Reference Material: Fundamentals of Machine Component
Design 4th ed. (2006). Juvinall, R. & Marshek, K. Wiley & Sons Objectives: • Overview of Machine Design • Safety and Machine Design • Ecological and Societal Considerations • Overall Design Considerations • Methodology for Solving Machine Component Problems An Overview of the Subject • Mechanical engineering design deals with conception, design development and application of machines. • Goal: obtaining solutions to practical problems. It involves, engineering science, empirical knowledge and engineering judgment. This is a professional engineering course. Science vs. Engineering • Engineering seeks solutions to practical problems • These solutions require an understanding of underlying sciences, but also require ingenuity and judgment • Science seeks to understand physical and biological phenomena to the highest detail • Science is a continual process of discovering deeper and deeper reasons for the observable universe. This process never ends. Science vs. Engineering • For example: A scientist may understand a lot about electricity, but never knows everything about electricity.
• An engineer uses what is presently known about
electricity to create a useful electrical device.
• As scientific understanding develops, an
engineer can create better and better solutions Technical Considerations • Machine design is largely concerned with the following technical considerations: – Stress/strain relationships on the bulk or body of a solid
– Surface phenomena such as friction, lubrication,
wear, and deterioration Stress • Stress: a physical quantity that expresses the internal forces that neighbouring particles of a continuous material exert on each other. • Example: The force that one particle of carbon applies on another when a diamond is compressed. • Stress = average force per unit area = F/m2 Stress • Types: – Normal stress • Ex: – Shear stress • Ex: – Bending stress • Ex: – Torsional stress • Ex: Strain • Strain (Deformation): a change in the shape or size of an object due to: – an applied force (the deformation energy in this case is transferred through work) or – a change in temperature (the deformation energy in this case is transferred through heat). Mechanical Engineering Design • In addition to traditional technological and economical considerations, Mechanical Engineering Design has to include the following considerations: - Safety - Ecology - Quality of Life - Overall Design Safety Considerations • Personal safety is a concern that engineers have always kept in mind but societal demands for safer products is increasing • Determining the overall safety of a design is a much more complicated issue than determining the physical strength or financial cost. • There is no formula to determine overall safety! Safety • The awareness of the importance of safety is increasing due to the interest of governments, lawyers, insurance companies etc. • However, it is only the engineer who can develop a safe design. • To do this an engineer must: – Anticipate all the possible hazards of a device – Be ingenious (creative) enough to find ways to reduce hazards through engineering design How safe is safe enough? • Answering this question is very difficult if not impossible. • Saying that something is “safe” is a relative term and requires value judgments which compare trade offs between safety, cost, weight etc. Safety Consideration
• 1.Imagination and Ingenuity
• 2.Techniques and Guidelines
• -Review the total life of cycle • -Safety provisions represent a balanced approach • -Make safety an integral feature • -A fail-safe design • -Check government and industry standards • -Provide warnings of all significant hazards Ecological Considerations • The products, machines, and devices that engineers build have a huge impact on our environment and the biosphere of the planet. • What are some major negative impacts of technological advances? • Ex.1: • Ex.2: • Ex.3: • Ex.4: Reducing ecological impacts • Mechanical engineers can minimize negative effects by: – Using materials that are economically recyclable without causing significant water and air pollution – Reducing consumption of non-recyclable resources of energy (fossil fuels) – Considering not only the impact on humanity, but on all life-forms Ecological Factors to Consider • Basic design objectives – Ex. ( Dam, Highway, Pipeline, railway ) • Review of overall design concept – Ex. (Phone case, panel for appliances) • Design for recycling – Ex. (Computer parts, car parts, Wires, ..) Ecological Factors to Consider • Material selection – Ex. (Availability, Processing and recycling Energy Requirements, Processing problems) • Material processing and manufacturing – Ex. ( forging and rolling vs cutting and machining) • Packaging – Ex. (reusable material) • Production location – Ex. ( Close to raw material resources and market) Societal Considerations • The basic objective of any engineering design is to provide a machine or device that will benefit humanity.
• Basic objectives of engineering design is to
improve the quality of life within the society.
