Mechanical Design I

Chapter 1, 2: Review Chapter from Solid Mechanics and Statics

These 2 chapters are basically the review of statics, dynamics and

mechanics of materials/solids.
The basic outcomes of this chapter are:
• To familiarize with the system of units used in the design calculations.
• To familiarize with the basic equilibrium equation that was studied in
the past
• Concept of centroid, moment of Inertia and application in the design
• Recall Shear Force and Bending Moment diagram and its application
in the design
• Bending and Shear Stress distribution in a beam

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System of units used in the Design
Basically 3 types of units systems are commonly used in the design
SI, English and British Gravitational units
Most commonly in our design we use: English and SI units

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 Detail Unit Conversion (Very Important
throughout the design)
• 1kg =2.2lbm (Approximately)
• 1ft=12 in
• 1in= 0.0254m=2.54cm =25.4mm
• g= 9.81m/sec2 = 32.1740ft/sec2 (where g is the acceleration due to gravity)
• 1lb/in2 = 6894.75 N/m2 , (Pa),= 0.006894MPa
• 1lb.ft=1.356J=1.356N.m
• 1 Watt= 1joule/sec, =0.74ftlb/sec
• 1hp= 746 Watt= 550ftlb/sec=6600lbin/sec (Approximately)
• 1N-m = 8.85lb-in
• 1N/m= 0.0057lb/in
• 1[mPa.s]= 1×10-3 Pa.s
• 1mile= 1.609km= 1609m
• 1 slug=14.59 kg

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General Equation of Equilibrium (Static Condition)
• A body is said to be in an equilibrium conditions: If sum of the force acting on a
body across each axis equals to zero and the sum of the moment at any point
equals to zero.
For Equilibrium:
∑ 𝐹𝑥 = 0, ∑ 𝐹𝑦 = 0, ∑ 𝐹𝑧 = 0,
∑ 𝑀𝑎 = 0, where a stands for the location of the moment point.
In order to apply the general equation of equilibrium, the free body diagram of a
body needs to be developed.
Free Body Diagram (FBD): The schematic representation of the force and moment
in a space. FBD shows the direction and the magnitude of the force and moment
acting on the body.

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Problem1:
A shaft of uniform diameter and given length supports gears located at known
positions B and C on the shaft. Determine the shaft cross section /critical section of
greatest loading (critical loading) based on bending and torsional shear stresses. The
diameter of the Gear B is 3.75 in and the Gear C is 2.25 in. (IV C=2in , BC= 5 in
and BIII = 2 in)

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Problem 2: Draw a free-body diagram for the gear and
shaft assembly shown in the figure below.

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 Beam Loading
• Beam Loading: Lateral loading of members that are relatively long in comparison with their cross-
sectional dimensions:
• Loading may involve: Bending, Torsional or Axial.

• Each loading incorporate three basic diagram:

External load, internal transverse shear force (V) and internal bending moments (M)

The Value of the shear force (V) at any point along the beam is
equal to the slope of the bending moment diagram (M) at that
point
Bending Moment across the length of the beam will be
maximum where the shear force is zero
The difference in the values of the bending moment, at any two
points along the beam, is equal to the area under the shear
diagram between these two points
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 Methodology for Solving Machine Component Problems
The first step in attacking machine component problems is to formulate them precisely.
Formulation requires consideration of the physical situation and the matching mathematical
situation.
Model: The mathematical representation of a physical situation (Ideal Description)
.most analysis directly or indirectly deals with the following parameters:
• Statics and Dynamics
• Mechanics of Materials
• Formulas (Tables, Diagrams, Charts)
• The conservation of mass principle
• The conservation of energy principle
• Physical characteristics of the materials
• Conduction and convective heat transfer equations
• Fourier laws of heat conduction
• Fluid Flow Problems
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Systematic Approach for Solving Machine Elements Problems
Design always deal with maximization of results and rewards, In order to achieve this, it is
necessary to develop a systematic approach.
Following are the 7 steps involved in solving the Machine Element Design
problem:
• Known- State briefly the known parameters
• Find- State concisely what is to be determined
• Schematic and Given Data: Sketch the component or system to be considered (FBD:
system, sub systems, components etc.)
• Assumptions: List all simplifying assumptions and idealizations that is made in your
particular design problem
• Decisions: subjective decision, geometric variables and types of materials)
• Analysis: Using decisions, assumptions and known parameters develop the appropriate
mathematical model for the system. Consider the table, charts or relationship needed to
solve the problems
• Comments: Comments on the solution and identify the key aspect of the solution. Discuss
how better or worse the design would be if you have considered the different design
decisions
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 Work, Energy and Power in Machine Component Design

• All Mechanical Systems involves Loads and motion. The combination of load and motion results
in Work and Energy.
• Work of a Force/ Work done by the Force:
• The work done by the force acting at a point on a component is the product of the applied force
times the distance the point moves due to the application of the force:
• 𝑊 = 𝐹 × (𝑠2-𝑠1) where 𝑠1 is the initial reference location point and 𝑠2 is the moment of the
reference point due to the application of the force

Example 1:
Figure shows the wheel Turned by the force F acting at the
Radius R, if the wheel rotate through “q” revolution, How much
work is done by the applied Force F ?
Suppose the same wheel is turned through an angle 𝜃 by
applying a Torque T , Draw the FBD and Calculate the work
done

Figure: Wheel Turned by a Tangential Force 10

 Work, Energy and Power in Machine Component Design
• The Time rate of Energy transferred by works is called power and is denoted by (𝑃/𝑊)
• 𝑃 = 𝐹𝑉, where 𝑉is the velocity of the point at the application of the force.
• In terms of vector representation,
• 𝑃 = 𝑭. 𝑽 , where . Stands for dot product of the two vectors F and V
• The power transmitted by rotating machine such as shaft, flywheel , gear, pulley is of great importance in
machine design

Example:
Consider the shaft of radius R subjected to the external torque
(T) and rotating with speed n revolution per minutes,
Calculate the power transmitted by the shaft?

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Conservation of Energy

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Problem 2
The crankshaft of a single-cylinder air compressor rotates 1800 rpm. The piston area
is 2000 mm2, and the piston stroke is 50 mm. Assume a simple “idealized” case
where the average gas pressure acting on the piston during the compression stroke
is1 MPa, and pressure during the intake stroke is negligible. The compressor is 80%
efficient. A flywheel provides adequate control of speed fluctuation.
(a) What motor power (kW) is required to drive the crankshaft?
(b) What torque is transmitted through the crankshaft?
[Ans.: 3.75 kW, 19.9 N #m]

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Problem 3
• A press provides a force of 8000 N through a distance of 18
mm at a rate of 120 strokes per minute. Determine the rate of
work output and the average motor torque if the press
efficiency is 90% and the motor speed is 1750 RPM
[Ans: 0.288kW, 1.746Nm)

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