Lecture Slides

Chapter 1

Introduction to
Mechanical Engineering
Design
The McGraw-Hill Companies © 2012
Chapter Outline

Shigley’s Mechanical Engineering Design

 Design In General

 Mechanical design is a complex process, requiring many skills.

Its an iterative process

 Design engineers should have technical competency, sense of

responsibility and strong work ethics

 Resources: Books, Codes & Standards, Design Tools

 Considerations: Economics, Safety, Product Liability, Dimensions

and Tolerances, Units and Calculations

 To formulate a plan for the satisfaction of a specified need; process

requires innovation, iteration, and decision-making

Shigley’s Mechanical Engineering Design

 Product Characteristics
 Products should be
◦ Functional
◦ Safe
◦ Reliable
◦ Competitive
◦ Usable
◦ Manufacturable (The Big Bang Theory)
◦ Marketable

 The engineering designer has to be personally comfortable with

a decision-making, problem-solving role
 Engineers have to communicate effectively and work with
people of many disciplines
 Mechanical Engineering Design

 Mechanical engineers are associated with the production and

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

 Mechanical engineering design involves all the disciplines of

mechanical engineering e.g. mechanics of solids and fluids, mass
and momentum transport, manufacturing processes
 Example (Mechanical Design)
Journal bearing: fluid flow, heat transfer, friction, energy
transport, material selection, thermomechanical treatments,
statistical descriptions, etc.
A bearing is a machine element that constrains relative motion to
only the desired motion, and reduces friction between moving
parts. The design of the bearing may provide for
free linear movement of the moving part or Shigley’s
for Mechanical
free rotation
Engineering Design
  Mechanical Engineering Design

 Example (Thermal Design)

environmentally controlled building: The heating, ventilation,
and air-conditioning considerations are required for this type of
design

 Similarly, there are phrases such as machine design, machine-

element design, machine-component design, systems design,
and fluid-power design. All of these phrases are somewhat
more focused examples of mechanical engineering design

Shigley’s Mechanical Engineering Design

The Design Process

Shigley’s Mechanical Engineering Design

  Mechanical Engineering Design

Identification of Need: It starts the design process. It may be a discontent,

a feeling of uneasiness, or a sensing that something is not right.

Definition of Problem: It is more specific and must include all the

specifications for the object that is to be designed. The manufacturing
processes that are available, together with the facilities of a certain plant,
constitute restrictions on a designer’s freedom
Synthesis: It is a scheme connecting possible system elements; sometimes
called concept design. Various schemes must be proposed, investigated,
and quantified in terms of established metrics

Analysis & Optimization: Analyses must be performed to assess whether

the system performance is satisfactory or better, and, if satisfactory, just
how well it will perform

Shigley’s Mechanical Engineering Design

  Mechanical Engineering Design
For example, the design of a system to transmit power requires
attention. to the design and selection of individual components (e.g.,
gears, bearings, shaft). However, as is often the case in design, these
components are not independent.

Evaluation: It is the final proof of a successful design and usually

involves the testing of a prototype in the laboratory

Presentation: Communicating the design to others is the final step

in the design process. Many great designs, inventions, and creative
works have been lost to posterity simply because the originators
were unable or unwilling to explain their accomplishments to others
Shigley’s Mechanical Engineering Design
  Mechanical Engineering Design

Detailed Process:
[Link]
ng-design-process/engineering-design-process-steps

Shigley’s Mechanical Engineering Design

 Design Considerations

 When we use the expression design consideration, we are

referring to some characteristic that influences the design of the
element or, perhaps, the entire system. Some characteristics that
influence the design

Shigley’s Mechanical Engineering Design

 Design Tools and Resources

Computational Tools
 Computer-Aided Engineering (CAE)
Any use of the computer and software to aid in the
engineering design process
 Computer-Aided Design (CAD)
Drafting, 3-D solid modeling, etc. (AutoCAD, Solid
Edge, Solid Works)
 Computer-Aided Manufacturing (CAM)
CNC toolpath, rapid prototyping, etc. (MasterCAM, Power
Shape)
 Engineering Analysis and Simulation
Finite element, fluid flow, dynamic analysis, motion, etc. (ANSYS, ABAQUS)
 Math solvers
Spreadsheet, procedural
programming language,
Shigley’s Mechanical Engineering Design
 Acquiring Technical Information

 Libraries
◦ Engineering handbooks, textbooks, journals, patents, etc.
 Government Sources
◦ Government agencies, U.S. Patent and Trademark, National
Institute for Standards and Technology, etc.
 Professional Societies (conferences, publications, etc.)
◦ American Society of Mechanical Engineers, Society of
Manufacturing Engineers, Society of Automotive
Engineers, American Petroleum Institute etc.
 Commercial Vendors
◦ Catalogs, technical literature, test data, etc.
 Internet
Access to much of the above information
Shigley’s Mechanical Engineering Design
 A Few Useful Internet Sites

