PAGE 1 OF 15

SAMPLE EXAM PAPER

INSTRUCTIONS

Answer ALL Questions

All questions carry equal marks

To gain full marks for any question, or any part of a question, the correct units must be stated, all
necessary working (including output of intermediate steps) must be shown, complete reference to
design tables/charts must be cited, and where necessary to support your answer, clear, neat sketches
should be provided.

Additional information (design Tables/Charts, formula sheet) is attached.

1.
(a) Describe the term “Life Cycle Assessment (LCA)”. Draw a schematic to illustrate
the relationship between different phases of LCA.
(4 Marks)
(b) What is the function of a flywheel? List four methods to connect flywheels to shafts?
(5 Marks)
(c) Bolts are tightened with automatic wrenches on a production line. Each bolt has a
mean twisting-off strength of 25 N.m with a standard deviation of 1.5 N.m. If the
automatic wrenches have a standard deviation of 2 N-m, calculate the mean value of
wrench torque setting that results in an estimated 2 bolts in 500 twisting off during
assembly. To achieve a reliability of 99.8 percent, what would be the new value of
the standard deviation of twisting-off strength with no other change?
(16 Marks)

(Total 25 Marks)
2.
(a) Define partial bearings. Draw a properly labelled sketch to indicate the location of
tangent point used in the design and analysis of columns.
(8 Marks)
(b) A helical compression spring of 15 mm outside diameter is to be made by a wire of
2 mm diameter. The spring has ten active coils with plain and ground ends. The least
expensive steel spring wire (G = 79 GPa) is to be used for the spring without
presetting.

(i) Estimate the maximum static load that can be applied without encountering more
than 2 percent long-term set.
(6 Marks)
(ii) What is the spring rate?
(2 Marks)
(iii) At what spring free length will the load determined in part (i) cause the spring to
become solid?
(6 Marks)
(iv) Would buckling problems be encountered if one end of the spring is free to tip?
(3 Marks)

(Total 25 Marks)
 PAGE 2 OF 15

3.
(a) Define backlash. Why is it required to provide some backlash? What are the
methods used to create backlash?
(4 Marks)
(b) Determine the numbers of teeth for each gear and pinion in a compound, reverted,
spur gear transmission which will give shiftable ratios of +6:1 and +3.5:1 forward,
and –4:1 reverse. All gears would be full depth gears with a 20o pressure angle and
a module of 4 mm. Demonstrate that there is sufficient space for an idler gear in
the reverse gear train.
(14 Marks)
(i) Neatly sketch the gear and shaft arrangement, with appropriate labelling of the
parts.
(3 Marks)
(ii) Compute base circle pitch and centre distance in each stage.
(4 Marks)

(Total 25 Marks)

4.
(a) Identify the difference between even and uneven materials. Explain why the factor
of safety for brittle materials is usually made twice that for ductile materials in the
same conditions.
(3 Marks)
(b) Make dimensional decisions for the shaft and hole sizes for a force fit using a basic
hole size of 10 mm
(10 Marks)
(c) A hot rolled steel bar is subjected to the following plane stresses:
σx = 84 MPa, σy = 28 MPa, τxy = 100 MPa.

(i) What tensile yield strength is required to provide a safety factor of 1.8
according to the maximum-normal-stress theory and the maximum-shear-stress
theory?
(8 Marks)
(ii) What is your best prediction of the safety factor with respect to initial yielding
if the material has a tensile strength of 350 MPa?
(4 Marks)

