01215452 Aircraft Mechanical Design

Week 2: Principles of mechanical design

 Principles of engineering design
PRINCIPLE definition (Oxford University Dict.)
• Origin, source; source of action
• That from which sth. Takes its rise, originates,
or is derived
• A fundamental truth of proposition, on which
many others depend; a fundamental
assumption forming a basis of a chain of
reasoning.

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" discover what is, create what
has never been.”
[Theodore Von Karman (a great mathematician), 1991]

"The seeks to understand the world and

operates against an absolute standard. His findings
either describe accurately or they do not.

By contrast, the is problem oriented. He

seeks not to describe the world but to it...

The engineer lives in the world where science and

values .”
[Edward B. Fiske, 1989]
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ROLE of the engineer:
“…harnessing the great forces in nature for the
use and convenience of Man.”
[The Royal Charter of the Institution of Civil Engineers, England]

“The ENGINEER is a mediator between the

philosopher and the working mechanic and like
an interpreter between two foreigners, must
understand the language of both, hence the
absolute necessity of possessing both practical
and theoretical knowledge.”
[Henry Palmer @inaugural meeting of the ICE on January 2, 1818]

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DESIGN is a particular aspect of the generalized
human activity of decision making.
• Engineering design is a precise, ordered type of
.
• Every time we make a decision we are using the design
process. It is of great importance to all engineers to
realize this - on the one hand it frees us from the feeling
that we are ‘special', cutting us off from the rest of
humanity as , and on the other it frees us to
use our skills at the earlier stages of decision making,
instead of leaving such decisions to be made by other
professionals - lawyers, politicians, accountants,
architects etc.
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 Engineering
requirements

time skill Performance

Products Quality specification

On time
Projects/Services
Budget

• To effect such a delivery, it is necessary to use

an ability of EDUCATION+TRAINING engineer
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• Because of this practical focus the importance
of the early decision making processes is
frequently not appreciated, and major
decisions are left in the hands of the non-
engineering professions, the politicians,
lawyers, accountants or marketing experts.

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• It is clear that the abilities of the engineer can make a
valuable contribution to primary decision making.
• Primary decision making is the first step in design.
• All human beings make decisions.
• The design process begins with major decisions as to
the need to be met.
• As it is important to recognize that this
stage benefits from, and indeed requires, a
professional engineering contribution. Paradoxically,
because of our great success in the delivery process,
we have reduced our contribution to primary decision
making by associating the design activity with the
development of made by others.
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 Improvement of the life’s quality
Need
(individuals/communities)

Engineering
Design Testing the quality of
Related basic design decisions
principles Assumption Engineering
judgement
Parameters
Physics Mathematics
Laws Standards
Statics Dynamics Practices Decision making
Codes
Regulations
Thermodynamics Particular constraints
and directions
Fluid dynamics
Practical design
Aerodynamics
exercises
etc.
Experience Case studies
Practice
etc.
Pragmatism 9
 Three steps to formulate principles
of engineering design
1. Definition of Need: All design begins with a clearly
defined need

2. Creative Vision: All design arise from a creative response

to a need

3. To Deliver: All designs result in a system, product or

project which meets the need
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 Machine design
• Machine composed of many components,
parts move relate to each other and transmit
the power to overcome all resistances of
machine in operating
• Machine design concern form, basic
calculation and principle in material selection
to be suitable with their mission.

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• Machine design is art on create new thing, show
the idea in paper, and rethink to improve the
prototype.
• Art is necessary in design. Good designer should
have art.
“Designer has to apply scientific knowledge to
create the product which can be fabricated with
the engineering basic. The product must work and
save cost of manufacturing and best efficiency”

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 • Imagination and Sketch it!!!
• From prototype, Improve to
working product
• Machine design depends on
industrial characteristic or
machine type. Missions and
Design objectives are the most
important!!!
philosophy • A/C design philosophy need
precision. Care must be
taken in aerodynamic load
and weight. Contrastly,
pressure vessel weight is
not the point.
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 Strength of material: stiffness,
strength

Material properties: material

selection
Machine
designer Manufacturing processes: cost
knowledge
1/2 Environment: corrosion,
temperature

Standard component
-- noise
Ready to make Formula
decision on -- vibration
testing

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 Product design

Economic and competitive cost

Machine
designer Instinct of innovation and creativity

knowledge
2/2 Moreover, safety condition of machine and
user are to be care. Vibration are not over
the safety limit, and assembly is easy.

“No engineer has all knowledges above.

Big company need a lot of specialist with
experience to work together.”

