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DoME Tutorial 7

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12 views4 pages

DoME Tutorial 7

Uploaded by

Joy Patel
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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ME3070: Design of Machine Elements

Tutorial 7
Indian Institute of Technology Palakkad

November 26, 2023

1. The detail of a clamping location of a holding fixture


for a 37.5 mm thick workpiece is shown above. The
clamp screw has M10 X 1.25 threads and the spring
is required to drive the clamp upward for removing
or inserting the workpiece. Clamping force is 45 N.
The base plate is 16 mm thick and the free length of
the spring should be short enough so that the clamp
screw can compress the spring during fixture reassem-
bly required for inspection and service. This requires
the free length of the spring should be less than 48
mm. Further, the spring solid height should be less
than 31.5 mm. Factor of safety when closed solid and
at service load should be no less than 1.2 and 1.5,
respectively. We need to design the helical coil com-
pression spring with a diametral clearance of 1.25 mm
between spring and clamp screw. Choose a starting
wire diameter d=2 mm. Wire diameters are available
Figure 1: Problem-1.
between 1.8 mm and 3.0 mm in increments of 0.2 mm.
Choose A227-HD for spring material for its low cost.
Must ensure that the spring is operating in the fully
linear range. Address the following questions.

a. List the general and the problem specific constraints first. (Mark: 2)
b. Iterate on wire diameter to see if all the constraints are satisfied. (Mark: 10)
c. If your design from part (b) is not satisfactory then discuss how you will proceed to make the
design work. Subsequently, design the spring. Note that you cannot change any of the constraints
mentioned. (Mark: 4)
d. Mass processing, at the rate of 5 pieces per second, of the workpiece requires the factory to put
the clamping device in an assembly line and for faster processing the clamp screw is replaced by
some magnetic device but the spring has to be retained for removal/insertion of the workpiece. Now,
the spring is under a fluctuating load between 0 N and 45 N. Also to save cost it is planned to use
the same spring as designed in part (c) placed between the flat parallel plates. You need to test the
feasibility of this decision. Check the fatigue factor of safety using Zimmerli data and for Modified
Goodman criterion. Also, check for buckling and resonance/spring-surge type instabilities. (Mark:
4)
Solution:
(a) General constraints:
4 ≤ 𝐶 ≤ 12
3 ≤ 𝑁𝑎 ≤ 15

1
𝜁 ≥ 0.15
𝑛 𝑠 ≥ 1.2
Problem specific constraints:
𝐿 𝑜 ≤ 48 mm
𝐿 𝑠 ≤ 31.5 mm
𝑛1 ≥ 1.5 mm

(b) Choose wire diameter: 𝑑 = 2 mm


Free length: 𝐿 𝑜 = 48 mm
Maximum deflection (at service load 𝐹𝑚𝑎𝑥 = 45 N): 𝑦 𝑚𝑎𝑥. = 48 − 37.5 = 10.5 mm
𝐹𝑚𝑎𝑥.
=⇒ Spring rate: 𝐾 = = 4.286 N/mm
𝑦 𝑚𝑎𝑥.
Sizes: Screw thread M10 X 1.25, clearance=1.25 mm

𝐼 𝐷 = 10 + 1.25 = 11.25 mm
𝑂𝐷 = 𝐼 𝐷 + 2𝑑 = 15.25 mm
𝐷 = 𝐼 𝐷 + 𝑑 = 13.25 mm
𝐶 = 𝐷/𝑑 = 6.625 mm
Shear Modulus: G = 79.3 MPa
(Table: 10-5: 𝑑 between 1.8-3 mm =⇒ 𝑑 0.064 − 0.125 in )

𝑑 4𝐺
𝑁𝑎 = = 15.9 turns (Not okay)
8𝐾 𝐷 3
𝑁𝑡 = 𝑁𝑎 + 2 = 17.9 turns (Table 10-1) (For squared and ground ends)

Solid height: 𝐿 𝑠 = 𝑑𝑁𝑡 = 35.8 mm (Table 10-1) (Not okay)

𝑦 𝑠 = 48 − 35.8 = 12.2 mm (deflection at solid length)


𝐹𝑠 = 𝐾 𝑦 𝑠 = 52.289 N
𝐹𝑠
𝜁= − 1 = 0.162 > 0.15
𝐹𝑚𝑎𝑥.
4𝐶 + 2
𝐾𝐵 = = 1.213
4𝐶 − 3
 
8𝐹𝑠 𝐷
=⇒ 𝜏𝑠 = 𝐾 𝐵 = 267.51 MPa
𝜋𝑑 3
Table 10-4: 𝐴 = 1783𝑀 𝑃𝑎 − (𝑚𝑚) 𝑚 ; 𝑚 = 0.19
Relative cost=1 (For A227-HD)
𝐴
𝑆 𝑠𝑦 = 0.45𝑆𝑢𝑡 = 0.45 𝑚 = 703 MPa
𝑑
𝑆 𝑠𝑦
𝑛𝑠 = = 2.63 > 1.2 (okay)
𝜏𝑠
 
