ME 417/517 Spring 2010

Advanced Machine Design

Instructor: Pranav Shrotriya

Associate Professor of Mechanical Engineering
2026 Black Engineering Building
Phone: (515) 294-9719;
Fax: (515) 294-3261
Email: shrotriy@iastate.edu
Today’s Lecture
• Course outline and syllabus
• Definition of preliminary concepts
• Mechanical Loading
• Material Response

• Reading assignment
– Chapters 1-3 and Appendix A from Ashby’s
Materials Selection in Mechanical Design
Course Meeting Times
Meeting time:
Monday and Wednesday from 3:10 to 4:30
Marston 0204
Instructor:
Pranav Shrotriya
2019 Black Engineering
Phone: (515) 294-9719
Fax: (515) 294-3261
Email: shrotriy@iastate.edu

Office Hours:
T: 1:00 -3:00 PM or by appointment
Course Books
Grading Policies
• Five to eight homework Assignments: 40% (32%
for 517)
• Two take-home exams: 40% (32% for 517)
– Tentatively, first week of March
– Third week of April

• Course Project 20%

• Concept Presentations 16% for 517 only
– Presentations before second exam
– Expect questions on project presentations on second
exam
Course project for all Students
• Group of 2 students
– Off campus students should use discussion board
to find students with common interests
• First task form a group
– signup sheet is posted on the webct page
• Group submission for homeworks
• Design project on
– Material and shape selection
– Hybrid materials
– Machine Component design
Second project for ME 517
Concept Presentations
• Teach rest of the class about concepts
• 7-8 Minute presentation + 2-5 minutes for question
• Assigned every 3 weeks
• Presentations on Feburary 9; March 9; and April 13
• 11 Students in 517 so 4 presentations at each time
• Topics on Next Slides
Course Topic Presentations
• Topics for Feburary 9th
– Fracture toughness and one ASTM standard method for
measuring fracture toughness
– J-integral and experimental method to measure critical J
– Fatigue crack propagation in metals
– Fatigue crack propagation in ceramics
– Fatigue crack propagation in polymers
• Topics for March 9th
– Surface Damage due to wear
– Fretting corrosion
– Fatigue of composite Materials
– Finite Element Analysis for Design against Fatigue Failure
– Finite Element Analysis for Design against Crack
propagation
• Topics for April 13
– Case study on Pressure vessel design
– Case study on selection of hybrid materials
– Case study on design of power transmission
– Case study on design of clutches and brakes
Course Policies
• Course will be administered through
WebCT
• All the lecture notes, streaming videos,
handouts, solutions and grades will be
posted on course webpage on WebCT
• I will not distribute any printed handouts
during the class
 Conceptual Design
Design Flow Chart

Figure 2.6

Figure 2.1
Mechanical Systems
Engineering Materials
Evolution of Materials

Figure 1.1
Approach to Mechanical Design
• Design to prevent failure
• Loading < Material Limit
– Static load Yield Strength
– Cyclic loading Endurance Limit
– Contact stresses Contact Strength
– Deflection Deflection limits
• Objective
– Minimize cost
– Minimize weight
– Minimize volume
Mechanics Preliminaries
• Continuum analysis
– Treat materials as continuum
– Properties, displacements, and force-fields are
continuous functions of position
– Molecular details inform material properties

• Strain and stress as fundamental scale-

independent measures of deformation and
internal forces
Stress and Strain
Design Large or small structures

~1m ~ .001 mm

  PA   l l
0

Fundamental Quantities Independent of size

Mechanical Response
• Deformation characterized by strain tensor

u
X
x
Referenceconfig Deform
edconfig
Physical Interpretation of Strain elements
Stress Tensor
• Internal forces that develop to resist
deformation
Stress Tensor
Generalized Hooke’s Law
Uniaxial Stress States
• Tension or compression
• Torsion
• Bending
Biaxial Stress State
• Pressure Vessels

• Shafts transmitting power and supporting

components
Contact Stresses
Hertz Contact Model - Cylinders

2F
Maximum stress =
bl
b depends on the modulus of the two
cylinders, the radii of cylinders and Force
applied

1
   1  12 1  22    2
  2  2  
 2F   E1 E2   
where b    
l 1 1

  
  d1 d 2  

Contact Stresses- Spheres
Typical Material Response - Metals
Typical polymer response
Distortion and Dilatation
Dilatational and distortional stress
Yield criteria
Typical Ceramics Response

Figure 3.5

Figure 3.6
Modulus-Strength Chart
Stress Concentrations
Fracture Mechanics

34
Crack and Stresses

 a
 max  1  2  
 b

35
Observations
• Critical load required for crack to advance
– Crack length
– Crack geometry
– Material
• Stress Intensity Factor
KI
  f   where K I    a
2 r

• Fracture toughness, KIc.

36
Stress intensity factor table

Figures 5-25 to 5-30

37
Designing with cracks
Structure fails at the load at which stress
intensity factor for smallest detectable
crack is greater than fracture toughness
KI  KIc For crack propagation or failure

Good for brittle materials and small scale

yielding

38
Material Property Chart
Hardness

Figure 3.8
Hardness Properties

Figure 3.9
Large scale plastic flow
Fatigue Failure
• Cyclic or fluctuating loads well below static
strength
• Accumulation of damage over a number of
loading cycles
• Sudden catastrophic failure

Three stages of fatigue failures

– Nucleation (Stage I) (localized stress conc.)
– Propagation or Damage accumulation (Stage II)
– Sudden, brittle failure (Stage III)

43
Characteristic Fracture Surface

44
Design to Prevent Fatigue Failure

• Estimate number of cycles to failure

1< N < 1000 Cycles low cycle fatigue
N >1000 Cycles high cycle fatigue

• Prediction of fatigue life

– Stress–life method
– Strain-life method
– Fracture mechanics based method
45
 Variable loading
Mean Stress or Mid-range Stress
  max   min 
m   
 2 
 max
Stress amplitude
  max   min  a
a   
 2 

Mean stress ratio

  max  m
R 

 min   min

Amplitude stress ratio

 
A a 
 m  46
Fatigue Failure of Material

Figure 3.7
Stress-Life – Metals Vs Polymers
Material Comparison
LEFM based method
• Cyclic loading
K I   a
 K I    max   min  a ai

K I 3  K I 2  KI 1

50
Paris’s Law for Stable Crack Growth
Threshold
Stable propagation
Unstable growth
For stable crack
propagation

 C K I 
da m

dN

51
Fatigue Crack Growth
• Steel • Polymers
Stress Corrosion Cracking
Surface Damage- Wear

Figure 3.12
Summary