EIM2202 TUTORIAL

THIS TUTORIAL CONTAINS EXAM TYPE QUESTIONS FROM THE PAST

THREE YEARS. IT IS INTENDED TO HELP YOU GO THROUGH THE COURSE
CONTENT AND GIVE YOU A FEEL OF WHAT TO EXPECT TOMORROW AND
HOW TO ANSWER THE WORDING OF EXAMS
THEORY
1. Explain the following concepts as used in engineering practice
 Poka-Yoke,
 Redundancy,
 Design for Manufacture,
 Maintainability,
 End-of-Life Design,
 Life Cycle Design,
 Ethical Design,
 Design Aesthetics.
2. Product design can be considered an “arm” of Engineering Design. Using an
appropriate example, articulate the process in which a Design Concept evolves to
become a Product that an end user can utilise.

3. Explain in brief, the material selection process undertaken in the design of any
one specialist component/machine/tool in your area of Engineering expertise and
interest. Particularly highlight the engineering design considerations and use
diagrams where necessary.

4. In the evolution of engineering materials, the discovery and subsequent

advancement of polymer technologies have revolutionised the Engineering
Design space. Using appropriate examples, discuss the impact that polymer
technology has had on the 21st Century world, clearly showing the pros and cons.

Ans: wood and rock used to be major engineering materials, until the discovery of oil where
polymeric materials began to be synthesised. Candidate should show cognizance of the facts
of how polymers replace many materials in the current world and made many engineering
Page 1 of 9
feats possible through longevity and different environment reactions together with versatility
and ease of cost and lightweighting etc. However the other end should also be shown by
candidate particularly in terms of pollution and sustainability, showing the consciousness of
the dangers of pollution caused by single use plastics etc.

5. Planned obsolescence is a method that has been employed by design engineers

and product designers over the ages with lasting impacts on commerce,
sustainability and maintenance models across sectors. Discuss the use of this
method, citing how it has been used ethically and/or otherwise. Use examples
where appropriate.

Ans: Candidate must show their consciousness of ethics in engineering design practice. This
covers from material selection, manufacturing processes and methods to issues relating to
maintainability with concepts such as planned obsolescence coming into play. The
understanding effect of ethics, the environment and technology matrix throughout the product
life cycle is to be shown to be understood. A further understanding of how planned
obsolescence is not only used for profiteering on the unethical scale, it can also be used
ethically to prevent hazardous operation or non-optimal operation of machines and devices in
operation ranges which may be unpredictable.

6. “With much of the technological first world already in the 5th Industrial
Revolution, many African countries find themselves having to chase
technological advancements that are advancing at an increased pace. This leaves
much of Africa on the backfoot. However, this can be taken advantage of, as we
can use the available technologies to catch up at an accelerated pace. This is
called the ‘backfoot advantage’.”
7. As a new age design engineer explain in detail how the listed concepts can aid in
utilising the ‘backfoot advantage’ in engineering design practice:

i. Generative AI, [5]

ii. Big Data Analytics, [5]
iii. Machine Learning, [5]
iv. Digital Decentralisation, and [5]
v. Blockchain Technology. [5]
Generative AI [5]
Page 2 of 9
Ans. Student must demonstrate the appreciation of artificial intelligence systems and how
they are used in the engineering design process today. This is especially in how AI is
embedded in modelling and simulation software today. Further to this student must zero in on
how generative AI is capable of speeding up the modelling process through generating
optimised design models from design specifications, considerations and data sets.
Machine Learning [5]
Ans. Candidate must show an appreciation for how todays research results in a data sets that
can be used to create smart products. Therefore, it is crucial to design for machine learning
capability right from the design stage. The candidate must further show that optimisation time
in engineering design is being reduced as the AI embedded in our software systems is
constantly learning to bring better results.
Blockchain Technology [5]
Ans. Student must show an appreciation of collaborative work and concurrent engineering in
engineering design. The use of collaborative work in real time requires security and
redundancy which are the cornerstones of Blockchain technology as it ensures security within
a given network and traceability of everyone’s input in the collaborative work during the
design phase.
Big Data Analytics [5]
Ans. Candidate must show an understanding of how the research in today’s world now
inherently involves working with copious amounts of data in large data sets which require the
skills of big data analytics to convert this data into useful information for application in the
design process.
Digital Decentralisation [5]
Ans. Candidate must show understanding of how the new world office space for
collaborative work is no longer centred in the office. People can now work real time from
anywhere in the world and this requires the concept of digital decentralisation where tasks are
given to different people worldwide and tasks are handled on the go. Student must further
show the importance of redundancy in such systems to ensure security as well as smooth flow
of the work.
[Total = 25 marks]

