22-Mec-A4 Design and Manufacture of Machine Elements, December 2014: worked solutions

Paper format. National Examinations, December 2014 — 07-Mec-A4, Design and Manufacture of Machine Elements. Three hours, open book, any non-communicating calculator permitted. Six questions divided into Part A (Q1–Q3, manufacturing processes) and Part B (Q4–Q6, machine elements); candidates answer two from Part A and two from Part B, and all questions carry equal value (25 % each). All six questions are worked here.

Reference texts.

S. Kalpakjian and S. R. Schmid, Manufacturing Engineering and Technology — Ch. 10–12 (casting processes and design), Ch. 1 and 3 (structure, cold work, annealing), Ch. 21–22 (machining and tool life).
R. G. Budynas and J. K. Nisbett, Shigley's Mechanical Engineering Design — Ch. 3 (stress, Mohr's circle, beam deflection), Ch. 4 (statically indeterminate shafts), Ch. 16 (clutches and brakes).
R. C. Hibbeler, Mechanics of Materials — Ch. 6–9 (bending, transverse shear, combined loading, stress transformation).
W. D. Callister and D. G. Rethwisch, Materials Science and Engineering — Ch. 7 (dislocations, strengthening, recovery and recrystallization).

it reports a single 5,200 N load and a dimension chain of 750 + 450 + 450 = 1,650 mm that "contradicts" the 2,400 mm overall. Q5 is solved against the drawing, not the caption. Likewise in Q4 the 3,000 lb load is read from the drawing as a horizontal force applied through the bolted plate on the neutral axis, and the section as a 8 in deep I-beam (¹⁄₂ + 3¹⁄₂ + 3¹⁄₂ + ¹⁄₂).

22-Mec-A4 Design and Manufacture of Machine Elements: December 2014