Production Engine
Second Year
ing Department
January 2011
Angwer th
-a- A hollow circular column of 250 mm external diameter
200 mm internal diameter carries a projecting bracket and lo
as shown in Fig (1) Caleulute the generated stresses at points.
and By
lowing questions :
b-A mild steel rod of 12 mm diameter was tested for tensile strength
with a gauge length of 60 mm .The recorded results were
The yield load = 3.4 KN , The ultimate toad = 6.1 KN , The fi
dis 7 mm and the final ength= 80 mm Calculate :
* the yield stress of the rod ,
the ult
* the percentage reduction of area and the percentage clo
te tensile strength of the rod,
Fig(1)
¢-The shaft shown in Fig(2 ) iy mounted in bearings A and Band loaded as shown
diameter d of the central portion of the shaft if the generated stress is not to execed 100 MP,
De
2- A cantilever beam of circular cross-section, Fig ( 3 ) , is subjected to a
load which varies from (-F ) to (3 F ). Determine the maximum value
of (F) so that the shaft can withstand indefinite life . Given that the
factor of safety = 2, the yield st 70 MP, . the endurance
: | 1
275 MP, and fatigue stress concentration factor at section Wve | eae
AB= 182. ie
Jimi
Ct
12] Power
~+,-Serew
3-A single start square thread power screw , Fig (4), is used to raise a eS
load W = 50 KN at a velocity V The rotation speed of the
serew =300 rpm and its root diamet -The friction coefficient _
of the nut thread and the collar are 0.1and 0.13 respectively .Phe mean __J4
collar diameter = 40 mm . The allowable shear stress =120MP,.and cl
the factor of safety is 2. Calculate :
“The outside diameter of the serew ,
* The height H of the nut ,
* The resultant stress at A-A 4-Two plates and a single strap cach of 150mm wide and 12 mm thickness and rivets of 20
mm diameter are used to make a single riveted single strap butt joint. The joint is subjected
to a tensile force of 70 KN . If the efficiency of the joint is 40 % ,find the number of the rivets
used given that the allowable stresses are 120 MP, for shear, 280 MP, for crushing and 140
MP, for tension .
5). The
-Four rivets cach of 20 mm diameter are used to fix the bracket shown in fig
allowable shear stress of the rivets = 100 MP. Find the maximum value of P.
Len eho oureta 200
a
Fig (5) Alexandria University ka Agua) Analy
Faculty of Engineering unigh 4S
Production Engineering Department es
january, 2011 . " ayy
Forming Technology Saal tap gl gist
Second year ast)
Time allowed: Three Hrs. lela EE: 0
Answer all the following quest
++ a) The following products are produced by forming processes. For each product, suggest
the most suitable forming process that can be used in its manufacturing
- Outer race of a large ball bearing ~ Long threads
~ Bolts ~ Structural shapes
~ Toothpaste tubes - Aluminum sections
b) Give an example for
1- Steady Compression ~ compression forming process
2. Plane strain forming process
3 Plane stress forming process.
4- Forming process that increases the wall thickness.
2- Aste! sheet 160 mm in width and 2 mm in thickness is used in producing blanks with
diameter of 100 mm. The ultimate tensile strength of steel is 400 N'mm®, calculate
‘the maximum utilization factor and the force required for shearing one blank. If the
blanks are then deep drawn to produce cups with a height of 25 mm, calcutate the
drawing ratio and the deep drawing force.
3a) Draw the stroke versus the load during the following forming processes.
i Forging in closed die with flash
ile Continuous extrusion (direct and indirect).
ili: Bending
b) Ina rolling process of a steel plate 400 mm in width, the maximum power of the
rolling machine is 150 kw, if the reduction in height is 2 mm, the roll speed is 20 rpm,
the yield strength of the steel is 400 N/mm’ and the coefficient of friction is 0.1, what
is the maximum and the minimum roll diameter that can be used.
°)
a) Mention and draw neat sketches for different three forming methods used in reducing
the thickness. of the walls of the cups. What is the method that gives the largest
reduction?
b) Inan upsetting process, a steel cylinder 50 mm in diameter and 80 mm in height is
compressed . If the final diameter of the cylinder after compression is 60 mm.
calculate the upsetting load at the end of the upsetting stroke, given that the yield
strength of the used steel is 500 Jmm* and the coefficient of friction is 0.3 gL wn
ea
5 a) Prove that the maximum reduction in wire drawing can be expressed by the relation:
eo ce
b) A copper wire 3 mm in diameter is drawn to a-final diameter of 2.5 mm, if the
coefficient of friction during the process is 0,1 and the yield strength of the coppe' is.
