CHAPTER 1

Introduction to
Mechanical
Engineering Design
1
2
 Machine Elements
One of the most important lecture in
MECHANICAL ENGINEERING

Because:
It aims to study how to design
an element of a machine

such as
shafts, springs, bearings,
brakes, bolts and nuts, gears, etc.
3
Starting Terminology…

Functional: The product must perform to fill its intended need

and customer expectation

Safe: The product is not hazardous to the user, by

standers, or surrounding property.

Reliable: Reliability is the conditional probabilty, at a given

confidence level without failure at a given age.

Competitive: The product is a contender in its market

4
Starting Terminology

Usable: The product is “user-friendly”.

Manufacturable: The product is suited to mass production.

Marketable: The product can be bought, and service

(repair) is available.

5
1-1.Design
The design is to formulate a plan for the
satisfaction of human need

If the plan results "the creation of something

having physical reality“,
then the product must be
functional, safe, reliable, competitive, usable,
manufacturable and marketable

6
1-1.Design….
Subject to certain problem-solving constraints

Design a component, system or process that

will perform a specified task optimally

Subject to certain solution constraints

Manufacturing

Solution is Safety & reliabilty

constrained by what Functionality

the designer knows! Marketability

Codes and standards

7
 Design problems has no unique answers in
contrast to math and other sci. problems
In fact
Good answer A poor answer
today tomorrow

Because there may be growth of knowledge during the period

Example
1949 2000s

8
 The design problem is a decision
making-process
includes
large group of interrelated complex
parameters

9
 The designer begin by identifying how to
recognize a satisfactory alternative
Following tasks are to be performed
 Invent alternative solutions

 Through analysis and test, simulate and predict the

performance of each alternative and discard
unsatisfactory ones.

 Choose the best satisfactory alternative discovered as

an approximation to optimality.

 Implement the design

10
 Example:
Determine satisfactory alternative for the
wheel hub of electric vehicle

 Lets invent alternative solutions for the wheel

hub

11
 Three alternative solutions of the wheel hub;
a) Type 1, b) Type 2, c) Type 3

(a)

(b)

(c)

12
What is next?

 Carry analysis and test,

predict the performance of each alternative
and discard unsatisfactory ones.
 Select the best

 Implement it.

…..
….
….
13
The input to, and the output from,
the design process INPUTS:
Opportunity of need Technical knowledge

Components and
connectivity
OUTPUTS:
Geometry and
tolerances Plans

Manufacturing and
processes Specifications
Thermo mechanical
treatments
Fig. 1.1 The input to, and the output from, the design process when the design is a
14
physical reality.
1-2.Mechanical Engineering Design
Mechanical design:
The design of things and systems
of a mechanical nature
- machines, products, structures, devices, and instruments-

Mechanical engineers are associated with

 the production and processing of energy,
 providing the means of production,
 the tools of transportation, and
 the techniques of automation

15
 Mechanical Engineering Design
involves all the disciplines of
Mechanical Engineering
such as the thermal- fluid, stregth, material, sci. etc.

16
MECHANICAL ENGINEERING DESIGN
AT TOP-DOWN MANNER

17
 How to Make Machine or System

Putting them together forms complete machines or systems

Brakes
shafts

springs

Bolts and nuts

18
 1-2..
Making Machine:
Elements of a Machine

Brakes
shafts

Bolts and nuts

19
 Design problems
has no unique answers
in contrast to math and other sci. problems

*Read the book 20

 Hence, designers have to make decisions.
Shorthand of pegs* for this.
Peg 1: Suitability, Feasibility, Acceptability
Peg 2: Satisfactory Alternative
Peg 3: Specification Set
Peg 4: Decision Set
Peg 5: A Priori Decisions vs. Design Variables
Peg 6: The Adequacy Assessment
Peg 7: Figure of Merit
Peg 8: A skill of Synthesis

*Read the book 21

…. Technology Can be Fragile

If you are using computers

we must be on guard!

• Keep your file in safe places with instructions

• Document your program

22
1-3 Phases and Interactions of the Design
Process
We are interested in total design process!
How does it begin? What the engineer does?

