Cosme Furlong's ME-3320

Center for Holographic Studies and Laser micro-mechaTronics (CHSLT)
NanoEngineering, Science, and Technology (NEST)
Mechanical Engineering Department
Worcester, MA 01609-2280
Cosme Furlong

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ME-3320. Design of Machine Elements
Term A, 2011

GENERAL INFORMATION

COURSE No.:           ME-3320, A’2011
REQUIRED TEXT:   R. L. Norton, "Machine Design. An Integrated Approach," Fourth Edition with CD
                                 Prentice-Hall, NJ, 2010

RECOMMENDED
TEXT:                      B. Hamrock, S. R. Schmid, and B. Jacobson, "Fundamentals of Machine Elements," Second Edition
                                 McGraw-Hill, NY, 2005

LECTURES:             M, Tu, Th, F @ 9:00 AM, Room WB-229
LAB MTGs:             Tu @ 10:00 AM, Room HL-230

INSTRUCTOR: C. Furlong
HL-151
(508) 831-5126
cfurlong@wpi.edu
http://www.wpi.edu/~cfurlong
OFFICE HOURS: M, W, Th, and F from 10:00 to 11:00 AM or by appointment (in HL-151).

TA: Brandon Bacon
HL-309/310
(508) 831-5976
baconb@wpi.edu
OFFICE HOURS: M, 1:00 to 1:50 PM
W, 1:00 to 1:50 PM (both in HL-310)

HELP SESSIONS:
                                First session:        Mondays at 2:00 pm, in HL-230
                                Second session:    Thursdays at 2:00 pm, in HL-230         ALL HELP SESSIONS BEGIN ON: Thursday, Setp 01, 2011

GRADING

THE GRADE FOR THE COURSE WILL BE BASED 60% ON THE EXAMS and 40% ON THE DESIGN PROJECT. Participation in course discussions will be taken into consideration.

HOMEWORK

PLACE ALL OF THE ASSIGNED AUTHOR’s EXAMPLES AND SOLVED PROBLEMS INTO A THREE-RING NOTEBOOK. Instructor will ask you to submit several of those problems -- randomly chosen -- for grading at each exam.

EXAMS AND DESIGN PROJECT

THERE WILL BE SEVEN (7) EXAMS, AND ONE DESIGN PROJECT, which will involve the use of computational tools (e.g., Matlab, MathCad, ANSYS). To ensure fairness in your evaluation, the lowest exam score will be dropped.

Most exams will be given on Tuesdays, during our Section/Lab meetings. Exams are open books and open notes. Each exam will include all of the material covered until Friday (inclusive) except during the last week of the term when exam will include all of the material covered until Tuesday (inclusive).

Do your best in attending Help Sessions. Key homework problems will be reviewed (Mondays) and Mathcad tutorials (Thursdays) will be given at these sessions.

DESIGN PROJECT

Objectives: (a) detailed design of the main shaft and selection of corresponding fixtures; and (b) detailed design of the tower of a Vestas' V52-850 kW wind turbine. Design Project is due the last day of the term, but it requires substantial work during the term to complete.

Selected technical references:

Vestas: V52-850 kW turbine
Technical paper: J. Twidell, "Technology Fundamentals: Wind Turbines," Renewable Energy World, pp102-111, 2003
The Wind Turbine: components and operation, Bonus Energy Newsletter, Denmark, 1999

COURSE OUTLINE
Entire Outline is here

First week:

DATE and LECTURE	TOPIC	READING ASSIGNMENT	HOMEWORK ASSIGNMENT
1. Aug 25, Th	Course organization. Introduction. Units. Work. Power. Engineering design methodology. Design Project for this course.	Ch. 1 and Ch. 2. Review notes and text: ES2001, ES2501, ES2502, ES2503	Author’s: 1-1 Solve: 1-5, 1-6, 1-9 (click here), 1-10 (click here)
2. Aug 26, F	Review of material properties. Stress-strain diagrams.	Ch. 2. Review notes and text: ES2001	Author’s: Solve: 2-1, 2-4, 2-8, 2-15, 2-21

Second week:

DATE and LECTURE	TOPIC	READING ASSIGNMENT	HOMEWORK ASSIGNMENT
3. Aug 29, M	Review: force analysis; free-body diagrams.	Ch 3. Review notes and text: ES2501, ES2502	Author’s: Case study 4A, 3-2A, 3-2B Solve: 3-1, 3-4, 3-8, 3-10
4. Aug 30, Tu Section Mtg. and Lecture	Force analysis. Location of critical section. Force flow method. (Included Design Project Report #1: format, specifications) Report #1 due next Tuesday Exam I. Project discussion. Homework review.	Ch 3. Ch. 1 and 8.	Author’s: 3-3A, 3-3B, 3-4 Solve: 3-23(b,h), 3-24(b,h) Solve: 1-7, 1-8
5. Sep 01, Th	Normal, shear, and principal stresses. Mohr’s circle.	Ch. 4: 4.0 to 4.6	Help session: 2:00 - 2:50 pm HL-230 Author’s: 4-2, 4-3 Solve: 4-1(a,c,f,i), 4-4
6. Sep 02, F	Stress distribution in cross-sections under load.	Ch. 4: 4.7 to 4.11	Author’s: 4-4, 4-6 to 4-9 Solve: 4-18, 4-22

