Introduction to Mechanical Engineering Design

LECTURE NOTES- MECE 304 Mechanical Machine Elements Chapter 1- Introduction to Mechanical Engineering Design (Notes from: Chapter 1 and 2 in Budynas R.G., Nisbett J.K., Shigleys Mechanical Engineering Design, Mc Graw Hill, 8th Edition)

Spring Semester 2008/2009 Halil Orhan YILDIRAN, MS

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Introduction to Mechanical Engineering Design 1-1* Design: Is an innovative and iterative process. 1-2*Mechanical Engineering Design: Machine design, machine elements design, machine component design, system design and fluid power design, internal combustion engine design etc are all focused to mechanical engineering design. 1-3*Phases of design process:

Fig- The phases in design

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Introduction to Mechanical Engineering Design *Design considerations:

1 Functionality 2 Strength/stress 3 Distortion/deflection/stiffness 4 Wear 5 Corrosion 6 Safety 7 Reliability 8 Manufacturability 9 Utility 10 Cost 11 Friction 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 Remanufacturing/resource recovery

Introduction to Mechanical Engineering Design 1-4*Design tools: *Computational tools: AutoCad, CadKey, Catia, ProEngineer, ANSYS, CFD++, ADAMS, Matcad, Matlab *Acquiring technical information 1-5*The design engineers professional responsibilities Satisfy the needs of a customer Use a systematic approach (Understand, Identify, assumptions, analysis, evaluation, presentation) 1-6*Standard and Codes A standard is a set of specification for the parts, processes and materials intent to achieve uniformity A code is a set of specifications for the analysis, design, manufacture and construction of something.
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Introduction to Mechanical Engineering Design 1-7*Economics *Standard sizes *Large tolerances *Breakeven points *Cost estimates

Fig- A breakeven point

Introduction to Mechanical Engineering Design

Fig-Cost vs tolerance/mch. process

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Introduction to Mechanical Engineering Design 1-8*Safety and Product Liability Manufacturer of an article is liable for any damage or harm that results because of a defect. Analysis and design, quality control and testing procedures are important. Warnings and instructions for use 1-9*Stress and Strength: Strength is a property of a material or of a mechanical element. Various metal working and heat treating processes cause variations in strength. Stress is a state of property at a specific point within a body which is a function of load, geometry, temperature and manufacturing process.
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Introduction to Mechanical Engineering Design

1-10*Uncertainty: Examples of uncertainties concerning stress and strength include: *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. Engineers must accommodate uncertainty.
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Introduction to Mechanical Engineering Design 1-11*Design Factor and Factor of Safety Load vs loss of function, nd (design factor) nd=loss of function/maximum allowable parameter
EXAMPLE 1-1 Consider the maximum load on the structure is known with an uncertainity of 20 %, the load causing failure is known within 15 %. If the load causing failure is nominally 9 kN, determine the design factor and the maximum allowable load that will ofset the absolute uncertainities. Solution: To account for its uncertainity the loss of function load must increase to 1/0.85, whereas the maximum allowable load must decrease to1/1.2. thus to offset the absolute uncertainities the design factor should be: 1 / 0.85 Ans wer nd = =1.4 1 / 1.2 From Eq 1-2 the maximum allowable load is found to be 9 Answer Maximum allowable load= =6.4 kN 14

Introduction to Mechanical Engineering Design

It is more common to express the design factor in terms of stress and a relevant strength. Thus: nd =loss-of-function strength/allowable stress=S/
EXAMPLE 1-2 A rod with a cross sectional area of A and loaded in tension with an axial force of P=9 kN undergoes a stress of = P/A. Using a material strength of 168 N/mm2 and a design factor of 3, determine the minimum diameter of a solid circular rod . Using Table A-15, select a preferred fractional diameter and determine the rods factor of safety. Solution: Since A=d2/4 and = S/nd, then, S 168 P 9000 = = = = nd 3 A .d 2 / 4 or
4 Pnd 4(9000)3 Ans wer d= = =14.3 mm .S .168 From Table A-15 the next higher preferred size is 16 mm. Thus, according to the same equation developed earlier, the factor of safety n is .Sd 2 (168)16 2 Answer n= = =3.75 4P 4(9000) Thus rounding the diameter has increased the actual design factor.
1/ 2 1/ 2

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Introduction to Mechanical Engineering Design 1-12*Reliability. Is the statistical measure of probability that a mechanical element will not fail in use . The failure of 6 parts out of every 1000 manufactured parts migth be considered as an acceptable failure rate for a certain class of products. This represents a reliabilty of R=1-(6/1000)=0.994

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Introduction to Mechanical Engineering Design

1-13*Dimension and Tolerances. The following terms are used generally in dimensioning: *Nominal size. The size we use in speaking of an element. For example, we may spec-ify a 40 mm pipe or a in bolt. Either the theoretical size or the actual measured size may be quite different. The theoretical size of a 40 mm pipe is 47.5 mm for the out-side diameter. And the diameter of the in bolt, say, may actually measure 0.492 in. *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. That is, the basic size is between the two limits, for example, 250.05 mm. The two parts of the tolerance need not be equal. *Unilateral tolerance. The basic dimension is taken as one of the limits, and variation is permitted in only one direction, for example, 25 +0.05-0.00 mm 12

Introduction to Mechanical Engineering Design 1-13*Dimension and Tolerances(contnd) *Clearance. A general term that refers to the mating of cylindrical parts such as a bolt and a hole. The word clearance is used only when the internal member is smaller than the external member. The diametral clearance is the measured difference in the two diameters. The radial clearance is the difference in the two radii. *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.

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Introduction to Mechanical Engineering Design 2-1*Material Strength and Stiffness

Fig-Stress strain diagram obtained through a standard tensile test; (a) ductile materials, (b) brittle materials
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Introduction to Mechanical Engineering Design 2-21*Material Selection List of important properties associated with the design eg., strength, stiffness and cost. For each property list all available materials and rank them in the order beginning with the best material.

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