(Total 25 Marks)
 PAGE 3 OF 15

APPENDIX 1: Cumulative Distribution Function of Normal (Gaussian) Distribution

K 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0.0 0.5000 0.4960 0.4920 0.4880 0.4840 0.4801 0.4761 0.4621 0.4681 0.4641
0.1 0.4602 0.4562 0.4522 0.4483 0.4443 0.4404 0.4364 0.4325 0.4286 0.4247
0.2 0.4207 0.4168 0.4129 0.4090 0.4052 0.4013 0.3974 0.3936 0.3897 0.3859
0.3 0.3821 0.3783 0.3745 0.3707 0.3669 0.3632 0.3594 0.3557 0.3520 0.3483
0.4 0.3446 0.3409 0.3372 0.3336 0.3300 0.3264 0.3238 0.3192 0.3156 0.3121
0.5 0.3085 0.3050 0.3015 0.2981 0.2946 0.2912 0.2877 0.2843 0.2810 0.2776
0.6 0.2743 0.2709 0.2676 0.2643 0.2611 0.2578 0.2546 0.2514 0.2483 0.2451
0.7 0.2420 0.2389 0.2358 0.2327 0.2296 0.2266 0.2236 0.2206 0.2177 0.2148
0.8 0.2119 0.2090 0.2061 0.2033 0.2005 0.1977 0.1949 0.1922 0.1894 0.1867
0.9 0.1841 0.1814 0.1788 0.1762 0.1736 0.1711 0.1685 0.1660 0.1635 0.1611
1.0 0.1587 0.1562 0.1539 0.1515 0.1492 0.1469 0.1446 0.1423 0.1404 0.1379
1.1 0.1357 0.1335 0.1314 0.1292 0.1271 0.1251 0.1230 0.1210 0.1190 0.1170
1.2 0.1151 0.1131 0.1112 0.1093 0.1705 0.1056 0.1038 0.1020 0.1003 0.0985
1.3 0.0968 0.0951 0.0934 0.0918 0.0901 0.0885 0.0869 0.0853 0.0838 0.0823
1.4 0.0808 0.0793 0.0778 0.0764 0.0749 0.0735 0.0721 0.0708 0.0694 0.0681
1.5 0.0668 0.0655 0.0643 0.0630 0.0618 0.0606 0.0594 0.0582 0.0571 0.0559
1.6 0.0548 0.0537 0.0526 0.0516 0.0505 0.0495 0.0485 0.0475 0.0465 0.0455
1.7 0.0446 0.0436 0.0427 0.0418 0.0409 0.0401 0.0392 0.0384 0.0375 0.0367
1.8 0.0359 0.0351 0.0344 0.0336 0.0329 0.0322 0.0314 0.0307 0.0301 0.0294
1.9 0.0287 0.0281 0.0274 0.0268 0.0262 0.0256 0.0205 0.0244 0.0239 0.0233
2.0 0.0228 0.0220 0.0217 0.0212 0.0207 0.0202 0.0197 0.0192 0.0188 0.0188
2.1 0.0179 0.0174 0.0170 0.0166 0.0162 0.0158 0.0154 0.0150 0.0146 0.0143
2.2 0.0139 0.0136 0.0132 0.0129 0.0125 0.0122 0.0119 0.0116 0.0113 0.0110
2.3 0.0107 0.0104 0.0102 0.00990 0.00964 0.00939 0.00914 0.00889 0.00866 0.00842
2.4 0.00820 0.00798 0.00776 0.00755 0.00734 0.00714 0.00695 0.00676 0.00657 0.00639
2.5 0.00621 0.00604 0.00587 0.00570 0.00554 0.00539 0.00523 0.00508 0.00494 0.00480
2.6 0.00466 0.00453 0.00440 0.00427 0.00415 0.00402 0.00391 0.00379 0.00368 0.00357
2.7 0.00347 0.00336 0.00326 0.00317 0.00307 0.00298 0.00289 0.00280 0.00272 0.00264
2.8 0.00256 0.00248 0.00240 0.00233 0.00226 0.00219 0.00212 0.00205 0.00199 0.00193
2.9 0.00187 0.00181 0.00175 0.00169 0.00164 0.00159 0.00154 0.00149 0.00144 0.00139
 PAGE 4 OF 15

APPENDIX 2: Descriptions of preferred fits (hole basis)

