CHAPTER2 MECHANİCAL DESIGN Design Process

Grand Engineering Challenges  Requirements Development (recognize

need, identify problem, define
• Make solar energy economical
requirements)
• Provide energy from fusion
Recognize need to consider the following
• Develop carbon sequestration methods issues:

• Provide access to clean water -Functional performance – what the product

must accomplish.
• Restore and improve urban infrastructure
-Environmental impact – during production,
• Enhance virtual reality use, and retirement.
• Advance health informatics
-Manufacturing – resource and material
• Engineer better medicines limitations.
• Reverse-engineer the brain -Economic issues – budget, cost, price, profit.
• Prevent nuclear terror -Ergonomic concerns – human factors,
• Secure Cyberspace aesthetics, ease of use.

• Enhance virtual reality -Global issues – international markets, needs,

and opportunities.
• Advance personalized learning
-Life cycle issues – use, maintenance, planned
• Engineer the tools of scientific discovery
obsolescence.
• Manage the nitrogen cycle
-Social factors – civic, urban, cultural issues
Product Archaeology
 Conceptual Design (generate
-Product archaeology is the process of innovative concepts, select best
reconstructing the life cycle of a product concept(s))

– the customer requirements, design -Engineers work collaboratively and creatively

specifications, and manufacturing processes to generate a wide range of potential
used to produce it solutions to the problem at hand, and then
select the most promising solution(s) to
-to understand the decisions that led to its
develop
development.
-Creativity is a critical part of an engineer’s
1. Preparation:
job, as product design requires engineers who
background research about a product are part rational scientists and part innovative
including market research, patent searches, artists.
and benchmarking existing products.
-A requirements list is used to eliminate
2. Excavation: component description, infeasible or inferior designs and identify the
dissection, and analysis concepts with the most potential to satisfy the
requirements well
3. Evaluation: benchmark existing products,
and conduct material and product tests.

4. Explanation: draw conclusions about the

issues that shaped the design of the product.
  Detailed Design (product layout, Patents
material selection, system simulation, § Patents are a key aspect of the business side of
prototype and testing, design engineering because they provide legal protection to those
documentation) who invent new technology.
In the detailed design of the product, a § Patents are one aspect of intellectual property, and they
number of issues must be determined are a right to property, analogous to the deed for a building
or a parcel of land.
-Developing product layout and § Patents are granted for a new and useful process,
configuration(düzen ve yapılandırma) machine, article of manufacture, or composition of matter
-Selecting materials for each component or for an improvement of them.
-Optimizing the final geometry, including
appropriate tolerances Utility Patents (Faydalı Patent)
-Developing completed digital models of all § Most commonly encountered in mechanical engineering,
components and assemblies the utility patent protects the function of an apparatus,
-Simulating the system using digital and process, product, or composition of matter.
mathematical models § The utility patent generally contains three main
-Prototyping and testing critical components components:
and modules - The specification is a written description of the purpose,
-Developing production plans construction, and operation of the invention
Design for reliability, manufacturing, - The drawings show one or more versions of the invention -
The claims explain in precise language the specific features
INNOVATİON
that the patent protects.
Innovation can help develop a wide range of technologies to provide
better-engineered solutions.

Considering different levels of style and technology provides a § Utility patents become valid on the date the patent is
framework to strategically develop innovative products for a wide range granted, and in the US, recently issued ones expire 20 years
of customers.
after the date of the application.

DOCUMENTATİON(BELGELEME)
Rapid Prototyping
§ Engineers must diligently(özenle) document the design process,
engineering drawings, meeting minutes, and written reports so that others § Rapid prototyping, 3D printing, and additive
will understand the reasons behind each of the decisions made. manufacturing enable complex three-dimensional objects
§ A design notebook effectively captures(yakalar) the information and to be fabricated directly from a computer-generated
knowledge created during a design process.
§ Design notebooks also help support the process of patenting new
drawing, often in a matter of hours.
technology. § Some rapid prototyping systems use lasers to fuse layers
§ Drawings, calculations, photographs, test data, and a listing of the dates of a liquid polymer together (a process known as
on which important milestones were reached are important to accurately stereolithography) or to fuse raw material in powder form.
capture the development of an invention.
§ Another prototyping technique moves a printhead to
spray a liquid adhesive onto a powder and “glue-up” a
assembly, variation, costing, and recycling prototype bit-by-bit.
  Production § Engineers select processes, identify the
machines and tools, and monitor production to
*Once the detailed design has been
ensure that the final product meets its
completed, a designer will be involved with the
specifications.
fabrication and production of the product
§ The main classes of manufacturing
*The fabrication techniques that an engineer
processes are casting, forming, machining,
selects will depend on the time and expense of
joining, and finishing.
setting up the tooling and machines necessary
for production. 1. CASTING (döküm)

*Some systems—for instance, automobiles, air Casting is the process in which liquid metal,
conditioners, microprocessors, hydraulic such as gray iron, aluminum, or bronze, is
valves, and computer hard disk drives—are poured into a mold, cooled, and solidified.
mass produced (toplu üretim), a term that § Complex shapes can be produced as solid
denotes the widespread use of mechanical objects without the need to join any pieces
automation. together.

