The powder compaction mechanism shown in the sketch (Fig. 1a) is to be designed such that...

Transcribed Image Text:

The powder compaction mechanism shown in the sketch (Fig. 1a) is to be designed such that the maximum compaction force, Fcomp = 2 kN. The dimensions at the point of maximum compression depth are clearly shown in the Figure. You are required to: 1) Draw free body diagrams for the frame (p1), input arm (p2), connecting rod (p3), compaction ram (p4) and mounting brackets (p5 & p6). 2) Calculate all the loads acting on the frame (p1), input arm (p2), connecting rod (p3), compaction ram (p4) and mounting brackets (p5 & p6). 3) Design the input arm (p2) and connecting rod (p3) based on static stress analysis. Select suitable materials and reasonable cross sections for the parts p2 and p3. Also, check for linear and transverse deflections in these parts. {Hint: select material properties & dimensions from a known standard} 4) Design the compaction ram (p4) against both yielding and buckling failure. Also, check for linear deflection in the compaction ram. • Which of the two failure modes is more critical? Also, check for fatigue failure in the compaction ram (p4). {Hint: Neglect the bending moment acting at D in the buckling and yielding failure analysis} 5) Design the cylinder (p7 in Fig. 1b) by considering both static and fatigue loads. 6) Design the bolted connection for the mounting brackets (p5 & p6) that are pulled by the connecting rod (p3). Determine the number and size of bolts for both brackets (Fig 1c). {Hint: consider only static loads in your design calculations for the bolts} 7) Make SW drawings of all the parts and assembly. In addition, prepare a typed final report that contains tasks 1-7. Fin AB = 105 AC = 304.6 BD = 172 All lengths in mm 45° 156.2 p2 60.64° e 148.4 E F B D fo p3 p7 15.64⁰ p1 Figure 1a p5 p4 p6 Fcomp 57 62.9 119.9 165 243 p4 slides in p5 & p6 ο ο Figure 1c: Bracket Compaction Ram Powder Figure 1b: Cylinder (p5 & p6) Support and Hint to complete the project Software: In addition to hand calculations, it is recommended to use the free software MDSolids for the following: 1. Force analysis to get the reaction forces 2. Shear force and bending moment diagrams 3. Slope and deflection diagrams The download link is as follows: http://web.mst.edu/~mdsolids/download.htm Assumptions: Assume a minimum design factor of 2.0 and make necessary assumptions to optimize your design. You can ignore the weights and friction in the calculations. The powder compaction mechanism shown in the sketch (Fig. 1a) is to be designed such that the maximum compaction force, Fcomp = 2 kN. The dimensions at the point of maximum compression depth are clearly shown in the Figure. You are required to: 1) Draw free body diagrams for the frame (p1), input arm (p2), connecting rod (p3), compaction ram (p4) and mounting brackets (p5 & p6). 2) Calculate all the loads acting on the frame (p1), input arm (p2), connecting rod (p3), compaction ram (p4) and mounting brackets (p5 & p6). 3) Design the input arm (p2) and connecting rod (p3) based on static stress analysis. Select suitable materials and reasonable cross sections for the parts p2 and p3. Also, check for linear and transverse deflections in these parts. {Hint: select material properties & dimensions from a known standard} 4) Design the compaction ram (p4) against both yielding and buckling failure. Also, check for linear deflection in the compaction ram. • Which of the two failure modes is more critical? Also, check for fatigue failure in the compaction ram (p4). {Hint: Neglect the bending moment acting at D in the buckling and yielding failure analysis} 5) Design the cylinder (p7 in Fig. 1b) by considering both static and fatigue loads. 6) Design the bolted connection for the mounting brackets (p5 & p6) that are pulled by the connecting rod (p3). Determine the number and size of bolts for both brackets (Fig 1c). {Hint: consider only static loads in your design calculations for the bolts} 7) Make SW drawings of all the parts and assembly. In addition, prepare a typed final report that contains tasks 1-7. Fin AB = 105 AC = 304.6 BD = 172 All lengths in mm 45° 156.2 p2 60.64° e 148.4 E F B D fo p3 p7 15.64⁰ p1 Figure 1a p5 p4 p6 Fcomp 57 62.9 119.9 165 243 p4 slides in p5 & p6 ο ο Figure 1c: Bracket Compaction Ram Powder Figure 1b: Cylinder (p5 & p6) Support and Hint to complete the project Software: In addition to hand calculations, it is recommended to use the free software MDSolids for the following: 1. Force analysis to get the reaction forces 2. Shear force and bending moment diagrams 3. Slope and deflection diagrams The download link is as follows: http://web.mst.edu/~mdsolids/download.htm Assumptions: Assume a minimum design factor of 2.0 and make necessary assumptions to optimize your design. You can ignore the weights and friction in the calculations.