How one starts the engineering
component analysis after
developing the engineering
concept draft
Clarify the Function of Each Component
• Review your concept draft and identify each functional block
(e.g., power source, actuator, sensor, structure, etc.)
• Ask: What is each part supposed to do?
Define Component Requirements
For each component:
•What loads or stresses will it experience?
•What precision or tolerance is required?
•What environmental factors (temperature, vibration, corrosion,
etc.) must it withstand?
•Are there weight, size, or cost constraints?
Select Candidate Technologies or Materials
•Pick initial candidates for materials, sensors, actuators, etc.
•Consider performance specs, availability, compatibility, and cost
Perform Preliminary Calculations or
Simulations
• Use FEA, thermal analysis, or kinematic modelling to validate the
feasibility of each component.
• Examples:
• Stress analysis on a structural frame
• Torque and speed requirements for a motor
• Thermal dissipation for a heat sink
Benchmark and Compare Alternatives
• Compare options based on performance, cost, and
manufacturability.
• Create a decision matrix if needed to choose the best
components
Iterate Based on Findings
• our analysis may show a component won’t work as originally
designed. Loop back to redesign or refine the concept accordingly
Document Assumptions and Results
Keep a record of:
• Chosen components and why
• Load assumptions, analysis results
• Trade-offs considered
BEST PRACTICE IN STARTING CALCULATION
• Writing a solid design calculation is all about clarity, logic, and
justification. Whether it's for structural analysis, machine design,
thermal systems, or anything else, a good write-up should guide
the reader through your thinking process clearly and
professionally. Here's a step-by-step format you can use:
Title of the Calculation
• Be specific. E.g., "Design Calculation for Shaft Diameter Under
Combined Bending and Torsion"
Objective / Purpose
Clearly state what you're trying to determine.
• Example: “To determine the required shaft diameter that transmits
5 kW power at 1200 RPM without exceeding allowable shear
stress.”
Known Data / Given
• List all known inputs with units and, if relevant, sources
• Given:
• - Power transmitted, P = 5 kW
• - Speed, N = 1200 RPM
• - Allowable shear stress, τ_allow = 40 MPa
• - Factor of Safety (FOS) = 2.5
Assumptions
• List your assumptions clearly and explain why they are
reasonable. Keep them realistic.
• Assumptions:
• - Shaft is solid and circular in cross-section.
• - Uniform material and no stress concentrations.
• - Torsion and bending are the only loads.
Unknowns / Parameters to Find
• Unknown:
• - Required shaft diameter (d)
Formulae Used
• Formulas:
• - T = (P × 60) / (2πN)
• - τ = (16T) / (πd³)
Calculation Steps
Walk through the solution step-by-step. Use consistent units. Show all intermediate steps, not just the
final result.
1. Calculate torque:
T = (5 × 10³ × 60) / (2π × 1200) = 39.79 Nm
2. Apply Factor of Safety:
τ_design = τ_allow / FOS = 40 / 2.5 = 16 MPa
3. Rearranging torque formula:
d³ = (16T) / (πτ_design)
d³ = (16 × 39.79) / (π × 16 × 10⁶) = 1.267 × 10⁻⁴ m³
4. Solve for d:
d = ∛(1.267 × 10⁻⁴) = 0.0503 m = 50.3 mm
Final Result
• Required shaft diameter = 50.3 mm
Validation / Remarks (Optional)
• Briefly state if the result seems realistic.
• Mention anything to be refined later
Known driving pulley diameter known
machine-driven diameter Known
Prime mover power determine the
number of belts required and belt
tension Give an Example, putting
known data, unknown data and
assumptions
complete example of a flat or V-belt drive
system design calculation
• Know the diameters of the driving and driven pulleys
• Know the prime mover power
• Want to determine the number of belts required and the belt
tensions
Objective
To determine:
[Link] number of V-belts required for power transmission
[Link] initial tension and tight side/loose side tensions in each
bel
Given Data
Known data Cont …
Unknowns
• Number of belts required: nBelt tensions:
• Tight side (T₁),
• Slack side (T₂),
• Initial tension (T₀)
Belt Speed (V)
Power Transmitted per Belt
Use a standard approximation formula (or data from belt
manufacturer tables).
For simplicity, let’s use:
Belt Tensions
Final Results
• Number of belts required = 3Tight side tension
• (T₁) = 850 NSlack side tension
• (T₂) = 340 NInitial belt tension
• (T₀) = 595 N