Type of fit Description Symbol

Clearance Loose running fit: for wide commercial tolerances or allowances H11 / c11
on external members

Free running fit: not for use where accuracy is essential, but good H9 / d9
for large temperature variations, high running speeds, or heavy
journal pressures

Close running fit: for running an accurate machines and for H8 / f7

accurate location at moderate speeds and journal pressures

Sliding fit: where parts are not intended to run freely, but must H7 / g6
move and turn freely and locate accurately

Locational clearance fit: provides snug fit for location of stationary H7 / h6

parts, but can be freely assembled and disassembled.

Transition Locational transition fit for accurate location, a compromise H7 / k6

between clearance and interference

Locational transition fit for more accurate location where greater H7 / n6

interference is permissible

Interference Locational interference fit: for parts requiring rigidity and H7 / p6

alignment with prime accuracy of location but without special
bore pressure requirements

Medium drive fit: for ordinary steel parts or shrink fits on light H7 / s6
sections, the tightest fit usable with cast iron

Force fit: suitable for parts that can be highly stressed or for shrink H7 / u6
fits where the heavy pressure forces required are impractical.
 PAGE 5 OF 15

APPENDIX 3: International tolerance grades

Basic Sizes Tolerance Grades

IT6 IT7 IT8 IT9 IT10 IT11
0–3 0.006 0.010 0.014 0.025 0.040 0.060
3–6 0.008 0.012 0.018 0.030 0.048 0.075
6 – 10 0.009 0.015 0.022 0.036 0.058 0.090
10 – 18 0.011 0.018 0.027 0.043 0.070 0.110
18 – 30 0.013 0.021 0.033 0.052 0.084 0.130
30 – 50 0.016 0.025 0.039 0.062 0.100 0.160
50 – 80 0.019 0.030 0.046 0.074 0.120 0.190
80 – 120 0.022 0.035 0.054 0.087 0.140 0.220
120 – 180 0.025 0.040 0.063 0.100 0.160 0.250
180 – 250 0.029 0.046 0.072 0.115 0.185 0.290
250 – 315 0.032 0.052 0.081 0.130 0.210 0.320
315 – 400 0.036 0.057 0.089 0.140 0.230 0.360

NOTE: Size ranges are over the lower limit and including the upper limit.
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APPENDIX 4: Fundamental deviations for shafts – metric system

