Simon Fraser University

Mechanical Elements
ENSC 305/440

Esmaeil Tafazzoli Spring 2006

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Outline:

Mechanical properties of materials Machine elements: 1) Motors (types, selection considerations) 2) Power transmission devices (gears, belt, pulley, chain, friction drive) 3) Miscellaneous: Bearings(types, selection issues, catalogs), springs, pins, retaining rings 4) Other motion generation devices (linkage mechanisms, cams) 5) Joining methods (welding, brazing, soldering, bolts, screws, rivet, )
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Mechanical properties of materials:

Behavior of materials in response to mechanical loads. Useful in material selection.

Most basic property: stress-strain relation

Stress:

load ( F ) area( A)

lengthchange(l ) Strain : originallength(l 0 )

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

Types:
- Tensile Strength - Compressive strength - Shear strength The definition of failure varies by the type of material and design method: Brittle (concrete, cast iron, glass,) Ductile (gold, Aluminum, copper, steel, )

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Stress-Strain relation
The stress caused by load must not exceed the failure stress. Always consider a Factor of Safety. FS= all /design

all = Allowable Stress design = Design Stress

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Stress-strain curve for structural steel[1]

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Stress-strain curve, Aluminum[1]

Stress-strain curve for a brittle material [1]

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Standards

SAE (Society of Automotive Engineers) AISI (American Iron and Steel Institute)

ASTM (American Society for testing and Materials)

ANSI (American National Standard Institute)

AISI-SAE designation for carbon and alloy steel

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

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

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Motor types
DC motors Stepper motors a) Permanent magnet (brushless) b) DC Shunt motor c) DC series motor

Gearhead motors
AC motors

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Characteristics
DC motor
a) Speed proportionate to voltage applied
b) Suitable current/torque and speed/torque curve properties c) Easy to control d) Position/Speed Servo e) No brush noise, durable, clean (brushless)
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Characteristics
Stepper motor
Can rotate in both directions

Moves in precise angular increments (steps)

Sustain a holding torque at zero speed

Easy to control

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Comparison of stepper and DC permanent-magnet motors

Robot mechanisms and mechanical devices illustration, McGraw Hill 2003 [2] Spring 2006 ENSC305/440 12

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Typical DC motor characteristic curves [3]

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Selection factors
When selecting a motor consider these issues:
Speed range Torque-speed variations Reversibility Required power Load inertia
Starting torque Size and weight restrictions Price Maintenance

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Selection factors (contd)

Consider these questions when selecting a motor:
1. Will the motor start under load? 2. What is the maximum speed the motor can produce?

3. How much power does the load require?

4. Is the load to be driven at constant speed? 5. Is transmission gearbox required?

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Typical specification sheet[4]

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Useful information sources

Experts Manufacturer specification sheets Product catalog Design handbooks Motor nameplate Web

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Gearhead motors

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Force ratio for gear trains

Wrr1 r2 F RR1 R 2
W=Load force F= balancing force

FR F1 r

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Gear train speed ratio

D1 D2 D3 driven speedratio d1 d 2 d 3 driver

N1 N 3 n4 drive n1 N 2 N 4 driven
n= speed N= number of teeth
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Different kinds of power transmission or motion control capability of gears:

a) Changing rotational speed. b) Changing rotational direction.

c) Multiplying or dividing torque.

d) Converting rotational to linear motion. e) Offsetting or changing the location of rotating motion.

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Motion and torque transmission examples ([5])

Right angle crossing shafts Self locking High friction and wear High speed reduction
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Right angle I/O torque Smooth tooth interaction Low noise

Rotary-Linear power transmission

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Bearing types
Ball bearing Thrust bearing

Tapered roller bearing

Needle roller bearing

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Important factors in bearing selection

Loads (radial, axial) Operating speed Size and weight

Information sources:
Experts Manufacturers catalog (SKF, TIMKEN, FAG,) Design handbook

A quick way of bearing selection

SKF online interactive catalog (www.skf.com)
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SKF interactive bearing selection example page

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Other ways of motion transmission: Linkage mechanisms

Intermittent rotary motion[6]

Rotary to back and forth motion[7]

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Alternative mechanism design

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

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Flexible transmission
Chain-sprocket Belt-pulley

Ref[8, 9]

Ref[10]
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Joining methods
Welding Brazing soldering

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Joining methods
Welding: (melting both material and filler, generally used for welding ferrous materials)
Brazing: (melting nonferrous metal, brass or bronze, as filler to join base materials by capillary action) Soldering: ( same as brazing but at lower temperatures)

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Joining method Soldering Brazing Welding

Joint strength Poor Good Excellent

temperature up to 400C 800-1000 C

Distortion None Minimal

Aesthetics Good Excellent Fair

above1500C Likely

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

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Welding types
Arc welding: An electric arc between material and filler melts them at the joining point. Gas welding (oxyacetylene): Widely used for welding pipes and tubes and repair work Resistance welding: Generating heat by passing current through resistance caused by joining metals. (widely used in automotive industry)
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Arc Welding: Setup configuration [11]

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

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Welding position

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

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Electrode position in groove welding

Electrode position in fillet welding

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Single stringer bead for narrow grooves

1- stringer bead (steady movement along seam)

Weave bead for wide groove or multiple stringer bead

2- weave bead (side to side movement along seam)

3- Weave pattern

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Properties of a good welding

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Troubleshooting

Excessive spatter
Cause: 1-Amperage too high 2-Arc length too long Correction: 1- Decrease amperage or select larger electrode 2- Reduce Arc length

Porosity Cause: 1-Dirty workpiece 2-Arc length too long 3-Damp electrode Correction: 1-Remove all grease, damp, oil, dust,..., from work surface 2-Reduce length 3-Use dry electrode
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Lack of penetration Causes: 1-Improper weld technique 2-insufficient heat input Correction: 1-Reduce welding speed 2-Increase amperage, use larger electrode
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Troubleshooting

Burn through Cause: Excessive heat Correction: Decrease amperage use smaller electrode Increase travel speed
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Wavy bead Cause: Unsteady hand Correction: Use two hands practice

Distortion Cause: Excessive heat Correction: Use clamp to hold base material Use lower amperage Make tack weld along the edge Weld in small segments, allow cooling between welds.
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Example of good and bad welds

2006 Miller Electric Mfg Co

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1) 2) 3) 4) 5) 6) 7)

8) 9) 10) 11)

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

References

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