Lecture Slides

Chapter 1

Introduction to
Mechanical
Engineering Design
 Chapter Outline
1–1 Design 4
1–2 Mechanical Engineering Design 5
1–3 Phases and Interactions of the Design Process 5
1–4 Design Tools and Resources 8
1–5 The Design Engineer’s Professional Responsibilities 10
1–6 Standards and Codes 12
1–7 Economics 13
1–8 Safety and Product Liability 15
1–9 Stress and Strength 16
1–10 Uncertainty 16
1–11 Design Factor and Factor of Safety 18
1–12 Reliability and Probability of Failure 20
1–13 Relating the Design Factor to Reliability 24
1–14 Dimensions and Tolerances 27
1–15 Units 31
1–16 Calculations and Significant Figures 32
1–17 Design Topic Interdependencies 33
1–18 Power Transmission Case Study Specifications 34
Problems 36

Shigley’s Mechanical
Engineering Design
 Design
• To formulate a plan for the satisfaction of a
specified need
• Design is an innovative and highly iterative
process. It is also a decision-making process.
• Engineers have to communicate effectively and
work with people of many disciplines.
• Engineering tools (such as mathematics, statics,
computers, 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
Shigley’s Mechanical
Engineering Design
 Mechanical Engineering Design
Mechanical engineering design involves all the
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.
Shigley’s Mechanical
Engineering Design
 The 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.
Shigley’s Mechanical
Engineering Design
 Phase of the Design Process
• Identification of need generally starts the design process. The
need may only be a vague discontent, a feeling of uneasiness, or a
sense that something is not right.
• The definition of problem is more specific and must include all
the specifications for the object that is to be designed.
• The synthesis of a scheme connecting possible system elements is
sometimes called the invention of the concept or concept design.
This is the first and most important step in the synthesis task.
• Analyses must be performed to assess whether the system
performance is satisfactory.
• Synthesis, analysis and optimization are intimately and iteratively
related.
• Evaluation is the final proof of a successful design and usually
involves the testing of a prototype in the laboratory.
• Presentation is a selling job.
 Design Considerations
• Some characteristics that influence the design

Shigley’s Mechanical
Engineering Design
Quiz:

In concurrent engineering, design and manufacturing

are:
(a) sequentially considered
(b)simultaneously considered
(c) separately considered
(d) none of above
 Computational Tools
• Computer-Aided Engineering (CAE)
– Any use of the computer and software to aid in the
engineering process
– Includes
• Computer-Aided Design (CAD)
– AutoCAD, CadKey, I-Deas, Unigraphics, Solid Works, and
ProEngineer,…..
• Engineering-based software for ME applications
– (FEA) programs (ANSYS, and MSC/NASTRAN), (CFD) programs ,
dynamic analysis& motion (ADAMS, DADS).
• Non-engineering-specific computer-aided applications
– Word processing, Spreadsheet software (e.g., Excel, Lotus),
and mathematical solvers (e.g., Maple, MathCad, MATLAB,
Mathematica, and TKsolver).
Shigley’s Mechanical
Engineering Design
 Acquiring Technical Information
• Libraries
– Engineering handbooks, textbooks, journals, patents, etc.
• Government sources
– Departments of Defense, Commerce, Energy, and
Transportation; etc.
• Professional Societies (conferences, publications, etc.)
– American Society of Mechanical Engineers, Society of
Manufacturing Engineers, Society of Automotive Engineers,...
• 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

• www.globalspec.com
• www.engnetglobal.com
• www.efunda.com
• www.thomasnet.com
• www.uspto.gov

Shigley’s Mechanical
Engineering Design
The Design Engineer’s 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 to 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 engineer’s professional obligations include
conducting activities in an ethical manner.
 The Design Engineer’s Responsibilities

• 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
 Standards and Codes
• Standards and codes represent a prescriptive approach to design
that may be incorporated into a design process
• Standard
– A set of technical definitions and guidelines for designers and
manufacturers (for parts, materials, or processes)
– Written by “experts” and are considered voluntary
– Intended to achieve uniformity, efficiency, and a specified quality
– Limits the multitude of variations
• Code
– A set of standards that has been adopted by one or more governmental
bodies or incorporated into a contract.
– Essentially, a code is a set of standards with the force of law behind it.
– It specifies 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
• According to its web site, ASME “maintains and distributes 600
codes and standards used around the world for the design,
manufacturing and installation of mechanical devices.”
• All of the organizations and societies listed below have established
specifications for standards and safety or design codes:
• Aluminum Association (AA) • American Welding Society (AWS)
• American Gear Manufacturers • American Bearing Manufactures
Association (AGMA) Association (ABMA)
• American Institute of Steel • British Standards Institute (BSI)
Construction (AISC) • Industrial Fasteners Institute (IFI)
• American Iron and Steel Institute • Institution of Mechanical Engineers
(AISI) (I.Mech.E)
• American National Standards • International Bureau of Weights
Institute (ANSI) and Measures (BIPM)
• ASM International • International Standards
• American Society of Mechanical Organization (ISO)
Engineers (ASME) • National Institute for Standards and
• American Society of Testing and Technology (NIST)
Material (ASTM) • Society of Automotive Engineers
(SAE)
 ASME Standards and Codes Related to Standardization

