Machine Design-I

Submitted By: Usman Hassan

Registration No: 2022-ME-115

Submitted To: Mr. Jaffer Hussain

Section: C

Date: 26-12-2024

Mechanical Engineering Department

University of Engineering and Technology, Lahore

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Contents
1 Critical Selection and Application of Engineering Principles 3

2 Objectives 3

3 Theoretical Analysis 3
3.1 Component Geometry Parameters . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Method to Determine Kt . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Calculated Kt Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 Part Modeling in SolidWorks 4

4.1 2D Sketching and dimensioning: . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Extrude the sketch into a 3D part : . . . . . . . . . . . . . . . . . . . . . 5

5 Simulation in SolidWorks 5
5.1 Apply material properties: . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2 Apply boundary conditions: . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2.1 Fixing one end : . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2.2 Applying force on opoosite side: . . . . . . . . . . . . . . . . . . . 6
5.3 Generating coarse mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.4 Coarse mesh simulation: . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.5 Generating fine mesh: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.6 Fine mesh simulation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 Experimental Calculation of Kt 9
6.1 Formula for Kt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2 Given Values and Calculation . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7 Results 10
7.1 Theoretical Kt: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.2 Simulated Results: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8 Results and Discussions: 10

9 Conclusion With Insights 11

10 Recommendations 11

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1 Critical Selection and Application of Engineering
Principles
The success of this analysis comes from using simple engineering principles to make
sure the results are accurate and reasonable. Key ideas like Kt from Shigley’s charts
help provide a basic understanding of the problem. This is supported by using modern
tools like SolidWorks. By using both methods the study combines simple models with
accurate simulations to get a strong and reliable result.This approach makes the results
more reliable and shows how important careful thinking and attention to detail are in
solving engineering problems.

2 Objectives
• To calculate the theoretical stress concentration factor (Kt) using Shigley’s Design
book.
• To simulate the part using SolidWorks and determine the stress distribution and sim-
ulated Kt.
• To compare and analyze the results from both approaches.

3 Theoretical Analysis
The value of Kt can be obtained from standard reference charts i.e Figure A-15-5 from
Shigley’s Mechanical Engineering Design

3.1 Component Geometry Parameters

The value of Kt is determined by the following geometric ratios:

• (D/d): 1.5

• (r/d): 0.25

3.2 Method to Determine Kt

To find the theoretical Kt , follow these steps:

1. Check the stress concentration factor charts in Shigley’s Mechanical Engineering

Design for a Rectangular filleted bar in tension or simple compression.

2. Locate the curve corresponding to a width-to-diameter ratio (D/d) of 1.5.

3. On this curve, find the point that corresponds to (r/d) at 0.25.

4. Read the Kt value at this intersection.

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3.3 Calculated Kt Value
Based on the reference charts, the theoretical stress concentration factor for D/d = 1.5
and r/d = 0.25 is:

Kt = 1.62

4 Part Modeling in SolidWorks

I opened SolidWorks and did the following steps for sketching and extruding the part:

4.1 2D Sketching and dimensioning:

The part consists of a rectangular section (5 in × 3 in) with a smaller extended portion
(3 in × 2 in), featuring a rounded fillet of R = 0.49.

Figure 1

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4.2 Extrude the sketch into a 3D part :
The part is a 3D extruded geometry,extruded to 0.8 in consisting of a rectangular base (5
in × 3) with a reduced rectangular extension (3 in × 2 in), joined through a fillet radius
of 0.49 in at the transition.

Figure 2

5 Simulation in SolidWorks
Simulation contains the following steps:

5.1 Apply material properties:

Material ’AISI 316 Annealed Stainless Steel Bar’ selected in solidworks with key proper-
ties: Elastic Modulus (192999.9974 N/mm²), Poisson’s Ratio (0.3), Mass Density (8000
kg/m³), Tensile Strength (550 N/mm²), and Yield Strength (137.895 N/mm²).

Figure 3

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5.2 Apply boundary conditions:
5.2.1 Fixing one end :
A rectangular block with a rectangular cutout extending from one side with one end
fixed.

Figure 4

5.2.2 Applying force on opoosite side:

A rectangular block with a cutout fixed at one end and subjected to a 4000 lbs force at
the opposite end for stress analysis.

Figure 5

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5.3 Generating coarse mesh
Rectangular block with cutout fixed at one end and loaded with 4000 lbs with a coarse
mesh for preliminary stress analysis.

