MEE552 Optimization Methods

Unit 5 Optimization Design of Machine Elements

General Characteristics of Mechanical Elements

1. All mechanical elements must satisfy certain functional requirements of the structure or machine wherein they are used. A functional requirement is a condition which must be satisfied by the mechanical element if the structure or the machine is to function properly. In the strict sense, functional requirements can either be positive and generally specified, or negative and generally implied. Ex: Design of a mechanical extension spring
In the design of a mechanical extension spring the function requirements of the machine from the spring might be a certain maximum force Fmax and a certain force gradient k. The values Fmax and k would be positive function requirements, since they must be directly obtained for proper functioning of the machine and they are conditions which we want. Maximum shearing stress in the spring wire should be equal to or less than an allowable shearing strength of the material, using an acceptable criterion for failure due to fatigue.

However, this specification is really for a negative functional requirement, since it states a condition which we do not want.

General Characteristics of Mechanical Elements

Negative functional requirements are really undesirable effects, where as positive functional requirements are really desirable effects. One example of functional requirements is shown in figure. In figure, in order for the mechanical structure to function properly, the beam must transmit a maximum force Fmax and it must have a specified length L.

Functional requirements are influenced by factors which are external to the element being designed, and this is generally true for mechanical elements. The functional requirements of an element are not always independent of each other.

Simple Beam

General Characteristics of Mechanical Elements

Hence functional requirements, if they can be changed at all from their specified values, are often dependent on each other as the results of conditions external to the element. Functional requirement is not always limited to a specific single value to obtain a satisfactory mechanical design. There might be a satisfactory feasible range over which a functional requirement could have a satisfactory value. Associated with functional requirements we often have limit equations, which define a satisfactory range for values of the functional requirement. The limit values for any range might very well be rigidly (loosely defined) established by explicitly defined unchangeable factors external to the element under design.

General Characteristics of Mechanical Elements

2. At least to some extent, all mechanical elements have certain undesirable effects. Associated with all mechanical elements is the very important undesirable effect of cost. Other common undesirable effects of importance might be deflections, stresses, weight, space occupancy, vibration, force and the like, and the degree of significance for nay such undesirable effect depends on the particular problem at hand. In order to have a satisfactory design of a mechanical element, feasible values for all undesirable effects must be limited to tolerable ranges. Maximum shearing stress max at any point in the mechanical element must be equal to or less than an allowable shearing stress related to a material strength, using the maximum shearing stress theory of failure. Limit equations exist for all undesirable effects, and they must be adhered to in the design procedure for obtainment of a satisfactory design. Limitations on deflections, weight, force, vibrations and other undesirable effects might be either rigid or loose, depending on the particular mechanical element being designed and its particular intended application. The tolerable limit for an undesirable effect can be determined only from a study of the particular element and its particular application, including the significance attached to the occurrence of the undesirable effect on the entire mechanical structure.

General Characteristics of Mechanical Elements

3. All mechanical elements are uniquely defined by a complete specification of the material and the geometry of the element. Many of the important properties of a material are given by the material parameters found in the literature, such as the modulus of elasticity, Poissons ratio, weight density and unit weight cost. Various machining properties, the extent of availability and the restriction to standard sizes are important considerations. Generally, in the conduct of a design study the selection of a material for a mechanical element will be based primarily on the material parameters which are explicitly defined. The geometry of a mechanical element can always be uniquely defined by specifying certain independent geometrical parameters. Also certain manufacturing error limits are specified. The significant geometry is explicitly defined only by specifying theoretical values for geometrical parameters and limits on manufacturing errors, and these tolerances must be adhered to in the actual manufacturing process for the element.

Functional Requirements
A functional requirement is a condition which must be satisfied by the mechanical element if the structure or the machine is to function properly. It can define as the selection of materials and geometry which satisfies specified and implied functional requirements while remaining within the confines of inherently unavoidable limitations. Adequate design: any possible design solution represents a synthesis which merely satisfies the functional requirements within the confines of the existing limitations. In order to obtain a more explicit method of design, the overall objective must be more clearly defined. Associated with any mechanical element are certain inherently unavoidable undesirable effects.
For instance, in any specific mechanical element such effects as stresses, deflections, vibrations, space occupancy, weight, and cost might be undesirable and the degree of significance for each effect depends on the particular application. Hence a tolerable limit will exist for the permissible degrees of each undesirable effect.

Associated with any mechanical element are certain desirable effects, such as power transmission capability, energy absorption capability, momentary overload capacity, varying force transmission capability, speed capability, usable length of life and factor of safety.

Functional Requirements
An explicit overall objective in mechanical design is obtained based on any one of desirable and undesirable effects. Conduct method of design as to minimize the most significant undesirable effect or to maximize the most significant desirable effect. Introduce an additional design objective in an explicit design procedure for selecting materials and geometry. Optimum design: a mechanical design which is the best possible one from the standpoint of the most significant effect. The method of optimum design is an explicit method of design. Also, it should be emphasized that the method does not ignore any of the functional requirements or any of the existing limitations. Satisfactory design is determined in an explicit manner, it is the best possible design from the standpoint of the most significant effect and all other undesirable effects are within their permissible ranges of magnitude.

Aspects of Design Solution

Adequate design solution
It is characterized by traditional influences and cut-try techniques It is entirely satisfactory from the standpoint of the overall objectives in the statement of the problem.

