2011

31 Mechanical (B) NS ZAIN JAVED 261 NS AHMAD NASIR 207 NS SYED HUSSAIN JAMAL 256 GC MUNEEB SAQLAIN 288 GC IHTASHAM UL AHSAN 281

[MECHANICS OF MATERIALS ASSIGNMENT NO. 2]

We the above mentioned declare that no part of this assignment submitted in partial fulfilment of the requirements for the course of Mechanics of Materials I has been plagiarised, copied or replicated from any source including but not limited to online sources, books and the notes/work of any students. If at any stage it is found that any part of the content submitted is plagiarised then we will be liable at the minimum for similar disciplinary action and punishment that is prescribed for exam cheating cases.

Mechanics of Material: Mini Design Project We are required to design 3 different bookshelves, with 3 different types of materials and 2 factors of safety. The general dimensions required for a bookshelf to hold 25 books and 4 ring binders will vary from designer to designer, therefore for the sake of our ease and convenience we have used the dimensions of the shelves installed in our rooms, which are as follows: Length = 1.00 m Width = 0.25 m Thickness = 0.03 m Apart from that another generalization that shall be applied to the designs is the weight of the books used according to Googleanswers.com between 1 and 1 1/2 pounds, in order to be on the safe side of the design we will be using the higher end of the range mentioned i.e. 1.5 pounds or 0.68 kg. The weight of a filled ring binder will vary but according to a few measurements made for this project the average weight of one ring binder (found after weighing about 10 to 15 ring binders) came out to be around 8 kgs. Also note that since some dimensions were unable to be found hence a value is either assumed for them or they have been measured from actual designs. These dimensions will be highlighted in the free body diagram of the design. The shear and normal stresses for the materials which shall be used and the corresponding allowable stresses for a chosen factor of safety is shown in the table below. Material Ultimate Tensile Stress (MPa) 414 370 450 Ultimate Shear Stress (MPa) 220 330 330 Allowable Normal Stress for FS = 4 103.5 92.5 112.5 Allowable Shear Stress for FS = 4 55 82.5 82.5 Allowable Normal Stress for FS = 5 82.8 74 90 Allowable Shear Stress for FS = 5 44 66 66

Aluminum Cast Iron Steel

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DESIGN 1:

Mechanics of Material: Mini Design Project

In this case the free body diagram can be drawn as

F1 F2 F5 0.40 m B 0.25 m FB C

F3

Now knowing that we are assuming a uniform weight distribution, therefore the force F5 is given by ( This is the force acting at B as well. Applying equations of equilibrium in x and y directions give the following equations: = 0 gives ) + F3 )( )

F5 + FB + F1 = F4 ( =0

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F2 + F4 (

Mechanics of Material: Mini Design Project )=0

Taking equilibrium at A to find F4: F4 ( = 0 yields ) = F5

Hence F4 = 144.5 N Substituting this in the equilibrium equation in x direction we get F2 = - 76.6 N (the negative sign shows its acting in the direction opposite to the one chosen) Now in order to find F1 and F3 we have only one equation and taking any moments about a point will not yield a proper result for them, either, as shown: = 0 yields

FB (0.25) + F2 (0.40) = F3 (0.25) + F1 (0.25) Hence to simplify we assume that one of the forces F1 or F3 will have a very little value and hence we can neglect it, in this case we assume that F1 will have a small value and hence it can be neglected. It can also be assumed that the downward force of 122.5 N is balanced by F3, therefore F3 = 122.5 N We can now compute the resultant force for the pin connection at C assuming it to be in single shear. C = 77.6 N FORCE IN CABLE AC = 144.5 N FORCE IN CABLE BC = 122.5 N We can now compute the diameters of the wires and the pin at C. DIAMETER OF CABLES AC & BC Allowable stress = force / area Allowable stress = 144.5 / Allowable stress = 122.5 / (for cable AC) (for cable BC)

Mechanics of Material: Mini Design Project FOR CABLE BC: Material Allowable Normal Stress for FS = 4 (MPa) 103.5 92.5 112.5 Allowable Normal Stress for FS = 5 (MPa) 82.8 74 90 Diameter of Cable for FS = 4 (mm) 1.228 1.299 1.177 Diameter of Cable for FS = 5 (mm) 1.372 1.452 1.316

