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2.007 Design and Manufacturing I

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 Page 1 of 2
2.007 Design and Manufacturing 1

Homework #1 Design Process & Machine Elements

NAME:____________________________________________________________

Date Issued: Tuesday 10 FEB, 11AM

Date Due: Tuesday 24 FEB, 11AM

Please answer the following 3 questions showing your work to the extent possible within
the allotted time. Point allocations are listed for each question. The points sum to 100.

As described in the course policies document, this is one of four homeworks you will
complete in this course. Each homework counts as 5% of your total grade. You will
submit your work via the course web site.

1) (50 total) It is proposed to develop and market a bicycle including a new feature.

A) (10 points) Make an annotated sketch of a standard bicycle. A side view could suffice.
Ensure the ways parts are interconnected are accurate, that the proportions are roughly
correct, and that key dimensions are labeled so that your functional understanding of the
bicycle is evident.

B) (20 points) Now consider a new feature. The bicycle should enable the rider to store
energy from pedaling or from going down hill and later use that energy to aid in either
acceleration from a stand still or else in hill climbing. Develop, at the conceptual level,
three very different ways of implementing this function. Simple abstract descriptions and
sketches will be enough.

C) (20 points) Begin to set up a Pugh chart for selection among your alternatives from B.
List at least three criteria by which you might choose among them. Choose a datum
concept. Then fill out a single row, rating the two concepts against the datum (“+”
indicates superior to, “-“ indicates inferior to, “S” indicates essentially the same as the
datum). That would imply you need to make just two relative assessments. Below your
Pugh chart, provide a few sentences of text, sketches, equations and so on that defend
each of these ratings. Be quantitative in your exposition to the extent possible.
 Page 2 of 2

2) (20 total) Consider a capstan such as the one as depicted below.

A) (5 points) How much tension, T, must be applied to raise the weight at a constant rate?

B) (5 points) How much tension, T, must be applied to lower the weight at a constant rate?

C) (5 points) How much tension, T, must be applied to hold the weight at a constant
position?

D) (5 points) Explain the differences in scenarios A, B, and C in a style that a bright ten-
year-old would understand.

rope
deg  static=0.3
 kinetic=0.2

T
capstan

5N

3) (30 points total) Consider a typical brushed DC permanent magnet motor

A) (15 points) Let’s say we connect the motor to a regulated 5V power supply. Further, let’s
say we have a means (such as a dynamometer) to apply a known torque to the shaft
even as we allow the shaft to continue spinning. We observe its performance as a
function of the applied torque. When no torque is applied, the motor operates at 10,000
rpm. When the motor is stalled, the torque on the shaft is 0.1 N*m. Draw a sketch of
torque versus speed and (on the same graph) power versus speed and indicate on the
graph the operating conditions for maximum power.

B) (15 points) Let’s say we remove the permanent magnets and put them in an oven. After
the magnets cool back down to room temperature, we install them again and let’s say
we find that the magnetic field strength has dropped by a factor of two. Then we
connect the reassembled motor to the 5V power supply and repeat the measurements
as before. Estimate how the performance of the motor will be affected by the heat
treatment of the magnets. Sketch the new torque speed curve and compare it to the
previous one (from part 3A).
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2.007 Design and Manufacturing 1

Homework #2 Servomotors, Mechanisms & CAD

NAME:____________________________________________________________

Date Issued: Tuesday 24 FEB, 11AM

Date Due: Thursday 5 MAR, 11AM

Please answer the following 4 questions showing your work to the extent possible within
the allotted time. This assignment should not take more than 6 hours.

Point allocations are listed for each question. The points sum to 100.

As described in the course policies document, this is one of four homeworks you will
complete in this course. Each homework counts as 5% of your total grade. You will
submit your work at lecture by hardcopy or via the course web site.

1) (25 total) You’re building a small, electric-powered vehicle to climb up a 20 degree ramp
(similar slope as the ramp into the contest starting box). The vehicle will be operated by two
servomotors that can continuously rotate the output shafts that attach directly to wheels on the
left and right sides of the vehicle. The manufacturer’s specifications indicate each servo is
capable of a no load speed of 50 rpm and a stall torque of 0.3 N*m (similar to the specs of the
HS-311 standard servos in the kit). The total vehicle weight along with its payload is 12 N (a
little more than the weight of a liter of water). All the wheels have a radius of 6cm. The front and
rear axles are 20cm apart. The center of gravity of the vehicle and payload is halfway between
the front and rear wheels and is 3cm above the surface on which the vehicle runs.