8. Concisely give notes on the material selection process undertaken in the design
for manufacture of the following day to day components and products. Take care

Page 3 of 9
 to highlight the engineering design considerations for each. Use diagrams where
necessary.

i. An athlete’s sports bottle. [5]

ii. A standard 13A plug top. [5]
iii. A construction vehicle windscreen. [5]
iv. A lathe machine turning tool. [5]

Ans. Candidate must be able to identify design considerations for each of the given scenarios
and give appropriate material selections based on known material properties citing real world
examples for each and every one of the scenarios.
9. Give a detailed description of the ethical design considerations made with respect to
sustainability for any one product or engineering component of your choice.
Ans. Candidate must show their consciousness of ethics in engineering design practice. This
covers from material selection, manufacturing processes and methods to issues relating to
maintainability with concepts such as planned obsolescence coming into play. The
understanding effect of ethics, the environment and technology matrix throughout the
product life cycle is to be shown to be understood.
10. As a Gen Z engineer at the precipice of the 4th Industrial Revolution peeking into
the 5th; explain in detail how the listed concepts have/are changing the field of
engineering design and how they can be used to optimise engineering design
practice:

i. Generative AI [5]
Ans. Student must demonstrate the appreciation of artificial intelligence systems and how
they are used in the engineering design process today. This is especially in how AI is
embedded in modelling and simulation software today. Further to this student must zero in on
how generative AI is capable of speeding up the modelling process through generating
optimised design models from design specifications, considerations and data sets.
ii. Machine Learning [5]
Ans. Candidate must show an appreciation for how todays research results in a data sets that
can be used to create smart products. Therefore, it is crucial to design for machine learning
capability right from the design stage. The candidate must further show that optimisation time
in engineering design is being reduced as the AI embedded in our software systems is
constantly learning to bring better results.
Page 4 of 9
 iii. Blockchain Technology [5]
Ans. Student must show an appreciation of collaborative work and concurrent engineering in
engineering design. The use of collaborative work in real time requires security and
redundancy which are the cornerstones of Blockchain technology as it ensures security within
a given network and traceability of everyone’s input in the collaborative work during the
design phase.
iv. Big Data Analytics [5]
Ans. Candidate must show an understanding of how the research in today’s world now
inherently involves working with copious amounts of data in large data sets which require the
skills of big data analytics to convert this data into useful information for application in the
design process.
v. Digital Decentralisation [5]
Ans. Candidate must show understanding of how the new world office space for
collaborative work is no longer centred in the office. People can now work real time from
anywhere in the world and this requires the concept of digital decentralisation where tasks are
given to different people worldwide and tasks are handled on the go. Student must further
show the importance of redundancy in such systems to ensure security as well as smooth flow
of the work.

11. Write detailed notes on the material selection undertaken in the design and
manufacture of the following engineering components. Take care to highlight the
design considerations for each. Use diagrams where necessary.

v. Conveyor Belt used to move crushed rock at a quarry.

vi. A drum for packaging for mineral oil lubricant.
vii. Vehicle disk brake (particularly the disk and brake pads).
viii. Coil over vehicle suspension springs.

Ans. Candidate must be able to identify design considerations for each of the given scenarios
and give appropriate material selections based on known material properties citing real world
examples for ach and every one of the scenarios.
12. Opine on how the advent of the utopian regenerative smart nano-materials would
affect the material selection processes described in Question 2a.

