DMC Spring 2015

Project Presentation

Clutch

What is a clutch?
A mechanical device that
engages and disengages
the power transmission
Used whenever the
transmission of power or
motion must be controlled
either in amount or over
time
In the simplest application,
they connect and
disconnect 2 rotating shaft
The motions involved are
rotary, linear clutches are
also possible

Types Of Clutches
Friction clutch
Contact made by two discs - made
of
metals
Positive drive clutch
Friction Clutch
Consists of two mating surfaces
with interconnecting elements, such as
teeth, that lock together during
engagement to prevent slipping
Centrifugal clutch
Used where speed of the engine
defines the state of the clutch
Centrifugal
Clutch

Mechanism Of a Clutch

Clutch is engaged when pedal is released, meaning

both rotating shafts are locked together and spin at
same speed
Clutch is disengaged when pedal is pressed,
meaning the rotating shafts are unlocked and spin at
different speeds

Major Types of Clutches by its

Application
Vehicular (general)
These are the different designs of clutches used
in vehicles.
They are based on one or more friction discs
pressed tightly together or against a flywheel using
springs.
Automobile Powertrain
In modern car with manual transmission operated by the left-most pedal using hydraulic or
cable
connection.

Automobile
powertrain

Major Types of Clutches by its

pplication (conti..)
Motorcycles
Wet clutch - riding in the same oil as
transmission - made of stack of alternating plain
steel and friction plates
Automobile non-powertrain
Use clutches in the places other than the drive
plain
driving and driven members are separated
by a silicone based fluid and a valve controlled by
a bimetallic spring

Motorcycle Clutch

Other Clutches and Applications

Friction
Clutch:
Belt Clutch

Used on agricultural equipment, lawn mowers, tillers,

and snow blowers
Dog Clutch
Used in the automobile manual transmissions
mentioned
Hydraulic Clutch
The driving and driven members are not in physical
contact

Belt Clutch

Dog Clutch

Other Clutches and Applications

(cont..)
Electromagnetic Clutch
Engaged by electromagnet
Over Running or Free Wheel Clutch
External force rotates the driven member faster
than the driver, the clutch effectively disengages
Wrap - Spring Clutches
These have a helical spring typically wound with
square cross section wire

Electromagnetic Clutch

Free Wheel Clutch

Wrap-Spring

References
http://en.wikipedia.org/wiki/Clutch
http://www.designworldonline.com/low-cost-load-control-with
-clutches-and-brakes/
http://www.gmnbt.com/free-wheel-clutches.htm
http://engineeringhindustan.tradeindia.com/stationary-fieldtype-electromagnetic-clutches-293730.html
http://www.custom-sportbike-parts.com/parts/hand-controls-hy
draulic-clutch/
http://en.wikipedia.org/wiki/Manual_transmission
http://www.obups.com/AC120/clutches.htm
http://www.motorcyclejazz.com/clutch.htm
http://www.wisegeek.com/what-is-a-powertrain.htm
http://www.google.com/search?biw=1366&bih=667&noj=1
&tbm=isch&q=car+clutches&revid=1506666678&sa=X&ei=NExVeGfHcOwsASbuoDYCg&ved=0CCUQ1QIoAg

Thank you
Have a Wonderful Summer Break
Team Clutch

Samantha Heller
Hunter Lankowski
Jason Kim
Alan Nortey
Matthew Tubman
Xiao Le Zheng

THE BASICS
A Spring is any elastic object that:
Exerts forces and torques
Absorbs energy that is later released

They are usually Metal

[1
]

TYPES OF SPRINGS
Torsion Bar Spring:

Helical Spring: A torsion bar wound into a

helix
Spring Index:

[2
]

DESIGNING THE
SPRING CONSTANT
Hookes Law: F = kx,
where: x is the deflection
k is the spring constant

TORSION BARS
Equations:
Torsional Stress:

Angular Deflection:

Effects of Curvature:
Static Loading:

Hookes Law:
Where K is the spring
constant [Nm]

Cyclic Loading:

COILS AND
DIFFERENT ENDS
Active Turns = N
Total Turns = Nt
Nt = N + 2
(+2)
accounts
for each
end of the
spring

The different ends of

springs:

DIFFERENT SHAPES
OF SPRINGS

APPLICATIONS OF
SPRINGS
Cars and Bikes
Po-Go Sticks and Toys
Pens and Mechanical
Pencils
Garage Doors
Staplers
Watches
Trampolines
Beds
And so much more

[3
]
[4
]

REFERENCES
[1] http://
hyperphysics.phy-astr.gsu.edu/hbase/permot2.html
[2] http://www.fea-optimization.com/ETBX/spring_help.html
[3] http://toys.lovetoknow.com/History_of_the_Pogo_Stick
[4] http://
leftbraincraftbrain.com/2015/03/10/10-ways-to-play-and-lea
rn-with-springs/
All other photos and information is from:
Juvinall, Robert C., and Kurt M. Marshek. "Chapter 12:
Springs."Fundamentals of Machine Component Design. 5th
ed. New Jsersey: John Wiley & Sons, 2006. 497-530. Print.

