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Alexandria University = Faculty of Engineering Production Engineering Department 3 June, 2010 A Machine Tool Elements Design-2 Second Year Time allowed: Three hours ___.___ Answer all the follo 1. a) With the aid of neat sketches, show the and butt weld. b) A steel bracket is welded as shown in figure. Find load F if the permissible shear stress is 140 MPa. c) If Load F = 15KN is applied as shown in figure. Pind primary and secondary shear stresses at point A, Given that: rey A=0.707A(2b+d) bo? 2. a) A spur gear (pinion) runs at 1750 rpm and transmits 2.5 KW to another gear. The pressure angle is 20 degrees, module is 2.5 mm and pinion pitch circle diameter is 50 mm. Find: i, Transmitted load. - Radial load. iii. Factor of safety if maximum allowable tensile stress is 180 MPa, J = 0.35, k= 0.62, and face width F= 30 mm. b) What is the main disadvantage of helical gear? c) With the aid of neat sketches, find the relation between F, , F, , F in helical gear. Examiners: Dr. Soheir Backar and committee a2) ake f helical gears is to design to transmit 35 KW and the pinion rotates at 1000 rpm. Ifthe pinion and gear has 20 and 48 teeth respectively, pinion pitch circle diameter is 60 mm, face width is 40 mm, module is 3mm, and helix angle is 15 degrees. Find: i, Dynamic load if linear velocity is 3.14 m/s. ii, Limiting load to wear if the wear load factor is SOMPa. iii. Is wear occurs or not? 3. a) Two bevel gears are used to transmit power between two perpendicular shafts. If module is 3 mm, pressure angle is 14.5 degrees, teeth of pinion and gears are 21 and 59 respectively, find: i. Pinion pitch angle. ii. Outer cone distance. iii. Face width. b) A 2 tooth right hand worm transmits 1 KW at 1500 rpm to 40 teeth worm gear. The worm has an axial pitch of 13 mm, a pitch diameter of 50 mm, and a pressure angle of 14.5 degrees. Find: i. Lead angle. ii. Normal pressure angle. fficiency if the coefficient of friction is 0.06. ii 4. a) What are the main advantages of V-belt over flat belt? b) Using only neat sketches show the main types of flat belt drives. ©) A rope drive transmits 30K W power from pulley of effective diameter 1.25, which runs at a speed of 90 rpm. The angle of lap is 160 degrees, angle of groove is 45 degrees, coefficient of friction is 0.28, centrifugal tension is 500 N, and the allowable tension in each rope is 2000 N. Find: i. Tension at tight side. ii. Tension at slack side. d) A chain drive RC60 is used to transmit 15 KW between two sprockets. If the number of teeth for small and large sprockets is 17 and 68 respectively, find: i. Pitch. ii, Pitch diameters of small and large sprockets, iii, Velocity ratio. Find the factor of safety if the ultimate tension is 800 N, centrifugal tension is |, and linear velocity is 20 m/s. Examiners:, Dr Sohelr Backar and committee 2) Mexandria University Faculty of Engineering *rodtuction Engineering Department ai EO ee pa May 2010 ecring Economy nts sas 3econd year FR LEEw Time allowed: three Hrs. els EOE Ges 1. By depositing $2,000 at the present, an individual wishes to generat a series of annual amounts that begin with $100 one year from the present and grow at the rate of 10% per year. It this series continues forever, what interest rate is being earned on the deposit? 2. A textile firm is considering the replacement of its 3-year-old knitting machine, which has a current market value of $8,000, Because of a rapid change in fashion styles, the need for the existing machine is expected to last only 5 more years The estimated operating costs and its salvage value for the ald machine are given as follows: End of Year 1 2 3 4 5 Operating cost $1,000 $1,500 $2,000 $2,500 $3,000 Salvage value 6,000 4,000 3,000 2,000 0 As an alternative, a new improved machine is available on the market at a price of $10,000 and has an estimated useful life of 6 years. The pertinent cost information can be summarized as follows: End of Your 1 2 3 4 5 6 Operating cost. $700 $900 $1,100 $1,300 $1,500 $3,000 alvage value 8,000 6,009 4,000 2000 0 a If the rate of interest is 5%, deiermine, which alternative should be selected and how long the selected machine should be kept in service. 3. Suppose that the parents of a young child decided 10 make annual deposits into a savings account, with the first deposit being made on the child’s fifth birthday and the last deposit being made on the fifteenth birthday. Then starting on the child’s eighteenth birthday, the withdrawals shown below will be made. If the effective annual interest rate is 6% during this period of time, what are the annual deposits in years five through fifteen? . $3,200 52800 24% Problem (1) atayve —r—— OF 5% per year, This bond will be redeemed at par value at the end of 20-year life, and the first interest Fe ey ave one year from now. How much should be aid now for this bond in order to receive a Yield of 10% per year on the investment? 