Mechanical Engineering Tools For Excel

MEboost
Mechanical Engineering Tools for Excel®
User Manual
Revised February 25, 2022

Vortarus Technologies LLC
Excel® is a registered trademark of Microsoft Corporation. Used with permission from Microsoft.
Contents
Chapter 1 –Introduction .............................................................................................. 8
Features ................................................................................................................. 8
System Requirements .............................................................................................. 8
Installing MEboost ................................................................................................... 8
Before Installation ................................................................................................ 8
Excel 2007 Installation Procedure ........................................................................... 9
Excel 2010 - 2019 Installation Procedure ............................................................... 11
Uninstalling MEboost .............................................................................................. 12
Trust Center Settings ............................................................................................. 12
Chapter 2 – Mohr’s Circle .......................................................................................... 15
Plane Stress Sign Conventions ............................................................................. 15
Plane Strain Sign Conventions .............................................................................. 16
Drawing Mohr’s Circle for Plane Stress................................................................... 16
Drawing Mohr’s Circle for Plane Strain ................................................................... 18
Principal Plane Angle ........................................................................................... 19
Mohr’s Circle ......................................................................................................... 20
Mohr’s Circle Report ............................................................................................ 22
Chapter 3 – Combined Stress .................................................................................... 23
Combined Stress ................................................................................................... 23
Chapter 4 – Beam Diagrams ...................................................................................... 25
Beam Diagrams..................................................................................................... 25
Units ................................................................................................................. 28
Beam Diagram Report ......................................................................................... 29
Chapter 5 – Fatigue Diagram ..................................................................................... 30
Material Strengths .............................................................................................. 30
Failure Criteria ................................................................................................... 30
Negative Mean Stress.......................................................................................... 31
Safety Factors .................................................................................................... 32
Fatigue Diagram .................................................................................................... 33
Fatigue Diagram Report ....................................................................................... 34
Chapter 6 – Spectral Loading ..................................................................................... 36
Vortarus Technologies LLC 2

Load Plot .............................................................................................................. 36
Load Plot Report ................................................................................................. 37
Pre-process Loads ................................................................................................. 38
Fatigue Damage .................................................................................................... 40
Analysis Algorithm .............................................................................................. 45
Handling More Than 1 Million Data Points............................................................... 46
Fatigue Damage Report ....................................................................................... 47
Chapter 7 – Sheet Metal ........................................................................................... 48
Sheet Metal .......................................................................................................... 50
Flat Blank Report ................................................................................................ 53
Chapter 8– 1D Tolerance Analysis .............................................................................. 56
1D Tolerance Stack-Up Analysis .............................................................................. 56
Stack Height ...................................................................................................... 56
Clearance .......................................................................................................... 56
Model Sheets ..................................................................................................... 57
1D Tolerance Analysis - RSS ................................................................................... 57
Set-up Page ....................................................................................................... 58
Assembly Stack Page .......................................................................................... 59
Results Page ...................................................................................................... 60
1D Tolerance Analysis – Worst Case ........................................................................ 61
Set-up Page ....................................................................................................... 61
Results Page ...................................................................................................... 63
1D Tolerance Analysis – Monte Carlo ....................................................................... 64
Set-Up Page....................................................................................................... 64
Results .............................................................................................................. 67
Tolerance Calculator .............................................................................................. 70
Specify Tolerance Limits ...................................................................................... 71
Specify Sigma Range .......................................................................................... 72
Chapter 9 – 1D/2D/3D Tolerance Analysis ................................................................... 75
Dimension Analysis ................................................................................................ 77
Clearance Analysis................................................................................................. 77
2D Clearance Example ........................................................................................ 78

3D Clearance Example ........................................................................................ 79
Limitations Due to Geometric Imperfections.................... Error! Bookmark not defined.
1D/2D/3D Worst Case ............................................................................................ 80
Results Page ...................................................................................................... 80
Dimension Chain Page ......................................................................................... 81
Calculation Results.................................................... Error! Bookmark not defined.
1D/2D/3D Monte Carlo ........................................................................................... 89
Set-Up Page....................................................................................................... 89
Dimension Chain Page ......................................................................................... 90
Calculation Results.............................................................................................. 92
Simulation Results Page ...................................................................................... 92
Deltas Page........................................................................................................ 94
Chapter 10 – Shaft Design ...................................................................................... 107
Coordinate System ........................................................................................... 107
Assumptions .................................................................................................... 107
Bending Calculations ......................................................................................... 108
Static Analysis .................................................................................................... 108
Static Stress .................................................................................................... 108
Combining Stresses .......................................................................................... 110
Fatigue Analysis .................................................................................................. 112
Fatigue Stress .................................................................................................. 112
Fatigue Safety Factors ....................................................................................... 115
Stress Concentrations .......................................................................................... 118
Critical Speed ..................................................................................................... 118
Shaft Design ....................................................................................................... 118
Model Page ...................................................................................................... 119
Report Page ..................................................................................................... 120
Shaft Page ....................................................................................................... 122
Torque, Radial Loads, Bearings........................................................................... 123
Axial Loading Page ............................................................................................ 124
Stress Concentration Page ................................................................................. 125
Critical Speed Page ........................................................................................... 126
Shaft Design Report............................................................................................. 127
Report Heading ................................................................................................ 127

Diagrams ......................................................................................................... 128
Data for Diagrams ............................................................................................ 128
Chapter 11 – Linkage Synthesis ............................................................................... 129
Terminology ....................................................................................................... 129
Kinematic Dimensional Linkage Synthesis ............................................................... 129
Slider Crank with Driving Link Acting as a Linear Actuator ...................................... 131
Interpretation of Error ....................................................................................... 132
Notes on Function Synthesis .............................................................................. 134
Notes on Motion Synthesis ................................................................................. 135
Cases That May Require Longer to Converge to a Solution ..................................... 136
If Error Does Not Reduce to an Acceptable Level................................................... 136
4 Bar Synthesis ................................................................................................... 136
Progress Form .................................................................................................. 138
Four Bar Synthesis Report ................................................................................. 139
Slider Crank Synthesis ......................................................................................... 140
Progress Form .................................................................................................. 144
Slider Crank Synthesis Report ............................................................................ 144
Chapter 12 – Linkage Analysis ................................................................................. 146
Kinematic Linkage Analysis ................................................................................... 146
4 Bar Classifier.................................................................................................... 146
4 Bar Analysis ..................................................................................................... 148
Linkage Page.................................................................................................... 148
Report Page ..................................................................................................... 150
Notation Page .................................................................................................. 151
4 Bar Analysis Report ........................................................................................ 152
Slider Crank Analysis ........................................................................................... 153
Linkage Page.................................................................................................... 153
Report Page ..................................................................................................... 155
Slider Crank Analysis Report .............................................................................. 156
Chapter 13 – Gearing ............................................................................................. 157
Gear Forces ........................................................................................................ 157
Spur Gear ........................................................................................................ 157
Helical Gear ..................................................................................................... 162
Straight Bevel Gear........................................................................................... 166

Spiral Bevel Gear .............................................................................................. 169
Worm Gear ...................................................................................................... 170
Planetary Gear Train ............................................................................................ 172
Chapter 14 – Vibration ............................................................................................ 175
Natural Frequency ............................................................................................ 175
Undamped Vibration ......................................................................................... 175
Damped Vibration ............................................................................................. 176
Vibration ............................................................................................................ 177
Report ............................................................................................................. 179
Chapter 15 – Hydraulics .......................................................................................... 180
Pump and Motor .................................................................................................. 180
Pump Equations – SI Units ................................................................................. 180
Motor Equations – SI Units................................................................................. 181
Pump Equations – US Units ................................................................................ 182
Motor Equations – US Units ................................................................................ 183
Cylinder ............................................................................................................. 186
Fluid Velocity ...................................................................................................... 187
Chapter 16 – Affinity Laws ...................................................................................... 190
Affinity Law Equations .......................................................................................... 190
Constant Impeller Diameter ............................................................................... 190
Constant Shaft Speed........................................................................................ 190
Constant Shaft Speed, Trimmed Impeller............................................................. 191
Affinity Laws ....................................................................................................... 191
Calculator Page ................................................................................................ 192
Charts Page ..................................................................................................... 193
Charts Report ..................................................................................................... 195
Chapter 17 – System Curve ..................................................................................... 196
System Curve ..................................................................................................... 196
Example ............................................................................................................. 198
Error When Pumps are in Parallel ........................................................................ 199
System Curve Report ........................................................................................ 200
Chapter 18 – Bernoulli Equation ............................................................................... 201
Bernoulli Equation ............................................................................................... 201
Report ............................................................................................................. 203

Chapter 19 – Pressure to Head Conversion ................................................................ 204
Pressure - Head .................................................................................................. 204
Example Conversion.......................................................................................... 205
Chapter 20 – Unit Conversion .................................................................................. 207
Unit Conversion................................................................................................... 207
Notes on Units .................................................................................................... 208
Chapter 21 – Integration ......................................................................................... 209
Model Set-Up ................................................................................................... 209
Integration Tool .................................................................................................. 210
Update Links ....................................................................................................... 212
Protected Sheets .............................................................................................. 213
Appendix A – Specifications & Protected Workbooks ................................................... 214
Specifications ...................................................................................................... 214
Protected Workbooks ........................................................................................... 214
Appendix B – Troubleshooting.................................................................................. 216
Appendix C – Probability Distributions for Monte Carlo Tolerance Analysis ..................... 217
Normal Distribution ............................................................................................. 217
Uniform Distribution ............................................................................................ 218
Triangular Distribution ......................................................................................... 219
Trapezoidal Distribution........................................................................................ 220
PERT Distribution................................................................................................. 221
Appendix D – Decimal Separators ............................................................................ 222

Chapter 1 –Introduction
MEboost is a suite of tools for engineering analysis and charts within Excel.
Features
• Mohr’s circle for plane stress and plane strain.
• Combined stress calculator.
• Beam shear, moment, and deflection diagrams.
• Fatigue diagrams. Goodman, Soderberg, Gerber, and ASME elliptic lines.
• Load plots.
• Spectral loading preprocessing.
• Fatigue damage using rainflow counting algorithm.
• Sheet metal flat blank calculator.
• Root sum squared, worst-case, and Monte Carlo tolerance analysis.
• Tolerance limit calculator.
• Shaft design tool.
• Linkage synthesis and analysis tools.
• Gearing calculation tool for gear forces and planetary gear train speeds.
• Vibration analysis.
• Hydraulics calculators.
• Pump affinity law calculator.
• System and pump curve generator.
• Bernoulli equation calculator.
• Pressure to head converter.
• Unit conversion calculator.
• Monte Carlo integration tool.
System Requirements
Excel Version: Excel 2007 to Excel 2019, Office 365 desktop; 32 and 64 bit
Systems: 32 bit and 64 bit
Windows: Vista to Windows 10
Installing MEboost
Place the MEboost add-in file in a folder that you have access.
Before Installation
Depending on your system settings, you may have to unblock the MEboost add-in file prior
to installing. Right click on the MEboost add-in file. Click on Properties. The following
window will appear:

Figure 1 - File Properties
Check Unblock if it is not already checked. Then click OK.
Excel 2007 Installation Procedure

Click the Office Button in the upper left corner of the Excel window.
Figure 2 - Office Button
Click on the Excel Options button.

Click on Add-ins menu item.

Figure 3 - Excel Options>Add-Ins
In the Manage drop-down box, select “Excel Add-ins” and click the Go button.
In the new window, click Browse and select the MEboost add-in file.
Check the box next to MEboost.
Figure 4 - Add-ins Window

Excel 2010 - 2019 Installation Procedure
Click the File tab in the upper left corner of the Excel window.
Figure 5 - File Tab
Click on Options menu item.

Click on Add-ins menu item.
Figure 6 – Excel Options>Add-Ins
In the Manage drop-down box, select “Excel Add-ins” and click the Go button.
In the new window, click Browse and select the MEboost add-in file.
Check the box next to MEboost and click OK.

Figure 7 - Add-ins Window
Uninstalling MEboost
1. Go to the manage Add-ins window (see Installation section).
2. Uncheck MEboost.
3. Close Add-ins window.
4. Delete theMEboost file or move it to a different folder.
5. Go to the manage Add-ins window.
6. Click on the MEboost check box.
7. A pop-up message will appear that MEboost cannot be found. Click Yes to delete
from list.
8. Close Add-ins window.
Trust Center Settings

Depending on the Trust Center settings, MEboost may not run, or a warning may appear
when Excel is started. To allow the add-in to run or to avoid a warning message on start-up
make sure the Trust Center Settings below are correct.
To open the Trust Center, click the Office Button in the upper left corner of Excel or the File
tab depending on the version of Excel. Then click on the Excel Options button or Options
menu item.

Figure 8 - Excel Options>Trust Center
Click the Trust Center Settings button to open Trust Center. Click on Add-ins menu item.
Make sure all checkboxes are unchecked.
Figure 9 - Trust Center>Add-Ins

Click on File Block Settings menu item. Make sure Excel 2007 and later Add-in Files is
unchecked.
Figure 10 - Trust Center > File Block Settings

Chapter 2 – Mohr’s Circle
Mohr’s circle can easily be generated for conditions of plane stress or plane strain. Principal
stresses (or strains) and maximum shear stress (or shear strain) are shown on the report.
Before discussing Mohr’s circle, let’s cover sign conventions required to draw a proper
diagram.
Plane Stress Sign Conventions

Consider the body under plane stress. In the x direction, it is under tensile stress. In the y
direction, it is under compressive stress. There is also a shear stress present where τyx = -
τxy.
Tensile stress is entered as a positive value. Compressive stress is entered as a negative

value. Shear stress is a bit more complicated. In this example, if τyx causes the body to
rotate clockwise, shear stress is positive. If shear stresses are reversed, shear stress is
entered as a negative value.
Figure 11 - Body Under Plane Stress

Plane Strain Sign Conventions
Plane strain sign conventions follow similarly to plane stress. Consider the body under
plane strain. There is tensile strain in the x direction, and compressive strain in the y
direction. Shearing strain, γyx = -γxy.
Tensile strain is entered as a positive value. Compressive strain is entered as a negative

value. If γyx produces a clockwise strain, then shearing strain is entered as a positive value.
If shearing strains are reversed, then shearing strain is entered as a negative value.
Figure 12 - Body Under Plane Strain
Drawing Mohr’s Circle for Plane Stress

To create Mohr’s circle, we plot the points (σx, -τyx) and (σy, τyx). A circle is drawn so that it
passes through these two points. The principal stresses are the intersection of the circle
with zero shear (the leftmost and rightmost points on the circle). The maximum in-plane
shear stresses are the highest and lowest points on the circle. The principal stress plane is
half the angle of the line between the two points and the x-axis.
Because of the plane stress condition, σz = 0. If we follow the convention that principal
stresses are ordered by σ1 ≥ σ2 ≥ σ3 this means that one of the principal stresses is zero.
What is drawn on the chart depends upon which principal stress is zero.

For example, the condition where σ1> 0, σ2 = 0, and σ3< 0. A Mohr’s circle for this condition
is shown below. A single circle is drawn that passes through σ1 and σ3. The maximum
shear stress is in the xy plane.
Figure 13–Explanation of Mohr's Circle for Plane Stress, σ1>0, σ2 = 0, σ3< 0
Now let’s look at the condition where σ1> 0, σ2> 0, and σ3 = 0. Both principal stresses in the
xy plane are positive. For this case, three circles are drawn. The first circle passes through
σ1 and σ2. The second passes through σ2 and σ3. Finally, the third circle passes through σ1
and σ3.
The top of the first circle is the maximum in-plane shear stress. Notice that the third circle
has a larger diameter so that the overall maximum shear stress is greater than the in-plane
shear stress. In this example, τ13 is the maximum shear stress.

Figure 14– Explanation of Mohr's Circle for Plane Stress, σ1 >0, σ2 > 0, σ3 = 0
If σ1= 0, σ2< 0, and σ3< 0, three circles will be drawn similar to the previous example.
Drawing Mohr’s Circle for Plane Strain

Mohr’s circle for plane strain has a key difference with plane stress. In plane stress,
maximum shear stress is at the top and bottom of the circle. In plane strain, the top and
bottom of the circle is maximum shearing strain divided by 2. The two strain points are also
plotted with shearing strain divided by 2.
For plane strain, if x-y is the plane of reference, εz = γzx = γzy = 0.
Where:
εz is strain in the z direction.
γzx is shearing strain in the z-x plane.
γzy is shearing strain in the z-y plane.
This is another difference from Mohr’s circle for plane stress. There will only be one circle
for plane strain.

Figure 15– Explanation of Mohr's Circle for Plane Strain
Principal Plane Angle

The principal plane angle from the x direction is given by ϴ. On Mohr’s circle, 2ϴ is the
angle between the red line and the x-axis. An example of principal stress planes is shown
below.

Figure 16 - Principal Plane Angle
Mohr’s Circle
Ribbon>MEboost tab>Mohr’s Circle button
MEboost can easily create Mohr’s circle with just a few inputs. The chart is created in a new
worksheet and includes the data used to create the plot. It is a native Excel chart and can
be edited to meet your formatting needs. Note: If editing the scale of axes, each axis must
have the same range to maintain a circle.
Clicking the Mohr’s Circle button on the ribbon will show the Mohr’s Circle form.

Figure 17–Mohr’s Circle Form
Report
Enter a name for the report. A new sheet in the current workbook or a new workbook will
be created and named using the report name.
Condition
Select either plane stress or plane strain.
Values
Enter values for stresses or strains. Be mindful of the sign conventions discussed earlier. If
you want to show labels for the points (σx, -τyx) and (σy, τyx) or (εx, -γyx) and (εy, γyx), check
Show stress labels.
To maintain a circle in the chart, all values on the x and y axes are set to 0 decimal places.
When creating Mohr’s circle for plane strain, this would result on all zeros, on both axes.
Strains should be entered as micro-strain or a conversion that eliminates decimals.
For example, suppose we have the following condition:
εx = .001044
εy = -.000651
γyx = .000289
To convert these values to micro-strain, we multiply each value by 106. The values entered
are now:

εx = 1044
εy = -651
γyx = 289
Click the Create button to generate the report.
Mohr’s Circle Report

The report will show principal stresses and shear (or strains). Theta is the angle from the x
direction of the principal stress plane. Note that the angle of the red line to the x-axis is
2ϴ.
An example report is shown in Figure 18. Data used to create the chart is included in the
worksheet and the chart is a native Excel chart. The chart’s appearance can be changed
using Excel’s editing tools.
Figure 18 - Mohr's Circle Report

Chapter 3 – Combined Stress
The combined stress tool calculates stresses applicable to various failure theories for a plane
stress condition. The stresses calculated are:
• Von Mises stress for the maximum distortion energy theory.

• Maximum shear stress for the maximum shear stress theory.
• Principal stresses for the maximum normal stress theory.
Combined Stress
Ribbon>MEboost tab>Combined Stress button
Clicking the Combined Stress button on the ribbon will open the following form.
Figure 19–Combined Stresses Form

Stress State
Enter stresses in the x and y direction as follows:
• A positive number for tensile stress
• A negative number for compressive stress
If there is no stress for a direction (or no shear stress), enter 0.
Figure 20 - Example Stress State
Results
After calculating, the results will appear in the box. The results can be pasted in a
worksheet.
For maximum shear stress, the maximum in-plane (xy) shear stress and maximum out of
plane shear stress (either xz or yz) are calculated.

Chapter 4 – Beam Diagrams
The beam diagrams tool can generate shear and moment diagrams for any statically
determinate beam. It can also generate a deflection diagram for a statically determinate
beam with constant moment of inertia and modulus of elasticity.
The following loads and couples can be applied to the beam:

• Point load
• Uniformly distributed load
• Linearly increasing distributed load
• Linearly decreasing distributed load
• Couples
Loads are specified in the up or down direction, and couples are specified as clockwise or
counterclockwise. Distributed loads are specified with a starting magnitude on the left side
and an ending magnitude on the right side.
To be statically determinate, a beam must meet either of the following support conditions:
• One fixed support located at either end of the beam.
• Two simple supports located anywhere on the beam.
Deflection is determined using the area moment method, and deflection due to shearing
stress is neglected.
Beam Diagrams
Ribbon>MEboost tab> Beam Diagrams button
Clicking on the Beam Diagrams button will show the following form.

