Assignment -2
Fxplain thne steps in volved in de siqn process.
factos
what is facfoy of safey 2 oh at ave the
affecfng fackoy of safehy ?
Steps inv olved in design PoceSs o
e Step l Product Speei fieaiens." o
The fiyst step consist of pveparinga
Complete ist of tne veauiements of the prodet.
output eapacihy
The vequivements incude theseovice
of the machine, and its ife, ost anc
Sn some cases the ovetall dimensins
eiability.
Cnd weiaht of the ymo duet ave 'speefied.
a: seleeion of Mechanisn
Peles cavehul sudy of the icayivements.
the dcigynes prepaves nough sketehes of
different poscible meehanisms foy the product.
The alternative mech anisms ave compared with
eash othes and also wite the mechanism of
he voducts that ave avaulable n the masket.
eot
An apptoximate csimaton of he ost of each
altemathive con fiqurahon is made and compavel
woith the cost ot exishng roccts. while
seuckng the nal con hgurahon ithe deiqney
should consi des whethey the taw matenala ad
standand pats neqizad foy makln tne
roduct ave available in the masket
Depending upor the cost- compehthyeness,availab
f saw maBenas and manutachiny faikhy
tne bes possible mechaism is seected foy
the pnoduct
Ste 3 : Layout of coniguration.
.he net step in a Aesign proedure u to
Pepare a block di aqram showing the geneial
layputf ne scleel ed conhquration. his
stepi the desi anespeei fies the joining
such as rive hng boling- oyoy welding to memoa
conne
te indivi dual weldhng
tomponents.
Step'y: Design of Lodividua componenb .
Ths step concis of ne folleuing stages 1
) oetesmine the forces achnq on the kom
poneat.
seeet pro pes mateial foy the
lomponent
dupending upon he funehonad teauiremenb
sueh as shength, igdiy, hardness and
weay esistance.
(h) Detesmine the ikey mode of faiune boy the
tomponent and dependinq upon it, seket he
citefon of faiye, sueh as yield strength,
ulhimate tensile stength.
iv) Dete mine he qeometne dimensiong ot the
Componen wing a suitable factoy of safehy
and modihy the dimensions fron assembuy
and manusaching Considerathons.
design proes is to
The last stage in a
assembly and the
Prepare diausings of the these drauings,
indivi dual tomponents. On dimenions
com ponent its
the mateal of the and
to\esanes,surfae tinish grades
machining ymbols aYe speci hed .
Factoy of safe y i- S
hile desi ging Component, it u
neuss ay 4o poi de suttiient ieS CTVe shent
in case of ann accdent. 1his is achieved
by taking suitable factoy of Satehy ( 5s)
fs = aiure stess
Allowable s e s s t c )
-he factoy affeuting the RachoyR sateky qye :
. effecd of failuye
3. Pegre of acusay in fovce analyst.
4. Matenal of component.
5. Reli ahiity of omponent.
b Cost ot componen
t Testing of machine element
8. Servee condihone
4 quai hy of manafa chuye
Explain the etfect of shbess coneeaton bn
duu cile and bittlo mateials undey stahe
and vaiable loaing
?sh2
Ans ) Duehile Mateials unde staie Load i
Vnder a staio oad
tsoVnder dueile matexals
ave not alfeted, byrshess cencuntator,to
the cxtent that photo- elastiu anaysis might
jndicate when the stss in the vicinihy of tne
disconfiity veaehes ne yield point tnere is
plastie detomaton,1esuling in a vedishibution
of shesses. This plasthe deto mator or yielding
s loca and estnted to a vey small avea
in the componunt There w no perephble
to tne payt as a whole. herefoye it
damage
is cornmon pyacti ee to iqnove the heoreheal
styess conientvahion factos fo component
hat ave made of duchle mateials and
Subieted to stahte Load.eeb
o Duchle Mateials unde Pucahng,
Howeves,ohen the load is Puchuaing.
Ane shss t ne dis coni nities mayy exceed
the endu ance imit and i hat cuse, the
Compenent mayy til fatig
bykahge. hesefoye
enuanu imit ofhe components made ol of
duchle matenial qneatuy vedee d due to
ncentation. Thi acounts foy tne
styess co
ionent ation factors foy duchl.
