Mechanical Engineerir Design Il (MEE 513) Course Lecturer: Dr. U.G. Okoro Course Credi Course Venue:108 Course outline MEE 513 MECHANICAL ENGINEERING DESIGN II (3 Credit Units) * Overview and definition of feasibility: synthesis, analysis, solutions formulation, optimum design in design processes, treated quantitati + Loads determination, material properties and selections, factor of sa failure criteria, stress concentration etc., in design. + Design of machines and machine components, using advanced con and analytical approach: Analytical design of machine transmission elements such as shafts, spindles, belt/pulley drive, and gear di (spur, helical, bevel, worm/wheel bearing selection, key, power and chain drive components. + Group design project.Course work: Homework: * This course will contain regular homework assig exercises will be designed to accomplish work midterm and final projects. Quizzes: * Quizzes will occur after each lecture, and are due b class session. Quizzes may cover the material in each readings, and class presentations, Answers to the quizzes discussed in class. Exams: + Midterm and final exam will occur in place of two of the qi Exams may cover the material in each lecture, required read material on prior quizzes, and class presentations (including tip and project presentations). Course work: Term (Team) Design Project: * This class emphasizes the importance of learning by doing. The best = way to understand the methods is to practice. The term project will begin at the midterm, and continue through the end of the class. The goal is to develop a conceptual product by the end of the course. 3 Teams may have a minimum of 2 members.Course Material: ‘There are required and optional textbooks for this cour handouts and reading materials may be provided as the class f Required Primary Textbook: * Clive L. Dym, Patrick Little and Elizabeth J. Orwin. “Engit Project-based introduction” 4" Edition. Wiley Recommended Textbook: aie * Budynas, Richard G,, 1K. Nisbett, and Joseph E. Shigley. “Shigley's mechanical engineering design”: 10th Edition New York, NY: Education, 2015. Print. Optional Secondary Textbooks: * Suh, N.P.: "Axiomatic Design - Advances and Applications", Oxford University Press. + Pahl, G. & Beitz, W.: “Engineering Design - A Systematic Approach", Springer Design challenge for student + Engineering students during their training are presented with avast amount of theoretical material and information. They only realize their weakness when they are faced with the task of logically applying what they | have learned to a specific end. mee * As long as their work is based on familiar models or previous designs: knowledge they possess perfectly adequate to enable them to ind a solution along conventional lines. Y * As soon as they are required to develop something already in existence more advanced stage or to create something entirely new without a peeled: design, they will fail miserably, unless they have reached a level of understanding. se * Without a set of guidelines, they are at a loss for a starting point clear finishing goal line.* The design engineer must learn to think i conclusions, and to combine solutions. * These skills are not acquired by attending textbooks. These only accumulating one fresh item after another. * Understanding, logical deduction, and judgment ca from outside; on the contrary, they are acquired only b thinking and working with the knowledge already * A basic precondition for independent design is a lively ‘Such imagination is required to do original work. Learning outcome At the end of the lecture series, student should be able to; + develop creativity, + use of open-ended problems, + develop and use of modern design theory and methodology, + formulate design problem statement and specifications, + gain knowledge of production processes, + gain knowledge of concurrent engineering design, and + detailed system description Furthermore, it is essential to include a variety of realistic cons as economic factors, safety, reliability, aesthetics, ethics, andDesign and * To design is to create a new product that turns inte benefits society in some way. * The design process is a sequence of events and a st that helps define a clear starting point that takes the d visualizing a product in his/her imagination to reali in a systematic manner—without hindering their creati Generic problem-solving methodology associated with the design process* Who is a customer? only the end users? + "Knowledge of the customer is important.” ’ * Customers of a product are everyone who will deal with tk at some stage during its lifetime. + Eg,, customer of an airplane: Passengers, Crew, Pilot, Engineers and service crew, Fueling companies, Airlines, Manufacturing and production departments, Baggage hand Cleaning and catering companies, Sales and marketing, Accc finance departments, Military/Courier/Cargo/ete., Authoriti official bodies, Companies involved with the items that will be outsourced + Each of the customers has entirely different (and sometimes conflicting) needs for the same product, and by identifying these customers first, itis. then possible to identify all the needs and arrive at a reasonable compromise according to priority and feasibility. + Forms of customers need: + Clients request: a direct (often vague)request for an artefact. + Exiting design modification: as requested by clients simpler, e959 to use * Generation of a new product: growth of companies often depends on the at generate new products. New products have a characteristic lifecycle volume and profit margins. A product will peak out when it has sa and then begin to decline. It is obvious that an industry must seek iow of new productideas. Tere new products are usaly patentsBasic lifecycle of new product. * Gather information about what is already available in ther what can the design team offer beyond what is? + Save companies from paying royalties to patent holders + sources of information on market availability: * Technical and trade journals + Research reports * Catalog of component suppliers + The internet + Knowledge of existing products will save the money. Once the designer determines tivity should be directed towards gener* Client request comes in vague statement. The des what must be done to resolve the need(s). * The goal definition is a general statement of the desi * Avoid poorly stated goals, or hastiness in writing goals. + Customers will most of the time offer solutions instead of aneed; designers must determine the real needs, define and act accordingly. Itis the duty of the designer to clarify design requirement. Definition of Goal ~ Cl of design requirement - * An objective tree may be constructed for clarification. Often the need statement and goals are combined into one process. An objective tr is a tool used by designers to organize the customer's wants into categories.