REE 302 - Fall 2022

Machine Design
Dr. Mohamed L. Shaltout
Associate Professor
Renewable Energy Engineering Program

1
Course Overview
Instructor:

Dr. Mohamed L. Shaltout – mshaltout@zewailcity.edu.eg

Room: G001 – HB
Office hours: To be announced

Teaching Assistants:

▪ Eng. Mohamed Abdelgaleel maabdelgaleel@zewailcity.edu.eg

▪ Eng. Mohamed Fouad s-mohamed_fouad98@zewailcity.edu.eg

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Course Overview
Objectives:
This course introduces the design principles of machines and machine elements.

Course Description:
REE 302 (3 Credits): Introduction to Conceptual Design: design considerations,
uncertainty, and reliability. Materials in design: material selection process, material
failure limits. Loading and stress analysis, stiffness, and stress concentration. Fatigue
failure of ductile and brittle materials. Analysis of combined loading: Goodman
diagram. Design of machine elements: shaft design, bearings.

Prerequisites:
▪ REE 202: Mechanics of Materials
▪ MATSCI 201: Fundamentals of Materials Science and Engineering
▪ REE 222: Introduction to Manufacturing Processes

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Course Overview
References:
1. R. G. Budynas and J. K. Nisbett, “Shigley’s Mechanical Engineering Design”, 11th
edition, McGraw Hill Education, 2020.
2. R. L. Mott, E. M. Vavrek, and J. Wang, “Machine Elements in Mechanical Design”, 6th
edition, Pearson, 2018.
3. R. L. Norton, “Machine Design: An Integrated Approach”, 4th edition, Pearson, 2010.

Grading:
▪ Assignments 10 %
▪ Quizzes 10%
At least
▪ Midterm Exams 30 % 75% attendance
▪ Project 10 % is required
▪ Final Exam 40 %

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Course Overview
Topics:
▪ Introduction to Mechanical Engineering Design

▪ Materials in Machine Design

▪ Loading and Stress Analysis

▪ Deflection and Stiffness

▪ Failure Resulting from Static Loading

▪ Fatigue Failure Resulting from Variable Loading

▪ Shaft Design and Shaft Components

▪ Bearing Selection

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 Introduction
to
Mechanical Engineering Design

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What is a Machine?
Machine: A collection of mechanisms arranged to
transmit loads and do work.

Mechanism: An assemblage of links and joints in

which at least one link has been “grounded”, or
attached, to the reference frame.

Link: A rigid body that possesses at least one point for

attachment to other links.

Joint: A connection between two or more links, which

allows some motion between the connected links

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What is a Machine?
Bearings
Types of Joints:

Revolute (Pin or hinge) Joint

Spherical Joint
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What is a Machine?
Types of Joints:

Prismatic (slider) Joint

Helical (screw) Joint

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What is a Machine?
Types of Joints:

Cylindrical Joint

Higher pair Joint (rolling and sliding) Cam-Follower Mechanism

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Machine Elements and Components
Shafts:
▪ A shaft is a rotating member used to transmit rotary motion and torque (POWER).
▪ It provides the axis of rotation of elements such as gears, pulleys, and sprockets.
▪ It is an essential component in all machines.

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Machine Elements and Components
Bearing: A component used to support a load
while permitting relative motion between two
elements of a machine.

Fluid Film (Journal) bearing

Rolling Element bearing Active Magnetic bearing

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Machine Elements and Components
Gear: Toothed, cylindrical wheels used for
transmitting motion and power from one
rotating shaft to another.

Spur Gear Helical Gear

Worm
Gear

Bevel Gear

Rack & Pinion

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Machine Elements and Components
Belts and Chains:
▪ Flexible power transmission elements used for transmitting motion and power from
one rotating shaft to another.
▪ They are used when the distance between the shafts is large.

Sheaves (pully) and Belts Sprockets and Chains Continuously Variable

Transmission (CVT)
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Machine Elements and Components
Clutches: A clutch is a friction device used to
connect or disconnect a driven component from the
prime mover of the system.

Brakes: A brake is a friction device used to bring a

moving system to rest, to slow its speed, or to control
its speed to a certain value under varying conditions.

Couplings: A coupling is an element used to

connect two coaxial shafts.

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Machine Elements and Components
Mechanical Springs:
▪ A spring is a flexible element used to exert a force or a torque and, at the same time, to
store energy.

Leaf Spring

Tension Spring
Torsion Spring
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Machine Elements and Components
Fastener: Any device used to connect or join
two or more components. Examples: bolts,
screws, nuts, studs.

Bolted Connections: used to join two or

more components in a machine frame using
bolts and nuts.

Riveted Connections: used to join two or

more components in a machine frame using
rivets.

Welded Connections: used to join two or

more components in a machine frame using
welding.

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Wind Turbine Drivetrain as a Machine

Bolted
Connections
between Hub
and Blades

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Mechanical Engineering Design
Mechanical Engineering Design:
▪ An innovative, decision-making, problem-
solving, and highly iterative process.

▪ Engineering tools (such as mathematics,

statistics, 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.

▪ Involves all the disciplines of mechanical

engineering (e.g., Mechanics of solids and
fluids, Thermodynamics, Materials and
Manufacturing, Dynamics and Control).