Aluminum Cast Iron Steel FOR CABLE AC: Material

Aluminum Cast Iron Steel FOR PIN C:

Allowable Normal Stress for FS = 4 (MPa) 103.5 92.5 112.5

Allowable Normal Stress for FS = 5 (MPa) 82.8 74 90

Diameter of Cable for FS = 4 (mm) 1.333 1.410 1.279

Diameter of Cable for FS = 5 (mm) 1.491 1.577 1.430

Allowable normal stress = force / area = 77.6 / Allowable shear stress = force / area = 77.6 / Diameter of Pin C for FS = 4 (mm) using Normal Stress 0.977 1.034 0.937 Diameter of Pin C for FS = 4 (mm) using Shear Stress 1.340 1.094 1.094 Diameter of Pin C for FS = 5 (mm) using Normal Stress 1.092 1.156 1.048 Diameter of Pin C for FS = 5 (mm) using Shear Stress 1.499 1.224 1.224

Material

Aluminum Cast Iron Steel

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DESIGN 2:

Mechanics of Material: Mini Design Project

This design involves two L brackets fixed with a wall using 1 bolt for each bracket to connect the bracket to the wall, and two bolts to connect the shelf to the bracket. Assuming a uniform weight distribution, the weight of the loaded shelf can be divided amongst the four bolts used to attach the wooden shelf to the brackets. Therefore the force acting on each bolt comes out to be: 122.5 N as in the above mentioned design since the weight of the books remains unchanged. This force will cause a normal stress on the bolts and that will be the allowable normal stress which can be computed using the formula of factor of safety. Using this stress the minimum diameter of the bolts can be found out. On the pins used to attach the brackets to the both shear and normal stresses will be acting, and this can be found by applying the principle of moments about the lower pin. The free body diagram then becomes

The above shown design is fairly simple as compared to Design 1. In this design shear stress acts on the pins due to forces F1 and F2, while both normal and shear stresses act in the pin at C.

Mechanics of Material: Mini Design Project Since the weight is uniformly distributed therefore forces F1 and F2 are equal to 122.5 N as already explained in Design 1. Thus the shear stress in the bottom two pins is due to the weight of the shelf. Applying the equilibrium equation in the y direction will give us the value of Cy. = 0 gives

Cy F1 F2 = 0 Cy = F1 + F2 Cy = 245 N Taking moments about the point shown as B in the free body diagram will yield us the value of Cx. = 0 yields

F1 (0.10) + F2 (0.20) Cx (0.20) = 0 Cx = 122.5 (0.30) / (0.20) Cx = 183.75 N Finding the resultant force acting in the pin at C C = ( ) ( )

C = 306.25 N DIAMETER OF PINS A and D Allowable stress = force / area Allowable stress = 122.5 / Material Aluminum Cast Iron Steel Shear Stress for FS = 4 55 82.5 82.5 Shear Stress for FS = 5 44 66 66 Diameter of Pin A (mm) 1.683 1.883 1.375 1.537 1.375 1.537 Diameter of Pin D (mm) 1.683 1.883 1.375 1.537 1.375 1.537

Mechanics of Material: Mini Design Project DIAMETER OF PIN C Allowable normal stress = force / area = 306.25 / Allowable shear stress = force /area = 306.25 / Diameter of Pin C for FS = 4 (mm) using Normal Stress 1.941 2.053 1.862 Diameter of Pin C for FS = 4 (mm) using Shear Stress 2.663 2.174 2.174 Diameter of Pin C for FS = 5 (mm) using Normal Stress 2.17 2.295 2.081 Diameter of Pin C for FS = 5 (mm) using Shear Stress 2.977 2.431 2.431

Material

Aluminum Cast Iron Steel

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DESIGN 3:

Mechanics of Material: Mini Design Project

This design is almost similar to the one mentioned in design 2, it differs in the sense that the weight now acts on the pins (whose number has increased). Also there are shear stresses acting in the bolts, and both normal and shear stresses in the top pin which connects the frame to the wall. Note that for this design the dimensions used are the same as that for the earlier two designs in order to keep the design criteria and conditions same for all the designs. The weight distribution can be calculated by dividing the total weight by the number of bolts i.e. Force on each pin = F1 = total weight / no. of pins = 490/8 = 61.25 N The vertical reaction force for the pin at the top can be calculated by applying the equilibrium equation in the y direction, this gives = 0 gives