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Design procedure
Requirement
Charactertistic
size, price, quantity, duration, operating
temp, reliability, parameter, code, etc.
Conceptual design
Detail study: declare technical/economic
failure possibility
Preliminary design

Detail design

Prototype

Design for manufacturing

Product
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roll-out
 Airplane design
Design
specification

Design criteria

Basic loads

Laboratory,
Flight test data A/c design
development
test data
Certification test program

Approved type certificate

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 Safety of A/c structure
• Objective: calculate and analysis strength and
safety of structural component. These include
the assemble part at the main frame junction.
• Stressman’s work
– Determine the load distribution througout the
structure.
– Determine the extent to which the element of the
structure are capable of supporting the loads
imposed on them.
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• Draftsman’s work: create lay-out design of
structures, in which he forms the parts for
manufacturing processes assemble plants
• Chief designer: connect between draftsman
and stressman, some component use
experience of draftsman w/o calculation and
analysis. The overview of design must be
approved by chief designer.

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Stressing method:
1. At the stressing stage means understanding the
drawing and visualizing it in your mind so it is being
loaded.
2. The loads are coming in and where the reactions are
being applied
3. The structure is a link between the loads and the
reactions. Between the two it will be pushed or
pulled or sheared or bent or twisted or be subjected
to all of these, some of them simultaneously.

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• Stress analysis
– Investigate the specifications and the
requirements,
– Calculate the loads on the whole structure,
– Multiply by proof and ultimate factors,
– Calculate the loads on the particular item in
question,
– Determine the stresses in the item.

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• Two common ways of quantifying this:
– British method ➔ “Reserve factor”
– American method ➔ “Margin of safety”

• Stressman analyses whether or not a structure

is strong enough.
• Margin of safety (MS)/Factor of safety (FS)
Allowable stress Allowable stress
MS = − 1 or FS =
Applied stress Applied stress
Note MS =0 no margin for safety 23
 LB
• Ex. Max. applied tens. stress = 45530 2
in
LB
Permissible ult. tens. stress of material = 51000 2
in
51000
British system  Reserve Factor , RF =
45530
= 1.12 RF = 1.12
51000 − 45530
American system  Margin of safety, MS =
45530
= 0.12 MS = 0.12

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• MS for BOLTED or RIVETED joints
– In practice, bolted/riveted joint need more
parameter in calculation from average stress
called “FITTING FACTOR, FF ”
– In general, FF  1.15 or 1.20 but in case of
“shock loads” it will be different
and FS = 1.5 lead to ULTIMATE load
Ultimate load = Design load  FF  FS
where
Design load = Applied load  Maneuver Load Factor
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 Design for manufacturing
• Design: responsibility
• Manufacturing: visible for customer
• Final product point of view: market viability,
operational efficiency, capacity for further
development and structural integrity
• Structure must not be so complex or difficult
to be fabrication (increase production cost)
Engineering’s drawing Production Final product

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How an airplane is built

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 Engineer’s responsibility
1. Co-ordinate thoroughly & integrate the
design package into design data NOT BY
ORAL.
2. Establish basics as early as possible; e.g.:-
loads, materials, drawing, design criteria, jug-
fixtures of all construction process.
3. Spend adequate time to plan the job.
4. If problems occurred make sure to give more
details.

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5. Review all fabrication processes, e.g.:-Heat
treatment, stress, forming techniques, etc.
6. Vender production joints for assemble must
conform to shipping limitations
7. Production joints resulting from all processes.
8. How sub-assemble are loaded into final
assembly jigs and fixtures
9. Finally, the most important one is that, the
engineer should dedicate himself/herself to
the job.
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 Principles of producibility design
• General configuration:
– Rectangular vs. tapered wing sections, flaps and control surfaces
– Minimum number of major structures
– Cylindrical, straight, or conical surfaces vs. compound curvature
– Extend of fairing and filleting required

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• Major breakdowns:
– Adequate access for
assembly
– Ease of handling
and transportation
– Completeness of
master breakdown
units
– Assembly joints
– Effectiveness
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• Structure and equipment:
– Simplicity
• Adequate access for fabrication and
subassembly
• Avoid compound curvature
• Free body principles
• Alignment relations
• Minimum fabricating and processing operations
• Straight line systems
• Mechanical simplicity
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• Structure and equipment:
–Detail design
• Adjustment and take-up
• Tolerance
• Adequate clearances
• Rework margins
• Adequate fastener edge distance
• Machining economy
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 Maintainability
Items Civil a/c Military a/c
Total life 15-20 Years, In peacetime (NOT apply
2000-3000 hours/Y, to transport or trainer or
30000-45000 hours coastal)4000-8000 hours
Life of components Spending more period
and wear of the a/c on ground even in
is very important wartime
facilities Amount of Inferior to those of civil,
maintenance is suggest to use built-in
followed by equipment to satisfy
standard law and with major overhauls.
regulation. 36
 Aircraft Loads
• Load factors

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Maneuvering flight path

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Pitching maneuvers

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V-n diagram for maneuver

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Example I: Shrink film oven

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[Advanced and Wise Solutions ]
Example II: Silo

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[Advanced and Wise Solutions ]

Example III: Eco robot 43

Example IV: R/C airplane

[RC Toys & Hobbies]

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Example IV: CH750 Cruzer

[Zenith Aircraft Company]

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