Mechanical Design (I)

(MCE 321)

Introduction
Dr. Lotfi Romdhane
lromdhane@aus.edu
Summer 2016

Course Description (catalog):

MCE 321 Mechanical Design I (3-0-3). Examines
properties of ductile and brittle materials. Explores
the concepts of stress, strain and deformation
analysis of solid elements as applied to mechanical
design, and the analysis of long and intermediate
compression members. Includes design to prevent
static and fatigue failures. Covers the design of
mechanical elements, including power screws, bolted
and welded joints and mechanical springs.

Course Description
MCE 321 Mechanical Design I (3-0-3).
Introduction and overview of materials related topics
Load and stress analysis
Deflection and Stiffness
Failure theories:
Steady loading
Variable loading

Screws, fasteners and connections

Welded, brazed, and bonded joints
Mechanical Springs

Course Description (catalog):

MCE 322 Mechanical Design II (3-0-3). Covers
the design of clutches, brakes and couplings;
power transmission equipment (shafts, axles
and spindles); flexible mechanical elements
(flat and V-belts, wire ropes and chains);
rolling and journal bearings; spur, helical,
bevel and worm gears; and utilization of
commercial computer-aided design software.
Requires a design project.

Course Description
MCE 322 Mechanical Design II (3-0-3).
power transmission equipment (shafts, axles
and spindles);
rolling and journal bearings;
spur, helical, bevel and worm gears;
clutches, brakes and couplings;
flexible mechanical elements (flat and V-belts,
wire ropes and chains);

Good to know

Instructor:
Dr. Lotfi Romdhane
Email:
lromdhane@aus.edu
Office:
EB2-207
Phone:
06 515 2497
Class 01: 09:30 am 10:45 am MTWRU
Room:
EB2-109
Office hours: 11:00 - 12:00 UTR
and by appointment

Course Related Information [Cntd.]

Textbook: Shigley, J.E., Mischke, C.R., Budynas, R.G., Mechanical Engineering

Design, 10th edition in SI units, 2014, McGraw-Hill, New York.
Handouts will be uploaded on iLearn
The class has a website on iLearn, use it, it will contain all the documents
related to the course
Homework solutions will be posted on iLearn
Grades will be maintained online on iLearn
Syllabus might get updated as we go and will contain info about
Topics covered
Homework assignments
Midterm exam date

Syllabus available at the course website

Grading:
Midterm exam 1
Midterm exam 2
Final exam

22.5 %
22.5 %
30 %

(Wednesday June 22, 2016)

(Sunday July 3, 2016)

Project
HW
Quizzes
and attendance

10 %
5%
10 %

Due July 14, 2016

All submissions are through iLearn, each as a single PDF file, no paper
submission is accepted
No late homework is possible (the submission link disappears
automatically after the due date)

Final Project
A topic will be assigned to your group.
The project requires the use of the design accelerator
toolbox under Inventor.
Team size: 3 members.
Use iLearn to show your progress

Design
Design is an innovative and highly iterative process. It is
also a decision-making process.
Decisions sometimes have to be made with limited
information, occasionally with just the right amount of
information, or with an excess of partially contradictory
information.
Engineers have to communicate effectively and work with
people of many disciplines.
Engineering tools (such as mathematics, statics,
computer graphics, and languages) are combined to
produce a plan that, when carried out, produces a
product that is functional, safe, reliable, competitive,
usable, manufacturable, and marketable, regardless of
who builds it or who uses it.

Mechanical Engineering
Mechanical engineering design involves all disciplines of
mechanical engineering.
A simple journal bearing involves fluid flow, heat transfer, friction,
energy transport, material selection, thermomechanical
treatments, statistical descriptions, and so on.
A building is environmentally controlled. The heating, ventilation,
and air-conditioning considerations are sufficiently specialized
that some speak of heating, ventilating, and air-conditioning
design as if it is separate and distinct from mechanical
engineering design.
Similarly, internal-combustion engine design, turbomachinery
design, and jet-engine design are sometimes considered discrete
entities.

The big picture

Mechanics
Time not a
factor
Stress and
deformation

Statics
forces

Change
with time

Dynamics

kinematics

Kinetics

rigid bodies

Motion
Mechanics of
material

Motion and forces

Design process
Design process is a collection of procedures
and habits that help teams design better
products

The Design Process

Designing is the process of making many
decisions that converts an abstract concept
into a hardware reality.

