03 KinematicsHertzFlexures Sullivan

Precision Machine Design ME 250
Kinematic Design 2 Hertz Contact Stresses Flexures

Mark Sullivan September 18, 2008
Agenda
Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures
Kinematic Couplings History, Design Guidelines, Load Capacity, Examples Quasi Kinematic Couplings Constraints Hertz Contact Stresses Flexures References
Sullivan Sep 18, 2008
Page 2
Acknowledgements
Text and figures in these lecture notes are taken from the following sources:
Blanding, D., Exact Constraint: Machine Design Using Kinematic Principles, ASME Press, New York, 1999. Hale, L. C., Precision Engineering Principles, ASPE Tutorial, Monterey, 2006. Smith, S. T., Chetwynd, D. G., Foundations of Ultraprecision Mechanism Design, Taylor & Francis, 1994. Hale, L. C., Principles and Techniques for Designing Precision Machines, UCRL-LR-133066, Lawrence Livermore National Laboratory, 1999. (http://www.llnl.gov/tid/lof/documents/pdf/235415.pdf) Slocum, A. H., Precision Machine Design, SME, 1992. Slocum, A. H., FUNdaMENTALs of Design, MIT, 2008. Precision Engineering Research Group, MIT
http://pergatory.mit.edu/ http://pergatory.mit.edu/kinematiccouplings/
Page 3
Kinematic Couplings and Exact Constraint
Chart from FUNdaMENTALs of Design, Slocum
Page 4
Kinematic Couplings
Two common forms of the kinematic coupling.
2 2 2 (Maxwell) 3 2 1 (Kelvin Clamp)
Page 5
Kinematic Couplings: Some History
Chart from Mechanics of Designing Precision Machines, Slocum
Page 6
Kinematic Couplings: Three-groove Design Guidelines
Page 7
Kinematic Couplings: Load Capacity of Couplings
Page 8
Kinematic Coupling Example: Bal-Tec Components

Bal-Tec Kinematic Coupling Components
High repeatability Low cost Limited load Limited stiffness
Ball Cone Vee
Flat
http://www.precisionballs.com/index.html
Page 9
Kinematic Coupling Example: Bal-Tec Clamp
http://www.precisionballs.com/index.html
Page 10
Example of Kinematic Coupling: Adjustable Mirror Mount
A common example of a kinematic coupling is the adjustable mirror mount found in most optics labs.
Page 11
Quasi-Kinematic Couplings
Page 12
Quasi-Kinematic Coupling Example: Ford Engine Assembly
Page 13
Quasi-Kinematic Couplings: Engine Assembly Performance
Page 14
Recall: The Size of Things

Always a good idea to keep in mind the size of things

The thickness of this paper = 100 m The diameter of a human hair = 20 180 m Computer hard drive track spacing = 1 m Diameter of a fiber optic = 4 or 62.5 m core, 125 m cladding Visible light wavelength (mid-spectrum) = 550 nm Size of a typical virus = 10 400 nm Atomic diameter = 0.1 0.6 nm (He to Cs)
Page 15
Quasi-Kinematic Couplings (2)
Quasi-Kinematic Couplings (QKCs) approximate Kinematic Couplings

Reduced repeatability Low cost Increased load Increased stiffness
Three tooth coupling
Three cones with radial flexures
Designs based on line contact offer a significant increase in load capability and stiffness (Hale).
Page 16
Quasi-Kinematic Coupling Example: Spherolinder