Basic Upper-Deviation Letter Lower-Deviation Letter

Sizes
c d f g h k n p s u
0–3 -0.060 -0.020 -0.006 -0.002 0 0 +0.004 +0.006 +0.014 +0.018
3–6 -0.070 -0.030 -0.010 -0.004 0 +0.001 +0.008 +0.012 +0.019 +0.023
6 – 10 -0.080 -0.040 -0.013 -0.005 0 +0.001 +0.010 +0.015 +0.023 +0.028
10 – 14 -0.095 -0.050 -0.016 -0.006 0 +0.001 +0.012 +0.018 +0.028 +0.033
14 – 18 -0.095 -0.050 -0.016 -0.006 0 +0.001 +0.012 +0.018 +0.028 +0.033
18 – 24 -0.110 -0.065 -0.020 -0.007 0 +0.002 +0.015 +0.022 +0.035 +0.041
24 – 30 -0.110 -0.065 -0.020 -0.007 0 +0.002 +0.015 +0.022 +0.035 +0.048
30 – 40 -0.120 -0.080 -0.025 -0.009 0 +0.002 +0.017 +0.026 +0.043 +0.060
40 – 50 -0.130 -0.080 -0.025 -0.009 0 +0.002 +0.017 +0.026 +0.043 +0.070
50 – 65 -0.140 -0.100 -0.030 -0.010 0 +0.002 +0.020 +0.032 +0.053 +0.087
65 – 80 -0.150 -0.100 -0.030 -0.010 0 +0.002 +0.020 +0.032 +0.059 +0.102
80 – 100 -0.170 -0.120 -0.036 -0.012 0 +0.003 +0.023 +0.037 +0.071 +0.124
100 – 120 -0.180 -0.120 -0.036 -0.012 0 +0.003 +0.023 +0.037 +0.079 +0.144
120 – 140 -0.200 -0.145 -0.043 -0.014 0 +0.003 +0.027 +0.043 +0.092 +0.170
140 – 160 -0.210 -0.145 -0.043 -0.014 0 +0.003 +0.027 +0.043 +0.100 +0.190
160 – 180 -0.230 -0.145 -0.043 -0.014 0 +0.003 +0.027 +0.043 +0.108 +0.210
180 – 200 -0.240 -0.170 -0.050 -0.015 0 +0.004 +0.031 +0.050 +0.122 +0.236
200 – 225 -0.260 -0.170 -0.050 -0.015 0 +0.004 +0.031 +0.050 +0.130 +0.258
225 – 250 -0.280 -0.170 -0.050 -0.015 0 +0.004 +0.031 +0.050 +0.140 +0.284
250 – 280 -0.300 -0.190 -0.056 -0.017 0 +0.004 +0.034 +0.056 +0.158 +0.315
280 – 315 -0.330 -0.190 -0.056 -0.017 0 +0.004 +0.034 +0.056 +0.170 +0.350
315 – 355 -0.360 -0.210 -0.062 -0.018 0 +0.004 +0.037 +0.062 +0.190 +0.390
355 – 400 -0.400 -0.210 -0.062 -0.018 0 +0.004 +0.037 +0.062 +0.208 +0.435

NOTE: Size ranges are over the lower limit and including the upper limit.
 PAGE 7 OF 15

APPENDIX 5: Relative cost of spring wire material

Relative Cost* of Common Spring Wire of 2-mm (0.079-in) Diameter

Wire Material ASTM Relative Cost
Specification

Patented and cold-drawn steel A227 1.0

Oil-tempered steel A229 1.3

Music (steel) A228 2.0

Carbon steel valve spring A230 2.5

Chrome silicon steel valve A401 4.0

Stainless steel (Type 302) A313 (302) 6.2

Phosphor bronze B159 7.4

Stainless steel (Type 631) A313 (631) 9.9

Beryllium copper B197 22.

Inconel alloy X-750 38.

*Average of mill and warehouse quantities

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APPENDIX 6: Tensile strengths of various spring wire materials and diameters, minimum
values

APPENDIX 7: Limiting stress values for compression springs

Maximum Stress (spring solid) Material
τs ≤ 0.45 Su Ferrous – without presetting
τs ≤ 0.35 Su Nonferrous and austenitic stainless – without presetting
τs ≤ 0.65 Su Ferrous - presetting
τs ≤ 0.55 Su Nonferrous and austenitic stainless – with presetting
 PAGE 9 OF 15