Figure 21 - Beam Diagrams Form
Loads, Couples, and Supports

Loads, couples, and supports are added one at time. First select the type of element to
add. Depending on the element, parameter boxes will appear to specify location and
magnitude.
After the parameters have been entered, click the Add button and the element will appear in
the box.
Beam ends are a special item that are used to specify an end of the beam that is unloaded.
This is used when we have an unloaded portion of the beam that extends beyond the last
load or support and we want to determine the deflection to the end of the beam. If one or
both beam ends are not specified, the diagrams will start with the first element’s x location
and end with the last element’s x location.
For example, consider the following simply supported beam with an increasing distributed
load.

15 lb/in
5 lb/in
X: 0 15 25 75 100
Example Beam Loading
To analyze this beam, we enter the following:
Figure 22 - Example Beam with Loads and Supports

Note that the left end of the beam extends to the left of any load or support. To include the
unloaded portion from X = 0 to 15, we use a beam end to specify that the beam starts at 0.
Without the left beam end, the diagrams would start at 15. Since the distributed load goes
to the right end of the beam, we do not need to specify a right beam end.
Diagrams
Check any diagrams that you want include in the report. You must also specify the X
increment that will be used to generate diagrams. For non-linear portions of the diagrams,
a smaller increment will result in a more precise curve. The default value is .001 for SI
units which results in 1000 increments per meter. The default value is .04 for US units
which results in 25 increments per inch.
Properties
If a deflection diagram is selected, you will need to specify the moment of inertia and
modulus of elasticity for the beam.
Report
Enter a name for the report and select the report location.
Units
If only shear and moment diagrams are desired, you can use any units you want if all X
values have the same units and all forces have the same units. The shear diagram will be
in the force units that you choose. The moment diagram will be in force-length units that
you choose.
If a deflection diagram is included, you must specify values in the following units.
System Value Units

SI Distance (X value) Meter
SI Force Newton
SI Distributed load Newton/meter
SI Couple Newton-meter
SI Moment of inertia m4
SI Modulus of elasticity GPa
US customary Distance (X value) Inch
US customary Force Pound-force
US customary Distributed load lb/in
US customary Couple in-lb
US customary Moment of inertia in4
US customary Modulus of elasticity Mpsi
For SI, deflection is in millimeters. For US customary, deflection is in inches.

Beam Diagram Report
An example report is shown below. Data used to create the chart is included in the
Figure 23 - Beam Diagrams Report

Chapter 5 – Fatigue Diagram
MEboost can construct various stress-life fatigue diagrams for infinite life which use different
fatigue failure models to determine safe load regions for combinations of alternating and
mean stress.
Material Strengths
Before describing the diagrams, let’s define a few terms.
Tensile Strength The maximum stress a material can withstand before the material
fractures.
Yield Strength The stress level where the material permanently deforms.
Fatigue Limit The maximum stress level that the material can be subjected to for a very
large number of cycles without failure. The term endurance limit is often used for the stress
that a material can withstand for an unlimited number of cycles. Some materials, aluminum
for example, do not have an endurance limit, and a fatigue limit is assumed for a large
number of cycles, such as 107 or 108 cycles.
Failure Criteria
A fatigue plot consists of alternating stress on the y-axis and mean stress on the x-axis.
MEboost can create diagrams with the following failure criteria:
Soderberg A line from fatigue limit on the y-axis to the yield strength on the x-axis. This
is the most conservative model.
Goodman A line from fatigue limit on the y-axis to the ultimate strength on the x-axis.
Gerber A parabolic curve from fatigue limit on the y-axis to ultimate strength on the x-
axis. This is the least conservative model.
ASME Elliptic An elliptic curve from fatigue limit on the y-axis to yield strength on the x-
axis.
Yield A line from yield strength on the y-axis to yield strength on the x-axis. This is used
in conjunction with the Goodman, Gerber and ASME elliptic lines when yielding is a criterion
of failure.
An example of each line is shown below for a material with a tensile strength of 55,000,
yield strength of 30,000, and fatigue limit of 22,500.

Figure 24 - Fatigue Diagram Lines
Negative Mean Stress

Negative mean stress is handled differently. Each mean stress correction theory is more
permissive regarding compressive mean stress. In the diagram below, the operating point
is a mean stress of -10,000 with an alternating stress of 15,000. Each mean stress theory
is a horizontal line at the fatigue limit.
We also need to consider first cycle yield failure which is denoted by the yield line. An
important assumption with the diagram is that yield strength in compression is the same as
yield strength in tension. For asymmetric materials, the compressive yield strength is
greater than tensile yield strength, and the diagram will not apply to these materials.

Figure 25 - Negative Mean Stress
Safety Factors
To this point, we haven’t accounted for safety factors. To add safety factors to the diagram,
we reduce the strength values. Let’s say we will use a safety factor of 1.75 for the example
in Figure 24. To construct the diagram with safety factors we reduce the strengths using
the following relations:
55,000
𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ (𝑤𝑖𝑡ℎ 𝑆. 𝐹. ) = = 31,429
1.75
30,000
𝑌𝑖𝑒𝑙𝑑 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ (𝑤𝑖𝑡ℎ 𝑆. 𝐹. ) = = 17,143
1.75
15,000
𝐹𝑎𝑡𝑖𝑔𝑢𝑒 𝐿𝑖𝑚𝑖𝑡 (𝑤𝑖𝑡ℎ 𝑆. 𝐹. ) = = 12,857
1.75
The diagram with safety factors is shown below.

Figure 26 - Fatigue Diagram with Safety Factors
Fatigue Diagram
Ribbon>MEboost tab>Fatigue Diagram button
Clicking the Fatigue Diagram button on the ribbon will show the Fatigue Diagram form.

Figure 27–Fatigue Diagram Form
Report
Strengths
Enter the strength values for the material. If safety factors are applied, enter the reduced
strengths.
Include Lines
Select any lines you want to include in the chart.
Operating Point (optional)

You can plot the operating point where alternating stress and mean stress meet on the
chart. Check Show operating point and enter the mean stress and alternating stress that
will be applied during operation.
Fatigue Diagram Report

An example report is shown in Figure 28. Data used to create the chart is included in the

Figure 28 - Example Fatigue Diagram Report

Chapter 6 – Spectral Loading
The spectral loading module contains tools for manipulating and analyzing spectral loading
data. In this chapter, loading is used in the generic sense; it can refer to load, stress,
torque, or strain.
Load Plot
Ribbon>MEboost tab> Spectral Loading button > Load Plot button
The load plot tool creates a plot of loading data vs. time. A column of data is selected and
plotted with data order from top to bottom on the x-axis.
Clicking on the Load Plot button will show the Load Plot form.
Figure 29 - Load Plot Form

Report
Data Range
Select or enter the range of cells containing the loading data.
Load Plot Report

Clicking the Create button will generate a report for the load plot. An example report is
shown in Figure 30. Data used to create the chart is included in the worksheet and the
chart is a native Excel chart. The chart’s appearance can be changed using Excel’s editing
tools.
Figure 30 - Example Load Plot Report

Pre-process Loads
Ribbon>MEboost tab> Spectral Loading button > Pre-process Loads button
When analyzing fatigue damage, the stress data must be filtered so that only peak and
valley loads are in the data. Peak and valley loads are defined as points where the first
derivative of load-time changes sign. When measuring loads, the measurement system
may be recording at a faster rate than load cycles which results in several measurements
that are increasing or decreasing in succession. Preprocessing will filter out any data points
that don’t indicate a load reversal.
An example is shown below. The first chart shows data before filtering.
Figure 31 - Data Before Filtering
The chart below shows the data after filtering. Note that only peak and valley amplitudes
are present. A peak is where the first derivative of the amplitude changes from positive to
negative. A valley is where the first derivative changes from negative to positive.

Peak
Valley
Figure 32 - Data After Filtering
Clicking the Pre-process Loads button will show the Pre-process Loads form.
Figure 33 - Pre-process Loads Form
Data Range
Select or enter the range of cells containing the raw loading data.
Top Cell of Processed Data

Processed data will be written to a range of cells in the workbook as a column. Select or
enter the top cell of the range where the data will be written. Note that any cell contents in
the range will be overwritten.

Fatigue Damage
Ribbon>MEboost tab> Spectral Loading button >Fatigue Damage button
The fatigue damage tool analyzes material damage caused by fatigue. Historical stress data
can be used to estimate material damage to existing parts or used to estimate life of new
parts. If projected stress levels are known, synthetic data can also be used. Stress cycles
are counted using the rain flow algorithm. Damage is calculated using Miner’s rule.
Clicking the Fatigue Damage button on the ribbon will show the Cumulative Fatigue Damage
form.
Figure 34–Cumulative Fatigue Damage Form

Report
Data Range
Select or enter the range of cells containing the stress data. The stress levels (peak to
valley or valley to peak) are binned. Enter the number of bins to use.
When stress values are binned, each value assigned to a bin assumes the midpoint of the
bin. This results in some values being rounded up, and some rounded down. The more
bins used, the more accurate the calculation. It’s recommended to use at least 50 bins.
The data must be in units of stress that are consistent with the S-N data. The stress data
must also be filtered so that only peak and valley data points are included. This can easily
be accomplished using the pre-process loads tool.
S-N Data
S-N data is the stress vs. number of cycles to failure for the material used. This data is
used for damage calculation using Miner’s rule which is discussed later.Place the S-N data in
a range of cells somewhere in the workbook. Requirements for S-N data are:
• Stress must be in the first column.

• Cycles to failure must be in the second column.
• Data must be sorted with N in ascending order.
An example S-N data set is shown below with the data selected.

Figure 35 - S-N Data Selection
If the stress amplitude exceeds the first data point, an error will result because the S-N
curve is undefined. Consider the S-N diagram below.
S = 65
Figure 36 - Example S-N Diagram with Undefined Region
If the stress amplitude is 65, the S-N curve is not defined in this region. Therefore, the
number of cycles to failure is not available. The C value in the report will have this
message: “Stress exceeds S-N data.”

There are two options for handling stress amplitudes that are less than the minimum S
value. For materials with a fatigue limit, damage is typically not calculated if the stress
amplitude below this threshold. For materials without a fatigue limit, damage can be
calculated using the highest N value supplied. This is somewhat conservative since actual
cycles to failure at stress levels below the last point is likely greater than the last point. In
the S-N diagram below, we see the two options.
Option 1: No damage region

Option 2: Uses 1 x 107 cycles in this
region
Figure 37 - Handling of Stress Below Fatigue Limit
Interpolation
To get a fatigue life value, N from the data, interpolation is used when a stress falls between
S-N data points.
There are three methods of interpolation:

• Log-log
• Semi-log
• Linear
The interpolation method selected can have a large impact on results. Shigley& Mischke [1]
show that when limited S-N data is available, the S-N curve can be approximated by a
power law where the data is a straight line when plotted log(S) vs. log(N).
S = aNb
Where a and b are constants.
Note that the slope is generally different for low cycle (N<1000) and high cycle (N>1000)
fatigue.

Thus, if there is limited data, we could assume the power law interpretation of the data and
use log-log interpolation.
Semi-log interpolation is used when the plot of S vs. log(N) is a straight line.
Linear interpolation is used when there are many data points. If this method is used with
few data points, it is far less conservative than the other two methods.
To illustrate differences for the methods, consider the S-N data that was selected earlier. It
is repeated here (in kpsi).
S N
58.50 1000
53.35 3000
48.22 10000
43.97 30000
39.74 100000
36.80 250000
34.72 500000
33.56 750000
32.76 1000000
32.76 10000000
Let’s say S is 40 and we want to interpolate the N value. First, we’ll use the data available
and interpolate between S,N (43.97,30000) and S,N(39.74,100000). Now, let’s say we only
have data at N=1000 and N = 1,000,000. We’ll use each method to interpolate between
these points.
Log-log Semi-log Linear

N @ S = 40 92661 92990 95775 Between S = 43.97 and 39.74
N @ S = 40 92661 143277 719007 Between S = 58.50 and 32.76
Notice in the first case where there are more data points, the three methods have relatively
small differences in the fatigue life. In the second case, there is a significant difference
between log-log and semi-log. There is a drastic difference between log-log and linear
interpolation.
If in doubt about which method to use, the conservative choice is log-log.
[1] Shigley, J., Mischke, C., Mechanical Engineering Design, 5th Edition, 1989, McGraw-Hill,
pp. 278-280.

Mean Stress Correction
Assuming the S-N data was generated with stress that has a mean of zero, a correction can
be applied to the stress amplitudes to account for non-zero mean stress. There are three
corrections available: Goodman, Gerber, and Soderberg.
Goodman
𝜎𝑎
𝜎𝑚𝑒𝑎𝑛 , 𝜎𝑎 > 0
σeff = 𝑓(𝑥) = {1 − 𝑈𝑇𝑆
𝜎𝑎 , 𝜎𝑎 ≤ 0
Where:
𝜎𝑒𝑓𝑓 = 𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
1
𝜎𝑎 = 𝑠𝑡𝑟𝑒𝑠𝑠 𝑎𝑚𝑝𝑙𝑖𝑡𝑢𝑑𝑒 ( 𝑠𝑡𝑟𝑒𝑠𝑠 𝑟𝑎𝑛𝑔𝑒)
2
𝜎𝑚𝑒𝑎𝑛 = 𝑚𝑒𝑎𝑛 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑐𝑦𝑐𝑙𝑒
𝑈𝑇𝑆 = 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
Gerber
𝜎𝑎
σeff = 𝑓(𝑥) = , − 𝜎𝑎 ≤ 𝜎𝑚𝑒𝑎𝑛 ≤ 𝜎𝑎
𝜎𝑚𝑒𝑎𝑛 2
1−[ ]
𝑈𝑇𝑆
Soderberg
𝜎𝑎
𝜎𝑚𝑒𝑎𝑛 , 𝜎𝑎 > 0
σeff = 𝑓(𝑥) = {1 − 𝑌𝑆
𝜎𝑎 , 𝜎𝑎 ≤ 0
Where:
𝑌𝑆 = 𝑦𝑖𝑒𝑙𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
Analysis Algorithm
During the first step, the software counts the number of stress cycles using the rain flow
counting algorithm. The rain flow counting algorithm is implemented per ASTM 1049-85.
When a cycle is counted, its stress level (peak to valley or valley to peak) is placed in a bin
for that level. The bin value, which covers a range of values, is used in the Miner’s rule
calculation. Bin values are the midpoint of their range.

After stress cycles have been counted, Miner’s rule is used to compute cumulative fatigue
damage. The report will show a value for C which is the fraction of fatigue life used during
loading. A value of C greater than or equal to one means the fatigue life has theoretically
been met or exceeded.
Miner’s Rule
Miner’s rule adds cumulative damage associated with different stress magnitudes. For each
magnitude, the number of cycles is multiplied by the stress level. These products
aresummed to determine the proportion of fatigue life incurred.
𝑘
𝑛𝑖
∑ =𝐶
𝑁𝑖
𝑖=1
Where:
k is the number of stress levels.
ni is the number of cycles at stress level i.
Ni is the fatigue life cycles at stress level i.
When mean correction is applied, Ni is the fatigue life at effective stress. When mean stress
is greater than zero, effective stress is increased. Therefore, Ni is less than if no correction
was made.
Limitations of Miner’s Rule

Miner’s rule has limitations which should be considered:
• S-N data will have a random element that results in scatter. The S-N curve will not
be exact.
• Miner’s rule does not consider the order in which high stress vs. low stress cycles
occur. The order can affect fatigue life.
Handling More Than 1 Million Data Points

The maximum number of rows in an Excel worksheet is 1,048,576. If there are more data
points than there are rows available, this can be handled by the following procedure:
1. Place stress data in several columns.

2. Run a separate fatigue damage report for each column.
3. Add all C values to get a total C value.
It is advisable to use the same number of bins for each report. One limitation of this
method is that the bin ranges for each run will likely be different since bin ranges are based
on the minimum and maximum stress in each data batch.

Fatigue Damage Report
An example report is shown below. It includes the calculated C value and a matrix of stress
cycle counts arranged by stress ranges vs. mean stress. Stress ranges and mean stress
values are the midpoint of each bin.
Figure 38 - Example Fatigue Damage Report

Chapter 7 – Sheet Metal
The sheet metal tool calculates flat blank dimensions.
An example flat blank is shown below with bends that are dimensioned in two directions.
The sheet metal tool can accommodate flat blank calculations in two directions.
Figure 39 - Flat Blank
MEboost uses the concept of a K factor to calculate flat blank dimensions. When a material
is bent, some material on the inside of the bend is compressed, and some material on the
outside of the bend is stretched. There is a point in the material thickness where the
material doesn’t compress or stretch. This is the neutral axis. The location of the neutral
axis is specified with the K factor. It is the fraction of material thickness from the inside of
the bend to the neutral axis. Flat blank dimensions are calculated by determining the path
length along the neutral axis.
For example, consider the following part that has a 90 o bend.

Figure 40 - Bend Terminology
To calculate the bend line location and flat blank overall dimension, the software calculates
the path length along the neutral axis. L1 and L2 are the straight legs of the part. The
location of the neutral axis affects the path length through the bend, L3. The K factor is
defined as:
𝑁
𝐾=
𝑇
The length of L3 is then the arc length through 90o. For non-90o bends, the ∏/2 term is
replaced with the bend angle in radians.
𝜋
𝐿3 = ( ) (𝐾𝑇 + 𝑅)
2
The distance to the bend line is:
𝑏𝑒𝑛𝑑 𝑙𝑖𝑛𝑒 𝑑𝑖𝑚𝑒𝑛𝑠𝑖𝑜𝑛 = 𝐿1 + 0.5𝐿3

The overall flat blank dimension is:
𝑓𝑙𝑎𝑡 𝑏𝑙𝑎𝑛𝑘 𝑑𝑖𝑚𝑒𝑛𝑠𝑖𝑜𝑛 = 𝐿1 + 𝐿2 + 𝐿3
K factor is a coefficient that is affected by the brake tooling as well as the material.
Publications such as Machinery’s Handbook give general recommendations for K factors, but
the best practice is to determine them from actual tool set-ups and materials.
Sheet Metal
Ribbon>MEboost tab>Sheet Metal button
Clicking the Sheet Metal button on the ribbon will show the Sheet Metal form.
Figure 41–Sheet Metal Form

Flat Blank Report
General Conditions
Enter the material thickness and K factor.
Select whether to use outside or inside dimensions. Depending on the selection, all
dimensions must be entered as inside or outside dimensions. If a dimension is “mixed”,
which means it’s partially inside and partially outside, it will need to be converted to either
inside or outside by adding or subtracting material thickness. Examples of dimension types
are shown below.
Figure 42 - Dimension Types
Add Bends
Each bend is added using add bends. Enter the bend radius, bend angle, bend type, and
dimension. Then select which direction to add the bend. Click the Add button and the bend
will appear either in Direction 1 bends or Direction 2 bends.

For angles that aren’t 90o, the dimensions entered should be to the theoretical edge as if it
were a 90o bend.
Figure 43 - Non-90o Bend Dimensions
Direction 1 and Direction 2 Bends

Bends for each direction will appear in each box. Bends can be edited by selecting a bend a
clicking the Edit buttons. Bends can also be removed using the Remove buttons.
Last leg dimension is the dimension from the last bend to the edge of the material.
The Sheet Metal form with bends added is shown below.

Figure 44 - Populated Sheet Metal Form
Flat Blank Report

Clicking the Create button will generate a flat blank report. The dimensions of the flat blank
in each direction will be calculated as well as the location to each bend line from the starting
edge of the material.
The report will show the total flat blank length for each direction. The first column lists the
straight leg length or the neutral axis arc length if there is a bend.

Figure 45–Example Flat Blank Report
If bends are too close together, the straight leg length between the bends will be negative.
That is, the second bend starts before the first bend ends. When this happens, the straight
leg length is highlighted in red. Note: This only calculates if bends are too close but does
not mean the bend is still possible. Tooling geometry may not allow for bends that are
theoretically possible.

