Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.
MODULE 1: INTRODUCTION System is a collection of various entities put together to get desired output. There are many complex system, examples are missiles, space shuttle, human body, a group of interacting mechanical and electrical components and many more. For design and development of a system lot of issues need to take into accounts. System design made systematic approach to reduce error or avoid accident. In a complex system design life cycle approach is very important where design, development, deployment, maintenance and disposal of the system are taken care. A mechanical system consists of (i) a power source and actuators that generate forces and movement, (ii) a system of mechanisms that shape the actuator input to achieve a specific application of output forces and movement, and (iii) a controller with sensors that compares the output to a performance goal and then directs the actuator input. This can be seen in EOT crane, where the power is provided by motor to hoisting drum through gear box and the rotation of the drum converted to linear movement of the rope and hence hoisting load. Similarly Belt Conveyor system, Centrifugal pump, Gear pump, IC Engine and Gear Box system are designed for desire output.
Power flow through a mechanical system provides a way to understand the performance of devices ranging from levers and gear trains to automobiles and robotic systems.
Design Methodology:
To prepare Specification List
Rough sketches of possible Mechanism
Block diagram/General layout for selected mechanism
Design individual components
Prepare Blue-print of design
Figure 1 : Flow Chart for Design Methodology
Step1: To prepare list of specification including the requirement of the products. These requirements include output capacity of product, its service life, Cost, Reliability for some cases. It may also include
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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.
the dimensions and weights of the components. For example: In the design of Motor Bike, the list of the specification will be
1. Fuel Consumption
2. Maximum Speed
3. Carrying Capacity
4. Overall Dimensions (Length, Width and Height)
5. Weight
6. Cost
Step 2: To prepare rough sketches of different possible mechanism. After carefully study of requirements of the product, the designer prepare rough sketches of different possible mechanism. For Example: In the design of punching and blanking, the following mechanism are possible.
1. Mechanism involving crank and connecting rod mechanism, converting rotary motion of the shaft into the translatery motion of the punch. 2. Mechanism involving nut and screw. It is simple and cheap configuration but having poor efficiency. 3. Mechanism involving Hydraulic Cylinder, Piston and Valves which is costly but highly efficient.
All possible mechanism are compared with each other depending upon their cost competitiveness, availability of raw materials and manufacturing facility and Best mechanism is selected.
Step 3: To prepare a Block diagram of general layout of selected configuration. For example the layout of EOT crane will include following components.
1. Motor for the supply of power
2. Clutch to connect and disconnect the motor at the will of operator 3. Coupling to connecting main shaft and clutch shaft. 4. Gear Box to reduce speed from motor speed to required speed. 5. Rope Drum to convert rotary motion to translatery motion of the wire rope. 6. Rope, pulley system and Hook to attach the load.
Step 4. To design individual components which involve following steps.
1. Determine the forces acting on the components.
2. Select the material of the components, depending upon the functional requirement such as strength, rigidity, hardness, wear resistance, fatigue resistance. 3. Determine the most likely mode of failure and depending upon it select the criteria of the failure such as yield strength, ultimate tensile strength, fatigue strength and permissible deflection. 4. Determine the dimensions of the components by assuming suitable factor of safety and the dimensions for the manufacturing facility.
Step 5: To prepare blue print of the design of assembly and components. The dimensions, tolerances surface finish and manufacturing methods are specified on the drawing.
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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.
Morphology of design
Morphology of design implies step by step procedure involved in the phase of design process. The flow chart for the morphology is as below.
Primitive Need
Feasibility Study
Preliminary Design
Detailed Design
Planning for Manufacturing
Planning for Distribution
Planning for Consumption
Planning for Retirement of the product
Figure 2 : Flowchart for the phases in the morphology of design
Design process begin with the realization of unfulfilled need of the society and ends with satisfying them. Feasibility study, Preliminary design and detailed design are the primary design phases and remaining are phases in production consumption cycle.
1. Feasibility Study involves:
• Verifying current existence of need. • Exploring design problem with constraints. • Effort to seek number of feasible solution. • Sorting of potential useful solution from feasible set. 2. Preliminary design involve: • Formation of mathematical model. • Sensitivity analysis, Compatibility analysis, Stability analysis. • Formal optimization. • Projection in future. • Testing design concept and simplification.
(Methods like FEA, CFD are used for design analysis)
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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.
3. Detailed Design involves
• Exploration in the large scale come to an end. • Simulation analysis may be tried. • Components and partial prototype can be tested. 4. Planning for Manufacturing involves • The decision to produce. • Economic commitment and financial capabilities • Business condition before arriving at a final decision. 5. Planning for Distribution involves • Designing the packaging of the product. • Planning warehouse system. • Planning Promotional activities. 6. Planning for Consumption involves • Design for maintenance. • Design for reliability. • Design for safety. • Aesthetic feature and operational economy. • Adequate duration of service. 7. Planning for Retirement • Often goods are retired more frequently because of technical obsolescence than for physical deterioration. • Sometime it may be deliberate attempt from the industry so as to bring in new improved product range.
Optimum design and system concept in design:
Optimum design is the process of selecting the best possible design satisfying certain criteria among many feasible design or adequate design. In optimum design desirable effects are maximized and undesirable effects are minimised. For Optimisation minimising parameters are cost, weight, size, stress, deflection etc. and maximizing parameters are Power transmitting capacity, load carrying capacity, energy storing capacity etc.
There are three design parameters: 1) Functional required parameter, 2) Material parameter and 3) Geometrical parameters.
For Optimum design, Johnson method is popular method. In this method Johnson suggested three different equation.
1) Primary Design Equation (PDE): These are most important equations which takes care of cost, weight and significant undesirable effect to be minimised. 2) Subsidiary Design Equation (SDE): These are other than primary design equations like stress equation. 3) Limit Equation (LE): Ranges of certain parameters are expressed in Limit Equation.
There are three categories of optimum design 1) Normal Specification 2) Redundant Specification and 3) Independent Specification
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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.
Optimum Design Procedure for Normal Specification
1. Selection of geometrical parameters. 2. Decide basis for optimum design. 3. Write Primary Design Equations (PDE). 4. Write all Subsidiary Design Equation (SDE) and Limit Equation (LE). 5. Classified all parameters from PDE, SDE and LE. 6. Combine SDE with PDE and eliminate common unspecified parameter. 7. Combined PDE with LE and eliminate common parameters. 8. Using PDE, find the material selection parameters. 9. Determine optimum values of eliminated parameters using original SDE.
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