LO65---

Understanding of basic terms and definitions in mechanical design.

1. Mechanical engineering: The branch of engineering that deals with the design, analysis,
manufacturing, and maintenance of mechanical systems.

2. Stress: The internal force that resists deformation of a material under an applied load.

3. Strain: The degree of deformation of a material under stress.

4. Deformation: The change in shape or size of a component under applied forces.

5. Fatigue: The weakening of a material due to repeated loading and unloading cycles.

6. Fracture: The breaking of a material due to excessive stress.

7. Yield strength: The maximum stress a material can withstand without permanent deformation.

8. Tensile strength: The maximum stress a material can withstand before failure due to breaking.

9. Compression strength: The maximum stress a material can withstand before failure due to crushing.

10. Shear strength: The maximum stress a material can withstand before failure due to a sliding or
twisting force.

11. Ductility: The ability of a material to undergo deformation under applied stress without breaking.
12. Brittleness: The opposite of ductility, where a material breaks easily under stress without significant
deformation.

13. Elasticity: The ability of a material to return to its original shape after deformation.

14. Plasticity: The ability of a material to permanently deform under stress.

15. Creep: The gradual deformation of a material under a constant load over time.

LO66---

Explain the stress-strain characteristics of different materials.

Sure, I'd be happy to explain the stress-strain characteristics of different materials!

When a material is subjected to a load or force, it undergoes deformation or strain. The relationship
between the deformation (strain) and the applied force (stress) is known as the stress-strain curve,
which varies for different materials.

- Metals: Metals have a linear portion of the stress-strain curve up to a certain point called the yield
strength. This is where the material begins to plastically deform (permanently). Beyond the yield point,
the curve becomes non-linear, indicating that the material has entered its plastic region. The curve
eventually plateaus at the ultimate tensile strength, which is the maximum amount of stress that the
material can withstand before it fails.

- Polymers: Polymers tend to have a sloped linear portion of the stress-strain curve before exhibiting a
yield point. The linear slope portion is referred to as the elastic region, where the material will return to
its original shape after the load is removed. Beyond the yield point, the material will plastically deform,
and the curve will continue to slope upward until the breaking point, also known as the ultimate
strength.
- Ceramics: Ceramics are brittle materials that have a sharp increase in stress with increasing strain, due
to their lack of ductility. For ceramics, the yield point is not well-defined since the material is prone to
cracking and failure at a very low strain.

- Composite materials: Composite materials are a combination of different materials and exhibit a more
complex stress-strain curve. Depending on the type of composite, the stress-strain curve can show a
combination of characteristics of each element in the composite.

I hope that helps explain the stress-strain characteristics of these different materials!

LO67---

Understand stress concentration and failure causes and types.

Stress concentration is a phenomenon wherein a stress state is elevated in a particular location due to
the presence of a geometric feature or alteration in the material. This elevated stress concentration may
lead to failure if the stress levels exceed the strength of the material.

The causes of stress concentration can be external or internal. External causes include the presence of
notches, holes, sharp corners, and abrupt changes in cross-section. Internal causes can arise due to non-
uniformity in material properties like grain size or texture, residual stresses, or microstructural defects.

There are various types of failure modes that can occur due to stress concentration. Some of the
prominent ones are:

1. Fracture: Failure due to excessive stress in a material resulting in physical separation of the material.

2. Fatigue: A type of fracture due to cyclic loading leading to the propagation of tiny cracks in the
material, resulting in a sudden failure.
3. Creep: Deformation of material due to the application of constant load over an extended period.

4. Plastic deformation: A permanent change in the dimensions of a material due to excessive stress
leading to yielding.

5. Buckling: Failure due to the sudden instability in a material caused by compressive stresses.

It's important to note that stress concentration can lead to any of the above failure types and can cause
catastrophic consequences if not accounted for in the design and use of the material.

LO68--

Comprehend and compare the various failure theories that suit the failure conditions.

There are several failure theories that can be used to explain different types of failure conditions. Here
are three common failure theories and where they can best be applied:

1. Maximum Shear Stress Theory: This theory states that material failure will occur when the maximum
shear stress in the material exceeds the strength of the material. This theory is often used to explain the
failure of ductile materials under torsional loading conditions.

2. Maximum Normal Stress Theory: This theory states that material failure will occur when the maximum
normal stress in the material exceeds the strength of the material. This theory is often used to explain
the failure of brittle materials under tensile or compressive loading conditions.

3. Von Mises Theory: This theory states that material failure will occur when the equivalent stress
exceeds a certain value dependent on the material's yield stress. This theory is often used to explain the
failure of ductile materials under complex loading conditions, where both normal and shear stresses play
a role in the material failure.
So, the choice of failure theory will depend on the material being investigated and the type of loading
condition being applied. Engineers and researchers will often use multiple failure theories to fully
understand the failure mechanisms of a material.

LO69---

Clarify the basic parameters and designing procedures for permanent and non-permanent joints.

Permanent joints are designed to join two or more components by means of welding, brazing, soldering
or adhesive bonding. These joints are meant to be permanent and usually require a high level of
precision in order to ensure that the joint is strong enough to hold the components together for a long
time.

When designing a permanent joint, the following parameters need to be considered:

1. Type of joint: Depending on the nature of the components being joined, the joint type needs to be
chosen. For instance, lap joints for sheet metal, butt joints for thicker plates, fillet joints for use in
corners or T-joints.

2. Materials of the components: The materials being joined must be compatible with each other, and the
type of joint used must be strong enough to hold the different materials in place.

3. Welding or bonding process used: The process used to join the components together needs to be
chosen based on the materials and the type of joint required. For example, MIG welding for thin sheets
and TIG welding for high-precision work.