A) (5 points) Make a free body diagram of the vehicle driving up a 20 degree ramp after
having reached its steady-state velocity. Label each force. Write three equations of
equilibrium.

B) (5 points) Estimate the steady-state velocity of the vehicle. Sketch the torque-speed
curve and power-speed curve of the servos and indicate on these curves the shaft
speed attained when climbing steadily up the 20 degree ramp.

C) (5 points) Estimate the smallest coefficient of friction needed between the wheels and
the ramp for which the vehicle will avoid slipping between the wheels and the ramp when
climbing steadily up the 20 degree ramp.

D) (5 points) Is the smallest coefficient of friction attained (from part C) in a front wheel drive
configuration or a rear wheel drive configuration? Explain with a few sentences and/or
sketches.

E) (5 points) Estimate the largest angle at which the vehicle will be able to proceed up the
ramp very slowly, but without stalling. Check that the center of gravity is placed so that
tipping dies not occur before stall.
 Page 2 of 4

2) (25 total) Consider the window glass mechanism shown in the two figures below. The
figure on the left shows shows the mechanism’s pin locations and its disassembled links, and
can be found on the course website in a file named “window08.sldprt”. The figure on the
right shows the assembled components (you’ll have to make this yourself).
A) (10 points) Make a 2D sketch in SolidWorks of the window glass mechanism, i.e.
assemble the links. Once you have a sketch that moves properly, you will find it useful to
apply a virtual work principle to attack part B.
B) (15 points) Estimate the magnitide of a force applied perpenducular to the handle
(labeled below) that would be just sufficient to keep the window glass from falling. You
can assume: 1) the mechanism is in the position shown in the figure below; 2) there is
negligable friction in the joints; and 3) the window glass has a mass of 1kg and that the
mass of the links and gears is small by comparison.

Handle
NOTE: Cars actually used to
require manual cranking to
raise and lower the windows!
 Page 3 of 4
3) (25 points total) You are to create parametric solid models of components for a simple car.

A) (10 points) Create a chassis for the car, consisting of a simple rectangular extrude
feature, 200 mm x 120 mm x 20 mm. There should be two axles, consisting of simple
circular extrude features. The axles should be 7mm in diameter, 15 mm in length,
centered vertically on the side of the chassis, and located 70 mm from the center of the
chassis, as shown in the figure below.

B) (15 points) Create a wheel for the car, consisting of a single revolved feature with the
dimensioned cross-section shown in the figure below.
 Page 4 of 4
4) (25 points total) Create an assembly model of the car, consisting of the chassis and two
wheels.

A) (20 points) For each axle/wheel pair, use 1 concentric mate and 1 coincident mate.
Generate a single figure (using View/Screen Capture/Image Capture) showing the
result.

B) (5 points) Examine the assembly carefully for any interferences. If you find an
interference, make a change to a single dimension to eliminate it. Generate a single
figure (using View/Screen Capture/Image Capture) showing the result.
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 Page 1 of 2
2.007 Design and Manufacturing 1

Homework #3 Pneumatics, CAD, & Gears

NAME:____________________________________________________________

Date Issued: Tuesday 17 MAR, 11AM

Date Due: Tuesday 7 APR, 11AM

Please answer the following 5 questions showing your work to the extent possible within
the allotted time. Point allocations are listed for each question. The points sum to 100.

As described in the course policies document, this is one of four homeworks you will
complete in this course. Each homework counts as 5% of your total grade. You will
submit your work at lecture by hardcopy or via the course web site (and your answers to
question 1 are automatically recorded on the web site we have provided).

1) (25 points) Complete 25 questions on forces and accelerations from the Forces Concept Inventory.

2) (25 total) Get the solid model depicted below on the 2.007 web site (chamber08.sldprt).

A) (15 points) Use Solidworks to make an

engineering drawing of the part. Make a top,
front, and side view and align them. Provide
complete dimensions so that a machinist could
make the part from the drawings alone without the
solid model. Print out your drawing on 8.5”X11”
paper.
B) (10 points) In about one page of words and
graphics, describe the procedures one might use
to make this part on machines in the Papallardo
lab (including mills and lathes). Pay careful
attention to sequence of operations and means
for holding the work in process. Are there any
small design changes that will make the part
much easier to fabricate (assume small quantities
are to be made, say a dozen)?
 Page 2 of 2
3) (25 total) You fill a two liter container with air at 60 psi gauge pressure and plan to use it as a
source of power for a machine.

