MachineComponentDesignI

(INME4011)
by
PabloG.CaceresValencia
(B.Sc.,Ph.D.U.K.)
GENERALINFORMATION
CourseNumber INME4011
CourseTitle MachineComponentDesignI
CreditHours 3
Instructor Dr.PabloG.CaceresValencia
Office Luccetti L212PhoneExt.2358
OfficeHours TuTh from7:30to10:45am
email pcaceres@me.uprm.edu
Website http://academic.uprm.edu/pcaceres
Assessment
Thecoursewillbeassessedinthefollowingmanner:
1
st
PartialExam 22%
2
nd
PartialExam 24%
Project 22%
Quizzes 24%(*)
ClassParticipationandAttendance 8%(**)
(*)DatedueMoodle QuizzesandPopQuizzes(max8).Missedquizzeswill
begradedwithzero.LackofaccesstoInternet(Moodle)isnotanexcusefor
notsubmittingyouranswers.
(**)ClassparticipationandAttendance.Afterthethirdmissedclass,one
pointwillbedeductedinthefinalgradeforeachmissedclass(upto8
points).
Grades
FinalGradeRange FinalLetterGrade
100 90 A
89 80 B
79 70 C
69 60 D
59 0 F
Attendance
Attendanceandparticipationinthelecturearecompulsory andwill
beconsideredinthegrading.Studentsshouldbringcalculators,
rulers,penandpencilstobeusedduringthelectures.Studentsare
expectedtokeepupwiththeassignedreadingandbepreparedto
solveproblemsinclassandforthepopquizzes.Pleaserefertothe
BulletinofInformationforUndergraduateStudiesforthe
DepartmentandCampusPolicies.
Texbooks
Mylecturenotesareavailableinthewebat
http://academic.uprm.edu/pcaceres
FundamentalsofMachineElements B.J.Hamrock,S.R.Schmid,B.Jacobson
MachineDesign:AnIntegratedApproach RobertNorton,3erEd.PrenticeHall
MechanicalEngineeringDesign J.E.Shigley,C.R.Mischke,R.G.Budynas.
Exams
Allexamswillbeconductedoutsidelectureperiodsonthespecified
dates.Thefinalprojectduedateisthedatefortheendofclasses.
Therewillbenofinalexam.
Neatnessandorderwillbetakingintoconsiderationinthegradingof
theexams.Uptotenpointscanbedeductedforthelackofneatness
andorder.Youmustbringcalculators,classnotesandblankpagesto
theexams.
TENTATIVESDATES
Week Week
09/13 IntroductiontoDesign,ReviewLoad,
Stress,Strain.
09/20
10/04
10/18
11/01
11/08 MaterialsandManufacturing
Q4
11/15 MaterialsSelection/Fracture
Toughness
12/20 FinalProjectPresentation
ClassesEnd
12/27 FinalProjectPresentation
ClassesEnd GRADES
11/29
12/13
ReviewLoad,Stress,Strain.
Q1
09/27 BasicElasticity BasicElasticity.
Q2
10/11 3DStressesandStrains StressConcentration.
Q3
10/25 StaticFailureTheories
Exam1
MidTermProjectPresentation
11/22 FractureToughness
Q5
FailurePredictionCyclic&Impact
12/06 FailurePredictionCyclic&Impact
Q6
FailurePredictionCyclic&Impact
Q7Exam2
01/10
Outcomes
Uponthecompletionofthecoursethestudentshouldbeableto:
Calculatetheprincipalstressesandstrainsinaloaded
component
Identifythelocationofthecriticalpointonamachine
componentandcalculatethestressesatthatpoint.
Applythebasicstatictheoriesoffailureinthedesigningof
machinessubjectedtostaticloading.
Applythebasicfatiguefailuretheoriesinthedesigningof
machinesubjectedtodynamicloading
Evolution of Engineering
Research & Education
1910
1960
2010
Sputnik
Quantum
Mechanics
Information
Technology
Nano-Bio-Info
Tables, formulae, etc.
If it moves, its Mechanical,
if it doesnt move, its Civil,
and If you cant see it, its Electrical
The era of science-based
engineering
We are entering an era of
integrated science &
engineering, during which
the boundaries of the
disciplines will grow
increasingly indistinct
Engineering disciplines
Engineering disciplines
Sciences
Engineering
Science
?
Taken from Tim Sands, Prof. UC. Berkeley
This approach is driven by the understanding that ME is
founded in and perpetuated through the innovation and
creation of products and therefore ME students should be
able to apply learned concepts and make real-world
connections.
Product Realization in Mechanical Engineering
The key to 21st century competitive advantage will be the
development of products with increasing levels of functionality.
Smart Materials will play a critical role in this development, where
we define these as materials that form part of a smart structural
system that has the capability to sense its environment and the
effects thereof and, if truly smart, to respond to that external
stimulus via an active control mechanism.
Smart Materials for the 21st century a publication of the Institute of Materials, Minerals
and Mining (IOM3) http://www.iom3.org/foresight/Smart%20materials%20web.pdf
Design
Transformation of concepts and ideas into useful machinery.
Machine
Combination of mechanisms and other components that
transforms, transmit or uses energy, load or motion for a specific
purpose
Design of Machine Component
Fundamental practice in engineering.
Code of Ethics for Engineers (ASME 1997)
Engineers shall hold paramount the safety, health and welfare of
the public in the performance of their professional duties
Product Scope and Characteristics
http://www.prz.tu-berlin.de/~www-kt/lehre/hs/ed/dokumente_ed_vl/2005,WS,ED,VL-01.Termin,Vortrag.pdf
Design
A design must be:
Functional- fill a need or customer expectation
Safe- not hazardous to users or bystanders
Reliable- conditional probability that product will perform
its intended function without failure to a certain age.
Competitive- contender in the market
Usable- accommodates human size and strength
Manufacturable- minimal number of parts and suitable for
production
Marketable- product can be sold and serviced
