Simon Fraser University

Mechanical Elements

ENSC 305/440

Esmaeil Tafazzoli
Spring 2006

Spring 2006 ENSC305/440 1

 Simon Fraser University
Outline:

•Mechanical properties of materials

•Machine elements:
1) Motors (types, selection considerations)
2) Power transmission devices (gears, belt, pulley, chain,
friction drive)
3) Miscellaneous: Bearings(types, selection issues,
catalogs), springs, pins, retaining rings…
4) Other motion generation devices (linkage mechanisms,
cams)
5) Joining methods (welding, brazing, soldering, bolts,
screws, rivet, …)
Spring 2006 ENSC305/440 2
 Simon Fraser University

Mechanical properties of materials:

 Behavior of materials in response to mechanical loads.

 Useful in material selection.

Most basic property: stress-strain relation

load ( F )
Stress:  
area ( A)

lengthchange(l )
Strain :  
originalle ngth(l 0 )

Spring 2006 ENSC305/440 3

 Simon Fraser University

Strength of a material
Maximum stress that can be applied to material before failure.

Types:
- Tensile Strength
- Compressive strength
- Shear strength

The definition of failure varies by the type of material and

design method:
Brittle (concrete, cast iron, glass,…)
Ductile (gold, Aluminum, copper, steel, …)

Spring 2006 ENSC305/440 4

 Simon Fraser University

Stress-Strain relation
The stress caused by
load must not exceed the
failure stress.

Always consider a Factor

of Safety.

FS= σall /σdesign

σall = Allowable Stress

σdesign = Design Stress Stress-strain curve for structural steel[1]

Spring 2006 ENSC305/440 5

 Simon Fraser University

Stress-strain curve, Aluminum[1] Stress-strain curve for a brittle material [1]

Spring 2006 ENSC305/440 6

 Simon Fraser University
Standards

• SAE (Society of Automotive Engineers)

• AISI (American Iron and Steel Institute)
• ASTM (American Society for testing and Materials)
• ANSI (American National Standard Institute)

AISI-SAE designation for carbon and alloy steel

Mild steel 0.1% - .25% Carbon e.g., AISI 1018
Medium carbon steel .25% - .45% e.g., AISI 1040

Spring 2006 ENSC305/440 7

 Simon Fraser University

Machine elements

•Motor •Bearing
•Gear •Joining methods
•Belt, pulley (welding, brazing, rivets,
•Chain, sprocket bolts, screws, etc)
•Universal joint
•Friction drive
•Cam-follower
•Mechanisms (linkages)

Spring 2006 ENSC305/440 8

 Simon Fraser University

Motor types

• DC motors a) Permanent magnet

(brushless)
• Stepper motors b) DC Shunt motor
c) DC series motor
• Gearhead motors

• AC motors

Spring 2006 ENSC305/440 9

 Simon Fraser University

Characteristics
DC motor

a) Speed proportionate to voltage applied

b) Suitable current/torque and speed/torque curve

properties

c) Easy to control

d) Position/Speed Servo

e) No brush noise, durable, clean (brushless)

Spring 2006 ENSC305/440 10

 Simon Fraser University

Characteristics

Stepper motor

• Can rotate in both directions

• Moves in precise angular increments (steps)

• Sustain a holding torque at zero speed

• Easy to control

Spring 2006 ENSC305/440 11

 Simon Fraser University

Comparison of stepper and DC permanent-magnet

motors

Robot mechanisms and mechanical devices illustration, McGraw Hill 2003 [2]

Spring 2006 ENSC305/440 12

 Simon Fraser University

Typical DC motor characteristic curves [3]

Spring 2006 ENSC305/440 13

 Simon Fraser University

Selection factors
When selecting a motor consider these issues:

• Speed range •Starting torque

• Torque-speed variations •Size and weight
• Reversibility restrictions
• Required power •Price
• Load inertia •Maintenance

Spring 2006 ENSC305/440 14

 Simon Fraser University

Selection factors (cont’d)

Consider these questions when selecting a motor:

1. Will the motor start under load?

2. What is the maximum speed the motor can produce?
3. How much power does the load require?
4. Is the load to be driven at constant speed?
5. Is transmission gearbox required?

Spring 2006 ENSC305/440 15

 Simon Fraser University

Typical specification sheet[4]

Spring 2006 ENSC305/440 16

 Simon Fraser University

Useful information sources

 Experts
 Manufacturer
specification sheets
 Product catalog
 Design handbooks
 Motor nameplate
 Web

Spring 2006 ENSC305/440 17

 Simon Fraser University

Gearhead motors

Spring 2006 ENSC305/440 18

 Simon Fraser University

Force ratio for gear trains

Wrr1 r2
F
RR1 R2
W=Load force
F= balancing force

FR  F1r r

Spring 2006 ENSC305/440 19

 Simon Fraser University

Gear train speed ratio

D1 D2 D3 driven
speedratio  
d1 d 2 d 3 driver

n4 N1 N 3 drive
 
n1 N 2 N 4 driven

n= speed
N= number of teeth

Spring 2006 ENSC305/440 20

 Simon Fraser University

Different kinds of power transmission or

motion control capability of gears:

a) Changing rotational speed.

b) Changing rotational direction.
c) Multiplying or dividing torque.
d) Converting rotational to linear motion.
e) Offsetting or changing the location of rotating motion.

