Thursday, August 13, 2020

Introduction to Design of Machine Elements and Machine


Design Philosophy
http://nptel.iitm.ac.in/courses/Webcourse-contents/IIT%20Kharagpur/Machine%20design1/pdf/Module-1_Lesson-1.pdf

Product Development Approaches
http://www.nd.edu/~manufact/FME%20pdf_files/FME_Ch01.pdf



Machine Design
Ch.8 of S.B. Mathur's Mechanical Engineering (Conventional & Objective)

1. Fasteners 380 - 390
2. Keys 391-393
3. Joints 393 - 400
4. Shafts 401 - 404
5. Couplings 404 - 410
6. Riveted Joints 410 - 417
7. Welded Joints 417 - 421
8. Transmission Systems 421- 428
9. Bearings 429 - 434
10. Gears 435 - 438
11. Springs 439 - 442


1. Fasteners

Standard screw thread forms

1. BSW
2.B.A.
3. Metric
4. Square
5. Acme
6. Buttress



Types of threaded fasteners

1. Through bolts
2. Tap bolt, cap screws
3. Studs
4. Machine screws
5. Set screws

Locking devices

1.Lock nut
2. Washer

Design of bolted joints

Stresses

Initial stress

Tensile stress
Compression and shearing

External stresses

stresses due to combined load - initial and external

Power Screws

Force analysis

Design of a power screw

Design of a nut

Compound screw

Differential screw

It is necessary to determine the stresses in screw fastening due to both static and dynamic loading in order to determine their dimensions based on the strength of material being used. In order to design bolts for static loading both initial tightening and external loadings need be known.

Initial tightening load

When a nut is tightened over a screw following stresses are induced:

(a) Tensile stresses due to stretching of the bolt
(b) Torsional shear stress due to frictional resistance at the threads.
(c) Shear stress across threads
(d) Compressive or crushing stress on the threads
(e) Bending stress if the surfaces under the bolt head or nut are not perfectly normal to the bolt axis.


(a) Tensile stress

Bolts are usually designed on the basis of direct tensile stress with a large factor of safety. The initial tension in the bolt is estimated by an empirical relation P1 =284 d kN, where the nominal bolt diameter d is given in mm. The relation is used for steam tight joints. If such leakproofing is not required half of the  above estimated load may be used (142 d kN).


2. Keys 391-393
3. Joints 393 - 400
4. Shafts 401 - 404
5. Couplings 404 - 410
6. Riveted Joints 410 - 417
7. Welded Joints 417 - 421
8. Transmission Systems 421- 428
9. Bearings 429 - 434
10. Gears 435 - 438
11. Springs 439 - 442

Updated on 13 August 2020
21 July 2012

Wednesday, July 15, 2020

Manufacturing Process Selection - Prima - Swift and Booker


27 March 2014
Swift and Booker published a book on Process Selection methodology from design for manufacturing perspective.

There created a table giving material as columns, quantity to be produced as rows and possible manufacturing processes in the cells. They also described each process with a standard format.

They provided a course page having good amount of content from their book and 10 descriptions of the processes (PRIMAs)

http://www.bath.ac.uk/idmrc/themes/projects/delores/co-design-website/dpg/prosel/proselhome.html  The link is not available now to access.


15 July 2020

Related Books


Designing Capable and Reliable Products


J. D. Booker, M. Raines, Ken G. Swift, K. G. Swift
Butterworth-Heinemann, 17-Apr-2001 - Business & Economics - 400 pages

Designing Capable and Reliable Products offers an introduction to the importance of capability, quality and reliability in
product development. It introduces the concept of capable design, focusing on producing designs that meet quality standards and also looks at linking component manufacture and its process capability with failure rates. It provides an introduction to reliable design, incorporating the probabilistic concept of reliability into the product design.