APPENDIX 8: Buckling conditions for helical compression springs

APPENDIX 9: Spring end conditions and active number of turns

 PAGE 10 OF 15

APPENDIX 10: Spring end conditions and active number of turns

𝜎𝜎𝑥𝑥 + 𝜎𝜎𝑦𝑦 𝜎𝜎𝑥𝑥 − 𝜎𝜎𝑦𝑦 2 𝜎𝜎𝑚𝑚𝑚𝑚𝑚𝑚 − 𝜎𝜎𝑚𝑚𝑚𝑚𝑚𝑚

𝜎𝜎1 = + �� 2
� + 𝜏𝜏𝑥𝑥𝑥𝑥 𝜏𝜏𝑚𝑚𝑚𝑚𝑚𝑚 = ℎ𝑘𝑘 = 2𝑎𝑎 𝑎𝑎 = 𝑘𝑘𝑘𝑘
2 2 2

𝜎𝜎𝑥𝑥 + 𝜎𝜎𝑦𝑦 𝜎𝜎𝑥𝑥 − 𝜎𝜎𝑦𝑦 2 𝑁𝑁 𝜋𝜋

𝜎𝜎2 = − �� 2
� + 𝜏𝜏𝑥𝑥𝑥𝑥 𝐷𝐷 = = 𝑚𝑚𝑚𝑚 𝑝𝑝 =
2 2 𝑃𝑃 𝑃𝑃

𝜎𝜎𝑥𝑥 − 𝜎𝜎𝑦𝑦 2 1.250 1.5708

𝜏𝜏𝑚𝑚𝑚𝑚𝑚𝑚 = �� 2
� + 𝜏𝜏𝑥𝑥𝑥𝑥 𝑏𝑏 = 𝑡𝑡 =
2 𝑃𝑃 𝑃𝑃

𝜎𝜎𝑥𝑥 − 𝜎𝜎𝑦𝑦 2
𝜏𝜏𝑚𝑚𝑚𝑚𝑚𝑚 = −�� 2
� + 𝜏𝜏𝑥𝑥𝑥𝑥 𝑐𝑐 = 𝑏𝑏 − 𝑎𝑎 tc = D sin(90 / N )
2

σ e = [(σ x ) 2 + (σ y ) 2 − σ xσ y + 3(τ xy ) 2 ] 2
1 1
𝑚𝑚 = ac = a + t 2 / 4 D
𝑃𝑃

σ e = [(σ x ) 2 + 3(τ xy ) 2 ] 2
1
ℎ𝑡𝑡 = 𝑎𝑎 + 𝑏𝑏 DB = D cos(φ )

2k
σ e = [(σ 1 ) 2 + (σ 2 ) 2 − σ 1σ 2 ] 2
1
N min = Pb = p cos φ
sin 2 φ

2
[ ]
2 2
1 �𝑟𝑟𝑎𝑎2𝑎𝑎 − 𝑟𝑟𝑏𝑏𝑏𝑏 + �𝑟𝑟𝑎𝑎2𝑎𝑎 − 𝑟𝑟𝑏𝑏𝑏𝑏 − 𝐶𝐶 𝑠𝑠𝑠𝑠𝑠𝑠∅
σe = (σ 2 − σ 1 ) 2 + (σ 3 − σ 1 ) 2 + (σ 3 − σ 2 ) 2 2
𝐶𝐶𝐶𝐶 =
2 𝑃𝑃𝑏𝑏

1 n 𝑇𝑇
σ= ∑ ( xi − µ ) 2
n − 1 i =1
𝐹𝐹𝑡𝑡 =
𝐷𝐷/2
𝐹𝐹𝑟𝑟 = 𝐹𝐹𝑡𝑡 × tan(∅)

1 n 2𝑇𝑇 4𝑇𝑇
µ= ∑ xi
n i =1
𝐿𝐿 =
𝜏𝜏𝑑𝑑 𝐷𝐷𝐷𝐷
𝐿𝐿 =
𝜎𝜎𝑑𝑑 𝐷𝐷𝐷𝐷

𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 (𝑟𝑟𝑟𝑟𝑟𝑟)

µz = µx − µ y 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 =
𝑊𝑊ℎ𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 (𝑟𝑟𝑟𝑟𝑟𝑟)

𝐹𝐹𝐹𝐹𝐹𝐹
σ z = σ x2 + σ y2 𝐷𝐷 = �2.94𝐾𝐾𝑡𝑡 (𝑉𝑉)( )
𝑆𝑆𝑛𝑛

1/3
𝜇𝜇𝑧𝑧 32(𝐹𝐹𝐹𝐹𝐹𝐹) 𝐾𝐾𝑡𝑡 𝑀𝑀 2 3 𝑇𝑇
2
𝑘𝑘 = 𝐷𝐷 = � �� � + � � �
𝜎𝜎𝑧𝑧 𝜋𝜋 𝑆𝑆𝑛𝑛 4 𝑆𝑆𝑦𝑦

