TTB207 Machine elements and automotive materials

Design Of A Protection System For A Motorcycle Lock Using MATLAB

Introduction - TTB207 Machine elements and automotive materials

The loads and pressures which the lock mechanism would be subjected to during the creation of a motorbike lock protection system should also be analyzed for what it is during the construction process most especially when attempts at tampering are expected; say through the use of a crowbar. Security of the motorcycle heavily relies on the lock integrity and selection of the bolt diameters and materials must be done correctly. The bolts of the case deliver forces which are both vertical as well as horizontal, and it is which the lock mechanism has to endure. Regarding whether the chosen bolt diameter exceeds the yield strength of the material under the applied loads, the analysis is performed by calculating stresses, with which these forces affect the bolt, based on the von Mises stress criterion. To ensure that after installation the bolts cannot be removed, together with the make-tight calculation, the rip-torque needed to pull the bolt head off is also determined. This all-embracing strategy ensures that the lock is well-built, well-protected and should be able to provide sound protection from any unauthorized intruder.

Determination of Bolt Diameter

Loading Analysis

The two major forces which the crowbar applies in the suggested design are the vertical force Fv and the force in the horizontal direction FH. While the horizontal force is exerted horizontally with a view of trying to separate the two sides of the lock casing, the vertical force is applied downwards on the top and the lower casing of the lock. Great attention must also be paid to the loads experienced by the bolts that join the casing together – these are also transmitted by these forces (Van et al, 2023) . Taking it that the horizontal and vertical forces are equally applied on each of the two bolts, the forces acting on each bolt are as follows: Pressure is determined by dividing each force with the cross-sectional area of the bolt, and will give out the stress due to that force. The distinctly vertical and horizontal stresses are added and between them an equivalent stress is created by the stress criterion von Mises, which is compared with the yield strength of the bolt material to assure safety (Lakhemaru and Adhikari, 2022). The bolt has to be designed in such a way that it can bear all the forces applied to it safely; this means that the bolt diameter has to be increased if the equivalent stress is more than the yield stress of the material. In this way, it is guaranteed that the bolt diameter chosen will be enough strong to bear forces which could be exerted by a crowbar and still not put the structure at risk of failing.

Figure 1: Input of cross-sectional area

(Source: Self-created in Matlab)

Stress Analysis

This is possible because while using the crowbar, the forces will bring about shear and tensile forces on the bolt of a motorcycle lock. Tensile stress occurs when forces attempt to separate the bolts, particularly the vertical force acting along the bolts’ length. On the other hand, shear stress occurs when the horizontal force tries to move the two sides of the lock casing in relation to each other applying pressure in plane of the bolts section. According to the mechanistic approach, the tensile and shear stress are calculated using the max forces and the bolt’s Cross sectional area for the tensile stress calculation where as for shear stress calculation the horizontal force is used (Maryati et al., 2023). This one is used to determine the ultimate impact of several types of stress being applied to the material. It provides one equivalent stress value that can be compared with the yield strength of the material to assure that the bolts will not fail when the loads are applied on them.

Bolt Diameter Calculation

Bolt design is achieved when the stress in the bolt does not go beyond the yield strength thus determining the needed bolt diameter. To ensure safety under the applied force the diameter of the bolt is required to be shifted through the calculated von mises equivalent stress. It a process of presupposing the bolt diameter and calculating the stresses therein (Zhang and Chen, 2022). The diameter is increased until the stresses are within safe limits, if von Mises stress value exceeds the permissible value of stress in the material. Certain formula include cross-sectional area and its calculations, tensile stress, shear stress and von Mises stress all of which are applied. The selected bolt diameter was justified by ensuring that it has a safety factor in as much as mechanical failure is involved in a crowbar attack on the lock mechanism.