OUR VIDEO

DMC Project:
Threaded Fasteners
by
Eric Hernandez
Jordan Rafalko
Edgard Jimenez

Faizan Ahmed
Angelo Gulo
Andrew Spano

Topics

Definitions and Standard Geometry

Threads and Sizes
Types of Fasteners
Common Screw and Bolt Head Types
Power Screws
Efficiency
Overhauling and Self-Locking

Types of Fasteners

Power Screws
convert rotary motion of either the nut or the
screw to relatively slow linear motion of the
mating member along the screw axis
aka linear actuators or translation screws

Efficiency
Efficiency = work output/work input
= (force*distance)/(2*pi*torque)

Conclusions from plot

Efficiency decreases with increasing
coefficient of friction
Efficiency approaches zero as lead angle
approaches zero
Efficiency approaches zero as lead angle
approaches 90 degrees

Overhauling and Self-locking

Self-locking screws require a positive torque to lower a load
Overhauling screws require that a negative external lowering torque must be
maintained to keep a load from lowering due to the low friction
If collar friction is neglected a screw is self locking if
A screw may be self-locking under static conditions, but it may overhaul during
vibration

References
Juvinall, Robert C., and Kurt M. Marshek. Machine Component Design.
Singapore: J. Wiley & Sons, 2012. Print.
http://en.wikipedia.org/wiki/Screw_thread#Pitch_diameter
http://www.accuratescrew.com/TechTips/?TipNO=8

Gears

By: Etebom obot, Mert kahyaoglu, Brandon

Wagner, Eamonn Hennessey, Matt
Sheleheda, Kyle Kourelakos

HISTORY
One of the oldest pieces of equipment. Can
be traced back to the 27th century BC
Used in water wheels and clocks
Used as a force multiplier
Most fundamental part of machinery

Common uses
Vehicles
Trains
Clocks
Bicycles

How gears work

Gears are used in transmitting power from
one part of a machine to another.
Combination of different sized gears are
used for increasing and decreasing speed
Angular velocity ratios are constant as
gears rotate

Load transmission
power is transmitted by force developed
between contact and teeth

Ft Fn cos
Fr Fn sin

2RPM
V d / 2 d *
60
dn
V
12
Tn
hp
63000
33000hp
Ft
V
FV
Tn
KW t
1000 9549

Types of gears
Spur gear

Rack and pinion

Worm gear

Spur gears

Most commonly used gear

Torque is transmitted from pinion to gear

Rack and pinion

Used to convert rotational motion to translation

eg rotating steering wheel to turn

Worm gear

Basically a screw on a gear

One directional in nature. Only worm can turn gear

Design/Manufacturing
Gears are made out of different materials
including cast iron and steel
Combinations of gears with different
materials can be used to attain certain
properties.
Gears made of cast iron are less expensive
and quieter than ones made of steel.

Why do we need gears

very efficient
Motors usually provide power at high
speeds and low torque
Torque provided by motor can be amplified
through larger gears to load.
Without gears it would be impossible to
operate a car or any mechanical device
efficiently.

Brakes
By:
Cynthia Ko, Jonathan Schwalm,
Kolung Chan,Peter Tran,
Trent Handlovsky

What is a Brake?
It is a mechanical device which inhibits
motion, slowing or stopping a moving object.
It depends on friction in order to function.
The main objective is to maximize the
friction coefficient, and keep it uniform over
a wide range of operating conditions, and at
the same time minimize wear.

History of Brakes
In 1902, Frederick
Lanchester patented the
disc brake that helped
make stopping cars
much easier. The first
time it was used was in
his 12 hp Lanchester
motor car in 1903.

Different kinds of Brakes

There are different types of brakes, both between vehicles and within a vehicle. The brakes used to
stop a vehicle while driving are known as service brakes, which are either a disc or drum brake.
Vehicles also come equipped with other braking systems including anti-lock and emergency brakes.

Disc Brakes
Drum Brakes
Emergency Brakes
ABS aka Anti-Lock Braking
System
Air brakes
Engine brakes
Exhaust Brakes
Parking brakes
Regenerative braking
Electric
Hydraulic (experimental)
Aircraft brakes (landing gear disc brakes, thrust reversers, air brakes that work by increasing
drag, and drogue parachutes)

Engine Brakes
Typically used in trucks and other large vehicles
Slow the vehicle by shutting off engine cylinders
Cylinders still move and compress air but they stop
firing and do not provide additional positive energy
The cylinder compression of the shut off cylinders slows
the engine when it pushes the air out the exhaust valve
The brakes are engaged with a switch when needed
This is very loud

Exhaust Brakes

Also works by slowing engine speed

Typically found in large vehicles
Usually connected to turbocharger
Limits exhaust flow to slow down
engine
These are generally quiet but still
mitigate normal brake wear on
vehicles
Ex: similar to taking a deep breath,
closing your mouth most of the way,
and trying to exhale

Regenerative Brakes
Used in vehicles that make use of electric
motors.
When the motor is run in one direction, it
converts electrical energy into mechanical
energy that can be used to perform work.
When the motor is run in the opposite
direction it becomes an electrical generator
converting mechanical energy into
electrical energy.
This electrical energy can then be fed into
a charging system for the cars batteries.

Conclusion
Brakes are an important feature for any kind
of vehicle. They help inhibit motion and
allow us to properly stop vehicles safely.