Concept

Product

http://cct2.edc.org/imagination_place/guide/design.htm

Engineering Design Process

The engineering design process involves a series of steps that lead to the
development of a new product or system. The designer should be able to
do the following:

STEP 1: Identify the Problem

the designer should state the challenge problem in their own words.
Example: How can I design a __________ that will __________?
STEP 2: Identify Criteria and Constraints
STEP 3: Brainstorm Possible Solutions
STEP 4: Generate Ideas
STEP 5: Explore Possibilities
STEP 6: Select an Approach
STEP 7: Build a Model or Prototype
STEP 8: Refine the Design

Standard Design Process

The complete design
process from start to finish,
is often outlined as in the
figure.
Begins with an identification
of need and a decision to do
something about it.
After many iterations, the
process ends with the
presentation of the plans for
satisfying the need.
Several design phases may
be repeated throughout the
life of the product.

Concurrent Engineering*

Introduction

Design Considerations

Functionality
Strength/stress
Distortion/deflection/stiffness
Wear
Corrosion
Safety
Reliability
Manufacturability
Utility
Cost
Friction
Weight
Life
Noise

Styling
Shape
Size
Control
Thermal properties
Surface
Lubrication
Marketability
Maintenance
Volume
Liability
Remanufacturing/resource
recovery

The Design Engineers Responsibilities

In general, design engineering is required to satisfy the
needs of customers ( management, clients, consumers,
etc. ) and is expected to do so in a competent,
responsible, ethical, and professional manner.
Careful attention to the following action steps will help
you organize your solution processing technique.

Understand the problem.

Identify the known.
Identify the unknown and formulate the solution strategy.
State all assumption and decision.
Analyze the problem.
Evaluate your solution.

The design engineers professional obligations include

conducting activities in an ethical manner.

Standards and Codes

A standard is a set of specifications for parts, materials, or processes intended

to achieve uniformity, efficiency, and a specified quality.

A code is a set of specifications for the analysis, design, manufacture, and

construction of something.

Standard means 'the usual way' and code is a very strict, specific way

All of the organizations and societies listed below have established

specifications for standards and safety or design codes.

Aluminum Association (AA)

American Gear Manufacturers Association
(AGM)
American Institute of Steel Construction (AISC)
American Iron and Steel Institute (AISI)
American National Standards Institute (ANSI)
ASM International
American Society of Mechanical Engineers
(ASME)
American Society of Testing and Material
(ASTM)
American Welding Society (AWS)
American Bearing Manufactures Association
(ABMA)

British Standards Institute (BSI)

Industrial Fasteners Institute (IFI)
Institution of Mechanical Engineers (I.Mech.E)
International Bureau of Weights and Measures
(BIPM)
International Standards Organization (ISO)
National Institute for Standards and
Technology (NIST)
Society of Automotive Engineers (SAE)

Cost and Design

Costs to implement changes increase exponentially as the project

lifetime increases
80% of the final cost is decided in the early stages of the design
process
It is easier to reduce the cost in the early stages of the design
process

Economics
The consideration of cost plays an
important role in the design
decision process.
The use of standard or stock sizes is
a first principle of cost reduction.
Among the effects of design
specifications on costs, tolerances
are perhaps most significant.
When two or more design
approaches are compared for cost,
there occurs a point corresponding
to equal cost, which is called the
breakeven point.

Stress and Strength

The survival of many products depends on how the
designer adjusts the maximum stresses in a
component to be less than the components strength
at specific locations of interest.
Strength is a property of a material or of a mechanical
element. The strength of an element depends on the
choice and the processing of the material.
Stress is a state property at a specific point within a
body, which is a function of load, geometry,
temperature, and manufacturing processing.
We shall use the capital letter S to denote strength,
the Greek letters (sigma) and (tau) to designate
normal and shear stresses, respectively.

Uncertainty
Examples of uncertainties concerning stress and
strength include
1.
2.
3.
4.

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 welds and shrink fits on stress
conditions.
5. Effect of thermomechanical treatment on properties.
6. Intensity and distribution of loading.
7. Validity of stress concentrations.
8. Influence of time on strength and geometry.
9. Effect of corrosion.
10. Effect of wear.

Engineers must accommodate uncertainty.

Reliability
The reliability method of design is one in which we
obtain the distribution of stresses and the distribution of
strengths and then relate these two in order to achieve
an acceptable success rate.
The reliability R can be expressed by a number having
the range
0<<1
In the reliability method of design, the designers task is
to make a judicious selection of materials, processes,
and geometry (size) so as to achieve a specific reliability
goal.
It is important to note that good statistical data and
estimates are essential to perform an acceptable
reliability analysis.