Wse of 6tsess
Componets. How eves, some mate nas aye
Moye senstve hanothers to Styess ai sina
nothes under a Ructuatin q toad o accoun
foy this etfect, a parametey ealed note
sensihih factoy t found foy each mateial
) 6ite matesials :
The eftect f hess oneentation is
move' seweYc Bn casc of bitMe mateials
due to theis aabiihy of plashie dema.hon
bitle materials do not yield loealey and
no veadjustment of shyesscs af the
dàs continihes. Once the lbcal shyess at he
disconhnui hy Neaches the Gachuye shengtn, a
Crackis fomed. This vedues the mateñal
availa be to vesist extema. oad and also
Inncases Ahe shess onuntaion at he
sack. he past then uiekly fails. heochos
stess onentya Hon fuctoys ave used o
compornents madeot bitte matenals
subjeeted to both steic as well as
loads. fuchahng
3. what are the fa choys af
feetina the eadasane
Ans(a) süsfac fnish Facho - (Ka).
hen he surfae fnish is pooy, these
arye Suratehes and geomehic inegulaiies,
on the surtace. Thesc sus tace scY atehes sevve
as .shes5 Yaisers and esult in, st ess
oncuntraion. The enduyane imit ia edueed
due to intro dueion of styess conuntaion
at nec seratchs. Az the ultimah tensile
sength inveaes, sutaee hnish factoy
dereascs.
(b) siz< factos: (Kb)
the machine pat, the
The larqes
probablihy that a flaw eas ts
qveateo tne
gYeates chances
s0yme wheYe in the Component . he
{ fai que failure oviginahng at any one of
hese faos one move. he endanee
Umät hesetoye,veduces oitn inereaing
the siae of the co mponnt.
C) Reiabi ihy fachoy ( Kc):.
The laboyahoy values of enduYanee
irmit are wsualy mean values. he standayd
deriahion of enduyane init tests i
fne mean vaue. The aeiabiihy tatoy K,
|dupenda upon the neli ability tnat i used,
n n the design of tho
component. me qteater
the ikihood mat a paYA lI suy ivene
Move is the tciabiihy and lawey s Ane
seli abiahy facoyilh
(a) Mod hying fa choy to avtount foy shess
Goncentrahon ( Ka):
he lndutance Lámit is edue d
due to stess
coneentrathonn. he styess
3
tonentnahar
Tedicethe
,tne deiqney can eithes
undun unit bu lkd) °
nvease the shess ampitude by
Kd
Ke
he above menhoned fou fachovs ave scd to
Aad out the enduanee i i t of tne aehual
fnd
compornt.
4. 5how by neat ske tehes he vanons modes
ef faiuve of veted joints ?
Ans: Vaiow modes of failuve are :
(a) sheay faiue of ivet.
(a
(b) Kensile faiuoe of plate behw en vel
Cc) Cushing Pailure
faiuse of Plate by Rivef :
ca) Sheav Failuve of Plate bu,
by Rivet.
1
feaing of Margin
5.
ohy do we desiqn tne weld joints ba ed
on hyoat aka 2
ns: The thdo at avea is the cttecive coe
$ecional ayea of the weld at its nawest
point. Reasons ohy thvoat area is an
imposfant consi desahon in weld joint testans
aYe
() Load Tran s iesio
he h1oat aea of a weld detemins
|how eHe cive it can tansmit th appied
load between the tuoo conneefed
memoers.
A larqe1 throat avea means a gieatey
Setional avea availabe hoy load tianstey
NulHing in a stronges and move etheient
eldjoint.
(2) Stength consi da raions i
he thyoat avea dieoity infucn es
no stenqth of the weld.he design hen
of a weld is caeatd bacd on yoat
have
ayea.
by deeigring he weld joint o
Speei hed ini mum hroat avea ,engineers
ean esure that the weld oill meet the
naired shengtn cite ria for the iatendd
applicaion.
) wele leg ungt i
he hvo at avea is velated to the
leq ength of the weld, ohich is the distanee
Prom the oot of.the weld to tne toe. lhe lea
lengt a fects the weld's penehaker and
ovevall stengte.