A112 Plumbing Materials and Equipment

B1 Screw Threads
B5 Machine Tools - Components, Elements, Performance, and Equipment
B18 Standardization of Fasteners
B29 Chains, Attachments and Sprockets for Power Transmission and Conveying
B32 Metal and Metal Alloy Wrought Mill Product Nominal Sizes
B40 Standards for Pressure and Temperature Instruments and Accessories
B46 Classification and Designation of Surface Qualities
B47 Gage Blanks
B73 Chemical Standard Pumps
B89 Dimensional Metrology
B94 Cutting Tools, Drivers, and Bushings
B107 Hand Tools and Accessories
B133 Gas Turbine Procurement
HST Overhead Hoists
MFC Measurement of Fluid Flow in Closed Conduits
MH1 Pallets, Slip Sheets, and Other Bases For Unit Loads
SRB Slew Ring Bearing
STS Steel Stacks
Y14 Engineering Drawing and Related Documentation Practices
 ASME Standards for Screw Threads (1)

B1.1-1989 Unified Inch Screw Threads (UN and UNR Thread Form)
B1.2-1983 (R1991) Gages and Gaging for Unified Inch Screw Threads
B1.3-1992 Screw Thread Gaging Systems for Dimensional Acceptability – Inch and Metric
Screw Threads (UN, UNR, UNJ, M, and MJ)
B1.5-1997 Acme Screw Threads
B1.7M-1984 (R1992) Nomenclature, Definitions and Letter Symbols for Screw Threads
B1.8-1988 (R1994) Stub Acme Screw Threads
B1.11-1958 (R1994) Microscope Objective Thread
B1.12-1987 (R1998) Class 5 Interference-Fit Thread
B1.13M-1995 Metric Screw Threads – M Profile
B1.15-1995 Unified Inch Screw Threads
B1.16M-1984 (R1992) Gages and Gaging for Metric M Screw Threads
B1.20.1-1983 (R1992) Pipe Threads, General Purpose (Inch)
B1.20.7-1991 (R1998) Hose Coupling Screw Threads (Inch)
B1.21M-1997 Metric Screw Threads – MJ Profile
B1.22M-1985 (1992) Gages And Gaging Practice For "MJ" Series Metric Screw Threads
B1.30M-1992 Screw Threads – Standard Practice for Calculating and Rounding Dimensions
Quiz:
1. Standardization deals with the characteristics of product that
include:
(a) dimensions of machine elements
(b) method of testing the product
(c) composition and properties of engineering materials
(d) all the three

2. The types of standards used in design office are

(a) standards prepared by National Building Council (NBC) ( ‫مجلس البناء‬
‫)الوطني‬
(b) standards prepared by International Standards Organization (ISO)
(c) standards prepared by professional bodies like American Gear
Manufacturing Association (AGMA)
(d) all the three
 Economics
• Cost is almost always an important factor
in engineering design decision process.
• Use of standard sizes is a first principle of
cost reduction.
• Table A-17 lists some typical preferred
sizes.
• Certain common components may be less
expensive in stocked sizes.
• Among the effects of design specifications
on costs, tolerances are most significant.

Shigley’s Mechanical
Engineering Design
 Tolerances
• Close tolerances
generally increase
cost:
– Require additional
processing steps
– Require additional
inspection
– Require machines
with lower
production rates

Shigley’s Mechanical
Engineering Design
 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 component’s strength at specific locations of interest.
• 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, fatigue strength
• Stress:
– A state property at a specific point within a body
– A function of load, geometry, temperature, and manufacturing
processing.
• We shall use S to denote strength, the Greek letters σ
(sigma) for normal stress and τ (tau) for shear stress.
Shigley’s Mechanical
Engineering Design
 Uncertainty
• Examples of uncertainties concerning stress and
strength include
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 weldments and shrink fits on stress conditions.
Effect of thermomechanical treatment on properties.
Intensity and distribution of loading.
Validity of stress concentrations.
Influence of time on strength and geometry.
Effect of corrosion.
Effect of wear.
Uncertainty as to the length of any list of uncertainties.

• Engineers must accommodate uncertainty.

Shigley’s Mechanical
Engineering Design
 Uncertainty
1. 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
 Uncertainty
2. Deterministic method
– Establishes a design factor, nd
– Based on absolute uncertainties of a loss-of-function
parameter and a maximum allowable parameter

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

strength
all 
nm
d
n  design factor
m  exponent in the load to strength relationship
  stress

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.
 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.
 After the design is completed, the actual design factor nd may
change as a result of changes such as rounding up to a standard
size for a cross section or using off-the-shelf components with
higher ratings → The factor of safety n.
 Factors of Safety
 Ratio of two quantities (unit less):
• Strength/stress
• Critical load / applied load
• Load to fail part/expected service overload
• Maximum cycles/applied cycles
• Maximum safe speed/operating speed
• Maximum safe deflection/design deflection

 Multiple modes of failure, therefore multiple safety factors

 Choosing a Safety Factor
 A measure of the uncertainty in the inputs to the analysis used
to design the part. Includes:
o Loads  Analytical models
o Geometry  Material property data

 Can be specified by either code or law

 Typically, the Safety Factor for brittle materials is at least twice
that of ductile materials
 Examples of safety factors
o Elevators — 8+
o Ski Lifts — 5.13
o Aircraft — 1.1
 Example 1-2

Solution

Answer

Answer

Shigley’s Mechanical Engineering Design

 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.
• Reliability, R – The statistical measure of the probability that a
mechanical element will not fail in use
• The reliability R can be expressed by a number having the range
0  R 1
• Probability of Failure, pf – the number of instances of failures per
total number of possible instances

• In the reliability method of design, the designer’s 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.

Shigley’s Mechanical
Engineering Design
 Dimensions and Tolerances
• Nominal (Basic) 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. 25  0.05mm
– 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 mm
0.00
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
 Units
• In the symbolic units equation for Newton’s
second law, F=ma. 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.
 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 d =11mm. The circumference is given
by C   d .Since d is given with two significant figures, C should
be reported with only two significant figures.