Spherolinder Quasi-Kinematic Coupling
Reduced repeatability Increased cost Increased load (~100X higher) Increased stiffness
Vee Cone
Spherolinder
Retainer
http://www.g2-engineering.com/index.html
Page 17
Pop Quiz: Constraints
How many degrees of freedom does this coupling have? What are they?
Page 18
Idealized Kinematic Constraint Configurations
Page 19
Review: Constraints
Constraints 1 2 Ball on flat Link on flat Ball in groove Ball in trihedral Link with one ball in groove and other on flat Three linked balls on flat Link with one ball in trihedral and other ball on flat Link with 2 balls both in a vee groove Link of 3 balls with 2 on a flat & one in a groove Link of 4 balls on 2 inclined flats Configuration
Link of 2 balls with one in a trihedral hole & the other in a vee groove Link of 3 balls with 2 in vee grooves & one on a flat Link of 4 balls with one in a vee groove & 3 on a flat Link of 5 balls on 2 inclined flats Link of 3 balls in 3 vees (2-2-2 kinematic mount) Link of 3 balls with one in a trihedral, one in a vee & one on a flat (3-2-1 kinematic mount)
Page 20
6
Constraint Model of Kinematic Couplings
Page 21
Rotational DOF
Statement 9: A constraint (C) properly applied to a body (i.e., without overconstraint) has the effect of removing one of the bodys rotational degrees of freedom (R). The R removed is the one about which the constraint exerts a moment. A body constrained by n constraints will have 6 n rotational degrees of freedom, each positioned such that no constraint exerts a moment about it. In other words, each R will intersect all Cs.
Page 22
Exercise 1
Pick one corner that is not on a constraint line and add one orthogonal constraint at a time until the block is fully constrained. How many constraints must you add? Identify each constraint added with the rotational axis that it constrains (Hint: Use Statement 9).
Page 23
Equivalent Pairs of Rotational DOF
Statement 10: Any pair of intersecting rotational degrees of freedom (R) is equivalent to any other pair intersecting at the same point and lying in the same plane. This holds true for small motions. Statement 11: Two parallel Rs are equivalent to any two parallel Rs parallel to the first pair and lying on the same plane. They are also equivalent to a single R parallel to the first pair and lying in the same plane; and a T perpendicular to that plane.
Page 24
Series and Parallel Connections
Statement 12: When parts are connected in series (cascaded), add the degrees of freedom. When the connections occur in parallel, add constraints.
Page 25
Hertz Contact Stresses
Mark Sullivan September 18, 2008
Hertz Contact Stresses
Page 27
Hertz Contact Stresses (2)
This is the general case.
For solved cases, see Roark or MathCAD
Equations from FUNdaMENTALs of Design, Slocum
Page 28
Shear
Radial
Compressive
Graph and equations from FUNdaMENTALs of Design, Slocum
Page 29
To reduce Hertz Contact Stresses:

Decrease force Increase ball radius Decrease E
To reduce deflection:
Decrease force Increase ball radius Increase E
To reduce contact area:

Decrease force Decrease ball radius Increase E
Page 30
Kinematic Coupling Analysis
Also, MathCAD
Page 31
Pop Quiz: Contact Stress
Which 3 DOF mount has lower Hertz contact stresses? Why? How could you make the stresses even lower?
3-Ball Nest
Tetrahedron
Page 32
Flexures
(Adapted from ME 119 / ME 324 material by D. DeBra, Stanford University) Mark Sullivan September 18, 2008
Conceptual Basis for Flexure Design

Kinematic Design
A rigid body has 6 DOF with respect to a reference frame (or another rigid body) With exactly 6 constraints suitably arranged, no relative motion. If more than 6 constraints are applied to the body, it is overconstrained and can be strained if its support base strains If less than 6 constraints are applied, movement is made possible (e.g., bearings):
1 rotation free - spindle, rotary bearing 1 translation free - carriage on ways
Page 34
Kinematic and Semi-Kinematic Constraint
Is this mount overconstrained?
From Hale, 1999

Page 35
Constraints and Strain Attenuation
A constraint is (relatively) stiff along its line of constraint

Can substitute suitable arranged flexible elements to provide functionally equivalent constraint
Ex. Your stick models
Strain attenuation is important

Frictional forces from contacts can transmit unwanted strain
Page 36
Basic Building Blocks of Flexures

Rod Which DOF are Stiff Which are Flexible?
x
Rz y Rx Rz y Rx Ry Ry
Bellows Which DOF are Stiff Which are Flexible?
z x
Ex. of combining rods and bellows to achieve flexural elements.
Page 37
Basic Building Blocks of Flexures (2)