This quantitative and highly practical volume provides practical methods for analysing mechanical designs with respect to their capability and reliability. Practising engineers who have to hit definite standards for design will find this book invaluable, as it outlines methods which use physically significant data to quanitify engineering risks at the design stage. By obtaining more realistic measures of design performance, failure costs can be reduced. Taking product design as its central theme, this book is a very useful tool for postgraduate students as well as professional engineers.

https://books.google.co.in/books?id=NIp5aMNECa0C




Manufacturing Process Selection Handbook
Front Cover
K. G. Swift, J. D. Booker
Butterworth-Heinemann, 15-Feb-2013 - Technology & Engineering - 456 pages
0 Reviews
Manufacturing Process Selection Handbook provides engineers and designers with process knowledge and the essential technological and cost data to guide the selection of manufacturing processes early in the product development cycle.

Building on content from the authors’ earlier introductory Process Selection guide, this expanded handbook begins with the challenges and benefits of identifying manufacturing processes in the design phase and appropriate strategies for process selection. The bulk of the book is then dedicated to concise coverage of different manufacturing processes, providing a quick reference guide for easy comparison and informed decision making.

For each process examined, the book considers key factors driving selection decisions, including:

Basic process descriptions with simple diagrams to illustrate
Notes on material suitability
Notes on available process variations
Economic considerations such as costs and production rates
Typical applications and product examples
Notes on design aspects and quality issues
Providing a quick and effective reference for the informed selection of manufacturing processes with suitable characteristics and capabilities, Manufacturing Process Selection Handbook is intended to quickly develop or refresh your experience of selecting optimal processes and costing design alternatives in the context of concurrent engineering. It is an ideal reference for those working in mechanical design across a variety of industries and a valuable learning resource for advanced students undertaking design modules and projects as part of broader engineering programs.

Provides manufacturing process information maps (PRIMAs) provide detailed information on the characteristics and capabilities of 65 processes in a standard format
Includes process capability charts detailing the processing tolerance ranges for key material types
Offers detailed methods for estimating costs, both at the component and assembly level
https://books.google.co.in/books?id=FfLpEgj5F_EC


Updated on 15 July 2020
27 March 2014

Tuesday, February 18, 2020

Automotive Body-in-White Design and Manufacturing - Bibliography


Role Of Robotic Simulation For BIW Assembly
https://www.automotive-technology.com/articles/roboticsimulation

Automotive Robotic Solutions - Pune
https://www.arapl.co.in/arapl-company-presentation.pdf

https://www.tatatechnologies.com/wp-content/uploads/2018/10/BodyInWhiteRoboticSimulation.pdf

2016

Sensors in Automotive Assembly
https://www.ifm.com/download/files/ifm-processes-in-the-automotive-industry-gb/$file/ifm-processes-in-the-automotive-industry-gb.pdf

2014

______________

______________

2013

______________


______________

19 September 2012

___________

___________


Design of Body-in-White


Automotive Body in White
http://girishravan.xomba.com/automotive_body_white

Body-in-White Parts
http://www.crateenginedepot.com/pdfs/BodyComponents.pdf


Generation of Hybrid electric vehicle BIW architecture from a styling envelop
2012 Paper
http://altairenlighten.com/wp-content/uploads/2011/12/1-Generation-of-Optimised-Hybrid-Electric-Vehicle.pdf


Strategic materials selection in the automobile body:
Economic opportunities for polymer composite design
Erica R.H. Fuchs *, Frank R. Field, Richard Roth, Randolph E. Kirchain
Massachusetts Institute of Technology,
2008 paper
http://msl.mit.edu/publications/02_Fuchs_Kirchain_CompositesEconomics.pdf



Saturn Outlook, GMC Acadia and Buick Enclave
BIW technology in the new 2007 presentation
http://www.autosteel.org/~/media/Files/Autosteel/Great%20Designs%20in%20Steel/GDIS%202007/06%20-%20Body%20in%20White%20Technology%20in%20the%20New%20Saturn%20Outlook%20GMC%20Acadia%20and%20Buick%20Enclave.ashx


