Hong Kong University of Science and Technology

Department of Mechanical Engineering

MECH152 Design and Manufacturing
Final Examination, May 2004
Please answer all questions.
QUESTION 1 (25%)
Given the power transmission shaft above:
(a) Use a separate sketch / drawing to indicate the two bearing support locations for the
shaft (4%)

(b) Explain why such locations are chosen? (6%)

These two locations are chosen because they are both assigned with
dimensional tolerance. (3%)

N7 surface finish (3%)

(c) Explain why there is chamfer at each end of the shaft. (3%)

The chamfer at each end of the shaft is to cater for easy entry of the bearing during the
assembly process. (2%)
The chamfer will ensure no sharp edge on shaft that leaves marks on the bearing (1%)
(d) Explain why there is a center hole at each end of the shaft. (3%)

The center hole at each end of the shaft is used to support the shaft during the
manufacturing process. (2%)
Their common axis is also used as a datum in the manufacturing process or in geometric
specification (1%)
(e) The power transmission shaft is made from a cold drawn steel bar of stock size 45.
State the manufacturing processes to be used for producing the shaft. Use sketches to
show the manufacturing steps and the associated machining set-up. (9%)

Center

Center

Dog

Center

Center

Dog
Grinding wheel

Center

Support wheel

Center

QUESTION 2 (35%)

The above shows a petrol-engine connecting-rod. The connecting-rod forms part of the
engine assembly linking the piston to the crank shaft. Please refer to the following web site on
the
machining
and
assembly
of
the
connecting-rod
(http://www.aichikikai.co.jp/english/mono/eng/05rodkako.htm).
(a) How many parts are there in the drawing? (2%)
Two (2%)
(b) What are the key considerations in the design of the connecting-rod? (3%)

(c)

Weight (1%)
Strength (1%)
Life / reliability (1%)
Add the necessary dimensional tolerances to the drawing. Show the answer to this part
of the question on a separate drawing. Explain why these dimensional tolerances are
necessary. (10%)

+0.059
+0.043

+0.020
+0.020

+0.048
+0.035

(d) Add the necessary geometric tolerances to the drawing. Show the answer to this part of
the question on a separate drawing. Explain why these geometric tolerances are
necessary. (10%)

(e) Use sketches to show the sequence of manufacturing steps for the connecting-rod.
Explain the selection of manufacturing process in each of the manufacturing steps.
(10%)
1.

Precision forging to obtain the overall shape. The tolerance should be at least

o.1.
2.
3.

4.
5.

Use CNC machine to bore and ream the hole at the small end and at the big
end.
Use a round pin + diamond pin location method to set up the connecting rod
for drilling the two holes at the big end and the lubrication small hole at the
small end.
Use the fixture of item 2 plus a diamond pin to saw the big end.
Dill the hole at the internal surface of the big end.

QUESTION 3 (40%)

(a) Complete the above part list for the assembly (10%)
Item Number

Description

Quantity

Material

Remarks

Key

Medium carbon steel

Screw

Mild steel

M12 x 30

Spring Washer

Spring steel

Washer

Mild steel

Pinion

Medium carbon steel

Shaft

Medium carbon steel

Spur Gear

Medium carbon steel

Bush A

Brass

Housing

Cast iron

10

Bush

Brass

11

Pulley

Cast iron

12

Nut

Mild steel

M12

13

Key A

Medium carbon steel

(b) Copy the figure to another sheet and show the dimensions directly controlling the axial
clearance x =1.0 mm (nominal). Determine the limiting size of the axial clearance if all

machined dimensions have a tolerance of

0
.
0.1

(15%)

(5%)
X=ABCEFG
X(max) = A (max) B(min) C(min) E(min) F(min) G(min)
Upper limit = 0 (-0.1)- (- 0.1) ( - 0.1) (- 0.1)- (- 0.1) = 0.5
(5%)
X(min) = A (min) B(max) C(max) E(max) F(max) G(max)
Lower limit =- 0.1 (0)- ( 0) ( 0) ( 0)- ( 0) = - 0.1

(c)

Explain the design concept for the housing (item 9), with particular reference to the
choice of the bushes (item10), the speed of the shaft, the fitting of components, and the
machining of the hole. (10%)

The speed is low because brass bushes are used. (2%)

The small hole is for oil lubrication (2%)
Two bushes are used as the shaft needs two support point to counteract turning
moment.(2%)
The bushes are interference fit on the housing (2%)
the shaft is running fit on the bushes (2%)
The larger diameter in the mid section is to reduce machining and to separate into
two supporting section.(2%)