Sheets or plates
Which DOF are Stiff Which are Flexible? bh determines strength L influences buckling strength
b h
z
L x y
Rz
Ex. of combining sheet flexures to reduce constraints. Ex. of combining sheet flexures to increase constraints.
Page 38
Blade Flexures
Rigid constraint in its own plane (x, y, & z) Three degrees of freedom: z, x, & y.
Page 39
Parallel-Blade Flexure
Page 40
Cross-Blade Flexure
Page 41
Commercial Flexures
http://www.c-flex.com/home.html
Page 42
Rowlands Ruling Engine
Henry Augustus Rowland III [1848-1901] - American physicist

Page 43
Anti-Distortion Mountings
Jones, 1961
Page 44
Other Flexures
Jones, 1962
Page 45
Other Flexures, cont.
Why have 2 sets of cantilevered blade flexures? (At least 2 reasons)
Jones, 1962
Page 46
Other Flexures, cont.
Jones, 1962
Page 47
Series and Parallel Connections of Springs
Rule 1: The equivalent compliance of springs connected in series is the sum of their individual compliances. Rule 2: The equivalent stiffness of springs connected in parallel is the sum of their individual stiffnesses.
cserie
s
Page 48
Series and Parallel Connections of Springs (2)
Corollary: When springs are connected in series, add stiffnesses in parallel. When springs are connected in parallel, add stiffnesses in series.
k1
k2
k3
Page 49
References
Blanding, D., Exact Constraint: Machine Design Using Kinematic Principles, ASME Press, New York, 1999. DeBra, D. ME 119 Lecture Notes on Flexures, Stanford University, 1987. Jones, R. V., Anti-distortion Mountings for Instruments and Apparatus, J. of Sci. Instr., vol. 38, October 1961, pp. 408-409. Jones, R. V., Some Uses of Elasticity in Instrument Design, J. of Sci. Instr., vol. 39, 1962, pp. 193-203. Hale, L. C., Principles and Techniques for Designing Precision Machines, UCRL-LR-133066, Lawrence Livermore National Laboratory, 1999.
(http://www.llnl.gov/tid/lof/documents/pdf/235415.pdf)
Smith, S. T., Chetwynd, D. G., Foundations of Ultraprecision Mechanism Design, Gordon and Breach Science Publishers, Switzerland, 1992.
Page 50

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Precision Machine Design ME 250

Kinematic Design 2 Hertz Contact Stresses Flexures

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Kinematic Couplings and Exact Constraint

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Chart from FUNdaMENTALs of Design, Slocum

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Kinematic Couplings: Some History

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Chart from Mechanics of Designing Precision Machines, Slocum

Kinematic Couplings: Three-groove Design Guidelines

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Chart from FUNdaMENTALs of Design, Slocum

Kinematic Couplings: Load Capacity of Couplings

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Chart from Mechanics of Designing Precision Machines, Slocum

Kinematic Coupling Example: Bal-Tec Components

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Kinematic Coupling Example: Bal-Tec Clamp

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Example of Kinematic Coupling: Adjustable Mirror Mount

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Chart from FUNdaMENTALs of Design, Slocum

Quasi-Kinematic Coupling Example: Ford Engine Assembly

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Chart from FUNdaMENTALs of Design, Slocum

Quasi-Kinematic Couplings: Engine Assembly Performance

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Chart from Mechanics of Designing Precision Machines, Slocum

Recall: The Size of Things

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Always a good idea to keep in mind the size of things

Sullivan Sep 18, 2008

Quasi-Kinematic Couplings (2)

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Quasi-Kinematic Couplings (QKCs) approximate Kinematic Couplings

Three cones with radial flexures

Quasi-Kinematic Coupling Example: Spherolinder

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Pop Quiz: Constraints

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Idealized Kinematic Constraint Configurations

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Sullivan Sep 18, 2008

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures

Constraint Model of Kinematic Couplings

Precision Machine Design Kinematic Design Hertz Contact Stresses Flexures