Machine Design and CAD II

(ME321)

Chapter 1
Introduction
- Engineering Design

As many definitions as many there are designs………

…. because process of design is such a common human

experience

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Introduction
- Engineering Design

What do we How can we

want to achieve achieve it

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Introduction
- Engineering Design
As per Webster’s Dictionary

“To fashion after a plan”

Is this definition complete…?

If NO…..What is missing in it….?

“the essential fact; design is to create something that has

never been”

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Introduction
- Engineering Design
• Engineering Designer, artist, a composer, a playwright
and other creative members practice design by this
definition
• Professional practice of Engineering is concerned with
Design

Then what is the …Formal Definition of Design..?

“Design establishes and defines solutions to and relevant

structures for problems not solved before or new solutions
to and which have previously been solved in a different
way”
Conclusion

Essence of Engineering is ‘DESIGN’

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Introduction
- Engineering Design
Ability to Design is both a Science and an Art

Science: is learned through techniques and methods used

Art: is best learned by doing Design
Discovery: Is getting the first sight of, or first knowledge of
something
We can discover what has already existed but has not
been known before

“Design should not be confused with Discovery”

Design is the product of “Planning and Work”
Invention:
“Design may or may not involve invention as some are
truly inventive but most are not”
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Introduction
- Engineering Design
What is a Good Design…… ?
“Good design requires both Analysis and Synthesis”
Analysis
Decomposing problem into manageable parts
• To understand performance/behavior of parts in service
using appropriate discipline of science/engineering and
computational tools
• Usually involves simplification of real world problems
through models
Synthesis
Identification of Design Elements that will comprise
• Product
• Its decomposition into parts
• Combination of part solutions into a totalworkable
system
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Introduction
- Engineering Design

What is Final Design…… ?

• Is it the best, most efficient. Only time will tell….!!!!!

• Rarely known the correct answer
• One is hopeful that “His Design will Work”

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Introduction
- Engineering Design

“Engineering Design extends beyond the boundaries of

Science”
As a Design Engineer during professional career you may
have the opportunity
• To create dozens of designs
• Have satisfaction of seeing them become working
reality
As Scientist during professional career you may have the
opportunity
• To make one creative addition to human knowledge in
your whole life and many never do so
• Can discover a new star but can not make one
• Have to ask an Engineer to do it for him
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Introduction
- Engineering Design

Set of decision making processes and activities to

determine the form of an object, given the customer’s
desired function.

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Introduction
- Engineering Design
control
hold
move
Function
protect
store
Design decision making processes

shape
configuration
Form
size
materials
manufacturing
processes

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Introduction
- Engineering Design

Material

Manufacturing Mechanics

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Introduction
- Stages of Design
Establish functional requirements
Formulating Determine constraints
Problem Set performance targets
Design specifications

Create alternative forms

Generating (shape, configuration, size, materials,
Alternatives manufacturing processes)
Redesign
iteration

all alternatives

Analyzing
Alternatives
feasible alternatives

Evaluating
Alternatives

best alternative design candidate

Manufacturing specifications
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Introduction
- Engineering Analysis

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Introduction
- Engineering Analysis

Form is the solution to a design problem.

Predicted behavior is the solution to an analysis

problem.

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Introduction
- Stages of Analysis

Understand the problem and plan its solution

Formulating

Determine unknowns
Solving

Examine the validity, accuracy and precision of

Checking solution

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Introduction
- Design Phases
The tool has a drive shaft that cannot be stopped other
than by turning off the power and waiting about 90
seconds for the shaft to spin-down.
The customer considers this a safety hazard and would
like to actuate some device that would bring the shaft to
a quicker stop.
Design and fabricate a solution to accomplish the rapid
stopping of the shaft.
(8 inch diameter, 1000 lbs, steel, 3000 rpm)

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Introduction
- Design Phases
Formulation

Concept

Preliminary Configuration
Design
Embodiment
Design
Parametric

Detail
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Introduction
- Design Phases
- Formulation Phase

we decide upon the specifics of the function to be

performed:

• Decide upon a satisfactory rate of deceleration

• Determine the length of the shaft
• Determine where it is supported
• Determine what actuating energy is available

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Introduction
- Design Phases
- Concept Design Phase

Decide physical principles that will perform the function

1. surface friction (e.g. drum brake, disk)

2. opposing magnetic fields (e.g. inverse motor)
3. air friction (e.g. fan blades)

Assume we decide on surface friction

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Introduction
- Design Phases
- Configuration Design Phase

Decide upon product components & how they are arranged

Decide upon part features & how they are arranged

Product configuration:
disk, or drum, or band brake
location on shaft (right. left, middle)
(Assume we decide on a disk brake)
Part configuration:
relative size of hub to disk
relative size of rotor thickness to diameter

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Introduction
- Design Phases
- Parametric Design Phase

Decide upon specific values for design variables

1. rotor diameter (outer)