4) Consisteney and qualihy -
Pesiqning weld joints based on toyoat
avea helps eneuYe consistency and yalihy in
fabi eati on. By speeihyina a minimum that
4Ya, emoineers estabish a measurable
emteion hat wldess ea Rollow to aehieve
Consi stent weld dimensi ons. his pvomotes
and helps prevent undey - or
auaiy Contol
me
Oversizd weldswih ean attect
Perfomance of hhe goint,
6. ohat t surgingin spings ?4
Ans Ohen the natral teaneny ot ibyak.
of he sping cincides oith he freaeney
of xtemal penio die force (ohic aets on
Yesoanee oceuYs. Ln this state, tne Spina
ubected to a wave of 3ueeessive
COmpvessions of coils that travels om one
end to the othe and baek. his tyee of
nbyatoy moion i called surgelo f sping
Surge is found in valve spfnqs ,whieh are
subjecte d to (eriodie orce. burge ls the
Mam eause offure in valve
iginge.
+.
Explain about eaulEing and falle ing on
viveted joints g
n appi eatons ike PYessure Vessels
and bálers he iveBed toin t should ba
lzakyoo and feid Hght and
Caulbingobtam
Rulle iny {oeesses ave wsed to
such
leakppoot iveke d foint. he caulking
proess b appied toho the edqes ol plates m
a lapjoint and the edoes of stap plate in
a butt joint Mese edqes ave hrst beveled to
and the
cauleing
tool is hammesed bn he edae. he cauihing
done eithes by hand hammey or by ihe
pneumahe o hydai hammer.
The head ot e mvet is aso hamnmed
dosn ) h ne
lauikinq touf
caul n
tool. he blows o
docs the Osuyface aspcihes and
saeks on tne conhactna su taces behween
hoo plates and lo behoen he ivet anl
the plates ,esultmg in leakpoof joint.
qeannot bo applied to plates ih
caulling
ess tnan bmm hic kness.hib
b similas to cal king ocess
fulleing
Keept f me shape of the too . The asidtn
ot the fulleing hool is equal to me tnickness
of he plate being hammered. he blows of
|he fuieing too YesuW m simultaneous
rrssure on the entie edye of tne plate
ohat ay& ne demeits of
welded joink
* As compave d uoit he cast iron stuck
he eapaci by of welded stmetue toto damp
vibrahions á poo y.
wel ding nesults in a themal dchoo.
"f me pab, theveby indeeing uidual
shesses.
4 he quaihy and shena th of the welded
join t depend upon the skill of me wldey.
u di Pfet to contol tne
a
quaihy when
numbey of weldus are invo\vedr
he inspeoi on of the welded joints ii
move speialiscd and cos tay kom pared otlih
the inspeehion of iveted oy taut stuefes.
4.
what isb wld nçn fovcement ohy is it dont
Ams
Rein fo vument in oelding is he tem
wazd
Wsed Ao descibe the ouess of ot im corpahng
addihona mateial in to a weld joi
oyder to împrove it3 shenghu oy othes
Mechani cal yopehes. he mos4 o o r
fomn of Nein fur eement u he addihon f
metal kLex matenial,but othe mateials
Suc as ceraies o plashes carn aLso be
used. Rein uycment ean also be aehien ed
by addm q mateial to he base me tal
qround tne weld joint, knownn as
claddiny
ngneral, the amount of vein fovcemint
should be kept tola minimum ,as too mue
neintove ment can weaken tne weld joint.
Reinfocement is often uscd when
oclding metals tnat ave subject to hi gh
levelsoshess stain,guch as moe uscd
in tme consmeion ot bidges oy essure
Ye.
et can also be sed to ve paiz damaged welds
oy to imMpyove hme appeaanee of a weld joit.
10. Lhat ae tho veqivemenb of a spohng.
mateial 2
* sping mateials should have high
gield shength and low modulus of ela huh
so tnat ney dont pemanenty de fom
und e the applied loads
spingsave made of matemals hat ean
be fomed to high sheng h and getan
enough du eiihy to fom oy ne alloy
ean be heat tyeated to hig hsength and
duchuhy befove of t tes foming. both hoty
and col woking roesses ave scd foy
manu fachin g spoengs.
* he seleekon of process dupen ds upon siaeof
mateial,imng
bpnng index and dhe propehes
desived.
* windmqs of sping indees eii dual
sheses due o bendingiohi ch are velead
with the hetp of heat ea hment.
* Mateials wsed foy spings aye
atn canbaiy
steels, alloy stels and also he non- feus
mateials uke phosphoy bonzes, sping bras,
and vaiows ickel alloys