The development of flexible manufacturing § Some examples of cast components include

systems allows a production line to quickly automotive engine blocks, cylinder heads, and
reconfigure to different components for brake rotors and drums.
different vehicles.
2. FORMİNG (şekillendirme)
Focus On: Global Design Teams § Forming encompasses a family of techniques
§ Technological advances in simulation and virtual in which a raw material is shaped by
prototyping are making geographic separation between stretching, bending, or compression.
product design teams irrelevant, as was realized in the
design and development of the Boeing 787 Dreamliner. § Large forces are applied to plastically deform
§ Virtual prototyping allows for new prototypes to be a material into its new permanent shape.
created quickly at a potentially greatly reduced cost § Rolling is the process of reducing the
§ Engineers can simulate and test many design scenarios thickness of a flat sheet of material by
at a fraction of the cost, allowing for changes to be made compressing it between rollers.
rapidly.
§ Forging is another forming process, and it is
based on the principle of heating, impacting,
and plastically deforming metal into a final
shape.
Manufacturing Processes §Extrusion is used to create long straight
metal parts with their cross sections having
§ Manufacturing technologies are
round, rectangular, L-, T-, or C-shapes, for
economically important because they are the
instance.
means for adding value to raw materials by
converting them into useful products. § In extrusion, a mechanical or hydraulic press
§ There are many different manufacturing is used to force heated metal through a tool
processes, and each is well suited to a (kalıp deniyor) that has a tapered hole ending
particular need based on environmental in the shape of the finished part’s cross
impact, dimensional accuracy, material section.
properties, and the mechanical component’s
shape. § Conceptually, the process of extrusion is not
unlike the familiar experience of squeezing
toothpaste out of a tube.
 MANUFACTURİNG TOOLS

-Band Saw

§ A machinist will use a band saw to make rough

cuts through metal. (fonksiyonu)
3. MACHINING (işleme)
§ The blade is a long, continuous loop that has
§ Machining refers to processes in sharp teeth on one edge, and it rides on the drive
which a sharp metal tool removes and idler wheels.
material by cutting it. § A variable-speed motor enables the operator to
§ The most common machining adjust the blade’s speed depending on the type and
methods are drilling, sawing, milling, thickness of the material being cut.
and turning.
-Milling Machine
§ Machining operations are capable of
producing mechanical components § A milling machine (or mill) is used for machining
with dimensions and shapes that are the rough surfaces of a workpiece flat and smooth,
far more precise than their cast or and for cutting slots, grooves, and holes.
forged counterparts. §The milling machine is a versatile machine tool in
which the workpiece is moved slowly relative to a
rotating cutting tool.
4. JOINING and FINISHING (birleştirme
ve son) §The workpiece is held by a vise on an adjustable
§ Joining operations are used to table so that the part can be accurately moved in
assemble subcomponents into a final three directions.
product by -Lathe (torna)
welding(kaynak),
soldering((lehimlemek), § A lathe holds a workpiece and rotates it about
the centerline as a sharpened tool removes chips of
riveting(perçinlemek),
material.
bolting(cıvatalamak),
adhesively bonding (yapışkan § The lathe is used to produce cylindrical shapes
birleştirme) and other components that have an axis of
-Many bicycle frames, for instance, symmetry.
are welded together from individual § Threads, shoulders that locate bearings on a
pieces of metal tubing. shaft, and grooves for holding retaining clips can
§ Finishing steps are taken to treat a each be made using a lathe.
component’s surface in order to make
-Numerical Control
it harder, improve its appearance, or
protect it from the environment. § Computer-aided manufacturing uses computers
- Some finishing processes include to control machine tools to cut and shape materials
polishing(cilalama), to remarkable precision.
electroplating(elektro kaplama), § Machining operations are controlled by a
computer when high precision is required, or when
anodizing(anotlama), and painting.
a repetitive task must be performed on a large
scale.
§ Computer-controlled machine tools offer
Machining Tools: Drill Press
the potential to produce physical hardware
§ The drill press shown is used to bore round holes into a seamlessly from a computer-generated
workpiece. drawing.
§ A drill bit is held in the rotating chuck, and as a machinist turns
the pilot wheel, the bit is lowered into the workpiece's surface.

• For safety reasons, vises and clamps are used to hold the
workpiece securely and to prevent material from shifting
unexpectedly.
Summary

§ Engineers reduce an open-ended problem

into a sequence of manageable steps:

ú Defining system requirements,

ú Conceptual design where concepts are

generated and narrowed down, and

ú Detailed design where all the geometric,

functional, and production details of a product
are developed.

§ Engineering is ultimately a business venture,

and you should be aware of that broader
context in which mechanical engineering is
practiced.

§ In the end, successful design is a function of

creativity, elegance, usability, and cost.

§ Throughout design, engineers use their

judgment and make order-of-magnitude
calculations to move ideas to concepts and
concepts to detailed designs.

§ Mechanical engineers also specify the

methods that will be used to produce
hardware, and those decisions are based on
the quantity that will be produced, the
allowable cost, and the level of precision
necessary.