Run two parameter sets side by side. Screening estimates — the dedicated tool governs any design you sign.
Comparison Mode — Side-by-Side Engineering Design Screening Calculator
Page last updated
The MechanixCalc Comparison Mode lets engineers run two design variants side by side across six mechanical component types — bearings, shafts, gears, beams, helical compression springs and bolted joints. Enter Design A and Design B and the tool shows every output metric, the delta between them, and which configuration is better on the metrics that have a better. Every panel is a screening estimate, marked as such on the page: the dedicated per-tool calculator implements the full standard method and governs any design you sign.
It is built for early-stage design decisions: swap a bearing for one with a higher dynamic capacity, widen a gear face, increase a shaft diameter, or change a bolt grade — and the safety-factor impact appears in real time. The clean three-column layout (A | B | Δ) makes it straightforward to document a design-trade rationale before committing to the full per-tool calculation with its complete standards-cited PDF report.
What this calculator does
- Side-by-side A/B comparison for six mechanical component types in one view
- Bearing L10 life and equivalent dynamic load comparison (ISO 281 e/X/Y interpolation)
- Shaft bending, von Mises and screening yield / DE-Goodman fatigue safety factor delta
- Gear pitch-point contact stress and root bending stress with gear ratio and tangential force
- Beam deflection and maximum bending stress for simply-supported and cantilever spans
- Spring rate, deflection, Bergsträsser-corrected shear stress and safety factor comparison
- Bolt preload, ISO 898-1 tensile stress area, clamp force and VDI 2230 reduced-stress safety factor
- Inputs outside a model are refused rather than compared, so a cleared field cannot win a row
Method & formulas
Bearing L10 life (ISO 281)
The bearing sub-calculator follows ISO 281: the equivalent dynamic load P is derived from the radial and axial forces using the interpolated e, X and Y factors from Table 11-1 based on the Fa/C0 ratio, with the ISO floor of P ≥ Fr always applied. L10 life in millions of revolutions is then the standard fatigue-life relation, and L10h converts that to hours at the given speed.
L10 = (C / P)^p × 10⁶ [revolutions]where C = dynamic load capacity (kN); P = equivalent dynamic load (kN), P = X·Fr + Y·Fa; p = 3 for ball bearings, 10/3 for roller bearings
L10h = L10 / (60 · n)where L10h = rating life (hours); L10 = rating life (revolutions); n = rotational speed (rpm)
Shaft stress and screening fatigue safety factor
The shaft panel is a SCREENING model for a single-diameter section, not the dedicated Shaft tool. Bending stress is the nominal M·c/I amplified by the user-supplied fatigue stress-concentration factor Kf; torsional shear is the un-notched T·c/J. The static yield check combines the NOMINAL stresses through the distortion-energy relation and carries no notch factor, because a ductile static yield check does not (Shigley 10e §5-2) — the same treatment the Shaft engine uses. The fatigue check treats bending as fully reversed and torsion as steady, so the von-Mises mean is √3·τ, and compares them on a Goodman line against a Marin-corrected endurance limit Se = ka·kb·ke·Se′ (Shigley 10e §6-8) using the surface finish you select. It is not a substitute for the Shaft tool, which runs a multi-segment beam FEM, the full modified-Goodman check and critical speed.
σ_vm = √(σ_nom² + 3·τ²)where σ_nom = M·c / I = nominal bending stress, no notch factor (MPa); τ = T·c / J = torsional shear stress (MPa); c = d/2; I = πd⁴/64; J = πd⁴/32
1 / n = σ′a / Se + σ′m / Su, Se = ka·kb·ke·Se′where σ′a = Kf·M·c/I = fully reversed bending amplitude (MPa); σ′m = √3·Kf·τ = von-Mises mean from steady torsion (MPa); Se′ = 0.5·Su capped at 700 MPa; ka = a·Su^b per surface finish (Shigley Table 6-2); kb = size factor; ke = 0.814 for 99 % reliability
Beam deflection and spring stiffness
The beam panel uses the elementary closed-form solutions for a prismatic beam: F·L³/(48·EI) for a central point load on a simply-supported span and F·L³/(3·EI) for a cantilever tip load, with the corresponding UDL terms superimposed — the two maxima coincide in each case, so the superposition is exact. Bending stress at the extreme fibre follows σ = M_max·c / I with c taken as h/2, which is exact only for a section symmetric about its neutral axis; for a channel or unequal-flange section use the Beams tool and its section library. The spring panel applies the BERGSTRÄSSER curvature-correction factor K_B = (4C+2)/(4C−3), which Shigley adopts in preference to the Wahl factor; stiffness follows the standard coil-spring relation.
δ = F · L³ / (48 · E · I)where F = point load (N); L = span (mm); E = elastic modulus (MPa); I = second moment of area (mm⁴)
k = G · d⁴ / (8 · D³ · n)where G = shear modulus (MPa); d = wire diameter (mm); D = mean coil diameter (mm); n = number of active coils
Worked example
A designer is comparing two deep-groove ball bearings for a shaft rotating at 1500 rpm under a purely radial load of 10 kN. Design A has C = 30 kN; Design B has C = 40 kN. Determine the L10h life of each bearing and the percentage improvement.