Dimensions and Tolerances

Nominal size 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
Bilateral tolerance The variation in both directions from
the basic dimension, e.g. 1.005 0.002 .
Unilateral tolerance The basic dimension is taken as one of
the limits, and variation is permitted in only one direction,
e.g. 25+0.05
0.00

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
Fit The amount of clearance or interference between mating parts
GD&T Geometric Dimensioning and Tolerancing, a comprehensive
system of symbols, rules, and definitions for defining the theoretically
perfect geometry, along with the allowable variation.

Choice of Tolerances
The designer is responsible for specifying tolerances
for every dimension.
Consideration is given to functionality, fit, assembly,
manufacturing process ability, quality control, and
cost.
Excessive precision is a poor design choice, in that it
limits manufacturing options and drives up the cost.
Less expensive manufacturing options should be
selected, even though the part may be less than
perfect, so long as the needs are satisfactorily met.

Choice of Dimensions
Dimensioning a part is the designers responsibility.
Include just enough dimensions
Avoid extraneous information that can lead to confusion or multiple
interpretations.
Example of over-specified dimensions. With +/ 1 tolerances, two
dimensions are incompatible.

Choice of Dimensions
Four examples of which dimensions to specify

Tolerance Stack-up
The cumulative effect of
individual tolerances must be
allowed to accumulate
somewhere. This is known as
tolerance stack-up.
Chain dimensioning allows
large stack-up of many small
tolerances in series.
Baseline dimensioning
minimizes large tolerance
stack-up.

Shigleys Mechanical Engineering

Design

Example 13

Example 17 (Continued)
Solution
Answer

Answer

Units
In the symbolic units equation for Newtons
second law, = . Units chosen for any three
of these quantities are called base units.
The International System of Units (SI) is an
absolute system. The base units are the meter,
the kilogram (for mass), and the second.

Table 1.4

Common Engineering Design Conversion Factors

Given
Multiply by
To Find
Length [L]
Foot (ft)
0.304800
Meter (m)
Inch (in)
25.4000
Millimeter (mm)
Mile (mi)
1.609344
Kilometer (km)
Area [L]2
ft2
0.092903
m2
in2
645.16
mm2
in2
6.45160
cm2
Volume [L]3 & Capacity
in3
16.3871
cm3
ft3
0.028317
m3
ft3
7.4805
Gallon
ft3
28.3168
Liter (l)
Gallon
3.785412
Liter
Energy, Work or Heat [M] [L]2 [t]-2
Btu
1.05435
kJ
Btu
0.251996
kcal
Calories (cal)
4.184*
Joules (J)
ft-lbf
1.355818
J
ft-lbf
0.138255
kgf-m
hp-hr
2.6845
MJ
KWH
3.600
MJ
m-kgf
9.80665*
J
N-m
1.
J

http://www.engineershandbook.com/Tables/conversionfactors.htm
Common Engineering Design Conversion Factors
Given
Multiply by
To Find
Force or Weight [M] [L] [t]-2
kgf
9.80665*
Newton (N)
lbf
4.44822
N
lbf
0.453592
Kgf
Fracture Toughness
ksi sqr(in)
1.098800
MPa sqr(m)
Mass Density [M] [L]-3
lbm/in3
27.68
g/cm3
lbm/ft3
16.0184
kg/m3
Power [M] [L]2 [t]-3
Btu/hr
0.292875
Watt (W)
ft-lbf/s
1.355818
W
Horsepower (hp)
745.6999
W
Horsepower
550.*
ft-lbf/s
Stress [M] [L]-1 [t]-2
kgf/cm2
9.80665 E-2*
MPa
ksi
6.89476
MPa
N/mm2
1.
MPa
kgf/mm2
1.42231
ksi

Significant Figures

The number of significant figures is usually inferred by the number of

figures given (except for leading zeros). For example, 706, 3.14, and
0.00219 are assumed to be numbers with three significant figures.

To display 706 to four significant figures, insert a trailing zero and

display either 706.0, 7.060 102 , or 0.7060 103 .

Computers and calculators display calculations to many significant

figures. However, you should never report a number of significant
figures of a calculation any greater than the smallest number of
significant figures of the numbers used for the calculation.

For example, determine the circumference of a solid shaft with a

diameter of = 11 . The circumference is given by = . Since
is given with two significant figures, should be reported with only two
significant figures.

If you have a series of calculations you should keep all the figures until
the final calculation and round at the end

We usually use at least 3 significant figures to represent physical

quantities, example: = 9.81 / 2 , = 207 ,