Optimum Design Solution

It will illustrate the possibility of reaping previously hidden benefits by such an approach. It will explicitly determine values for geometry and material and illusrate the effects of existing limitations on the optimum design.

Desirable design solution It is illustrate to an improvement in basic geometrical shape or to an improvement in manufacturing technique. Illustrating the value of the optimum design approach in providing an explicit method of synthesis and simultaneously result.

Typical Design Equations

Design equations generally express either functional requirements or undesirable effects in terms of parameters which can be classified according to three basic groups.
Functional requirement parameters (or undesirable effect parameters) other than the one explicitly expressed by the design equation. Material parameters Geometrical parameters

Functional requirement parameters generally are primarily influenced by factors external to the element, and depending on the particular mechanical structure, these parameters can possibly be dependent upon each other. In a typical design equation, the specified functional requirement parameter group is independent of both the material parameter group and the geometrical parameter group. The material parameters in a design equation are generally not independent of each other. The characteristic parameters of any specific material can be thought of as independent of both the functional requirement parameters and the geometrical parameters in a typical mechanical element design equation. It is always possible and desirable to select independent geometrical parameters which uniquely define the geometry of the mechanical element. Redundancy in defining the geometry of the element generally should be avoided in the design procedure. Hence, choosing independent geometrical parameters will allow the independent variation of each in the design procedure. Although geometrical parameters which are independent of each other can always be selected, the geometrical parameter group in a typical design equation is often dependent on the specified functional requirement parameter group and the material parameter group.

Typical Design Equations

Summery of typical skeleton design equation, which figuratively expresses the quantity B.

Optimum Design
The optimum design of a mechanical element is the selection of the material and the values for the independent geometrical parameters with the explicit objective of either minimizing an undesirable effect or of maximizing a functional requirement, making certain in the design procedure that the element satisfied other functional requirements and that other undesirable effects are kept within tolerable limits. It should be conducted on the basis of the most significant quantity to be minimized or to be maximized, and the particular basis of optimum design depends on the particular application in its particular structural or machine setting. Primary Design Equation
The most important design equation is the one which expresses the quantity upon which the particular optimum design is based, since essentially it controls the procedure of design. For any particular case this equation will be known as the primary design equation. It will be determined by the most significant functional requirement or by the most significant undesirable effect

Optimum Design
Subsidiary Design Equation
In the optimum design of a mechanical element, the design equations other than the primary design equation will be called the subsidiary design equations. Hence the subsidiary design equations generally express either functional requirements or significant undesirable effects, whether they are directly specified or indirectly implied.

Limit Equations
Limitations on stress in a mechanical element are imposed by certain material properties called strengths, in conjunction with an appropriate theory of failure. Limitations on geometry are imposed by certain functional requirements of the mechanical structure or machine as by space restrictions, by practical manufacturing limitations in conjunction with material characteristics and by availability of standard sizes. Limitations on functional requirements are imposed by factors peculiar to the entire mechanical structure or machine.

Method of Optimum Design: Procedural Steps

Step1: Draw a free-hand sketch of the mechanical element showing the significant basic geometry. Select the independent geometrical parameters which will be used for uniquely defining the geometry of the element. Setp2: Decide on the significant explicit objective for conduct of design, write the primary design equation which expresses the optimum design quantity. It is in terms of functional requirement parameters, material parameters and goemetrical parameters. Step3: Write all subsidiary design equations, which express functional requirements and significant undesirable effects, other than the primary design equation. Step4: Write all limit equations, for functional requirement parameters, for significant undesirable effect parameters, for material parameters and for geometrical parameters. Indicate any limits which are definitely of the loose type. Setp5: Combine all subsidiary design equations with the primary design equation by eliminating an unlimited and unspecified common parameter from the primary design equation for each subsidiary design equation. It is suggested that geometrical parameters be eliminated, since they can be varied independently of eah other and generally then can be varied continuously; these are important desired characteristics for eliminated parameters because of step 9, in view of the fact that steps 7 and 8 necessarily will be made first.

Method of Optimum Design: Procedural Steps

Setp6: Using the developed primary design equation from step 5, roughly determine the variation of the optimum design quantity with respect to each independent parameter or independent parameter group in the primary design equation. Step7: Considering the variations from step 6 together with the previously written limit equations, determine the optimum value for each independent parameter or independent parameter group in the developed primary design equation; because of the explicit objective initially chosen for conduct of design, the optimum values will be uniquely determined. It is important to remember that limit values can be substituted in the procedure of design only for parameters or parameter groups which are independent of the other terms in the developed primary design equation. The primary design equation will be expressed in terms of functional requirement parameters, material parameters, limits, and occasionally, specific optimum values other than limits; this will be called the final primary design equation. Setp8: From the final primary design equation, select the optimum material on the basis of the material parameter group in that equation. This group will be called the material selection factor, and its value will determine the optimum available material. Occasionally it will be impossible to separate the material parameters from the geometrical parameters in the developed primary design equation.

Method of Optimum Design: Procedural Steps

Step9: From the final primary design equation at the end of step 7, many of the optimum values fo the geometrical parameters of the mechanical element will already have been determined. However, in order to determine the optimum values for the geometrical parameters which were eliminated form the primary design equation in step 5, merely solve for the parameter values using the original subsidiary design equations at this time.