A) (10 points) How much energy will be required to fill the tank to 60 psi assuming that you
pump the air slowly enough for the reservoir to be at thermal equilibrium (therefore P*V
is constant) with the ambient air at a temperature of 20 degrees Centigrade and 1
atmosphere of pressure?

B) (5 points) What will be the temperature of the air in the tank if we fill the tank assuming
that you pump the air quickly enough so that heat transfer to the surrounding air can be
neglected (therefore P*V1.4 is constant)?

C) (5 points) Estimate the force applied if 60 psi air at 20 degrees C is released into a
piston with a 1 inch internal diameter and a two inch throw?

D) (5 points) How much energy will be released by the air if it is expanded very rapidly to
ambient pressure (1 atmosphere) so that heat transfer to the surrounding air can be
neglected (therefore P*V1.4 is constant)?

4) (25 total) Consider a set of spur gears of 24 pitch and 20o pressure angle and either 12, 24,
or 48 teeth.

A) (10 points) Make a sketch of a of 24 pitch gear with a 1 inch pitch diameter and about a
20o pressure angle. You can use Solidworks and can employ the DXF file on the 2.007
web site (24tooth.dxf) as a starting point.
B) (5 points) A 12 tooth gear is mated with the 48 tooth gear. Make a drawing of the two
gears with their pitch diamters tangent. You can use Solidworks and can employ the
DXF files on the 2.007 web site (12tooth.dxf and 48tooth.dxf) A torque of 1 Nm is
applied to the 12 tooth gear and the 48 tooth gear is prevented from rotating. Estimate
the separation forces between the gears. Indicate on the drawing where the forces are
applied and where a reaction force is generated to maintain the gears in static
equlibrium.
C) Using only 24 pitch gears with 12, 24,

and 48 teeth and ¼ inch face width,

design a compound spur gear train for a

ratio of 32:1 Sketch the train to scale.

(Note: there are many different solutions

possible, you should make design

decisions and explain your rationale.)

D) Imagine the gear train from (part C) is

driven by a servo motor with the

manufacturer’s specifications shown to

Image removed due to copyright restrictions. Please see

the right. Estmate the factor of safety
http://www.hitecrcd.com/product_file/file/66/hs805.pdf
for the gear train assuming the largest

load applied to it will be the stall torque

of the servomotor. You can assume the

gears are molded from Delrin.

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Spring 2009

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 Page 1 of 1
2.007 Design and Manufacturing 1

Homework #4 Pneumatics, CAD, & Gears

Date Issued: Tuesday 30 April, 11AM
Date Due: Wednesday May 13, 5PM

As described in the course policies document, this is one of four homeworks you will
complete in this course. Each homework counts as 5% of your total grade.

The purpose of this homework is to strengthen your

knowledge of the materials covered under exam #2.

You do not have to do this homework at all. If you hand in

nothing, your grade for the assignment will be the same as
your exam #2 grade.

If you decide to do this homework, pick from 1 to 5 topics

on exam #2 that you don’t currently understand fully.
a) Go learn more about that topic. For example, if the exam solution
states that a differential gear on a rear wheel drive vehicle has 2
degrees of freedom, you might be surprised by that or think it sounds
wrong. So you go down to the lab and run some experiments with
the differential there. Then you read some articles on differential
gears. Eventually, you may decide you are comfortable with it.
b) Write about what you did and/or what you learned. In about one
page of text and graphics, explain what you did. Discuss the
relevance of the knowledge to the exam and to machine design more
generally.
c) Attach your work to your exam #2. Place it so that it’s relatively clear
what part of the exam you were addressing.
d) Turn in your work. Place the graded exam #2 (now with extra
material attached) in the bin outside 3-449 marked “HW#4”.
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2.007 Design and Manufacturing I

Spring 2009

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 ͞^ŽůƵƚŝŽŶ͟ƚŽϮ͘ϬϬϳ,ŽŵĞǁŽƌŬηϭ

This ͞solution͟is just a composite of students͛solutions that I considered particularly good.

