Cairo University

Faculty of Engineering
Mechanical Design and Production Department – Fourth year

CAD
MDP 4160
2024/2025
Mini Project (1)

Name Code
Seif Eldeen Emad Saad Abd El-Nabi 9210506
Seif Eldeen Adel Fouad Mohamed El-Gendy 9210505
Ahmed Bahaa Mohamed Abd El-Mobdee 9210049
 Table of Contents
Stress Analysis: .......................................................................................................................... 2
Bearing Selection: ...................................................................................................................... 3
Radial Bearing at B. ............................................................................................................... 3
Thrust bearing at C: ............................................................................................................... 4
Suggested Shaft Design: ............................................................................................................ 4
Lever Design: ............................................................................................................................. 5
Handle Design:........................................................................................................................... 5

Page 1 of 5
 Mini Project (1)
Stress Analysis:
𝑚@𝑧 = 0 ∴ 9810 × 100 = 𝐹 × 200 ∴ 𝐹 = 4905 𝑁

∑ 𝐹𝑦 = 0 ∴ 𝐵𝑦 + 𝐶𝑦 = 9810 + 4905

𝑚𝐵 = 0 ∴ 9810 × 100 + 125𝐶𝑦 − 4905 × 225 = 0

𝐶𝑦 = 981 𝑁 , 𝐵𝑦 = 13734 𝑁

Page 2 of 5
Critical section due to bending:
𝑚𝑦 1962000 × 32 19984.767 × 103
𝜎= = =
𝐼 𝜋𝑑3 𝑑3
𝑇𝑟 981000 × 16 4996191.974
𝜏= = =
𝐽 𝜋𝑑3 𝑑3

𝜎𝑥 + 𝜎𝑦 𝜎𝑥 + 𝜎𝑦 2
𝜎1,2 = ± √( 2
) + 𝜏𝑥𝑦
2 2

2
19984.767 × 103 19984.767 × 103 4996191.974 2
𝜎1,2 = ± √( ) + ( )
2𝑑 3 2𝑑 3 𝑑3
1
31 × 𝐹. 𝑆 3
𝑑=[ √(𝐶𝑏𝑚 𝑀)2 + (𝐶1 𝑇)2 ]
𝜋𝑆𝑦

Material: 201 Annealed Stainless Steel with 𝜎𝑦 = 292 𝑀𝑃𝑎

1/3
32 × 2 2 2
∴𝑑=[ √(1.5 × 1962000) + (0.2 × 981000) ] = 59 𝑚𝑚 ≈ 60 𝑚𝑚
𝜋 × 292
𝑆𝑒′ = 0.5𝑆𝑢𝑙𝑡 = 0.5 × 685 = 342.5 𝑀𝑃𝑎
𝑆𝑒 = 𝑘𝑎 𝑘𝑏 𝑘𝑐 𝑘𝑑 𝑆𝑒′ = 0.83 × 0.83 × 342.5 = 235.948 𝑀𝑃𝑎
1/3
2
32 × 2 292
𝑑=[ √( × 1.5 × 1962000) + (981000)2 ] = 64 𝑚𝑚 ≈ 70 𝑚𝑚
𝜋 × 292 285.948

Bearing Selection:
Radial Bearing at B.
Recommended Life: 8000 ∶ 14000 ℎ𝑟 = 𝐿
𝑃 = 13734𝑁𝐹𝑟
𝐾𝑠𝑓 × 𝑃 = 1.1 × 13734 = 15107.4 𝑁 = 151 𝑘𝑁

60 × 10000 × 63.662 1/3

𝐶 = 15107.4 × ( )
106
𝑃𝑜𝑤𝑒𝑟 = 𝑇𝜔 Assume time to do process = 6 𝑠
𝑤 = 𝐹. 𝑑 = 9810 × 40 × 103 = 392400
392400 × 103
𝑃𝑜𝑤𝑒𝑟 = = 6540 𝐾𝐽/𝑠
60

Page 3 of 5
 6540 × 103 20
𝜔= = 𝑟𝑎𝑑/𝑠
981000 3
20 60
𝑛= × = 63.662 𝑟𝑝𝑚
3 2𝜋
𝐶 = 50.878 𝑘𝑁
Bearing B: Single row deep groove ball bearing.
𝑑 = 70 𝑚𝑚 , 𝐷 = 125 𝑚𝑚 , 𝑐𝑜𝑑𝑒 = 6214

