Assistant Professor, Mechanical Engineering Department

Faculty of Engineering at Helwan, Helwan University

Today Lecture
• Basic Definitions

• Role of Design in Product cycle

• Classifications of Machine Design

• General Considerations in Machine Design

• Importance of Design

• General Design Procedure in Machine Design

What is “Design” ?
It Can Be Defined As:

“ The art of planning for devising new or

improved products to accomplish specific

purposes”.
What is a Machine ?
In general, a machine consists of a combination of

several different mechanical elements properly

designed and arranged to work together, as a whole.

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In
Mechanical Engineering:
A machine is a group of mechanical components
assembled together to perform a specific function.

These components are first Designed then

Manufactured according to

“The Product Cycle”

 • The Role of Machine Design In The Product Cycle
Machine
Design

Product Engineering Working

Concept (2) Design (3) Drawing (4)

Customers
& Process
Markets Planning (5)
(1)

Quality Control Manufacturing Production

(8) Processes (7) Scheduling (6)
Machine Design Requirements

In designing a machine component, it is necessary to have a

good knowledge of many subjects such as Mathematics,

Engineering Mechanics, Strength of Materials, Theory of

Machines, Workshop Processes and Engineering

Drawing.
Classifications of Machine Design

1. Adaptive design: In most cases, the designer’s work is

concerned with adaptation of existing designs. This type of

design needs no special knowledge or skill and can be

attempted by designers of ordinary technical training. The

designer only makes minor modification in the existing

designs of the product.

2. Development design. This type of design needs

considerable scientific training and design ability in order

to modify the existing designs into a new idea by

adopting a new material or different method of

manufacture. In this case, though the designer starts from

the existing design, but the final product may differ quite

markedly from the original product.

3. New design: This type of design needs lot of research,

technical ability and creative thinking. Only those

designers who have personal qualities of a sufficiently

high order can take up the work of a new design.

The designs, depending upon

the methods used ,

may be classified as follows :

(a) Rational design. This type of design depends upon

mathematical formulae of principle of mechanics.

(b) Empirical design. This type of design depends upon

empirical formulae based on the practice and past

experience.

(c) System design. It is the design of any complex

mechanical system like a motor car.

(d) Element design. It is the design of any element of the

mechanical system like piston, crankshaft, connecting rod,

etc.

(e) Computer Aided Design. This type of design depends

upon the use of computer systems to assist in the

creation, modification, analysis and optimization of a

design.
Defining Computer Aided Design (CAD)

Computer Aided Design (CAD) is the modeling of physical

objects on computers , allowing both interactive and automatic

analysis of design, and the expression of design in a form suitable

for manufacturing.
 Examples of CAD Software

SolidWorks SolidEdge

Inventor Iron CAD

General Considerations

in Machine Design
1. Type of load and stresses caused by the load. The load,

on a machine component, may act in several ways due to

which the internal stresses are set up.

2. Motion of the parts or kinematics of the machine. The

successful operation of any machine depends largely

upon the simplest arrangement of the parts which will

give the motion required.

3. Selection of materials. It is essential that a designer

should have a thorough knowledge of the properties of

the materials and their behavior under working

conditions. Some of the important characteristics of

materials are : strength, weight, resistance to heat and

corrosion, ability to cast, welded or hardened,

machinability, electrical conductivity, etc.

4. Form and size of the parts. In order to design any

machine part for form and size, it is necessary to know

the forces which the part must sustain. It is also

important to anticipate any suddenly

applied or impact load which may cause failure.

5. Frictional resistance and lubrication. There is always a

loss of power due to frictional resistance and it should be

noted that the friction of starting is higher than that of

running friction. It is, therefore, essential that a careful

attention must be given to the matter of lubrication of all

surfaces which move in contact with others, whether in

rotating, sliding, or rolling bearings.

6. Convenient and economical features.

The economical operation of a machine which is to be

used for production, or for the processing

of material should be studied, in order to learn whether it

has the maximum capacity consistent with

the production of good work.

7. Use of standard parts.

The use of standard parts is closely related to cost, The

standard or stock parts should be used whenever possible ;

such as gears, pulleys and bearings and screws, nuts and pins.

Bolts and studs should be as few as possible to avoid the delay

caused by changing drills, reamers and taps.

8. Safety of operation. Some machines are dangerous to

operate, especially those which are speeded up to insure

production at a maximum rate. Therefore, any moving

part of a machine which is within the zone of a worker is

considered an accident hazard and may be the cause of an

injury.
9. Workshop facilities. A design engineer should be familiar

with the limitations of his employer’s workshop, in order

to avoid the necessity of having work done in some other

workshop. It is sometimes necessary to plan and supervise

the workshop operations and to draft methods for casting,

handling and machining special parts.

10. Cost of construction.

The aim of design engineer under all conditions, should

be to reduce the manufacturing cost to the minimum.

11. Assembling. Every machine or structure must be

assembled as a unit before it can function.

Importance of design
Failure can be Fetal and Disaster
That is why the students should be familiar with

➢ Accuracy of the design calculations

➢ The unit systems (the units should be written in

your solutions).

➢ The number of digits (30.0 or 30.00).

➢ Free hand sketches (clear )

Fundamental Units
Fundamental Units :Every quantity is measured in terms of
some internationally accepted units, called fundamental units.
All physical quantities, met within this subject, are expressed in terms of
the following three fundamental quantities :
1. Length (L or l ),
2. Mass (M or m), and
3. Time (t).

