2.

72 Elements of Mechanical Design

Session #1

Course Introduction

Instructors = Dan Frey and Amy Smith

Todays Agenda
What is this course about? Who are the instructors? Course structure, expectations, policy, etc. Pass out first reading packet

Introduce project ideas

Topics of Interest

Photo courtesy of Audrius Meskauskas. Source: Wikipedia.

[Photos of electric motor, small circuit board, and diagram of prosthetic hand (vector prehensor) removed for copyright reasons.

Photo and courtesy of Jared C. Benedict. Source: Wikipedia.

Amy Smiths hammer mill for grain

Blooms Taxonomy of Educational Objectives

Educational Objective 5. Synthesis 6. Evaluation 4. Analysis 3. Application 2. Comprehension 1. Knowledge Associated Action Verbs Design, invent, propose Judge, critique, justify Predict, model, derive Calculate, solve Explain, paraphrase List, recite

Learning Objectives
Design electro-mechanical devices making advanced use of the core mechanical engineering disciplines For all the common machine elements including fasteners, joints, springs, bearings, gearing, clutches, couplings, belts, chains, and shafts Describe the function of the element List common uses in mechanical systems and give examples Analyze its performance and failure modes based on core disciplines Describe how they are manufactured and the implications of the alternatives Select an element for a specific use based on information such as that typically available in a manufacturers catalog Apply statistical principles relevant to mechanical design Communicate a design and its analysis

Dan Frey
Research on
Systems engineering Robust design Reliability
Run a resolution III outer array of noise factors Change one control factor b a c b b a c b A a c Repeat the outer array. If there is an improvement, retain the change Reverse any changes that appear unfavorable before proceeding with further exploration Repeat the process for each control factor

B C a c

Formerly a Naval Officer Hooked on 70s cars

Amy Smith, MIT 84, 95?? Inventor/Instructor at the Edgerton Center Peace Corps Volunteer, 1986-1990

Design for Developing Countries Agriculture Energy Water Health

Todays Agenda
What is this course about? Who are the instructors? Course structure, expectations, policy, etc. Pass out first reading packet

Introduce project ideas

Grading
Homework (8 assignments at 5% each) Exams (2 exams at 15% each) Project Participation 40% 30% 25% 5%

MIT Grading Policy

A - Exceptionally good performance, demonstrating a superior understanding of the subject matter, a foundation of extensive knowledge, and a skillful use of concepts and/or materials. B - Good performance, demonstrating capacity to use the appropriate concepts, a good understanding of the subject matter, and an ability to handle the problems and materials encountered in the subject. C - Adequate performance, demonstrating an adequate understanding of the subject matter, an ability to handle relatively simple problems, and adequate preparation for moving on to more advanced work in the field.

There is no curve in 2.72

Collaboration
We encourage you to work together and learn from one another What you submit should be your own work Acknowledge the contribution of others The course policy handout lays out many examples:
After working an assignment independently, you compare responses with another student which alerts you to an error in your own work which you then correct. You should state at the end of your submission that you corrected your error on the basis of checking responses with the other student. No credit will be lost if the response is correct, the acknowledgment is made, and no direct copying of the other response is involved.

Time Required
This subject is 12 units 3-3-6 3 hours of lectures 3 hours of lab 6 hours outside of scheduled class time
Reading ahead / studying for exams Doing homework Doing your projects

Computers and Software

We will use computers a lot Everyone should have a laptop for 2.72 The laptop loaner program will set you up if you dont have a laptop We will use
MathCad SolidWorks Working Model

Labs
Fridays 2-5 Meets in Ocean Engineering Teaching Lab A required element of the course Hands-on activities to support
Learning the content Advancing your projects Linked to homework and exams

No formal lab reports

Projects
Content
Electro-mechanical design Machine elements

Teams of typically 3-5 Budget = $500 Required elements

Significant, challenging objectives Analysis to support design decisions Working hardware Measurements Well-documented

Todays Agenda
What is this course about? Who are the instructors? Course structure, expectations, policy, etc. Pass out first reading packet

Introduce project ideas

Project Ideas
Phase Change Incubator Vector Prehensor Peanut Press WGBH bicycles Pedal powered cement mixer SAE shocks Foldable walker Tie-in to ocean capstone

Phase Change Incubator

Photos: Amy Smith

Photo removed for copyright reasons.