Thrust bearing at C:
𝐹𝑎 = 𝐶𝑧 = 0 𝑃 = 𝐹𝑟 = 981
𝑃′ = 1.1 × 981 = 1079.1 𝑁

60 × 10000 × 63.662 1/3

𝐶 = 1079.1 ( ) = 3634.172 𝑁
106
𝐷 = 90 𝑚𝑚 , 𝐵 = 10 𝑚𝑚 , 𝑑 = 70 𝑚𝑚 , 𝑐𝑜𝑑𝑒 = 61814

Suggested Shaft Design:

Page 4 of 5
Lever Design:

Using AISI 1010 HR with 𝜎𝑦 = 170 𝑀𝑃𝑎

𝑚𝑦 𝜎𝑦 4905 × 200 × 50 170
= ∴ = ∴ 𝑡 = 10.534 𝑚𝑚 ≈ 15 𝑚𝑚
𝐼 𝑆. 𝐹 1 2
(1003 − 703 )
12 × 𝑡 ×

Handle Design:
𝑚 = 4905 × 50 = 245250 𝑁. 𝑚𝑚
𝑚𝑦 245250 × 32 2498095.987
𝜎= = =
𝐼 𝜋𝑑3 𝑑3
Using Rol-Annealed Stainless Steel with 𝜎𝑦 = 292 𝑀𝑃𝑎
2498095.987 292
= ∴ 𝑑 = 23.41 𝑚𝑚 ≈ 25 𝑚𝑚
𝑑3 1.5

Page 5 of 5
 8 7 6 5 4 3 2 1

F F
472.26

.41
3
R8
R35
R5 .5 0 100.10 125.00 87.60
0.0
77

.00
0 R

50
R12.
E E
115.00

65.00

15.00
24.00
24.00

D D

C C

B B

A A

8 7
SOLIDWORKS Educational Product. For Instructional Use Only.
6 5 4 3 2 1
 8 7 6 5 4 3 2 1

F F

66.40
70.00
84.00
E E

2.40 2.40

D 40.00 D

15.00
10.00

127.60
10.00
24.00

C C
418.00
125.00
24.00

112.60

B B

A A

8 7
SOLIDWORKS Educational Product. For Instructional Use Only.
6 5 4 3 2 1
 8 7 6 5 4 3 2 1

F F

. 00
70

.00
25
E E

D D
15.00

R2
00

7.5
0.
R5

200.00

0
C C

B B
277.50

A A

8 7 6
SOLIDWORKS Educational Product. For Instructional Use Only.
5 4 3 2 1
 8 7 6 5 4 3 2 1

F F

E E

25.00

D D
65.00

C C

B B

A A

8 7 6
SOLIDWORKS Educational Product. For Instructional Use Only.
5 4 3 2 1
 8 7 6 5 4 3 2 1

F F

15.00

00
7.00

5.
R3
17.75
E E

137.00

166.83
144.83

90.00

8.31
40.00
D D

C C

B B

A A

8 7 6
SOLIDWORKS Educational Product. For Instructional Use Only.
5 4 3 2 1
 8 7 6 5 4 3 2 1

F F
5 .00
12

50
R77.

E E
177.50

0
R55.0

D D

24.00
20.35

180.00

C C

B B

A A

8 7 6
SOLIDWORKS Educational Product. For Instructional Use Only.
5 4 3 2 1
 8 7 6 5 4 3 2 1

F F

15.00

E E

15.00
D 40.00 D

C C

B B

A A

8 7
SOLIDWORKS Educational Product. For Instructional Use Only.
6 5 4 3 2 1
 8 7 6 5 4 3 2 1

F F

E E

125.00

D D

C C

B B

A A

8 7 6
SOLIDWORKS Educational Product. For Instructional Use Only.
5 4 3 2 1
 Finite Element Analysis
Shaft:
Stress:
Max. Stress = 120.782 𝑀𝑃𝑎

Deflection:
Max. Deflection = 0.059 𝑚𝑚

Page 1 of 6
Factor of Safety:
FOS = 2.418

Calculations FEA
Max. Stress (𝑴𝑷𝒂) 61.7032 120.782
FOS 2 2.418

Page 2 of 6
Lever:
Stress:
Max. Stress = 38.99 𝑀𝑃𝑎

Deflection:
Max. Deflection = 0.1 𝑚𝑚

Page 3 of 6
Factor of Safety:
FOS = 4.616

Calculations FEA
Max. Stress (𝑴𝑷𝒂) 85 38.99
FOS 2 4.616

Page 4 of 6
Handle:
Stress:
Max. Stress = 236.475 𝑀𝑃𝑎

Deflection:
Max. Deflection = 0.062 𝑚𝑚

Page 5 of 6
Factor of Safety:
FOS = 1.235

Calculations FEA
Max. Stress (𝑴𝑷𝒂) 194.66 236.475
FOS 1.5 1.235

Page 6 of 6