BEARINGS
Alexander Hobbs, Timothy Beyer, Brian Blaney,
Pierre Pais, Timothy Pearson, Gerome David

WHAT IS A BEARING?
A component with contacting surfaces through
which a load is transmitted
Keeps motion between two parts on the desired
axis and helps to prevent friction and wear
between them
Widely used in machines which involve rotational
motion

Examples

include vehicle gearboxes, bicycle wheels ,

and industrial machinery

Two major types: sliding and rolling element

SLIDING BEARINGS
Direct sliding of the loading on the support
Two types:

Journal

- support perpendicular loads to shaft axis

Thrust - generally flat and support parallel loads to
the shaft axis

Withstand higher temperatures and

contamination better than rolling element
bearings

Examples of sliding bearings

ROLLING ELEMENT BEARINGS

Contain balls or rollers which separate the bearing
and its force member
Sliding friction is replaced with rolling friction

Lower

starting friction, good for large loadings

Can reduce cost by making extensive lubrication
unnecessary in certain applications

Requires shielding of ball bearings to prevent

contamination

IMPORTANT PROPERTIES FOR

BEARING MATERIALS

Important properties
Mechanical

Conformability (low modulus of elasticity)

Indentation softness
Low shear strength
Sufficient fatigue strength for repeated loadings

Thermal

Good heat conductivity

Thermal coefficient of expansion similar to housing

Metallurgical

Compatible with journal material to resist welding, seizing

Chemical

Corrosion resistance

COMMON BEARING MATERIALS

Babbitt
Tin

Base
Lead base

Copper Alloys
Copper

lead
A babbitt bearing
Leaded bronze
Tin bronze
Aluminum bronze

Aluminum
Silver

Copper alloy
bearing

Aluminum bearing
Silver
bearings

PETROFFS EQUATION FOR

BEARING FRICTION
Quick

method of estimating reasonable

coefficients of friction for bearings

Where:

= viscosity
n = rotating speed
P = bearing load
R = shaft radius
c = radial clearance

Linear bearing

BEARING SELECTION

Must take into account loading, lubrication,

operating environment, speed of rotation, cost, and
other factors
Bearing life varies greatly with the intensity of shock
and axial loadings
Individual fatigue life has a skewed Weibull
distribution

WORKS CITED (IMAGES)

"Aluminum Anti-Frction Bearings."Odessa Babbitt Bearing Company. N.p., n.d. Web. 28 Apr. 2015.
<http://www.obbco.com/babbitt-bearings/aluminum-bearings.html>.
"Bearings."LinearBearings.com. N.p., n.d. Web. 28 Apr. 2015. <http://www.linear--bearing.com/CNCBushing-16mm-Linear-Bearing-Open-Sliding-Unit.htm>.
"BL Bearings - Bearings, Chains, Sprockets, Bushings."BL Bearings - Bearings, Chains, Sprockets,
Bushings. N.p., n.d. Web. 28 Apr. 2015. <http://www.bearingslimited.com/>.
"Copper Alloy Bearing Promotion."Alibaba.com. N.p., n.d. Web. 28 Apr. 2015.
<http://www.alibaba.com/copper-alloy-bearing-promotion.html>.
Juvinall, Robert C., and Kurt M. Marshek.Fundamentals of Machine Component Design. 5th ed.
Hoboken, NJ: John Wiley & Sons, 2012. Print.
Repairpal.com. N.p., n.d. Web. 28 Apr. 2015.
<http://repairpal.com/images/managed/content_images/encyclopedia/CM_Steering_Suspension/F
ront_Wheel_Bearing_Set_08.11.png>.
"Silver Bearings."The Silver Institute. N.p., n.d. Web. 28 Apr. 2015.
<https://www.silverinstitute.org/site/silver-in-industry/bearings/>.
"Submarine Main Propulsion Diesels - Chapter 3."Maritime.org. N.p., n.d. Web. 29 Apr. 2015.
<http://maritime.org/doc/fleetsub/diesel/chap3.htm>.

Now for our video.

Rivets and Welding

Muaz Billoo, Martin Mora, Allison Pelszynski,
Mike Czerhoniak, Benjamin Ratzersdorfer

What are Rivets?

Short metal pin or bolt used for holding

together two plates of metal

When placed between two metals, hammers
or rivet guns generally used to fix them
between the metals.

Pros/Cons of Rivets
Stress analysis is the same as that of bolts
Cheaper than screws
High Speed Riveting machines can assemble
1000 rivets/hour
Can be made from any ductile material
Cannot provide an attachment as strong as a

bolt/screw with the same diameter

Simple repair of electric appliances become
difficult

What is Welding?
To join together metal parts by heating their

surfaces to the point of melting

Welding is generally accomplished through
the use of blow torches, or electric arcs.

Pros/Cons of Welding
Literally fusing two metals together to form a

single, homogeneous member

With rivets, if the rivet fails then the metals will

have nothing to hold them together

Either electric or gas powered

Riveting can be done with hammer
If one is not skilled in welding, they will leave

really bad trails on the metals

Release of bright lights can damage a
persons vision

Impact
Robert Napoleon
Charlene Vance
Nolan Barolin
Jack Kelliher
Joe Zevits
Khang Lam

What is
impact?
Impact refers
to an applied force that
occurs over a short period of time
when two or more bodies collide,
causing a displacement
It can be described by three types:
gradual application of force,
instantaneous application of the
complete load value, and
instantaneous application plus
kinetic force of the object

Slap experiment: Direct Impact

forces

Determining load
application
Load is slowly applied to an object
such that it can be considered static.

Static Impact
Imagine a spring mass
system.
When load is rested on top
of an object and there is no
deflection.

Dynamic Impact
Spring mass system
Mass is suspended
above the spring, and is
release on to spring
creating deflection.

Impact Factor

Guidelines for the presentation

4/29 W: Group 1~10
Two parts
Live presentation
Short lecture explaining the principle/concept, issues, examples, etc.
2 Minutes, PowerPoint or PDF
Video: 2 Minutes, <100 MB
Demonstration, experiment, lecture, story, examples, etc.
Evaluation criteria:
1. Understanding of the principle/concept
2. Demonstration of the importance of the principle/concept
3. Clarity of the presentation
4. Technical aspect of the presentation
5. Creativity

Surface Damage Presentation

14:650:342

Design of Mechanical Components

Brought to you by Juan Academy

Emily Lopez, Chris Fuscoletti, Diego Achury Triana, Juan Escobar, Christopher
Gabrielski, Greg Smith

*Slides inspired by Professor Lee

Outline
Ch. 9
Importance
Types of Surface Damage
Corrosion
Cavitation Damage
Wear

Importance

Many materials fail due to the effects of surface damage before breakage actually
occurs.