Does he sit down and draw some ideas?

What happens next?
What factors control or affect the design?

23
 Concept
Generation
and
selection

Fig. 1-1 The phases in design 24

Definition of a problem:

The most critical step in the design process

Because
This step requires such a small part of the total
time to create the final design.
It is often overlooked!!!

Figure below illustrates how the final design

can differ greatly depending upon how the
problem is defined.

25
The most important stage:
Problem Definition:

26
As proposed by project As specified in the As designed by the
sponsor project request senior designer

As produced by As installed at the What the user wanted!

manufacturing user’s site
Figure: Note how the design depends on the viewpoint
of the individual who defines the problem.

27
 Presentation is selling the Job to
administrative, management etc.
For this there are only 3 means of
communication
These are;
1. Written
2. Oral and
3. Graphical form

The successful engineer will be technically

competent and versatile in all 3 forms

28
Design Considerations
Design consideration means referring to
some characteristics which influences
the design of the element

For instance
Sometimes strength is an important
design consideration
because
geometry and the dimensions of the
element are related to strength

29
 Many of the Important Design
Considerations
1 Strength/stress 14Noise
2 Distortion/deflection/stiffness 15Styling
3 Wear 16Shape
4 Corrosion 17Size
5 Safety 18Control
6 Reliability 19Thermal properties
7 Friction 20Surface finish
8 Usability 21Lubrication
9 Utility 22Marketability
10Cost 23Maintenance
11Processing 24Volume
12Weight 25Liability
13Life 26Scrapping/recycling
27Flexibility 30
Mini-size kids' bike,
tricycle for children

31
1-4 Design Tools and Resources
Engineer has a great variety of
tools and resources

1. Computational Tools (CAE, MathCad, MATHLAB)

2. Acquiring Technical Information
 Libraries
 Government sources (patents, standards etc.)
 Professional Societies (Turkish Society of Mechanical Engineers)
 Commercial vendors (catologs, test data, technical literature)
 Internet

32
1-5 The Design Engineer’s Professional
Responsibilities

The design engineer is required to satisfy

the need of customers
and
is expected to do so in
a competent,
responsible,
ethical, and
professional manner

33
 Develop a systematic approach when
working on a design problem
 Understand the problem

 Identify the known

 Identify the unknown and formulate the solution strategy

 State all assumptions and decisions

 Analyze the problem

 Evaluate your solution

 Present your solution

34
 …. Your Path the Competence

Along the path from Novice to beginner (you)

novice to expert performer

Competent performer

instruction will cease,

and Proficient performer

self-instruction will replace it.

Expert performer

35
1-6 Codes and Standards

Definition and Purpose of Standard:

A "standard" is a set of specifications

for parts, materials, or processes
intended to achieve
uniformity, efficiency, and a specified quality.

Purpose: is to place a limit on the number of items

so as to provide a reasonable inventory tooling,
sizes, shapes and varieties.

36
Definition and Purpose of Code:

A "CODE" is a set of specifications

for the analysis, design, manufacture, and
construction of something.

Purpose: is to achieve a specified degree of

safety, efficiency, and performance or quality.

37
 The name of the organisation
provides a clue
to the nature of the standard or code
(i.e. ASME)

38
 Some important organisations are:
Aluminium Association (AA)
American Gear Manufacturers Association (AGMA)
American Institute of Steel Construction (AISC)
American Iron and Steel Institute (AISI)
American National Standards Institute ( ANSI)
American Society of Mechanical Engineers (ASME)
American Society for metals
American Society of Testing and Materials (ASTM)
American Welding Society (AWS)
Anti-Friction Bearing Manufacturers Association (AFBMA)
British standard Institute (BSI)
Industrial fasteners Institute (IFI)
International Standard Organisation (ISO)
Society of Automotive Engineers (SAE)

39
1-7 Economics
Cost plays an important role in the design decision.
Cost design factor studies takes
as much time as the study of design itself

In more general
materials and labour INCREASE
but
the cost of processing the material
DECREASE
because of the use of the automated machine