Page 5 of 9
Ans. Candidate must show that the materials being referred to are not yet existent; further to
this the student must show understanding of the existent concepts however. i.e., regenerative
materials being materials that rebuild themselves from debris, smart materials being those
that show a degree of adaptability to avoid failure and the basic precepts of nanomaterials.
Having these together would allow engineers to move away from material selection and
move toward full on material design for specific applications. Thereafter student then uses
examples of the materials selected in part a.
13. For the following commonly found day to day items, give a detailed description
of the types of joining methods used in their manufacture. Take care to give us
your educated recommendation on any improvements that may be introduced in
terms of methods of joining. Use diagrams where necessary.

i. A 9kg domestic LPG gas cylinder. [3]

ii. A wooden batten single door. [3]
iii. A cardboard carton for carrying toilet soap. [3]
iv. A plastic toilet seat and lid. [3]
v. A 2l Kango pot [3]
Ans. In all parts of the question, candidate must show goo knowledge of permanent and non-
permanent joints in machine design. An appreciation of alternative joining methods to those
used should also be demonstrated.
14. For the same products listed below Describe how the following engineering design
concepts may have been applied in the design stage of their product lives.
i. Fits and tolerances. [3]
ii. Design for manufacture. [4]
iii. Factor of Safety. [3]
Ans. An appreciation of he basic concept listed should be shown and how they are applied in
the design stage of the listed products.

15. With the aid of a diagram, give a concise description of the engineering design
process.

Ans: Student must show basic knowledge of the design process showing emphasis on its
iterative nature.

Page 6 of 9
 16. Explain the following concepts as they pertain to engineering design:

vi. Fits and tolerances

vii. Factors of safety

viii. ergonomic considerations in Design

ix. Design for Manufacturing

x. Concurrent engineering

Ans: Students should insight knowledge of the basic concepts of engineering design
questioned.

17. Write concise notes on the characteristics of the following engineering materials:

Page 7 of 9
 i. spring Materials

ii. ferrous materials

iii. nonferrous materials

iv. thermoplastics

v. thermosets [3]

Ans: Student must show basic knowledge of the behavior of different classes of materials as
they’re applied in engineering applications.

18. Define and differentiate the theories of failure in Ductile materials (yield criteria)
and the theories of failure in brittle materials (fracture criteria). Give examples
of each of the theory categories. [10]

Ans: Candidate must show knowledge og the different theories as applied to ductile and
brittle materials i.e.

Theories of failure in Ductile materials (yield criteria)

• Maximum shear stress (MSS), Sec. 5–4

• Distortion energy (DE), Sec. 5–5

• Ductile Coulomb-Mohr (DCM), Sec. 5–6

Theories of failure in Brittle materials (fracture criteria)

• Maximum normal stress (MNS), Sec. 5–8

• Brittle Coulomb-Mohr (BCM), Sec. 5–9

• Modified Mohr (MM), Sec. 5–9

• Elasticity and Plasticity

19. Define, relate and differentiate the fundamental solid mechanics concepts of
stress and strain, showing how they form the basis for Hooke’s Law.
[10]

Ans. Student should show knowledge of the two concepts in their diffent forms and how
they relate in Hooke’s law whilst under proportional strain.

Page 8 of 9
Normal stress is the intensity of the force, ∆F acting normal to the defining area, ∆A which
notated by σ. On the other hand, shear stress is the intensity of force acting tangential or
parallel to the defining area ∆A. It is notated by τ.

Normal stress (σz) and shear stress (τzx and τzy) on a plane of elemental area ∆A.
Normal strain and shear strain.

Normal strain, ε, is the ratio of the elongation or contraction, d, of a body to the original
length, L.

On the other hand, shear strain is the change in angle from the perpendicular.

Undeformed body Deformed body

20. Give short notes on the importance of a material’s stress-strain graph in

engineering practice.

Ans. Student should exhibit knowledge of how the stress strain graph shows the failure
characteristics and parameters of a material under loading. This can be seen through different

Page 9 of 9
salient point or the lack thereof of such points on a materials curve. Examples can be very
useful and a common one being that of steel as given below.

