Mechanical

Elements

Outline:
Mechanical properties of materials
Machine elements:
1) Motors (types, selection considerations)
2) Power transmission devices (gears, belt, pulley,
chain,
friction drive)
3) Miscellaneous: Bearings(types, selection issues,
catalogs), springs, pins, retaining rings
4) Other motion generation devices (linkage
mechanisms,
cams)
5) Joining methods (welding, brazing, soldering, bolts,
screws, rivet, )
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Mechanical properties of
materials:
Behavior of materials in response to mechanical
loads.
Useful in material selection.

load ( F )stress-strain relation

Most basic property:
Stress:

area ( A)

lengthchange(l )
Strain :
originallength(l 0 )
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Strength of a material
Maximum stress that can be applied to material before failure.
Types:
- Tensile Strength
- Compressive strength
- Shear strength
The definition of failure varies by the type of material and
design method:
Brittle (concrete, cast iron, glass,)
Ductile (gold, Aluminum, copper, steel, )

Stress-Strain relation
The stress caused by
load must not exceed the
failure stress.
Always consider a Factor
of Safety.
FS= all /design
all = Allowable Stress
design = Design Stress
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Stress-strain curve, Aluminum[1]

Stress-strain curve for a brittle material [1]

Standards
SAE (Society of Automotive Engineers)
AISI (American Iron and Steel Institute)
ASTM (American Society for testing and Materials)
ANSI (American National Standard Institute)
AISI-SAE designation for carbon and alloy steel
Mild steel
Medium carbon steel

0.1% - .25% Carbon

.25% - .45%

e.g., AISI 1018

e.g., AISI 1040

Machine elements
Motor
Gear
Belt, pulley
Chain, sprocket
Universal joint
Friction drive
Cam-follower
Mechanisms (linkages)

Bearing
Joining methods
(welding, brazing, rivets,
bolts, screws, etc)

Motor types
DC motors
Stepper motors

a) Permanent magnet
(brushless)
b) DC Shunt motor
c) DC series motor

Gearhead motors
AC motors

Characteristics
DC motor
a) Speed proportionate to voltage applied
b) Suitable current/torque and speed/torque curve
properties
c) Easy to control
d) Position/Speed Servo
e) No brush noise, durable, clean (brushless)
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Characteristics
Stepper motor
Can rotate in both directions
Moves in precise angular increments (steps)
Sustain a holding torque at zero speed
Easy to control

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Comparison of stepper and DC permanentmagnet motors

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Selection factors
When selecting a motor consider these
issues:

Speed range
Torque-speed variations
Reversibility
Required power
Load inertia

Starting torque
Size and weight
restrictions
Price
Maintenance

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Selection factors (contd)

Consider these questions when selecting a
motor:
1. Will the motor start under load?
2. What is the maximum speed the motor can
produce?
3. How much power does the load require?
4. Is the load to be driven at constant speed?
5. Is transmission gearbox required?
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Useful information sources

Experts
Manufacturer
specification sheets
Product catalog
Design handbooks
Motor nameplate
Web

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Gearhead motors

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Force ratio for gear trains

Wrr1 r2
F
RR1 R2
W=Load force
F= balancing force

FR F1 r

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Gear train speed ratio

D1 D2 D3 driven
speedratio

d1 d 2 d 3
driver

n4 N1 N 3
drive

n1 N 2 N 4 driven
n= speed
N= number of teeth
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Different kinds of power transmission

or motion control capability of gears:
a) Changing rotational speed.
b) Changing rotational direction.
c) Multiplying or dividing torque.
d) Converting rotational to linear motion.
e) Offsetting or changing the location of rotating
motion.

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Motion and torque transmission examples

([5])

Right angle
crossing shafts
Self locking
High friction
and wear
High speed
reduction

Right angle I/O

torque
Smooth tooth
interaction
Low noise

Rotary-Linear power
transmission

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Bearing types
Ball bearing

Tapered roller
bearing

Thrust bearing

Needle roller
bearing

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Important factors in bearing

selection

Loads (radial, axial)

Operating speed
Size and weight

Information sources:
Experts
Manufacturers catalog (SKF, TIMKEN, FAG,)
Design handbook

A quick way of bearing selection

SKF online interactive catalog (www.skf.com)
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SKF interactive bearing selection example

page

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Other ways of motion transmission:

Linkage mechanisms

Intermittent rotary motion[6]

Rotary to back and forth motion[7]

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Alternative mechanism design

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Flexible transmission
Chain-sprocket
Belt-pulley

Ref[8, 9]

Ref[10]
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Joining methods
Welding
Brazing
soldering

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Joining methods
Welding: (melting both material and filler, generally
used for welding ferrous materials)
Brazing: (melting nonferrous metal, brass or bronze, as
filler to join base materials by capillary action)
Soldering: ( same as brazing but at lower temperatures)

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Joining
method

Joint
strength

temperature

Distortion

Aesthetics

Soldering

Poor

up to 400C

None

Good

Brazing

Good

800-1000 C

Minimal

Excellent

Welding

Excellent

above1500C Likely

Fair

e.g., Brazing with Bronze alloy as filler with 870-980C for joining mild
steel with melting temperature of 1600C[1].

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Welding types
Arc welding: An electric arc between material and filler
melts them at the joining point.
Gas welding (oxyacetylene):
Widely used for welding pipes and tubes and repair
work
Resistance welding:
Generating heat by passing current through resistance
caused by joining metals. (widely used in automotive
industry)
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Arc Welding: Setup configuration [11]

1- power supply
2- electrode holder
3- workpiece
4- work clamp

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Welding position

1- workpiece
2- work clamp
3- slag
4- electrode
5- electrode holding position

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Electrode position
in groove welding

Electrode
position in
fillet
welding

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Single stringer
bead for narrow
grooves

Weave bead
for wide groove
or multiple
stringer bead

1- stringer bead
(steady
movement along
seam)

2- weave bead
(side to side
movement
along seam)

3- Weave pattern

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Properties of a good welding

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Troubleshooting

Excessive spatter

Porosity

Lack of penetration

Cause:
1-Amperage too high
2-Arc length too long

Cause:
1-Dirty workpiece
2-Arc length too long
3-Damp electrode

Causes:
1-Improper weld
technique
2-insufficient heat
input

Correction:
1- Decrease
amperage or select
larger electrode
2- Reduce Arc length

Correction:
1-Remove all grease,
damp, oil, dust,...,
from work surface
2-Reduce length
3-Use dry electrode

Correction:
1-Reduce welding
speed
2-Increase amperage,
use larger electrode
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Troubleshooting

Burn through

Wavy bead

Distortion

Cause:
Excessive heat

Cause:
Unsteady hand

Cause:
Excessive heat

Correction:
Decrease
amperage
use smaller
electrode
Increase travel
speed

Correction:
Use two hands
practice

Correction:
Use clamp to hold
base material
Use lower amperage
Make tack weld along
the edge
Weld in small
segments, allow cooling
between welds.
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Example of good and

bad welds

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