Mechanical Engineering Design

Introduction to Mechanical

‫فراس الشمراني‬
 Introduction to Mechanical Engineering
Design
• Design 4
• 1–2 Mechanical Engineering Design 5
• 1–3 Phases and Interactions of the Design Process 5
• 1–4 Design Tools and Resources 8
• 1–5 The Design Engineer’s Professional Responsibilities 10
• 1–6 Standards and Codes 12
• 1–7 Economics 13
• 1–8 Safety and Product Liability 15
• 1–9 Stress and Strength 16
• 1–10 Uncertainty 16
• 1–11 Design Factor and Factor of Safety 18
• 1–12 Reliability and Probability of Failure 20
• 1–13 Relating the Design Factor to Reliability 24
• 1–14 Dimensions and Tolerances 27
• 1–15 Units 31
• 1–16 Calculations and Significant Figures 32
• 1–17 Design Topic Interdependencies 33
• 1–18 Power Transmission Case Study Specifications
 Design
 To design is either to formulate a plan for the satisfaction
of a specified need or to solve a specific problem to
produces a product that is:
Functional
Safe.
Reliable.
Competitive.
Usable.
Manufacturable.
Marketable.
 Mechanical Engineering Design
• Mechanical engineers are associated with the production and
processing of energy and with providing the means of
production, the tools of transportation, and the techniques of
automation.
 Phases and Interactions of the Design
Process
• The complete design process, from start to finish, is often
outlined as in Fig. 1–1. The process begins with an
identification of a need and a decision to do something about
it.
 Design Considerations
1.Functionality 14.Noise
2.Strength/stress 15.Styling
3.Distortion/deflection/stiffness 16.Shape
4.Wear 17.Size
5.Corrosion 18.Control
6.Safety 19.Thermal properties
7.Reliability 20.Surface
8.Manufacturability 21.Lubrication
9.Utility 22.Marketability
10.Cost 23.Maintenance
11.Friction 24.Volume
12.Weight 25.Liability
13.Life 26.Remanufacturing/resource recovery
 Design Tools and Resources
• Computational Tools:
 Aries
 AutoCAD
 CadKey
 I-Deas
 Unigraphics
 Solid Works
 ProEngineer
 Acquiring Technical Information
• Libraries (community, university, and private).
• Government sources.
• Professional societies.
• Commercial vendors.
• Internet.
 The Design Engineer’s Professional
Responsibilities
• Understand the problem.
• Identify the knowns.
• Identify the unknowns and formulate the
solution strategy.
• State all assumptions and decisions.
• Analyze the problem.
• Evaluate your solution.
• Present your solution.
 Standards and Codes
• A standard is a set of specifications for parts,
materials, or processes intended to achieve
uniformity, efficiency, and a specified quality.
• A code is a set of specifications for the
analysis, design, manufacture, and
construction of something.
 Economics
• Standard Sizes
The use of standard or stock sizes is a first principle of cost reduction.
• Large Tolerances
Among the effects of design specifications on costs, tolerances are perhaps
most
significant.
• Breakeven Points
depends on a set of conditions such as the quantity
of production, the speed of the assembly lines, or some other condition.
• Cost Estimates
depending upon the application, such as area, volume, horsepower, torque,
capacity, speed, and various performance ratios.
 Safety and Product Liability
• This concept states that the manufacturer of
an article is liable for any damage or harm that
results because of a defect.
 Stress and Strength
• the designer adjusts the maximum stresses in
a component to be less than the component’s
strength at critical locations.
Strength is a property of a material or of a mechanical element.
Stress is a state property at a specific point within a body, which is a function of
load, geometry, temperature, and manufacturing processing.
 Uncertainty
• • Composition of material and the effect of variation on properties.
• • Variations in properties from place to place within a bar of stock.
• • Effect of processing locally, or nearby, on properties.
• • Effect of nearby assemblies such as weldments and shrink fits on stress
conditions.
• • Effect of thermomechanical treatment on properties.
• • Intensity and distribution of loading.
• • Validity of mathematical models used to represent reality.
• • Intensity of stress concentrations.
• • Influence of time on strength and geometry.
• • Effect of corrosion.
• • Effect of wear.
• • Uncertainty as to the length of any list of uncertainties.
 design factor