Figure 2: Output of Bolt stress

(Source: Self-created in Matlab)

Torque Calculation for Bolt Non-Removal

Torque and Shear Force Relationship

It is vital to understand the connection between torque and shear force for threading a bolt that cannot be easily unbolted after assembly. Bolt: This is a fastener that, when torque is applied, the bolt material turns causing the bolt head to generate shear stress (Kolla et al., 2023). If this torque is applied beyond a certain value, then this shear stress may cause the bolt head to shear off entirely, depending on the torque applied and the diameter of the bolt.

Figure 3: Input of Torque Calculation for Bolt Non-Removal

(Source: Self-created in Matlab)

The calculation process begins with determining the shear force acting on the bolt head with any loads. This force is proportional to the torque and can be calculated using the formula "T=tr" where "r" is the radius of the bolt "T" is the shear stress and "T" is the torque. This is where the maximum allowable shear stress is used as a control point so as not to exceed the shear strength of the material in order to get the maximum permissible torque (Wei et al., 2021). This computation is required so that the bolt remains in its correct position especially in case of anyone tries to interfere or when there exists high levels of stress in order to safeguard motorcycle lock from being untightly from its rightful place.

Figure 4: Output of calculation for shearing Bolt Head

(Source: Self-created in Matlab)

Application to M8 Bolt

The torque calculated to shear off bolt head of M8, with nominal diameter of 8mm is done using the torque and shear stress relation as before. The values that can be demanded depend on modifications of the material parameters and the bolt radius in the formula above. This number is important because it gives would-be users of the bolts a measure of the capacity of the bolt head to withstand application of torque safely when using it in an application.

Figure 5: Input for calculation of stress of new diameter

(Source: Self-created in Matlab)

That is the worst-case calculation; once the bolt is in place and torqued to the preferred number, it is almost impossible to remove it without doing substantial damage (Ulum and Patriawan, 2022). This feature is critical in the design of this motorcycle lock, for it guarantees that would be thieves will not be able to take out or interfere with this lock in any way; thus offering the car steadfast security.

Figure 6: Output of safe bolt diameter, equivalent stress and required torque

(Source: Self-created in Matlab)

Engineering Judgments and Assumptions

Assumptions Made

The following basic assumptions were made in the design and analysis of the motorbike lock protection system to ease the computations and the sustainability of the project. First of all, it was believed that there are no significant material imperfections or deviations and all the study material characteristics like yield strength and shear strength, for the instance, are the same for both bolts and casing (Purba et al., 2021). This assumption is made permissible because they allow the component to perform consistently when it is under load and also have a stress distribution pattern. Moreover, the conditions of loading were assumed to be perfect; and in reality, there was no such a condition as eccentric loading or certain effects such as vibrations or impacts to affect the application of the crowbar, which with uniform distribution of force acted only on the bolts (Wafi, 2020). This makes the analysis easier because it only focuses on the main force system involved. Thirdly, it has been assumed that bolts were tightened and aligned well enough so there is certainty about computed stresses to reflect actual state of affairs. In addition, it is assumed that the bolts undergo only such stresses as are calculated, and not such external factors as corrosion, fluctuation in temperatures, and other signs of ageing. These presumptions provide a controlled evaluation paradigm through which there are different approaches to scrutinize the reliability of the lock system as a whole, and the ability of the bolt.

Engineering Considerations

Technological factors such as corrosion can be a threat to the design and may shorten the lifespan of the lock especially when used in unfriendly terrains (Sun et al, 2020). The choice of material is critical given that steel is very strong but it is also very prone to corrosion and therefore it needs to be galvanized. While aluminum has lower ultimate strength in comparison with steel, it presents increased resistance to corrosion and improved strength to weight ratio.

Figure 7: Input for propose different materials for plot

(Source: Self-created in Matlab)

This trade-off must be well thought out depending on the aspect of being a frequently exposed to the environment or if weight is of essence. In order to ensure the highest possible level of functionality and durability of the lock system, selecting the material should take into consideration the issues of strength, weight, cost, and adaptability to the environmental conditions.