Figure 46 - Example of Bends That Are Too Close Together

Chapter 8– 1D Tolerance Analysis
MEboost can perform tolerance stack-up analysis of an assembly and determine tolerance
limits for a part dimension.
1D Tolerance Stack-Up Analysis

MEboost has three 1D tolerance stack-up analysis tools available:
• Root sum squared
• Worst case
• Monte Carlo simulation
For each tool above, there are two types of calculations: stack height and clearance.
Stack Height
The stack height calculation assumes parts are in a single stack and the stack height is
calculated. For RSS a minimum and/or maximum stack height is specified, and the
rejection rate is determined from these values.
For worst case, the maximum and minimum stack heights are calculated based on either
minimum material condition or maximum material condition.
Monte Carlo simulation treats each part’s dimension as a random variable that is repeatedly
sampled. Each simulation trial, the sampled dimensions are added together to determine
stack height. From all the trials we get summary statistics for the stack such as mean,
variance, and percentiles. The probability of the stack being greater or less than a value
can easily be determined from the simulation data.
Clearance
To calculate clearance, we need to define parts in the assembly as either inner or outer
parts. Inner parts are assembled to fit inside one or more outer parts. Clearance
calculations determine the clearance between inner and outer parts. Outer part dimensions
must be greater than inner part dimensions to have clearance.

Figure 47 - Example Assembly with Inner and Outer Parts
Figure 47 shows an assembly with greatly exaggerated part clearances. Parts A and B must
fit inside part C. For tolerance analysis in MEboost, we define parts A and B as inner parts
and part C as an outer part.
Model Sheets
After an assembly is created, it can be saved to a worksheet called a model sheet. This
sheet contains all information about the assembly and can be loaded later for further
analysis.
1D Tolerance Analysis - RSS

Ribbon>MEboost tab>Tolerance Analysis button> 1D RSS button
Root sum squared (RSS) analysis assumes that each part’s dimension is normally
distributed and that we know the mean and standard deviation of the dimension. When
normally distributed random variables are added or subtracted, we can add or subtract the
mean values to get the mean for the stack. To get the nominal dimension for a stack, we

simply add the mean of each part. To get the nominal clearance, we subtract the mean of
the inner parts from the mean of the outer parts.
Standard deviations cannot be added, but variances can. Variance is the square of standard
deviation. This is where the root sum squared name comes in. Note that when subtracting
one normal random variable from another, the variances are added, not subtracted. To get
the standard deviation of the stack we sum the square of each standard deviation to get the
total variance. We then take the square root of the stack variance to get the standard
deviation.
Clicking the 1D RSS button on the ribbon will open the RSS Tolerance Analysis form.
Set-up Page
Figure 48–RSS Tolerance Analysis > Set-up page
Model Sheet
If you want to load an existing assembly, select it from the drop-down box. Only RSS
models will appear. To create a new assembly, select New Model and enter the model
name.
Calculate…
Select the type of analysis you want to perform. Note that if stack height is selected and
the assembly contains outer parts, they will be ignored when calculating stack height.

Parameters for Rejection Rate
When doing RSS analysis, rejection rate is calculated. For clearance calculations, the
percentage of assemblies that have interference fits is the rejection rate. To calculate
rejection rate with a clearance other than zero, enter the minimum acceptable clearance in
the box. A negative value of minimum clearance means that some level of interference is
acceptable.
For stack height calculations, a minimum stack dimension, maximum stack dimension, or
both must be entered. Any assemblies ≤ minimum or ≥ maximum are rejected.
Saving the Model

To save a new or existing model, click the Save button. The Save button only creates or
overwrites a worksheet with the model information. The workbook must be saved
to avoid losing data when the workbook is closed.
Assembly Stack Page

The assembly stack page is used to create the assembly by defining each part.
Figure 49 -RSS Tolerance Analysis >Assembly Stack page
Add Part to Stack

To add a part, enter a unique part name, the nominal dimension, standard deviation, and
type. Then click the Add Part button.
Since each part is assumed to follow the normal distribution, the nominal dimension is
considered the mean.

Part type is used to determine how the parts fit together. Inner parts are assumed to mate
together and are used to calculate stack height. Outer parts contain inner parts and are
used when calculating clearance. Clearance is calculated by:
𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = ∑ 𝑜𝑢𝑡𝑒𝑟 𝑝𝑎𝑟𝑡𝑠 − ∑ 𝑖𝑛𝑛𝑒𝑟 𝑝𝑎𝑟𝑡𝑠
Assembly Stack
When parts are added, they will appear in the assembly stack box. Parts can be edited by
selecting one and clicking the Edit Part button. Parts can be deleted by selecting one and
clicking the Delete Part button.
Results Page
After set-up and assembly stack information has been entered, the results page shows the
final calculations.
Figure 50 - RSS Tolerance Analysis >Results page
Calculate
Click the Calculate button to generate results. If the assembly or set-up information is
changed, click Calculate again to update results.

Results
Results will appear in the results box. Different calculations will be made depending on the
set-up settings.
Report
Click Create Report to generate a report in a new worksheet or new workbook.
1D Tolerance Analysis – Worst Case

Ribbon>MEboost tab> Tolerance Analysis button> 1D Worst case button
Worst case tolerance analysis, for the most part, guarantees that all parts will fit. In worst
case analysis we are simply using either maximum or minimum material condition to set
tolerances so that they always fit.
Clicking the 1D Worst Case button on the ribbon will open the Worst Case Tolerance
Analysis form.
Set-up Page
Figure 51 - Worst Case Tolerance Analysis Form > Set-up page

Model Sheet
If you want to load an existing assembly, select it from the drop-down box. Only worst case
models will appear. To create a new assembly, select New Model and enter the model
name.
Calculate…
Saving the Model

Assembly Stack Page

The assembly stack page is used to create the assembly by defining each part.
Figure 52 - Worst Case Tolerance Analysis Form >Assembly Stack page
Add Part to Stack

To add a part, enter a unique part name, the nominal dimension, minimum value, maximum
value, and type. Then click the Add Part button.
The minimum value is the minimum dimension of the part. The maximum value is the
maximum dimension of the part.

Assembly Stack
Results Page
After set-up and assembly stack information has been entered, the results page shows the
final calculations.
Figure 53 - Worst Case Tolerance Analysis Form >Results page
Calculate
Click the Calculate button to generate results. If the assembly or set-up information is
changed, click Calculate again to update results.
Results
Results will appear in the results box. Different calculations will be made depending on the
set-up settings. In the example above, there is interference between parts A & B and part
C. To avoid interference, dimensions and/or tolerances on the parts must be adjusted to
obtain zero interference.

Report
1D Tolerance Analysis – Monte Carlo

Ribbon>MEboost tab> Tolerance Analysis button> 1D Monte Carlo button
Monte Carlo simulation is the most general statistical method of tolerance analysis. Like
RSS, each dimension is treated as a random variable. Monte Carlo simulation doesn’t limit
each dimension to the normal distribution as was the case for RSS. MEboost has five
probability distributions available:
• Normal
• Uniform
• Triangular
• Trapezoidal
• PERT
The normal and uniform distributions are typically used when there is data available on the
manufacturing process. The triangular, trapezoidal, and PERT distributions rely on
estimates for parameters and are used where limited data is available. Refer to Appendix C
for more information on the probability distributions.
Clicking the 1D Monte Carlo button on the ribbon will open the Monte Carlo Tolerance
Analysis form.
Set-Up Page
Model Sheet
If you want to load an existing assembly, select it from the drop-down box. Only Monte
Carlo models will appear. To create a new assembly, select New Model and enter the model
name.
Calculate…

Simulation Trials
Enter the number of simulation trials to run.
Histogram Bins
When a simulation is run, stack height or clearance from each trial is binned to create a
histogram. You can enter the desired number of bins or use the default value.
Running the Simulation

Click the Run Simulation button to perform the simulation. Note: The assembly stack must
be created, and the model saved prior to running a simulation. Simulation data is written to
the worksheet containing the assembly information.
Report
Saving the Model

To save a new or existing model, click the Save button. Note: to save a simulation, click
the Save button after running the simulation. The Save button only creates or
Figure 54 - Monte Carlo Tolerance Analysis Form > Set-up page

Assembly Stack Page
Add Part to Stack
Enter a unique part name, select the part type and its distribution. Parameter boxes for the
distribution will appear and the parameter values are entered. For more on distribution
parameters, refer to Appendix C. When done click the Add Part button.
Assembly Stack
Figure 55 - Monte Carlo Tolerance Analysis Form >Assembly Stack page

Results
After set-up and assembly stack information has been entered, click the Run Simulation
button. The results page shows the simulation results.
Simulation Results
After running a simulation, click on the results page. Summary statistics will appear along
with a histogram of the results. The values used to calculate statistics and shown on the
histogram are based on either stack height or clearance, depending on the setting chosen
on the set-up page. Simulation data for the last simulation is on the model worksheet.
Figure 56 - Monte Carlo Tolerance Analysis Form >Results page
Percentiles
Percentiles are calculated using Excel’s PERCENTILE.INC function.
Probability Grab Bars

The histogram has two bars that can be moved to get a look at the probabilities of various
outcomes. To adjust the bars, click on the red squares and drag to the desired position. An
example with the grab bars adjusted is shown below.
The grab bars and their associated values can be hidden by checking the Hide box.

probability > right bar
left bar ≤ probability ≤ right bar
probability < left bar
Grab bar output values.
Figure 57 - Grab Bar Adjustment
Probability Analysis
To conduct a probability analysis of the model output falling within a range of values use the
Lower Set Point and Upper Set Point boxes.
To determine the probability above and below a single output value, enter that value in
either the Lower Set Point or Upper Set Point box as shown below and click the Update
button. The lower set point was used in the example shown in Figure 58.
If the lower or upper set points are used without the other, they calculate probability
differently to accomplish different goals.
When a value is entered in the lower set point, but not the upper set point, the probability
will be calculated for less than or equal to the lower set point. The probability of greater
than the lower set point will also be calculated.
When a value is entered in the upper set point, but not the lower set point, the probability
will be calculated for less than the upper set point. The probability of greater than or equal
to the upper set point will also be calculated.

The use of single set points is summarized in the table below:
To Determine Set Point to Use

Probability < set point Upper
Probability <= set point Lower
Probability > set point Lower
Probability >= set point Upper
Figure 58 - Single Point Probability Analysis
In the example above, the model output is clearance. We would like to know the probability
of interference which would result in rejection. Entering 0 (zero clearance) in the lower set
point box and clicking Update, we see that the probability of an interference fit is 2.664%.
To determine the probability between two output values, enter the lower value in the Lower
Set Point box and the upper value in the Upper Set Point box as shown in Figure 59 and
click the Update button. In the example, the probability of the clearance from 0 to .001 is
0.916%.

Figure 59 - Range Probability Analysis
Tolerance Calculator
Ribbon>MEboost tab> Tolerance Analysis button> Tolerance Calculator button
The tolerance calculator allows you to estimate the rejection rate given a probability
distribution for a dimension. A tolerance range is specified by a range of sigmas (standard
deviation) around the nominal dimension, or you can directly specify the dimensional
tolerance limits.

There are five probability distributions available:
• Normal
• Uniform
• Triangular
• Trapezoidal
• PERT
The normal distribution is generally used when there is data available on the manufacturing
process and is normally distributed. The uniform distribution might be used to model
machine tool wear. The remaining distributions are generally used when you can only
estimate the parameters of the distribution.
Specify Tolerance Limits

In the example below we have a part with a nominal dimension of 5 that is normally
distributed. We have determined the standard deviation of the manufacturing process is
.0001. We have already set the tolerance limits at +/- .010 and want to find the
percentage of parts outside the tolerance limits (rejected parts).
Figure 60 - Tolerance Calculator Form
If we click the Calculate button, we get the results shown in Figure 61.
Nominal dimension is the mean of the distribution.

The results include both the +/- tolerance value and actual upper and lower tolerance limits.
In our example, we could specify a dimension of 5 +/- .003 or a dimension of 5.003/4.997.
The rejection rate for our example is .086%. Given the probability distribution, we would
expect .086% of the parts to either be < 4.990 or > 5.010 and would therefore be out of
tolerance.
Figure 61 - Tolerance Calculator Results
Specify Sigma Range

In the example below we have a part with a nominal dimension of 5 that is normally
distributed. We have determined the standard deviation of the manufacturing process is
.003. We want to determine the tolerance limits of the dimension at the six-sigma range.

Figure 62 - Tolerance Calculator Form
Sigma range is the number of standard deviations between the tolerance limits. For
example, a sigma range of 6 means that we are setting the tolerance limits at +/- 3
standard deviations from the mean (nominal value).
If we click the Calculate button, we get the results shown in Figure 63.
Nominal dimension is the mean of the distribution. Tolerance limits are centered on the
nominal dimension.
The results include both the +/- tolerance value and actual upper and lower tolerance limits.
In our example, we could specify a dimension of 5 +/- .009 or a dimension of 5.009/4.991.
The rejection rate is also calculated, and for our example is .27%. Given the probability
distribution, we would expect .27% of the parts to either be < -3 standard deviations or >
+3 standard deviations and would therefore be out of tolerance.
If either the rejection rate or the tolerance limits are unacceptable, you can specify a new
sigma range and recalculate to balance these competing factors.

Figure 63 - Tolerance Calculator Results
You can create a report of the results in a new worksheet in the current workbook or in a
new workbook.

Chapter 9 – 1D/2D/3D Tolerance Analysis
The 1D/2D/3D tolerance analysis tools are not limited to dimensions that are parallel as
described in Chapter 8. 1D/2D/3D can be defined as:
1D All dimensions are parallel.

2D All dimensions share the same plane or parallel planes. In MEboost, all 2D
models are assumed to be in the xy plane or planes parallel to xy.
3D Dimensions can be in any plane. Any plane that is not parallel to the xy plane is
denoted as non-xy.
The multi-dimensional tools can perform the following tolerance analyses:
• Worst case analysis.

• Monte Carlo analysis.
The tolerance analysis tools can solve open loop problems where each input dimension is a
vector. The loop is “closed” by calculating the resultant dimension that starts at the
beginning of the first input vector and ends at the end of the last input vector. This is
illustrated below.
Figure 64 - Dimensions in 3D space
The resultant dimension is determined by:
r = d1 + d2 + d3

Where:
r is the resultant dimension vector
d1…dn are the input dimension vectors
The resultant dimension begins at the start of d1 and ends at the end of dn.
The magnitude of the resultant dimension is:
𝑛 2 𝑛 2 𝑛 2
𝑟 = √(∑ ∆𝑥𝑖 ) + (∑ ∆𝑦𝑖 ) + (∑ ∆𝑧𝑖 )

1 1 1
Where:
r is the resultant dimension magnitude
n is the number of input dimensions
Δxi is the x component of the ith dimension
Δyi is the y component of the ith dimension
Δzi is the z component of the ith dimension
Because of the sum of squares for each delta, the resultant dimension is always positive.
For clearance analysis, we must use the deltas to determine the condition of clearance or
interference.
There are two use cases for the tolerance analysis tools:
Dimension Analysis Analyze the resultant dimension on a part or an assembly of

parts. This is analogous to a 1D stack height.
Clearance Analysis The resultant dimension represents the clearance/interference
between assembled parts.

Dimension Analysis
For this use case, we simply would like to know the variation in a dimension that is the
result of other dimensions. Consider the plate below that has two holes. Each hole is
dimensioned from the edges of the part.
Figure 65 - Example part
Each input dimension is labeled with letters A through E. Starting with A, each of these
dimensions form a chain from the left hole to the right hole. In this case, the resultant
dimension is the distance between the holes.
Clearance Analysis
Clearance analysis is more involved, and the order of input dimensions is important to
determine if a clearance or interference fit is present. Let’s look at two examples of
clearance analysis.

2D Clearance Example
The assembly below shows a rectangular bar inserted into an extrusion.
Figure 66 - Example assembly
Note that the bar is shown tight against one side and the bottom of the extrusion. The
clearance gaps are exaggerated. Again, if we letter each input dimension from A to D, we
see the input chain starts at the upper right corner of the bar, down the side of the bar,
across the bottom of the bar, back across the bottom of the extrusion, and up the side of
the extrusion.
The resultant dimension starts at the upper right corner of the bar and ends at the upper
right corner of the extrusion. This is important when interpreting results. For a clearance
fit, delta x and delta y will be positive (up and to the right).
If we had chosen to reverse the input dimension chain, D-C-B-A, the resultant vector would
be down and to the left. In this case a negative delta x and y would be a clearance fit.

Because the resultant dimension is always positive, and does not indicate a clearance or
interference fit, delta x, y, and z are necessary to understand the fit.
3D Clearance Example
A channel is placed in a pocket and a cover is mounted over the pocket to completely
encase the channel. The blue lines represent the inside envelope of the pocket. The gaps
between the channel and inside of the pocket are greatly exaggerated. The red line in each
view is the resultant dimension.
Figure 67 - Pocket Assembly
This is a 3D situation since width, height, and length all can result in an interference fit.
Selection of the dimension chain requires that we capture all dimensions that contribute to
the variation of fit.
It’s important to understand and apply the coordinate system to correctly interpret the
results. In this example, to achieve a clearance fit delta x and delta y must be positive.
Delta z must be negative.
The dimension chain is ordered A-B-C-D-E-F. The resultant dimension starts at the corner
of the channel and ends at the corner of the pocket.

1D/2D/3D Worst Case
Ribbon>MEboost tab>Tolerance Analysis button> 1D/2D/3D Worst Case button
Clicking the 1D/2D/3D Worst Case button on the ribbon will open the Worst Case Tolerance
Analysis form.
Results Page
Figure 68 - Worst Case Tolerance Analysis Form > Results page
Model Sheet
If you want to load an existing model, select it from the drop-down box. Only 1D/2D/3D
worst case models will appear. To create a new model, select New Model and enter the
model name.

Report
Calculate
For 1D analysis, the maximum and minimum resultant dimension occurs when input
dimensions are at their minimums and maximums. This is straightforward to calculate. For
2D and 3D, the minimum and maximum resultant may occur with input dimensions at
intermediate values. To estimate the resultant extreme values, input dimensions are
sampled as uniformly distributed random variables. Enter the number of iterations used to
find extreme values of the resultant. The greater the iterations, the better chance of finding
a close approximation of the resultant extremes.
There is the option to find min/max resultant dimensions or min/max deltas. When doing
dimension analysis, select Find resultants. Since the resultant dimension magnitude is
always positive, it will not indicate an interference fit when doing clearance analysis. For
clearance analysis, select Find deltas. Find deltas will determine the min/max delta in each
direction. A negative delta indicates an interference fit.
After the dimension chain is entered and iterations are entered, click the Calculate button to
generate results. If the dimension chain is changed, click Calculate again to update results.
When an existing model is loaded, you will need to recalculate the results.
Sensitivity
When the model is calculated, a sensitivity analysis of the input dimensions is performed.
This allows you to see which dimension's variation has the greatest impact on the resultant
dimension.
The analysis is performed by calculating the resultant dimension with a dimension at either
the minimum or maximum value. All other dimensions are held at their nominal values. If
a dimension's alpha or beta angle is variable, it is set at the midpoint of its range of values
except when calculating sensitivity for that alpha or beta angle.
The change in the resultant dimension from its nominal value is shown in the sensitivity box
for each dimension when they are at minimum and maximum values.
Saving the Model

Dimension Chain Page

Input dimensions are entered in the dimension chain page. The dimensions must be
entered in order so that the end of one dimension corresponds to the start of the next
dimension.