Mild steel is a ductile material. The straight line from the origin O to point A, the relationship
between stress and strain in this initial region is proportional and the material undergoes
elastic deformation. The stress at Point A is called the proportional limit and beyond this
point, the proportionality between stress and strain no longer exists. The stress at point B is
called the yield stress. At this point the material begins to undergo plastic deformation. After
undergoing the large strains that occur during yielding in the region BC, the steel begins to
strain harden. This results in increased resistance of the material to further deformation, and
hence the positive slope from point C to D. The load eventually reaches its maximum value,
and the corresponding stress (at point D) is called the ultimate stress. Further stretching of the
bar is actually accompanied by a reduction in the load. The material begins undergoes
necking and then fracture finally occurs at a point such as E.

21. Explain the following concepts as they pertain to engineering design:

xi. Fits and tolerances

xii. Factors of safety

xiii. ergonomic considerations in Design

xiv. Design for Manufacturing

xv. Concurrent engineering

Page 10 of 9
Ans: Students should insight knowledge of the basic concepts of engineering design
questioned.

Page 11 of 9
Joints
1. example 10.5 khurmi page 370

Stress Concentration Factors in Fillet Welds

Type of Joint Stress Concentration Factor
Reinforced Butt Welds 1.2
Toe of Transverse Fillet Welds 1.5
End of Parallel Fillet Weld 2.7
T-Butt Joint with sharp corner 2.0
Static Loading on all joint types 1.0

Fillet Welded Plates

A plate 75mm wide and 12.5mm thick is joined to another plate by a single transverse
fillet weld and a double parallel fillet weld as shown in Fig. Q4a. The maximum tensile
and shear stresses are 70MPa and 56MPa respectively and related stress concentration
factors can be found in Table Q4a. Considering the joint to be under both static and
fatigue load, determine the:
i. Maximum load which the plate can carry,
ii. Load carried by the single transverse load under static load,
iii. Load carried by the double parallel fillet weld under static load,
iv. Length of the transverse fillet weld for static loading,
v. Length of each parallel fillet weld for static loading,
vi. Permissible stresses on the welds under fatigue load,
vii. Load carried by the single transverse load under fatigue load,
viii. Load carried by the double parallel fillet weld under fatigue load,

Page 12 of 9
 ix. Length of the transverse fillet weld for fatigue loading, [2]
x. Length of each parallel fillet weld for fatigue loading, and [2]
xi. Lengths of each weld to be used on the piece. [2]

Ans:

2. Joining methods are an important part of engineering design. They affect the
complete life cycle of a physical product. From its manufacturability, to its
maintainability up to its disposal at end of life. For the given engineering joining

Page 13 of 9
 methods, discuss the pros and cons of them with respect to manufacturability,
maintainability and end of life. Use examples in your discussion.

 Welding. [5]
 Adhesives. [5]
 Screwing. [5]
 Riveting. [5]
 Bolt fastening. [5]
Ans. In all parts of the question, candidate must show goo knowledge of permanent and non-
permanent joints in machine design. An appreciation of alternative joining methods to those
used should also be demonstrated.
a) Illustrate the types of welds used most frequently by designers, giving their common
applications. [5]

For general machine elements most welds are fillet welds, though butt welds are used a great
deal in designing pressure vessels. Of course, the parts to be joined must be arranged so that
there is sufficient clearance for the welding operation. If unusual joints are required because
of insufficient clearance or because of the section shape, the design may be a poor one and
the designer should begin again and endeavor to synthesize another solution. Since heat is
used in the welding operation, there are metallurgical changes in the parent metal in the
vicinity of the weld. Also, residual stresses may be introduced because of clamping or
holding or, sometimes, because of the order of welding. Usually these residual stresses are
not severe enough to cause concern; in some

3. The joint shown in Fig. Q6b is fastened together by two bolts. Determine the
required diameter of the bolts if the failure shear stress for the bolts, τfail is 350MPa.
Use a factor of safety for shear of F.S. = 2.5.
[10]

Page 14 of 9
 Fastened Joint

Ans.