Figure 8: Input for all plots

(Source: Self-created in Matlab)

This motorcycle lock protection system assignment demonstrates the integration of MATLAB-based stress analysis with practical engineering design. From bolt diameter selection to torque resistance, the study ensures a secure and tamper-proof locking mechanism. If you’re working on complex projects in machine elements, automotive materials, or mechanical engineering, professional guidance can make your work stand out. Our experts deliver accurate simulations, detailed reports, and reliable solutions tailored to your coursework. Get ahead in your academics with expert assignment help and achieve higher grades with confidence.

Recommendations

When it comes to a protective system of a motorbike Lock, one must always contemplate safety margins, needed torque, stress distribution and even material selection. In order to follow these elements, the offered code mimics the stresses produced on the bolts, the torque required to shear the bolt head, and the safety factors for different sizes of bolts (Moaaz et al, 2020). Material properties are primary, and the actual properties of the steel used, its yield strength (Sy) and ultimate strength (Su), must be taken into consideration in order to ensure that the bolt can carry the applied stress and not undergo permanent set or breakage (Emam and Mohamed, 2020). The algorithm works precisely under load since it considers the material did not have Areas of low strength, overloads or other variations that give inconsistent mechanical properties.

Figure 9: Safety Factor vs Bolt Diameter

(Source: Self-created in Matlab)

The next issue of concern is the division of troops. A crowbar is assumed to apply pure vertical force (Fv) and force perpendicular to the bolt axis (FH), both of which are distributed over the cross-sectional area of the bolt. These forces are then employed in the von Mises stress analysis to determine the equivalent stress to compare it with the yield strength to check on the safety of the bolt under the applied loads. The amount of torque that transmits the bolt head; the level of torque required to shear the bolt head is another important consideration. In this way, the code defines this torque so that the bolts cannot be removed after they have been tightened to the necessary amount, based on the diameter and material properties of the bolt. This feature is needed to prevent tampering with the lock and its removal by anyone who does not have the rights to do that.

Figure 10: Required Torque vs Bolt Diameter

(Source: Self-created in Matlab)

Thus, after the deformation, stress, and strain analyses, safety factor is determined to ensure that the bolts have enough margin of safety under the loads applied. Greater safety indicates a stronger design that can accommodate occasional loads or variations in material properties that may not have been taken into account. The code outputs diagrams depicting how stress, torque, and safety facets vary as a function of bolt diameter. This assists in establishing the most appropriate size of bolts that should be used and the right size that will not be very costly, but will also have the capacity to handle the expected load and last for the expected period of time.

Figure 11: Stress vs Bolt Diameter

(Source: Self-created in Matlab)

Conclusion

The principles which have to be considered to ensure the appropriate protection and durability of the lock mechanism have been explained while studying the protection system of the motorbike lock. In doing this, the study insures that the lock withstands all the probable attempts at tampering including those involving the use of a crowbar, by correctly calculating the forces and accompanying stresses on the bolts as well as the required bolt diameter. The investigation includes both vertical and horizontal forces by employing the von Mises stress criteria reducing them to one factor which is then tested against the understanding of strength of the material. In this way the diameter of the bolt selected will comfortably be able to handle the forces that are applied in the structure without compromising the strength of the structure. To ensure that these bolts remain fixed in position once in place the force required to pull of the Head of the bolt is estimated making the lock more secure. It is such a feature that is very important in order to prevent unauthorized removing and to ensure the reliability of the lock in the course of its usage. Sustaining this it is possible to make a wise decision in achieving a right compromise between strength and weight on one hand, as well as corrosion resistance and cost on the other hand, all by reference to the qualities of the material particularly in relation to steel as against other materials such as aluminum. In other words, the specific design of the motorbike lock protection system does all that must be incorporated in its construction to meet the basic needs of durability and security. Thus, a solid understanding of stresses, torque and choice of the right bolt material and size is obtained from the study. It also makes certain that the lock system will function in many conditions to enhance the guarded coverage of the motorcycle.

Reference List

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