2. rotor thickness
3. brake pad width
4. pad material
5. hydraulic pressure on piston

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Introduction
- Design Phases
- Detailed Design Phase

Decide upon the remaining manufacturing specifications

• machined rotor tolerances

• pad bonding resin
• assembly/testing procedure

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Introduction
- Types of Design

• Variant Design
• Adaptive Design
• Original Design
• Selection Design
• Redesign

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Introduction
- Types of Design

 Variant Design

• Modify the performance of an existing product by

varying some of its design variable values or
product parameters such as size, or specific material
or manufacturing processes
• Using aluminum for a part rather than steel to
reduce weight

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Introduction
- Types of Design

 Adaptive Design
• Adopt a known solution to accomplish a new task
• Adapting the cell phone concept to include personal
digital assistant functions.

 Original Design
 Development of a new component, assembly, or
process that had not existed before

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Introduction
- Types of Design

 Selection Design
• Match the desired functional requirements of a
component with the actual performance of standard
components.
 Redesign
 Modify parts , subassemblies by changing their
shapes, sizes, configuration, materials, and
manufacturing processes.

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Introduction
- Types of Design
Formulation
original
design selection
Redesign design
Concept Design variant
design
Configuration Configuration
Design Design

Parametric Design Parametric Design Parametric Design

Detail Design Detail Design Detail Design Detail Design

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Introduction
- Design Process

 Iterative in nature
 Requires initial estimation,
followed by continued
refinement

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Introduction
- Final Product

 Products should be
 Functional
 Safe
 Reliable
 Competitive
 Usable
 Manufacturable
 Marketable

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Introduction
- Final Product
 Some characteristics that influence the design

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Introduction
- Computational Tools
 Computer-Aided Engineering (CAE)
 Any use of the computer and software to aid in the
engineering process
 Includes
 Computer-Aided Design (CAD)
 Drafting, 3-D solid modeling, etc.
 Computer-Aided Manufacturing (CAM)
 CNC tool path, rapid prototyping, etc.
 Engineering analysis and simulation
 Finite element, fluid flow, dynamic analysis, motion, etc.
 Math solvers
 Spreadsheet, procedural programming language, equation
solver, etc.
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Introduction
- Standards and Codes
 Standard
 A set of specifications for parts, materials, or processes
 Intended to achieve uniformity, efficiency, and a specified quality
 Limits the variations
 Code
 A set of specifications for the analysis, design, manufacture, and
construction of something
 To achieve a specified degree of safety, efficiency, and performance
or quality
 Does not imply absolute safety
 Various organizations establish and publish standards and
codes for common and/or critical industries
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Introduction
- Standards and Codes
 Some organizations that establish standards and codes of
particular interest to mechanical engineers:

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Introduction
- Economics

 Cost is almost always an important factor in

engineering design.
 Use of standard sizes is a first principle of cost
reduction.
 Certain common components may be less
expensive in stocked sizes.

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Introduction
- Breakeven Points
 A cost comparison between two possible production methods
 Often there is a breakeven point on quantity of production
EXAMPLE
 Automatic screw
machine
 25 parts/hr
 3 hr setup
 $20/hr labor cost
 Hand screw machine
 10 parts/hr
 Minimal setup
 $20/hr labor cost
 Breakeven at 50 units 36
Introduction
- Tolerances

 Close tolerances
generally increase cost
 Require additional
processing steps
 Require additional
inspection
 Require machines with
lower production rates

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Introduction
- Safety and Product Liability

 Strict Liability concept generally prevails in U.S.

 Manufacturer is liable for damage or harm that results
because of a defect.
 Negligence need not be proved.
 Calls for good engineering in analysis and design, quality
control, and comprehensive testing.

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Introduction
- Stress and Strength

 Strength
 An inherent property of a material or of a mechanical element
 Depends on treatment and processing
 May or may not be uniform throughout the part
 Examples: Ultimate strength, yield strength
 Stress
 A state property at a specific point within a body
 Primarily a function of load and geometry
 Sometimes also a function of temperature and processing

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Introduction
- Example 1-1

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Introduction
- Design Factor or 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.
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Introduction
- Example 1-2

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Introduction
- Dimensions and Tolerances
 Nominal size: The size we use in speaking of an element.
 Limits: The stated maximum and minimum limits.
 Tolerance: The difference between the two limits.
 Bilateral tolerance: The variation in both directions from the basic
dimension.
 Unilateral tolerance: The variation is permitted in only one
direction.
 Clearance: Refer to cylindrical parts, the measured difference in
the two diameters
 Interference: Opposite of clearance, internal member is larger
than external member (press fit).
 Allowance: The minimum stated clearance or the maximum
stated interference for mating parts.
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Introduction
- Summary
 J.E. Shigley, et.al, “Mechanical Engineering Design,” 9th Edition, McGraw
Hill (Read Chapter No 1)

 Rudolph J. Eggert; “Engineering Design” Prentice Hall (Read Chapter No 1)

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