A nice example of 1A
A strong performance on 1B
A fine job on 1C
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Spring 2009

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 Page 1 of 8
2.007 Design and Manufacturing 1

Homework #2 Servomotors, Mechanisms & CAD

SOLUTION
Date Issued: Tuesday 24 FEB, 11AM
Date Due: Thursday 5 MAR, 11AM

1) (25 total) You’re building a small, electric-powered vehicle to climb up a 20 degree ramp (similar slope as
the ramp into the contest starting box). The vehicle will be operated by two servomotors that can continuously
rotate the output shafts that attach directly to wheels on the left and right sides of the vehicle. The
manufacturer’s specifications indicate each servo is capable of a no load speed of 50 rpm and a stall torque of
0.3 N*m (similar to the specs of the HS-311 standard servos in the kit). The total vehicle weight along with its
payload is 12 N (a little more than the weight of a liter of water). All the wheels have a radius of 6cm. The front
and rear axles are 20cm apart. The center of gravity of the vehicle and payload is halfway between the front
and rear wheels and is 3cm above the surface on which the vehicle runs.

A) (5 points) Make a free body diagram of the vehicle driving up a 20 degree ramp after having reached
its steady-state velocity. Label each force. Write three equations of equilibrium.

Fnormal_front

Fnormal_rear Ffriction_front will be

zero if we assume
rear-wheel-drive and
It’s a good idea to so this front wheel
sum forces about Ffriction_rear rotates freely on a
Weight= bearing
this point to
minimize the
12N
number of terms in
the equation.

Three Equations of Equilibrium (assuming x is chosen along the direction parallel to the table)
Sum forces in the x direction Ffriction_rear  Weight  sin ( 20 degrees ) 0

Sum forces in the y direction Fnormal_rear  Fnormal_front  Weight  cos ( 20 degrees ) 0

Sum moments about rear contact point 20 cm Fnormal_front  ( 10 cm  3 cm sin ( 20 degrees ) )  Weight 0
 Page 2 of 8

B) (5 points) Estimate the steady-state velocity of the vehicle. Sketch the torque-speed curve and power-
speed curve of the servos and indicate on these curves the shaft speed attained when climbing steadily
up the 20 degree ramp.

Ramp_ang  20 deg Stall_torque  0.3N

 m

rev These are some given values

No_load_speed  50 Weight  12N from the problem statement
min
Rwheel  6 cm

Stall_torque
 ( )  Stall_torque   This is just a linear function that fits the two points we know from the
No_load_speed servo specifications.

Pservo ( )   ( )   This is straight from the defition of power.

rev
  01  No_load_speed This defines a range over which to plot the curves.
min

This torque value required from the servos comes This speed of the car would result if there is no slip

straight from summing forces along the direction between the wheel and the ramp.

parallel to the ramp.

speed car ( )  6 cm 

Power is speed of the car times the component of force

Weight  Rwheel  sin ( Ramp_ang) parallel to the velocity vector.
 req ( Weight ) 
2 Pcar (  Weight )  speed car ( )  Weight  sin ( Ramp_ang )

If the weight is 12 N, then here is the result.

0.3 0.8
Shaft Power (Watts)
Torque (N*m)

0.2 0.6

0.4
0.1

0.2
0
0 10 20 30 40 50
0
Shaft Sp eed (rpm) 0 10 20 30 40 50

Servo performance Shaft Sp eed (rpm)

Requirement of car Servo performance
Operating point Requirement of car
Operating point
rad
guess  0
sec
   guess  3.087s
1
ss  root   req ( 12 N)   guess

rev
ss  29.479
Vss  Rwheel  ss m min
Vss  0.185
s
 Page 3 of 8

If the weight is 6 N, then there is a different result with a

slightly higher speed.

0.3 0.4

Shaft Power (Watts)

Torque (N*m)

0.2 0.3

0.2
0.1

0.1
0
0 10 20 30 40 50
0
Shaft Sp eed (rpm) 0 10 20 30 40 50

Servo performance Shaft Sp eed (rpm)

Requirement of car Servo performance
Operating point Requirement of car
Operating point
rad
guess  0
   guess  4.161s
sec 1
ss  root   req ( 6 N)   guess rev
 ss  39.739
Vss  Rwheel  ss min
m
Vss  0.25
s

If the weight is 60 N, then the weight actually drives the vehicle down the
ramp with the wheels spinning backwards and mechanical power of the
servomotor being negative.   60
rev
59
rev
 No_load_speed
min min