Page 15 of 9
Gears

1. Unique and special effects can be obtained in a gear train by permitting some of the
gear axes to rotate about others. Such gear trains are called epicyclic or planetary
gear trains. Using diagrams where necessary, describe the salient characteristics of
planetary gear trains.

Ans: Planetary trains always include a sun gear, a planet carrier or arm, and one or more
planet gears. Planetary gear trains are unusual mechanisms because they have two degrees of
freedom; that is, for constrained motion, a planetary train must have two inputs. For example,
these two inputs could be the motion of any two of the elements of the train. We might, say,
specify that the sun gear rotates at 100 rev/min clockwise and that the ring gear rotates at 50
rev/min counter clockwise; these are the inputs. The output would be the motion of the arm.
In most planetary trains one of the elements is attached to the frame and has no motion.

2. A gearbox is needed to provide an exact 30:1 increase in speed, while minimizing

the overall gearbox size. The input and output shafts should be in-line. Determine
the appropriate teeth numbers.
[15]

Ans. EXAMPLE 13–5 Shigley’s Mechanical Design of Machine elements 10th edition

3. For the common types of gears i.e., spur, bevel, worm and helical gears; write
concise notes on their descriptions, applications and advantages in design. Use
diagrams when needed.

Ans: Candidate should demonstrate a good and apt understanding of the generic types of
gears and their uses. Also giving insight as to advantages in their different distinct designs.

4. A gearbox is needed to provide an exact 30:1 increase in speed, while minimizing

the overall gearbox size. The input and output shafts should be in-line. Determine
the appropriate teeth numbers.
[14]

Ans:EXAMPLE 13–5 Shigley’s Mechanical Design of Machine elements 10th edition

Page 16 of 9
5. “Unusual effects can be obtained in a gear train by permitting some of the gear axes
to rotate about others. Such trains are called planetary, or epicyclic, gear trains.”

i. Give a detailed description of the important aspects of the planetary gear trains
described in Question 4b. Use diagrams where necessary. [8]

ii. Give typical applications of epicyclic gear trains. [3]

Ans: Planetary trains always include a sun gear, a planet carrier or arm, and one or more
planet gears, as shown in Fig. 13–30. Planetary gear trains are unusual mechanisms because
they have two degrees of freedom; that is, for constrained motion, a planetary train must have
two inputs. For example, in Fig. 13–30 these two inputs could be the motion of any two of
the elements of the train. We might, say, specify that the sun gear rotates at 100 rev/min
clockwise and that the ring gear rotates at 50 rev/min counter clockwise; these are the inputs.
The output would be the motion of the arm.nIn most planetary trains one of the elements is
attached to the frame and has no motion. Figure 13–31 shows a planetary train composed of a
sun gear 2.

Page 17 of 9
Power screws

1. A square-thread power screw has a major diameter of 32mm and a pitch of 4mm
with double threads, and it is to be used in an application similar to that in a worm
gear screw jack. The given data is:

f = fc = 0.08,

dc = 40mm, and

F = 6.4kN per screw.

Determine the:

i. thread depth, thread width, pitch diameter, minor diameter, and lead.

ii. torque required to raise and lower the load.

iii. efficiency during lifting the load.

iv. thread bending stress at the root of the thread.

v. the maximum shear stress at the root of the thread.

Ans: Example 8,1 Shigley’s Design of Engineering Elements.

Page 18 of 9
2. In reference to power screws; write short notes on the following:

i. The concept of self-locking. [5]

Ans. TL is the torque required to overcome a part of the friction in lowering the load. It may
turn out, in specific instances where the lead is large or the friction is low, that the load will
lower itself by causing the screw to spin without any external effort. In such cases, the torque
TL from Eq. (8–2) will be negative or zero. When a positive torque is obtained from this
equation, the screw is said to be self-locking. Thus, the condition for self-locking is π f dm >
l
ii. The types of threads that can be used. [5]
Ans. Square and Acme threads, whose profiles are shown in Fig. 8–3a and b, respectively,
are used on screws when power is to be transmitted. Table 8–3 lists the preferred pitches for