Figure 69 - Worst Case Tolerance Analysis Form > Dimension Chain page
Add Dimension to Chain

To add a dimension, enter the dimension information. Then click the Add Dimension button.
The minimum value is the minimum dimension of the part. The maximum value is the
maximum dimension of the part.
Plane is the coordinate system plane that contains the dimension. Alpha is the angle of the
dimension relative to the positive x axis. Beta is the angle of the dimension from the xy
plane. Any dimension that is on a plane parallel to the xy plane should be entered as an xy
plane dimension. For 1D and 2D analysis, beta will be zero. Refer to the reference page for
more information on alpha and beta.
Input Dimension Chain

When dimensions are added, they will appear in the input dimension chain box. Dimensions
can be edited by selecting one and clicking the Edit Dimension button. Dimensions can be
deleted by selecting one and clicking the Delete Dimension button.
Input dimensions should be entered in order. The start of the first dimension is the start of
the resultant dimension. The end of the last dimension is the end of the resultant

dimension. Input dimensions can be reordered by selecting a dimension and clicking the
up/down spinner button to the right of the box.
Worst Case Examples

Using the three examples earlier in this chapter, we will do a dimension analysis, a 2D
clearance analysis, and a 3D clearance analysis.
Dimension Analysis Example

The dimension chain for the plate in Figure 65 is shown below.
Figure 70 - Plate Dimension Chain
Switching to the results page, we will iterate 250,000 times. Since this is a dimension
analysis, we will select Find resultants. Click the calculate button to run the analysis.

Figure 71 - Plate Results
The nominal resultant dimension is 3.6056. The minimum resultant dimension is 3.5732
and the maximum is 3.6396. The delta x, y, and z of the resultant dimension are shown at
each condition.
The resultant dimension is most sensitive to dimensions A, C, and E.

2D Clearance Analysis Example
The dimension chain for the assembly in Figure 66 is shown below.
Figure 72 - Assembly Dimension Chain
Switching to the results page, we will iterate 250,000 times. Since this is a clearance
analysis, we will select Find deltas. Click the calculate button to run the analysis.

Figure 73 - Assembly Results
For clearance analysis, resultant clearance is not very useful since it will always be positive.
How do we know there is interference? By looking at delta x, y, and z. The deltas are
where we can glean information about fit. They will show the direction and magnitude of
clearance/interference.
Minimum delta x and delta y are both negative (-0.00997). This indicates an interference fit
when delta x or delta y is at their minimums.

Dimensions A, B, and D are for the channel which is inside the pocket. Dimensions C, E,
and F are for the pocket. Switching to the results page, we will iterate 250,000 times.
Since this is a clearance analysis, we will select Find deltas. Click the calculate button to
run the analysis.

Figure 75 - Assembly Results
Because of the coordinate system, clearance occurs when delta x and delta y are positive,
and delta z is negative.
At nominal dimensions there is .01 clearance in all three directions. At the minimum delta x
and delta y there is a 0.010 interference in each direction. At the maximum delta z, there is
a 0.0149 interference in the z direction.

1D/2D/3D Monte Carlo
Ribbon>MEboost tab>Tolerance Analysis button> 1D/2D/3D Monte Carlo button
Clicking the 1D/2D/3D Monte Carlo button on the ribbon will open the Monte Carlo
Tolerance Analysis form.
Set-Up Page
Model Sheet
If you want to load an existing model, select it from the drop-down box. Only 1D/2D/3D
Monte Carlo models will appear. To create a new model, select New Model and enter the
model name.
Simulation Trials
Enter the number of simulation trials to run.
Histogram Bins
When a simulation is run, the resultant dimension from each trial is binned to create a
histogram. You can enter the desired number of bins or use the default value.
Running the Simulation

Click the Run Simulation button to perform the simulation. Note: The input dimension chain
must be created, and the model saved prior to running a simulation. Simulation data is
written to the worksheet containing the model information.
Delta Directions (Clearance)

These settings are only used with clearance analysis. Depending on the coordinate system
chosen, a clearance fit may be indicated by positive or negative deltas. For the example in
Figure 67 a positive delta x, positive delta y, and negative delta z indicates a clearance fit.
For each delta, select the direction that results in a clearance fit.

Figure 76 - Monte Carlo Tolerance Analysis Form > Set-Up page
Report
Saving the Model

To save a new or existing model, click the Save button. Note: to save a simulation, click
the Save button after running the simulation. The Save button only creates or
Dimension Chain Page

Add Dimension to Chain
To add a dimension, enter the dimension information. Parameter boxes for the distribution
will appear and the parameter values are entered. For more on distribution parameters,
refer to Appendix C. Then click the Add Dimension button.

Plane is the coordinate system plane that contains the dimension. Alpha is the angle of the
dimension relative to the positive x axis. Beta is the angle of the dimension from the xy
plane. Any dimension that is on a plane parallel to the xy plane should be entered as an xy
plane dimension. For 1D and 2D analysis, beta will be zero. Refer to the reference page for
more information on alpha and beta.
There are two ways to model a dimension with Monte Carlo analysis. The first is to assume
the dimension is not inspected prior to assembly and some dimensions may be out of
tolerance. The dimension will simply follow its probability distribution. The second way is to
assume 100% inspection and that all dimensions are within tolerance.
The lower level (LL) and upper level (UL) boxes are used to specify tolerances that will limit
dimension values to >= LL and <= UL. When a dimension is sampled, if it falls out of
tolerance it is discarded and sampling continues until an in-tolerance value is sampled. If LL
and UL are not specified, dimensions will be sampled from the entire distribution.
A dimension's alpha and beta angles can either be fixed or be treated as a random variable.
If a dimension is in the xy plane, its beta will be fixed at zero. If alpha or beta is variable,
specify the probability distribution in the appropriate pane. You can also specify upper and
lower limits similar to the dimension length.
Input Dimension Chain

When dimensions are added, they will appear in the input dimension chain box. Dimensions
can be edited by selecting one and clicking the Edit Dimension button. Dimensions can be
deleted by selecting one and clicking the Delete Dimension button.
Input dimensions should be entered in order. The start of the first dimension is the start of
the resultant dimension. The end of the last dimension is the end of the resultant
dimension. Input dimensions can be reordered by selecting a dimension and clicking the
up/down spinner button to the right of the box.

Figure 77 - Monte Carlo Tolerance Analysis Form > Dimension Chain page
Calculation Results
Results from a simulation are shown in two pages: Simulation Results and Deltas. The
simulation results page shows statistics and a histogram for the resultant dimension. It also
includes the sensitivity for each input dimension.
Simulation Results Page

Sensitivity
When the model is calculated, a sensitivity analysis of the input dimensions is performed.
This allows you to see which dimension’s variation has the greatest impact on the resultant
dimension. Sensitivity is the Spearman Rank correlation coefficient for an input variable
and the resultant dimension. The correlation ranges from -1 to 1.
A correlation coefficient near 1 shows a strong positive correlation. As the input dimension
increases, the resultant dimension also increases, and vice versa. A coefficient near 0 is a

weak correlation. A coefficient near -1 is a strong negative correlation. As the input
dimension increases, the resultant dimension decreases, and vice versa.
Percentiles
Percentiles are calculated using Excel’s PERCENTILE.INC function.
Probability Grab Bars

The histogram has two bars that can be moved to get a look at the probabilities of various
outcomes. To adjust the bars, click on the red squares and drag to the desired position. An
example with the grab bars adjusted is shown below.
The grab bars and their associated values can be hidden by checking the Hide box.
probability > right bar
left bar ≤ probability ≤ right bar
probability < left bar
Grab bar output values.
Figure 78 - Grab Bar Adjustment
Probability Analysis
To conduct a probability analysis of the model output falling within a range of values use the
Lower Set Point and Upper Set Point boxes.
To determine the probability above and below a single output value, enter that value in
either the Lower Set Point or Upper Set Point box as shown below and click the Update
button.

If the lower or upper set points are used without the other, they calculate probability
differently to accomplish different goals.
When a value is entered in the lower set point, but not the upper set point, the probability
will be calculated for less than or equal to the lower set point. The probability of greater
than the lower set point will also be calculated.
When a value is entered in the upper set point, but not the lower set point, the probability
will be calculated for less than the upper set point. The probability of greater than or equal
to the upper set point will also be calculated.
The use of single set points is summarized in the table below:
To Determine Set Point to Use

Probability < set point Upper
Probability <= set point Lower
Probability > set point Lower
Probability >= set point Upper
Clearance Analysis Considerations

At the beginning of the chapter, it was noted that the resultant dimension is always positive.
For clearance analysis, this doesn’t give useful information to determine the fit condition. If
this is a 1D clearance situation, it is better to use the 1D Monte Carlo tool where the
simulation output shows positive values for clearance and negative values for interference.
To accommodate clearance, the “Interference” statistic is used for clearance analysis. For
each trial, if one of the deltas has interference, the trial is counted as an interference fit.
Interference is the percentage of trials that had at least one delta with interference. This
gives a more accurate estimate of rejection due to interference than adding probabilities of
the individual deltas since two or three deltas can have interference in the same trial.
While you can calculate the probability of each delta having interference, there will likely be
cases where x, y, or z deltas have interference at the same time. Calculating the probability
of each delta having interference and adding the probabilities will likely overestimate the
rejection rate. The interference statistic takes this overlap into account and gives a better
estimate of rejection rate.
Deltas Page
The deltas page shows summary statistics for each delta. Probability analysis of each delta
can be performed as well.

Figure 79 - Monte Carlo Tolerance Analysis Form > Deltas page

Monte Carlo Examples
Using the three examples earlier in this chapter, we will do a dimension analysis, a 2D
clearance analysis, and a 3D clearance analysis.
Dimension Analysis Example

For the plate in Figure 65, we set up a model as shown on the Set-up page.
Figure 80 - Model Set-up
The dimension chain for the plate in Figure 65 is shown below.

Figure 81 - Plate Dimension Chain

Switching to the set-up page and clicking run simulation, we get the following results.
Figure 82 - Plate Results

From Figure 66, the resultant starts at the corner of the bar and ends at the corner of the
extrusion. Therefore, there is clearance if both delta x and delta y are positive. The delta
directions are selected to reflect this condition. Delta z is not used since this is a 2D
problem and its setting will not affect the results.
Figure 83 - Assembly Set-up


Figure 85 - Assembly Results Page
As was the case with worst case, the resultant dimension doesn’t tell much for clearance
analysis. The resultant dimension is always positive regardless of clearance/interference fit.
A useful statistic for clearance on the simulation results page is the “Interference” statistic.
If any delta has an interference fit, then the trial is counted as an interference fit regardless
of the other deltas. In this example 1.914% of the trials had an interference fit.

The deltas page is shown below.
Figure 86 - Assembly Deltas Page

In Figure 67 we see that for clearance we need delta x and delta y to be positive while delta
z is negative. In the set-up page we select delta directions to reflect this case.
Figure 87 - Assembly Set-up


Figure 89 - Assembly Results Page
The interference is 3.294%, so this percentage of assemblies will not fit in at least one
direction.

The deltas page is shown below.
Figure 90 - Assembly Deltas Page

Chapter 10 – Shaft Design
The shaft design tool allows for comprehensive calculations typical for the design of a
rotating shaft. Design of a shaft must take the following items into consideration:
• Combined stresses from torque, bending, and axial loads.

• Shaft deflection which can cause problems such as gear mesh.
• Shaft twist (torsional deflection).
• Shaft slope at bearings. Bearings that aren’t self-aligning can bind with too much
slope.
• Fatigue.
• Critical rotational speed to avoid resonance.
You can easily create diagrams or calculations of the above items to evaluate a shaft design.
Coordinate System
All data entered, and the report output are based on a coordinate system where the origin is
at the left end of the shaft. The x-axis is along the length of the shaft.
Figure 91 - Coordinate System
Assumptions
The following assumptions go into the analysis.
• Bearing reactions are concentrated forces at the bearing x location.
• The shaft is simply supported.
• Shaft material’s yield strength in compression is the same as tension.

• Fatigue: Torque and axial loads are constant and result in mean stress. Bending
creates alternating stress.
• Critical speed: The weights on the shaft are concentrated at their x locations.
Bending Calculations
The shaft design tool allows for radial loads in all directions around the shaft (non-planar
loads). To do this, radial loads are entered by specifying their Y and Z components. Shear,
moment, slope and deflection are initially calculated in the Y and Z planes separately. The
shear diagram will show shear in both planes. You can also create a moment diagram for
the Y and Z planes.
To calculate stresses, slopes and deflections, the resultant moment at each point is
determined and used in the calculations.
𝑀𝑟𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 = √𝑀𝑦 2 + 𝑀𝑧 2
Where:
Mresultant is the resultant moment
My is the moment in the y plane
Mz is the moment in the z plane
Likewise, slope and deflection are initially calculated for the Y and Z planes and then the
resultant is displayed on their diagrams. Because a resultant is always positive, the
diagrams will only have positive values that will not look like a situation where all loads are
in a single plane.
Static Analysis
The shaft design tool performs static analysis to determine stresses, deflection and slope
along the shaft.
Static Stress
The calculation of stress considers applied torque, bending and axial loads. Let’s use the
shaft below as an example.

Figure 92 - Example Shaft
There is a radial load and torque midway between the bearings. There is an opposing
torque and axial load at the right end of the shaft. Point A is the worst-case combined
loading case. Bending moment is greatest at A, is under torque, and has an axial load in
tension.
Let’s look at an element on the surface of the shaft at point A.
Figure 93–Static Stresses at Point A
The element is under tension from bending and the axial load. It also has a shear stress
from the torque.
Now consider that same shaft configuration except the axial load is compressive.

Figure 94 - Example Shaft with Compressive Axial Load
In this situation, the compressive stresses from bending and axial loads add at point B. The
stress element at point B on the surface shows the stress state.
Figure 95 - Static Stresses at Point B
The shaft design tool checks the stress state at points A and B. When static stresses are
plotted, the worst-case of the two is shown on the plot. It should be noted that depending
on the axial loads, the worst-case can change from point A to B and vice versa. Whichever
is worse at a given x, will be shown on the plot. Therefore, the stresses shown could be at
either A or B, depending on whether the axial load is tensile or compressive.
Combining Stresses
We can choose an appropriate failure theory to determine an equivalent stress for the
combined loading.
MEboost can determine stresses for the following failure theories:

• Maximum distortion energy theory (Von Mises stress).
• Maximum shear stress theory.

• Maximum normal stress theory (principal stresses).
Maximum Distortion Energy Theory
𝜎𝑉𝑜𝑛 𝑀𝑖𝑠𝑒𝑠 = √𝜎12 − 𝜎1 𝜎2 + 𝜎22
Where:
σVon Mises is the Von Mises stress
σ1 is principal stress 1
Maximum Shear Stress Theory

Refer to Principal Stress Convention section.
𝜎1 − 𝜎3
𝜏𝑚𝑎𝑥 =
2
Where:
τmax is maximum shear stress
Maximum Normal Stress Theory
𝜎𝑏𝑒𝑛𝑑 + 𝜎𝑎𝑥𝑖𝑎𝑙 𝜎𝑏𝑒𝑛𝑑 + 𝜎𝑎𝑥𝑖𝑎𝑙 2

𝜎1 , 𝜎2 = ± √( 2
) + 𝜏𝑡𝑜𝑟𝑞𝑢𝑒
2 2
Where:
σbend is stress due to bending
σaxial is stress due to axial loading
τtorque is shear stress due to torque
Principal Stress Convention

The worst-case point on the shaft is at the surface and is therefore assumed to be in a state
of plane stress. The stress normal to the shaft surface is zero. In the formulas above, we
calculate σ1 and σ2 which are the in-plane principal stresses. By the definition of plane
stress, σz = 0 and σ3 = 0. To determine the maximum shear stress, we need to reorder the
principal stresses.
The numbering of principal stresses is reassigned according to the following convention: σ 1>
σ2> σ3.

Fatigue Analysis
The shaft design tool will perform fatigue analysis using the stress-life method for infinite
life. It calculates alternating and mean stresses along the shaft and determines the location
of the minimum fatigue safety factor (worst-case).
A fatigue diagram is created showing the mean stress correction for Soderberg, Modified
Goodman, Gerber, and ASME Elliptic.
Fatigue Stress
To calculate stress values for fatigue, we need to determine mean and alternating stress.
The shaft design tool assumes torque and axial loads are constant. Radial loads induce fully
reversed alternating stresses due to bending. The stress element for each condition is
shown below. Note that in Figure 92 the axial stress is shown as tensile. It could also be
compressive.
Figure 96 - Mean Stress Element
Figure 97 - Alternating Stress Element

Since there are combined stresses, we need to use an effective stress from an appropriate
failure theory. The shaft design tool has five options:
Von Mises The maximum distortion energy theory is used to determine Von Mises
stress.
Signed Von Mises Von Mises stress is calculated, and then a +/- sign is applied
based on the sign of the principal stress with the highest absolute value.
TrescaCriterion The maximum shear stress theory is used where stress =

2*(maximum shear stress).
Worst-caseprincipal Principal stresses are determined, and the principal stress

with the lowest fatigue safety factor is used.
Principal 1 Principal stresses are determined, and σ1 is used where σ1> σ2> σ3.
The table below shows how each effective stress is determined and used.
Effective Stress Alt. Stress Mean Stress
Von Mises Von Mises stress at extreme Von Mises stress from torsion
point from neutral axis due to and axial load.
bending.
Signed Von Mises Von Mises stress at extreme Von Mises stress from torsion
point from neutral axis due to and axial load. Sign of Von
bending. Mises stress is same as largest
magnitude principal stress.
Tresca Criterion Max shear stress at extreme Max shear stress from torsion
point from neutral axis from and axial load. Stress =
bending. Stress = 2*max 2*max shear stress.
shear stress.
Worst-case principal Principal stresses at extreme Principal stresses from torsion
point from neutral axis due to and axial load. Check fatigue
bending. Principal 1 is used for safety factors of both principal
alternating stress (principal 2 stresses and use worst-case.
is always zero).
Principal 1 Principal stresses at extreme Principal stresses from torsion
point from neutral axis from and axial load. Principal 1 is
bending. Principal1 is used for used for mean stress.
alternating stress.
The formulas below show these calculations for each failure theory.