Studying and preventing the various types of surface damage is a key importance in
preserving the life expectancy of U.S. infrastructure

It is estimated that the U.S spends roughly $90 billion dollars annually repairing damages
from Corrosion and Wear alone.

Types of Surface Damage

Corrosion

Materials chemical or electrochemical reaction with its

environment that slowly deteriorates or erodes the
material.

Most familiar type of corrosion is the rusting of metals

Pitting Corrosion is another form of corrosion which is

normally undetectable because it is the forming of
miniscule cavities in a metal that damage its structural
integrity.

A few ways to increase a materials resistance to

corrosion include painting, anodization, hot dip
galvanization (coating the material in a layer of zinc)

Mostly corrosion occurs in metals, but can also happen

with polymers and glass materials

Cavitation Damage (Section 9.7)

Explanation

Formation of gas bubbles or cavities in a liquid that with respect to a nearby solid

Creation and collapse of these bubbles on the solid creates pressure waves, which
over time create plastic deformation and eventually failure

Possible Prevention

Modify liquid composition, velocity, flow pattern or static pressure

Increase surface hardness of the solid (Stainless steel is the most effective
reasonable cost)

Wear
When the members are in sliding contact
The severity of wear can be reduced by using a lubricant (as an oil,
grease, or solid film)
Types of Wear:
Adhesive Wear
Sliding metal surfaces increase pressure and temperature,
causing welding of imperfections (peaks) as a result
Abrasive Wear
The term wear most often refers to abrasive wear, which is
due to the rubbing of abrasive particles on a surface. These
particles are typically small and hard and have sharp edges
like grains of sand or particles of metal or metal oxide that rub
off a wearing metal surface.
Fretting
Basically is the combination of abrasive wear and corrosion
film wear. Fretting happens when two surfaces are pressed
together, experience slight relative motion.

Analytical Approach to Wear

Where:
=Wear Depth
t = Time
K = Wear Coefficient
H = Surface Hardness
p = Surface Interface Pressure
v = Sliding Velocity

Where:
W = Volume of Material Worn Away
K = Wear Coefficient
H = Surface Hardness
F = Compressive Force
S = Total Rubbing Distance

SHAFTS
Miguel Ferrer, Lewis Beekman, Jesus Bravo,
Dong Kwak, Akshita Kapasiawala,
Ryan Wilson

Definition
Usually a long rotating member with a circular
cross section that transmits power through its
rotation.
But it can also not have one or more of those
traits, for example

Types of SHAFTS
Spindles- short small diameter
Axle- stationary, supports rotational members
Stub shafts- Connects multiple parts easily
Line shaft- connected between motor and multiple
parts
Flexible shaft- transmits power between parts whose
rotational axes are not aligned and or can move

Universal Joint

Very important in shaft

applications.
Allow articulation between
Used in cars to allow the travel
of drive wheels for suspension
and steering.

Properties of SHAFTS
Critical Speed: and multiples
For its only type of loading (dynamic):
-SN curves are those
standard for steel
going through torsion.
- Sn= 0.58*Sn = 0.29*Su
- S10^3=.9*.8*Su

Maximum Torque Capacity

Different shaft geometries have different critical
loadings that can be supported by each shaft.

Square Shaft Joint

Materials
SHAFTS are commonly made from steel,
aluminum, and titanium alloys, carbon fibers, and
carbon-fiber/glass composites.
Steels strongest, carbon fiber is lightest, etc.
Not only designed for strength but also max
deflection.

Keys
For SHAFTS to transmit power to
other components, keys are necessary.
A shaft and its connected component
have grooves in which a key is
inserted. Keys help bind the pieces
and transmit rotational power.
Different types of keys include:
Square, gib-head, Pratt&Whitney keys

Bearings
-Fits around a shaft locking it in its location and
orientation
-allows rotation of the shaft at an
increased effeciency
-minimizes friction
-reduce wear

Failure
-Incorrect meshing occurs in SHAFTS when they go through too much
lateral deflection (st)., Too much torsional deflection ruins the
cooperation between the key and grooves
-The surfaces that endure the most pressure may experience wear
-Fracture only occurs though fatigue generally

References
-"Failure Analysis Of Machine Shafts - Maintenance
Technology." Maintenance Technology. N.p., 16 July 2012. Web. 29 Apr.
2015.
-"Fundamentals of Machine Component Design Hardcover September 27,
2011." Fundamentals of Machine Component Design: Robert C. Juvinall,
Kurt M. Marshek: 9781118012895: Amazon.com: Books. N.p., n.d. Web. 29
Apr. 2015.
-"Propeller Shaft Assemblies." Propeller Shaft Assemblies. N.p., n.d. Web. 29
Apr. 2015.
-"Torsion of Shafts." Torsion of Shafts. N.p., n.d. Web. 29 Apr. 2015.

DMC Final Project

FATIGUE
Nicole Paulino
Dante Levari
Louis Morales
Tyler Schiff
Shail Amin
Aakash Hathi
14:650:342
Section 1

Definition

Fatigue is the weakening of a material caused by

repeatedly applied loads

Fatigue fractures begin with a minute crack at a

critical area of high local stress. This is almost always
at a geometric stress raiser.

Fatigue failure results from repeated plastic

deformation, such as the breaking of a wire by
bending it back and forth repeatedly.

Fatigue failures typically occur after thousands or even

millions of cycles of minute yielding that often exists
only on a microscopic level.

