03MCHQD MACHINE DESIGN 2016-2017

TECHNICAL REPORT 4

CONTACT STRESSES HERTZ THEORY

PROBLEM 1 DESIGN OF A TRANSLATION STAGE

The figure below shows a translation stage on rolling elements. The stage should carry at least a
load F=16 kN distributed on eight rolling elements. The material is steel (yield stress Rp0.2 = 1500
MPa).

Consider three different solutions:

A) Rolling balls mounted as in Figure - Solution A, angle = 90.

B) Rolling balls mounted as in Figure - Solution B with the same ball dimension as Solution
A with a ratio ball diameter-ball race diameter D/d = 1.04

C) Rollers with the same diameter as the balls in Solution A and axial roller length equal to
its diameter.

Solution A Solution B Solution C

F F F

- Choose the balls diameter by imposing that in the solution A the contact pressure pMAX is
lower than 2340 MPa.
- Calculate the value of the force FMAX which causes in the three different solutions a
maximum contact pressure pMAX =2340 MPa.
- For the three solutions calculate the values of the vertical approach v of the stage for a
given range of force values (0- FMAX ) and plot the curve v - F of the stage

Comments the results of the three solutions:

- why pMAX is chosen higher than the material yield stress Rp0.2?
- which is the more and the less stiff stage?
- which is the stage with more and the one with less load capability?

2016/2017 03MCHQD Machine design 1

CALCULATION OUTLINE

1) For the solution A:

- determine the force Fc on the single contact ball-plane by a balancing equation;
- using the Hertz formulas in the table below calculate the ball diameter d by imposing the
maximum contact pressure pMAX =2340 MPa (D= since the contact is sphere-plane);
- the diameter value should be chosen as an integer number x or x.5;
- using the Hertz formulas in the table below calculate the value of the force FMAX which
causes a maximum contact pressure pMAX =2340 MPa with the chosen ball diameter;
- using the Hertz formulas in the table below calculate the relationship between the contact
approach and the contact force Fc;
- calculate the relationship between the contact approach and the total vertical approach v
of the stage;
- calculate the values of the vertical approach v of the stage for a given range of force
values (0- FMAX ) and plot the curve v - F of the stage

2) For the solution B and C assuming the same ball and roller diameter chosen for solution A :
- calculate the value of the force FMAX which causes in the three different solutions a
maximum contact pressure pMAX =2340 MPa, use Hertz formulas of the table below for the
solution C and the general formulas (see slides 39-41 Chapter 1 Hertz theory) for solution
B;
- calculate the values of the vertical approach v of the stage for a given range of force
values (0- FMAX ) and plot the curve v - F of the stage

2016/2017 03MCHQD Machine design 2