Maximum Distortion Energy Theory
𝜎𝑉𝑜𝑛 𝑀𝑖𝑠𝑒𝑠 𝑚𝑒𝑎𝑛 = √𝜎12𝑚𝑒𝑎𝑛 − 𝜎1 𝑚𝑒𝑎𝑛 𝜎2 𝑚𝑒𝑎𝑛 + 𝜎22𝑚𝑒𝑎𝑛
𝜎𝑉𝑜𝑛 𝑀𝑖𝑠𝑒𝑠 𝑎𝑙𝑡 = √𝜎12𝑎𝑙𝑡 − 𝜎1 𝑎𝑙𝑡 𝜎2 𝑎𝑙𝑡 + 𝜎22 𝑎𝑙𝑡
Where:
σVon Mises is the Von Mises stress
σ1 mean is mean principal stress 1
σ1 alt is alternating principal stress 1
Maximum Shear Stress Theory
𝜎1 𝑚𝑒𝑎𝑛 − 𝜎3 𝑚𝑒𝑎𝑛
𝜏max 𝑚𝑒𝑎𝑛 =
2
𝜎1 𝑎𝑙𝑡 − 𝜎3 𝑎𝑙𝑡
𝜏max 𝑎𝑙𝑡 =
2
Where:
τmax mean is maximum mean shear stress
τmax alt is maximum alternating shear stress
σ1 mean is maximum mean principal stress
σ3mean is minimum mean principal stress
σ1 alt is maximum alternating principal stress
σ3 alt is minimum alternating principal stress
Maximum Normal Stress Theory
𝜎𝑎𝑥𝑖𝑎𝑙 𝜎𝑎𝑥𝑖𝑎𝑙 2 2
𝜎1 𝑚𝑒𝑎𝑛 , 𝜎2 𝑚𝑒𝑎𝑛 = ± √( ) + 𝜏𝑡𝑜𝑟𝑞𝑢𝑒
2 2
𝜎𝑏𝑒𝑛𝑑 𝜎𝑏𝑒𝑛𝑑 2
𝜎1 𝑎𝑙𝑡 , 𝜎2 𝑎𝑙𝑡 = ± √( )
2 2
Where:

σ2 alt is alternating principal stress 2 (always zero)
σbend is stress due to bending
σaxial is stress due to axial loading
τtorque is shear stress due to torque
Fatigue Safety Factors

If fatigue analysis is selected, fatigue safety factors for each failure criterion will appear in
the report heading. These safety factors are based on the load line intersecting with the
appropriate failure criterion curve. First cycle yielding is also checked, and the yielding
safety factor is shown in the report.
To illustrate fatigue safety factor, let’s say we want to calculate the safety factor for the
Modified Goodman failure criteria. In Figure 98 we have an alternating stress of 8 and a
mean stress of 9. The load line is drawn from the origin through the operating point. The
safety factor is the ratio of distance A to B.
𝐴
𝑛𝐺𝑜𝑜𝑑𝑚𝑎𝑛 =
𝐵
Figure 98 - Safety Factor Visual Representation

The equations for each safety factor are shown below. You can plot each safety factor as a
function of x. In order to maintain readable charts, safety factors are plotted as 1/safety
factor. When stress is small, safety factor becomes very large and results in an unreadable
chart, hence 1/n is used.
Langer Yield Line
1 𝜎𝑎 + 𝜎𝑚
=
𝑛 𝑆𝑦
Where:
n is safety factor
Sy is yield strength
σa is alternating stress
σm is mean stress
Soderberg
1 𝜎𝑎 𝜎𝑚
= +
𝑛 𝑆𝑒 𝑆𝑦
Where:
Se is the fatigue limit
Modified Goodman
1 𝜎𝑎 𝜎𝑚
= +
𝑛 𝑆𝑒 𝑆𝑢𝑡
Where:
Sut is tensile strength
Gerber
−1
2 2
1 1 𝑆𝑢𝑡 𝜎𝑎 2𝜎𝑚 𝑆𝑒
={ ( ) [−1 + √1 + ( ) ]}
𝑛 2 𝜎𝑚 𝑆𝑒 𝑆𝑢𝑡 𝜎𝑎

ASME Elliptic
−1
1 1
= 2
𝑛 √ 𝜎𝑎 2 𝜎
( ) + ( 𝑚)
[ 𝑆𝑒 𝑆𝑦
]
Special case when using worst-case principal effective stress

When using worst-case principal stress, principal 1 and 2 mean stresses are checked for
fatigue safety factors and the one with the lowest safety factor is used. The safety factor
for yielding is also checked. There can be a situation where principal 1 mean stress is
positive, and principal 2 mean stress is negative. The fatigue safety factor for principal 1
mean stress is the governing factor, but the yield safety factor for principal 2 is less than
principal 1. This situation is shown below using the Modified Goodman criterion.
Figure 99 - Special Case When Using Worst-Case Principal
The yield safety factor shown in the report heading will be the lower of the two yield safety
factors (principal 2), while the fatigue safety factor will be for principal 1. The worst-case
operating point plotted on the fatigue diagram will be determined by fatigue safety factor,
therefore principal 1 mean stress will be plotted.

Stress Concentrations
Stress concentrations for static and fatigue analysis can be applied to the shaft. Since
stress concentrations are usually different depending on the load type, they can be applied
separately to account for different values.
For fatigue, you can specify stress concentrations for the mean and alternating stress
components separately. For example, you may want to use stress concentrations for
alternating stress, but not mean stress. If a stress concentration is for bending, it will be
applied to the alternating stress calculations. If a stress concentration is for either torsion
or axial stress, it will be applied to the mean stress calculations.
Critical Speed
The first critical speed of the shaft can be estimated using the Rayleigh-Ritz and Dunkerley
methods. The Rayleigh-Ritz method tends to overestimate the critical speed, and the
Dunkerley method tends to under-estimate the critical speed. Thus, both methods are used
to determine upper and lower bounds of the actual critical speed.
Shaft Design
Ribbon>MEboost tab> Shaft Design button
Click the Shaft Design button on the ribbon to start the tool.
The form is divided into seven pages.

Figure 100 - Shaft Design Form> Model Page
Model Page
A shaft design can be saved as a model on a new worksheet in the current workbook. This
allows you to load a model and run new reports without having to re-enter data. You can
also load a model, make changes, and run a report. The revised design can be saved as a
new model by selecting “New model” and saving it. You can revise the original model by
making changes and clicking the Save Model button.
NOTE: You must save the workbook to keep any models.
Units
Units can be SI or US customary. When entering data, the appropriate units to use will
appear throughout the form.
X Increment
For most diagrams and calculations, the shaft is divided into increments determined by this
setting. A smaller x increment will result in more accurate data but will take longer to
process. The default value is .001 for SI units which results in 1000 increments per meter.
The default value is .04 for US units which results in 25increments per inch.

Figure 101 - Shaft Design Form > Report Page
Report Page
Transverse Shear
For shafts of length to diameter ratios of less than 10, deflection due to transverse shear
can be significant [1]. To include the deflection from transverse shear, check the box.
Deflections due to bending and transverse shear are superposed in the y and z direction
prior to calculating resultant deflection.
For bearing slope, the slope due to bending and the slope due to shear are superposed prior
to calculating the resultant slope. At diameter changes or shear change locations, the slope
prior to and after the change is averaged per the procedure outlined in [1].
Note: Slope due to transverse shear is only calculated at the bearings. The slope diagram
will not contain slope due to transverse shear.
[1] Shigley, J., Mischke, C. Standard Handbook of Machine Design, 3rd Ed., 2004, McGraw-
Hill, pages 17.8-17.12.
Report Diagrams
Numerous diagrams can be generated in the report. The following is a description of each
diagram.
• Torque The applied torque as a function of x.

• Twist Angular deflection of the shaft. The left end of the shaft starts with zero twist.

• Shear If radial loads are present, this is the shear diagram. There are two curves,
one for the shear in the y direction and one for the z direction.
• Y & Z momentsIf radial loads are present, this is the moment diagram. There are
two curves, one for moment in the y direction and one for the z direction.
• Resultant moment This is the resultant of the Y and Z moments. 𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 =
√𝑌 2 + 𝑍 2 Since this is a resultant, all values will be positive.
• Slope The resultant slope of the shaft due to bending. Since this is a resultant, all
values will be positive.
• Deflection The resultant deflection of the shaft due to bending, and if selected, due
to transverse shear. Since this is a resultant, all values will be positive. This
diagram also shows resultant deflection angle measured counterclockwise from the
positive Z axis.
• Von Mises stress Von Mises stress due to combined loading of torque, radial and
axial loads.
• Max. shear stress Maximum shear stress due to combined loading of torque, radial
and axial loads.
• Max. normal stressMaximum and minimum principal stresses due to combined
loading of torque, radial and axial loads. Maximum and minimum principal stresses
may not be at the same point around the circumference of the shaft. For example,
max principal stress may be at the point furthest from the neutral axis in bending
tension and min principal stress may be at the point furthest from the neutral axis in
bending compression.
• Fatigue A fatigue diagram can have Goodman, Soderberg, Gerber and yield lines.
The operating point of alternating stress and mean stress is plotted using stresses
according to the effective stress type chosen.
• Alternating & mean stress Plot of alternating and mean stress using the effective
stress chosen.
• Fatigue safety factor plotsFor each criterion checked, a plot of x vs. 1/safety
factor.
If there are no radial loads, i.e. no bending, the shear, moment, slope and deflection
diagrams will not appear on the report even if they are selected. Additionally, fatigue
diagrams and data will not appear on the report if they are selected.
Effective Stress
Since combined stresses are present, we need to choose an effective stress to use for
fatigue analysis. Alternating and mean stress values will depend on the effective stress
chosen.
Plot Worst-Case By
On the fatigue diagram, the operating point is plotted to indicate where the worst-case
stresses are in relation to the failure criterion selected. For each failure criterion, the
alternating and mean stress is calculated at each x increment. Then the fatigue safety
factor is calculated for each criterion. Finally, the x location that results in the lowest safety
factor is found for each criterion. Usually it’s at the same location for all criteria.

Select the failure criterion to use. The alternating and mean stress at the worst-case
location for that criterion will be plotted.
Figure 102 - Shaft Design Form > Shaft Page
Shaft Page
Material properties and dimensions of the shaft are entered on this page.
Shaft Dimensions
The shaft can be solid or hollow. Enter the overall shaft length, and if hollow is selected,
enter the inside dimension.
Material Properties
Enter the shaft material properties.
Fatigue limit is the maximum stress level that the material can be subjected to for a very
large number of cycles without failure. The term endurance limit is often used for the stress
that a material can withstand for an unlimited number of cycles. Some materials, aluminum
for example, do not have an endurance limit, and a fatigue limit is assumed for a large
number of cycles, such as 107 or 108 cycles. The fatigue limit should be adjusted for
various Marin factors such as surface finish, loading, temperature, etc.
E is the modulus of elasticity and G is the modulus of rigidity.
Shaft Steps
Stepped shaft dimensions are entered here. For each “step”, enter the starting x coordinate
from the left end of the shaft for a given diameter, and click the Add button. The last step
entered will be assumed to go to the right end of the shaft.

If the diameter of the shaft is constant, enter the starting x value and the diameter. The
diameter will be constant for the entire length.
Figure 103 - Shaft Design Form > Torque, Radial Loads, Bearings Page
Torque, Radial Loads, Bearings

Applied torques, radial loads, and bearing locations are specified on this page.
Two bearings are required. Additional bearings are not allowed. Bearing reactions are
treated as point loads on the shaft, and the shaft is assumed to be simply supported.
Shaft weight is ignored for static and fatigue analysis. To include shaft weight, add a
distributed load for each shaft step. Likewise, the weights of any attached components such
as gears, pulleys, etc. are ignored for static and fatigue analysis. To include the weight of
these components, add an appropriate concentrated or distributed load for each item.
Adding Items to the Model

Select an element type to add to the model. Depending on the selection, parameter boxes
will appear to define the element.
Bearing Specify the x coordinate of the bearing centerline.
Torque Specify the location of the applied torque. Enter a positive value when the
torque is clockwise when viewed from the left end of the shaft. Enter a negative
value when the torque is counterclockwise.

Concentrated Load Specify the location of the load. The force must be entered as
y and z component forces. If the force acts in the positive y or z direction, enter a
positive number, otherwise enter a negative number.
Distributed Load Specify the start and end location of the load. The distributed
load value (force/distance) must be entered as y and z component loads.
After all parameters are entered, click the Add button. The element will appear in the
listbox.
Figure 104 - Shaft Design Form > Axial Loading Page
Axial Loading Page

Axial loading in the x direction is specified on this page. Axial loads are specified by the
state of loading along the shaft instead of applying specific loads. The loading specified is
the net loading due to the sum of tensile or compressive loads.
Adding Items to the Model

Select either compressive or tensile loading from the drop-down box. Then specify the start
and end x coordinates of the loading. Finally, enter the loading value as a positive number.
After all parameters are entered, click the Add button. The loading will appear in the
listbox.

Figure 105 - Shaft Design Form > Stress Concentration Page
Stress Concentration Page

Stress concentrations are specified on this page. A stress concentration is applied over an x
interval. Any stress calculations for the type (static or fatigue) are applied while x is within
the interval.
Adding a Stress Concentration

Select the type of stress concentration. For example, if the type is static, the stress
concentration will only be applied for static stress calculations. It will not affect fatigue
calculations.
Select the type of loading. Each stress concentration is for one loading type and will only be
applied when calculating stress for the loading type. For combined stress, enter a separate
stress concentration for each load type.
Enter the starting x location of the stress concentration and the ending x location. The
stress concentration will be applied for the appropriate stress calculations during this
interval. Enter the stress concentration factor in the Factor box.
After all parameters are selected or entered, click the Add button. The stress concentration
will appear in the listbox.

Figure 106 - Shaft Design Form > Critical Speed Page
Critical Speed Page

The first critical speed of the shaft can be estimated using the Rayleigh-Ritz and Dunkerley
methods. Weights on the shaft are entered. These weights are due to items such as gears,
pulleys, flywheels, etc. and not applied loads. All weights are concentrated at the specified
location. To include the weight of the shaft, enter a shaft density. Otherwise, enter 0 for
density to ignore shaft weight.
When shaft weight is included, the shaft is divided into segments of length = X increment to
approximate the shaft’s critical speed. If there is a diameter change within a segment, the
average of the starting and ending diameters is used to calculate shaft weight for the
segment.
If deflections due to transverse shear was selected on the Report page, these deflections
will be accounted for in critical speed calculations.
The estimated critical speed will appear in the report heading.
Adding Weights
Enter the x coordinate and weight of the item. Then click the Add button. The weight and
location will appear in the listbox.

Shaft Design Report
The shaft design report contains three sections:
1. Report heading.
2. Diagrams.
3. Data for diagrams.
Report Heading
The report heading contains material properties and calculated results.
Figure 107 – Example Report Heading

Diagrams
Diagrams are located below the report heading.
Figure 108 - Example Report Diagrams
Data for Diagrams

The data used to generate diagrams is located to the right of the diagrams. This data is
useful for finding values at a specific x location. Click on a curve and the data will be
highlighted. For example, to find the Von Mises stress at x=4.25 go to the x column for Von
Mises stress and locate the row where x = 4.25 (or the nearest x value if not exactly 4.25)
and then find the corresponding Von Mises stress.

Chapter 11 – Linkage Synthesis
The linkages module contains tools for the synthesis of four bar and slider crank linkages.
Although a slider crank is a four bar mechanism, in MEboost the term 4 bar refers to a four
bar mechanism that has four revolute joints. Before discussing synthesis, we will define
linkage terms as they are implemented in MEboost. This also applies to Chapter 12.
Terminology
Synthesis The path of a point on a linkage is specified with a number of precision points.
The linkage is designed (synthesized) given desired output characteristics.
Analysis A linkage is already specified and its positions, velocities and accelerations are
analyzed. Analysis is the reverse of synthesis.
Four bar linkage In MEboost, four bar linkage refers to a four bar linkage with revolute
joints.
Slider crank linkage A four bar linkage with three revolute joints and one prismatic joint.
Fixed Link or Frame One of the links is fixed and is also known as the frame. All motion
is relative to this link. MEboost designates the fixed link as link 1.
Inversion An inversion of a linkage is when the fixed link is changed. The slider crank
linkage has four inversions. Each inversion is a different link being fixed.
Driver One of the links is driving the linkage. In the case of a four bar linkage, link 2 is
the driver. For a slider crank linkage, the driver link may vary depending on the inversion.
A slider crank driver link may rotate, or may change length by acting as a linear actuator.
Precision point A specified x,y value on a path that a point on the linkage must pass
through.
Kinematic Dimensional Linkage Synthesis

Kinematic dimensional linkage synthesis (referred from here on as synthesis) is starting
with a desired output such as a path that a point on a link must follow and designing the
linkage dimensions. It is the reverse of analysis where we start with a linkage design and
find things such as point paths or link angles.

There are three types of synthesis in MEboost:
Path A path is specified that a point on a link must follow. The path can be timed
or untimed. When timed, the point must be at a precision point and the input link
(driver link) must be at a specified angle. With untimed path synthesis, the input
link can have any angle.
Function The purpose of function synthesis is to design a linkage that acts as a

function generator. For a given input link angle, the output link angle must be at a
specified angle.
Motion With motion synthesis a path is specified that a point on a link must follow,
and the angle of that link at each precision point is also specified. The motion can be
timed or untimed. When timed, the point must be at a precision point, the link with
the point at a specified angle, and the input link (driver link) must be at a specified
angle. With untimed motion synthesis, the input link can have any angle.
The table below shows the types of synthesis that can be performed for each linkage.
Path Function Motion

Untimed Timed Timed Untimed Timed
Four bar ● ● ● ● ●
SC inversion 1 ● ● ● ● ●
SC inversion 2, link 4 driver ● ● ● ● ●
SC inversion 2, link 2 driver ● ●
SC inversion 3 ● ● ● ● ●
SC inversion 4, link 3 driver ● ● ● ● ●
SC inversion 4, link 2 driver ● ●
With traditional analytic synthesis methods, only a few precision points can be specified.
MEboost uses teacher learning based optimization (TLBO) to synthesize a linkage. The
advantage of this method is that we are not limited to a few precision points. Increasing
the number of precision points does come at a computational cost.
Synthesis does not guarantee that the point on the linkage will only follow the path defined
by precision points. In fact, it can vary quite differently. For example, consider the
synthesized four bar linkage below. The point on the linkage passes near each precision
point, but also varies from what we might think is the specified path.

Figure 109 - Synthesized Four Bar Linkage Path
While the point on the linkage follows the precision points fairly well, it also travels to
additional points that are not near any precision point.
MEboost treats synthesis as an optimization problem. Starting with a trial solution, we

compare the deviation of the solution linkage point with each precision point. Likewise, if
required, we also compare the input and output angles to the specified angles. These
deviations are the error. The solution is updated, and the error recomputed. This process
proceeds for many iterations until error is at an acceptable level.
The goal of the optimization algorithm is to minimize error to design a linkage that most
closely follows the desired output.
Slider Crank with Driving Link Acting as a Linear Actuator

For slider crank inversions 2 and 4, link 2 can be the driving link while acting as a linear
actuator. If the path is a closed loop, this condition will not produce an acceptable result. A
closed loop occurs when each point is on a unique path for a full revolution of the driver. A
non-closed loop would be a point on a following link that does not fully rotate and traces

back on the same path. When the driving link is a linear actuator, the driven link can only
rotate at most 180o, and cannot trace a closed loop.
Interpretation of Error
While the synthesis algorithm is running a window will appear that shows errors as it
progresses. The meanings of these errors depend upon the type of synthesis.
Path
Path synthesis will show the average error and the maximum error. Error is measured by
the distance of the linkage point to its corresponding precision point. Maximum error is the
worst error of a linkage point from its corresponding precision point.
The TLBO algorithm attempts to minimize either average error or maximum error.
2 2
𝐸𝑟𝑟𝑜𝑟𝑖 = √(𝑥𝑖 − 𝑥𝑝𝑖 ) + (𝑦𝑖 − 𝑦𝑝𝑖 )
2 2
∑𝑛1 √(𝑥𝑖 − 𝑥𝑝𝑖 ) + (𝑦𝑖 − 𝑦𝑝𝑖 )
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟 =
𝑛
Where
Errori is the error at the ith precision point
n is the number of precision points
xi is the x coordinate of the ith point location on the synthesized linkage
xpi is the x coordinate of the ith precision point
yi is the y coordinate of the ith point location on the synthesized linkage
ypi is the y coordinate of the ith precision point
Function
Function synthesis will show the average error and the maximum error. Error is measured
by the difference in linkage output angle to the desired output angle. Maximum error is the
worst error of a linkage output angle to its corresponding desired angle.
The TLBO algorithm attempts to minimize either average error or maximum error.
𝐸𝑟𝑟𝑜𝑟𝑖 = |𝜃𝑜𝑢𝑡𝑝𝑢𝑡 − 𝜃𝑑𝑒𝑠𝑖𝑟𝑒𝑑 |
∑𝑛1|𝜃𝑜𝑢𝑡𝑝𝑢𝑡 − 𝜃𝑑𝑒𝑠𝑖𝑟𝑒𝑑 |
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟 =
𝑛

Where
Errori is the error at the ith desired angle
n is the number of desired angles
θoutput is the angle of the output link on the synthesized linkage
θdesired is the desired output angle
Motion
If average error is selected, motion synthesis will show the average point error and the
average angle error. If maximum error is selected, motion synthesis will show the
maximum point error and the maximum angle error. These errors are used in compromise
programming to create a composite error that is minimized.
If maximum error is used, the maximum point error and maximum angle error that is
displayed in the progress form will not necessarily be from the same precision point. One
precision point may have the maximum point error, and another may have the maximum
angle error. These maximum errors are shown to give an indication of progress.
2 2
𝑃𝑜𝑖𝑛𝑡 𝑒𝑟𝑟𝑜𝑟𝑖 = √(𝑥𝑖 − 𝑥𝑝𝑖 ) + (𝑦𝑖 − 𝑦𝑝𝑖 )
𝐴𝑛𝑔𝑙𝑒 𝑒𝑟𝑟𝑜𝑟𝑖 = |𝜃𝑜𝑢𝑡𝑝𝑢𝑡 − 𝜃𝑑𝑒𝑠𝑖𝑟𝑒𝑑 |
2 2
∑𝑛1 √(𝑥𝑖 − 𝑥𝑝𝑖 ) + (𝑦𝑖 − 𝑦𝑝𝑖 )
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑝𝑜𝑖𝑛𝑡 𝑒𝑟𝑟𝑜𝑟 =
𝑛
∑𝑛1|𝜃𝑜𝑢𝑡𝑝𝑢𝑡 − 𝜃𝑑𝑒𝑠𝑖𝑟𝑒𝑑 |
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝑎𝑛𝑔𝑙𝑒 𝑒𝑟𝑟𝑜𝑟 =
𝑛
Where
Point errori is the error at the ith precision point
Angle errori is the angle error at the ith precision point
n is the number of precision points
xi is the x coordinate of the ith point location on the synthesized linkage
xpi is the x coordinate of the ith precision point
yi is the y coordinate of the ith point location on the synthesized linkage
ypi is the y coordinate of the ith precision point
θoutput is the angle of the output link on the synthesized linkage
θdesired is the desired output angle

Motion is a multi-objective optimization problem. We want to minimize both the point error
and the angle error. It’s tempting to simply add the errors and minimize the sum. This
does not work very well in many situations. Instead, MEboost uses a technique called
compromise programming as described by [1].
The objective function is determined by:
2 2
𝑤𝑝𝑡 𝑒𝑟𝑟𝑝𝑡 𝑤𝑎𝑛𝑔 𝑒𝑟𝑟𝑎𝑛𝑔
𝐸𝑟𝑟𝑜𝑟 = √( ) +( )
𝑒𝑟𝑟𝑝𝑡−𝑤𝑜𝑟𝑠𝑡 𝑒𝑟𝑟𝑎𝑛𝑔−𝑤𝑜𝑟𝑠𝑡
Where
errpt is the average or maximum point error
errang is the average or maximum angle error
errpt-worst is the worst average point error (error from initial iteration)
errang-worst is the worst average angle error (error from initial iteration)
wpt is the point weight
wang is the angle weight
There are optional weighting factors for point and angle errors. These can be used for two
purposes.
1. To give more importance to either point or angle error. For example, if point error is
more important, a higher point weight can be assigned to force the algorithm to
lower point error at the expense of angle error.
2. In some instances, one of the objectives is easier to find. Weights can be used to
balance the errors to find a better overall solution. For example, if average angle
error quickly goes to a small value while average point error does not converge very
well, assigning a high point weight of say .95, and a low angle weight of say .05 will
put more focus on reducing point error. Weights can be of any value, except they
both cannot be zero.
If point and angle weights are not entered, it is assumed that each weight = 1.
[1] Vanderplaats, G. Multidiscipline Design Optimization, 1st edition, 2007, Vanderplaats

Research & Development, Inc., Colorado Springs, CO, pp. 297-298.
Notes on Function Synthesis

Since function synthesis is only concerned with the relationship between the input link angle
(driver) and the output link angle, the location of joint 12 is not needed and will not be
shown on the synthesis report.