• Engineering profession promotes changes in the
direction of increasing the life quality index. Societal Considerations • Put simply:
If a design detriments (negatively
impacts) society, it is a poor design and needs major improvement! Overall Design Considerations • All engineering designs involve multiple considerations, making it a challenge to recognize all of them in proper proportion or priority. • In this course, we will focus on component strength, deflection, weight, size, shape, wear, corrosion, lubrication, and friction. Overall Design Considerations • However many more exist: Technical Modern Miscellaneous
Materials Safety Reliability
Geometry Ecology Maintainability
Operating conditions Quality of life Ergonomics
Cost Visual appearance
Availability
Producibility
Component lifespan How to solve machine design problems • Every profession has its own types of problems to solve, and therefore its own method of attack. • To solve machine design problems, the engineer should: – Formulate the problem precisely – Present the solution accurately – Match physical situation with correct mathematical model Methods for solving problems • Although there is no single right way to approach and solve design problems, the good ones share common characteristics: – Identify the problem clearly – State givens – Make assumptions – Sketch design decisions – Mathematical models – Analysis – Evaluation Solving Problems • For this course the following headings will be used in the examples: – Known – Find – Schematic – Decisions – Assumptions – Analysis – Comments (example to follow) Important Concepts • Stress – Design stress – Allowable stress – Failure stress
• Strain/Deformation – Acceptable – Excessive Important Concepts Load Classification Static load A. With respect Impact load to Time Cyclic Load B. Area of Concentration Load Distributed Load Application Normal Load Shear Load C. Method of Bending Load Application Torsion Load Combined Load Work, Power, and Energy • All mechanical apparatus experience loads and motion. • Therefore all mechanical devices do work to transfer energy
• Energy: The ability of a physical system to do
work. Energy Energy • Law of conservation of energy: Energy can neither be created or destroyed, only transferred.
• In other words, the total energy of a closed
system never changes
• Energyin = Energyout Energy • While the kinetic energy of translational (linear) movement is 0.5*mv2 • The kinetic energy of rotational movement is: KErotation = 0.5 * Iω2
Where: I is the rotational inertia of the object
ω is the angular velocity (in rad/s) Work • If the energy of one object decreases, it is able to do work on another object
• A force is said to do work when acting on a
body there is a displacement of the point of application in the direction of the force Work • Work = Force Distance W=F·d • Unit for work is Nm = 1J (Joule) for SI Units
Example: Lift a 2 kg book 0.5m above your head
and put it on the shelf. What is the work you perform? Work • When a force is applied to rotate an object, the distance travelled is the circumference of a circle. Therefore: W = FxD = F(2πR)q where q = # of turns If ϴ = angle of rotation (in rad) then: W = F(Rϴ) = (FR)ϴ = Tϴ where T = torque Power • Power is the rate of energy or work exchanged per time (P = W/t) • SI Unit of power is the Watt (Joule/s) • One horsepower = 745 W = 0.745 kW
• More Power = more work done in a given time
Power • Example: A 60 kg person climbs 5m (vertical) upstairs in 6 seconds. What is the power necessary to perform this work? Power • Example: A 60 kg person climbs 5m (vertical) upstairs in 6 seconds. What is the power necessary to perform this work?
F=m*g
(60kg)(10m/s^2) = 600 N
P=W/t=F.d/t
P=(600N).(5m) / (6 seconds) = 500 w
Power • Power transmitted by a rotating machine component such as shaft, flywheel, gear or pulley is common in the study of machine design.60
Power = W/t = F*D/t = (Force) X (Velocity)
= (T/R)*(Rω) = Tω where ω is in rad/s Power • Many devices have a rotational velocity given in RPM instead of ω
• The power (in Watts) transmitted by a shaft
operating at n RPM is: P = Tω = T(2πn)/60 = T.n/9.549 (Watts) = T.n/9549 (kW) For rotating shaft rpm Torque N.m efficiency
Angular velocity rad/sec
Conservation of Energy • Example 1: An object is suspended from a pulley as shown in the figure. If the 0.25 ft
mass falls at constant
velocity, determine the power transmitted to the pulley in Watts and the f/s 5 lb rotational speed of the pulley in RPM. Conservation of Energy • Example 2: A rotating cam lobe causes a valve stem to move vertically downwards. Mid- stroke the valve stem is being pushed by 1 N and moves 1mm when the cam rotates 0.1 rad. What is the average torque required to turn the cam during this interval? 1. The work done on the camshaft is equal to the work done by the follower, if friction can be neglected. 2. Work in = T.ϴ = T(0.1 rad) 3. Work out = FS = (1 N)(0.001 m) The input shaft to a gearbox rotates at 2000 rpm and transmits a power of 40 kW. The output shaft power is 36 kW at a rotational speed of 500 rpm. Determine the torque of each shaft What is the rate of work (power) output of a press that delivers 120 strokes per minute, each stroke providing a force of 8000 N throughout a distance of 18 mm? If the press efficiency is 90%, what average torque must be provided by a 1750-rpm driving motor? A punch press ( efficiency 80 %) with flywheel adequate to minimize speed fluctuations produces 120 punching strokes per minute, each providing an average force of 10000 N over a stroke of 50 mm. The press is driven through a gear reducer by a shaft rotating 900 rpm. (a) What power (W) is transmitted through the shaft? (b) What average torque is applied to the shaft? SOLUTION
