Machine design 2

selection of materials,
stressing

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 aim
• to introduce the structure of machines, the
function, type and load of machine
elements and the main methods of
designing them
• Main chapters of this semester:
– Fits & tolerances
– Basics of stressing
– Joints
– Drive systems 1.

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 Requirements
3 hours weekly (mostly 2 lecture, 1 laboratory)
Attendance and participation are important!
Engineering is not a spectator sport.
(allowed absence four occasions)

Course requirements:
Tests (tolerances, stressing) 10+10 points
Assignments (valve, key joint, coupling) (10+15+15)
Written exam 60 point

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machine elements

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 general purpose machine elements
static elements (mechanical) drive systems
• joints • bearings
• frames • shafts
• couplings & clutches
• springs • drives

vessel systems
• pipes
• valves
• tanks
• (technical fluids) 5
 material

DESIGN

manufacturing money

optimum - opportunism
time, place 6
 aims
• no failure (surface or volume)
• no big deformations
• enough service time

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 loads
• mechanical  forces, moments…
• thermal 
• chemical changing in place/ time
• …
static cyclic dynamic

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 materials
• metals • density
– ferrous/ non~ • conductivity
• cast iron • …
• steel • elasticity
– carbon/ alloy
• plasticity
• plastics • ductility
• ceramics • brittleness
• composite • toughness (impact)
• creep
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loads & stresses

Stress distribution uniforn/linear

(Mohr, H-M-H)
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 loss of stability

Buckling

elastic/ plastic

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 Tensile test
Load  deformation
stress – strain diagrams

ductile – carbon steel rigid – cast iron

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simplifyed material models

elasto-plastic rigid

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test YS ReH

UTS Rm
UTS

YS
real
eng.

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strain hardening

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 elastic properties

elastic (Young) modulus: E [MPa]

(Hook’s law s = Ee)
shear modulus: G [MPa] (t = Gg)

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 main static properties
elastic limit Rp0.2
yield strength ReH
ultimate tensile strength Rm
maximal strain A
hardness HHB…
Charpy (V-notch) test Kcu

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 Influencing factor – (not only) static load

Stress concentration

shape factor
αk > 1

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sudden area changes

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Influencing factor – dynamic load

s Tényl= d s

dynamic load factor

1.1~ 3
Depending on machine type &
size (handbooks,
measurements, calculations)
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 Periodic stresses
fatique

propagating crack – final static break

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90-95% of all failures!
 Wöhler- curve

Rm

 fatique limit
 N > 106

load cycles

many factors - stohastic phenomenon

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 types of varying load
Fatique limits σv σr

s min
r cycle assymetry ratio
s max
sm
v cycle mean stress ratio
s max 23
constructing Smith- diagram
constructing Smith- diagram
constructing Smith- diagram
constructing Smith- diagram
constructing Smith- diagram
constructing Smith- diagram
constructing Smith- diagram
using Smith-diagram

no failure 31
 Influencing factors – fatique
strength

size

surface roughness

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notch sensitivity ηk (0.5-1.0 )

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 Stress concentration factor βk
k  1
k  σaver.
k  1

stress conc.
sensitivity
shape

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 Safety factor (SF; n)
• importance of
• load, material… element
all bears uncertainity • manufacture
to be on the safe side • material testing
use SF
• calculations

n>1 (1.15 ~ 8-10!)

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That’all, folks!

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