Component Design

Professor V N Achutha Naikan

IIT Kharagpur
 Simple Stresses in Mechanical
Components
• Components are subjected to various forces
due to:
– Energy transmitted
– Weight of machine
– Frictional resistances
– Inertia of reciprocating parts
– Change of temperature
– Lack of balance of moving parts
– Other forces
 Load
• An external force acting on a component
• Types:
1. Dead or steady load: does not change magnitude
and direction
2. Live or variable load: it changes continuously
3. Shock load: suddenly applied or removed
4. Impact load: it is applied with an initial velocity
 Stress
• When external forces (P)act on a component, it
develops internal forces (equal & opposite) to
resist, at various sections of the component.
• The internal force per unit area (A) is known as
stress. Typical unit is Pascal (Pa)
𝑃𝑃
• 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆, 𝜎𝜎 =
𝐴𝐴
• 1 𝑃𝑃𝑃𝑃 = 1 𝑁𝑁/𝑚𝑚2
• 1 𝑀𝑀𝑃𝑃𝑃𝑃 = 106 𝑁𝑁/𝑚𝑚2
• 1 𝐺𝐺𝑃𝑃𝑃𝑃 = 109 𝑁𝑁/𝑚𝑚2
 Strain
• A component under external forces undergoes
deformation (𝛿𝛿𝑙𝑙) from its original dimension (𝑙𝑙)
𝛿𝛿𝛿𝛿
• 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆, ∈=
𝑙𝑙
Tension, Compression and Shear Stress
and Strain
 Young’s Modulus
• Hook’s Law: When a
material is loaded
within elastic limit, the
stress is directly
proportional to strain
• 𝜎𝜎 ∝ 𝜖𝜖 𝑜𝑜𝑜𝑜, 𝜎𝜎 = 𝐸𝐸𝐸𝐸
• E : Young’s Modulus, or
modulus of elasticity
𝜎𝜎 𝑃𝑃𝑃𝑃
• 𝐸𝐸 = =
𝜖𝜖 𝐴𝐴𝛿𝛿𝛿𝛿
Young’s Modulus for Some Materials
 Factor of Safety (FS)
• In engineering, a factor of safety (FS), also known as (and used
interchangeably with) safety factor (SF), expresses how much
stronger a system is than it needs to be for an intended load.
 Design of Wire in a Elevator
• Elevator in a shopping complex.
• Function: Taking people and
material up and down in a
building
• Capacity: 10 people/800 Kg
• The elevator is operating on
four steel ropes of circular CS
• Factor of Safety?
• Strength of rope material
against tension = 2500 Kg/sq
cm
 Elevator Wire
• Elevator rope wire is made from
bright phosphated and redrawn
galvanized wires. They are
designed for use in traction- and
deflection sheaves. Featuring
high tensile strength and
excellent ductility, the wire helps
increase the service life of your
rope.
• Shape: Wire
• Bulk Material: C-steel
Note: Ductility is the ability of a material
to be drawn or plastically deformed
without fracture.
Material strength of Steel Ropes
Design of Rope in an Elevator
Self weight of Lift = Kg
Max Applied Load Kg
No. of ropes=
Load on each rope= Kg
FS=
Load capacity on each rope = Kg
Strength of material Kg/sqcm
CS Area required= sqcm
dia of rope = cm
Dia of Standard rope available cm
Actual FS?
Actual strength of rope = Actual CSA * Strength
New FS =804.25/200
 Design of Rope in an Elevator
Self weight of Lift = 10000 Kg
Max Applied Load 800 Kg
No. of ropes= 4
Load on each rope= 2700 Kg
FS= 2
Load capacity on each rope = 5400 Kg
Strength of material 2500 Kg/sqcm
CS Area required= 2.16 sqcm
dia of rope = 1.658372 cm
Dia of Standard rope available 1.8 cm
Actual FS?
Actual strength of rope = Actual CSA * Strength 6361.725
New FS = 2.356194
Standard Wires
 Design of Rope in a Lift
• If redundancy is provided with two more
ropes what is the improved Factor of Safety?
• What are the uncertainties in this case?
• How do you take care these in the design?
 A Simple Electrical Circuit
• Function: Lighting a bulb of
100 W.
• Design a circuit for this
purpose
• Application: To light a
newly constructed room
(16 X 12 sq. ft.) in a house.
• What parts are required?
• What are the specifications
of each part?
• Factor of Safety?
 A Simple Electrical Circuit
Applied Voltage (V) V
Connected Load W
FS =
Design Load W
Design Equation W = VI Cos(φ)
Assume PF = 1
Current (I) = A
Available wires A
Available Switch Capacity A
Available Fuse Capacity A
Actual FS=?
Max Load Cap of Wire = W = VI Cos(φ) W
Actual FS =
Design of a Simple Electrical Circuit
Applied Voltage (V) 120 V
Connected Load 100 W
FS = 2
Design Load 200 W
Design Equation W = VI Cos(φ)
Assume PF = 1 1
Current (I) = 1.666667 A
Available wires 2 A
Available Switch Capacity 5 A
Available Fuse Capacity 2 A
Actual FS=?
Max Load Cap of Wire = W = VI Cos(φ) 240 W
Actual FS = 2.4
 Design of I-Section Beam
• Figure shows a simply supported beam carrying a
uniformly distributed load ‘u’ in Kg/cm. The applied
load follows a lognormal distribution with a mean of
3.5 Kg/cm. The mean yield strength properties of the
beam material (steel) from material hand book
is1650 Kg/cm2.
Design the I-section beam. The required beam length is
5.32 m. Assume a factor of safety of 2.2.
Also estimate the dimensions of the section and the
requirement of extra material in case a higher FS = 3
is required.
Simply supported beam and its sectional
view
Solution
Solution…FS = 2.2
ISWB – Standard Wide Flange Beams
(IS 808: 1989)
 Solution…
• From the Steel tables the required section of beam can be selected
• The selected beam is ISWB 175 with section modulus Z=172.5 cm3

