Chapter 1:

Introduction
 WHAT IS A MACHINE
 MACHINE : A device for
transforming or transferring energy.

An apparatus consisting of
interrelated units (machine
elements).

A device that modifies force and

motion.
 A machine receives energy in some
available form and uses it to do
some particular kind of work

 A petrol engine is a machine, which

may use the heat energy derived
from the combustion of the fuel to
propel a vehicle along the road
 A lathe is a machine which receives
mechanical energy from the line shaft
through the belt or gears and uses that
energy to remove metal from a bar or
other piece of work.

 LINK OR ELEMENT : Each part of a

machine which has motion relative to
some other part.

 STRUCTURES : Made up of series of

members of regular shape that have a
particular function for load carrying.
 SYNTHESIS : Concerned with the
problem of selecting the size of the
mechanism to perform a given
function

 STRESS : Internal reacting force per

unit area due to the effects of
external applied forces
DESIGN
 Formulate a plan for the satisfaction
of a human need

 The need for the problem has to be

identified

 Design problem have no unique

answer
 A good answer today may well turn
out to be a poor answer tomorrow, if
there is a growth of knowledge
during the period

 A design is always subject to certain

problem-solving constraints

 A design problem is not a

hypothetical problem
 Design has an authentic purpose

the creation of an end result by

taking definite action, or

the creation of something

having physical reality
ENGINEERING DESIGN
 The process in which scientific
principles and the tools of
engineering mathematics,
computers, graphics and English are
used to produce a plan which, when
carried out, will satisfy a human
need.
 MECHANICAL
ENGINEERING DESIGN
 Design of things and systems of
mechanical nature, machines,
products, structures, devices, and
instruments

 For the most part, mechanical

design utilizes mathematics, the
materials sciences, and the
engineering mechanics sciences
 The ultimate goal in machine design
is to

size and shape the parts

choose appropriate material and
choose manufacturing process

So that resulting machine can be

expected to perform its intended
function without failure
 An engineer should be able to
calculate and predict the mode and
conditions of failure for each
element and then design it to
prevent that failure

 This requires stress and deflection

analysis for each part
 Stresses are functions of applied and
inertial loads

 An analysis of the forces, moments,

torques and dynamics of system
must be done before stresses and
deflections can be completely
calculated
Design
 A design must be:
 Functional- fill a need or customer expectation
 Safe- not hazardous to users or bystanders
 Reliable- conditional probability that product will
perform its intended function without failure to a
certain age.
 Competitive- contender in the market
 Usable- accommodates human size and strength
 Manufacturable- minimal number of parts and
suitable for production
 Marketable- product can be sold and serviced
Design Process Actions
 Conceive alternative solutions
 Analyze, test, simulate, or predict
performance of alternatives
 Choose the “best” solution
 Implement design
Design is…
 An innovative and iterative process
 A communication intensive activity
 Subject to constraints
Steps to Design
 Design Considerations
1. Strength 14. Noise
2. Stiffness 15. Styling
3. Wear 16. Shape
4. Corrosion 17. Size
5. Safety 18. Control
6. Reliability 19. Thermal Properties
7. Friction 20. Surface
8. Usability 21. Lubrication
9. Utility 22. Marketability
10. Cost 23. Maintenance
11. Processing 24. Volume
12. Weight 25. Liability
13. Life 26. Recovery
 Codes and Standards
 Code- a set of specifications for the
analysis, design, manufacture, and
construction of something

 Standard- a set of specifications for

parts, materials, or processes
intended to achieve uniformity,
efficiency, and a specified quality
 Organizations
 Aluminum Association (AA)  American Bearing
 American Gear Manufacturers Association
Manufacturers Association (ABMA)
(AGMA)  British Standards Institute (BSI)
 American Institute of Steel
 Industrial Fasteners Institute
Construction (AISC) (IFI)
 Institution of Mechanical
 American Iron and Steel Engineers (I. Mech. E.)
Institute (AISI)  International Bureau of Weights
 American National Standards and Measures (BIPM)
Institute (ANSI)  International Standards
 American Society for Metals Organization (ISO)
(ASM)  National Institute for Standards
 American Society of and Technology (NIST)
Mechanical Engineers  Society of Automotive
(ASME) Engineers (SAE)
 American Society of Testing  American Society of
Materials (ASTM) Agricultural and Biological
 American Welding Society (AWS) Engineers (ASABE)
 Economics
 Cost plays an important role in design
decision process
 No matter how great the idea may be, if
it’s not profitable it may never be seen
 The use of standard sizes and large
manufacturing tolerances reduce costs
 Evaluating design alternatives with
regard to cost
 Breakeven Points
 Cost Estimates
 Product Liability
 “Strict liability” concept prevails in
the U.S.
 Manufacturers are liable for any
damage or harm that results from a
defect.
 Uncertainty
 Roman Method- repeat designs that are
proven
 Factor of Safety Method of Philon- separate
the loss-of-function load and the impressed
Loss of Function
load using a ratio
n 
d
Impressed Load

 Permissible Stress- fraction of significant

material property (i.e., strength)
 Uncertainty
 Design Factor Method- factor of safety is
increased with rounding error to achieve
nominal size (5.3 mm designed bolt size is
increased to 6.0 mm)
 Stochastic Design Factor Method-
uncertainty in stress and strength is
quantified for linearly proportional loads
s Average Strength
nd  
 Average Stress
 Measures of Strength
 S – Strength
 Ss – Shear Strength
 Sy – Yield Strength
 Su – Ultimate
S
Strength
 - Mean
Strength
 Measures of Stress
  – Shear Stress
 –Normal Stress
 –Principal Stress
 y– Stress in y-direction
 r– Radial Stress
 t– Tangential Stress
 Stress Allowable
(AISC)
 Tension: 0.45 Sy ≤ all ≤ 0.60 Sy
 Shear: all = 0.40 Sy
 Bending: 0.60 Sy ≤ all ≤ 0.75 Sy
 Bearing: all = 0.90 Sy
 Loads Used to Obtain
Stresses
F  W   W   kF  F   F
d l l w misc

 Where:
Wd- dead loads
Wl- live loads
k- service factor
Fw- wind load
Fmisc- locality effects (earthquakes)
 Service Factors
Applications k
Elevators 2
Traveling Crane 1.25
Supports
1.20
Light Machinery
1.50
Supports
Reciprocating
Machinery Supports 1.33
Floor and Balcony
Supports
 Factor of Safety
 Design factors (nd) are defined as:
strength
nd 
stress
and

n d n s n z
where
ns-accounts for uncertainty of strength
nd-accounts for uncertainty of loads
Realized Factor of Safety

S
nr 

Ss
nr 

 Reliability
 Probability that a mechanical element
will not fail in use
0≤R≤1
 Reliability approach to design: judicious
selection of material, processes, and
geometry to achieve reliability goal
 Factor of Safety Method- time proven,
widely accepted
 Reliability Approach- new, requires data