250 Nimm” , calculate:
~The optimum drawing angle
- The drawing force.
- The max reduction at the optimum drawing angle.
- The number of drawings, if the final diameter is 0.5 mm and “he
maximum reduction per'pass is 20%.
a) Compare between direct and indirect extrusion,
) Sketch the fotlowing forming processes:
1- Stretching
2 Ring rolling
3- Necking
4- Bulging
Dr. Gaber Kershah
[Bixamminers: “Page? of 2 Alexandria University
Faculty of Engineering
n Engineering Department Design of Machine Element (1)
ar Time Allowed : 3 Hrs
January 2011
Producti
Second Y
Answer the following ques:
A hollow circular column of 250 mm external diameter and
200 mm internal diameter carries a projecting bracket and loaded
shown in Fig (1) Caleulate the generated stresses at points
and B
b-A mild steel rod of 12 mm diameter was tested for tensile strength
with a gauge length of 60 mm .The recorded results wer
The yield load = 3.4 KN , The ultimate load = 6.1 KN , ‘he fi
7 mm and the final length= 80 mm Calculate :
* the yield stress of the rod ,
* the ultimate tensile strength of the rod ,
* the percentage reduction of area and the percentage elongation .
diametel
nd B and loaded as shown . Find the
ated stress is not to exeeed 100 MP
n bearings
the shaft shown in Fig(2 ) is mounted
diameter d of the central portion of the sh:
te Dy
210 mm —Le
(2) X
2- A cantilever beam of circular cross-section, Fig (3), is subjected to a
load which varies from (-F ) to (3 F ). Determine the maximum value
of (F) so that the shaft can withstand indefinite life . Given that the
AL! dinsions in mm
Fig (3)
factor of safety = 2, the yield stress = 470 MP, the endurance 4
limit = 275 MP, . and fatigue stress conventration factor at seetion Gin
A-B= 1.82. oe
3A single start square thread power serew , Fig (4) ,is used to rais ae
load W = 50 KN at a velocity V =20 mm/sec. The rotation speed of the
serew =300 rpm and its root diameter =30 mm .The friction cvetficient
of the nut thread and the collar are @.1and 0.13 respectively .The mean
collar diameter = 40 mm . The allowable shear stress =120MBy_
the factor of safety is 2. Caleulate =
* The outside diameter of the serew
* The height H of the nut,
* The resultant stress at A-A.
Fig (4) Alexandria University
Faculty of Engineering
Production Ergineering Department Design of Machine Element (1)
Second Year ‘Time Allowed : 3 Hrs
January 2011
Answer the following questions
L-a-A bar of a rectangular cross-section is used to carry the
shown loads. If S,=290 MR, , and the factor of safety = 2.0
find the cross-section dimensions of the bar if its width is
20mm.
b-Determine the induced stresses in sections A-A , B-B and
C-C of the rod shown in the figure , given that F = 20 KN,
X= 70 mm , y= 100 mm and the rod diameter is 50 mnt,
c-a brass rod of 20 mm diameter and 1000 mm long is
subjected to an axial pull of 400 KN . Find the resulting
stress , strain and percentage elongation if the modulus
of elasticity of the bar material is 100 GP . 5 mn
2. The shaft shown is subjected to a steady
pull of SOKN and a uniform bending moment
MNm.If$ =300 MN/m?, S = 200 MN/ nf, and
1.5 , find the maximum value of M to
avoid fatigue failure .
3- a) Using neat drawings to differentiate between the following:
i- Plain taper key and Gib head taper key.
ii- Dowel pin and Grooved pin.
b) A shaft of 45 mm diameter is made from material having S=600 MPa, Sy= 850
MPa. A square key 20 mm wide and 100 mm long is placed at interface between this
shaft and the hub of a power transmitting element. If the allowable compressive yield
strength of the key material is 320 MPa and factor of safety=2, find:
i- The maximum torque capacity of the shaft.
ii- The maximum torque capacity of the key.
4- a) Use neat sketches to show the follo
i- Double riveted lap joint (chain riveting).
ii- Single riveted double strap butt joint. ©) Double riveted double strap butt joint (zig-zag riveting) is used. If 15mm,
d=20mm, P=90mm, Sy= 150 MPa, S,.= 180 MPa, S,;= 130MPa, find:
i- The shearing resistance of the joint.
ii- The tearing resistance of the joint.
i
iii- The strength of the unriveted or solid plate per pitch length.