Fatigue failure can occur at stress levels far below the

conventionally determined yield point or elastic limit.

Example
-The engineer must focus
attention on all potentially
vulnerable locations such as
holes, sharp corners, threads,
keyways, surface scratches, and
corrosion.
-Strengthening these vulnerable
locations is often as effective as
making the entire part from a
stronger material.

Fatigue Strength in Ductile

Materials

Moores Endurance Limit (Sn) is defined as the

highest stress that a material can withstand for a
given number of cycles without breaking. It is
found experimentally with a Moores fatigue
testing machine (shown in next slide).

Endurance Limit (Sn). The equation for Sn is

Sn=(Sn)(CL)(CG)(CS)(CT)(CR).

CL is the Load Factor, CG is the Gradient Factor, CT

is the Temperature Factor, CR is the Reliability
Factor and CS is the Surface Factor.

Each factors value can be determined by the

type of loading and dimensions of specimen.

Types of Fatigue Loads

Rotating Bending (Moore testing)-maximum stresses on

surface. Weakest point-fatigue start.

Reversed Bending-One end of specimen fixed and free end is

pushed up and down. Maximum stresses only at top and
bottom. Fatigue strength usually slightly greater. Not the
weakest point.

Reversed Axial Loading-One end of specimen fixed and free

end is pushed and pulled left and right. Maximum stresses
entire cross section. Fatigue strength about 10% less. No
reserve.

Reversed Torsional Loading- Maximum stresses on surface.

Shear stresses=fatigue starts. S_us=.8*S_u

Fatigue Load Examples

Fatigue Surface
Treatments

Surface treatments : It influences the Surface strength in comparison

with the strength of the surface material, and The Surface Residual
stress.

There are 2 types of Surface treatments: 1) Mechanical Surface

Treatments, and 2) Thermal and Chemical surface treatments.

After the treatment: Surface strengthening, & compressive residual

stresses substantially increases the load that can be carried.

Mechanical Surface Treatments: cold-work the surface material,

causing compressive residual stresses and, depending on the properties
of the material, and often strengthening the surface against strain.

Examples of Mechanical Surface Treatments: Shot peening, Cold rolling,

and Coining

Chemical Surface Treatments: The purpose of thermal and chemical

surface-hardening treatments is usually to provide surfaces with
increased resistance to wear; however, they also serve to increase
fatigue strength.

Examples of Chemical surface treatments: Induction Hardening,

Carburising, and Nitriding.

Avoiding Fatigue

Stress concentrations should be avoided where

possible; a design with smooth flowing lines is usually
the optimum

The tendency for surfaces to fail in fatigue can

obviously be reduced by decreasing loads and
decreasing sliding

In general, increased surface hardness increases

resistance to surface fatigue.

Precise accuracy of surface geometry and extreme

surface smoothness are highly beneficial.

Surface porosity, or a pattern of minute depressions

on one of the mating surfaces, may help by providing
tiny reservoirs for holding lubricant.

Questions?

LUBRICATION
Akofa Elike-Avion
Bryan Stonkus
Kareem Soliman
Robert DeSimone
Yianni Frangos

Definition
Any substance that reduces friction and wear
Usually a liquid (sometimes a solid)
Characterized by their viscosity

Types of Lubriction
Hydrodynamic Lubrication The lubricant separates the

moving surfaces. The surface wear is nonexistent in this

condition.
Mixed-Film Lubrication The surfaces of each object are
constantly lubricated and are intermittently in contact.
Surface wear mildly occurs here.
Boundary Lubrication the surface contact is continuous
and extensive, while the lubricant is constantly applied so
that there is a continuous film on each object. Surface
wear is mild to high in this condition.

Ways to Supply Lubricant

Oil Ring Usually in use with shafts with journal bearings. As

the shaft rotates, the oil ring supplies oil to the top of the
journal bearing
Oil Collar Like the oil bearing, but a collar brings oil to the top
of the shaft and has the lubricant flow through gravitational
forces.
Splash Oil that is splashed due to rapidly moving parts is
channeled into small reservoirs and is supplied to the bearings
Oil Bath Oil is supplied by submerging the journal bearing
into an oil reservoir
Oil Holes and Grooves Oil is supplied to the bearings
through holes and flows by either gravitational forces or
pressure.

Heat Dissipation
Extremely important and useful quality of lubrication
Heat in bearings is generated through friction and the rate

at which the shafts are moving

Equilibrium Conditions The rate at which heat is
generated through friction in the system is equal to the
rate in which heat is being taken away.
The temperature of the oil at thermal equilibrium depends
on the effectiveness that the lubricant has at transferring
internal heat to the outside environment

Linear Motion Devices

Michael Han, Shaun Kenny, Krishna Yellayi,
Rahul Upadhyay, Bryan Arcos, Matthew Kelsten

 Roller-screw jack

Very similar to ball screws with

respect to backlash, torque, and
efficiency
Utilized when there are strict
regulations placed upon axial
stiffness, linear speed, and
acceleration rates
Very expensive to manufacture

Machine screw jack

The leadscrew converts rotary motion

to linear motion
Rolling gears support the mechanism
and minimalize friction as the
apparatus rotates
Almost all machine screw jacks are
installed with self-locking
mechanisms in case of power failure
Can weigh anywhere from 1 250
tons
Drawbacks include low efficiency
(usually around 25%) and can
generate heat due to sliding between
screw and drive nut

Screw Jacks

 Backlash

The overall precision of a ball screw is

dependent on the measured distance
between the nut and the screw
Average backlash range is .002-.013 in.
often the nuts and preloaded so that
there is so distance between the two.