* An excellent technique to guide the desi decision regarding these alternatives is a a more penetrating study of each alter + The embodiment design does not include any deta yet—i.e., no dimen tolerances, etc, but wil begin to illustrate a clear detnition of apa and how it interfaces withthe rest ofthe parts in the product a This stage is separated fram both the conceptual design and the deta ‘new technologies can replace old ones based on the exact same The concept of a traffic ight system will remain the same (three i green), perform the same functions and specifications, and work eo ‘way, but as technologies advance, the lights themselves can cha the way the lights change can be from using a timer to cycle t system that is connected to a modern traffic network. Possil where te traffic light sable to sense the most ‘Congestion and change the lights accordingly, = The concept still ins but the the dengn'can change, Chapter escssesemboolopem* The synthesis phase of the design e1 the stated goal has been completed. phase which is also known as the det + The chosen solution must be tested/evalu laws and the manufacturability. * The analysis stage is put in iterative sequenci synthesis phase. Often, analysis requires a redefined then reanalyzed, so that the design is between analysis and synthesis. Analysis starts wit followed by order of magnitude calculation. magnitude analysis is a rough calculation of the s The order of magnitude does not provide an exa¢ gives the order in which the solution should be ex:* Step 1: Check for the design safety in act on each component. Evaluate the stres ‘components, * Step 2: List the materials that would t Students are assumed to have some physical classes before this course. It is assumed that * Step 3. Students at this stage are also encourage ‘on the analysis. Software that incorporates the mode is available, a * Note: Steps 1, 2, and 3 are iterative until optimum rest + Step 4: Manufacturability of the components needs to be a sketch of a component doesn’t mean that the machinis produce the component. You need to provide the mac! engineering drawings before the product component engineering drawings should be detailed. Use CAD soft, your drawings. * Step 5: Cost analysis of the components (obtained fro produced at the machine shop) needs to be conduc vary among components listed in the morp components are cost effective or fit the product * Step 6. The aesthetics or the “look” of the pr ‘Several customer surveys have shown that’ product much more highly than its perfort* The step 2 of the analysis procedure would satisfy the stress requirement” + The design, even of the simplest el suitable material and a decision regal to be used in producing the element. These and the choice will affect the shape, appear also determine the difference between a co commercial failure. As the desig more elements, the selection of suitable mater production becomes more difficult. + The design engineer must be sufficiently famili and properties of the materials and the way in. to ensure that his or her decisions are well made. Materials that may be used in a products design are cl follows: 1. Metals: can be further divided into ferrous and Ferrous alloys are based on iron. Nonferrous alloys are | other than iron, such as copper, tin, aluminum, and lead. . Ceramics and glass: These are the result of ‘metallic and nonmetallic elements. They a thermally stable, and more wear resistant They are also harder and lower in therma metals. i‘Woods and organics: These are obtal major advantage is that they are a rene of their drawbacks include that they « Polymers or plastics: These materials cl temperature; therefore, they are easy to. are several benefits of polymers: They are &¢ resistant to chemicals and water; they have a: they are available in many colors, which elit There are several drawbacks to polymers, strength; they deteriorate in ultraviolet light, creep at all temperatures. The properties of materials can be divided into six categories: Mecha physical, chemical, electrical, and fabrication, 4. Mechanical properties include fatigue, strength, wear, hi 2. Thermal properties include absorptivity, fire resistance, 3. Physical properties include permeability, viscosity, crystals porosity. 4. Chemical properties include corrosion, oxidation, an Four important electrical properties are hysteresis, co _and the dielectric constant. ies: eae fabrication neverof the several systematic processes of selecting mates environmental and service con suitable materials: Ths obtaining Sonera Suite L. Perform a material requirements analysis: This aitions ulOne of the several systematic processes of selecting material i * Sten 6. Cost: This important factor plays a dominant role inthe * Step 7. Material availability: The selected material must be available * Step 8. Material joining approach: Under real-ite conditions, It Produce an element using a single plece of material, This may eal Eomponents with ditieren pieces of materia joined together te forma single 2. Fabrication: Engineering products usualy requite some level of fabri aiferent fication techniques re avaloble. fatto affecting the abneationm selected include time constraints, material type, product appl ion, cost, io be manufactured * Step 