MTE 427 Machine Design

Introduction to Mechanical Engineering Design

1st teaching

Pichet PINIT
What will we learn in this course?
Introduction to Mechanical Engineering Design
Engineering Materials (short version)
Load and Stress Analysis
Deflection and Stiffness
Failure Theories for Static and Dynamic Loading
Design of Machine Elements
Shafts and Its Components
Screws and Fasteners
Mechanical Spring
Roller Contact Bearing
Gears (Spur, Helical, Bevel, and Worm Gears)
Flexible Mechanical Elements
Clutches, Breaks and Coupling
Introduction to Mechanical Engineering Design

What is design?
Design is the application of creativity to planning the optimum solution of
a given problem and the communication of that plan to others.

Given problem
Creativity
Planning
Optimum solution (the best solution for such problem at a time)
Communication
Introduction to Mechanical Engineering Design

What is design?
Design is the application of creativity to planning the optimum solution of
a given problem and the communication of that plan to others.

Given problem
Creativity
Planning
Optimum solution (the best solution for such problem at a time)
Communication

Given problem
Society’s needs
Introduction to Mechanical Engineering Design

What is design?
Design is the application of creativity to planning the optimum solution of
a given problem and the communication of that plan to others.

Given problem
Creativity
Planning
Optimum solution (the best solution for such problem at a time)
Communication

Creativity
Information from society that needs
Designer’s knowledge related to such information
Coming up with something NEW
Introduction to Mechanical Engineering Design

What is design?
Design is the application of creativity to planning the optimum solution of
a given problem and the communication of that plan to others.

Given problem
Creativity
Planning
Optimum solution (the best solution for such problem at a time)
Communication

Planning
Guide map to optimum solution based on such
something NEW
Introduction to Mechanical Engineering Design

What is design?
Design is the application of creativity to planning the optimum solution of
a given problem and the communication of that plan to others.

Given problem
Creativity
Planning
Optimum solution (the best solution for such problem at a time)
Communication

Optimum solution
Solutions to such something NEW are infinite.
Make decision using Engineering Tools such as Mathematics,
Statistics, Computers, Graphics coupled with society’s information.
Optimum solution should be functional, safe, reliable, competitive,
usable, manufacturable, and marketable.
Introduction to Mechanical Engineering Design

What is design?
Design is the application of creativity to planning the optimum solution of
a given problem and the communication of that plan to others.

Given problem
Creativity
Planning
Optimum solution (the best solution for such problem at a time)
Communication

Communication
Tell other people (society) what you have done
Engineer’s success depends on communication skill (writing,
presenting, and speaking)
Introduction to Mechanical Engineering Design

Phases in design
Introduction to Mechanical Engineering Design

What is engineering design?

Design is the application of creativity to planning the optimum solution of
a given engineering problem and the communication of that plan to
others.

Focus on engineering problem.

What is mechanical engineering design?

Design is the application of creativity to planning the optimum solution of
a given mechanical engineering problem and the communication of that
plan to others.

Focus on mechanical elements.

Introduction to Mechanical Engineering Design

Why do we design?
To response such need

What are to be considered when designing?

Functionality, Safety, and Reliability
Strength and Stress
Deflection, Distortion, and Stiffness
Wear, Corrosion, Friction, Thermal, Surface, Noise, and Lubricant
Weight, Shape, Size and Life
Cost, Competition, and Marketability
Much more …
Introduction to Mechanical Engineering Design

Designers’ tools and resources

Computational Tools
CAD/CAM/CAE

Acquiring Technical Information

Libraries
Government sources
Professional societies (Standards: ISO, DIN, JIS, TIS, etc.)
Commercial vendors
Internet (Lots of information )
Introduction to Mechanical Engineering Design

Designing action steps

Understand the problem clearly
Identify what are known
Identify what are unknown and formulate solution strategy
State all assumptions and decisions
Analyze the problem with the solution strategy
Evaluate your solution (Is it sound good for real life?)
Present your solution

As seen in phase design, the design process are interactive and iterative.
Therefore, it may be necessary to repeat some or all of the above steps more
than once if less than satisfactory results are obtained.
Introduction to Mechanical Engineering Design

Economics and environment

Use standard sizes as possible (stock sizes).
Use large tolerances as possible.
Think of mass products (breakeven point).
Think hard of environmental effect.