0.8 4
Shaft Power (Watts)
Torque (N*m)

0.6
2
0.4
0
0.2
2
0

 0.2 4
 50 0 50
6
Shaft Sp eed (rpm)  50 0 50

Servo performance Shaft Sp eed (rpm)

Requirement of car Servo performance
Operating point Requirement of car
Operating point

rad
guess  0
   guess  5.509s
1
ss  root   req ( 60 N)   guess
sec  rev
ss  52.606
min
Vss  Rwheel  ss m
Vss  0.331
s
 Page 4 of 8

C) (5 points) Estimate the smallest coefficient of friction needed between the wheels and the ramp for
which the vehicle will avoid slipping between the wheels and the ramp when climbing steadily up the 20
degree ramp.

Normal force on the front wheel (from sum of moments)

( 10 cm  3 cm sin( 20 deg ) )  Weight

Fnormal_front   2.692N
20 cm

Normal force on the rear wheel (from sum of forces in the y direction)

Fnormal_rear  Fnormal_front  Weight  cos ( 20 deg )  2.946N

Required frictional force on the rear wheel (from sum of forces in the x direction)

Ffriction_rear  Weight  sin ( 20 deg )  2.052N

Ffriction_rear
 
Fnormal_rear   0.697

Required frictional coefficient if we used front wheel drive

Ffriction_rear
 
Fnormal_front   0.762

Rear wheel drive is somewhat better for climbing hills without slipping.

NOTE: This answer is not affected by the weight of the vehicle that you assumed. In a Coulombic
model of friction, the frictional force is proportional to the normal force, so the ratios are not a function
of weight. Reality is a little different.

D) (5 points) Is the smallest coefficient of friction attained (from part C) in a front wheel drive configuration
or a rear wheel drive configuration? Explain with a few sentences and/or sketches.

As seen in the calculations for part C. The required friction coefficient is lower if we assume rear wheel drive
rather than front wheel drive. This is due to the shifting of weight from the frnt wheels to the rear wheels with
increasing slope of the hill. This effect is mild in this vehicle because the center of gravity is so close to the
surface. The effect would be more pronounced if the c.g. were higher. The effect will be extreme in any case
when the vehicle is on the verge of tipping aftward and therefore all the weight is on the rear wheels.
 Page 5 of 8

E) (5 points) Estimate the largest angle at which the vehicle will be able to proceed up the ramp very
slowly, but without stalling. Check that the center of gravity is placed so that tipping does not occur
before stall.

Stall_torque  0.3N
 m

max_angle  asin 
2 Stall_torque
  56.443deg
 12 N  Rwheel 

This answer is for an assumed weight of 12N.

max_angle  asin 
2 Stall_torque
If you assumed a weight of 60N, you’d find:   9.594deg

 60 N  Rwheel 

If you assumed a weight of 6N, you’d find that even at a 90 degree incline, the torque demanded of the servos
is less than the stall torque. The vehicle could climb straight up as long as the wheels could somehow have
adequate traction. This could be done by having the wheels ride up on a length of string that wraps around the
wheels and is laid out along the path ahead.
 Page 6 of 8

2) (25 total) Consider the window glass mechanism shown in the two figures below. The figure on the left
shows shows the mechanism’s pin locations and its disassembled links, and can be found on the course
website in a file named “WindowMechanism”. The figure on the right shows the assembled components (you’ll
have to make this yourself).

A) (10 points) Make a 2D sketch in SolidWorks of the window glass mechanism, i.e. assemble the links.
Once you have a sketch that moves properly, you will find it useful to apply a virtual work principle to
attack part B.

The assembled mechanism is shown below with some notes:

Point and line made

Two points made coincident coincident

Point made fixed

Two points made coincident

Traction
between
two
circles
 Page 7 of 8

B) (15 points) Estimate the magnitide of a force applied perpenducular to the handle (labeled below) that
would be just sufficient to keep the window glass from falling. You can assume: 1) the mechanism is in
the position shown in the figure below; 2) there is negligable friction in the joints; and 3) the window
glass has a mass of 1kg and that the mass of the links and gears is small by comparison.