40
STANDARD SIZES:
In design, some machine elements or parts may be
readily purchased and used such
bolts,
rolling contact bearings,
pumps,
electric motors,
various fasteners and
other miscellaneous machine elements

41
Briefly,
when ordering a material or a machine
1) choose standard sizes and
2) readily available materials which are in stock

USUALLY CATALOGUES ARE AVAILABLE BY SUPPLIERS

42
LARGE TOLERANCES:
Tolerances play an important role among the
design specifications on cost

large tolerances Low manufacturing cost

(because large tolerances can be produced by automatic machines

so labour costs are smaller)

49±0.150 49±0.030
(large tolerance) (small tolerance)

43
 Low tolerance-
High cost

Large tolerance-
low cost

Fig. 1-2
Cost versus
tolerance/
machining
process

44
BREAKEVEN POINTS:
When two or more design approaches
are
compared for cost
the choice depends on another set of conditions
such as
 the quantity of production

 the speed of the assembly lines,

Then
the BREAKEVEN point is used for the cost decision

45
An example
Suppose that 2 options are available for screw poduction.
 These are

1. Automated screw making machine

2. Hand screw making machine

Which one is suitable?

46
 Suppose that set up time for the automatic: 3h
total labour cost for either machine: $20/h

Breakeven point

Fig. 1-3
A breakeven point

47
COST ESTIMATES:
There are many ways of obtaining cost figures
to roughly compare two or more designs

For instance
compare the relative value of two cars
by simply
1) comparing the $/Kg or TL/Kg
2) count the number of parts

The design having

the smallest number of parts is likely to cost less

48
1-8 Safety and Product Liability

This concept prevails in U.S and Europe.

It is very strict.

Manufacturer of part is liable for any damage

or
harm that results because of a defect.

This applies
even 10 or 15 years of later purchasing!
49
1-8 Safety and Product Liability… Example

Chrysler Hit With Big Penalty

Detroit Free Press, October 9, 1997
in Turkish!

10-October-1997 Hürriyet
Chrysler'e 262.5 Milyon dolar ceza
Hatalı kapı kolu yüzünden arka koltuktan fırlayan
ve can veren 6 yaşındaki bir çocuğun ölümünde
ihmalkarlıkla suçlanan otomobil devi Chrysler
yaklaşık 262.5 Milyon dolar rekor tazminat
cezasına çarptırıldı.

50
1-8 Safety and Product Liability… Example

Chrysler Hit With Big Penalty

Detroit Free Press, October 9, 1997
A jury Wednesday ordered Chrysler Corp. to pay $262.5
million to the parents of a 6-year-old boy who was killed
when he was thrown from the family minivan in a crash
because a rear latch was defective.

The $12.5 million in actual damages and $250 million in

punitive damages awarded to the parents of Sergio
Jimenez II.
the largest award against
the automaker
http://www.prenhall.com/divisions/bp/app/phblaw/html/legreg/legreg9.html

51
minivan door and rear latch

52
 Why Chrysler was punished with
Big (deterrent) Penalty?
The jury in U.S. District Court said
Chrysler was negligent
in the design and testing of the minivan
and
that negligence on the part of the company led to
the boy's death.

http://www.prenhall.com/divisions/bp/app/phblaw/html/legreg/legreg9.html

53
 Why Chrysler was punished with
Big (deterrent) Penalty?
said the family's lawyer,
David Dwares

``Chrysler knew about the defect

and
covered up the defect
while at the same time advertising its minivans to
American families as safe,''.

http://www.prenhall.com/divisions/bp/app/phblaw/html/legreg/legreg9.html

54
 Why Chrysler was punished with Big
(deterrent) Penalty?
 Chrysler / DaimlerChrysler Steering Related Lawsuit For Chrysler LH
Vehicles

 Chrysler Continued To Use Obviously Defective Seatbelt Design. At

Least 28 Known Deaths Due to Defectively Designed Chrysler Generation
3 Seatbelts. Chrysler Blamed One Consumer Who Died Alleging
Consumer Was Not Wearing Seatbelt, Later Proven to Be Untrue.