 [Link]
 [Link]
 [Link]
 [Link]
 [Link]

Shigley’s Mechanical Engineering Design

 The Design Engineer’s Professional Responsibilities

 Satisfy the needs of the customer in a competent, responsible,

ethical, and professional manner.
 To start on the road to success, you should start to develop these
characteristics early in your educational program
 Communication skills play a large role here and wise students
who continuously works to improve these skills
 Some key advise for a professional engineer
◦ Be competent
◦ Keep current in field of practice
◦ Keep good documentation
◦ Ensure good and timely communication
◦ Act professionally and ethically

Shigley’s Mechanical Engineering Design

 The Design Engineer’s Professional Responsibilities

 Careful attention to the following action steps will help you to

organize your solution processing technique

◦ 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

Shigley’s Mechanical Engineering Design

 Ethical Guidelines for Professional Practice
 National Society of Professional Engineers (NSPE) publishes a
Code of Ethics for Engineers and an Engineers’ Creed.
 [Link]/ethics
 Six Fundamental Canons
 Engineers, in the fulfillment of their professional duties, shall:
◦ Hold paramount the safety, health, and welfare of the
public.
◦ Perform services only in areas of their competence.
◦ Issue public statements only in an objective and truthful
manner.
◦ Act for each employer or client as faithful agents or
trustees.
◦ Avoid deceptive acts.
◦ Conduct themselves honorably, responsibly, ethically, and
lawfully so as to enhance the honor, reputation, and
usefulness of the profession. Shigley’s Mechanical Engineering Design
 NSPE Engineers’ Creed

 As a Professional Engineer I dedicate my professional

knowledge and skill to the advancement and betterment
of human welfare.
 I pledge:
◦ To give the utmost of performance;
◦ To participate in none but honest enterprise;
◦ To live and work according to the laws of man and the highest
standards of professional conduct;
◦ To place service before profit, the honor and standing of the
profession before personal advantage, and the public
welfare above all other considerations.
 In humility and with need for Divine Guidance, I make
this pledge.

Shigley’s Mechanical Engineering Design

 Standards and Codes

 Standard (ASTM A36)

◦ A set of specifications for parts, materials, or processes
◦ Intended to achieve uniformity, efficiency, and a specified
quality
◦ Limits the multitude of variations
 Code (API 579)
◦ A set of specifications for the analysis, design,
manufacture, and construction of something
◦ To achieve a specified degree of safety, efficiency, and
performance or quality
◦ Does not imply absolute safety
 Various organizations establish and publish standards and codes
for common and/or critical industries
Shigley’s Mechanical Engineering Design
 Standards and Codes
 Some organizations that establish standards and codes of
particular interest to mechanical engineers:

Shigley’s Mechanical Engineering Design

 Economics

 Cost is almost always an important factor in engineering

design process.

 Materials and labor usually increase while costs of

processing the materials can be expected to exhibit a
decreasing trend because of the use of automated
machine tools and robots (Industries near raw material
source)

Standard Sizes
 Use of standard sizes is a first principle of cost reduction.
 Hot-rolled steel 53 mm square, Mobile chargers
 Table A-17 lists some typical preferred sizes
 Parts that are made and sold in large quantities usually
cost somewhat less than the odd sizes
Shigley’s Mechanical Engineering Design
 Tolerances

 Tolerances, manufacturing processes, and surface finish

are interrelated and influence the producibility of the
end product in many ways

 Close tolerances generally increase cost (Engine Parts

of Ferrari)
◦ Require additional processing steps
◦ Require additional inspection
◦ Require machines with lower production rates

 Manufacturing cost increase drastically as

tolerance diminishes with finer machining
processing
Shigley’s Mechanical Engineering Design
 Breakeven Points

When two or more design approaches are compared for cost, the
choice between the two depends on a set of conditions such as the
quantity of production, the speed of the assembly lines, or some other
condition
There then occurs a point corresponding to equal cost, which is
called the breakeven point
EXAMPLE
 Automatic screw machine
 25 parts/hr
 3 hr setup
 $20/hr labor cost
 Hand screw machine
 10 parts/hr
 Minimal setup
 $20/hr labor cost
 Breakeven at 50 units
Shigley’s Mechanical Engineering Design
 Safety and Product Liability

 Strict Liability concept generally prevails in USA

 It states manufacturer is liable for damage or harm that results
because of a defect (Samsung Battery & Toyota Crankshaft)
 Negligence need not be proved.
 Calls for good engineering in analysis and design,
quality control, and comprehensive testing
 Marketing managers often make glowing promises in the
warranties (PM’s Bullet Train Example)
 These statements should be reviewed carefully by the
engineering staff to eliminate excessive promises