Page 19 of 9
inch-series Acme threads. However, other pitches can be and often are used, since the need
for a standard for such threads is not great. Modifications are frequently made to both Acme
and square threads. For instance, the square thread is sometimes modified by cutting the
space between the teeth so as to have an included thread angle of 10 to 15◦. This is not
difficult, since these threads are usually cut with a single-point tool anyhow; the modification
retains most of the high efficiency inherent in square threads and makes the cutting simpler.
Acme threads are sometimes modified to a stub form by making the teeth shorter. This results
in a larger minor diameter and a somewhat stronger screw.
iii. The benefits of using multiple threads over a single thread. [5]
Ans. A multiple-threaded product is one having two or more threads cut beside each other
(imagine two or more strings wound side by side around a pencil). Standardized products
such as screws, bolts, and nuts all have single threads; a double-threaded screw has a lead
equal to twice the pitch, a triple-threaded screw has a lead equal to 3 times the pitch, and so
on.

Page 20 of 9
Clutches and Brakes

Shoe Brake

1. The shoe brake shown above is 300 mm in diameter and is actuated by a mechanism that
exerts the same force F on each shoe. The shoes are identical and have a face width of 32
mm. The lining is made of molded asbestos that has a coefficient of friction of 0.32 and a
pressure limitation of 1000 kPa. Determine the maximum:
i. Actuating force, F.
ii. Braking capacity.
Ans: Example 16.2 Shigley’s Engineering Design of Machine Elements 10th Edition

Page 21 of 9
Page 22 of 9
2. Differentiate the basic principles of application of clutches and brakes in
engineering practice.

Ans: Candidate should concisely and effectively show knowledge about how differently
clutches and brakes use the concepts of friction material, especially the concept that brakes
are meant to retard motion, and clutches are meant to engage and disengage driving and
driven mechanisms, although both systems take advantage of friction in achieving their
intended uses.

Example 23.1 kurmi page 854

Page 23 of 9
 Drum and Shoe Brake

3. The drum and shoe brake in the figure above has a brake drum 400mm in
diameter with four internally expanding shoes. Each of the hinge pins A and B
supports a pair of shoes. The actuating mechanism is to be arranged to produce
the same force F on each shoe. The face width of the shoes is 75mm. The lining
material used permits a coefficient of friction of 0.24 and a maximum pressure of
1000kPa. The dimensions in millimetres are:
a = 150mm
c = 165mm
R = 200mm
d = 50mm
Therefore, for the given system:
i. Determine the actuating force.
ii. Estimate the brake capacity.
Ans. Prob 16-4 Shigley’s Mechanical Engineering Design Tenth edition.
a) Define and differentiate the basic principles of application of clutches and brakes
in engineering practice.
Ans:
Candidate should concisely and effectively show knowledge about how differently
clutches and brakes use the concepts of friction material

4. Describe characteristics that an ideal friction material would exhibit for it to be

suitable for use in the lining of brakes and clutches.

Ans:

Page 24 of 9
A brake or friction clutch should have the following lining material characteristics to
a degree that is dependent on the severity of service:
• High and reproducible coefficient of friction
• Imperviousness to environmental conditions, such as moisture
• The ability to withstand high temperatures, together with good thermal conductivity
and diffusivity, as well as high specific heat capacity
• Good resiliency
• High resistance to wear, scoring, and galling
• Compatible with the environment
• Flexibility

Page 25 of 9
Springs
1. A compression coil spring made of an alloy steel has:
Mean diameter of coil = 50mm,
Wire diameter = 5mm, and
Number of active coils = 20.
If this spring is subjected to an axial load of 500N; calculate the maximum shear
stress which the spring material is subjected to (neglecting the curvature effect).
Ans:

2. A composite spring has two close-coiled helical spring connected in series; each
spring has 10 coils at a mean radius of 15mm.

i. If the stiffness of the composite spring is 750N/mm and the diameter of one of
the springs is 2.5mm. Determine the diameter of the other spring.
[4]
ii. For a maximum shearing stress of 200N/mm2 , calculate the greatest load that
can be carried by the composite spring and the corresponding extension.
[6]
Take G = 80GPa.

