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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