Technological Innovations in Body in White Design and Manufacturing of the BMW X6
Markus PfestorfBMW GroupDuane CopelandBMW MCBMWGroup
Alternative materials and their strength discussed in this presentation
http://www.autosteel.org/~/media/Files/Autosteel/Great%20Designs%20in%20Steel/GDIS%202008/04%20-%20Technological%20Innovations%20in%20Body%20in%20White%20Manufacturing%20of%20the%20BMW%20X6.ashx


http://www.slideshare.net/altairhtcus/optimising-full-electric-vehicle-body-in-white-architecture-from-a-styling-envelope


http://www2.honsel.com/en/products/automotive/body-in-white/



The Application of Multiphase Steel in the Body-in-White
Dr.-Ing. Markus Pfestorf
BMW AG
http://www.autosteel.org/~/media/Files/Autosteel/Great%20Designs%20in%20Steel/GDIS%202005/07%20-%20The%20Application%20of%20Multiphase%20Steel%20in%20the%20Body%20in%20White.ashx

http://www.autosteel.org/~/media/Files/Autosteel/Great%20Designs%20in%20Steel/GDIS%202006/07%20-%20BMW%20-%20Functional%20Properties%20of%20High-Strength%20Steel%20in%20the%20BIW.ashx


A case study of structural optimization of an automotive biw design
2008, SAE paper
http://www.grm-consulting.co.uk/Portals/1/Docs/chrysler.pdf

Manufacturing of Body-in-White



Joining Aluminium Sheets in Automotive Industry - 30 year history
2012 January Welding Journal Research Article
http://www.aws.org/wj/supplement/WJ_2012_01_s23.pdf

Hyundai hmmausa plan - welding body-in-white process short video
http://www.hmmausa.com/?page_id=2296

A baehelor's report on Body-in-white manufacturing process - 2008 - only literature review is available
http://umpir.ump.edu.my/248/1/Mohd_Najmi_Bin_Mohamad.pdf




Meeting the Challenges of Modern Body-In-White Inspection
Leica Geosystems’ high-speed T-Scan hand scanner assures optimal part fitting
2007
http://www.qualitydigest.com/inside/cmsc-article/meeting-challenges-modern-body-white-inspection#



Automating Body-In-White
Modular bodyshop systems automate automotive manufacturing.
2005
http://americanmachinist.com/metal-forming/automating-body-white

Automating Body-In-White
Modular bodyshop systems automate automotive manufacturing.

Leslie Gordon
FEB 28, 2005
Modular bodyshop systems automate automotive manufacturing.
ABB's roller-hemming cells can feature multiple robots — one robot hems the part's upper section, while the others do the sides and bottom.



New Rapid InfraRed Curing Process - Body-in-White application
2003
http://www1.eere.energy.gov/vehiclesandfuels/pdfs/success/rapid_curing_jan03.pdf

http://solutions.3m.com/wps/portal/3M/en_US/3M_Automotive/OEMs/Product_Center/Products_By_Segment/Body-In-White/

OPTIMAL AUTOMOTIVE DOOR-BODY FlTTlNG
FOR BODY-IN-WHITE ASSEMBLY
by
Essam Shalash
MS Thesis 1996
http://www.nlc-bnc.ca/obj/s4/f2/dsk2/ftp01/MQ31001.pdf




Turnkey laser cells for in-line body-in-white applications
U. Widén
Permanova Lasersystem AB, Mölndal, Sweden
2003
http://www.permanova.se/public/browsing/GetFile.aspx?id=845




Integration of Dimensional Quality and Locator Reliability in Design and Evaluation of
Multi-station Body-In-White Assembly Processes
Yong Chen
Department of Mechanical and Industrial Engineering, The University of Iowa
Iowa City,
http://www2.isye.gatech.edu/~jshi33/Publications/JournalPapers/p54.pdf

Vehicle mass reduction opportunities
http://www.epa.gov/air/caaac/mstrs/oct2010/5_peterson.pdf

welding alternatives and cost for BIW
http://msl1.mit.edu/MIB/3.57/LectNotes/gm_tech_assembly.pdf
The above material is a part of Basic List - Materials From 3.57- LectNotes Directory of materials selection mit course  3.57 (Materials Selection & Design - Lots of Cost Modeling Information)
http://msl1.mit.edu/MIB/3.57/LectNotes/lectnotes.html



Sheet metal assembly - BIW
http://www2.isye.gatech.edu/~jshi33/Publications/JournalPapers/p09.pdf