4. Amount of heat input: The heat input during the welding process should be controlled to prevent
excessive distortion or warping of the components.
5. Joint preparation: Proper joint preparation, including cleaning, fit-up, and alignment, is essential for a
strong and reliable joint.

Non-permanent joints, on the other hand, are designed to allow for easy assembly and disassembly.
Common non-permanent joints include bolts, screws, nuts, clips and pins. When designing a non-
permanent joint, the following parameters need to be considered:

1. Type of joint: The joint type has to fit the application and allow for the desired movement or
articulation.

2. Material of the components: The materials used in the joint need to be compatible and provide the
necessary strength to hold the joint together.

3. Design of the fasteners: The fasteners used for the joint need to be designed to provide adequate
clamping pressure and resist loosening during use.

4. Tolerance and fit-up: The tolerances of the parts need to be considered in the fastening design,
allowing for easy assembly and providing the correct level of clamping force.

5. Environmental factors: The joint design must consider the environmental conditions it will be exposed
to, such as temperature, moisture, or corrosion, and the potential impact on the joint's performance.

Overall, the key to designing both permanent and non-permanent joints is to ensure they provide the
desired level of strength, stability and durability for the intended application.
LO70---

Understand the major principles behind the function of mechanical springs and design different types
of springs.

The major principles behind the function of mechanical springs are elasticity and potential energy. When
a mechanical spring is compressed or stretched, it stores potential energy, which can be released later
for various applications. The amount of potential energy stored in a spring is proportional to its
deformation or displacement from its equilibrium position, which is the position where the spring is
relaxed and has no potential energy.

There are several types of mechanical springs that can be designed based on their shape and function:

1. Torsion springs: These springs are designed to twist or rotate around an axis, and they store potential
energy based on their torsional deformation. They are commonly used in vehicles, watches, and door
hinges.

2. Compression springs: These springs are designed to resist compression or pressing, and they store
potential energy based on their compression deformation. They are commonly used in shock absorbers,
mattresses, and packaging materials.

3. Extension springs: These springs are designed to resist extension or pulling, and they store potential
energy based on their extension deformation. They are commonly used in garage doors, trampolines,
and toys.

4. Flat springs: These springs are designed as thin, flat strips, and they store potential energy based on
their bending deformation. They are commonly used in electronics, appliances, and switch contacts.

5. Belleville springs: These springs are designed as disc-shaped springs, and they store potential energy
based on their deflection. They are commonly used in valves, clutches, and aircraft landing gear.
Designing a spring requires careful consideration of the material properties, dimensions, and loading
conditions. The spring must be designed to safely store and release potential energy without
experiencing permanent deformation or failure.

LO71---

Make dimensional and material decisions for pressure vessels

Dimensional and material decisions for pressure vessels are essential to ensure their safe and optimal
performance. Here are some factors to consider:

1. Design pressure and temperature: The design pressure and temperature of the vessel determine its
thickness and material requirements.

2. Vessel geometry: The shape of the vessel, such as its diameter and length, affects its strength and
stability.

3. Operating conditions: The type of fluid or gas being stored and the operating conditions such as
temperature and pressure also have a significant impact on the material selection.

4. Regulatory requirements: The standards and regulations for pressure vessels vary by country and
industry. Compliance with these regulations is essential for safety and legal purposes.

5. Material properties: The material selection should be based on its mechanical properties, such as
strength, ductility, and fatigue resistance, as well as its resistance to corrosion and other environmental
factors.

6. Manufacturing considerations: The fabrication method and equipment used to manufacture the vessel
will also have an impact on the material selection.
Common materials used for pressure vessels include carbon steel, stainless steel, and various alloys such
as Inconel and Hastelloy. The material selection should be made based on the above factors and the
specific application requirements. It is recommended to consult with an experienced engineer or
pressure vessel manufacturer to ensure the optimal design and material selection for your pressure
vessel.

LO72---

Understanding typical characteristics and design of principal machine elements (Shafts, gears, belts,
bearings, and friction elements.

Shafts:

Typical characteristics of shafts include their diameter, length, material composition, and surface finish. A
shaft is a rotating component that transmits power and torque from a drive source to a driven
component. Shafts can be solid or hollow and can be designed to support axial or radial loads. They are
commonly made from materials such as steel, aluminum, titanium, or ceramics. Shaft design must take
into account factors such as the applied loads, operating speed, and environment to ensure proper
operation and reliability.

Gears:

Gears are mechanical components used to transmit power and motion between rotating shafts. They are
typically designed to mesh with each other to transmit power in a specific direction and speed. Gears
can have varying numbers of teeth, different shapes, and materials of construction. Factors such as tooth
profile, pitch, and pressure angle are important factors in gear design, as they affect gear strength, noise,
and efficiency. Lubrication is also important for maintaining proper gear performance.

Belts:

Belts are flexible mechanical components used to transmit power between rotating shafts. They are
typically made from materials such as rubber, neoprene, or polyurethane and can come in different
lengths and widths. Belt design is important to ensure proper compatibility between the belt and pulley
or sprocket, with factors such as belt tension, speed, and load capacity affecting performance.

Bearings:
Bearings are components used to support rotating shafts and reduce friction between moving parts.
They are designed to handle radial and axial loads and can come in a wide range of sizes and
configurations, such as ball bearings, roller bearings, and plain bearings. Bearing design must take into
account factors such as the type and magnitude of applied loads, operating speed, and environmental
conditions to ensure optimal performance and reliability.

Friction elements:

Friction elements are components used to absorb and dissipate energy by converting motion into heat
through frictional contact. Common examples include brakes and clutches, which are used to stop or
control the motion of rotating components. Friction element design must consider factors such as the
type and magnitude of applied loads, operating speed, and thermal characteristics to ensure proper
performance and reliability.