 Chrysler Seats That Collapse Backwards in Low Speed Impacts and Kill
Small Children Behind Them. Chrysler Made Deal With Department of
Justice to Keep Information About Safety Problems From Public?
http://www.daimlerchryslervehicleproblems.com/

55
1-8 Safety and Product Liability…….

Ekonomi 20 August 2004 Hürriyet

Ford 150 milyon dolar tazminat ödeyecek, Boston

Ford, Explorer marka aracıyla takla attıktan sonra belden
aşağısı felç olan iki çocuk annesi ABD'li Benetta Buell-
Wilson'a (49), 150 milyon dolar tazminat ödeyecek.
ilk mahkeme yargılamasında “Ford'un hatalı davrandığı ve
başkalarının emniyetini sağlamaya kayıtsız kaldığının tespit
edildiğini” ifade etti.

56
The best approach to the prevention of product
reliability is GOOD ENGINEERING in

Analysis and design and Quality control and Testing

In addition,
do not give extreme promises in WARRANTIES

57
Case Study:
Engineering
Failure
Steel Construction with 100
ton capacity
failed in Ceyhan TMO
and
killed a lorry driver during
wheat unloading from the
tank

TMO (Turkish Grain Board)

58
 Engineering
Failure
Steel Construction with 100 ton
capacity
failed in Ceyhan TMO
and
killed a lorry driver during wheat
unloading from the tank

TMO (Turkish Grain Board)

59
Design engineers were arrested according to our report
handed to the court of justice.
.

Steel Construction with 100 ton capacity

failed in Ceyhan TMO

60
 Sign if you are
absolulty sure of the
safety of design!

Bulk material loading into a lorry

61
Engineering Failure in RUSSIA

Tower crane
collapsed on
to the
apartments

Rusya’nın Kirov kentinde kuvvetli rüzgar sonucu vinç

karşıda duran apartmanın üzerine yıkıldı.

62
Engineering Failure in Adana-TURKEY

Derivation door was

bursted in dam
construction in Adana
Turkey, killed 10
workers and loss of
10 construction
machinery.

Adana Kozan ilçesindeki Gökdere köprü barajı derivasyon tüneli kapağının

patlaması sonucu 10 işçi yaşamını kaybetti. Ayrıca 4 kamyon, 1 dozer,
değişik ebatlarda 6 iş makinesi de akıntıyla birlikte sürüklendi.

63
 Worksite chief engineer Ö.P. and
design engineer E. N. were arrested.

If you are not sure of

the safety of design project
you should not sign any
Project!

64
 Engineering Failure in Automobil world
…… Viper Defect History - Alarming
Several Consumers Have Experienced

Defects and Faults!

………Vehicle Fires From Fuse Blocks

or Faulty Wiring In Some Vehicles.

…. Suspension Control Arm

Bracket Defect

65
1-9 Stress and Strength
Stess: 
Strength (S):
is a property of a material
> is a function of force
or and area
of a mechanical element
S : Strength
 : Normal Stress
Ss: Shear strength
Sy: Yield strength
: Shear stress
Su: Ultimate strength

S : mean strength
obtained by sampling test data

66
1-10 Uncertainty (in loads + Materials etc)
Uncertainties in machinery design abound. Among these;

 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 thermo-mechanical treatment on properties.
 Intensity and distribution of loading
 Validity of mathematical models used to represent reality
 Intensity of stress concentrations.
 Effect of corrosion
 Etc.

67
 ENGINEERS
MUST ACCOMMODATE UNCERTAINTY
By using factor of safety or design factor (nd)

68
1-11 Design Factor and Factor of Safety

There are categories of situations confronting

engineer during design

 The product is made in large quantities, is valuable, or n≥1

dangerous, justifying elaborate testing of components
and prototypes in the field.

