Introduction to Design

Mechanical basis of design

MATE, Institute of Technology Engineering Design and Development Lecture #1. 1.

 Introduction, requirements
Lecturer: Prof. Dr. László KÁTAI, Aula Building, No:320
katai.laszlo@uni-mate.hu
Requirements
Mini project 1. : 5 points (Adhesive joint calculation, 5th Oct.)
Mini project 1. : 5 points (Joint diagram, 2nd Nov.)
Mini project 1. : 5 points (Mount., dism. tech. Rolling bearings, 23rd Nov.)
Final test: 85 points (51 points) 30th Nov.
100 points

MATE, Institute of Technology Engineering Design and Development Lecture #1. 2.

 Introduction
Design: Requirements is converted to a meaningful and functional plan.
Innovative, iterative, decision-making process.

MATE, Institute of Technology Engineering Design and Development Lecture #1. 3.

 Introduction
Activities may involve: design, research, development, testing,
manufacturing, technical service, construction, sales,
management,...

MATE, Institute of Technology Engineering Design and Development Lecture #1. 4.

 Introduction
Desing information need to be collected from many sources...

MATE, Institute of Technology Engineering Design and Development Lecture #1. 5.

 Phases of the Design Process
• Shape forming
• calculation - design Overlaps
• documentation
• Prototype development
• Manufacture process planning
• Manufacturing (standardized production)

MATE, Institute of Technology Engineering Design and Development Lecture #1. 6.

 Engineering points of view of design

Stress and strain!

• statics (salow , tallow )
• deformation (dallow, l allow )
Combination
• Lubrication, wear ( pallow)
• Temperature conditions, heat (tallow ,Qallow )
• … etc.

MATE, Institute of Technology Engineering Design and Development Lecture #1. 7.

 Technical Modell Creation I.
Mechanical model

• force, torque
• stress analyses
• geometrical size
• deformation

MATE, Institute of Technology Engineering Design and Development Lecture #1. 8.

MATE, Institute of Technology Engineering Design and Development Lecture #1. 9.
MATE, Institute of Technology Engineering Design and Development Lecture #1. 10.
MATE, Institute of Technology Engineering Design and Development Lecture #1. 11.
 Technical Modell Creation II.
Material model

Reh

s= E·e

elasto-plastic ideal-elastic ideal-plastic

Proportional limit, Elastic limit, Yield strength

MATE, Institute of Technology Engineering Design and Development Lecture #1. 12.
 Technical Modell Creation III.
Load model
Stress
Completely Completely
Character Static fluctuating reversed

v- amplitude ratio
r- stress ratio

MATE, Institute of Technology Engineering Design and Development Lecture #1. 13.
 Factor of Safety
Unknown uncertanties involving strength and loading

allowable load
n=
failure load

material strength
n=
load stress

s £s = s
n
failure

calculated allowable

MATE, Institute of Technology Engineering Design and Development Lecture #1. 14.
 Design for Fluctuating Loads (Fatigue)
Duration
Static phase phase Fatigue

The Wöhler
curve

Number of cycle
Number of cycle

MATE, Institute of Technology Engineering Design and Development Lecture #1. 15.
 Design for Fatigue
Smith - Safety area

MATE, Institute of Technology Engineering Design and Development Lecture #1. 16.
 Endurance Limit Reduction Factors I.

• shape of the component (ak)

• material and shape of the
component (bk)
• Sensibility 𝛽! − 1
𝜂=
𝛼! − 1

MATE, Institute of Technology Engineering Design and Development Lecture #1. 17.
 Endurance Limit Reduction Factors I.
Sensibility (h) - Stress gradient (c)

𝛽! − 1
𝜂=
𝛼! − 1

MATE, Institute of Technology Engineering Design and Development Lecture #1. 18.
 Endurance Limit Reduction Factors I.
Sensibility (h) - Stress gradient (c)

Δ𝜎(
𝜒= Δ𝑥
𝜎!

2
related stress gradient - tensile stress 𝜒=
𝜌
4 2
related stress gradient - bending stress 𝜒= +
𝐷+𝑑 𝜌 𝛼!
4 1 𝛽! =
related stress gradient - torsion stress 𝜒= + 𝑛"
𝐷+𝑑 𝜌

MATE, Institute of Technology Engineering Design and Development Lecture #1. 19.
 Endurance Limit Reduction Factors
• size factor (g) II.
• surface finish factor (k)
• temperature
• … etc. k
grinding

corrosion

Rm

MATE, Institute of Technology Engineering Design and Development Lecture #1. 20.
 Endurance Limit Reduction Factors
III.

g × k × s fatigue
n=
b × s calculated

MATE, Institute of Technology Engineering Design and Development Lecture #1. 21.