NUST School of Mechanical and Manufacturing Engineering

ME-311 Machine Design

Lecture 1

Instructor: Dr. Jawad Aslam

• Introduction:
– Meaning of Design
– Mechanical Engineering Design
– Design Phases
– Design Considerations
– Design Tools and Resources
– The Design Engineer’s Professional Responsibilities
– Codes & Standards
– Economics
– Stress and Strength
– Uncertainty
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• Meaning of Design
To design is to formulate a plan or strategy for satisfaction of
specified need or solve a problem
Design is a highly innovative and iterative process
Design is also a decision making process
Sometimes, when information is limited, decisions are made
tentatively, with the provision to adjust when more
information is available
A designer will have to effectively communicate and work
with people from different fields and specialisations

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• Meaning of Design
Engineering tools (such as mathematics, statistics, computers,
graphics, languages) are combined to produce a plan that ,
when carried out, produces a product that is functional, safe,
reliable, competitive, usable, manufacturable, and
marketable, regardless of who builds or uses it

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• Mechanical Engineering Design
Mechanical engineers are associated with the production and
processing of energy and with providing means of production,
the tools of transportation, and the techniques of automation
The skills and knowledge base are extensive
Among the disciplinary bases are mechanics of solids and
fluids, mass and momentum transport, manufacturing
processes, and electrical and information theory/technology
Mechanical engineering design involves all the disciplines of
mechanical engineering
Example: A simple journal bearing involves fluid flow, heat
transfer, friction, energy transport, material selection,
thermo-mechanical elements, statistical descriptions and so
on
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• Design Phases
Identification of need
The complete design process, from
start to finish, is often as outlined in
Definition of problem
the figure on the right
Identification of need generally Synthesis
starts the design process
The definition of problem is more Analysis and optimisation
specific and must include all the
specifications for the object that is to Evaluation
be designed Iteration

Presentation

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• Design Phases
The synthesis of a scheme connecting possible system
elements is sometimes called the invention of concept or
concept design
Synthesis and analysis and optimisation are intimately and
iteratively related. Emphasize that design is an iterative
process in which we proceed though several steps, evaluate
the results, and then return to an earlier phase of the
procedure
Evaluation is a significant phase of the total design process.
Evaluation is the final proof of a successful design and usually
involves testing the prototype in a lab
Communicating the design to others is the final, vital
presentation step in the design process
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• Design Considerations
1. Functionality 14. Noise
2. Strength / Stress 15. Styling
3. Distortion / Deflection / 16. Shape
Stiffness 17. size
4. Wear 18. Control
5. Corrosion 19. Thermal properties
6. Safety 20. Surface
7. Reliability 21. Lubrification
8. Manufacturability 22. Marketability
9. Utility 23. Maintenance
10. Cost 24. Volume
11. Friction 25. Liability
12. Weight 26. Remanufacturing/ Resource
13. Life recovery
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• Design Tools and Resources
Computational Tools
CAD
CAE
CFD
FEA
Acquiring Technical Information
Libraries
Government Sources
Professional Societies
Commercial Vendors
Internet Page 9
• The Design Engineer’s Professional Responsibilities
In general, the design engineer is required to satisfy the needs
of customers (management, clients, consumers, etc.)
It is expected to do so in a competent, responsible, ethical
and professional manner
To start on the road to success, you need to cultivate your
professional work ethic and process skills before graduation,
so that when you begin your formal engineering career, you
will be prepared to meet the challenges
Development of communication skills

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• Codes and Standards
A code is a set of specifications for the analysis, design,
manufacture and construction of something
A standard is a set of specifications for parts, materials, or
processes intended to achieve uniformity, efficiency and a specified
quality
Aluminium Association (AA) American Welding Society (AWS)
American Gear Manufacturers American Bearing Manufacturers
Association (AGMA) Association (ABMA)
American Institute of Steel Construction British Standards Institute (BSI)
(AISC) Industrial Fasteners Institute (IFI)
American Iron and Steel Institute (AISI) Institute of Mechanical Engineers
American National Standards Institute (I.Mech.E)
(ANSI) International Bureau of Weights and
ASM International (formerly American Measures (BIPM)
Society for Metals) International Standards Organisation
American Society of Mechanical (ISO)
Engineers (ASME) National Institute for Standards and
American Society for Testing and Technology (NIST)
Materials (ASTM) Society of Automotive Engineers (SAE)Page 11
• Economics
The consideration of cost plays an immensely important role
in the design decision process
We could easily spend as much time in studying the cost
factor as in the study of the entire subject of design
The use of standard or stock sizes is the first principle of cost
reduction
Among the effects of design specifications on costs,
tolerances are perhaps the most significant. Tolerances,
manufacturing processes and surface finish are interrelated
and influence the producibility of the end product in many
ways.
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• Economics
Close tolerances may necessitate additional steps in
processing and inspection or even render a part completely
impractical to produce economically
At times, it happens that when two or more design
approaches are compared for cost, the choice between the
two depends on a set of conditions such as the quantity of
production, the speed of the assembly lines, or some other
condition
There then occurs a point corresponding to equal cost, called
the breakeven point

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• Economics
There are many ways of obtaining relative cost figures so that
two or more designs can be roughly compared
Comparing the monetary cost per unit weight
Compare the number of parts
Other cost estimators such as area, volume, horsepower,
torque, capacity, speed and various other performance ratios

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• Stress and Strength
The survival of many products depends on how the designer
adjusts the maximum stress in a component to be less than
the component’s strength at specific locations of interest
The designer must allow the maximum stress to be less than
the strength by a sufficient margin so that despite the
uncertainties, failure is rare
Strengths are the magnitudes of stresses at which something
of interest occurs, such as the proportional limit, 0.2 percent-
offset yielding, or fracture
Strength is a property of a material or of a mechanical
element
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• Stress and Strength
The strength of an element depends on the choice, the
treatment and the processing of the material
Remember that strength is an inherent property of a part, a
property built into the part because of the use of a particular
material and process
Various metalworking and heat-treating processes, such as
forging, cold forming, cause variations in strength from point
to point throughout a part

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• Uncertainty
Examples of uncertainties concerning stress and strength
include
Composition of material and the effect of its 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
fit on stress conditions
Effect of thermomechanical treatment on properties
Intensity and distribution of loading
Validity of mathematical models used to present reality
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• Uncertainty
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

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Thank you

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