The link dimensions can also be scaled from the synthesized linkage to any size you want
provided that each link is scaled properly. Consider an example where a four bar linkage is
synthesized with the following dimensions:
Synthesized Linkage
Dimension Value
Link 1 length 10
Link 2 length 2.5
Link 3 length 7
Link 4 length 8
Beta -14
Let’s say that we want a linkage to perform the same function, except that link 1 length
should be 25. The scaling factor is 25/10 = 2.5. The scaling factor is multiplied by each
synthesized link length to get the desired linkage size.
Scaled Linkage
Dimension Value
Link 1 length 25
Link 2 length 6.25
Link 3 length 17.5
Link 4 length 20
Beta -14
Beta must remain the same.
An alternative to scaling is to use constraints to force the linkage size. For example, if a link
2 length of 10 is desired, set the minimum and maximum constraints for link 2 = 10. The
remaining link sizes will be found.
Notes on Motion Synthesis

As described earlier, point and angle weights can be specified to place more emphasis on
one of these objectives. It’s recommended to start by not specifying weights (each
objective has equal weight). You can see how well each objective is converging and, if
necessary, start a new synthesis by adjusting the weights.
For example, if angle error is converging quickly while point error is still high, applying a
high point weight and low angle weight is advised. You may have to perform a grid search
of several synthesis runs while varying weights to find a good solution.
Because of the requirements of motion synthesis, a linkage may not be able to perform the
required motion. It’s advisable to use the bare minimum of precision points to allow for a
possible solution.

Cases That May Require Longer to Converge to a Solution
Some synthesis problems will be more difficult to solve and will require a very large number
of iterations (on the order of tens of thousands) to converge to a solution. This is generally
due to linkages where the driver does not fully rotate or where the driver acts as a linear
actuator.
With timing, a candidate linkage’s driver may not rotate through the range of timing angles.
If this happens, the candidate linkage is discarded, and the algorithm continues. A large
percentage of candidate linkages may be discarded which increases the iterations required
to converge.
For slider crank inversions 2 and 4, link 2 can be the driver and acts as a linear actuator.
Unlike a four bar linkage where the maximum range of driver angles is 360 degrees, a linear
actuator has a virtually unlimited length range as far as the TLBO algorithm is concerned.
The search for a linkage that has feasible lengths for link 2 can result in many candidate
solutions being discarded and increasing the iterations required.
The use of loose constraints may help improve search time by reducing the search space.
Be sure not to apply constraints that may eliminate the best solution.
If Error Does Not Reduce to an Acceptable Level

Always keep in mind that a particular linkage type may not be capable of the desired
output. Another linkage type may be capable, or a more complicated linkage such as a six
bar may be required.
4 Bar Synthesis
Ribbon>MEboost tab> Linkages button> 4 Bar Synthesis button
The four bar synthesis form is where data and constraints are entered. Path point data and
link angles must be located in a worksheet. Each range of cells must be in order so that the
first cell of link 2 angles correspond to the first cell x and y values, and so on. Data must be
in order from start to end. For timed synthesis, the start angle of the driver must be first in
the range.

Link of Interest
The link of interest is one of the following:
• For path and motion synthesis, it is the link on which the point that follows the path
is located.
• For function synthesis, it is the output link.
Path
If timed positions is selected, enter or select the range of cells containing link 2 angles. For
timed and untimed, enter or select the range of cells containing path x values, and path y
values.
Function
For function, link 2 angles are the input, and the link of interest angles are the output.
Enter or select the range of cells containing the input and output angles.
Motion
If timed positions is selected, enter or select the range of cells containing link 2 angles.
Since motion is concerned with the path of a point on the link of interest, and the angle of
the link of interest, enter or select the range of cells containing link of interest angles, path
x values, and path y values.
Figure 110 - Four Bar Synthesis

Constraints
Constraints can be imposed on the linkage to meet design constraints. For example, the
frame (link 1) may be limited to 20 and its mounting angle (beta) is limited to +/- 20
degrees.
It’s important to only use constraints that are necessary and to not over-constrain. The
optimal solution may lie outside the constraints and will never be found.
When a linkage is synthesized, a J12x and J12y dimension is generated. This is the location
of the joint that connects link 1 and 2. This joint is the base location of the linkage relative
to the origin of the xy coordinate system.
To completely fix a dimension, enter the same value in the minimum and maximum boxes.
For example, if link 2 must be exactly 4, enter 4 in minimum and maximum constraint
boxes.
Error
You can set a tolerance for error so that when error goes below the tolerance, the synthesis
will stop. Synthesis can also be manually stopped at any time during the synthesis process.
You can select either the average error or maximum error to be minimized.
Progress Form
When the Run button is clicked, the progress form will appear.
Figure 111 - Synthesis Progress Form
The stop button will end the synthesis and create a synthesis report. The abort button will
end the synthesis and not create a report.

Four Bar Synthesis Report
When the synthesis process is stopped, a report will be created. The heading of the report
shows the synthesized linkage dimensions and the point location.
For path synthesis (shown below) an overlay of the precision points and the synthesized
linkage point path is created. For function synthesis, an overlay of output angles is shown.
For motion synthesis, path and angle overlays are shown.
Figure 112 - Example Four Bar Synthesis Report

Slider Crank Synthesis
Ribbon>MEboost tab> Linkages button> Slider Crank Synthesis button
The slider crank synthesis form is where data and constraints are entered. Path point data
and link angles must be located in a worksheet. Each range of cells must be in order so
that the first cell of link 2 angles correspond to the first cell x and y values, and so on. Data
must be in order from start to end. For timed synthesis, the start angle of the driver must
be first in the range.
Figure 113 - Slider Crank Synthesis

Inversion
There are four inversions of the slider crank. In each inversion a different link is fixed.
MEboost uses the link numbering convention where the fixed link is always link 1. Each
inversion is shown below.
Figure 114 - Inversion 1

Driver
Select the driver. Some inversions have more than one possible driver.
Inversion 1: Link 2 is always the driver by rotating.

Inversion 2: Link 4 can be the driver by rotating. Link 2 can be the driver by acting as a
linear actuator.
linear actuator.

Link of Interest
The link of interest is one of the following:
• For path and motion synthesis, it is the link on which the point that follows the path
is located.
• For function synthesis, it is the output link.
Path
If timed positions is selected, enter or select the range of cells containing driver angles.
Note that for inversions 2 and 4, if link 2 is the driver (linear actuator) timed positions is not
possible. For timed and untimed, enter or select the range of cells containing path x values,
and path y values.
Function
For function, driver angles are the input, and the link of interest angles are the output.
Enter or select the range of cells containing the input and output angles.
Motion
If timed positions is selected, enter or select the range of cells containing driver angles.
Note that for inversions 2 and 4, if link 2 is the driver (linear actuator) timed positions is not
possible. Since motion is concerned with the path of a point on the link of interest, and the
angle of the link of interest, enter or select the range of cells containing link of interest
angles, path x values, and path y values.
Constraints
Constraints can be imposed on the linkage to meet design constraints. For example, the
link 1 offset may be limited to 30 and its mounting angle (beta) is limited to +/- 45
degrees.
It’s important to only use constraints that are necessary and to not over-constrain. The
optimal solution may lie outside the constraints and will never be found.
When a linkage is synthesized, a J12x and J12y dimension is generated. This is the location
of the joint that connects link 1 and 2. This joint is the base location of the linkage relative
to the origin of the xy coordinate system.
To completely fix a dimension, enter the same value in the minimum and maximum boxes.
For example, if link 2 must be exactly 4, enter 4 in minimum and maximum.
Error
You can set a tolerance for error so that when error goes below the tolerance, the synthesis
will stop. Synthesis can also be manually stopped at any time during the synthesis process.
You can select either the average error or maximum error to be minimized.

Progress Form
When the Run button is clicked, the progress form will appear.
Figure 118 - Progress Form
The stop button will end the synthesis and create a synthesis report. The abort button will
end the synthesis and not create a report.
Slider Crank Synthesis Report

When the synthesis process is stopped, a report will be created. The heading of the report
shows the synthesized linkage dimensions and the point location.
For path synthesis (shown below) an overlay of the precision points and the synthesized
linkage point path is created. For function synthesis, an overlay of output angles is shown.
For motion synthesis, path and angle overlays are shown.

Figure 119 - Example Slider Crank Synthesis Report

Chapter 12 – Linkage Analysis
NOTE: Refer to the beginning of Chapter 11 for linkage definitions and terminology.
The linkages module contains tools for the kinematic analysis of four bar and slider crank
linkages.
• 4 bar classifier tool to determine the type of linkage and driver limits for a linkage
with all revolute joints.
• Kinematic analysis of 4 bar linkages with all revolute joints.
• Kinematic analysis of slider crank linkages.
Kinematic Linkage Analysis

Kinematic linkage analysis (referred from here on as analysis) starts with a known linkage
design, and determines positions, velocities, and accelerations.
Analysis is the reverse of synthesis. To perform analysis, we must already have a linkage
design. Given a design, MEboost can perform kinematic analysis of linkages. This includes
the following:
• Link angles, angular velocities, and angular accelerations.

• Joint positions, velocities, and accelerations.
• You can specify a point on a link and determine point position, velocity, and
acceleration.
4 Bar Classifier
Ribbon>MEboost tab> Linkages button> 4 Bar Classifier button
The 4 bar classifier tool allows for a simple check of a linkage’s Grashof condition, linkage
type, and crank angle limits.
The tool assumes the following configuration:

• Link 1 is fixed.
• Link 2 is the crank, or driver.
• Link 3 is the coupler.

• Link 4 is the follower.
To run the tool, enter the length for each link and click the Calculate button.
Figure 120 - 4 Bar Classifier
The linkage type is calculated using the following criteria [1]:
Type Shortest Link Link Length Relationship

Grashof
Crank rocker Link 2 Lmax + Lmin ≤ La + Lb
Drag link Link 1 Lmax + Lmin ≤ La + Lb
Double rocker Link 3 Lmax + Lmin ≤ La + Lb
Crossover-position change point Any Lmax + Lmin = La + Lb
Non-Grashof
Triple rocker Any Lmax + Lmin ≥ La + Lb
Where:
Lmax = longest link length
Lmin = shortest link length
La and Lb = lengths of intermediate links
[1] Wilson, C., Sadler, J., Michels, W, Kinematics and Dynamics of Machinery, Harper
Collins, 1983, page 21.

4 Bar Analysis
Ribbon>MEboost tab> Linkages button> 4 Bar Analysis button
Linkage Page
The linkage page is where the linkage is defined, and analysis parameters are entered.
Figure 121 - 4 Bar Linkage Analysis Form > Linkage Page

Linkage Dimensions
Link 1 is always fixed and link 2 is always the driver. Joints are referred to by beginning
with a J. For example, J23 is the joint connecting links 2 and 3. All positions are calculated
relative to the xy system origin. The linkage is located relative to the origin by J12. The
location J12 is specified by entering its x and y coordinates relative to the origin (J12x and
J12y).
Orientation
Beta is the angle from the x axis to J12 to the link 1 centerline. This allows for linkages to
be rotated relative to the xy coordinate system.
Parameters
Analysis is performed over the range of link 2 angles entered. If analyzing a single angle of
link 2, enter the same value for link 2 start and end angles. Calculations are made at
discrete points between link 2 start and end angles. The increment parameter determines
the granularity of calculations as link 2 sweeps from start to end. For example, if link 2
start is 0, end is 360, and increment is 10 then calculations will be made at the following
values of link 2 angle: 0, 10, 20, … , 340, 350, 360.
Assembly Configuration
Four bar linkages can be assembled in open or closed configurations. Except for crossover-
position change point mechanisms, the links must be disassembled to change
configurations.

Report Page
Figure 122 - 4 Bar Linkage Analysis Form > Report Page
Report Charts
Numerous analysis charts can be included in the report. To include/exclude a chart,
check/uncheck the chart.
Point on Link
Often the reason for analysis is to find position, velocity, or acceleration for a point on one
of the links. The point parameters are entered in this pane and the point charts to be
included in the report can be checked/unchecked.

Notation Page
The notation page is for reference only. It defines various dimensions and name/sign
conventions.
Figure 123 - 4 Bar Linkage Analysis Form > Notation Page

4 Bar Analysis Report
The report contains all selected charts on the left and all data used to create the charts on
the right.
Figure 124 - Example 4 Bar Analysis Report

Slider Crank Analysis
Ribbon>MEboost tab> Linkages button> Slider Crank Analysis button
Linkage Page
The linkage page is where the linkage is defined, and analysis parameters are entered.
Figure 125 - Slider Crank Analysis Form > Linkage Page

Inversion
Select the inversion to analyze.
Select the driver. Some inversions have more than one possible driver.

linear actuator.
linear actuator.
For inversion 3 there is also an assembly selection. This inversion can have an open
assembly as shown in the drawing on the form. The assembly can be crossed by rotating
link 4 and inserting link 3 in the opposite end.
Linkage Dimensions
Link 1 is always fixed. Joints are referred to by beginning with a J. For example, J23 is the
joint connecting links 2 and 3. All positions are calculated relative to the xy system origin.
The linkage is located relative to the origin by J12. The location J12 is specified by entering
its x and y coordinates relative to the origin (J12x and J12y).
The beta angle allows for linkages to be rotated relative to the xy coordinate system.
Parameters
Analysis is performed over the range of driver angles/lengths entered. If analyzing a single
driver angle/length, enter the same value for start and end angles/lengths. Calculations are
made at discrete points between start and end angles/length. The increment parameter
determines the granularity of calculations as the driver moves from start to end. For
example, if link 2 start is 0, end is 360, and increment is 10 then calculations will be made
at the following values of link 2 angle: 0, 10, 20, … , 340, 350, 360.

Report Page
Report Charts
Numerous analysis charts can be included in the report. To include/exclude a chart,
check/uncheck the chart. Depending on the inversion selected, some charts may be
disabled because they are not applicable.
Point on Link
Often the reason for analysis is to find position, velocity, or acceleration for a point on one
of the links. The point parameters are entered in this pane and the point charts to be
included in the report can be checked/unchecked.
Figure 126 - Slider Crank Analysis Form > Report Page

Slider Crank Analysis Report
The report contains all selected charts on the left and all data used to create the charts on
the right.
Figure 127 - Example Slider Crank Analysis Report

Chapter 13 – Gearing
The gearing module contains two tools for the analysis of gear trains.
• Gear forces tool to determine gear reaction forces on shafts and bearings.
• Planetary gear train tool to analyze gear and carrier speeds in common planetary
gear trains.
Gear Forces
The gear forces tool calculates shaft and bearing loads created by gear mesh. The tool can
handle five types of gears:
• Spur
• Helical
• Straight bevel
• Spiral bevel
• Worm
Ribbon>MEboost tab> Gearing button> Gear Forces button
Spur Gear
Spur gears are analyzed as a single gear with one or more gears that mesh with the gear in
question. Consider the gear train below where there is a driver, an idler, and a driven gear.

Figure 128 - Spur Gear Train
First, we will calculate gear forces for the driver gear.
Gear to Analyze
Data for the gear that is being analyzed is entered here. Gear function determines whether
the gear is driving other gears or if it is being driven by one or more gears. A driving gear
has a torque being applied to its shaft. A gear that is driven by another gear, and in turn,
drives a third gear is not a driving gear.
If the gear is a driver, the shaft torque applied to the gear must be specified.

Figure 129–Driver Gear Forces
Meshing Gears
All gears that mesh with the gear to analyze are entered here. The mesh action is the
relationship between the meshing gear and the analyzed gear. If the meshing gear drives
the analyzed gear, the tangential force that the meshing gear exerts on the gear must be
specified. Tangential force is calculated by:
𝑇
𝐹𝑡 =
𝑟
Where:
Ft is tangential force
T is meshing gear torque
r is pitch radius of meshing gear
If more than one meshing gear drives the gear, all tangential forces must be equal. For
example, if analyzing a gear driven by more than one meshing gear, each meshing gear
must have the same tangential force.

Mounting angle is the angle from a chosen coordinate system to the line that extends
between the centers of the meshing gear and the gear to analyze. For example, let’s say
we choose an xy coordinate system shown below.
Meshing gear
Mounting angle
x
Gear
Figure 130 – Example Mounting Angle Coordinate System
The radial force angle will be calculated relative to the mounting angles of meshing gears
and therefore will be based on the coordinate system you choose.
Results
In the case of the driver gear, the shaft load in the x direction is equal to the tangential
force and the shaft load in the y direction is equal to the separating force. This is a result of
a single mesh gear located at a mounting angle of 90 degrees.
Now, let’s look at the idler gear where there are two meshing gears in Figure 128. To
determine the load on the shaft we need to combine forces from the two gear meshes.
The shaft radial forces in the x and y directions are the x and y components of the resultant
shaft radial force. The resultant shaft radial force angle is the angle from the positive x axis
to the force vector acting ON the shaft.
The results also show the tangential and separating force for each gear mesh.

Figure 131 - Idler Gear Forces
The diagram below shows the forces on the idler gear. The dashed force is the resultant
shaft radial force that acts on the shaft.

Figure 132 - Idler Gear Forces
Helical Gear
Helical gears are analyzed as a single gear with one or more gears that mesh with the gear
in question.
For a single helical gear, axial force is shown as a positive value. Axial force direction
depends on the hand of the gear and direction of rotation.
We will analyze the idler gear from the helical gear train shown below.