Given
- Radial load Fr (both designs)10 kN
- Speed n (both designs)1 500 rpm
- Load exponent p (ball bearing)3
- Dynamic capacity C — Design A30 kN
- Dynamic capacity C — Design B40 kN
Result
- L10h — Design A300 h
- L10h — Design B≈ 711 h
- Improvement (B vs A)+137 %
- For a purely radial load, P = Fr = 10 kN (no axial component, so X = 1, Y = 0).
- Design A — L10 life in millions of revolutions: L10_A = (C/P)^p = (30/10)^3 = 3^3 = 27 Mrev.
- Design A — L10h life in hours: L10h_A = 27 × 10⁶ / (60 × 1 500) = 27 000 000 / 90 000 = 300 h.
- Design B — L10 life: L10_B = (40/10)^3 = 4^3 = 64 Mrev.
- Design B — L10h life: L10h_B = 64 × 10⁶ / (60 × 1 500) = 64 000 000 / 90 000 ≈ 711 h.
- Percentage improvement: Δ = (711 − 300) / 300 × 100 ≈ +137 %. Design B wins.
Illustrative only — assumes purely radial load (Fa = 0). The full Comparison Mode tool uses ISO 281 Table 11-1 interpolation for combined radial + axial loads. Verify against your own bearing catalogue data.
Frequently asked questions
Which standard does the Comparison Mode use?
None — and that is deliberate. Comparison Mode is a screening tool: every panel is a simplification of the dedicated calculator and is marked with an "Engineering estimate" badge naming the tool that governs. Two pieces are exact: the bearing equivalent dynamic load is the same ISO 281 interpolation the Bearings engine uses, and the bolt tensile stress area is the ISO 898-1 definition. Everything else deliberately omits factors the full standard requires — the gear panel applies no ISO 6336 load factors, the shaft panel assumes a single diameter with fully reversed bending, the beam panel assumes a symmetric section and a midspan or tip load. Use the dedicated per-tool calculator for any design you will sign.
Is the Comparison Mode free?
Yes — the Comparison Mode is fully free with no sign-up required. You can also use every other MechanixCalc tool during a free 30-minute preview with no account, and a 14-day account trial (no credit card) unlocks the full suite. Saving calculations to your account and generating branded PDF engineering reports are available on a paid plan.
Which component types can I compare?
Six: deep-groove ball bearings (ISO 281 L10 life), solid circular shafts (bending, torsion, screening DE-Goodman fatigue), SPUR gear pairs (pitch-point contact stress, root bending stress, gear ratio — no helix angle or profile shift), beams (simply-supported or cantilever, point load + UDL), helical compression springs (stiffness, deflection, shear stress), and metric bolted joints (preload, clamp force, stress area, VDI 2230 reduced-stress safety factor).
How is the delta calculated and what does it mean?
For each output metric the tool computes Δ = (B − A) / |A| × 100 %, and a positive Δ means Design B is higher than A. A winner is marked only on metrics that HAVE a better: higher is better for the safety factors and for bearing life; lower is better for stresses, deflections, and the loads and moments that drive them. Metrics that are design targets rather than objectives — gear ratio, the two pitch diameters, spring rate, spring index, spring deflection, bolt stress area, preload per bolt and total clamp force — show the delta with no winner, because neither direction is an improvement on its own. On the shaft panel, read the "SF Governing" row rather than either safety factor alone: the yield check deliberately carries no notch factor, so it reads higher than the fatigue check. If either design falls outside its screening model — a cleared field, a negative value, or a magnitude the model cannot represent — that column is refused and the comparison is withheld entirely rather than ranked.
When should I use Comparison Mode rather than a dedicated calculator?
Use Comparison Mode for rapid early-stage trade studies — comparing two bearing sizes, two shaft diameters, or two spring wire gauges — where you need a quick delta before committing time to a full standards-cited calculation. For a final design sign-off, use the dedicated per-tool calculator: it applies the complete standard method, stress-concentration factor libraries, material databases and generates a reviewable PDF report with the governing standard cited on every output.
Related calculators
- Bearing Analysis (ISO 281)Full ISO 281 bearing selection with combined radial/axial loading, L10m modified life and heat generation.
- Shaft AnalysisModified-Goodman shaft fatigue safety factor, multi-segment beam-FEM deflection and critical speed.
- Beam AnalysisRoark beam deflection, slope and bending stress for standard load cases with section library.
- Spring DesignHelical compression and extension spring design: Wahl stress, fatigue life and clash clearance.
- Bolt / Fastener AnalysisFull VDI 2230 bolt-joint analysis: preload, clamp force, thermal delta and fatigue safety factor.
Run the Comparison Mode on your own numbers
Free 30-minute preview — no sign-up. A free 14-day account trial unlocks every tool and the branded PDF report, no credit card required.
Start freeUsing MechanixCalc at work? See plans & pricing — one subscription unlocks all 50 calculators, PDF reports and saved projects.