German University in Cairo

Engineering and Material Science

Lecture Notes
Engineering Design
BY : Dr. M. K. Shoukry
Winter 2009-2010
Lecture 1 Introduction
Design
To design is either to formulate a plan for
the satisfaction of a specified need or to
solve a problem.
Engineering design is the process of
devising a component, a system or a
process to meet desired needs
Machine Design:
It is the art o deeloping new ideas or the
construction o a machine to accomplish a speciic
purpose.
1he purpose of machine design calculation:
is to predict the stress or deormation in the part
in order that it may saely carry the loads which will
be imposed upon it. All calculations are dependent
on the shape and dimensions o the part and the
physical properties o its materials ,Steel, C.I,
aluminum, plastic,...,.
Design is
An innovative and iterative process
A communication intensive activity
Subject to constraints
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
Product Life Cycle:
Design
Phase
Production
Phase
Operation
(Utilization)
Retirement
Design Phase
Specification
& Planning
Conceptual Design
Phase
Product Design
Phase
The design phase may be classified into:
Design Procedure
Classification of Machine Drawings
Assembly Drawings
Detail (working or part) Drawings
Schematic Drawings
(Representations)
Patent Drawings
Drawings for Catalogues
Drawings for Instruction Manuals
Assembly Drawing:
A drawing that displays the parts of a machine or a
machine unit assembled in their relative working
positions.
It should satisfy manufacturing, operational and
maintenance requirements.
The main or important view is usually in section to
show all the individual parts, other views or sections
are shown only if they add needed information.
Hidden (dashed or dotted) lines are usually omitted.
Only the overall dimensions and center-to-center
distances, illustrating the relationship of parts to the
machine as a whole are shown. Marking and
numbering of parts are also shown.
Shows a title block or table containing information
about the company, the names of designer and drafter,
the scale and a bill of materials.
Detail (working) Drawing:
Contains, at least, the following information for
the part in the drawing sheet:
1- shape description ( necessary views and
sections )
2- size description ( dimensions)
3- Tolerances ( dimensional and geometrical)
4- Surface roughness
5- Material
Note: every part ( component ) should be drawn
in
a separate drawing sheet.
Design Considerations
1. Strength
2. Stiffness
3. Wear
4. Corrosion
5. Safety
6. Reliability
7. Friction
8. Usability
9. Utility
10. Cost
11. Processing
12. Weight
13. Life
14.Noise
15.Styling
16.Shape
17.Size
18.Control
19.Thermal Properties
20.Surface
21.Lubrication
22.Marketability
23.Maintenance
24.Volume
25.Liability
26.Recovery
Codes and Standards
Standard- a set of specifications for the
analysis, design, manufacture, and
construction of parts, materials, or
processes intended to achieve uniformity,
efficiency, and a specified quality
Code- a set of specifications (standards)
that has been adopted by one or more
governmental bodies or incorporated into
a contract.
Essentially, a code is a set of standards
with the force of law behind it.
Economics
Cost plays an important role in design
decision process (product development cost,
material and manufacturing cost)
The use of standard sizes and large
manufacturing tolerances reduce costs
Evaluating design alternatives with regard to
cost
No matter how great the idea may be, if its
not profitable it may never be seen
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. It doesnt
matter how long after manufacture the
damage occurs, or if the defect is due to a
design or manufacturing error.
Stress & Strength
Strength is a property of a material or of a
mechanical element. It depends upon the
choice, the treatment, and the processing of
the material.
Stress is a state property of a body, which
is a function of load, geometry, temperature
and manufacturing processing.
One of the problems in design is how to
relate the two in order to develop a safe,
reliable, efficient, and economical design.
Measures of Strength
S Strength
S
s
Shear Strength
S
y
Yield Strength
S
u
Ultimate Strength
Measures of Stress
Shear Stress
Normal Stress

1
Principal Stress

y
Stress in y-direction

r
Radial Stress

t
Tangential Stress
Stress Allowable
(AISC)
Tension: 0.45 S
y

all
0.60 S
y
Shear:
all
= 0.40 S
y
Bending: 0.60 S
y

all
0.75 S
y
Bearing:
all
= 0.90 S
y
Loads Used to Obtain Stresses
Where:
W
d
- dead loads
W
l
- live loads
k- service factor
F
w
- wind load
F
misc
- locality effects (earthquakes)

+ + + + =
misc w l l d
l l kl \ \ l
Service Factors
Applications
Elevators
Traveling Crane
Supports
Light Machinery
Supports
Reciprocating
Machinery Supports
Floor and Balcony
Supports
k
2
1.25
1.20
1.50
1.33
Factor of Safety
Design factors (n
d
) are defined as:
and
where
n
s
-accounts for uncertainty of strength
n
z
-accounts for uncertainty of loads
stress
strength
n =
d
z s d
n n n =
Reliability
Probability that a mechanical element will not
fail in use
0 R 1
A reliability of 90% (0.9) means that there is a
90 percent chance that the part will perform its
proper function without failure
Reliability approach to design: the designer
should do his best in the selection of material,
processes, and geometry to achieve reliability
goal
Factor of Safety Method- time proven, widely
accepted
Reliability Approach- new, requires data
Units:
Stress = Force / Area = N / m
2
= Pa (Pascal)
MPa = 10
6
Pa
MPa (N/mm
2
)
- The basic SI units are:
Length m
Mass kg
Time s
Electric current A
Thermodynamic temperature K
o
- The unit of force: F = m.a = kg. m/s
2
= N (Newton)
Units (continued)
The velocity: v = distance / time = m / s
The acceleration a = v / t = (m/s)/s = m / s
2
The moment (Torque) M = force x displacement
M = N . m
The Work done W = force x displacement
W = N . m ( Joule) or J
The Power H = Work / time = (N . m) / s
H = J / s = Watt (W)
or H = Force x velocity = N . (m/s) = W
or H = Torque x angular speed
H = (N . m) . S
-1
= N.m/s = J/s = W
English ( U S A ) units:
Unit of Mass = pound ( lb ) , lbf for force
Unit of distance = foot ( ft )
1 ft = 12 inch ( in )
1 yard ( yd ) = 3 ft
Unit of Moment = ft . lbf
Unit of Power = horsepower ( hp )
1 hp = 550 ft . lbf / s
Unit of Pressure or stress = pound / inch
2
= ( psi )
1 kpsi ( ksi ) = 1000 psi
Units Conversion Factors:
1 inch ( in ) = 25.4 millimeter ( mm )
1 pound ( lb ) = 0.454 kilogram ( kg )
1 mile ( mi ) = 1.61 kilometer ( km )
NOTES:
1 ton ( short ton ) = 2000 lb
1 tonne ( metric tonne) = 1000 kg
kilo = x 10
3
, Mega = x 10
6
, Giga = x
10
9
milli = x 10
-3
, micro = x 10
-6
, nano = x
10
-9