ENGINEERING DESIGN PRESENTATION

INDEX
INTRODUCTION PROCEDURE EXAMPLE

AXIAL FLUCTUATING LOAD

It is stress induced due to change of magnitude with respect to time. It is time delayed fracture under cyclic loading. So it is called as FATIGUE FAILURE. 80% of mechanical components fails due to this only. Eg: Crank,Connecting rod ,Gearsetc This is represented by endurance limit.

ENDURANCE LIMIT
It is maximum amplitude of stress a material can handle for unlimited number of cycles without failure. Endurance limit for a component . Where Se=endurance limit for a material. Ka=surface finish factor. Kb=size factor

Kc=reliability factor. Kd=modifying factor.

COMPLETELY REVERSED STRESS

It means that stress variation occurs equally on both positive and negative side. In other words stress which varies from one value of tensile to same value of compressive is called as COMPLETELY REVERSED STRESS. sm=0

STRESS CONCENTRATION
Whenever a mechanical component changes shape of its cross section the simple stress distribution no longer holds good as stress at neighbourhood of discontinuity varies. This stress discontinuity due to abrupt changes in form is called as STRESS CONCENTRATION. This occurs due to presence of fillets,notches,holes,

Stress concentration factor,

FORMS OF STRESS CONCENTRATION

1)Rectangular plate with transverse hole:

Where w=width of plate t=thickness of plate d=diameter of hole

2)Plate with shoulder fillet: so=P/dt

PROCEDURE

STEP 1:CALCULATION OF ENDURANCE LIMIT STRESS

Se=(KaKbKcKd)Se Where Se=e.l.s for whole material Se=.5(Sut) Ka=surface finish factor Ka=a(Sut)^b Kb=size factor Kc=reliability factor Kd= stress concentration factor Kd=Endurance limit of notch free specimen/Endurance limit of notched specimen

Kd=1/ Kf Kd=1/1+q(Kt-1) Kd=1 if there is no stress concentration q=notch sensitivity factor

STEP 2:CALCULATION OF STRESS AMPLITUDE

(Se)axial=.8(Se) sa=(Se)axial/FOS where FOS=factor of safety

STEP 3:CALCULATION OF GEOMETRIC CHARACTERISTICS:

(s)a = P/A here A= (w-d)t for transverse hole P= dt for fillet so , by using the above formula we find the geometric characteristic of system.

EXAMPLE :
A rectangle plate in a chassis has transverse hole in it .It is made steel alloy whose Sut=650N/mm^2 and FOS is 2.It is subjected to completely reversed axial load of 15 KN .The plate is in the hot rolled condition .The notch sensitivity factor is 0.8. The expected reliability is 90%.if the diameter of hole is 10mm and width of plate is 70mm.find the thickness of the plate .

GIVEN
Sut=650 N/mm^2 P =15KN q =0.8 R =90% d =10mm w =70mm FOS =2

STEP 1:CALAULATION OF ENDURANCE LIMIT STRESS:

Se= (Ka Kb Kc Kd) Se Se= 0.5 (Sut) =0.5(650)=325N/mm^2 Ka = a(Sut)^b mode of surface finish :hot rolled condition so a =57.7 b =-0.718 By subs above values in formula we get , Ka =0.5514 Kb =0.85[d<50mm] Kc =0.897[R=90%]

CONTD..
Kd =1/Kf Kd =1/1+q(Kt-1) d/w =10/70 =0.143 Kt =2.61 (from DD book 7.10) Kd =1/1+0.8[2.61-1] =0.437 Se =(0.5514*.85*.897*.437)325 = 59.718N/mm^2

STEP 2: CALCULATION OF STRESS AMPLITUDE:

(Se) axial =0.8 times Se =47.77 sa =(Se)axial/FOS = 47.77/2 => 23.885 sa =P/A =P/(w-d)t 23.885 =15000/(70-10)t t =10.467mm

By

10a207 10a243 10a251 10a254 11a443 11a444