Machine Design EML 4501 Fall 2012 Instructor: Dr.

. Nathan Crane Office Hours: 2-3 PM TTh ENC 2206 (or by appointment) Contact: Office: ENC 2206 Phone: (813) 974-8586 Email: nbcrane@eng.usf.edu Lead TA: Jose Carballo Office Hours: 9-10 AM MW ENG 019C (or by appointment) Contact: Email: jcarball@mail.usf.edu Grading TA: Hesham Mraied Office Hours: 9-10 AM TTh ENG 019C (or by appointment) Contact: Email: Hesham@mail.usf.edu Textbook: Machine Design: An Integrated Approach by Norton 4th Edition Available in the bookstore. The text is required. Some quizzes will be open book.

No electronic versions of the book are accepted for quizzes.

Course Summary We are surrounded by machines everyday ranging from the simple (stapler) to the complicated (automobile). In general, machines consist of multiple pieces produced from different materials using different processes. Designing, manufacturing, and assembling machines also tie together all the disciplines of mechanical engineering. Given this breadth, we cannot cover all the important aspects of machine design in one 3 credit course. We will focus on the fundamental principles and then apply these to specific components and a design project. The course is divided into 3 components. 1. Predicting mechanical failure We will review methods for analyzing mechanical elements to determine the applied loads and resulting stresses. We will identify possible failure modes, and learn about the criteria that can be used to predict failure. 2. Design and specification of mechanical components Machines are made from many different mechanical components including joints, couplings, shafts, bearings, gears, and fasteners. We will review the basic characteristics of these devices and learn about criteria for their design. 3. Design Process There are many things you can learn that will improve your ability to solve design problems. This includes techniques for developing our creativity, structuring a design problem, and borrowing ideas from other applications. We will discuss these concepts and practices solving design problems throughout the semester through homework and projects. Course Objectives: (Related Program Outcomes in parenthesis) 1. Create Engineering models of systems. Students will develop their skills in recognizing important interactions, selecting appropriate simplifications, identifying the limitations of the models, and checking for accuracy. (e) 2. Understand 2D and 3D stress states and how to apply failure criteria to them. (a) 3. Learn to select appropriate failure criteria for the material and loading conditions. (a) 4. Develop an understanding of basic engineering design components. Know the basic uses of the different items, most common variants and their relative strengths. Understand the design issues to be considered with their use, and how to design the component. (c) 5. Gain experience delving into something you dont know much about, learning it, and applying it. (i) 6. Increase your confidence and experience in communicating technical ideas to supervisors and peers. (g) 7. Learn to work cooperatively as a member of a team. (d)

Tentative Grading:

Chapter Quizzes Homework Individual Projects (paper design analysis) Group Projects (Build, Test, and Evaluate) Total Typically: A (>90), B (80-90), C(70-80), D (60-70) (Plus/Minus grades are used.)

40% 20% 30% 10% 100%

Class Preparation There are recorded introductions to some course topics posted on Blackboard. There are also outlines posted to blackboard for many topics that explain what you are expected to learn. Some topics also have video presentations posted to Blackboard to supplement or in some case replace classroom lectures on the topics. Please review these materials before class where indicated in the syllabus. This will leave more class time available for solving problems. Additionally, please come to class prepared to solve problems. You will need your textbook, paper, calculator, etc. We may break from lectures to permit group work and individual conversations with instructor and TAs. This time will be more productive if you have reviewed the appropriate material before class. Homework Homework assignments are posted on Blackboard under Assignments. Homework is the key to learning the material in the course and you should plan to spend an average of 6 hours/week on the homework for the course. Completing the homework is key to preparing for the quizzes and the individual projects. Homework is due by the start of class on the day indicated. It should be given to the instructor in class or slipped under his door before he leaves for class. Any material turned in after the start of class will be considered late. Late homework submitted before the solutions are posted will receive credit. Work must be presented neatly and in an organized manner to receive full credit. Half credit is given for making a good effort on each problem with work to support your answer, 25% for using the appropriate equations and assumptions. The other 25% is for the correct answer. Format: To facilitate grading of the homework, there is a strict homework formatting requirement. The formatting instructions are clearly described in a document on Blackboard. Your work should be shown neatly on separate sheets of paper for full credit. Do not write on the backs of the sheets of paper. I encourage you to work together in groups on all your homework. You will find that you will benefit from discussing the problems with others and the best way to learn the material is to help explain it to someone else. However, everyone must be a contributor to the group and not just a recipient. Additionally, each person should write their own solutions unless a specific homework assignment specifies otherwise. For those who like to study solutions to similar problems, I encourage you to use honest sources of solutions such as Schaums outline series. I also make solutions of previous semesters homework problems and some of the current problems available on Blackboard as video presentations, pencasts, and/or static pdf summaries. Individual Projects You will work on two individual projects. These projects will apply the analysis skills you have developed to simple (but challenging) problems. While the homework will focus on solving well-defined problems, the projects will require that you make more assumptions, find more information, and select among a variety of alternative methods and solutions. The problems are posed by the instructor and posted on Blackboard. You will submit design memos that summarize your methods and results and include an appendix with all of the details of the solutions. You will complete these independently. Group Project At the end of the semester you will complete a group project that will require you to develop several design alternatives, select between them, and produce a prototype of your design. You will submit a design report summarizing your design and predicted performance. You will then have the opportunity to test your project

