Announcements

Adjustable Wrench due today. Table Vise is due in 2 weeks (November 17th).

Project #3 on FEA will be assigned next week.

In Lab: Currently working on Ch.4 in Mechanica: Solid Models Part 2. Reproduction of Figures 29 and 30 to be collected next week. In Lecture:

Prof. Dargush covering FEA until Thanksgiving break.

Last 2 weeks I will be available in 1019 for help on final project.

Revisions List Isometric

Cross-section View Individual views of parts that have changes

One sheet for each design solution.

Names, description (Table Vise Re-Design), etc.

Bearings

Bearings
A device that allows constrained relative motion between two or more parts. Plain Bearings Rolling Elements Bearings Ball, cylindrical roller, needle, tapered roller, and spherical roller Fluid Bearings Magnetic Bearings

Plain Bearings
Consists of a bearing surface and no rolling elements Least expensive, compact, high load carrying capacity Relatively high friction Can be used with or without lubrication

Bushing

Two-Piece Spherical Plain Bearing

Plain Bearings
Bearing Materials

Standard Handbook of Machine Design- Available online through UB Libraries

Plain Bearings
Bearing Materials

Optimization process can be used to select appropriate material.

Rolling Element Bearings

Ball Bearings
Spherical balls are used to maintain the separation between the bearing races. Large reduction in rotational friction compared to plain bearings. Capable of supporting both radial and axial loads. Can tolerate some misalignment of the inner and outer races.

Rolling Element Bearings

Cylindrical Roller Bearings
Use cylinders (with slightly longer length than diameter) as rolling elements. Higher radial load capacities than ball bearings due to increased surface area. Lower capacity and higher friction when subjected to axial loads.

Rolling Element Bearings

Needle Bearings
Use long, thin cylinders as rolling elements.

More compact and require less clearance.

Extremely high radial loading possible due to the large number of rolling elements.

Rolling Element Bearings

Tapered Roller Bearings
Use conical rollers that run on conical races.

Whereas most rolling bearings are suitable for only radial or axial loading, tapered roller bearings are suitable for both.
Due to manufacturing complexities they are usually more expensive than ball bearings.

Rolling Element Bearings

Spherical Roller Bearings
Use rollers that are thicker in the middle and thinner at the ends, with matching profile on races. Adjust to support misaligned loads. Difficult to produce (expensive) and have higher friction than a comparable ball bearing. Commonly suspensions. used in vehicle

Fluid Bearings
Support loads solely on a thin layer of gas or liquid. Hydrostatic: externally pressurized fluid bearings. Usually oil, water, or air that is pressurized by a pump. Hydrodynamic: rely on the speed of the journal self-pressurizing the fluid in a wedge between the surfaces. Frequently used in high load, high speed, or high precision applications where ball bearings have shorter life or higher noise and vibration.

Magnetic Bearings
Supports a load using magnetic levitation. Very low friction mechanical wear. and no

Can support the highest speeds of any bearing, no known maximum relative speed.
Usually require constant power and complex control systems. Can run without lubrication and in a vacuum- used turbo molecular pumps due to low contamination.

Methods of Bearing Retention

From Pg. 2225 of Machinerys Handbook.

Gear Geometry

Spur Gears
External
Cylindrical gears with straight teeth cut parallel to the axes. Tooth loads produce no axial thrust. Shafts rotate in opposite directions.

Spur Gears: from Machinerys Handbook

Helical Gears
Cylindrical gears with teeth cut at an angle to the axes. Provides drive between shafts rotating in opposite directions.

Superior load carrying capacity and quieter than spur gears Due to a more gradual tooth engagement.

Helical Gears
Beginning on Pg. 2100 in Machinerys Handbook

Helical Gears
Chapter 10 in Standard Handbook of Machine Design.

Bevel Gears
Straight Bevel Gears
Straight teeth are radial towards the apex and are of conical form. Used to connect two shafts on intersecting axes. End thrust developed under load acts to separate the gears.

Straight Bevel Gears: Machinerys Handbook

All dimension formulas given on pages 2088-2089.

Final Project Expectations

40% of Final Grade

Problem Identification & Product Description

Identify the product you are designing and describe the need for that product. Emphasis should be placed on how your product is different than what is currently available.

Hand Sketches
Detailed hand sketches clearly showing the intended product and how it works.

You will get no credit if you show a picture- this has to be a hand sketch.

Pro-Engineer Solid Modeling

Entire project must be accurately modeled in Pro-Engineer (time-consuming but easy 10 points).

Working Drawings showing full detail

I should be able to go to the machine shop and produce your final product based on what you specify in this section.

Working Drawings Parts

Should include adequate dimensioning of all parts (10-12 required).
All drawings should include a template with the following information: Your name Product name Part name Part material When applicable, proper tolerances should be given. You will loose a lot of points here for sloppiness.

Working Drawings Assembly Drawings

Both assembled views and exploded views are required. Should include all the information required for assembly. All parts should be properly labeled.

Bill of Materials (BOM)

A list of all required (custom and off-the-shelf) parts. Quantity and part names are required (another easy 10 points here).

Materials Selection & Manufacturing Processes

Identify materials being used and why that material was chosen. Aluminum due to lightweight Teflon due to low friction Stainless steel due to low corrosion Identify manufacturing processes to be used and why. Casting or forging due to irregular shapes. Raw material processed on milling machine or lathe. Purchased part (give vendor and part number) Reaming or grinding required for special tolerances. Include each part regardless of complexity.

Design Analysis
Comparison of your product with what already exists. Why you chose your design over alternate designs. Give some advantages and disadvantages.

Finite Element Analysis (FEA)

Every project is required to have some aspect of the design analyzed using Pro-Engineer FEA. Due to the wide variation of products it is up to you to decide what the critical parts of your design are and how you want to analyze them. If you are unclear on how you should approach this with your project then it is your responsibility to ask someone.

Cost Analysis
How much will your product sell for? Price breakdown for each part. How does this cost compare with competitive products? Is this a reasonable price for someone to pay?

For price breakdown there are several sources For purchased items and raw materials (list your source): McMaster Carr Fastenal MSC Industrial Supply It is fine to use bulk quantities and determine per unit price For machined parts I would recommend talking to the Machine Shop Staff to determine a time estimate for machining. Machine shop rates vary but use $35-50 per hour.