SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.

1.
Introduction to Design
Mechanical basis of design

2. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Introduction
Design: Requirements is converted to a meaningful and functional plan.
Innovative, iterative, decision-making process.
3. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Design Process
Identification of needs
Definition of problem
Synthesis
Analysis
Testing
Manufacturing
4. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Phases of the Design Process
Shape forming
calculation - design
documentation
Prototype development
Manufacture process planning
Manufacturing (standardized production)
Overlaps
5. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Engineering points of view of design
statics (o
alow
, t
allow
)
deformation (o
allow,

allow
)
Lubrication, wear ( p
allow
)
Temperature conditions, heat (t
allow
,Q
allow
)
etc.
Combination
Stress and strain!
6. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Technical Modell Creation I.
Mechanical model
force, torque
stress analyses
geometrical size
deformation
7. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Technical Modell Creation II.
Material model
elasto-plastic ideal-elastic ideal-plastic
R
eh
s = Ee
Proportional limit, Elastic limit, Yield strength
8. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Technical Modell Creation III.
Load model
Completely fluctuating
Completely reversed
Static
v- amplitude ratio
r- stress ratio
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Factor of Safety
Unknown uncertanties involving strength and loading
( )
( ) load working load allowable
imum load failure
n
max
=
stress allowable
strength material
n =
n
allowable calculated
failure
o
o o = s
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Variate of strength and stress
(probability)
Stochastic material and load features
Duration strength
Stress (load) distribution
11. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Design for Fluctuating Loads (Fatigue)
The Whler
curve
Static phase Fatigue
Duration phase
Number of cycle
12. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Design for Fatigue
Safety area
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Endurance Limit Reduction
Factors I.
shape of the component (a
k
)
material of the component (b
k
)
Sensibility

b
a
k
k
k
=

1
1
14. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Endurance Limit Reduction
Factors II.
size factor
surface finish factor
temperature
etc.
calculated
fatigue
n
o |
o k

=
15. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Mechanics of materials
Principle of stresses
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Mechanics of materials
Components of stress
(Infinitesimal cubic element)
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Normal Stress
Normal tensile stress Normal compressive stress
uniform stress distribution
- the axial force acts through the centroid of the cross section
- the rod is straight and made of homogenous material
The force and the surface (cross section) are perpendicular (normal)!
A
F
= o
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Shear Stress
The force and the surface are paralel.
A
F
= t Stress distribution.
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Torsion Stress
Deformation (strain) due to torsion torque.
20. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Torsion Stress
Stress due to torsion torque.
Distribution!
t - torsion stress (N/mm
2
, MPa)
M torsion torque (Nmm)
I
p
(polar)moment of inertia (mm
4
).
y distance from the neutral axix (N.A.) (mm)
Kp polar section modulus (mm
3
)
y
I
M
p
= t
21. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Bending Stress
Stress due to bending moment.
Distribution!
o - bending stress (N/mm
2
, MPa)
M bending moment (Nmm)
I
x
moment of inertia (on x axis) (mm
4
).
y distance from the neutral axis (N.A.) (mm)
K
x
ekvatorial section modulus (mm
3
)
y
I
M
x
= o
22. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Combined Stresses
Normal + bending stress (same direction).
bending normal
o o o + =
max
Normal + shear stress.
2 2
max
4
shear norm
t o o + =
Bending + torsion stress.
2 2
max
4
torsion bend
t o o + =
23. SZIU, Institute of Machinery and Mechanics Machine Elements Lecture #1.
Hooks Law
c o = E
Stress is directly proprtional to the strain.
E modulus of elasticity (Young modulus) N/mm
2
, MPa
c strain (relative deformation)
l
l A
= c