 The product is made in sufficient quantities to justify

a modest material test program,

 The product is made in such small quantities that

testing is not justified! or not enough time for tests n≥ 2-10
There is also faulty product inquiry: Why?
69
A general approach to the allowable load
is the design factor method

loss  of  function load

Allowable load 
nd

The term "factor of safety" is applied factor used to

evaluate the safeness of a member

70
The term "factor of safety" is applied factor used to
evaluate the safeness of a member

nd=design factor n=factor of safety

?
Design factor = Factor of safety

Used for design Used for analysis

71
 This is analysis
This is design of design
Sy=700 Mpa, nd=2, d=? Sy=700 Mpa, d=6,031 mm, n=?

d F=10 KN d
F=10 KN

d=6,031 mm
72
If F=force
FU=ultimate or limiting force

Fu Strength
nd  nd 
F stress

Design factor

73
When
Fu =F then n=1 and there is no safety

Consequently, the term "margin of safety" is used

and defined as
m=n - 1
m= margin of safety

Both terms are widely used in industrial practice

It is essential to use "n >1 " as allowances for the

uncertainties of load and strength

74
75
1-12 Reliability
Reliabity method of design is:

We learn or determine

the distribution of stresses

and

distribution of strengths

and then relate these two

in order to achive an acceptable success rate

76
Reliabity method of design is….

The statistical measure of the probability that a

mechanical element will not fail in use is called the
reliability of that element.

Reliability is the statistical measure of the probability

measured by a number having the range
0 ≤ R< 1

77
 R= 0.90 means
there is a 90 % chance that the part will perform its
proper function without failure

In the reliability of method of design,

the designer’s task
is to make
a judicious selection of
materials,
processes, and
geometry (size)
so as to achive a reliability goal.

78
 1-12 Dimensions and Tolerances
 Nominal size: The size we use in speaking of an element
25 mm
 Limits: The stated maximum and minimum dimensions

 Tolerance: The difference between the two limits

 Bilateral tolerance: The variation in both directions from the

basic dimensions 25± 0.05 mm

 Unilateral tolerance: The difference between the two limits

25 00..0500 mm

79
Clearence: when the internal
member is smaller than the
external member

Interference: when the

internal member is larger
than the external member

Allowance: The minimum

stated clearance or the
maximum stated
interference for mating
parts.

80
1-14 Units

We use SI UNITS

ML ( Ki log ram)(meter)
F 2  2
 kg.m / s 2
N
T (second )

No marks are given to

results without units!!!!
in the exams and projects.

81
Table 1-4 SI Base Units
Quantity Name Mass
length meter m

Mass Kilogram kg

Time second s

Electric current ampere A

Temperature and difference Kelvin K

Amount of substance mole mol

Luminous intensity candela cd

82
 Metric mishap caused loss of
NASA orbiter
September 30, 1999
Web posted at: 4:21 p.m. EDT (2021 GMT)

(CNN) -- NASA lost a $125 million Mars orbiter

because a Lockheed Martin engineering team used
English units of measurement
while the agency's team used
the more conventional metric system for a key spacecraft
operation.

http://edition.cnn.com/TECH/space/9909/30/mars.metric.02/

83
 Sonuçları vahim olan tarihi hatalar!
NASA’da bir grubun
yarısının metrik
diğer yarısının ise İngiliz ölçülerini
kullanması sonucu Mars yörünge aracı uzayda kaybedildi...

http://fotoanaliz.hurriyet.com.tr/galeridetay/83679/4369/9/sonuclari-
vahim-olan-tarihi-hatalar

84
 Preferred units are:

MPa for STRESS MPa = N/mm2

Mpa for pressure
mm for dimensions
N (Newton) for Force

85
1-15 Calculations and Significant Figures

Real numbers not integers

must be described by 3 or 4 significant figures
for engineering accuracy

i.e.:
56,973 - 56,9736

Real numbers

86
1-16 Power Transmission Case Study
Specifications
Design Requirements Design Specifications
Power to be delivered:15 kW Power to be delivered:15 kW
Input speed:29 rev/s Power efficiency: 95 %
Output speed: 1.4 rev/s Steady state input speed:29 rev/s
Targeted for uniformly loaded Maximum input speed: 40 rev/s
applications; such as Steady-state output-speed:1.3-1.5
conveyor belts rev/s
Output shaft and input shaft in Targeted for uniformly loaded
line applications; such as conveyor
Base mounted with 4 bolts belts
Continuous operation ……….
…..

87
End of Chapter 1

88