Figure 133 - Helical Gear Train
Gear to Analyze
Data for the gear that is being analyzed is entered here. Gear function determines whether
the gear is driving other gears or if it is being driven by one or more gears. A driving gear
has a torque being applied to its shaft. A gear that is driven by another gear, and in turn,
drives a third gear is not a driving gear.
If you have normal pressure angle for the gear, it must be converted to the transverse
pressure angle by the following formula:
tan ∅𝑛
∅𝑡 = 𝑡𝑎𝑛−1 ( )
cos 𝜓
Where:
∅t is transverse pressure angle
∅n is normal pressure angle
𝜓 is helix angle
If the gear is a driver, the shaft torque applied to the gear must be specified.
Meshing Gears
All gears that mesh with the gear to analyze are entered here. The mesh action is the
relationship between the meshing gear and the analyzed gear. If the meshing gear drives

the analyzed gear, the tangential force that the meshing gear exerts on the gear must be
specified. Tangential force is calculated by:
𝑇
𝐹𝑡 =
𝑟
Where:
Ft is tangential force
T is meshing gear torque
r is pitch radius of meshing gear
If more than one meshing gear drives the gear, all tangential forces must be equal. For
example, if analyzing a gear driven by more than one meshing gear, each meshing gear
must have the same tangential force.
Mounting angle is the angle from a chosen coordinate system to the line that extends
between the centers of the meshing gear and the gear to analyze. Refer to the spur gear
section for a diagram.
The radial force angle will be calculated relative to the mounting angles of meshing gears
and therefore will be based on the coordinate system you choose.

Figure 134 - Helical Gear Page
Results
Radial loads are calculated and presented in a similar manner as spur gears. Refer to the
spur gear section for an explanation of these loads.
For a single helical gear, axial loads are also present. The results will show a net axial load.
This is the sum of all axial forces from each gear mesh. The net axial load can be zero, but
this does not mean axial loads should be ignored when calculating bearing reactions. These
axial loads may cancel in the z direction, but they can induce moments that result in
bearing loads in the x and/or y directions.
In the example we have a net axial load of zero. Looking at the loads from each mesh, we
have an axial load of 46.68 for mesh 1 and -46.68 for mesh 2. The negative axial force is
used to denote that the two axial forces are in opposite directions. The hand of the helix
and rotation direction determines the direction of each force. In our example, the axial
forces are shown below.

Figure 135 - Idler Gear Axial Forces
Straight Bevel Gear

Straight bevel gears are analyzed as a pair with a driving pinion and a driven gear. Forces
are calculated assuming the forces are concentrated at the center of each tooth.
Consider the pair of bevel gears below.
Figure 136 - Bevel Gears

Enter the appropriate data for each gear. The pinion is the driving gear. Pitch diameters
are measured to the outside edge of the teeth where the pitch cone intersects the outside
edge of the tooth. Refer to the diagram below. Sometimes this is referred to as the outside
pitch diameter.
Shaft angle is the angle between each gear’s shaft. This is most often 90 degrees but can
have other angles.
Face width is the width of the teeth.
Pinion torque is the applied torque to the pinion’s shaft.
Pitch cone
Pitch
Face width angle
Pitch diameter
Figure 137 - Bevel Gear Dimensions

Figure 138 - Straight Bevel Gear
Results
The results will show the tangential, radial, and axial forces for each gear. The tool also
calculates pitch angles. The diagram below explains each force.

Figure 139 - Bevel Gear Forces
Spiral Bevel Gear

Spiral bevel gears are analyzed as a pair with a driving pinion and a driven gear. Forces are
calculated assuming the forces are concentrated at the center of each tooth. Spiral hand
and direction of rotation affect axial and radial force directions. Forces that tend to push
the gears apart (separating force) are shown as positive values. Forces that tend to draw
gears together are shown as negative values.
Axial and radial forces are calculated depending on whether the forces are on the convex or
concave side of the teeth. For example, pinion radial force, convex is the radial force when
the convex side of the pinion’s teeth are driving the concave side of the gear’s teeth. In this
case the gear radial force, concave would be used in conjunction with pinion radial force,
convex.

Figure 140 - Spiral Bevel Gear Page
Data is entered similar to straight bevel gears except that a spiral angle must be specified.
Refer to the bevel gear dimensions in the straight bevel gear section. If the spiral angle is
zero, this is a Zerol gear.
Depending on the hand of the spiral for each gear and the direction of rotation, the axial
and radial forces will be different. Axial forces can be separating (pushing the gears apart)
or they can be in the opposite direction and pull the gears together. The results will show
the combinations where the pinion’s concave side of the teeth work against the convex side
of the gear’s teeth. It will also show the opposite case if rotation were reversed.
Worm Gear
Worm and worm gears are analyzed as a pair. The tool makes the following assumptions:
• The worm is the driver and the worm gear is driven.

• The worm and gear shafts are 90 degrees apart.
Sliding friction between the worm and gear are accounted for with the coefficient of friction.
The efficiency calculated is for mesh efficiency and does not account for other losses.

Figure 141 - Worm Gear Page
Results
The worm and gear forces are shown in the diagram below. The tool also calculates mesh
efficiency that result from friction as well as the gear torque (output torque).

Figure 142 - Worm and Gear Forces
Planetary Gear Train

The planetary gear train tool calculates the rotational speeds of all gears and the carrier.
When one gear or the carrier is fixed, an input speed is entered for another item in the train
with the remaining item being considered the output.
When no items are fixed, two input speeds are required. The remaining item is considered
the output.
There are 12 possible planetary configurations that can be analyzed. Each configuration has
a number from 1 to 12 for identification. Refer to the configuration reference tabs to see
the number associated with each configuration. The configurations are shown in simplified
schematic form. For analysis, it’s assumed that one planet is rotating about a sun gear or
within a ring gear. This is done for simplicity but does not affect the results when multiple
planets are used for the same function.

For example, in configuration 1 there is a sun gear S1, a planet gear P1, and a ring gear R1.
There could be three P1 planet gears and speeds will not be affected. All P1 planets will
have the same speed.
The planetary gear train tool assumes that all gears have the same pitch.
Ribbon>MEboost tab> Gearing button> Planetary Gear Train button
Figure 143 - Planetary Gear Train Form

Fixed Item
If an item is fixed (sun, ring, carrier) select the checkbox for the appropriate item. If no
items are fixed, leave all check boxes unchecked.
Gear Teeth
Enter the number of teeth for each gear type.
Inputs
For input 1, select the item with a known speed. Enter the speed and direction of rotation.
If an item is fixed, there will be no input 2. In this case select “N/A” for input 2. If no items
are fixed, select the second input, its speed and direction of rotation.

Chapter 14 – Vibration
The vibration tool creates a transmissibility plot for a mass-spring-damper system.
Transmissibility is the ratio of force applied to the system (often through imbalance) to the
force transmitted by the system to its base. Maximum transmissibility occurs when the
forcing function is the same as the natural frequency. Transmissibility plots are useful to
determine if operating points are close to natural frequency and the response if the forcing
frequency changes during operation.
Natural Frequency
The natural frequency is calculated by:
𝑘
𝜔𝑛 = √𝑚 (SI units)
𝑘𝑔
𝜔𝑛 = √ 𝑚𝑐 (US customary units)
Where:
ωn is the natural frequency, rad/s
k is the spring constant
m is the mass
gc is a constant = 32.2 lbf∙s2/lbm∙ft
Natural frequency is converted to Hertz when the report is created.
Undamped Vibration
For undamped vibration, the transmissibility is determined by:
1
𝛽=| 2|
𝜔
1 − (𝜔 )
𝑛
Where:
β is transmissibility
ω is the forcing frequency, rad/s
ωn the natural frequency, rad/s

Damped Vibration
For damped vibration, a damping ratio is calculated. This is the ratio of the damping
coefficient to the critical damping coefficient. The units entered are converted to
appropriate units for calculation.
𝐶 𝐶
𝜁= = (SI units)
𝐶𝑐𝑟𝑖𝑡 2𝑚𝜔𝑛
𝐶 𝐶𝑔𝑐
𝜁= = (US customary units)
𝐶𝑐𝑟𝑖𝑡 2𝑚𝜔𝑛
Where:
ζ is the damping ratio
C is the damping coefficient
Ccrit is the coefficient for critical damping
ωn is the natural frequency, rad/s
m is the mass
gc is a constant = 32.2 lbf∙s2/lbm∙ft
For damped vibration, the transmissibility is determined by:
2
| √1 + [2𝜁 ( 𝜔 )] |
𝜔𝑛
𝛽=
| 2 2 2|
√[1 − ( 𝜔 ) ] + [2𝜁 ( 𝜔 )]
𝜔𝑛 𝜔𝑛
Where:
β is transmissibility
ω is the forcing frequency, rad/s
ωn the natural frequency, rad/s
ζ is the damping ratio

Vibration
Ribbon>MEboost tab>Vibration button
Clicking the Vibration button on the ribbon will show the Vibration form.
Figure 144 - Vibration Form Single Curve
MEboost allows for a single transmissibility curve, or you can create up to 25 curves at
equally spaced damping coefficient intervals.

Report
Values
Enter values for mass, spring constant, and damping coefficient. The values entered must
match the units shown.
Spring constant is the combined system spring constant. For example, if the mass is
mounted with four springs that are not connected to each other, we have four springs in
parallel. Therefore, the combined spring constant is:
𝑘 = 𝑘1 + 𝑘2 + 𝑘3 + 𝑘4
Linear damping is supported using a damping coefficient. The damping coefficient is

force/speed. If the system is undamped, enter 0 for damping coefficient. For multiple
curves, enter the minimum damping coefficient and the damping coefficient interval
between curves. In the example below, the first curve is created with a damping coefficient
of 200, the second curve with 250, the third with 300, and so on.
Figure 145–Vibration Form Multiple Curves

Report
The report includes input information, damping ratio, and natural frequency.
Transmissibility is plotted on the y-axis in log scale. The ratio of forcing frequency, f to
natural frequency, fn is on the x-axis.
Figure 146 - Example Transmissibility Report

Chapter 15 – Hydraulics
MEboost has three tools for hydraulic calculations:
• Hydraulic pump and motor tool.

• Hydraulic cylinder tool.
• Fluid velocity tool.
Pump and Motor

Ribbon>MEboost tab> Pump and Motor button
The pump and motor tool is used for calculations relating to hydraulic pumps and motors.
Pump/motor parameters can be solved knowing other conditions. The difference between
pump and motor equations is how efficiencies enter into the equations.
Pump Equations – SI Units
𝑃𝑄
𝑃𝑜𝑤𝑒𝑟𝑖𝑛 =
600𝜂𝑡𝑜𝑡
Where:
Powerin is the input power required, KW
P is the pressure increase through the pump, bar
Q is the flow rate, liters/minute
ηtot is total efficiency of the pump.
𝑃𝑄
𝑃𝑜𝑤𝑒𝑟𝑜𝑢𝑡 =
600

Where:
Powerout is the output fluid power, KW
62.832𝑇
𝐷=
𝑃𝜂𝑚ℎ
Where:
D is pump displacement, cubic cm/revolution
T is input torque to pump, Newton-meter
ηmhis the mechanical/hydraulic efficiency of the pump.
DSηvol
Q=
1000
Where:
S is pump speed, revolutions/minute
ηvol is the volumetric efficiency of the pump.
62.832𝑇𝜂𝑚ℎ
𝑃=
𝐷
𝑃𝐷
𝑇=
62.832𝜂𝑚ℎ
1000𝑄
𝑆=
𝐷𝜂𝑣𝑜𝑙
Motor Equations – SI Units
𝑃𝑄
600
Where:
Powerin is the input fluid power, KW
P is the pressure drop through the motor, bar
Q is the flow rate, liters/minute
𝑃𝑄𝜂𝑡𝑜𝑡
600
Where:
Powerout is the output mechanical power, KW
ηtot is total efficiency of the motor.

62.832𝑇
𝐷=
𝑃𝜂𝑚ℎ
Where:
D is motor displacement, cubic cm/revolution
T is output torque, Newton-meter
ηmh is the mechanical/hydraulic efficiency of the motor.
DS
Q=
1000ηvol
Where:
S is motor speed, revolutions/minute
ηvolis the volumetric efficiency of the motor.
62.832𝑇
𝑃=
𝐷𝜂𝑚ℎ
𝑃𝐷𝜂𝑚ℎ
𝑇=
62.832
1000𝑄𝜂𝑣𝑜𝑙
𝑆=
𝐷
Pump Equations – US Units
𝑃𝑄
1714.293𝜂𝑡𝑜𝑡
Where:
Powerin is the input power required, HP
P is the pressure increase through the pump, psi
Q is the flow rate, gallons/minute
ηtot is total efficiency of the pump.
𝑃𝑄
1714.293
Where:
Powerout is the output fluid power, HP

2𝜋𝑇
𝐷=
𝑃𝜂𝑚ℎ
Where:
D is pump displacement, cubic inch/revolution
T is input torque to pump, foot-pound
ηmh is the mechanical/hydraulic efficiency of the pump.
DSηvol
Q=
231
Where:
S is pump speed, revolutions/minute
ηvol is the volumetric efficiency of the pump.
2𝜋𝑇𝜂𝑚ℎ
𝑃=
𝐷
𝑃𝐷
𝑇=
2𝜋𝜂𝑚ℎ
231𝑄
𝑆=
𝐷𝜂𝑣𝑜𝑙
Motor Equations – US Units
𝑃𝑄
1714.293
Where:
Powerin is the input fluid power, HP
P is the pressure drop through the motor, psi
Q is the flow rate, gallons/minute
𝑃𝑄𝜂𝑡𝑜𝑡
1714.293
Where:
Powerout is the output mechanical power, HP
ηtot is total efficiency of the motor.

2𝜋𝑇
𝐷=
𝑃𝜂𝑚ℎ
Where:
D is motor displacement, cubic inch/revolution
T is output torque, inch-pound
ηmh is the mechanical/hydraulic efficiency of the motor.
DS
Q=
231ηvol
Where:
S is motor speed, revolutions/minute
ηvol is the volumetric efficiency of the motor.
2𝜋𝑇
𝑃=
𝐷𝜂𝑚ℎ
𝑃𝐷𝜂𝑚ℎ
𝑇=
2𝜋
231𝑄𝜂𝑣𝑜𝑙
𝑆=
𝐷
Click the Pump and Motor button on the MEboost ribbon to open the tool.
Figure 147 - Pump and Motor Tool

There are separate tabs for pumps and motors. Select the appropriate tab depending on
whether you are calculating for a pump or motor.
Solve For
Select the parameter that you need to solve. The selected parameter will be determined
using one of the equations shown earlier. When a parameter is selected, the appropriate
inputs will appear in the Given pane.
Given
Enter the known values in this pane.
When the information has been entered, click the Calculate button to see the results.
Figure 148 - Pump Calculation Results
The results can be pasted into cells in an existing worksheet. Any contents of the cells will
be overwritten.

Cylinder
Ribbon>MEboost tab> Cylinder button
The cylinder tool performs calculations for double acting hydraulic cylinders given a design
constraint such as extend force, retract speed, etc. All calculations assume 100%
efficiency.
The tool assumes you have a candidate cylinder with known dimensions. The tool will
calculate piston area (extend) and annulus area (retract). It also calculates extend and
retract volumes. The appropriate calculation(s) based on the design constraint will also be
made.
NOTE: The cylinder tool assumes 100% volumetric efficiency and 100%
hydraulic/mechanical efficiency.
Click the Cylinder button on the MEboost ribbon to open the tool.
Figure 149 - Cylinder Tool

Design Constraint
Select a design constraint for the cylinder. In the example above, we need an extend force
of 500 lbs. For this example, we need the pressure required to develop 500 lbs of extend
force.
Cylinder Dimensions
The tool assumes you have a candidate cylinder selected. Enter the dimensions of the
cylinder here.
When the information has been entered, click the Calculate button to see the results.
Figure 150 - Cylinder Calculation Results
be overwritten.
Fluid Velocity
Ribbon>MEboost tab> Fluid Velocity button

The fluid velocity tool calculates average hydraulic fluid velocity in hose/tubing/pipes. The
tool allows for mixed units. Click the Fluid Velocity button on the MEboost ribbon to open
the tool.
Figure 151 - Fluid Velocity Tool
Enter the line inside diameter and the fluid flow rate in the inputs pane. Then select the
appropriate units for each in the drop-down boxes. Velocity can be calculated in either m/s
or ft/s. Select the appropriate velocity units and click the Calculate button.
Figure 152 - Fluid Velocity Calculation Results

be overwritten.

Chapter 16 – Affinity Laws
Pump affinity laws can be calculated at a single point or charts of flow rate, head, and
power can be plotted against changes in impeller speed or diameter. Changes to a pump’s
configuration, such as impeller diameter or pump size in general can be analyzed for these
conditions:
• Constant impeller diameter with changing speed.
• Constant speed, with two pumps of different size as measured by impeller diameter.
• Constant speed, with a trimmed impeller. Trimmed impeller means that diameter is
changed, but the pump casing has not.
The first two conditions are also applicable for fans. For the purposes of discussion in this
chapter, pump terminology will be used.
The affinity law calculations assume that each pump operates at the same efficiency and
that the pumped fluid does not change (constant density).
Affinity Law Equations

Terms:
N is shaft rotational speed
D is impeller diameter
Q is flow rate
H is head
P is power
Constant Impeller Diameter

These equations model the effect on flow rate, head, and shaft power from changes to shaft
rotational speed.
𝑄1 𝑁1
=
𝑄2 𝑁2
𝐻1 𝑁1 2
=( )
𝐻2 𝑁2
𝑃1 𝑁1 3
=( )
𝑃2 𝑁2
Constant Shaft Speed

These equations are developed from pump similarity and assume two pumps that are
geometrically similar (homologous). They model the effect on flow rate, head, and shaft
power from changes to impeller diameter.

𝑄1 𝐷1 3
=( )
𝑄2 𝐷2
𝐻1 𝐷1 2
=( )
𝐻2 𝐷2
𝑃1 𝐷1 5
=( )
𝑃2 𝐷2
Constant Shaft Speed, Trimmed Impeller

These equations apply to a pump where the impeller diameter is changed, but not the
casing, or impeller eye diameter. This is often the case where the impeller is machined to a
smaller diameter. This is where the term trimmed impeller comes into play. This could also
apply where a smaller impeller is initiallyinstalled andreplaced with a larger impeller that
still fits in the casing.
One of the conditions for pump similarity is that the two configurations are geometrically
similar. When an impeller is trimmed (or enlarged), geometric factors such as casing
clearance, vane angles, and eye to outside diameter ratio change. Therefore, the
assumption of geometric similarity is not valid, and different equations must be used.
𝑄1 𝐷1
=
𝑄2 𝐷2
𝐻1 𝐷1 2
=( )
𝐻2 𝐷2
𝑃1 𝐷1 3
=( )
𝑃2 𝐷2
Affinity Laws
Ribbon>MEboost tab>Affinity Laws button

After clicking the Affinity Laws button, the Affinity Laws form will appear. There are two
tabs (pages) on the form. The calculator page will calculate an operating point given
another operating point. The charts page will plot flow rate, head, and power against
variations in speed and impeller diameter.
Calculator Page
The calculator page is used to determine a single operating point for flow rate, head, or
power.
Condition
Select the condition under consideration. The three conditions are:
• Constant impeller diameter. This condition is used when speed is changed.
• Constant shaft speed. This condition is used when pump size is changed.
• Constant shaft speed, trimmed impeller. This condition is used when impeller
diameter would be changed by machining to a smaller diameter or installing a larger
impeller in the same casing. The affinity laws for this condition are different than the
constant shaft speed condition since the two pump configurations are not
geometrically similar.
Parameter
Select the unknown parameter to solve.
Equation
When the radio buttons for condition and parameter are selected, the appropriate affinity
law equation will appear. There is a box for each of the four parameters in the equation.
Three of the four boxes must have known values entered. When the Solve button is clicked,
the empty box will contain the solved value.