5- a) Differentiate between the following using only neat drawings:
- Sleeve coupling and Compression coupling.
ii- Square thread and ACME thread.
b) A flange coupling fits in a 25 mm diameter shaft. Some shear bolts are used in
radius 75 mm, each bolt is 15mm diameter. Find
- Force acting on each bolt if the shear strength of the bolt is 55 MPa and f=2.
The minimum required number of bolts if the torque capacity is 500 N.m.
ii-
c-A single start square thread power screw is used to raise a load W=50 KN If the outside
diameter of the screw is 34 mm, the pitch is 4 mm ,the friction coefficient of the nut thread
and the collar are 0.1and 0.13 respectively .The mean collar diameter is 40 mm . Calculate:
the lead angle, and the collar friction torque cote eal) ig haat
a3
Aaa yall y Chad Bale
seb os — Ga ag
Saga Vs aed
Bj gSe RENE oh A (30.
GHPPQIIR S/T
| ae
nay SINT pS BASICA tise (33 |
Ses
INT(ALY} 34 psOINTTA.9) 38 leh BU case |
| Agee
| INPUT N
10 PRINT N MOD 2:
| nes INT (N/2}
IFN > OTHEN 10
| END
| satel gas Si Se oe Up py Sa IH Dp
Bus)
CO0}-A
i 842-8
}o000000 «Cc
&D
10 PRINT “HELLO”
| asdel
|IEI= 0 gS baie Jal se ati a ils YC
Sal se ad pls = D
Page 3of §
| END
“(Gaal 8 Gt mod 4 ie ae 3s xe (31 |
INPUT |
S=0
FOR j= 110N |
IF §mod 2= 1 THEN !
ENDIF
NEXT J
PRINTS
Nghe 05 gl ef
NL ce Seal YI & pee ctl go
1 AE gat ge
M1 gS ptt yl ga D
i
|
|
|
wD eld oh (32
X=0
Y=0 {
FOR A=1 TO 10 1
IF A>5 THEN
X=XHA
ELSE
Yel
ENDIF
NEXT A i
PRINT X.Y i
END |
gs
105 -A i
405 -B |
W1-C | ert at a fgaitey! tnt
~~. iol Us
saenit weenie
Mika V1 5 Baal ed
INPUT N,
|N=N*(N=1)
| PRINT N/2
| END
| fat ee ps 5 OS se
120-A
input A
inpul B
| Product = 1
Fori= A1oB
| Product = Product *i
| Next i
| Print Product
eli tin
asa Ja Vy B lA ce Le & gana ac A,
|
Asus
Sees BANA ce alae pie ual isens 9 gy - B
| ADB US I Lan
[ame Day Uy BGA Ge alae Ng pee leas pie
ASB OS
| sooyy BMA eae pe ale Gas as D
AsB JS i lose
esa Sa
| Nall aX oS
| 20-A
15-B
| 25-6
2D
Lo
Page 4 of 5
Sh ae as Bs SBS
Fori=] to-7 step -3
Nexti
X=10
10 X=X42
IF X<19 THEN 10
END
VOX=X +2 det sis
eA
ciye B
aint
anid
gn UHL U' U4 Us 37
3
4
“gVS BASICS
U(1/2°U)42+(1/3°U) N34 (1/4°U) 84 A
USU/2N24U/3A3+U/494 -B
UFUA2/2UN3/3+UNE/4 -C
abe -D
| 2h ua gt lata . :
chal Gaal ig olaial Precip,
si! ss) da
4 Chal 8 Hash Ais
Banal 5 Gat 5a . neh hs
ania ps — oun 4 in ABS ata at
VY baal)
input x
‘IfXmod to5 |
Print "yes" | 1 to 5-42
"else | ffisj then Print "x"
| Print "no’ | Next [-43
Endif | Next i
tights yete x!
sat AIO yes gale A |
110 ate -B
oc |
L _ { = i 4
|
i jNe7
| PIB) =O
FIB2 = 1 |
FORI=lioN For i:
INPUT NUM. | Prin
Sime | FB2 i
| Nex!
| PRINT 2°5/N |
END i
6AM lA | eta |
SAL HERES eee |
7 adil gle | 11235813 em-A
| 6B nba eke Df 1248163264am-B |
112481632 q»-C
sboe-D |
BS
i Foris] toN
| Wf 2mod ir? then S=Sti
|
|
Next i
Print S
NET NG ae a lg
Noh 2 a ab Mg pees ed Go -B
NBS oe BI Eee el eee C
ey i
Page 5 of § Production
versity Losey 4
wri :
gineering Bepartusent Z ge i
Jan, 2011 Teyy gy
Dimensional Metrology ~ PE 241 PE 241-4 aw gs
* Year ~ Higher studies Complementary We ala phat + nt aa
Time allowed: 3 Hours SHEL TiC pel a
CBS AUB 5 al AA Ll as AY eb AY) ts gle
ai1S gh Ula i AMSG Auth Cpe eo
FIRST QUESTION: (25 Marks)
1.4 Two similar measuring instrument's (A & B) are used to perform measurements with allowable error of + 0.005 mm.
"the two instruments, when calibrated for a standard height, have the following characteristics
instrument Giese
__Average Error” Standard Deviation
AL 0.000 — 0.005
0.005 0.002
State which instruments more retable to perform the required measurement and why?