Page 26 of 9
3. Two close-coiled helical springs are compressed between two parallel plates by a
load of 1000N. The springs have a wire diameter of 10mm and radii of the coils are
50mm and 75mm. Each spring has 10 coils and of the same initial length. If the
smaller spring is placed inside the larger one, calculate the:

i. Total deflection.
ii. Maximum stress in each spring.
Take G = 40GPa.

Page 27 of 9
4. With the aid of diagrams, describe the concept of compound springs highlighting
possible uses.
Ans. Compound springs are when two or more springs are used in combination. This can be
done for a few reasons including space saving and increasing stiffness of a spring setup. The
springs can be arranged in series or in parallel. And the effects of this can reduce the spring
stiffness of increase the stiffness of the setup and a unique combination can give a desired
result.

Page 28 of 9
 Flexible Drives
1. Belt drives and chain drives are often competing solutions to the same engineering
design problems. Describe and differentiate the two components, highlighting
each’s most appropriate applications.

Ans: Student must exhibit the knowledge of flexible power transmission mechanisms, case
in point chain drives and belt drives.
Basic descriptions must be given of the two and their advantages and disadvantages
culminating in the differentiation in their applications.

Flat Belt Drive

2. The figure above shows a flat belt drive for an engine running at 150rpm that drives a
dynamo through a line shaft. The engine pulley is 750mm diameter and the pulley on the
line shaft has 450mm diameter. A 900mm diameter pulley on the line shaft in turn drives
a 150 mm diameter pulley keyed to a dynamo shaft. Determine the speed of dynamo
shaft when there is no slip.

Ans:

Page 29 of 9
3. Chain drives are classified under flexible mechanical elements. Describe briefly the
features of chain drives giving details of where and how they are used in day-to-day
engineering applications.

Ans: Student must exhibit the knowledge of flexible power transmission mechanisms, case in
point chain drives. Basic descriptions must be given of the sprockets, chain link types and
their advantages and disadvantages culminating in their applications. Basic features of chain
drives include a constant ratio, since no slippage or creep is involved; long life; and the
ability to drive a number of shafts from a single source of power. Student should also
highlight the importance of lubrication in chain drive maintenance.

4. Give a description of the four main types of belts, being sure to highlight their main
areas of application with reference to their salient characteristics.
Ans:
The four principal types of belts are shown, with some of their characteristics, in Table 17–1.
Crowned pulleys are used for flat belts, and grooved pulleys, or sheaves, for round and V
belts. Timing belts require toothed wheels, or sprockets. In all cases, the pulley axes must be
separated by a certain minimum distance, depending upon the belt type and size, to operate
properly. Other characteristics of belts are:
• They may be used for long center distances.

Page 30 of 9
• Except for timing belts, there is some slip and creep, and so the angular-velocity ratio
between the driving and driven shafts is neither constant nor exactly equal to the ratio of the
pulley diameters.
• In some cases an idler or tension pulley can be used to avoid adjustments in center distance
that are ordinarily necessitated by age or the installation of new belts.

5. Explain how the use of a flat belt can be used in a belt drive mechanism can be used
to eliminate the need for using a clutch. [4]
Ans:
Candidate should show astute knowledge about applying the use of flat belts in variable
speed drives.

Page 31 of 9
6. Explain where the chain drive may be more appropriately used over belt drives,
citing the characteristics that make it more appropriate for the particular
application chosen. [5]

Ans:
Basic features of chain drives include a constant ratio, since no slippage or creep is involved;
long life; and the ability to drive a number of shafts from a single source of power. Student
should also highlight the different basic differences between application of the 4 types of belt
drives vs the roller chain.

