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MTE Exam: Gear Types and Design Principles

The document discusses various types of gears (spur, helical, worm, bevel) and their applications, as well as the importance of flywheels in engines and the advantages and disadvantages of welding. It emphasizes the significance of material selection in design and provides calculations for designing a shaft. Additionally, it explains energy fluctuation in internal combustion engines and defines the factor of safety in material and stress analysis.

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Peace Avwenayeri
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8 views3 pages

MTE Exam: Gear Types and Design Principles

The document discusses various types of gears (spur, helical, worm, bevel) and their applications, as well as the importance of flywheels in engines and the advantages and disadvantages of welding. It emphasizes the significance of material selection in design and provides calculations for designing a shaft. Additionally, it explains energy fluctuation in internal combustion engines and defines the factor of safety in material and stress analysis.

Uploaded by

Peace Avwenayeri
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd

MTE 362: Mechanical Engineering Design

Answers to Questions 3, 4, 5, and 6

Question 3
With a well-labelled diagram, show the difference between spur, helical, worm, and bevel
gears.

Spur Gear:
- Teeth are parallel to the axis of rotation.
- Used for transmitting power between parallel shafts.
- Simple design, noisy at high speed.
Example: Gearbox, clocks.

Helical Gear:
- Teeth are cut at an angle to the shaft axis.
- Engage gradually for smooth and quiet operation.
- Can transmit power between parallel or crossed shafts.
Example: Car transmission systems.

Worm Gear:
- Consists of a screw (worm) meshing with a gear (worm wheel).
- Provides high torque reduction and non-reversible motion.
Example: Lifts, conveyors.

Bevel Gear:
- Teeth are cut on a conical surface.
- Transmit power between intersecting shafts (usually at 90°).
Example: Differential of a car.

Diagram: Label four simple sketches showing the gear types and their shaft orientations.

Question 4
(a) Why is a flywheel necessary in a mechanical engine?

- It stores rotational energy during power strokes.


- It releases energy during non-power strokes.
- It maintains uniform engine speed.
- It reduces speed fluctuations and vibrations.

(b) List the advantages and disadvantages of welding.

Advantages:
- Produces strong, permanent joints.
- Allows joining of complex shapes.
- Lightweight compared to mechanical joints.
- Economical for mass production.

Disadvantages:
- Residual stresses and distortion.
- Requires skilled operators.
- Inspection of internal defects is difficult.
- Not suitable for all materials or field conditions.

Question 5
(a) What are the importance of material selection in design?

- Determines strength and durability.


- Affects weight and cost.
- Influences manufacturability and performance.
- Ensures safety under load and environmental conditions.
- Helps achieve optimum balance between cost, function, and reliability.

(b) Design a shaft supported at the ends in ball bearings...

Given:
Power, P = 7.5 kW = 7500 W
Speed, N = 300 rpm
Pitch circle diameter, D = 150 mm
Allowable shear stress, τ = 45 MPa = 45 × 10⁶ N/m²

Torque, T = (P × 60) / (2πN)


T = (7500 × 60) / (2π × 300)
T = 238.73 N·m = 238.73 × 10³ N·mm

For a solid circular shaft: T = (π/16) × τ × d³


So, d³ = (16T) / (π × τ)
d³ = (16 × 238.73 × 10³) / (π × 45)
d³ = 27,054 mm³
d = (27,054)^(1/3) ≈ 30 mm

Answer: Diameter of shaft = 30 mm

Question 6
(a) Explain fluctuation of energy in internal combustion engines (ICE).

- During each cycle, energy output varies because torque from the piston is not uniform.
- Power stroke supplies excess energy.
- Suction, compression, and exhaust strokes absorb energy.
- This causes speed variation in the crankshaft.
- Flywheel helps balance these fluctuations.
(b) Define factor of safety (FOS) in material and stress analysis.

- FOS = Ratio of material strength to working stress.


- It ensures the structure or component remains safe under unexpected loads.
Formula: FOS = Ultimate Stress / Working Stress
or FOS = Yield Stress / Design Stress
Example: If yield stress = 300 MPa and design stress = 100 MPa, FOS = 3.

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