Machines threads

Threads are physically pre-machined

into the ball screw
Higher precision, but often
unnecessary
Compared to formed threads, which
have lower precision but also lower
manufacturing cost

Drive Torque

T = PL / 2(pi)E
T = torque input, lb-in.
P = Operating Load. lb
L = Lead, in/rev
E = efficiency

Life expectancy

Applied force, best when applied in

same axis as ball screw
Number and length of strokes

Standard of 1 million inches of travel

Ball Screws

 Moon rover

Utilizes a screw jack to

vertically dig up samples
from the moons surface
Is easily stored when not
being used
Provides an efficient
method to dig vertically
into the ground

CNC

Precise measurements and

placements using all
previously mentioned
devices to cut material into
specific shapes

3D Printer

Applications

 Utilize a belt in their linear travel path as seen in model (B)

Belt-Driven Linear Motion

Devices

 Wheel and pulley

system.
Rotating wheel moves
the belt to produce
linear motion.
Includes chain and
cable drives, not
limited to belts.

Belt-Driven Linear Motion

Devices Cont.

 When speed and acceleration

are critical.
Able to achieve high speed
motion with long stroke
lengths.
Quiet, consistent, and smooth
motion.
Not as expensive as screw
jacks.
Valued in various applications
including laser cutting,
wielding, and packaging
machining.

Why Use Belt-Driven?

 Device type: Actuator

An Actuator is a type of motor that is
responsible for moving or controlling a
mechanism or system.
Motors convert electrical energy into
mechanical energy. A stepper motor converts
electrical pulses into specific movements. The
movement created by each pulse is precise and
repeatable, which is why stepper motors are so
effective for positioning applications.
Comes in Rotational or Linear forms.

Stepper (Step) Motors

 There are 4 coils with 90 angle between each other fixed on

the stator. The way that the coils are interconnected, will
finally characterize the type of stepper motor connection. In
the above drawing, the coils are not connected together. The
above motor has 90 rotation step. The coils are activated in
a cyclic order, one by one. The rotation direction of the
shaft is determined by the order that the coils are activated.

Stepper Motor Design

Stepper Motors vs.

Regular Motors

DMC Spring 2015

Sarath Jaladi
Adam Rupp
Mohanish Shinde
Dylan Robertson
Kent Christian
Dylan Bryan

SPROCKETS AND
CHAIN

What are Sprockets and Chain?

Sprockets and Chain transmit
power
Sprockets are toothed wheels on
which chain rides
Similar to gears, different sized
sprockets may be chained together
to increase or decrease speed and
torque.
Unlike gears, however, Sprockets
that are chained together rotate in
the same direction (depending on
the side of the chain).

Where are Sprockets and Chain

Used?
Bicycles
o

Derailleur sprockets for shifting. Takes advantage of gear ratio

equation to alter horsepower and speed.

Continuous Tracks (Tank Treads)

o

Distribution of weight and traction for heavy vehicles. Increased

mobility and toughness.

Mechanical Power Transmission

o

Continuous power transport between two drive shafts over

distance.

Cinema
o

Used to run film through movie projectors and cameras.

Pros and Cons of Sprockets and

Chain
Pros:

Less frictional loss than belts. No

slip.
Gear ratio is easily adjusted.
Eliminates gear trains.
All sprockets turn in the same
direction.
Lighter than an all gear system.
Allows for more tolerance than
gears.

Cons:

Requires lubrication to prevent wear.

Can be noisy due to metal contact
points and vibrations.
Chain breakage can lead to
catastrophic failure.
Sprockets wear out faster than either
pulleys or gears.
Idler sprockets may be needed to
gain maximum efficiency and reduce
wear.

Common Configurations
Type A- No hub
Type B- Hub on one side
Type C- Hub on each side
Type D- Bolt on plate attached to
hub

Types of Chains
Roller Chain
o Most commonly used for power
transmission
o

Consist of a series of cylindrical

roller links connected with plates and
pin

Inverted Tooth Chain

Also called a silent chain, for

relatively quiet operation
o Toothed link plates connected with
pins
o

Sprocket Dimensions
Bottom Diameter: Diameter of the circle
running tangent to the bottom of each tooth
gap
Caliper Diameter: Distance from the bottom
of two tooth gaps nearly opposite each other,
useful in sprockets with odd numbers of
teeth
Pitch Diameter: Diameter of the circle
tangent to the points of contact between the
chain and sprocket teeth
Sprocket Diameter: Diameter of circle
tangent to each tooth tip
Face Width: Width of tooth tip

Chain Dimensions and Terms

Roller Diameter: The outside diameter of

the chain roller. This diameter engages with
the sprocket.
Pitch: The average distance from one chain
pin to the next pin.
Inner Width: The dimension between the
two inner plates. This dimension will be a
little greater than the width of the sprocket
teeth to allow for smooth engagement.
Connecting Link: A special link designed to
connect two free ends of a chain together.
Offset Link: A modified connecting link that
adds half of what a connecting link adds.

Belts
Robert Kertz, Ani Thuppul, John Sengco, Calen
Fields, Brian Connolly, Kushal Darji

Flat Belts
Flat belts were often used for transmission of power

from flywheels to other parts of machinery.

Commonly seen in use as conveyor belts or parts
of belt arrays.
Types
Small Woven Endless Belts
Higher Power Flat Belts

Sources:
http://machinedesign.com/basics-design/flat-belts 2 .http://en.wikipedia.org/wiki/Belt_(mechanical) 3 .
http://www.wisegeek.com/what-is-a-flat-belt.htm

V-Belt
Sheaves (V-shaped grooves)
Wedging action (V shape)

provides more normal force,

allowing greater torque
Used to drive accessories in
cars, internal comb. Engines
Blowers, compressors,
appliances, etc.

