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Machine Design 2 Project

The document describes Design Project #2 for ME 424 Machine Design II. Students are tasked with designing a bolted joint for a pressure vessel considering factors like minimum safety factors, load cycles, reliability, bolt spacing, and cost. They must develop a computer code to iteratively select the optimal number of bolts, bolt properties, preload, and material to minimize cost while meeting all design requirements. The output should report the selected bolt design values and safety factors.

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267 views

Machine Design 2 Project

The document describes Design Project #2 for ME 424 Machine Design II. Students are tasked with designing a bolted joint for a pressure vessel considering factors like minimum safety factors, load cycles, reliability, bolt spacing, and cost. They must develop a computer code to iteratively select the optimal number of bolts, bolt properties, preload, and material to minimize cost while meeting all design requirements. The output should report the selected bolt design values and safety factors.

Uploaded by

Sadık
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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ME 424 Machine Design II

DESIGN PROJECT # 2

Due to Sunday, January 24, 2021


Use the following numbers in your calculations

Consider a pressure vessel with an unconfined gasket between the head and the body of the cylinder. The
pressure vessel is aluminum with elastic modulus 𝐸𝑎 = 71.7 GPa; the gasket is (1.8 + 0.05𝑎) mm-thick
Teflon. The elastic modulus of the gasket material is 𝐸𝑔 = 240 MPa. The pressure inside the vessel varies
between 𝑝𝑚𝑖𝑛 = 0 and is 𝑝𝑚𝑎𝑥 = (8 + 0.06𝑏) MPa. The diameter of the head exposed to pressure, 𝐷𝑝 , is
(72 + 2𝑎) mm, bolt circle diameter, 𝐷𝑏𝑐 , is (102 + 2𝑎) mm, outside flange diameter, 𝐷𝑓 , is (122 + 2𝑎)
mm. The total thickness of the head and flange at the bolt circle, ℓ, is (72 + 2𝑏) mm.

Develop a computer code to design the bolted joint by choosing a suitable number of bolts, property
class, diameter, and preload for the bolts such that the safety factors for leakage and gross yielding are
above 1.5, safety factor for fatigue failure is at least 2.0, and the cost is minimum. The bolted joint should
endure 2 × 105 load cycles with a reliability of 99.9%. In order to provide uniform pressure on the gasket,
the ratio of the distance between the centers of adjacent bolts along the bolt circle to the major diameter
of the bolts should be less than 6.0 and this ratio should be larger than 3.0 in order to allow sufficient
spacing for wrench. The preload factor, 𝐾𝑖 , should be chosen between 0.6 and 0.9. A standard bolt size
should be selected. The parameters to be optimized are the number of bolts, bolt size, pretension level,
and material. If multiple optimum solutions are found with the same minimum cost, choose the one with
the highest safety factor. 80% of the bolt shank under tension is unthreaded. In calculating effective
compressed area for the gasket, you may assume that the pressure is uniform on its entire surface area.
The computer code should read the inputs from an input file or within the code and find the values of the
design variables without user intervention through iterations. Print out your code and output file; also
return a softcopy of the code. The output file should include the following in the given order: The number
of bolts, property class of the material, major diameter (𝑑), pitch (𝑝), pitch diameter (𝑑𝑝 ), tensile stress
area (𝐴𝑡 ), preload factor (𝐾𝑖 ), initial load (𝐹𝑖 ), stiffness of the bolt (𝑘𝑏 ), effective compressed area of flange
(𝐴𝑐 ), stiffness of the clamped member (𝑘𝑐 ), joint stiffness factor 𝐶, maximum external separating force
per bolt (𝐹𝑒𝑀𝑎𝑥 ), maximum tension in the bolt (𝐹𝑏𝑀𝑎𝑥 ), minimum tension in the bolt (𝐹𝑏𝑀𝑖𝑛 ), minimum
compression in the clamped member (𝐹𝑐 ), alternating force in the bolt (𝐹𝑎 ), mean force in the bolt (𝐹𝑚 ),
ME 424 Machine Design II

fatigue stress concentration factor (𝐾𝑓 ), alternating stress (𝑎 ), standard endurance limit (𝑆𝑛′ ), load factor
(𝐶𝑙𝑜𝑎𝑑 ), gradient (or size) factor (𝐶𝑠𝑖𝑧𝑒 ), surface factor (𝐶𝑠𝑢𝑟𝑓 ), reliability factor (𝐶𝑟𝑒𝑙 ), corrected endurance
limit (𝑆𝑛 ), fatigue strength for 2 × 105 reversed cycles (𝑆𝑓 ), maximum allowable alternating stress (𝑆𝑎 ),
safety factor against fatigue failure, safety factor against yielding, safety factor against leakage, bolt-
spacing ratio, cost of the bolted joints.
Completely describe the problem, derivations, your solution method, and calculations in a report.
Note: Two people may form a project group and work on the project together. However, project groups
may not get any help from each other. Do not show your code to another group. Any similarity in the
algorithm and computer code will be presumed as cheating.

The material cost of each class is given in the table. Cost of opening a hole and assembly of a bolt and nut
is 2.0 units.

Prices of bolt classes


Class Price
4.6 1.0 + 0.2 × 𝑑 (mm)
4.8 1.1 + 0.22 × 𝑑 (mm)
5.8 1.3 + 0.26 × 𝑑 (mm)
8.8 3 + 0.6 × 𝑑 (mm)
9.8 6 + 1.2 × 𝑑 (mm)
10.9 9 + 1.8 × 𝑑 (mm)
12.9 11 + 2.2 × 𝑑 (mm)

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