Spring 2006 ENSC305/440 21

 Simon Fraser University

Motion and torque transmission examples ([5])

•Right angle •Right angle I/O

Rotary-Linear power
crossing shafts torque
transmission
•Self locking •Smooth tooth
•High friction interaction
and wear •Low noise
•High speed
reduction
Spring 2006 ENSC305/440 22
 Simon Fraser University

Bearing types

Ball bearing Thrust bearing

Tapered roller Needle roller

bearing bearing

Spring 2006 ENSC305/440 23

 Simon Fraser University

Important factors in bearing selection

• Loads (radial, axial)
• Operating speed
• Size and weight

Information sources:
• Experts
• Manufacturer’s catalog (SKF, TIMKEN, FAG,…)
• Design handbook

A quick way of bearing selection

SKF online interactive catalog (www.skf.com)

Spring 2006 ENSC305/440 24

 Simon Fraser University

SKF interactive bearing selection example page

Spring 2006 ENSC305/440 25

 Simon Fraser University

Other ways of motion transmission:

Linkage mechanisms

Intermittent rotary motion[6]

Rotary to back and forth motion[7]

Spring 2006 ENSC305/440 26

 Simon Fraser University

Alternative mechanism design

Robot mechanisms and mechanical devices illustration, McGraw Hill, 2003 [2]
Spring 2006 ENSC305/440 27
 Simon Fraser University

Flexible transmission

• Chain-sprocket
• Belt-pulley

Ref[8, 9]

Ref[10]

Spring 2006 ENSC305/440 28

 Simon Fraser University

Joining methods
• Welding
• Brazing
• soldering

Spring 2006 ENSC305/440 29

 Simon Fraser University

Joining methods

• Welding: (melting both material and filler, generally

used for welding ferrous materials)

• Brazing: (melting nonferrous metal, brass or bronze,

as filler to join base materials by capillary action)

• Soldering: ( same as brazing but at lower

temperatures)

Spring 2006 ENSC305/440 30

 Simon Fraser University

Joining Joint temperature Distortion Aesthetics

method strength

Soldering Poor up to 400°C None Good

Brazing Good 800-1000 °C Minimal Excellent

Welding Excellent above1500°C Likely Fair

e.g., Brazing with Bronze alloy as filler with 870-980°C for joining mild
steel with melting temperature of 1600°C[1].

Spring 2006 ENSC305/440 31

 Simon Fraser University

Welding types

Arc welding: An electric arc between material and filler melts

them at the joining point.

Gas welding (oxyacetylene):

 Widely used for welding pipes and tubes and repair work

Resistance welding:
Generating heat by passing current through resistance
caused by joining metals. (widely used in automotive
industry)

Spring 2006 ENSC305/440 32

 Simon Fraser University

Arc Welding: Setup configuration [11]

1- power supply
2- electrode holder
3- workpiece
4- work clamp

Spring 2006 ENSC305/440 33

 Simon Fraser University

Welding position

1- workpiece
2- work clamp
3- slag
4- electrode
5- electrode holding position

Spring 2006 ENSC305/440 34

 Simon Fraser University

Electrode position
in groove welding

Electrode
position in
fillet
welding

Spring 2006 ENSC305/440 35

 Simon Fraser University

1- stringer bead
(steady
Single stringer movement along
bead for narrow seam)
grooves

2- weave bead
(side to side
movement
Weave bead along seam)
for wide groove
or multiple
stringer bead
3- Weave pattern

Spring 2006 ENSC305/440 36

 Simon Fraser University

Spring 2006 ENSC305/440 37

 Simon Fraser University

Properties of a good welding

Spring 2006 ENSC305/440 38

 Simon Fraser University
Troubleshooting

Excessive spatter Porosity Lack of penetration

Cause:
1-Amperage too high
2-Arc length too long
Correction:
1- Decrease
amperage or select
larger electrode
2- Reduce Arc length
Spring 2006
Cause: Causes:
1-Dirty workpiece 1-Improper weld
2-Arc length too long technique
3-Damp electrode 2-insufficient heat
input
Correction:
1-Remove all grease, Correction:
damp, oil, dust,..., 1-Reduce welding
from work surface speed
2-Reduce length 2-Increase amperage,
3-Use dry electrode use larger electrode
ENSC305/440 39
 Simon Fraser University
Troubleshooting

Burn through Wavy bead Distortion

Cause: Cause: Cause:

Excessive heat Unsteady hand Excessive heat

Correction: Correction: Correction:

Decrease Use two hands Use clamp to hold
amperage practice base material
use smaller Use lower amperage
electrode Make tack weld along
Increase travel the edge
speed Weld in small
segments, allow cooling
between welds.
Spring 2006 ENSC305/440 40
 Simon Fraser University

Example of good and

bad welds

2006 Miller Electric Mfg Co

Spring 2006 ENSC305/440 41

 Simon Fraser University

References
1) http://en.wikipedia.org
2) Robot mechanisms and mechanical devices illustration,McGraw Hill 2003
3) www.igusa.com
4) http://www.bodine-electric.com
5) http://www.engr.utexas.edu/dteach/Experience/mechanisms/brief_mecha
nisms.htm
6) http://www.cabaret.co.uk/education/geneva.htm
7) Mechanism Design: Enumeration of Kinematic Structures According to
Function, Lung-Wen Tsai, Copyright © 2006 Taylor and Francis group,
LLC.
8) http://www.thesaabsite.com/95/95pulleys
9) http://microhydropower.net/index.php
10) http://www.goldstarind.com/prdndx1.htm
11) Slides 32-39 were adapted from: ‘Guideline for shielded metal arc
welding, http://www.millerwelds.com/pdf/guidelines_smaw.pdf

Spring 2006 ENSC305/440 42