8𝐹𝑠 𝐷
𝜏𝑚𝑎𝑥 = 𝐾 𝐵 = 230 MPa
𝜋𝑑 3

2
𝑆 𝑠𝑦
=⇒ 𝑛1 = = 3.054 > 1.5 (okay)
𝜏𝑚𝑎𝑥
−𝜋 2 𝐷 2 𝑁𝑡
𝑓 𝑜𝑚 = = −2341
4
Since we do not satisfy all the condition especially we are outside linear operation region. Need to
reiterate.
d 1.8mm 2mm 2.2mm
ID 11.25 11.25 11.25
OD 14.85 15.25 15.65
D 13.05 13.25 13.45
C 7.25 6.625 6.11
𝑁𝑎 10.9 15.9 22.2
𝐿𝑜 48 48 48
𝑁𝑡 12.9 17.9 24.2
53.24> 𝐿 𝑜
𝐿𝑠 23.22 35.8
(not okay)
𝜁 1.36 0.139
𝑛𝑠 0.994 2.63
𝑛1 2.3 3.054
fom -1345 -2341
Observations:

• for 𝑑 = 2 mm: 𝜁 = 0.139 < 0.15 =⇒ outside linear regime. 𝑁𝑎 = 15.9 may be still tolerated.
• 𝑑 = 1.8 mm: 𝑛 𝑠 = 0.994 < 1 This is not at all desirable.
• 𝑑 = 2.2 mm and higher: 𝐿 𝑠 > 𝐿 𝑜 = free length, can not be manufactured.

=⇒ need to iterate again.


(c) One more parameter that we can vary is 𝐿 𝑜 , satisfying 𝐿 𝑜 < 48 mm.
=⇒ Choose 𝐿 𝑜 < 45 mm.
=⇒ 𝑦 𝑚𝑎𝑥 = (45 − 37.5) = 7 mm
45
=⇒ 𝐾 = = 6 kN/mm= 6000 N/m
7.5
=⇒ For 𝐿 𝑜 = 45mm:
d 1.8mm 2mm 2.2mm
ID 11.25 11.25 11.25
OD 14.85 15.25 15.65
D 13.05 13.25 13.45
C 7.25 6.625 6.11
𝑁𝑎 7.8 11.36 15.9
𝐿𝑜 45 45 45
𝑁𝑡 9.8 13.36 17.9
39.38> 37.5 = workpiece
𝐿𝑠 19.04 26.72
thickness (not feasible)
𝜁 3.528 1.437
𝑛𝑠 0.554 1.228
𝑛1 2.3 3.054
fom -1022.4 -1747
=⇒ Only the wire diameter d=2 mm satisfy all the criteria.
=⇒ This should be chosen.

3
2.63𝐷
(d) Buckling: 𝐿 𝑜 < = 5.26𝐷 = 69.7 mm (Table − 10 − 2 : 𝛼 = 0.5) (safe)
𝛼
Critical frequency:
𝛾𝜋 2 𝑑 2 𝐷𝑁𝑎
𝑊= = 0.113 N (from Table A-5); 𝛾 = 76𝑘 𝑁/𝑚 3
4
√︂
1 𝐾𝑔
𝑓 = = 361 Hertz
2 𝑊
Since operating frequency is 5Hz, the spring is safe.
Fatigue factor of safety:
Zimmerli Data (unpeened):

𝑆 𝑠𝑎 = 241 MPa, 𝑆 𝑠𝑚 = 379 MPa


𝐴
Table 10-4: 𝑆𝑢𝑡 = = 1563 MPa
𝑑𝑛
𝑆 𝑠𝑢 = 0.67𝑆𝑢𝑡 = 1047 MPa
Using Goodman’s criterion along with
Zimmerli Data:
𝑆 𝑠𝑒 𝑆 𝑠𝑎 241
= =
1047 (1047 − 𝑆 𝑠𝑚 ) (1047 − 379)
𝑆 𝑠𝑒 = 377.7 MPa
1
𝑛𝑓 = 𝜏 𝜏𝑚
𝑎
+
𝑆 𝑠𝑎 𝑆 𝑠𝑢
𝜏𝑚 = 𝜏𝑎 = 115 MPa =⇒ 𝑛 𝑓 = 2.414 Figure 2: Goodman criterion

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