Toothed Belt

AKA timing belts.

Since the drive is by means of teeth rather than friction, there is no slippage and
the driving and driven shafts remain synchronized.
Toothed belts are relatively lightweight, and can give efficient operation at speeds
up to at least 80 m/s (16,000 ft/min).
Their principal disadvantage is the higher cost of both the belt and the toothed
pulleys.
Typically used for driving an engine camshaft from the crankshaft.

Roller Chains
The most widely used power transmission chain
The load is initially transferred to the chain by a driving
sprocket tooth
The load is then
transferred to a bushing,
then a pin, then a pair of
link plates
The full load is then
transferred through
successive link plates
along the tight side
of the chain

Equations
Flat Belt:

Pc = m = m
Torque = (P1 - P2)r Where Pc is tension on belt due
to rotation.
P1/P2 =
Where f is coefficient
of friction and is
angle of contact with
the pulley

V-Belt:

Example

References

Juvinall, Robert C. (2012). Fundamentals of Machine

Component Design. John Wiley and Sons, Inc.
www.sudarshantools.com (image of V-belt)

What is a Cam?
A cam is a mechanical linkage whose purpose is to
translate rotational motion into linear motion with specific
timing.
The cam itself comes in many shapes but it is often an
irregular cylinder.
The cam is paired with, and maintains contact with, a
follower which provides the linear motion of the system.
Mass produced cams are made using chilled iron castings
while high quality cams are made using billet steel in CNC
A simple
milling machines.

cam with a
follower.

History of the Cam

Early cams were found in the 3rd century BC in ancient
Greek water powered automata.
In Mesopotamia, the camshaft was first used in the early
13th century AD by Al-Jazari in his automata, water raising
machines, and water clocks.
The cam and camshaft later appeared, and became more
widely used, in the 14th century in European machines.
An Al-Jazari
Automata

Cams Today
Today, cams are used in household appliances, industrial
machinery, and high powered industrial tools.
The most common application is in internal combustion
engines.
In automobiles, cams on a camshaft are responsible for
translating the rotary motion of the engine into
reciprocating motion to operate the poppet valves in the
cylinder.
4-stroke
The timing cams provide in enginesA is
crucialengine
to gas and
with intake and
vapor intake and exhaust.

A high-quality
automotive camshaft.

exhaust
controlled by
cams and
followers.

Displacement of A Cam
Displacement diagrams relate angular
position to the radial displacement
experienced at that position.

The rise is the motion of the follower

away from the center of the cam.
Dwell is the motion at which the
follower is at rest.
Return is the period of motion that the
follower moves toward the cam center.
C = L/(1-sin )
r = R Lsin / (1 sin )

Plate Cam

Cylinder Cam

Snail Cam
Used to gradually rise the follower
then drop suddenly, hence its
second name: Drop Cam
Can only turn in one direction or it
will lock up
Center of rotation is placed slightly
off-center to ensure a smooth spin
Examples: invented for use in
watches
was used to change the day
presented on the watch at the
perfect time
Also used in bike chains: makes use
of the one possible direction

Mechanical representation of
snail cam

Linear Cam
Different from other cams in that it moves in a
straight line rather than rotational
versatile: can be cut into different shapes to
determine height of cam follower as well as
Very
operating several followers at once
prevalent
also utilizes a return spring to ensure a
camsmooth follow
Most
common
example is
the pin
tumbler lock
Even used
in a hole

Face Cam
Produces motion by using a
follower riding on the face of
the disk
Has a groove cut or slot in
which the follower rides
Eliminates the need for a
return spring to keep the
follower in contact with the
control surface
Example: Sash window lock
Cam is mounted to the top

A sash window lock.

Heart Shaped Cam

Allows the follower to rise
and fall with uniform
velocity, giving it a smooth
continuous motion
Causes the follower to rise
three times in one rotation
Used to return the shaft
holding the cam to a set
position by pressure from a
roller
Examples:
Used in stopwatches and

A heart shaped cam in a chronogr

Failure Theories and

Reliability
Alex Weingarten, Chris Nazareno, Brandyn Merkle,
Carlos Mora, Antonio Montanaro, Dan Nemeth

Failure
Any materials behavior that renders a
loaded member unsuitable for its
intended function.
o Static loading- deflection, buckling, plastic

distortion, and fracture.

Plastic Distortion
Associated with shear stresses and
involves slip along natural slip planes.
Failure occurs when plastic deformation
reaches an arbitrary limit.

Fracture Mechanics- Basic Concepts

The separation or fragmentation of a member into two
or more pieces.
Normally constitutes a pulling apart associated with
tensile stress.
o Brittle fracture- occurs when conditions cause
instantaneous propagation to cause failure of one
or more of the original cracks.
o Fatigue loading- initial cracks grow slowly until one
reaches a critical size at which total fracture
occurs.