Photo removed for copyright reasons.

Battery-operated field incubator $1250

Thermo-electric field incubator $500

Phase change incubator $50

Deliverables
Proof-of-concept prototype
Production rate: >5 balls per minute Leakage rate: <1/1000 balls Cost: <$0.05/ball

Vector Prehensor:
Need for Adjustable Prehension
Upper limb amputees most often use body-powered, voluntary-opening hooks Hooks usually provide just one grip force But a variety of grip forces are needed throughout a typical day

The Current Designs

Photos / diagrams removed for copyright reasons.

A Remaining Challenge
We were never quite satisfied with the polyurethane springs fatigue life In theory, steel springs should be able to store as much energy per unit volume and would have a longer life

Ashby diagram of ModulusStrength removed for copyright reasons.

Deliverables
Redesign the spring and/or prehensor Provide a life of 10,000 cycles Match characteristics of current design Build a prototype Provide data to demonstrate performance

Peanut Press

Deliverables
Proof-of-concept prototype
Throughput: >5 kg/hour Ergonomic power stroke Cost: <$500

A New Childrens Television Show

Saturday morning television, movies, and other popular media should be strongly pursued to incorporate engineering, math, and science messages. The full resources of the engineering professionshould be brought to bear on this action.
Lance A. Davis and Robin D. Gibbin (editors), 2002, Raising Public Awareness of Engineering, report of the National Academy of Engineering Committee on Public Awareness of Engineering, National Academies Press, Washington, DC.

The Concept
Kids design and build things in response to challenges posed by other kids Sometimes practical, often whimsical Real technology, not just junk Reality TV format
team competition with recurring players

Interactive media tie-ins

Show video clip?

An Episode on Bicycles
Think of the unusual variants of bicycles that are possible Perhaps consider how a CNC waterjet cutter creates possibilities Demonstrate one exciting example and, if its good, it will be featured in an episode

Photos of bicycles removed for copyright reasons.

Project Deliverables
A working bicycle Analysis and experimental assessment of performance A list of needed materials and components Lessons learned document for use this summer in filming the episode

Problems With Narrow Passages

Standard walker is often too wide for the users everyday environment, including their home. 1988 Housing Act to make door widths at least 32 inches wide.

The Problem
Design a walker mechanism that allows width adjustment, while maintaining structural stability and parallel sidebars.
Specifications:
Width spread of at least 18 32 inches. Input control while in use. Locking feature. Maximum weight capacity 300 lbs.

Deliverables
Detailed mechanism analysis Functional drawings Analysis for safety (weight capacity) Functional prototype

Formula SAE
A great club at MIT International competition every spring MIT is making progress each year

Photo of cars removed for copyright reasons.

Need for a Shock

Photo of shock absorber and graphs of force vs. velocity removed for copyright reasons.

Project Deliverables
The design well documented so that it can be judged A prototype Test data demonstrating desired performance

Photo removed for copyright reasons.

A Shock Dynomometer

Pedal Powered Cement Mixer

Photos removed for copyright reasons.

Pedal Powered Cement Mixer

Picture removed for copyright reasons.

Deliverables
Proof-of-concept prototype
Capacity: 2 gallons Power source: human Cost: <$100*

* excluding the cost of used bicycle parts

The Ocean Engineering Capstone

Diagram of kayak outfitted for ocean sensing application removed for copyright reasons.

Azimuth Motor

Photo of motor in kayak removed for copyright reasons.

12v Servo motor Integrated encoder Watertight housing Self-homing

hall sensor & magnet

Chain & sprocket drive:

3:1 reduction

Proportional control with 60 degrees per second max slew rate Power consumption:
2 A @ max slew

Project Deliverables
Find a machine elements challenge within the ocean engineering capstone Negotiate timing and deliverables with them and us Create hardware Prepare analysis and experimental data to demonstrate performance

Next Steps
Right now, a walking tour of labs Soon, read the handout on gears
Shigley and Mishke chapter 13

Next class session is Thursday 9 FEB right here Begin to develop project ideas
Email your slides to Prof. Frey by Friday noon

On Friday 10 FEB (right here) you will present

A project idea OR what youre looking for in a project Who are you? What do you bring to a project team? Then fill out a project preference form

On Tues 14 FEB (right here) project teams will be announced