Figure 153–Affinity Laws Form> Calculator Page
Charts Page
The charts page is used to generate charts with flow rate, head, and power on the y-axis.
Shaft speed or impeller diameter can be plotted on the x-axis.
Charts
Two charts can be included in the report.
• Varying speed. A chart as a function of shaft speed.
• Varying diameter. A chart as a function of impeller diameter. If varying diameter is
selected, select untrimmed or trimmed depending on how diameter will be changed.
See earlier discussion on trimmed impellers.
The maximum ratio determines the maximum scale of the x-axis. It is the ratio of the base
value of speed or diameter. For example, if base speed is 1750 RPM and maximum ratio is
2.0, then the chart will be created up to 3500 RPM.
There are two ways to generate charts:

• Generic. In this case initial values are set to 1. For example, if head is plotted vs.
diameter, H1 and D1 are both set to 1. D2 is varied from 0 to maximum ratio and
H2 is solved and plotted. To create generic charts, leave all base values blank. This
is primarily used to visualize how parameters change in a general way.

• Actual values. Base case values for speed or diameter are entered. For each curve,
the base case for flow rate, head, or power is also entered. The charts are
generated using these base case values.
Curves
Select the curves to include in each chart. Also enter any base case values if necessary.
Report
Figure 154 - Affinity Laws Form > Charts Page

Charts Report
An example charts report is shown in Figure 155. Data used to create the charts is included
in the worksheet and the charts are native Excel charts. Each chart’s appearance can be
changed using Excel’s editing tools.
Figure 155 – Example Affinity Charts

Chapter 17 – System Curve
The system curve tool can generate a system curve approximation as well as up to four
pump curves on the same chart. The system curve is approximated by the following
equation:
ℎ𝑓1 𝑄1 2
=( )
ℎ𝑓2 𝑄2
Where:
hf1 is friction head at operating point 1
hf2 is friction head at operating point 2
Q1 is flow rate at operating point 1
Q2 is flow rate at operating point 2
Given a known friction head and flow rate at one operating point, we can approximate the
friction head at other flow rates.
The system curve is based on the following assumptions:

• Pressure at the source reservoir and destination are equal.
• The fluid level of the source reservoir and destination remain constant.
• The velocity head is neglected.
• Friction factor remains constant. While the system curve is drawn from a flow rate
of zero to a specified maximum, it may only be valid for a reasonable range around
operating point 1 flow rate. A large change in flow rate will likely cause a change in
friction factor.
System Curve
Ribbon>MEboost tab> System Curve button
Clicking the System Curve button on the ribbon will show the System Curve form.

Figure 156 - System Curve Form
Known Operating Point

Enter the data for the known operating point. Pressure may be in units of pressure or head.
Pressure, static head, and pump curve data must all have the same units to be consistent.
A positive static head is where the fluid source is below the fluid destination. A negative
static head is where the fluid source is above the fluid destination. Again, if pressure is
being used, static head must be converted to pressure.
Pump Curve Data (optional)

You can plot up to four pump curves, as well as a combined pump curve. To add pump
curves, the pump curve data must be in a worksheet in two columns. The first column is
flow rate, and the second is pressure/head.
Enter or select the pump curve data range starting with pump 1.

If a combined curve is plotted, all pumps can be in series or parallel. For pumps in series,
the head for each pump is added at a given flow rate. For pumps in parallel, the flow rate
for each pump is added at a given head.
When creating a combined pump curve, pump curve data is linearly interpolated.
Report
The report can be created in a new worksheet in the current workbook, or in a new
workbook. Enter the maximum flow rate to plot. The system curve will be plotted from a
flow rate of 0 to this maximum. If a pumps capacity exceeds this maximum, the pump
curve will be plotted up to this point.
Example
Suppose we have a system with a known operating point of head = 100 at a flow rate of 50.
We want to plot the system curve along with two pump curves and their combined pump
curve in parallel.
We have already entered the pump data into a worksheet. Note that the data for each
pump must be entered in two adjacent columns. The first column is flow rate, and the
second is pressure/head.
Figure 157 - Pump Data
With the pump data in place, we can open the System Curve form. The known operating
point is entered, and the pump data ranges are selected by clicking the minimize button
next to each pump data range box.

Figure 158 - System Curve Form for Example
Error When Pumps are in Parallel

When creating a combined curve for pumps in parallel, you may get an error that the
combined curve cannot be created. This occurs when one pump’s minimum head exceeds
the maximum head of another pump. Consider the two pump curves below.
Pump 2 minimum head is greater than the maximum head of pump 1. When pumps are in
parallel, the maximum head of the combined curve is the maximum head of the pump with
the lowest maximum head. Therefore, if the pump heads do not overlap, a combined
parallel curve cannot be created.

Figure 159 - Example Where Combined Parallel Pump Curve Cannot Be Created
System Curve Report
Figure 160 - Example Report

Chapter 18 – Bernoulli Equation
The Bernoulli equation is a useful method for determining the state of a fluid at a point on a
streamline given known conditions at another point on the streamline. The Bernoulli
equation is given by:
𝑣2 𝑝
+ + 𝑔𝑧 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
2 𝜌
Where:
v is fluid velocity
p is fluid pressure
ρ is fluid density
g is gravitational constant
z is elevation
To find an unknown value at one point, given known values at another point, we set the two
Bernoulli equations equal to each other and solve for the unknown value.
𝑣12 𝑝1 𝑣22 𝑝2
+ + 𝑔𝑧1 = + + 𝑔𝑧2
2 𝜌 2 𝜌
The use of the Bernoulli equation assumes:

• Incompressible fluid.
• No fluid friction.
• Adiabatic process, i.e. no heat or mass transfer.
Bernoulli Equation
Ribbon>MEboost tab>Bernoulli Equation button
Clicking the Bernoulli Equation button on the ribbon will show the Bernoulli Equation form.

Figure 161–Bernoulli Equation Form
Solve for…
It is assumed that the velocity, pressure, and elevation at point 1 are known. It’s also
assumed that two of velocity, pressure, and elevation at point 2 are known. Select the
unknown value at point 2 that will be solved. The unknown value’s box will be highlighted
as shown above.
Known Values
Enter the known values in each box and click Solve to determine the unknown value. The
Reset button will clear all boxes for another calculation.

Report
To create a report of the calculation, click the Create Report button. A new form will appear
to create the report.
Figure 162- Create Report Form
The report can be created on a new sheet in the active workbook, or in a new workbook.
Figure 163- Example Bernoulli Report

Chapter 19 – Pressure to Head Conversion
The Pressure-Head tool allows for conversion of pressure to head and vice versa. The tool
assumes standard earth gravitational acceleration.
Pressure - Head
Ribbon>MEboost tab>Pressure - Head button
After clicking on the Pressure-Head button, the following form will appear.
Figure 164 - Pressure-Head Conversion Form

Fluid
MEboost has density values for water at 4 oC and 60 oF. These can be selected from the
drop-down box. If you are converting for a different fluid, select “User entered” and enter
the density in the box. Select the appropriate units for density.
Pressure
Select the desired pressure units.
Head
Select the desired head units.
Conversion
Select a radio button for the desired conversion from either pressure to head or head to
pressure. Enter the value to be converted from in the top box. Click the Convert button to
show the converted value in the bottom box.
Example Conversion
We have water assumed to be at 4 oC with a head of 42 meters. We want to convert head
in meters to pressure in psi.
Figure 165 - Example Conversion
We select Water, 4 deg. C from the drop-down, and it populates 1000 kg/m3 in the density
box. Since we want pressure in psi, we select the PSI radio button. Head is in meters, so
we select the meters radio button.

The conversion is from head to pressure, so the head to pressure radio button is selected.
The known head is 42 meters, and it is entered in the top box. Finally, clicking the Convert
button shows that the pressure is 59.7497 psi.

Chapter 20 – Unit Conversion
The unit conversion tool offers a wide array of most commonly used units. Unit conversion
factors are based on National Institute of Standards and Technology (NIST) conversion
factors. For more information, visit this link.
Unit Conversion
Ribbon>MEboost tab>Unit Conversion button
Clicking the Unit Conversion button on the ribbon will open the Unit Conversion form.
Figure 166 - Unit Conversion Form

Select Unit Type
Select a unit type from the drop-down box. Unit types are categorized into the following
types:
• Area
• Density
• Energy
• Flow Rate
• Force
• Heat
• Length
• Mass
• Pressure
• Power
• Temperature
• Torque
• Velocity
• Viscosity – dynamic
• Viscosity - kinematic
• Volume
Unit Conversion
Enter a value to be converted in one of the boxes and select the units associated with that
value. Then select the units you want to convert to in the other drop-down box. Click the
Convert button to calculate the converted value. Note: If values are entered in both boxes,
the top box is assumed to be the original value and the calculated value will appear in the
lower box.
Notes on Units
British thermal unit is based on the international table and is denoted in the software as
BTU (int). NIST lists this as BTUIT.
Therm is based on the international table BTU and is denoted in the software as Therm
(EC). The EC refers to the original designation from European Communities, now the EU.
NIST also lists this as Therm (EC).
Fluid ounce and gallon are United States ounce and gallon.
Inches of water (pressure) is based on 39.2 oF (4 oC).
Inches of Hg (pressure) is based on 32oF (0 oC).
Millimeters of Hg (pressure) is based on 32 oF (0 oC).

Chapter 21 – Integration
The integration tool estimates the value of definite integrals up to four dimensions
(quadruple integrals). The method used is the so-called basic or ordinary method.
Model Set-Up
Prior to using the integration tool, the function must be set-up in a worksheet. Consider the
triple integral:
𝜋 2 2
∫ ∫ ∫ 𝑥𝑦𝑠𝑖𝑛𝑒(𝑧) 𝑑𝑥 𝑑𝑦 𝑑𝑧
0 1 0
To model this, we use uniformly distributed random variables over the bounds for each x, y,
and z variable. Then the function is evaluated in a cell. The integral is set-up in the
worksheet below.
Figure 167 - Integral Set-Up
To generate uniformly distributed random variables, we make use of the MEBUNIFORM

function. This function uses two parameters, the minimum and maximum. For example,
the x variable (cell B2) is evaluated from 0 to 2. To model this variable, enter
=MEBUNIFORM(0,2) when using decimal point. For decimal comma, enter
=MEBUNIFORM(0;2).

Integration Tool
Ribbon>Simulation Tab>Special Tools>Integration
Once the function model has been setup, the integration tool can be run. Click the
Integration button on the ribbon. The following form will appear.
Figure 168 - Integration Tool Form
Function Cell
Select or enter the cell where the function is evaluated. In the example, it is cell B6.

Iterations
Enter the number of simulation iterations to run. More iterations will result in a more
precise result.
Integral Parameters
Select the dimension of the integral. In the example, it is a triple integral. Then enter the
bounds for each variable.
When everything is entered, click the Run button to start the simulation. After the
simulation is complete, the estimated value and error will appear in the result box.
Figure 169 - Result After Simulation
Paste Results
The estimate and error can be pasted to cells in the workbook to save the result.
Simulation Data
If you do not want to save the simulation data, check the box to delete it when the form is
closed.

Error
Error [1] is the standard deviation of the estimate and is determined by:
𝜎2
𝐸𝑟𝑟𝑜𝑟 = 𝜎𝐼 = √
𝑛
Where:
σI is the standard deviation of the integral estimate.
σ2 is the variance of the simulation data.
n is the number of simulation iterations.
[1] Ross, S., Introduction to Probability Models, 7th Ed., Academic Press, 2007, page 720.
Update Links
Ribbon>MEboost tab>Update Links button
When an MEboost function is entered in a workbook for integration, Excel creates a link
between the workbook and the MEboost add-in on the current machine. When the
workbook is opened on another machine, you may get a message that links could not be
updated.
Figure 170 - Links Warning Message
Click the Don’t Update button to close the message. Then click the Update Links button on
the Simulation Master ribbon. This utility will update the link to the current machine.

The following conditions must be met for update links to work properly:
• Do not break the links using the Edit Links tool in the Excel ribbon.
• Do not rename the MEboost add-in file. Its name should be "MEboost.xlam".
• Protected sheets may affect the update (see below).
Protected Sheets
The presence of protected sheets will affect the update process depending on the situation:
Protected Sheet Active

If a protected sheet is active when the Update Links button is clicked, you will get an error
message and the links will not be updated.
Unprotected Sheet Active, First Function Entered in Unprotected Sheet

If an unprotected sheet is active when the Update Links button is clicked, the functions in
unprotected sheets will be updated if the first function entered in the workbook is in an
unprotected sheet. Any functions in protected sheets will not be updated.
Unprotected Sheet Active, First Function Entered in Protected Sheet

If an unprotected sheet is active when the Update Links button is clicked, and the first
function entered in the workbook is in a protected sheet, all functions will not update. The
sheet containing the first function must be unprotected prior to updating links.

Appendix A – Specifications & Protected
Workbooks
Specifications
• Maximum data points per fatigue damage calculation: 1,048,576
• Maximum bins for fatigue damage calculation: 16,383
• Pseudo-random number generation: Excel RAND function.
• RAND interval: Excel RAND generates a number on the interval [0,1). However,
some distribution functions will generate an error if random number is 0. In these
cases, interval is (0,1]. Refer to Appendix C for distributions that use this interval.
• Maximum trials per Monte Carlo simulation (tolerance analysis): 1,048,575
• Maximum iterations per Monte Carlo integration: 1,048,575
• Simulation time: Limited by processor speed and model complexity.
Protected Workbooks
Some MEboost operations create new worksheets such as data sheets, reports, and
temporary calculation sheets. When a workbook is protected, new sheets cannot be added.
For some operations, the software will check if the workbook is protected, and if protected
will show the following message.
Monte Carlo tolerance analysis and integration is not available in protected workbooks.
In protected workbooks, new models cannot be created for 1D RSS, 1D worst case, and
1D/2D/3D worst case tolerance analysis.

In protected workbooks, these operations can only create reports in a new workbook:
• Mohr’s circle
• Beam diagrams
• Fatigue diagram
• Load plot
• Fatigue damage
• Sheet metal
• 1D RSS tolerance analysis
• 1D Worst case tolerance analysis
• 1D/2D/3D Worst case tolerance analysis
• Tolerance calculation
• Shaft design
• Linkage synthesis
• Linkage analysis
• Gear forces
• Planetary gear train
• Vibration
• Affinity laws
• System curve
• Bernoulli equation

Appendix B – Troubleshooting
Mohr’s circle is not round

When editing axes, the range of values for each axis must be the same.
Mohr’s circle for plane strain shows all zeros on both axes
To maintain a circle in the chart, all values on the x and y axes are rounded to 0 decimal
places. Enter strains as micro strain or another scale that avoids decimal values. For
example, a strain of .000600 should be entered as 600.
Error generating histogram on Monte Carlo tolerance analysis form

Possible causes:
• Workbook has not been saved.
• Workbook is located on a network server, and server connection lost.
The histogram on the results page is generated by creating a .gif image in the file directory
of the workbook. If the workbook has not been saved, there is no file directory. If the
workbook is in a network location, any loss to the network connection will not allow the .gif
file to be saved.
When the Monte Carlo tolerance analysis form is closed, the .gif file will be deleted.

Appendix C – Probability Distributions for
Monte Carlo Tolerance Analysis
Normal Distribution
A normal random variable has the parameters mean and standard deviation.
Figure 171 - Normal Probability Density Function
RAND pseudo-random number range [1] (0,1]

Random variable generation method Excel NORMINV for Excel 2007
Excel NORM.INV for Excel 2010 and later
Input parameter 1 mean
Parameter 1 valid range positive real number
Input parameter 2 standard deviation
[1] Lower bound set to non-zero value to avoid error with Excel function.

Uniform Distribution
A uniform random variable has the parameters minimum and maximum. Each value
between minimum and maximum have equal probabilities.
Figure 172 - Uniform Probability Density Function
RAND pseudo-random number range [1] [0,1)

Random variable generation method Inverse transform
Input parameter 1 minimum
Input parameter 2 maximum

Triangular Distribution
The triangular distribution is a general-purpose distribution generally used when there is not
a well-known underlying probability distribution. The parameters are minimum value,
maximum value, and a most likely value to define the random variable. Probability is
highest at the most likely value and linearly decreases to zero at minimum and maximum.
Figure 173 - Triangular Probability Density Function
RAND pseudo-random number interval [0,1)

Input parameter 2 most likely

Trapezoidal Distribution
The trapezoidal distribution is a more general version of the uniform and triangular
distributions (both are a special case of the trapezoidal distribution). The parameters
minimum, maximum, and two most likely values are used to define the random variable.
There is an equal probability of occurrence for each value between the two most likely
values. Probability is highest between the most likely values and linearly decreases to zero
at minimum and maximum.
Figure 174 - Trapezoidal Probability Density Function
RAND pseudo-random number interval [0,1)

Input parameter 2 likely 1
Input parameter 3 likely 2

PERT Distribution
The parameters define the minimum value, most likely value, and maximum value. The
PERT distribution is a transformed Beta distribution. The most likely value has the highest
probability and the shape of the distribution places most of the probability around the most
likely value.
Figure 175 - PERT Probability Density Function
RAND pseudo-random number range [1] (0,1]

Random variable generation method Excel BETAINV for Excel 2007
Excel BETA.INV for Excel 2010 and later
Input parameter 2 [2] most likely
[1] Lower bound set to non-zero value to avoid error with Excel function.
[2] When most likely case is exactly halfway between minimum and maximum; an error
would result. To avoid error, .0000000001 is added to most likely value.

Appendix D – Decimal Separators
This appendix describes how MEboost works with decimal separators. Decimals are usually
specified using either the decimal point (.) or the decimal comma (,). The choice of which
decimal separator used is determined by the Windows regional settings.
To make things more complicated, Excel allows you to override your Window settings (also
known as system settings) and specify a different decimal separator in Excel worksheets.
The system settings can be overridden by clicking on File > Options. Uncheck the “Use
system separators” box and specify the decimal separator to be used.
Figure 176 - Excel Options> System Separator Setting

MEboost is designed to work with either decimal point or decimal comma and to make
decimal separator conversion as simple as possible. The following guidelines are important
for correct calculations.
• Enter all data in forms using the system decimal separator. If your Windows
regional settings use decimal point, always use decimal point when entering data in
forms. If your Windows regional settings use decimal comma, always use decimal
comma when entering data in forms.
• If using the Excel decimal override, MEboost will automatically convert decimals
when reading or writing data from forms. For example, if the system setting is
decimal point, and the Excel override is decimal comma, pasting the calculation
results from a form will convert from decimal point in the form to decimal comma in
the worksheet.

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MEboost

Mechanical Engineering Tools for Excel®

Revised February 25, 2022

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Check Unblock if it is not already checked. Then click OK.

Excel 2007 Installation Procedure

Figure 2 - Office Button

Click on the Excel Options button.

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Figure 4 - Add-ins Window

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Figure 5 - File Tab

Click on Options menu item.

Figure 6 – Excel Options>Add-Ins

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Trust Center Settings

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Figure 9 - Trust Center>Add-Ins

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Figure 10 - Trust Center > File Block Settings

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Plane Stress Sign Conventions

Tensile stress is entered as a positive value. Compressive stress is entered as a negative

Figure 11 - Body Under Plane Stress

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Tensile strain is entered as a positive value. Compressive strain is entered as a negative

Figure 12 - Body Under Plane Strain

Drawing Mohr’s Circle for Plane Stress

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Figure 13–Explanation of Mohr's Circle for Plane Stress, σ1>0, σ2 = 0, σ3< 0

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Drawing Mohr’s Circle for Plane Strain

For plane strain, if x-y is the plane of reference, εz = γzx = γzy = 0.

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Principal Plane Angle

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For example, suppose we have the following condition:

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Click the Create button to generate the report.

Mohr’s Circle Report

Figure 18 - Mohr's Circle Report

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• Von Mises stress for the maximum distortion energy theory.

Figure 19–Combined Stresses Form

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If there is no stress for a direction (or no shear stress), enter 0.

Figure 20 - Example Stress State

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The following loads and couples can be applied to the beam:

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Loads, Couples, and Supports