10. Technical issues: Technica factors are mainly concerned with the| mechanical properties. Examples include strength compared with antici factors, temperature variation, and potential loading changes. Primary Ma Methods ‘The primary manufacturing methods, which are used to convert a material into the Basie shape required, areas follows; ating! Casings widely used fist step inthe manufacturing process. Dur an Etat aati ieee al ace Bless Purngssing ae {Emperatre level the molten meteral's then poured ito mond made make tees items may range in size ana weight from aration ofan Inch to several yards Typeal areas Zippers indiial eth andthe stern fomes of ships a Forging: Forging, which is among the most important methods of manufacturing tems of onan ate qos chanang te sage ofthe ce of ie Sy ecting ean ne methods ofappiing pressure include the mechankeal press nraukt sree {roduets such a cranks, wrenches, nd connecting rods are the reas Weise aR forged may be hot or cold . : ‘Machining: Machining iwolves removing unwanted materia from aback of mater spteicons tha be shave and fhe oducts tl fade Tee a processes, sich a ling bog, aindng ra Sig Welding Welding i versatile production process that | sed for combining ems ather means of manclacturing Westin ie paces of hone rat nescence, which voles acambinabon of pesere oes geone of the most important material p ight of the component. The range of, ic mass and the volume the material Melting Point: The melting point of a materials directly proportion energy of its atoms. Melting point becomes an important factor pnerating conditions of the material are in high-temperature e internal combustion engines and boilers environment temperature: . 30% lower than the melting point of the material. In design, the rule h Generally is used is that the (7/Tm < 0.3). Designers should also keep. that when a material is subjected to high temperature and undergoes creep occurs (slow change of dimensions over time). Introduction t selection theor * Coefficient of Linear Thermal Expansion: Defined as a = “4; wher L > Linear dimension of the object; dl change in the linear dimension of the object, and dT —chai inge in the temperature that _ causes the change in the length.+ Thermal Conductivity: The thermal condu property of the material by which one can d material is a good heat conductor or insulator. In the carriers of heat. A relation between the heat conductivity is established as ..where k thermal conductivity; s electrical conductivity; T + Strength of Material: The strength of the material determines t tt amount of load a material can sustain before it breaks. In design criterion is based on the yield stress of the mate strength of the material is measured experimentally testing machine. In a design-testing machine, a speci with a certain load and the elongation that is associat is measured. The load is converted to stress and the converted into strain, There are two general represer data: the stress-strain diagram and the true diagram. In the stress-strain ciagratny the $=change inlength _ AL ahaha ateersremesrrat * In the true-stress-true-strain diagram, the change in area after each is recognized and the true stress and true strains are obtained by, load P de ie stress ae hs oss ~ Instantenous area Ate oe * Instantaneous area can be obtained by conservation of volume as; Apolo = AL = Constant * Once the diagram is obtained, the modulus of elasticity can be obt finding the slope of the straight ine wae oe viell ost * Designers apply a safety factor based on the application ‘material.rmation is called a brittle material, Ductility is as either percent elongation, %e , ii al ep 1 %e , int ct reduction in area, %AR. naa Ly Li Ao - A, i e= + 2, 10007 AR = oe Lo ei introduced at a stress lower than the yield stress. A correlation that has been used to estimate the fatigue limit is Fatigue limit = 0.5Sues + Impact Properties: The impact property of a material is its resistance to fracture under sudden impact. 5 + Hardness: Hardness is the measure of the material’s resistance to. indentation. Hardness can be measured in three different tests: Brin (uses balls to indent in the surface), Vickers (uses pyramids to it surface), and Rockwell (measures the depth of indentation).* Hardness: The Brinell hardness number ea ca ~ D[D- VD? = a ..where P is the load, D is the diameter of the indenter, measure of the diameter of the indentation. The BHN is used” estimate the ultimate tensile strength as follows; Siac Pass 3.45 BHN BHN Information that should be included in a bill of material. The item number: This is a key to the components on the as The part number: This is a number used throughout the purche manufacturing, and assembly system to identify the co! number sa specific index tothe assembly drawing the part index to the company system. vee ee . The quantity needed in the assembly, The name and description of the component. ~The material from which the component is made, ‘The source of the component. 0 st of the individual componerOnce the materials have been selected, abil of materials, This is an index of the parts that product. A typical bill of materials is shown in Ta Quantity Name Governer body Governer flange Govemner bolt Part 1: Design processes, overview and definitions Feasibility, Synthesis, Analysis, So! ti ‘mulation, Optimum design, :Preamble Engineering design * Design Engineering (DE) is a discipline * creates and transforms ideas and concepts into a product definition that satisfies customer requirements. drive, and gear drivers (spur, helica worm/wheel bearing selection, key, screw and chain drive components. Industrial Design * An applied art * The aesthetics and usability of products: may be improved. 3 * Design aspects specified m. overall shape of the abject the of details with Tespect to one. Colors, texture, sounds, and as Concerning the use ofthe pro ergonomicsnents in a de a more efficient/improv we want to achieve. |) understand transform this knowledge into a mini (otherwise known as Functional requiré describes “what we want to achieve” to sa