Initial Position with Reference Measurements:

Note: Without loss of generality, the handle has been chosen to be in the horizontal position at the starting
configuration to facilitate small displacement measurements.
 Page 8 of 8
Final Position:

Using Small Angular Displacement:

(Note: measured handle length from center is 20.4mm)

 4.29 
Fy y   handle handle  (9.8 N )(0.001m)   handle     handle  0.131Nm
 180 
 handle
Fhandle   6.42 N
0.0204m

Using Small Linear (Tangential) Displacement:

Fy y  Fhandlexhandle  (9.8 N )(0.001m)  Fhandle(0.011447m  0.0009917m)

Fhandle  6.41N
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 2.007 Design and Manufacturing 1

Homework #3 Pneumatics, CAD, & Gears

SOLUTIONS

1) (25 points)

Note from Professor Frey:

The questions on the survey are taken from a body of test material in physics known as
the Force Concept Inventory. In order to preserve the value of the test for future
administrations of the same test, I can’t distribute detailed solutions to the Force Concept
Inventory. Suffice it to say, the questions are all based on Newton’s three laws of
motion.

First Law: A body persists its state of rest or of uniform motion unless acted upon by an
external unbalanced force.

Second Law: Observed from an inertial reference frame, the net force on a particle of
constant mass is proportional to the time rate of change of its linear momentum: F =
d(mv)/dt. This law is often stated as, "Force equals mass times acceleration (F = ma)."

Third Law: Whenever a particle or body exerts a force on another particle or body, that
second body simultaneously exerts a force the other body with the same magnitude in the
opposite direction. "To every action there is an equal and opposite reaction.”

2)

a)

See attached drawing. Making a good engineering drawing takes a lot of time and
attention to detail. It’s not as simple as putting in dimensions, although as a first criterion
the drawing must have all the dimensions required to create the part. Even a single
missing or ambiguous dimension will put your part on hold in the shop.

There are also conventions and good practices which were introduced during the CAD
lectures. Some common mistakes based on a random sampling of submissions:

 Use third angle projection, align views, and show hidden lines in all three views.
 Don’t put dimensions inside the part. Use extensions to bring all dimensions to
the outside of the views. If necessary, reduce the scale of the drawing to leave
more room for dimensions.
 Clearly indicate center lines and center marks for holes. Assumptions of
symmetry can only be made if the centerlines are clearly marked.
 Don’t forget to dimension fillet radii and centers. This is usually more useful than
dimensioning the length of tangent lines between fillets.
 Use the views to your advantage. Don’t load all the dimensions into a single view.
Use a scheme that makes sense, such as dimensioning all the features to be milled
in the front view. Keep the machining process in mind.
 Indicate critical dimensions. The distance between two holes might be more
important than the distance between one hole and the edge of the part. Leave non­
critical dimensions to be “driven.” This requires you to know the functionality of
the part, of course.
b)

There are obviously many good answers to this part. The consensus seemed to be that
there were both milling and turning/facing operations required. The order in which you
do these operations is important. The “favorite” order of operations was:

1. Turn and face, drill, and bore (in that order) the cylindrical stock into a shape
looking roughly like this (half section view):

Which actually requires you to flip the piece in the lathe to get access to both
sides.
2. Mill the two-dimensional details of the flanges, including the holes. This also
requires you to flip the part once in the mill to get access to both flanges. The
fillets can be programmed into a CNC mill.
3. Drill the two small 1mm cross-holes. This will be hard since you are drilling into
a curved surface. Need to use a stiff center drill first, as a few people correctly
noted.

Variations on this including starting with rectangular stock and drilling the cross-holes
first, a solution that I think makes sense, or doing things in a slightly different order.
Milling the large bore was another common choice, although you would have to describe
a good centering procedure.

The other common solution, which some listed as an improvement option, was to make
this out of several parts:
 and

The procedure includes milling the flat pieces and turning/facing/drilling/boring the
cylindrical piece, then assembling them by various means. Cutting the flat pieces on the
water jet is an option, but you will have some taper on the edges.

Solutions which have the two small flanges integrated into a single rectangular piece
which fits into rectangular holes in the main cylinder will lose some credit: You can’t
easily make the rectangular holes and this does not exactly correspond to the model.