Patents

Roller hemming machine
US20060075797A1
United States
Application US11/247,885 events
2004-10-08
Priority to US61754204P
2005-10-10
Application filed by Valiant Corp
2005-10-10
Priority to US11/247,885
2005-11-10
Assigned to VALIANT CORPORATION
2006-04-13
Publication of US20060075797A1
2006-10-24
Application granted
2006-10-24
Publication of US7124611B2
2020-02-19
Application status is Active
2025-10-10
Anticipated expiration
https://patents.google.com/patent/US20060075797


US20130091699A1
United States
2011-10-13
Priority to KR1020110104652A
2011-10-13
Priority to KR10-2011-0104652
2012-06-08
Application filed by Hyundai Motor Co, Kia Motors Corp
2012-06-08
Assigned to HYUNDAI MOTOR COMPANY, KIA MOTORS CORPORATION
2013-04-18
Publication of US20130091699A1
2015-04-14
Application granted
2015-04-14
Publication of US9003646B2
2020-02-19
Application status is Active
2033-09-09
Adjusted expiration
https://patents.google.com/patent/US20130091699

2007-10-05
Priority to US99781007P
2012-03-06
Application granted
Application status is Active
Adjusted expiration

https://patents.google.com/patent/US20090089995

GM Roller Hemming patent
http://www.freepatentsonline.com/7290423.html


Updated on 19 February 2020
19 Sep 2012

Thursday, January 23, 2020

IAS - Mechanical Engineering Syllabus and Study Materials - Notes



MECHANICAL  ENGINEERING

PAPER  I

1. Mechanics :
1.1 Mechanics of Rigid Bodies  :
Equations  of  equilibrium  in  space  and  its  application;  first  and  second  moments  of  area;
simple  problems  on  friction;  kinematics  of  particles  for  plane  motion;  elementary  particle
dynamics.
1.2  Mechanics of Deformable Bodies  :
Generalized  Hooke’s  law  and  its  application;  design  problems  on  axial  stress,  shear  stress  and
bearing stress; material properties for dynamic loading; bending shear and stresses in beams;
determination  of  principle  stresses  and  strains-analytical  and  graphical;  compound  and  combined
stresses; bi-axial stresses-thin walled pressure vessel; material behaviour and design factors for
dynamic load; design of circular shafts for bending and torsional load only; deflection of beam for
statically determinate problems; theories of  failure.


2.  Engineering Materials :
Basic concepts on structure of solids, common ferrous and non-ferrous materials and their
applications;  heat-treatment  of  steels;  non-metals, plastics,  ceramics,  composite  materials  and
nano-materials.

3.  Theory of Machines  :


Kinematic  and  dynamic  analysis  of  plane  mechanisms.  Cams,  Gears  and  empicyclie  gear  trains,
flywheels, governors, balancing of rigid rotors, balancing of single and  multicy -  linder engines,
linear vibration analysis of mechanical systems (single degree of freedom),  Critical speeds and
whirling of  shafts.


4.  Manufacturing Science :

4.1 Manufacturing Process:

Machine tool engineering - Merhant’s force analysis: Taylor’s tool life equation; conventional
machining; NC and CNC machining process; jigs and fixtures.

Non-conventional machining-EDM, ECM, ultrasonic, water jet machining etc.; application of
lasers and plasmas; energy rate calculations.

Forming and welding processes-standard processes.

Metrology-concept  of  fits  and  tolerances;  tools  and  guages;  comparators;  inspection  of  length;
position; profile and surface  finish.

4.2  Manufacturing Management :

System  design:  factory  location—simple  OR  models;  plant  layout-methods  based;  applications
of  engineering  economic  analysis  and  break-even  analysis  for  product  selection,  process  selection and capacity planning; predetermined time standards.

System planning; forecasting methods based on regression and decomposition, design and
balancing  of  multi  model  and  stochastic  assembly  lines;  inventory  management-probablistic
inventory  models  for  order  time  and  order  quantity  determination;  JIT  systems;  strategic
sourcing; managing inter plant logistics.

System  operations  and  control:  Scheduling  algorithms  for  job  shops;  applications  of  statistical
methods for product and process quality control applications of control charts for mean, range,
percent  defective,  number  of  defectives  and  defects  per  unit;  quality  cost  systems;  management  of resources, organizations and risks in  projects.