Safety and product Liability

Manufacturer and designer always take responsibility no matter how
long is the life of a product.
Be careful of excessive promises
Be sure to provide adequate warning and instruction

Designer should always review, test, and control the quality of a product.
Introduction to Mechanical Engineering Design

Stress and strength

Strength is a build-in or inherent property of a material used to manufacture
a product.
Depending on the choice, the treatment, and the processing
of the material
Obtaining by testing (tension test, torsion test, etc.)

Stress is an induced property of a product under a service.

Depending on the external load applied on the product, geometry,
temperature, etc.
Obtaining by analyzing (Mechanics of Materials, Theory of Elasticity,
etc.)
Introduction to Mechanical Engineering Design

Uncertainty concerning stress and strength

Composition of material and effect of variation on properties (Isotropic,
anisotropic, orthotropic materials)
Variation on properties for different places or stocks
Effect of assemblies
Intensity and distribution of loading
Validity of mathematical models used to represent reality (do not forget
your assumptions when making analysis)
Stress concentration
Influence of time (time edge effect, creep)
Effect of corrosion and wear
Much more …
Designers themselves
Introduction to Mechanical Engineering Design

Design factor and factor of safety

How to deal with such uncertainties? Use a design factor.
The design factor is defined as

(1-1)

The parameter can be load, stress, deflection, etc. If the parameter is

load, the maximum allowable load is, then,

(1-2)

Ex 1.1
Introduction to Mechanical Engineering Design

Design factor and factor of safety

After the design completed, the actual design factor may change as a
result of changes such as rounding up to a standard size for cross section
or using off-the-shelf components with higher ratings instead of using
what is calculated by the design factor. The factor, now, refers to as the
factor of safety, . n

Factor of safety has the same definition as the design factor, but it
generally differs numerically.
Generally, n  1.3.
Introduction to Mechanical Engineering Design

Design factor and factor of safety

Stress may not vary linearly with load, using load as the loss-of-
function parameter may not be acceptable. The best way is to use the
design factor in terms of a stress and a relevant strength. Then,

(1-3)

The stress and strength terms must be of the same type and unit.

Ex 1.2
Introduction to Mechanical Engineering Design

Units
Use SI unit system (see more details by yourself).
Some useful rules for number:
1924 or 1 924 but not 1,924
0.1924 or 0.192 4 but not 0.192,4 (Decimal point should always be
preceded by a zero for number less than unity.)
192 423.618 50 but not 192,423.61850
Use prefixes for large and small numbers of possible.
Use the right symbols (k means kilo not K)
Introduction to Mechanical Engineering Design

Calculations and significant figures

The number of significant figures is usually inferred by the number of
figures given (except for leading zeros) showing the accuracy of a
measurement of physical parameters.

Ex. 706, 3.14, and 0.002 19 have three significant figures.

In engineering work, report your results with three or four significant
figures.
Use scientific notation to clarify the accuracy.
91 600 should be 91.6  103 or 91.60  103.
Never report a number of significant figures of a calculation any
greater than the smallest number of significant figures used for the
calculation.
Make all calculations to the greatest accuracy possible and report the
results within the accuracy of the given input.
Introduction to Mechanical Engineering Design

Be Professional

Be ethical people (know what

is right and wrong, what
should and shouldn't do.)
Introduction to Mechanical Engineering Design

Assignment

Read the text book on Load and Stress Analysis.

Introduction to Mechanical Engineering Design

Phases in design (just a copy slide)

Identification of need

Definition of problem

Synthesis or conceptual design

Analysis and optimization

Evaluation
Iteration process

Presentation