Brittle vs. Ductile Fracture

Buckling
Buckling is a sudden sideways failure of a
structural member under high compressive stress
This stress at the point of failure is less than the
ultimate compressive stress that the material is
capable of withstanding.
As a load is applied and increases large enough,
the member will become unstable and buckles.
Continual increasing of the load will cause
unpredictable deformations
Potential loss of the members carrying load
capacity

Fracture Mechanics- Basic Concepts

Stress Intensity Factor (K)
o Measure of the effective local stress at the crack
root. Expressed in Pam.
Critical Stress Intensity Factor (Kc, fracture toughness)
Failure occurs when K > Kc
Safety Factor SF defined as Kc/K
o or SF = (design overload)/(normally expected load)

Stress Intensity Factor

Thin Plate

Thick Plate

Cylindrical Tube

Static Failure Theories

Maximum-Normal-Stress Theory
Failure when greatest tensile stress exceeds tensile strength of the material
Maximum-Shear-Stress Theory
Failure when maximum shear stress exceeds shear strength of the material
Maximum-Distortion-Energy Theory (Maximum-Octahedral-Shear-Stress Theory)
Equivalent Stress
Failure when e > Syt
Mohr Theory and Modified Mohr Theory
Generally a modification of maximum-shear-stress theory, derived including
the effect of internal friction

Static Failure Theories

Maximum-NormalStress Theory

Maximum-Distortion-Energy
Theory

Maximum-ShearStress Theory

Modified Mohr Theory

Reliability
Reliability is a components ability to perform what is
needed under certain conditions for a period of time.
If 200 identical parts are tested and 4 fail, the parts
are 98% reliable.
Usefulness of reliability depends on having proper info
on the statistical distribution of:
o Loading applied to the parts
o significant strength of production runs of
manufactured parts

Reliability

z = x - y

Valve(s)
(Not the Company)

What is a Valve?

any device for halting or controlling the flow of a liquid, gas, or other material through a
passage, pipe, inlet, outlet, etc.-Dictionary.com
Used throughout the world to control fluid or gas flow around systems
Found both in industrial settings as well as in the organic world (Heart Valves)
A great many types, well only cover the most common or useful valves here

Needle Valve

Allow for very fine control of flow rate, results in very low flow rates as a trade-off
Flow rate is controlled by a ratio between the length of the needle and its own diameter
With a very long needle, the change in diameter is very low, which allows for the accuracy of
flow
Needle valves are generally used in situations where exact control of flow is important, like
sampling systems of pressure gauges
Also capable of function in a vacuum, and
so are used to fill certain types of
vacuum tubes as well as gas Lasers
Not capable of quickly closing, make poor
shut off valves
Also difficult to tell if the valve is open at
a glance, the small distances involved
make it difficult to easily tell by sight
alone

Pressure Relief Valve

"Lets off steam" when safe pressures are

exceeded, then closes again when
pressure drops to a preset level selfoperating valve
A helical or hydraulic pressure spring is
used to maintain constant force acting on
the backside of the valve disk or
diaphragm
When the force exerted by the process
stream (i.e. fluid pressure) on the valve
disk is greater than the constant force
exerted by the spring, the valve opens
until the fluid pressure falls below the
preset value

Ball Valve

They are wide duty valves, able to

transfer gases, liquids and liquids with
suspended solids (slurries).
Ball shaped disc within the valve is
opened by a quarter turn of the actuator.
Disc allows free flow or completely blocks
flows.
Maintains and regulates high volume, high
pressure, and high temp flow
Not designed to be gradually opened.
Design Types
Floating Ball- The upstream pressure
helps create the seal by pushing the ball
back against the rear or downstream seat.
Trunnion-pin secures the ball so it doesn't
dislodge; provide less friction between
the ball and seal.

Tesla Valve(Correct Direction)

Tesla Valve (Wrong direction)

Globe Valve

Advantages of the GLobe valve include the

speed with which it can be closed and
opened, as well as the precision of control
allowed for due to the use of a screw
Disadvantages include a certain amount of
head loss, a low flow coefficient, and its its
inappropriateness for sterile applications
Also known as a stop valve or a disk valve
The valve functions via a movable plug set in
a orifice of similar shape
To open or close the valve, the plug is raised
or lowered by turning the handle

Pinch Valve

Controls flow by compressing

flexible interior piping
Used mostly for solutions
containing particulate matter
Similar in function to how a kink
in a hose reduces flow rate
Inappropriate for high pressure
situations
Commonly used in situations
containing particulate matter,
such as clinical or chemical
analyzers and a wide range of
laboratory equipment

Thanks! Any Questions?

https://www.youtube.com/watch?v=6WUWuNVMy8
https://www.youtube.com/watch?
v=zBrbWPy6hXY

Team 1

Clutches

Team 2

Springs

Team 3

Screws

Team 4

Gears

Team 5

Brakes

Team 6

Bearings

Team 7

Rivets
/Weldings

Team 8

Impact

http://youtu.be/BbZSiBoZ-xY

Team 9

Surface
Damage

https://www.youtube.com/watch?
v=D6xILtd2sbQ

Team 10

Shafts

Team 11

Fatigue

Team 12

Lubrication

Team 13

Linear motion device

Team 14

Chain and Sprockets

Team 15

Belts

Team 16

Cams

Team 17

Failure/reliability

Team 18

Valves

https://youtu.be/jOVIom_8pEc
https://www.youtube.com/watch?v=d4lmpB8mmE&feature=youtu.be
https://www.youtube.com/watch?
v=bGztsbHewec
https://www.youtube.com/watch?
v=vnsHKdFrUTo&feature=youtu.be
https://www.youtube.com/watch?
v=yim_PULfrVw

http://youtu.be/7oIolLXgIYU
https://www.youtube.com/watch?
v=dKleYzF9G3M&feature=youtu.be
https://www.youtube.com/watch?
v=iEFbveEBeIk
https://youtu.be/QcgX5tCcguM
https://www.youtube.com/watch?
v=jAfCqfNhOQo&feature=youtu.be
https://www.youtube.com/watch?v=o9IO-Fy8EI&feature=youtu.be
https://m.youtube.com/watch?v=7hRNGqj38R4
https://www.youtube.com/watch?
v=PQaM4Z3iNiQ&feature=youtu.be
http://youtu.be/A05iLhcMDiA