Cookbook of common mechanical designs
http://www-mdp.eng.cam.ac.uk/nagty/resources/enginfo/cookbook/cookbook.html
An online course in mechanisms is provided by technologystudent.com and gives a good
overview of some of the kinds of mechanisms you may wish to think about using.
http://www.technologystudent.com/
D&T Online provide a wide range of information on all kinds of mechanisms on their website.
Also included are many example calculations.
http://www.dtonline.org/apps/infopage/app?3&6&1&0&1&0
Some useful lectures http://pergatory.mit.edu/2.007/lectures/lectures.html
Potentially useful staff http://www.tribology-abc.com/calculators/
MatWeb http://www.matweb.com/index.asp?ckck=1
Design handbook http://pergatory.mit.edu/2.007/Resources/index.html
 General Requirements & Grading Criteria

• Midterm Grading (30%): Your project will be graded at midterm.

• Oral Presentation. Each group has 10 minutes oral presentation on your design and your
design concepts (you must use PowerPoint slides). You need to present but not limit to the
following contents:

1. What is the application(s) of this device?.

2. Explain each of your calculations.
3. Explain each of your diagrams V,M, stress, etc.
4. Explain your design considerations (safety factor, type of load, etc)

All students in your group must attend the oral presentation.

• Final Grading (70%) Your design will be judged on how well and clear are your calculations.
Your calculations should use a flexible format, done in Excel or MatLab. Ease to assembly and
fabricate.

• Project Report. The project report must follow the given format.

Important: Your PowerPoint presentation and additional details from your report and
calculations will be posted in the web.
 (cover page)
Term Project Report Format
INME 4011 Machine Component Design 1, 2010-II
Title of the project, Group Number, or the team name
Students’ names
Department of Mechanical Engineering
University of Puerto Rico at Mayaguez
Date

Objectives
(Maximum 50 words)

1. Description

Briefly describe your project (200 words), your goals, etc.

2. Design Details (7-10 pages)

Describe the mechanical design of your device (about 600-800 words, excluding the figures,
diagrams, drawings, etc). It must include the following for one component:
• Calculations of stresses under static loads (consider the maximum forces, torques and
moments as static). Use matrices.
• Drawing of free-body diagrams, shear force, moment and torque diagrams.
• Calculations of deflections under static loads (consider the maximum forces, torques
and moments as static). Use matrices.
• Calculation of materials indices and reasons for materials selection.
• Calculations in at least two critical sections and using stress concentrations.
• Estimation of stresses, component life, safety factor, etc under dynamic loads.

3. Discussion (1page)
Discuss its advantages and disadvantages of your design. List merits of your design, which
improvements or suggestions would make your design better, main problems, etc.

4. Conclusions (~200 words)

5. Appendix
Detailed calculations, tables used, web-page visited, similar designs available, etc.
You need to write the equations used clearly in the text.

Note:
1. The detail design of your component must be computer drawing. Hand-sketch will be allowed
for all other components.
2. Put theoretical equations in the design part and explain why you use them, then give the
calculation results in that part. However you need to put the detailed calculations in Appendix.
Note that in Appendix the calculation can be handwriting.
 Project Groups
A1.

A2

A3

A4
A5
B1

B2

B3

B4
B5
C1

C2

C3

C4
C5
D1

D2

D3

D4
D5
E1

E2

E3

E4
E5
 Project A
Determine the diameter of the shaft AB in at least three different positions, under the following
consideration:
(1) The 5kN load due to mud is continuous and it should be lifted at a speed of 120 meters within
30 seconds.
(2) Power is input through the motor attached to shaft S1.
(3) The extra power spins a 6 kW generator by shaft S3.
(4) The tension ratio for all the belts is 3:1. Also, assume that the angle of wrap of the belts is 20
degrees (with respect to the horizontal line for I and II and with respect to the vertical line for III
and IV).
DATA: All dimensions in mm; pressure angle for the gears = 20degrees ; belt diameters
dI=dIV=320mm ; dII=dIII=500mm
 Project B
Design the shaft EF, under the following considerations:
(1) The 8kN load due to mud is continuous and it should be lifted at a speed of 120 meters within
30 seconds.
(2) Power is input through the motor attached to shaft S1.
(3) The extra power spins a 4 kW generator by shaft S3.
(4) The tension ratio for all the belts is pulley 2:1. Also, assume that the angle of wrap of the
belts is 20 degrees (with respect to the horizontal line for I and II and with respect to the vertical
line for III and IV).
DATA: All dimensions in mm; pressure angle for the gears = 20degrees ; belt diameters
dI=dIV=320mm ; dII=dIII=500mm
 Project C
The layout of a two-stage 20 kW V-belt speed reduction is shown below. The first stage consists
of a 125 mm diameter engine-driven input pulley rotating at 2400 rev/min and driving a 400 mm
diameter pulley mounted on an intermediate shaft. The 200 mm diameter small pulley of the
second stage is also mounted on this intermediate shaft, and drives the 630 mm diameter output
pulley connected to the load. Tensions obtained from belt analyses are indicated on the sketch.

The intermediate shaft abcd has to be designed; the preliminary layout illustrated is based upon
known widths of the pulleys and estimated widths of the bearing housings. The second stage
small pulley is placed between the bearings as the belt loads are higher than those of the first
stage, whose lesser loaded pulley is overhung. (Recall that the stresses in a simply supported
beam are less when the load is situated between the supports than when it lies outside the
supports.)
Determine suitable diameters D1 and D2 for the intermediate shaft
 Project D:
A horizontal shaft AD supported in bearings at A and B and carrying out pulleys at C and D is to
transmit 75kW at 1200RPM from drive pulley D to off-take pulley C (as shown in the figure).
The tension ratios in the pulleys are equal to 3. The pulley tensions at D are inclined 60 degrees
with respect to the horizontal. The radius of pulley C and D are 360mm and 280mm respectively.
The pulley C and D weigh 2200N and 1400N respectively.
Assuming that the weight of the shaft is negligible in comparison with the other loads, determine
the diameter in three different areas of the shaft.

All dimensions are in mm.

 Project E
The figure shows a shaft carrying a pulley A and a gear B and supported in two bearings C and D.
The shaft transmits 20kW at 500RPM. The force on gear B acts horizontally with a pressure
angle of 20 degrees.
The pulley delivers the power through a belt to another pulley of equal diameter, positioned
horizontally on the side of pulley A. The ratio of tensions T1/T2 is equal to 3.0. The gear and the
pulley weigh 1200N and 3600N respectively.
Assuming that the weight of the shaft is negligible in comparison with the other loads, determine
the diameter in three different areas of the shaft.