Shigley’s Mechanical Engineering Design

 Stress and Strength

  The designer must allow the maximum stress to be less than the
strength by a sufficient margin so that despite the uncertainties,
failure is rare (Factor of Safety)
 Strength
◦ An inherent property of a material or of a mechanical
element
◦ Depends on treatment and processing
◦ May or may not be uniform throughout the part
◦ Examples: Ultimate strength (), yield strength (), Shear
Strength ()
 Stress
◦ A state property at a specific point within a body
◦ Primarily a function of load and geometry
◦ Sometimes also a function of temperature and Shigley’s
processing
Mechanical Engineering Design
 Uncertainty

 Engineers must accommodate uncertainty. Uncertainty always

accompanies change
 Common sources of uncertainty in stress or strength

Shigley’s Mechanical Engineering Design

 Methods to Address Uncertainty
 Deterministic method
◦ Establishes a design factor, nd
◦ Based on absolute uncertainties of a loss-of-function parameter
and a maximum allowable parameter, e.g. load, stress &
deflection

◦ If, for example, the parameter is load, then

Shigley’s Mechanical Engineering Design

 Factor of Safety & Design Factor
 Factor of safety expresses how much stronger a system is than it needs to be for an
intended load. (Bridges, Columns)

 Design load is the maximum load the part should ever experience in service

 So a structure with a FOS of exactly 1 will support only the design load and no more. Any
additional load will cause the structure to fail. A structure with a FOS of 2 will fail at twice
the design load. (Six Hitting in Cricket)

 Factor of Safety: The ratio of a structure's absolute strength (structural capability) to

actual applied load; this is a measure of the reliability of a particular design. This is a
calculated value.

 Design Factor: A constant required value, imposed

by law, standard, specification, contract or custom, to which a structure must conform or
exceed.

 Difference b/w FOS & DF: The FOS or yield stress, is how much the designed part
actually will be able to withstand while DF or working stress, is what the item is required
to be able to withstand
 Methods to Address Uncertainty

 Stochastic method
◦ Based on statistical nature of the design parameters
◦ Focus on the probability of survival of the design’s function
(reliability)
◦ Often limited by availability of statistical data

Shigley’s Mechanical Engineering Design

 Example 1-1

Solution

Answer

Answer

Shigley’s Mechanical Engineering Design

 Design Factor Method

 Often used when statistical data is not available

 Since stress may not vary linearly with load, it is more
common to express the design factor in terms of strength and
stress.

 All loss-of-function modes must be analyzed, and the mode with

the smallest design factor governs (Cantilever Beam)
 Stress and strength terms must be of the same type and units.
 Stress and strength must apply to the same critical location in
the part.
 The factor of safety is the realized design factor of the final
design, including rounding up to standard size or
available components.
 Design is all about playing with the options while
satisfying the constraints; don’t under/over designShigley’s Mechanical Engineering Design
 Example 1-2

Solution

Answer

Answer

Shigley’s Mechanical Engineering Design

 Reliability
 It is very important for the designer and the manufacturer to know
the reliability of their product to follow regulations issued by
governmental agencies such as EPA and OSHA
 Reliability (R) – The statistical measure of the probability that a
mechanical element will not fail in use

 Probability of Failure (pf ) - the number of instances of failures

per total number of possible instances

 Example: If 1000 parts are manufactured, with 6 of the parts

failing, the reliability is 99.4 %

 Selection of products is then done using the reliability values.

Shigley’s Mechanical Engineering Design

 Reliability

 Series System – a system that is deemed to have failed if

any component within the system fails (power transmission
systems, desktop)
 The overall reliability of a series system is the product of
the reliabilities of the individual components.

(1-5)
R   Ri
n
i1
 Example: A shaft with two bearings having reliabilities of
95% and 98% has an overall reliability of
R = R1 R2 = 0.95 (0.98) = 0.93 or
 Parallel System
93% – In a parallel system at least one of the units
must succeed for the system to succeed (Gates of dams, support
cables in bridges)

Shigley’s Mechanical Engineering Design

 Dimensions and Tolerances

 Nominal size (nickname) – The size we use in speaking of an

element. Is not required to match the actual dimension

 Limits – The stated maximum and minimum dimensions

 Tolerance – The difference between the two limits (Packaging)

 Bilateral tolerance – The variation in both directions from the

basic dimension, e.g. 1.005 ± 0.002 in.

 Unilateral tolerance – The basic dimension is taken as one of

the limits, and variation is permitted in only one direction, e.g.

Shigley’s Mechanical Engineering Design

 Dimensions and Tolerances

 Clearance – Refers to the difference in sizes of two mating

cylindrical parts such as a bolt and a hole.
◦ Assumes the internal member is smaller than the external
member
◦ Diametral clearance – difference in the two diameters
◦ Radial clearance – difference in the two radii
 Interference – The opposite of clearance, when the internal
member is larger than the external member
 Allowance – The minimum stated clearance or the
maximum stated interference or mating parts

Shigley’s Mechanical Engineering Design

 Example 1-3

Figure 1-4

Shigley’s Mechanical Engineering Design

 Example 1-3 (Continued)
Solution

Answer

Answer

Answer

Shigley’s Mechanical Engineering Design