Third week:

DATE and LECTURE	TOPIC	READING ASSIGNMENT	HOMEWORK ASSIGNMENT
7. Sep 05, M	Labor day No classes
8. Sep 06, Tu Section Mtg. and Lecture	Exam II. Project discussion. Homework review. Beams Mathcad Sample: fully-constrained beam (example E4)	Ch. 8. Design case studies Ch. 4: 4.12 to 4.19	Author’s: 4-9 Solve: 4-23e, 4-24e, 4-25e, 4-26e
9. Sep 08, Th	Columns. Torsion. Cylinders	Ch. 4: 4.12 to 4.19	Help session: 2:00 - 2:50 pm HL-230 Author’s: 4-8, 4-10 Solve: (4-33, 4-34, 4-35, 4-36) rows e and m, 4-42, 4-51 (all cases), 4-52 (all cases) Project report #1 due: a. Introduction b. Background c. FBD's See course notes for report format
10. Sep 09, F	Columns. Torsion. Cylinders continued Remarks on columns	Ch. 4: 4.12 to 4.19

Fourth week:

DATE and LECTURE	TOPIC	READING ASSIGNMENT	HOMEWORK ASSIGNMENT
11. Sep 12, M	Static failure theories: ductile materials	Ch. 5: 5.0 to 5.1	Help session: 2:00 - 2:50 pm HL-230 Author’s: 5-1 Solve: 5-1(g,h,i,j) 5-4, 5-23e, 5-25e, 5-33m, 5-34m
12. Sep 13, Tu Section Mtg. and Lecture	Exam III. Project discussion. Homework review. Static failure theories: ductile materials, continued	Ch. 8: Design case studies Ch. 5: 5.0 to 5.1	Project report #2 due next Tuesday, Sept 20, at lecture time: a. Updated FBD's b. Critical Sections c. Critical Points d. Stress Analysis Comments on Report #1 Work on your Design Project
13. Sep 15, Th	Static failure theories: brittle materials, continued	Ch, 5: 5.2 to 5.5	Help session: 2:00 - 2:50 pm HL-230 Author’s: 5-2 Solve: 5-10, 5-12, 5-30, 5-35m Work on your Design Project
14. Sep 16, F	Static failure theories: brittle materials, finish See lecture notes for: (a) design project; (b) extra credit problem	Ch. 8: Ch. 5: 5.2 to 5.5	Author’s: 5-3 Solve: 5-36m, 5-39, 5-42 Work on your Design Project

Fifth/Sixth week:

DATE and LECTURE	TOPIC	READING ASSIGNMENT	HOMEWORK ASSIGNMENT
15. Sep 19, M	Fatigue failure theories	Ch. 6: 6.0 to 6.4	Help session: 2:00 - 2:50 pm HL-230 Author’s: Solve: 6-1(a,b,c), 6-2(a,b,c) Work on your Design Project
16. Sep 20, Tu Section Mtg. and Lecture	Exam IV. Project discussion. Homework review. Fatigue failure theories	Ch. 8: Design case studies Ch. 6: 6.0 to 6.4	Project report #2 due at lecture time Author’s: Solve: 6-5(a,f,k) Work on your Design Project
17. Sep 22, Th	Fatigue failure theories	Ch. 6: 6.0 to 6.4	Help session: 2:00 - 2:50 pm HL-230 Author’s: 6-1, 6-2, 6-3 Solve: 6-15 (all cases), 6-19 Work on your Design Project Project report #3 due Tuesday, Oct 04
18. Sep 23, F	Fatigue strength and stress concentration factors	Ch, 6: 6.5 to 6.8	Author’s: 6-4, 6-5, 6-6 Solve: 6-23(a,b,c), 6-33m, 6-34m, 6-42 Work on your Design Project

Seventh week:

DATE and LECTURE	TOPIC	READING ASSIGNMENT	HOMEWORK ASSIGNMENT
23. Oct 03, M	Shaft design	Ch. 10: 10.0 to 10.8	Help session: 2:00 - 2:50 pm HL-230 Author’s: 10-1, 10-2 Solve: 10-1e, 10-4e, 10-9e Work on your Design Project
24. Oct 04, Tu Section Mtg. and Lecture	Exam VI. Project discussion. Homework review. Shaft design	Ch. 10: 10.9 to 10.16	Project report #3 due at lecture time Author’s: 10-3, 10-4 (solutions must include your numerical determination of deflections) Solve: 10-15e, 10-19(a,b,f) Work on your Design Project
25. Oct 06 Th	Shaft design: Natural frequencies of vibration. Numerical integration	Ch. 10: 10-14	Help session: 2:00 - 2:50 pm HL-230 Author’s: 10-8 (solutions must include your numerical determination of deflections) Solve: 10-14a Work on your Design Project
26. Oct 07, F	Bearings and lubrication	Ch. 11: 11.0 to 11.7	Work on your Design Project Author’s: 11-1 Solve: 11-1e, 11-3

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