Ways to improve the part or fabrication were equally varied. Simplifying the geometries,
separating the parts, using rapid-prototyping capabilities are all good ideas. Credit given
for most reasonable proposals!
3)

Credit goes to Michael Roberts and Rachel Batzer for the basics of this solution. Most
were close on this, maybe not accounting for work done by/on the atmosphere or not
using gauge pressure appropriately. Substantial partial credit will be given in most cases.

a)

P1  Patm  1.0110 5 Pa
P2  60 psig  (4.14  1.01) 10 5 Pa  5.15 10 5 Pa
V2  2L  0.002m 3
P2V2
V1   10.2L  0.0102m
3
P1

Integral of gauge pressure has two parts: work done total and work done by atmosphere.
The net is the work we need to do to compress the gas.

PV   Patm   dV
V2
W 
V1

1
V2 V2
W  P1V1   dV   Patm  dV
V1 V V1

W  P1V1 ln V V12  Patm V V12

V V

V 
W  P1V1 ln 2   Patm V2  V1 

 V1 

W  1678J  828J  850J

b)

To find the new initial volume:

PV 1.4  K
1
 P2V21.4  1.4
 V1   
 P1 
V1  6.4L

The ideal gas law still holds:

PV  mRT
PV PV
 1 1
 2 2
T1 T2
P2V2
 T2  T1
P1V1
T2  467K  194º C

c)

F  PA  60 psig  (0.5in)

2
F  47lbf  209N

Assuming the pressure drop due to expansion is negligible and steady-state (no losses in

tubing/valves). Slightly lower if an adiabatic or isothermal expansion is assumed.

d)

Same procedure as part a but with a different function for P(V):

P2  Patm  1.0110 5 Pa
P1  60 psig  (4.14  1.01) 10 5 Pa  5.15 10 5 Pa
V1  2L  0.002m 3
1
 P V 1.4  1.4
V2   1 1   6.4L  0.0064m 3
 P2 

Integral of gauge pressure has two parts: work done total and work done on the
atmosphere. The net is the work useful work done by the expanding gas.
 PV   Patm  
dV
V2
W 
V1

V2 1 V
2
1 1 
W  PV   V1 Patm
 dV
1.4
dV
V1 V
1.4
V
 1 0,4 
2

 Patm V
V12

V
W  P1V11.4  V 
 0.4  V
1

W 
P1V11.4
0.4
0.4
V2  V10.4

 Patm V2  V1 

W  958J  445J  513J

This shows the relevant integral components for both 3a and 3d. The adiabatic curve does
less work than the isothermal curve puts in, as expected. The efficiency in this case is
about 60%.
4)

a)

Here is the construction of a single gear tooth:

If you showed this construction, using arc lengths to generate the shape from the base
circle, either in SolidWorks or by hand, that was worth full credit. Simple extruding the
provided drawing into a 3D part was not the intent of part a), but given the server issues
substantial credit will be given for just about anything that looks like a 24-tooth gear.

b)

Here, use of the available drawings is perfectly acceptable. For example:

The true force between the gears acts along the pressure line. The tangential force is one
component of this true force. The separation force is the other component. Then, the
calculation of the separation force goes like:

 1Nm
Fsep  Ft tan( )  tan( )  tan(20º )  57N
r12 0.00635m

c)

This can be done with a compound gear train. The most direct solution is 12:48, 12:48,
and either 12:24 or 24:48. Just a couple examples:
The latter is probably easier to build since all the gears can be supported by bearings on
both sides. (The final output gear of the former cannot.) There are obviously many more
ways of arranging this.

d)

Again, there are many ways of approaching this problem. The web tool, SolidWorks, or
simple beam bending equations can all get to a good estimate. The steps involved are:

1. Determine the force on each gear in your specific gear train solution from part c).
The forces will generally increase with each compound gear set, so the output
gear will probably see the highest force.
2. Since the pitch is the same for all gears, the shape of the teeth will be roughly the
same. It might make sense, then, to analyze the stress on the last stage of the gear
train. It will see 32 times the stall torque, or just about 2Nm. If it is a 48-tooth
gear, that will act at a radius of 1in or 0.0254m. This gives a force of 78N.
Applying this load in COSMOS to a Delrin-like material:

This is just a very rough approximation, since the load won’t be evenly distributed
and SolidWorks doesn’t even have a Delrin model. But it shows a maximum
stress of 92MPa at the tooth base. This is greater than the yield stress of Delrin.
The factor of safety in this case would be below one, meaning the gear is likely to
fail. Your exact calculation will depend on your gear train design, but many
would likely fail under the stall torque of the servo.