System  improvement:  Implementation  of  systems,  such  as  total  quality  management,
developing and managing flexible, lean and agile Organizations.

PAPER  II

1.  Thermodynamics, Gas Dynamics Turbine  :

1.1  Basic concept of First-law and Second law of Thermodynamics; concept of entropy and
reversibility; availability and unavailability and  irreversibility.
1.2  Classification  and  properties  of  fluids;  incompressible  and  compressible  fluids  flows;
effect of Mach number and compressibility; continuity momentum and energy equations; normal
and oblique shocks; one dimensional isentropic  flow; flow or fluids in duct with frictions that
transfer.
1.3  Flow through fans, blowers and compressors; axial and centrifugal flow configuration;
design  of  fans  and  compressors;  single  problems  compresses  and  turbine  cascade;  open  and
closed  cycle  gas  turbines; work  done  in  the gas turbine;  reheat and  regenerators.


2.  Heat Transfer  :
2.1  Conduction  heat  transfer—general  conduction  equation-Laplace,  Poisson  and  Fourier
equations; Fourier law of conduction; one dimensional steady state heat conduction applied to
simple wall, solid and hollow cylinder and  spheres.

2.2  Convection heat transfer—Newton’s law of convection; free and forces convection; heat
transfer  during  laminar  and  turbulent  flow  of  an  incompressible  fluid  over  a  flat  plate;  concepts  of
Nusselt  number,  hydrodynamic  and  thermal  boundary  layer  their  thickness;  Prandtl  number;

analogy  between  heat  and  momentum  transfer—Reynolds,  Colbum,  Prandtl  analogies;  heat
transfer  during  laminar  and  turbulent  flow  through  horizontal  tubes;  free  convection  from
horizontal and vertical plates.
2.3  Black  body  radiation—basic  radiation  laws  such  as  Stefan-boltzman,  Planck  distribution,
Wein’s displacement etc.
2.4  Basic heat exchanger analysis; classification of heat  exchangers.


3.  Engines :
3.1  Classification,  themodynamic  cycles  of  operation;  determination  of  break  power,  indicated
power, mechanical efficiency, heat balance sheet, interpretation of performance characteristics,
petrol, gas and diesel  engines.
3.2  Combustion in SI and CI engines, normal and abnormal combustion; effect of working
parameters  on  knocking,  reduction  of  knocking;  Forms  of  combustion  chamber  for  SI  and  CI
engines; rating of fuels; additives;  emission.
3.3  Different  systems  of  IC  engines-fuels;  lubricating;  cooling  and  transmission  systems.
Alternate fuels in IC  engines.

4.  Steam Engineering :

4.1  Steam  generation—modified  Ranking  cycle  analysis;  Modern  steam  boilers;  steam  at
critical  and  supercritical  pressures;  draught  equipment;  natural  and  artificial  draught;  boiler
fuels  solid,  liquid  and  gaseous  fuels.  Steam  turbines—Principle;  types;  compounding;  impulse  and
reaction turbines; axial  thrust.
4.2  Steam nozzles—flow of steam in convergent and divergent nozzle pressure at throat for
maximum  discharge  with  different  initial  steam  conditions  such  as  wet,  saturated  and  superheated,
effect  of  variation  of back  pressure;  supersaturated  flow  of  steam  in  nozzles,  Wilson  line.
4.3  Rankine  cycle  with  internal  and  external  irreversibility;  reheat  factor;  reheating  and
regeneration,  methods of governing; back pressure and  pass out turbines.
4.4 Steam  power  plants—combined  cycle  power  generation;  heat  recovery  steam  generators
(HRSG) fired and unfired, co-generation  plants.

5.  Refrigeration and Air-conditioning  :

5.1  Vapour  compression  refrigeration  cycle—cycle  on  p-H  &  T-s  diagrams;  ecofriendly
refrigerants—R  134a.  123;  Systems  like  evaporators,  condensers,  compressor,  expansion  devices.
Simple vapour absorption  systems.
5.2  Psychrometry—properties;  processes;  charts;  sensible  heating  and  cooling;
humidification  and  dehumidification  effective  temperature;  air-conditioning  load  calculation;
simple duct design.