Machine Design REE 302: CH 1: Introduction To Mechanical Engineering Design

Machine Design
REE 302
Ch 1: Introduction to Mechanical Engineering Design
(1) Estimate how many times more expensive it is to grind a steel part
to a tolerance of ±0.0005 in versus turning it to a tolerance of ±0.003
in using figure 1-2.
(1) Estimate how many times more expensive it is to grind a steel part
to a tolerance of ±0.0005 in versus turning it to a tolerance of ±0.003
in using figure 1-2.
• Cost of grinding to ± 0.0005 in is 270%.
• Cost of turning to ± 0.003 in is 60%.
• Relative cost of grinding vs. turning = 270/60 = 4.5 times
Uncertainty
• Stochastic method
• Based on statistical nature of the design parameters.
• Focus on the probability of survival of the design’s function (reliability).
• Often limited by availability of statistical data.

Uncertainty
• Deterministic method
• Establishes a design factor, nd
• Based on absolute uncertainties of a loss of function parameter and a

maximum allowable parameter
(2) A cylindrical part of diameter d is loaded by an axial force P. This
causes a stress of P/A, where A = πd2/4. If the load is known with an
uncertainty of ±10 percent, the diameter is known within ±5 percent
(tolerances), and the stress that causes failure (strength) is known
within ±15 percent, determine the minimum design factor that will
guarantee that the part will not fail.
(2) A cylindrical part of diameter d is loaded by an axial force P. This
causes a stress of P/A, where A = πd2/4. If the load is known with an
uncertainty of ±10 percent, the diameter is known within ±5 percent
(tolerances), and the stress that causes failure (strength) is known
within ±15 percent, determine the minimum design factor that will
guarantee that the part will not fail.
Solution
• Max. load = 1.10 P
• Min. area = 0.952 A
• Min. strength = 0.85 S
• To offset the absolute uncertainties, the design factor, from Eq. (1-1)
should be
1.10
nd = 0.85 ∗ 0.952 = 1.43
(3) A fatigue test is performed on rotating beam specimens where, for each
rotation cycle, the specimens experience tensile and compressive stresses of equal
magnitude. The cycles-to-failure experience with 69 specimens of 5160H steel from
1.25-in hexagonal bar stock was as follows:
where L is the life in thousands of cycles, and f is the class frequency of failures.
(a) Estimate the mean and standard deviation of the life for the population from
which the sample was drawn.
(b) Presuming the distribution is normal, how many specimens are predicted to fail
at less than 115 kcycles?
(a) Estimate the mean and standard deviation of the life for the
population from which the sample was drawn.
From the data, the number of instances less than 115 kcycles =
2 + 1 + 3 + 5 + 8 + 12 = 31 (the data is not perfectly normal)
(4) A mechanical system comprises three subsystems in series with
reliabilities of 98, 96, and 94 percent. What is the overall reliability of
the system?
(4) A mechanical system comprises three subsystems in series with
reliabilities of 98, 96, and 94 percent. What is the overall reliability of
the system?
Solution
R = 𝑛𝑖=1 𝑅𝑖 = 0.98*0.96*0.94 = 0.88

Overall reliability = 88 percent
Relating Design Factor to Reliability:
(5) The maximum shear stress in a solid round bar of diameter, d, due
to an applied torque, T, is given by tmax = 16T/(πd3). A round, cold-
drawn 1018 steel rod is subjected to a mean torsional load of T = 1.5
kN.m with a standard deviation of 145 N.m. The rod material has a
mean shear yield strength of 𝑠sy = 312 MPa with a standard deviation
of 23.5 MPa. Assuming the strength and load have normal
distributions, what value of the design factor nd corresponds to a
reliability of 0.99 against yielding? Determine the corresponding
diameter of the rod.
• For R = 0.99, from Table A-10, z = - 2.326.
(6)
(a)
a = 1.500 ± 0.001 in
b = 2.000 ± 0.003 in
c = 3.000 ± 0.004 in
d = 6.520 ± 0.010 in
𝑤 = d - a - b - c = 6.520 - 1.5 - 2 - 3 = 0.020 in
Tw = tall = 0.001 + 0.003 + 0.004 +0.010 = 0.018
w = 0.020 ± 0.018 in
(b)
From part (a), wmin = 0.002 in. Thus, must add 0.008 in to d . Therefore,
d = 6.520 + 0.008 = 6.528 in

Machine Design REE 302: CH 1: Introduction To Mechanical Engineering Design

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Machine Design

• Focus on the probability of survival of the design’s function (reliability).

• Often limited by availability of statistical data.

• Based on absolute uncertainties of a loss of function parameter and a

R = 𝑛𝑖=1 𝑅𝑖 = 0.980.960.94 = 0.88

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