Effects of Manufacturing and Assembly
Design of a Reciprocating Power Saw: Effects on Manufacturing and
Assembly
(1) Original Design: 41 parts, assembly time: 6:37min.
(2) Modified Design: 29 parts, assembly time: 2:58min. (Boothroyd 1992)
Approaches to
Product
Development
(a) Over-The-Wall Engineering
Approach (from Kalpakjian
[1997]).
(b) Concurrent Engineering
Approach (adapted from Pugh
[1996]).
Over-the-Wall (OTW)
One designer applies his/her particular skill and send it OTW to the
next step in development. If a problem is discovered, for example
in manufacturing, the product is send back to be redesigned.
The design is sent to
The design is sent to
the manufacturer
the manufacturer
In manufacturing:
an Engineer must first design something.
an Engineer must first design something.
The design phase
The design phase
For every design there
For every design there
is eventually a
is eventually a
manufacturing phase
manufacturing phase
Design
Manufacture
In practice, the design may well be impossible to manufacture.
In practice, the design may well be impossible to manufacture.
Concurrent Engineering Approach
Philosophy of involving many disciplines from the beginning of a
design effort and keeping them involved throughout product
development.
Design is a multidisciplinary endeavor
Boeing 747 being
manufactured in
Seattle
Examples of
Examples of
manufacturing
manufacturing
Boeing 777
One of the first examples of Concurrent Engineering
Design Methodology: what engineers do
Define the function
component to carry a load
Material Selection
Component Design
Tentative component design
Approximate stress analysis
Tentative choice of material
Assemble Materials Data
Analysis of Materials Performance
iterate
from Ashby and Jones; Engineering Materials 2
Detailed Specifications and Design
Choice of Production Methods
Prototype Testing
Establish Production
Further Development
iterate
iterate
iterate
Example: A Cantilever
This Cantilever Stand is intended for moderate to heavy-duty use
with either the Frontier III or Glas-Hide Boards in certain lengths on
residential pools. There are no unusual climatic restrictions for this
stand's use.
Look at the Engineering Science of this design scheme:
Define the function
component to carry a load
Material Selection
Component Design
Tentative component design
Approximate stress analysis
Tentative choice of material
Assemble Materials Data
End Load
Uniform Distribution
End Moment
Intermediate Load
Triangular Distribution
Choose materials for components from
metals, ceramics, plastics, composites?
Assemble Materials Data?
Cost, density, elastic properties, yield
stress, hardness, tensile stress, strength
to weight ratio, ductility, fracture
toughness, fatigue stress, thermal
expansion coefficient, thermal
conditioning, specific heat, thermal
shock resistance, creep,
oxidation/corrosion rates
Codes and Standards
Code- a set of specifications for the analysis, design, manufacture,
and construction of something
Standard- a set of specifications for parts, materials, or processes
intended to achieve uniformity, efficiency, and a specified quality
Product Liability
Strict liability concept prevails in the U.S.
Manufacturers are liable for any damage or harm that
results from a defect.
Organizations
Aluminum Association (AA)
American Gear Manufacturers
Association (AGMA)
American Institute of Steel
Construction (AISC)
American Iron and Steel Institute
(AISI)
American National Standards
Institute (ANSI)
American Society for Metals
(ASM)
American Society of Mechanical
Engineers (ASME)
American Society of Testing
Materials (ASTM)
American Welding Society (AWS)
American Bearing Manufacturers
Association (ABMA)
British Standards Institute (BSI)
Industrial Fasteners Institute (IFI)
Institution of Mechanical
Engineers (I. Mech. E.)
International Bureau of Weights
and Measures (BIPM)
International Standards
Organization (ISO)
National Institute for Standards
and Technology (NIST)
Society of Automotive Engineers
(SAE)
American Society of Agricultural
and Biological Engineers
(ASABE)
Design Philosophy
Also check deflection!!
Also check deflection!!
Design
If the load is known and
the geometry is specified,
determine the material and
the safety factor.
If the load is known and
the material is specified,
determine the safety factor
and the geometry
(dimensions).
Analysis
If the load is known
and the material and
geometry are specified,
determine the safety
factor Is it safe??
Critical Section
The critical section is the location in the design where the largest
internal stress is developed and failure is most likely.
In general, the critical section will often occur at locations of
geometric non-uniformity, such as where a shaft changes its
diameter along a fillet.
Safety Factors
N = 1.25 to 2.0 Static loading, high level of confidence in all design
data
N = 2.0 to 2.5 Dynamic loading, average confidence in all design
data
N = 2.5 to 4.0 Static or dynamic with uncertainty about loads,
material properties, complex stress state, etc
N = 4.0 or higher Above + desire to provide extra safety
FOR DUCTILE MATERIALS:
Uncertainty
Stochastic Design Factor Method- uncertainty in stress
and strength is quantified for linearly proportional
loads
Stress Average
Strength Average
= =