Formula sheet continued ……

 PAGE 11 OF 15

𝐽𝐽 =
𝜋𝜋
(𝑑𝑑𝑜𝑜4 − 𝑑𝑑𝑖𝑖4 ) πd 4 πd 4
32 J= I=
32 64
Tr PL3 30 g
τ= δ st = nc =
J 48 EI π δ st
Clearance fits Interference fits
Dmax = D + ΔD Dmax = D + ΔD
Dmin = D Dmin = D
dmax = d + δF dmin = d + δF
dmin = d + δF – Δd dmax = d + δF + Δd
Radial contact bearings

For 0 < Ft / Fr < 0.35 𝐹𝐹𝑒𝑒 = 𝐹𝐹𝑟𝑟 𝐿𝐿 0.3

𝐶𝐶 = 𝐹𝐹𝑟𝑟 � �
𝐿𝐿𝑅𝑅

For 0.35 < Ft / Fr < 10 𝐹𝐹𝑡𝑡 𝐿𝐿 0.3

𝐹𝐹𝑒𝑒 = 𝐹𝐹𝑟𝑟 �1 + 1.115( − 0.35)� 𝐶𝐶 = 𝐹𝐹𝑒𝑒 𝐾𝐾𝑎𝑎 � �
𝐹𝐹𝑟𝑟 𝐾𝐾𝑟𝑟 𝐿𝐿𝑅𝑅

For Ft/Fr > 10 𝐹𝐹𝑒𝑒 = 1.176𝐹𝐹𝑡𝑡

Angular contact bearings (α = 25°)

For 0 < Ft / Fr < 0.68 𝐹𝐹𝑒𝑒 = 𝐹𝐹𝑟𝑟 𝑊𝑊

𝑃𝑃 =
𝐿𝐿𝐿𝐿

For 0.68 < Ft / Fr < 10 𝐹𝐹𝑡𝑡 4𝜋𝜋 2 𝜇𝜇𝜇𝜇𝜇𝜇𝑅𝑅3

𝐹𝐹𝑒𝑒 = 𝐹𝐹𝑟𝑟 �1 + 0.870( − 0.68)� 𝑇𝑇𝑓𝑓 =
𝐹𝐹𝑟𝑟 𝑐𝑐

For Ft/Fr > 10 𝐹𝐹𝑒𝑒 = 0.911𝐹𝐹𝑡𝑡

𝜋𝜋 2 𝐸𝐸 𝑆𝑆𝑦𝑦 𝑙𝑙𝑒𝑒 2
𝜎𝜎𝐶𝐶𝐶𝐶 = 𝐼𝐼 𝜎𝜎𝑐𝑐𝑐𝑐 = 𝑆𝑆𝑦𝑦 �1 − � �𝜌𝜌 � �
𝑙𝑙 𝜌𝜌 = � 4𝜋𝜋 2 𝐸𝐸
( 𝑒𝑒 )2 𝐴𝐴
𝜌𝜌