Cy 61.25 61.25 61.25 61.25 = 0 Cy = 245 N Taking moments about B will give the horizontal component of the reaction force at C. = 0 yields

Cx (0.08) 2 (61.25) (0.0625) 2 (61.25) (0.1875) = 0 Cx = 382.81 N

Mechanics of Material: Mini Design Project Therefor the resultant force acting at pin C is then equal to C = ( ) ( )

C = 454.5 N DIAMETER OF PINS: These pins include the ones on which a force of 61.25 N acts, their number is 8. Allowable stress = force / area = 61.25 / Material Aluminum Cast Iron Steel Shear Stress for FS = 4 55 82.5 82.5 Shear Stress for FS = 5 44 66 66 Diameter of Pins for FS = 4 (mm) 1.191 1.00 1.00 Diameter of Pins for FS = 5 (mm) 1.331 1.087 1.087

DIAMETER OF PIN C Allowable normal stress = force / area = 454.5 / Allowable shear stress = force /area = 454.5 / Diameter of Pin C for FS = 4 (mm) using Normal Stress 2.365 2.501 2.268 Diameter of Pin C for FS = 4 (mm) using Shear Stress 3.244 2.648 2.648 Diameter of Pin C for FS = 5 (mm) using Normal Stress 2.644 2.796 2.536 Diameter of Pin C for FS = 5 (mm) using Shear Stress 3.627 2.961 2.961

Material

Aluminum Cast Iron Steel

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Mechanics of Material: Mini Design Project COMPARISON OF THE DESIGNS: Designs 2 and 3 are more or less the same. In design 3 the number of pins has increase from that of 4 (in design 2) to 8, thereby reducing the force acting on each pin. But due to this the diameters of the pins (if made out of cast iron and steel) comes out to be quite small. In design 1 the results of the diameter of the pin at C might not hold true for most cases due to the assumption that the vertical reaction force does not have much of an effect. Design 1 does have the advantage that it involves the least number of pins (only the top two pins which connect the wires to the wall). RELATION TO FACTOR OF SAFETY: Two factors of safety have been chosen in order to show their effect on the diameter of the pins and/or the cables used in the designs. In general as factor of safety is increased the allowable stress decreases, thus the area increases this will cause an increase in the cost of the material being used, or another material will have to be chosen which has better properties, this too will cause an increase in the cost of the design. ASSUMPTIONS: The above design analysis involves a few assumptions that are common to all the designs they are: 1. All the joints made whether with pins or otherwise are all connected perfectly. 2. With the above assumption mentioned it is also stated that any sort of concentration factors around the pins or any other joints are neglected. 3. The weight of the entire assembly that is the struts as well as the shelf, and the pins is neglected since it is assumed that their weights would not have much of an effect on the results. 4. The entire weight distribution of the loaded shelf is assumed to be uniform hence equilibrium equations were able to be applied at all the joints. 5. All struts and the shelf are assumed to be rigid that is any sort of deformation is neglected. 6. Poissons ratio has not been accounted for. 7. Effects such as fatigue, creep, and thermal stress have not been accounted for since they have not been covered at the moment of this assignment. 8. Also one main assumption in all of these designs is that these designs will be able to support the weight of the books. 9. Any sort of frictional forces between the shelf and the supports, or the pins and the supports have been neglected for a better design. 10. Net and bearing stresses have not been accounted for, since we are finding out the diameters of the components ourselves.

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Mechanics of Material: Mini Design Project REFERENCES: 1. Values for Ultimate Tensile and Shear Stresses - Engineering Mechanics of Solids by Egor P Popov. 2. Design 1 - http://www.uniquestylesolutions.com/expo-cable_shelf_kit.asp 3. Design 2 - http://www.ikeafans.com/galleries/images/2339/large/1_IMG_0277.jpg 4. Design 3 - http://static1.bonluxat.com/cmsense/data/import/big/nisse-strinning-stringpocket_rd.jpg 5. Weight of an average book http://wiki.answers.com/Q/How_much_does_an_average_book_weigh 6. Highlighted dimensions have been measured on an actual design for Designs 1 & 2, and assumed for Design 3.
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