7. Describe one scenario where a flexible shaft may be appropriately used citing the
reasons for your selected application. [5]

Ans. One of the greatest limitations of the solid shaft is that it cannot transmit motion or
power around corners. It is therefore necessary to resort to belts, chains, or gears, together
with bearings and the supporting framework associated with them. The flexible shaft may
often be an economical solution to the problem of transmitting motion around corners. In
addition to the elimination of costly parts, its use may reduce noise considerably. There
are two main types of flexible shafts: the power-drive shaft for the transmission of power
in a single direction, and the remote-control or manual-control shaft for the transmission
of motion in either direction.
Example 18.1. A Textbook of Machine Design R.S. Khurmi

Page 32 of 9
Shafts and affiliated components
1. Compare and contrast in detail the applications of keys and couplings in
mechanical power transmission.

Ans. A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley
to connect these together in order to prevent relative motion between them. It is always
inserted parallel to the axis of the shaft. Keys are used as temporary fastenings and are
subjected to considerable crushing and shearing stresses. A keyway is a slot or recess in a
shaft and hub of the pulley to accommodate a key. Shafts are usually available up to 7 metres
length due to inconvenience in transport. In order to have a greater length, it becomes
necessary to join two or more pieces of the shaft by means of a coupling. Shaft couplings are
used in machinery for several purposes, the most common of which are the
following : 1. To provide for the connection of shafts of units that are manufactured
separately such as a motor and generator and to provide for disconnection for repairs or
alternations. 2. To provide for misalignment of the shafts or to introduce mechanical
flexibility. 3. To reduce the transmission of shock loads from one shaft to another. 4. To
introduce protection against overloads. 5. It should have no projecting parts.
2. Two 35mm shafts are connected by a flanged coupling. The flanges are fitted with 6
bolts on a 125mm bolt circle. The shafts transmit a torque of 800Nm at 350rpm.
Given the safe stresses mentioned below:

Safe shear stress for shaft material = 63MPa

Safe stress for bolt material = 56MPa
Safe stress for cast iron coupling = 10MPa
Safe stress for key material = 46MPa
Calculate:
i. Diameter of bolts.
ii. Thickness of flanges.
iii. Key dimensions.
iv. Hub length.
v. Power transmitted.
Ans. R.S Khurmi Example 13.10

Page 33 of 9
Page 34 of 9
3. Compare and contrast in detail the applications of keys and couplings in
mechanical power transmission.
Ans. A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley
to connect these together in order to prevent relative motion between them. It is always
inserted parallel to the axis of the shaft. Keys are used as temporary fastenings and are
subjected to considerable crushing and shearing stresses. A keyway is a slot or recess in a
shaft and hub of the pulley to accommodate a key. Shafts are usually available up to 7 metres
length due to inconvenience in transport. In order to have a greater length, it becomes
necessary to join two or more pieces of the shaft by means of a coupling. Shaft couplings are
used in machinery for several purposes, the most common of which are the
following : 1. To provide for the connection of shafts of units that are manufactured
separately such as a motor and generator and to provide for disconnection for repairs or
alternations. 2. To provide for misalignment of the shafts or to introduce mechanical
flexibility. 3. To reduce the transmission of shock loads from one shaft to another. 4. To
introduce protection against overloads. 5. It should have no projecting parts.
4. Describe one scenario where a flexible shaft may be appropriately used citing the
reasons for your selected application.
Ans. One of the greatest limitations of the solid shaft is that it cannot transmit motion or
power around corners. It is therefore necessary to resort to belts, chains, or gears, together
with bearings and the supporting framework associated with them. The flexible shaft may
often be an economical solution to the problem of transmitting motion around corners. In
addition to the elimination of costly parts, its use may reduce noise considerably. There are
two main types of flexible shafts: the power-drive shaft for the transmission of power in a
single direction, and the remote-control or manual-control shaft for the transmission of
motion in either direction.

5. Compare and contrast in detail the applications of keys and couplings in shafting.
[10]
6. Concisely explain the importance of considering the design of keyways, collars and
couplings in the designing of shafts for stress.

Ans:

Page 35 of 9
Student should exhibit knowledge of stress concentrations in shaft swaign and the effects
they have on shaft design. Knowledge should also be known on standardization of sizes
of keys, collars and couplings.

Page 36 of 9