4.2 Accuracy, orecision, and sensitivity are parameters used for the characterization of measuring instruments. Define and
show how to evaluate these parameters for an instrument.
ine the following: Systematic error and Random error. Show by neat sketch two examples for the systematic error
lated with the measuring process and slate how ‘o evaluate these errors.
SECOND QUESTION: (10 Marks)
State, briefly in points, the following:
2.4 Bases of standardization, 2.2 Meaning of ‘standard’
2.3 Search means for ISO standards, 24° Principle of ‘ISO/ICS”
25 iases of !SC standards development
THIRD QUESTION: (30 Marks)
Draw only one neat sketch to illustrate, instrument amplification andlor magnification elements’ ratio, displacement.
and motion, as well as the instrument overalt ratio, for each of the followin
34 rellection with Twisted hand 3.2 Optical projection with Cross reeds.
33 ction. 3.4 Airflow rate with Contact head.
3.5 Eectrical Rotational variable capacitance for Rectilinear measurements.
Fe (25 Marks)
tl he extreme sizes (D; and Ds} are 600 and 630 mm respectively. The formula for evaluating the
stondard tolerance ('T) is: T = 25! um; where /is the standard tolerance factor and rounding values are in multiples of
5 um, The formula for evaluating the shatts fundamental deviation (ei) is: ei = 0.04D + 21 jum; where el is positive, Dis
al niean and rounding values are in multiples of t ym.
4.1.1. Evaluate the size tolerance for both holes and shafts,
4.1.2 Evaluate the Maximum and Minimum limits of size for both holes and shafts.
4.4.3 State the type of fit then evaluate the maximurn clearance.
4.4.4 Using ISO standard symbols and rotations, illustrate the following; (a)Zero line and asic size, (bjTolerance
zone for botis holes and shatts, (cjUpper and lovier deviations for both holes and shatts.
ign a set of unified limit gauges used to check a group of holes having a basic size of 150.000 mm and a tolerance
‘ue of + 20 1m, What are the maximunt and minimum limits of size for the go and not go limit gauges? Ilustrate your
answer on a neat drawing,
tional requirements mus: be considered during the process of dimensional tolerance allocation’. With ine aid of @
clear ilustraton, exovain the previous statement,
42
43
Examiners: Prot, Nasr Damir, Dr, Ashrat Rashed, and Dr. Abdallah Kh
ay Alexandria University By aio Aas
Faculty of Engineering aap 4s
Production Engineering Department = af cy Raaia aad
Jan, 2011 re
Fluid Mechanics (MEX32) (MEX32) Gia
2s4 Year Sat eat a a
Time allowed: 3 hr chet 20 ofa Bae
persver
{a) Prove that the flow rate measured by horizontal venturi for ideal flow is given by
uP d
Qa, PER TPO where a= st >1
\ wa’ by
(b) For ideal flow of water through the venturi meter and constant value of P; =250 kPa
Py (vapor pressure) = 4.3 kPa
30mm. d-20 mm
Calculate
© Flow rate if P2=100 kPa
© Draw the TELL and H.G.L for the above venturi with suitable scale, State the
weak points of possible cavitation.
«Ifthe flow rate required is 6 L/s calculate the pressure at throat Pz
«Ifthe flow rate required is 8 L/s, is this flow possible (comment)
(a) The flow between through a pipe connecting two tanks is real Flow (comment by
example).
(b) Explain the hydraulic jack principal of operation.
(c) State the methods used to determine the head loss across partially open valves.
(a) Water (11=0.001Pa.s) flow from upper tank to lower one as shown , assume laminar
flow then calculate the flow rate, Neglect eddy losses (secondary losses).
t
ose
ot Question Three (25% of full maria:
(a) Compare between principal of operation of positive and dynamic pumps.
(b) The performance ofa centrifugal water pump is given by:
H=24.62 wa 1 n= 9.86Q-0.33Q"
0
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