BK50A2200 DESIGN METHODOLOGIES AND APPLICATIONS OF MACHINE ELEMENT DESIGN Introduction and contents of the course D.Sc Harri Eskelinen Briefly about the lecturer… • Harri Eskelinen, GSM +358 40 1979 280, email:harri.eskelinen@lut.fi • Senior Research Scientist at LUT since 1999, before that lecturer and assistant since 1985. • Since 2011 nominated as an adjunct professor. • Since 2014 Head of the Master Degree Programme in Mechanical Engineering • D.Sc 1999 • Main research topics: – – – – DFMA MW-mechanics Green technology in material selection Distance learning • Supervising following courses: – – – – – Technical Drawing and 3D-modelling Material Science Engineering Design and Mechanisms Machine Element Design Research Methods and Methodologies Aim of the course • To provide understanding of functions and dimensioning of the most important mechanisms and their machine parts, such as: – – – – – – Springs Shafts Bearings Slides Gears Different types of fasteners Contents of the course • • • • • • • Basic mechanisms types Mechanisms analysis and synthesis Analysis of some selected machine parts Reliability based machine design and lifetime analysis Wear phenomena Fundamentals of systematic design approach Practical applications from industry Practical arrangements • Teaching and teaching material is divided into three main sections: 1 2 Lectures Text Books Special topics of Engineering design - Systematic Design - Mechanisms analysis and synthesis - Wear phenomena -Erdman:Fundamentals of mechanisms design -Norton: Design aspects of some important machine elements 3 Exercises and Teamwork Practical applications from industry CONTENT Spur gears Belt drives Rolling bearings Roller chain drives Introduction Stress and deflection analysis Helical compression springs Power transmission shafts BK50A2200 DESIGN METHODOLOGIES AND APPLICATIONS OF MACHINE ELEMENT DESIGN Glued joints Distribution analysis Rotational shaft sealing washers Shaft-hub-joints with conical geometry Shaft keys Types of lubrication Worm gears Wear phenomena INTRODUCTION Main criteria dealing with lifetime evaluation Main criteria dealing with reliability • S-N-curves • fatigue failure •crack propagation • lifetime evaluation equations • Distributions - loads - load bearing capacity - dimensions - material properties • Distribution analysis - curve fitting - overlapping distributions • Safety factors • Failure mode matrixes and fault tree analysis Main criteria dealing with strength Main criteria dealing with wear • combined loading cases • dynamic/static loads • impact loading • stress concentrations and peaks • brittle and ductile materials • dynamic contact stresses • Adhesive wear • Abrasive wear • Tribochemical wear • Surface fatigue • Pitting • Corrosion phenomena • Fretting • Cavitation, Erosion •Peeling BK50A2200 DESIGN METHODOLOGIES AND APPLICATIONS OF MACHINE ELEMENT DESIGN Schedule / autumn semester 2014 / 1ST PERIOD: LECTURES ON FRIDAYS AT 12.15-14.00 IN ROOM 213 IN STUDENTS’ UNION HOUSE Week Lectures (Fridays 12.15-14.00, room 213 Students’ Union House) Homework (Discussed during the lectures) 37 (8.9.- 14.9.2014) Introduction and guidelines of the university course module BK50A2200 38 (15.9.- 21.9.2014) L1. Fundamentals of the systematic design approach 39 (22.9.- 28.9.2014) L2. Introduction to the textbook: “Norton: Machine Design” Discussion of the homework results: E1. Comparison of different design approaches and requirement lists 40 (29.9.- 5.10.2014) L3. Reliability based machine design and lifetime analysis Discussion of the homework results:: E2. Integration of strength, reliability, lifetime and wear analyses 41 (6.10.- 12.10.2014) L4. Wear phenomena Discussion of the homework results: E3. Reliability based machine design 42 (13.10.-19.10.2014) L5. Machine elements I L6. Machine elements II Discussion of the homework results: E4. Wear phenomena L7. Machine elements III L8. Machine elements IV Discussion of the homework results: E5. Shafts, bearings, shaft seals E6. Gears Organization of the project team and working groups (43) (20.10.- 26.10.2014) No lectures nor exercises (Exam week) 2ND PERIOD: PROJECT WORK ON FRIDAYS AT 8.15-10.00 IN ROOM 213 IN STUDENTS’ UNION HOUSE Meeting number: Theme 44 (27.10.- 2.11.2014) Official project meeting I Requirement list 45 (3.11.- 9.11.2014) Official project meeting II Strength 46 (10.11.- 16.11.2014) Official project meeting III Wear 47 (17.11.- 23.11.2014) Official project meeting IV Reliability 48 (24.11.- 30.11.2014) Official project meeting V Lifetime 49 (1.12.- 7.12.2014) Project/Team work Presentations of the team works Tentative project meeting I (arranged by the project manager) Tentative project meeting II (arranged by the project manager) Exercises and teamwork • Teamwork – Project work, the whole class forms the project team, which consists of smaller groups (4-5 students/group) – Weekly project meetings, Patricia Nyamekye has been nominated as the project manager and she will invite the meetings • Brief exercises – Brief exercises will be giving after each lecture and the answers will be discussed at next week’s lectures – Based on the topic of each lecture – All kind of source material is allowed – 100% requirement for acceptance! • Presentations of the results of the teamwork (project work) – Week 49 – Topics will be decided in details during the project meetings • No written exam, the grading is based on the results of exercises and team works. Project work Project manager Team leader 1 Team leader 2 Team leader 3 Team leader 4 Team 1 Gears Team 2 Bearings Team 3 Seals Team 4 Shafts and Shaft-hub-joints Team leader 5 Team 5 ”Accessories” - belt-drives - chain-drives - clutches - etc. Power transmission capacity Wear Lifetime Reliability Project manager Team leader 1 Team leader 2 Team leader 3 Team leader 4 Team 1 Gears Team 2 Bearings Team 3 Seals Team 4 Shafts and Shaft-hub-joints Team members 1…4 Strength Wear Lifetime Reliability Team members 1…4 Strength Wear Lifetime Reliability Team members 1…4 Strength Wear Lifetime Reliability Team members 1…4 Strength Wear Lifetime Reliability Team leader 5 Team 5 ”Accessories” - belt-drives - chain-drives - clutches - etc. Team members 1…4 Strength Wear Lifetime Reliability Strenght Wear Lifetime R E L I A B I L I T Y Machine element Team leaders’ task is to take care of the overlapping areas Power transmission capacity Wear and lifetime Project manager’s task is to take care of the overlapping areas and the summarized reliability aspects R E L I A B I L I T Y