The sectional dimensions are:

Depth of section h = 175 mm
Width of flange, b = 125 mm
Thickness of flange, tf = 7.4 mm
Thickness of web, tw = 5.8 mm
Section area, a = 28.11 cm2
Radius at root, r1 = 8 mm
Radius at toe, r2 = 4 mm
Slope of flange, D = 960
Solution…, FS = 3
Design of L section
 Design
• Application – for supporting a passenger seat
• Load – 4 people to sit or to keep 6 packets of luggage
- vibration load, other loads
• Type of load – tension, compression, torsion, bending…
- static/ dynamic / fatigue
• Factor of Safety – to be decided
• Reliability – target?
• Strength – to be calculated using failure theories
• Material – to be decided
• Dimensions – cross section, length, width, etc
• Tolerances – of each dimension – tolerance allocation
 Design of Process
• Production / Manufacturing Technology
- Casting
- Cutting from steel plates
- From steel bars
- bending – cold/hot – direct/air/water/oil bath
- welding-fillet/butt/resistance/gas/hydrogen/electron beam /
ultrasonic/friction welding, length, leg
- soldering – soft: tin-lead, hard: silver
- riveting – lap / butt / parallel / zigzag /no of rivets
with/without straps
- use screws
- nuts & bolts
- adhesives – phenolic elastomers, vinyl-phenolics, epoxy-resin
• Reliability, cost, technical feasibility to be compared
 Cost & its allocation
• Direct cost
- material
- power
- consumables
- labour

• Indirect cost
– Utility
– Salaries
– Administrative
– Tools
– Machinery
– Building
– Transportation
– Quality assurance
– Maintenance
– Consultancy
– Taxes - VAT
 Safety & Risk
• Modes of failure
• Effects of each failure mode
• Risk of failures
• Maintainability and maintenance
 Home Work
• Actual Electrical circuit will consists of Fans,
Light bulbs, Television set, Music set, Geyser,
Induction Cooker, Refrigerator, Air
Conditioners, MV Oven, etc.
• How will you proceed in designing such a
circuit(s)?
 Electrical Amplifier
• A voltage amplifier is to be designed for a gain
of 10.
 Water Pump
• A building design
engineer wants to pump
water from the
underground sump to the
30th floor of the building.
• What specifications are
required?
• How this system can be
designed, including
piping, storage tank, and
distribution network to
each flat?
Design of Simply Supported Beam
Cross sections of available beams
 Development of a New UPS
• Is there a market gap
available?
• What are the output
specifications?
• New features?
• Cost?
• Design?
• Manufacture?
• Testing?
• Marketing policy?
• Service policy?
• Warranty policy?
End