Derived Units:
All units which can be expressed in terms of fundamental units.
The volume of a substance is proportional to its length, width and height
or V = l x b x h . So, the derived unit of volume ( V ) is ( m3).
 International System (SI) of Units

Fundamental or basic units

Quantity Unit Symbol

Length(L) Meter m

Mass (m) Kilogram Kg

Time (t) Second s

Electric current (I) Ampere A

Temperature (T) Kelvin K

 International System (SI) of Units

Derived Units
Quantity Unit Symbol

Area Square meter m2

Volume Cubic meter m3

Linear Velocity (v) Meter per second m/s

Linear Acceleration (a) Meter per square second m/s2

Density (ρ) Kilogram per cubic meter Kg/m3

 International System (SI) of Units

Derived Units (cont.)

Quantity Unit Symbol

Force (F) Newton N=1Kg. m/s2

Pressure (P) Pascal Pa= N/m2

Power (P) Watt W = J/s

Energy (E) Joule J = N.m

The radian per

Angular acceleration rad/s2
second squared
Metric Multiplication Units
standard abbreviations
General Design Procedure in

Machine Design
 Design Procedure
1. State the purpose of design, considering special

requirements and limitations.

2. Select the possible solutions by free hand sketching.

3. Determine the nature of loading (i.e. static, dynamic,

shock, thermal).
4. Select the suitable material for each element.

5. Determine the size and shape by doing force and stress

analyses.

6. Modify the element in shape and size to facilitate the

method of manufacturing ( Design for Manufacturing
DFM )

7. Make the detail drawings and assembly drawings,

specifying properly all dimensions, tolerances, materials,
heat treatments, and surface finish.
Product Concept
 Product Concept Representation
Engineering design starts with a need directly communicated

by the customer or with an innovative idea developed by a

research team that would lead to an incremental improvement

on a totally new product.

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Product Concept Representation

➢ A technical person can use the graphic language as powerful

means of communication with others for conveying ideas on

technical matters.

➢ Engineering drawing is a suitable graphic language from which

any trained person can visualize the required object.

 Importance of Drawing
1. Try to write a description of
this object.
2. Test your written description
by having someone attempt
to make a sketch from your
description.
You can easily understand that …
The word languages are unsuitable for describing the
size and shape completely.
 Composition of Drawing
Graphic language in “engineering application” use lines to
represent the surfaces, edges and contours of objects.

The language is known as “drawing” or “drafting” .

A drawing can be done using freehand,

instruments or computer methods.

Freehand drawing
The lines are sketched without using instruments other
than pencils and erasers.

Example
Instrument drawing
Instruments are used to draw straight lines, circles, and

curves accurately. Thus, the drawings are usually made to scale.

Example
Computer Drawing
The drawings are usually made by commercial software

such as AutoCAD, solid works etc.

Example
Product Concept Considerations
1. Product Concept is an approximate description of a

product, and is usually expressed by 2D or 3D sketches.

2. Keep It Simple and Short (KISS)
 3. Free hand sketch should be containing on 3F
(Fit, Form, and Function)
• Fit refers to the ability of the part to connect to

another part within an assembly.

• Form refers to such characteristics as external

dimensions, weight, size, and visual appearance of

a part or assembly.

• Function is a criterion that is met when the part

performs its stated purpose effectively

4. Draw a 2D or 3D sketching not a schematic
drawing
 Practical Applications on the first two steps in
Design Procedure

1. State the purpose of design, considering special

requirements and limitations.

2. Select the possible solutions by free hand sketching.

Question

➢ Make a free hand sketch for a …………………..

Or

➢ Apply steps no.1 and no.2 of design procedure for ….

(given : max or / and min dimensions, load , height,
angle or / and weights, etc….
Answer

➢ State the purpose, requirements and limitations.

➢ free hand sketch (2D or 3D).

Example No.1

Make a free hand sketch for a free holding book stand

capable for height adjustment and swiveling head. The
max. height is 160cm, the min. height is 50 cm and the
swiveling angle range is +/- 45 degree.

Solution
1. Purpose : design a free holding book stand.
2. Requirements : the stand should capable for height
adjustment and swiveling head.
3. Limitations: The max. height is 160cm, the min.
height is 50 cm and the swiveling angle range is +/-
45o.
Product concept no.1
Product concept no.2
Product concept no.3
Example No.2

Apply steps no.1 and 2 of design procedure for a selfie

stick / stand with change distance and total length is 1.5m

Solution
1. Purpose : design a selfie stick / stand .
2. Requirements : the stick should capable for changing the
mobile distance .
3. Limitations: The max. distance is 1.5m.
Product concept no.1
Product concept no.2
Product concept no.2
Product concept no.3
free hand sketch
Some basic knowledge
Gear types
 Gears
A gear is a wheel with teeth on its outer edge.

The teeth of one gear mesh (or engage) with the teeth of
another.

Gears meshing or engaged

 Gears
Driver and Driven

• Two meshed gears always rotate in opposite directions.

Spur Gears

Driven gear
Driver gear
 Gears
Idler gear
Driver

Idler gear

Driven
 Gears
Simple Gear Train

• Multiple gears can be connected together to form a gear train.

Each shaft carries only

one gear wheel.

Intermediate gears are known as

Idler Gears.
 Gears
Worm gear and wheel

• The worm gear is always the

drive gear

Worm and wheel

 Gears
Rack and Pinion

• The rack and pinion gear is

used to convert between
rotary and linear motion.

Heavy Duty
Car Jack
 Gears
Bevel gears
• Bevel gears are used to transfer drive through an angle of
90o.

Bevel Gears
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