Machine Design. See attached file

Diameter ratio, fillet radius and location of the transition are detailed in the sketch . - Incorporate stress conc entration in your calculation even if the material is not considered brittle . - Option VI assigns the “design factor” for your design. The design factor is the target safety factor that you are asked to provide for your machine. Based on your design soluti ons, your final (calculated) safety factors will not necessarily be exactly equal the design factor, they might exceed it. - For each section, make sure to show ALL non -zero internal forces and moments, find the location of the point subjected to the great est combined stress and base your design off analysis of that point . - Neglect shear stress due to shear force . - Static analysis: use von Mises criterion for bulk yielding and Linear Elastic Fracture Mechanics (LEFM) assuming an edge crack of length 0.5mm of length located halfway between points B and C . - Fatigue analysis: calculate the number of cycles to failure of section BC for fully reversing loading . - Let me know if you have any questions or comments by e -mail ASAP and I will update this page . - Material properties for steel can be found in Text Table A-9 and in the AISI1040 table included with the assignment . The fracture toughness values are: AISI 4140 (normalized ): K IC = 60 MPa*m 1/2 (54.6 ksi*in 1/2 ); AISI 1040 (as forged): K IC = 50 MPa*m 1/2 (45.5 ksi*in 1/2 ) Deliverable : PDF of the final report Report requirements: Projects will be graded based on the reports. Imagine your report being read by a person who found it online and wants to understand what you did for the course project. • make sure to provide sufficient details on all aspects of your analysis and design • your report has to be professional in terms of language, formatting, graphics, absence of obvious misprints and omissions (all these will be considered during final grading). My strong recommendation: plan to finish the report several days before it's due, put it away for one -two day s, reread and correct the new mistakes you find • make generous use of graphics, but do not overdo it • formatting: 1" margins, double space d; 11pt Times New Roman; all captions (tables, figures) - 9pt Times New Roman • plan ahead Content :

o cover page (course number title, instructor, semester, title of the project) o abstract (separate page, limit to 400 words, mention the design objective, discuss key elements of your final design) o analysis and design ▪ describe design and purpose of a winch ▪ provide a copy of the sketch below along with a table of your options and material properties ▪ static analysis ▪ cross -section dimensions are unknown, you must design them. Treat each section separately ▪ include diagrams of internal forces and moments for each section (use some software, do not provide scans of hand -drawn sketches) ▪ identify the most dangerous locations in each sect ion (justify your answer) ▪ find points with maximum stresses in each "dangerous" cross section ▪ find equivalent von Mises stresses for the "dangerous" points ▪ find the minimum dimensions (where appropriate) to prevent yielding (don't forget about design facto rs) ▪ in case minimum dimensions cannot be found (too many unknowns), substitute standard dimensions starting with the smallest you can find and working your way up until the design criteria are satisfied , see STEEL TUBING table included with the assignment ▪ find the final safety factor once the standard dimensions are selected ▪ check whether an edge crack of 0.5mm in the middle of the section BC will grow under the given loading and with the selected cross section dimensions. If your analysis shows the crack w ill grow, provide recommendations on how the part can be fixed (cite your sources) ▪ fatigue analysis ▪ consider section BC and assume that there is only internal bending moment due to fully reversing force Fz ▪ focus on point C and calculate the number of cycles to failure ▪ make sure to include C_size and C_surf modification factors (for C_surf parameters of AISI 4140 (normalized), use as -forged surface finish parameters from Table 6 -3) ▪ deflection analysis of point A in the z -direction (I recommend using Castigliano's theorem, but other approaches are also allowed) ▪ bonus 10 points for : ▪ 4-view drawing with dimensions of the final CAD model: top, front, right and isometric (create one with final dimensions and cross sections, see software recommendations below; separate page, landscape orientation) ▪ bonus 10 points for: ▪ FEA stress analysis of the component. Include original shape, exaggerated deformed shape, contour plot of von Mises stress distribution, calculate safety factor, ide ntify most likely failure location. o references (if any) Software recommendations : Report : Microsoft Word or LaTeX (make sure to show your calculations) Calculations : Matlab or calculator CAD model and FEA : SolidWorks, Marc/Mentat (available for UNH students in ME cluster ) or Abaqus . Use whatever is more convenient in terms of access; see tutorials in the software, online. Deadline Final report must be submitted by 11 :59 PM on Tuesday May 11 . Options Make sure to use your own set of options . The key will be provi ded as a comment next to your HW#5 grade