5. A tint requites power shovels for its seat mining operation. The mining equipment with a first cost Of $500,000 has an estimated salvage value OF $70,000 at the end of 10 years service. It the firm uses {ate ofiterest of 16% for the project evaluation, howe [puch must be earned on an equivalent annual bests Fr to the equipment during its lifetime? 6 nt Howing project balance profiles, Identify the discounted payment period, Project Balance (End of Year) ~ — [PRG )sT PBG, $1,200 Best of luck Second Year Production Date: June 2010 Time: 3 Hours jexandria university culty of Engineering Final Exam - Year 09 —10 Material Technology (2 Answer the following Questions : 1- In the iron carbon diagram for the following steel = 0.3 %C = 18%C - Draw the cooling curves , when it is cooled from etch the final micro structure of such steels - Deseribe the steps to be followed to harden such steels uid state to room temp. 2~ Use neat sketches to show the Following : - The Micro ~ structure of ( Pearlite - Nodular Cast iron ) - The heating cycle of Annealing heat treatment process - The final structure of a large ingot ~The Cu—Ni phase diagram 3a) Design a Material Certificate * for a Steel plate required to implement an Upright Storage Tank. b) What are the different methods used to change the m of metallic materials « ¢) Discuss , how to get fine grain using Heterogeneous nucleation . hanical properties 4 - Select the suitable Engi ‘tructural steel - Cutting tools - Vehicle suspension . 4 computer case trical conductors & heat exchanger - Engine body Machine parts , - Turbine Blades ~ Automotive spare parts, - Food packing cering Materials for the following applications + 5—a) Differentiate between Thermoset & Thermoplastic materials give applications b) Inan aligned & continuous carbon fiber ~ reinforced nylon composite are to carry 97% of a load applied in the longitudinal direction . Modulus of Elasticity for a fiber material is 260 GPa , where it is 2.8 GPa for nylon . Determine the required volume fraction of the fiber. P10. Hardrss, HR 40 wesc Ks 7 _ : | a 100 - | Cong era # 7006 130017 % —— “| liao mS125 55 162-1074 A 6—a) Explain the main aim of Tempering process ? b) Sketch the TTT diagram of 0.8 % carbon steel and describe the coo! eyeles to be followed to obtain the following microstructures : +A microstructure of 100 % Martensite ~ A microstructure of 50% Bianite & 50 % Martensite ©) A cylindrical piece of 4140 steel is to be quenched in moderately agitated oil . If the microstructure consisting of at least 50 % Martensite throughout the entire piece , what is the maximum allowable diameter . Justify your answer . ( Use the following diagrams ) ng, Contig ae O07C IY = Pesan martenote ya 70 118 9 56 EB 100 Lap f® 1 ; = == 21 a b 1080 3 \| : 50 ~ 2B a a rr i Lititbitititiiiiiys a a ood ¢ 2 a bo a am Distance hm quand on quaint cltanen am unneod ord o (b) Oil BEST OF LUCK DR. 1. A. ABDALLAH ~ ae \Z Alexandri 1 Examination Solid Mechanics Faculty of Fall 20092010 Time: Shes Production Eng, Dept 2" Year Production Jan 2010 Answer The following Ques (cost oh set oo La ll aly faked Jy SU! eel) 1. A tensile test specimen is made of a materia) represented by @ = Ke + ny Determine the true strain at which necking will begin. 0%} 2. A thin cylinder 75mm internal diameter, 250 mim tong with walls 2.5 man thick is internal pressure of JMNin*. Determine the change in internal diameter and the change in length. If in addition to the intemal pressure, the cylinder is subjected to a torque of 200 Nm, find the magnitude and nature of the principal stresses set up in the cylinder. (Young's modulus has a value of 200 GNvim? and Poisson's ratio has a Vatue of 0.3) (20%) 3. A cube of metal having a constant yield stress Y of 360 MPa (such behavior is called rigid-plasiie since ¥ would not change after initial yielding) experiences a stress stale of 6 * 0.3 o, and 65 = =0.5 a4. Ifthe sirssses are gradually increased in these constant ratios, find 6; at yielding: (aj using the von-Mises criterion and (bp using the Tresca criterion. (20%) 4. Determine the radia! and hoop stresses at the internal and external surface of a thick-walled eylinder of internal and external radii % mm and 152. mm respectively, when acted upon by internal and exierna! pressures of 124 Mia” 46 MNim* resp Show by means of a diagram how each stress varies over the thickness, 20%) ‘Vhe 45 degree strain rosette is mounted on the si following readings are obtsined for each gai ace of an aluminum plate, The 8, ~ 47910"), & = 250(10%) and ). Determine the in plane principal strains, (15%) 6. A certain steet has a yield stress in simple tension of 270 MNim’. Under a certain vo dimensional sires system the principal stresses are 108 MN/m* and 30. MNin” (compressive). Under this situation calculate the factor of safety according, to maximum shear stress theory anid to the von Mises theory (15%) Framinior: Prof. Dr Galat A Newel