8𝐹𝐹𝐷𝐷3 𝑁𝑁 8𝐹𝐹𝐹𝐹 1
𝛿𝛿 = 𝜏𝜏 = 𝐾𝐾 𝐾𝐾𝑠𝑠 = 1 +
𝑑𝑑 4 𝐺𝐺 𝜋𝜋𝑑𝑑3 𝑠𝑠 2𝐶𝐶

𝐹𝐹 𝑑𝑑𝑑𝑑
𝑘𝑘 = 𝑘𝑘 =
𝛿𝛿 8𝑁𝑁𝑁𝑁 3

𝐹𝐹 4𝐹𝐹 𝐹𝐹
𝜎𝜎𝑡𝑡 = 𝜏𝜏𝑠𝑠 = 𝜎𝜎𝑐𝑐 =
(𝑏𝑏 − 𝑁𝑁𝑟𝑟 𝐷𝐷ℎ ) × 𝑡𝑡 𝜋𝜋𝐷𝐷𝑟𝑟2 𝑁𝑁𝑟𝑟 𝑡𝑡 × 𝐷𝐷𝑟𝑟 𝑁𝑁𝑟𝑟

1 𝜋𝜋 𝛾𝛾 4
𝐸𝐸2 − 𝐸𝐸1 = 𝐼𝐼𝐶𝐶 𝜔𝜔 𝐼𝐼 = × (𝑟𝑟 − 𝑟𝑟𝑖𝑖4 )𝑡𝑡
2 𝑠𝑠 2 𝑔𝑔 𝑜𝑜

𝛾𝛾 2 3 + 𝜐𝜐 𝑟𝑟𝑖𝑖2 𝑟𝑟𝑜𝑜2 1 + 3𝜐𝜐 2 𝛾𝛾 2 3 + 𝜐𝜐 𝑟𝑟𝑖𝑖2 𝑟𝑟𝑜𝑜2

𝜎𝜎𝑡𝑡 = 𝜔𝜔 � � �𝑟𝑟𝑖𝑖2 + 𝑟𝑟𝑜𝑜2 + 2 − 𝑟𝑟 � 𝜎𝜎𝑟𝑟 = 𝜔𝜔 � � �𝑟𝑟𝑖𝑖2 + 𝑟𝑟𝑜𝑜2 − 2 − 𝑟𝑟 2 �
𝑔𝑔 8 𝑟𝑟 3 + 𝜐𝜐 𝑔𝑔 8 𝑟𝑟

- END OF EXAMINATION PAPER -

 PAGE 12 OF 15

PARTIAL SOLUTIONS
 PAGE 13 OF 15

QUESTION – 1(c)

From Appendix 1, for 0.4% failures, k = 2.66

σ z = 2.5 N .m
µz = 6.65 N-m
µy = 18.35 N-m

From Appendix 1, for 0.2% failures, k = 2.87

𝜎𝜎𝑧𝑧 = 2.32 𝑁𝑁. 𝑚𝑚

𝝈𝝈𝒙𝒙 = 𝟏𝟏. 𝟏𝟏𝟏𝟏 𝑵𝑵. 𝒎𝒎

 PAGE 14 OF 15

QUESTION 2b(i)
From Appendix 5, the least costly spring wire is cold drawn ASTM A227.
From Appendix 6, for a 2-mm ASTM227 spring wire, Su ≈ 1550 MPa

The maximum shear stress without causing “set”,

τmax = 0.45 Su
= 697.5 MPa

𝐹𝐹𝑚𝑚𝑚𝑚𝑚𝑚 = 𝟏𝟏𝟏𝟏𝟏𝟏. 𝟓𝟓𝟓𝟓𝟓𝟓

QUESTION 2b(ii)
𝑘𝑘 = 𝟕𝟕. 𝟐𝟐 𝑵𝑵/𝒎𝒎𝒎𝒎

QUESTION 2b(iii)

Lf = Ls + δ

𝛿𝛿 = 21.74 𝑚𝑚𝑚𝑚

Ls = Nt x d
Ls = 22 mm

Now, the free length will be equal to the solid length plus the deflection. That is
Lf = 22 + 21.74
= 43.74 mm

QUESTION 2b (iv)
To check the bucking status, we need to calculate the following ratios,

Lf / D = 3.36

δ/ Lf = 0.5

From Appendix 8, it is confirmed that BUCKLING will not occur.

 PAGE 15 OF 15

QUESTION – 3(b)
Refer to Tutorial # 4 (Gear Trains & Gear Force Analysis).

QUESTION – 4(b)
Dmax = 10.015 mm
Dmin = 10 mm
dmin = 10.028 mm
dmax = 10.037 mm

QUESTION – 4(c)
Refer to the second Tutorial (Failure theories).