s
n
d
Measures of
Strength
S Strength
S
s
Shear Strength
S
y
Yield Strength
S
u
Ultimate Strength
- Mean Strength
S
Measures of Stress
Shear Stress
Normal Stress

1
Principal Stress

y
Stress in y-direction

r
Radial Stress

t
Tangential Stress
Stress Allowable (AISC)
Tension: 0.45 S
y

all
0.60 S
y
Shear:
all
= 0.40 S
y
Bending: 0.60 S
y

all
0.75 S
y
Bearing:
all
= 0.90 S
y
SUGGESTED SAFETY (DESIGN) FACTORS FOR ELEMENTARY WORK
based on yield strength - according to Juvinall & Marshek op cit.
1.25 - 1.5 for exceptionally reliable materials used under controllable
conditions and subjected to loads and stresses that can be determined
with certainty - used almost invariably where low weight is a
particularly important consideration
1.5 - 2 for well-known materials under reasonably constant
environmental conditions, subjected to loads and stresses that can be
determined readily.
2 - 2.5 for average materials operated in ordinary environments and
subjected to loads and stresses that can be determined.
2.5 - 3 for less tried materials or for brittle materials under average
conditions of environment, load and stress.
3 - 4 for untried materials used under average conditions of
environment, load and stress. It should also be used with better-
known materials that are to be used in uncertain environments or
subject to uncertain stresses.
Repeated Cyclic loads : the factors established above are acceptable
but must be applied to the endurance limit (ie. a fatigue strength )
rather than to the yield strength of the material.
Impact forces : the factors given above are acceptable, but an impact
factor (the above dynamic magnification factor ) should be
included.
Brittle materials : the
ultimate strength is
used as the theoretical
maximum, the factors
presented above should
be doubled.
Where higher factors
might appear desirable,
a more thorough
analysis of the problem
should be undertaken
before deciding on
their use.
Need to take into account
the statistical nature of
materials properties