performance and you will submit a memo that compares your predicted and actual performance and explains any differences observed. Scheduled Chapter Quizzes Chapter quizzes will be given regularly through the class. These will typically cover one chapter of material. They will also be used to provide you feedback on your understanding of the pre-requisite material (Chapters 24). They will typically last 30 minutes and be administered in class. I will drop your lowest Chapter Quiz grade for the semester. Most quizzes will be open book. (No Electronic books permitted.) Academic Honesty Cheating will not be tolerated in any form. Any cheating on an assignment will receive a minimum of a zero on the assignment and may receive up to an FF on the course per University policies. Copying anothers work without attribution (including the solution manual) is considered cheating. Please review the University policies on academic honesty and plagiarism and ask any questions you have before turning in assignments. Course Communications Blackboard is the primary means of communicating with the class. If there is information for the class it will be posted on Blackboard. Urgent information may also be sent by email. You are responsible to make sure that you check Blackboard and the email account that it has on record at least every 24 hours Monday-Friday. In the event of an emergency, it may be necessary for USF to suspend normal operations. During this time, USF may opt to continue delivery of instruction through methods that include but are not limited to: Blackboard, Elluminate, Skype, and email messaging and/or an alternate schedule. Its the responsibility of the student to monitor Blackboard site for each class for course specific communication, and the main USF, College, and department websites, emails, and MoBull messages for important general information. Under extenuating circumstances, the syllabus may be amended during the semester.

Students in need of academic accommodations for a disability may consult with the office of Students with Disabilities Services to arrange appropriate accommodations. Students are requiredto give reasonable notice prior to requesting an accommodation. Special Addendum on absences: In the event of illness, you are encouraged to remain at home to avoid infecting your classmates. However, assignments are still due as scheduled unless you make other arrangements with the instructor prior to the assignment deadline. The instructor may ask for proof of illness such as a doctors note particularly in cases of extended delasys in completing work or repeated illness

Date Aug 28 Aug 30 Sep 4

Class Topics Course Intro, Safety Factors, Materials Statics Review (FBD), Impact Loading, Vibration Loading Ch 2& 3 Quiz In Class Mechanics Review: Principal Stresses vs. Applied Stresses, Mohrs Circle, Axial Loading, Torsion Loading Mechanics Review: Direct Shear, Tearout, Combined Loading Mechanics Review: Columns, Stress Concentration Fundamentals of FEA Analysis in SolidWorks Fundamentals of FEA Analysis in SolidWorks Static Failure: Ductile Materials, Brittle Materials CH 4 Quiz in Class Static Failure: Fracture Mechanics Static Failure: Problem Solving Ch 5 Quiz in Class Fatigue Failure: Fully Reversed Fatigue Failure: Mean + Alternating Fatigue Failure: Stress Concentrations Fatigue Failure: Problem Solving Ch 6 Quiz in Class Surface Failure (Ch 7) Overview of Key Components Shafts, couplings, Bolts/Leadscrews Bearing, Power transmission elements Overview

Reading Ch 1, 2* 3.0-3.2*, 3.7-3.8 4.1-4.6

Assignments Due

HW 1: Materials and Product Disassembly

Sep 6 Sep 11 Sep 13 Sep 18 Sep 20 Sep 25 Sep 27 Oct 2 Oct 4 Oct 9 Oct 11 Oct 16 Oct 18 Oct 23 Oct 25 Oct 30

3.9, 4.7, 4.910 4.16 Ch 8 Ch 8 Ch 5 Ch 5 Ch 5 Ch 6* Ch. 6 Ch 6 Ch. 6 Ch 7 Couplings* Shafts* Bearings* Gears*

HW 2: Stress Analysis (Ch. 4)

HW 3: Static Failure (Ch 5)

HW 4: Fatigue Failure (Ch 6)

Nov 1 Nov 6 Nov 8 Nov 13 Nov 15 Nov 20 Nov 22-23 Nov 27 Nov 29 Dec 4 Dec 6

HW 5: Machine Components Engineering Design & Analysis IP 1 Process discussion Quiz on Machine Component Overview and Ch. 7 (Closed Book) Writing effective Design Reports Testing the Parts Individual Project 1: Prediction Report Due Shaft Sizing Ch 10 Key Design Ch 10 Spur Gears Ch 12 Spur Gears Ch 12 Design Process--Design objectives & requirements, HW 6: Shafts, Couplings, and Gears (Ch 12) Generating Design Ideas Thanksgiving Holiday Sliding bearing Design Ch 11 Ch11 Quiz on Gearing & Shaft Calculations (Ch 10,12) Individual Project #2 due Rolling Element Bearing Life Estimations Leadsrew Design Ch 15 Bolted Joint Design Ch 15 Complete Testing of Project Group Report Project Presentations

Design Report & Presentation Group Project Design Report Due

*Denotes topics for which a video is available on Blackboard