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Subject Code – MECH7007
Subject Name – Mechanical System Design
University Name – Western Sydney University

Mechanical System Design, MECH7007

Mechanical System Design:

Mechanical design entails the creation of mechanical parts, components, products, and systems. Mechanical design, for example, encompasses the design of numerous machine elements such as shafts, bearings, clutches, gears, and fasteners.

This subject helps students learn how to use systems engineering methodologies to design and manufacture machine components and assemblies. The unit examines the design of primary equipment components to verify their usefulness, strength, and longevity, including drive components such as gears, shafts, belt drives, and bearings, as well as structural components such as welds and threaded fasteners. Systems engineering is used to deliver the machine assembly design.

Learning Outcomes

⦁ Apply machine design concepts to the creation of machine components.
⦁ Recognize common engineering representations of machine elements.
⦁ To assess and evaluate mechanical component and system design,
⦁ Apply the design process to a practical goal.
⦁ Examine the normal design process by looking at the fundamentals of primary machine components, bearing design, and bearing selection.
⦁ Using commercial software, practice design alternatives to improve CAD abilities.
⦁ Conduct mechanical design in a collaborative setting.

Western Sydney University

Western Sydney University has expanded its network of campuses in a number of different places like Sydney, Liverpool, Parramatta, Campbellton, Bankstown, Hawkesbury, Penrith, Nirimba, and Vietnam. The university is ranked in the top 2% of the universities globally offering undergraduate, postgraduate, and research degrees to students.

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Question 1: Design of Belt Drives. ( 10 marks )
A cross belt drive has two pulleys with radii of 300 mm and 150 mm, respectively, mounted on two parallel shafts 2.5 + 0. Pm apart as shown in Figure 1.1 below. Assume that the tight tension, T1 is 1500 + 0. P N, the smaller pulley rotates at 150 + 0. P rpm and the frictional coefficient are chosen as 0.20.
As the design engineer, you are required to determine:
a) what the datum lengths of the belts are required for this drive;
b) what the contact angles at two pulleys are; and
c) what the capacity of power transmission of the belt drive.

Mechanical System Design

Question 2: Design of Chain Drives. ( 10 marks )
As the design engineer, you are required to specify the required length of no. 60 chain to mount on sprockets having 15 and 50 teeth, respectively, with a guess center distance of 40 + 0. P pitches, and compute the actual center distance.
As shown in Figure 1.2, the chain connects a hydraulic drive with a meat grinder with an input speed of 300 + 0. P rpm and an input power 3 + 0.P hp. You are also required to
a) Determine what would be the rating for the two-strand chain; and
b) Design the chain drive according to the input speed and power requirement.
Mechanical System Design
Question 3: Design of Spur Gears ( 10 marks )
A pair of spur gears with 20°, full-depth, involute teeth transmits 0.75 + 0. P hp as shown in Figure 1.3. The pinion is mounted on the shaft of an electric motor operating at 3,000 + P rpm. The pinion has 24 teeth and a diametral pitch of 24. The gear has 110 teeth.
As the design engineer, you are required to compute:
a. The rotational speed of the gear
b. The velocity ratio and the gear ratio for the gear pair
c. The pitch diameter of the pinion and the gear
d. The center distance between the shafts carrying the pinion and the gear
e. The pitch line speed for both the pinion and the gear
f. The torque on the pinion shaft and on the gear shaft
g. The tangential force acting on the teeth of each gear
h. The radial force acting on the teeth of each gear
i. The normal force acting on the teeth of each gear
Mechanical System Design
Question 4: Shaft Design ( 10 marks )
Figure 1.4 shows a rotating shaft carrying two steady downward loads F at C and D, respectively, and D is right in the middle between A and B. The shaft is held by a pair of bearings at A and B, respectively. As the design engineer, you are required to specify a suitable material for material selection by setting up the value of F using F = 200 + P/100 (N) with a design factor of 2.5 + 0. P.
Mechanical System Design
Question 5: Key Design ( 10 marks )
Specify a key for a gear to be mounted on a shaft of a 2.50-in diameter. The gear transmits a torque of 21,000 + P lb-in and has a hub length of 4.00 + 0. P in.
As the design engineer, you are required to determine the required key geometry as shown in Figure 1.5: length, width, and height. Use AISI 1020 cold-drawn steel for the keys if a satisfactory design can be achieved.
If not, use a higher-strength material. Unless otherwise stated, assume that the key material is weakest when compared with the shaft material or the mating elements.
Mechanical System Design
⦁ Make sure that the answers must be given in a step-by-step manner to show your understanding and problem-solving clearly. The final result should be expressed in SI units.

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