the design factor nd is defined as

 Design Factor and Factor of Safety
 Often used when statistical data is not available
 Since stress may not vary linearly with load, it is more common to express the
design factor in terms of strength and stress.
 All loss-of-function modes must be analyzed, and the mode with the smallest design
factor governs.
 Stress and strength terms must be of the same type and units.
 Stress and strength must apply to the same critical location in the part.
 The factor of safety is the realized design factor of the final design, including
rounding up to standard size or available components.
Example 1–2
Reliability and Probability of Failure
• The reliability method of design is one in which we obtain the
distribution of stresses and the distribution of strengths and
then relate these two in order to achieve an acceptable
success rate.
• The statistical measure of the probability that a
• mechanical element will not fail in use is called the reliability
of that element and as we will see, is related to the
probability of failure, pf.
 Probability of Failure
The probability density function (PDF) of the Gaussian distribution is expressed
in terms of its mean, mx, and its standard deviationˆx
• To obtain values of pf, integration of Eq. (1–4)
is necessary. This can come easily from a table
if the variable x is placed in dimensionless
form. This is done using the transform
 Discrete Mean and Standard Deviation

• xi is the value of an event (i = 1, 2, … k)

• fi is the class frequency, or number of times the event xi occurs
within the class frequency range
• The discrete mean is

• The discrete standard deviation is

Shigley’s Mechanical Engineering Design

Example 1–5
 Reliability
• The reliability is related to the probability of failure by

• Example: If 1000 parts are manufactured, with 6 of the

parts failing, the reliability is
 Reliability
• Series System – a system that is deemed to have failed if
any component within the system fails
• The overall reliability of a series system is the product of
the reliabilities of the individual components.

• Example: A shaft with two bearings having reliabilities of

95% and 98% has an overall reliability of
R = R1 R2 = 0.95 (0.98) = 0.93 or 93%
 Relating Design Factor to Reliability
• Reliability is the statistical probability that machine systems and
components will perform their intended function satisfactorily
without failure. Stress and strength are statistical in nature and
very much tied to the reliability of the stressed component.
Consider the probability density functions for stress and strength,
s and S, shown in.
 the “average” design factor is

Fig. 1–7a. The mean values of stress and strength are s 5 ms and S 5 mS, respectively.
Here, the “average” design factor is

The margin of safety for any value of stress s and strength S is defined as
• Reliability is the probabilityp that m . 0. That
is,
 Comparing Fig. 1–7b with Table A–10, we see that

 Torelate to the design factor, , divide each term on

the right side of Eq. (1–10) by ms and rearrange:
 Define coefficients of variance for strength and stress

 Rewrite Eq. (e),

 Squaring and solving for the design factor,

 The plus sign is for R > 0.5, and the minus sign for R ≤ 0.5
 Insummary, Eq. (1–12) relates the design factor to the reliability
goal (through the transform variate) and the coefficients of
variation of strength and stress.
Example 1–6
Example 1–6
 Dimensions and Tolerances
• Nominal size. The size we use in speaking of an element.
• Limits. The stated maximum and minimum dimensions.
• Tolerance. The difference between the two limits.
• Bilateral tolerance. The variation in both directions from the basic
dimension.
• Unilateral tolerance. The basic dimension is taken as one of the limits, and
variation is permitted in only one direction.
• Clearance. A general term that refers to the mating of cylindrical parts such
as a bolt and a hole.
• Interference. The opposite of clearance, for mating cylindrical parts in
which the internal member is larger than the external member.
• Allowance. The minimum stated clearance or the maximum stated
interference for mating parts.
• Fit. The amount of clearance or interference between mating parts.
• GD&T. Geometric Dimensioning and Tolerancing (GD&T).
 Choice of Tolerances
• The cumulative effect of individual tolerances must be
allowed to accumulate somewhere. This is known as
tolerance stack-up.
• Chain dimensioning allows large stack-up of many small
tolerances in series.

• Baseline dimensioning minimizes large tolerance stack-

up.
 Choice of Dimensions
• Dimensioning a part is the designer’s responsibility.
• Include just enough dimensions
• Avoid extraneous information that can lead to confusion or multiple
interpretations.
• Example of over-specified dimensions. With +/– 1 tolerances, two
dimensions are incompatible.