Figure 6

5.4 Coarse mesh simulation:

Rectangular block with cutout fixed at one end loaded with 4000 lbs and with a coarse
mesh showing stress distribution and deformation.

Figure 7

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5.5 Generating fine mesh:
Rectangular block with cutout fixed at one end and loaded with 4000 lbs with a fine mesh
for preliminary stress analysis.

Figure 8

5.6 Fine mesh simulation:

Rectangular block with cutout fixed at one end loaded with 4000 lbs and with a fine mesh
showing stress distribution and deformation.

Figure 9

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6 Experimental Calculation of Kt
The stress concentration factor (Kt ) is calculated using the maximum stress from the
SolidWorks simulation and the nominal stress.

6.1 Formula for Kt

The experimental value of Kt can be calculated using:
σmax
Kt =
σnominal
where:

• σnominal = F
A

6.2 Given Values and Calculation

• Load: F = 4000 lbs

• Cross-sectional area:

A = (0.8)(2) in2 = 1.6 in2

Nominal stress is calculated as:

F 4000
σnominal = = = 2500 psi
A 1.6

The maximum stress obtained from the Coarse mesh simulation is σmax = 3843 psi, the
experimental stress concentration factor is:
σmax 3843
Kt = = = 1.53
σnominal 2500
The maximum stress obtained from the fine mesh simulation is σmax = 4367 psi, the
experimental stress concentration factor is:
σmax 4367
Kt = = = 1.74
σnominal 2500

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6.3 Results
The experimental calculations for Kt for various loads are summarized below:

Load (lbs) Area (in2 ) Nominal Stress (psi) Max Stress (psi) Experimental Kt
4000 1.6 2500 3843 1.53
4000 1.6 2500 4367 1.74

Table 1: Experiemntal values of Kt

Mesh Density Theoretical Kt Simulated Kt Difference (%)

Coarse 1.62 1.53 5.56
Fine 1.62 1.74 7.41

Table 2: Comparison of Theoretical and Simulated Kt for Coarse Mesh Density

7 Results
7.1 Theoretical Kt:
The Kt value obtained from Shigley’s Design book is 1.62.

7.2 Simulated Results:

• Maximum von Mises stress for coarse and fine meshes are 3843 psi and 4367 psi respec-
tively.
• Simulated Kt (maximum stress / nominal stress) for coarse and fine meshes is 1.53 and
1.74 respectively.

8 Results and Discussions:

Comparing the theoretical value of Kt with the simulated Kt as follow:
• The theoretical Kt was found to be 1.62, while the simulated Kt for the coarse and fine
meshes were 1.53 and 1.74, respectively.

The difference between the theoretical and simulated Kt values happens because of the
way each method works. The theoretical Kt of 1.62 is based on ideal conditions like
perfect shapes and materials with no errors. However, in simulations the results depend
on the mesh quality. A coarse mesh has fewer elements and cannot accurately show sharp
stress changes which leads to lower values. When the fine mesh cretaed it gives these
stress details better giving a more accurate Kt like 1.74. Still small differences remain
because of slight errors in calculations, software’s limitations and the model’s shape.

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9 Conclusion With Insights
The comparison between the theoretical and simulated stress concentration factors Kt
reveals a deviation ranging from 5.56 percent (for Kt =1.53) to 7.41 percent (for Kt
=1.74).This variation arises due to differences in idealized assumptions in theoretical
models and the dependency of simulations on parameters like mesh density and solver
precision. The discrepancy between coarse and fine mesh results highlights the impor-
tance of proper meshing in finite element analysis. Despite these differences, the error is
within acceptable engineering limits, validating the reliability of simulations for design
validation. Refining mesh density, validating results against experiments, and consider-
ing advanced material models can further improve accuracy. This study underscores the
importance of combining theoretical and simulation approaches to achieve robust and
reliable engineering designs’

10 Recommendations
To improve the accuracy and reliability of the analysis, several recommendations can be
made. First refining the mesh density in simulations is essential to reduce discrepancies
and achieve more precise results. Validating the simulated Kt values against experimental
data can provide a reliable benchmark. Accurate representation of material properties
and boundary conditions is crucial for aligning simulations with real-world scenarios.
Sensitivity analyses on parameters like mesh density and load application can identify
key factors influencing results. Utilizing advanced simulation tools and ensuring team
expertise in their usage will further enhance reliability. Iterative analysis with varying
parameters can help refine outcomes, while incorporating safety margins into designs
ensures robustness against uncertainties. These steps will improve the consistency and
practical application of theoretical and simulation-based analyses.

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