Question: help PROBLEM 5 [ 2 0 MARKS ] At a prominent bearing manufacturing facility in the Malaysia - China Kuantan Industrial Park ( MCKIP )

help PROBLEM 5[20 MARKS]
At a prominent bearing manufacturing facility in the Malaysia-China Kuantan Industrial Park (MCKIP), a unique design challenge has emerged for a newly recruited design engineer, a recent graduate from Universiti Malaysia Pahang. The task involves designing a critical bearing component for a specialized gearbox application, targeting Malaysia's growing automotive manufacturing sector. This project aligns with Malaysia's National Automotive Policy (NAP)2020, which aims to enhance local technological capabilities and strengthen the domestic automotive supply chain. The design specifications require a bearing solution for a stepped shaft rotating at (350 plus the last two digits of your student ID) revolutions per minute. The operating conditions are particularly demanding, with the inner ring bearing combined radial and axial loads of (5.5 kN plus the last digit of your student ID) and 2.5 kN , respectively. These load requirements reflect the robust performance demands of modern automotive applications in Southeast Asian markets, where vehicles must withstand diverse driving conditions from urban highways to rural terrains. The bearing must demonstrate exceptional durability, with an operational schedule of 8 hours daily, 5 days per week, extending over a 6-year lifespan. This longevity requirement aligns with Malaysia's automotive industry standards and the growing emphasis on reliability in ASEAN markets. The design specifications mandate a highreliability factor of \(99\%\) for the bearing ensemble, reflecting the industry's commitment to quality and safety standards. The design process involves a comprehensive analysis of equivalent radial loads and rating life calculations, incorporating a load application factor of 1.1 to account for real-world operating conditions in Malaysia's tropical climate. The engineer must evaluate two primary bearing options: single-row 2-series angular-contact bearings and cylindrical roller bearings, considering load capacity, speed capability, and thermal performance in local environmental conditions. A critical decision point emerges when the senior manager, drawing from extensive experience in Malaysia's automotive sector, directs the consideration of a single-row 02-series ball bearing with identical bore diameter to the cylindrical roller bearing. The final design selection must adhere to International Organization for Standardization (ISO) standards while meeting the specific needs of Malaysian automotive manufacturers. The engineer must provide a detailed reliability analysis to justify the selected bearing's suitability for achieving the \(99\%\) reliability target. This analysis should consider local operating conditions, including temperature variations, humidity levels, and typical usage patterns in Southeast Asian markets.
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