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Mechanical Engineering Design
Phases of the Design Process:
▪ Identification of need, e.g., Transmit
power from a wind turbine rotor hub to a
generator.

HAWT
?
Generator

VAWT
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Mechanical Engineering Design
Phases of the Design Process:
▪ Definition of problem, e.g., specifications
of the inputs and outputs, dimensions,
weight, cost, life.

Power
Transmission Power
Diameter
System Speed
Inertia
Speed Torque
Torque Inertia
Thrust
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Mechanical Engineering Design
Phases of the Design Process:
▪ Synthesis, e.g., propose design concepts

Gears
Belts & Chains
Hydraulics
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Mechanical Engineering Design
Phases of the Design Process:
▪ Analysis and optimization, e.g., detailed
design, components sizing and matching,
material selection, dynamic modeling

Gear Design

Shaft Design

Bearing Selection Gearbox

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Mechanical Engineering Design
Phases of the Design Process:
▪ Evaluation, e.g., prototyping, testing,
performance evaluation, economics,
assembly , maintainability, reliability

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Mechanical Engineering Design
Phases of the Design Process:
▪ Presentation, e.g., design reports,
drawings, detailed specifications, user
manuals, and maintenance manuals.
Gearbox
Rotor
Hub

Generator

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Mechanical Engineering Design
Design Considerations:
▪ Characteristic that influences the design of an element or, perhaps, the entire system.
▪ Characteristics may be related to dimensions, material, processing, and joining of the
elements of the system.

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Mechanical Engineering Design
Design Considerations:
▪ Design for X (DFX) stands for a concurrent engineering mindset, where the design
team has recognized that product design is greater than the sum of its elements.

❑ Design for Manufacturing/Material ❑ Design for Aesthetics

❑ Design for Maintainability/Serviceability ❑ Design for Logistics

❑ Design for Assembly/Disassembly ❑ Design for Quality

❑ Design for Environment/Sustainability ❑ Design for Simplicity/Usability

❑ Design for Affordability/Cost ❑ Design for Reliability

❑ Design for Safety ❑ Design for Ergonomics

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Mechanical Engineering Design
Design Tools and Resources:
▪ Design engineers have a great variety of tools and resources available to assist in the
solution of design problems.

Textbooks & Handbooks CAE/CAD software Manufacturer Catalogs

Publications & Reports Codes and Standards Online Resources

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Mechanical Engineering Design
Design for Economics:
▪ The consideration of cost plays an
important role in the design decision
process.

▪ Rules for cost reduction: The use of

standard or stock sizes (Fasteners, Gears,
Bearings, Belts, Chains, Pulleys,
Sprockets).
o Requesting special sizes add cost to
the product.

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Mechanical Engineering Design
Design for Economics:
▪ The consideration of cost plays an
important role in the design decision
process.

▪ Rules for cost reduction:

Manufacturing processes, tolerances,
and surface finish.
o High surface finish and tight
tolerances require high precision
machines and processes.

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Mechanical Engineering Design
Design for Economics:
▪ The consideration of cost plays an
important role in the design decision
process.

▪ Rules for cost reduction:

Breakeven point: Cost versus
Production quantity
o Manual: 10 parts per hour
o Automatic: 25 parts per hour
o The breakeven point
corresponds to 50 parts (Equal
cost $100).

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Mechanical Engineering Design
Uncertainty in Machine Design (Design Factor & Factor of Safety):
▪ Material properties, load variability, fabrication fidelity, and validity of mathematical
models are among concerns to designers.

▪ Uncertainty in machine design can be addressed using a deterministic mathematical

method based on a design factor (𝒏𝒅 ),

≥𝟏

Here the “parameter” can be load, stress, deflection, etc.

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Mechanical Engineering Design
Uncertainty in Machine Design (Design Factor & Factor of Safety):
F
Example:
▪ Load causing failure (𝑃 = 2000 𝑁) is known with an uncertainty of ±15%

▪ Maximum allowable load (𝐹) is known with an uncertainty of ±20%

Determine the design factor and the maximum allowable load that will guarantee
that the part will not fail.
F

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Mechanical Engineering Design
Uncertainty in Machine Design (Design Factor & Factor of Safety):
Solution: F
𝑷
= 𝒏𝒅
𝑭
Let (worst case scenario),

𝑷(𝟏−𝟎.𝟏𝟓) 𝑷(𝟎.𝟖𝟓) 𝑷 𝟏.𝟐

= = 𝟏, then =
𝑭(𝟏+𝟎.𝟐) 𝑭(𝟏.𝟐) 𝑭 𝟎.𝟖𝟓
From both equations:
𝟏. 𝟐
𝒏𝒅 = = 𝟏. 𝟒𝟏𝟐
𝟎. 𝟖𝟓
F
For 𝑃 = 2000 𝑁,
𝟐𝟎𝟎𝟎
𝑭= = 𝟏𝟒𝟏𝟔. 𝟔𝟕 𝑵
𝟏. 𝟒𝟏𝟐

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Mechanical Engineering Design
Uncertainty in Machine Design (Design Factor & Factor of Safety):
▪ If the used parameters are stress and material strength, the design factor can be called
factor of safety (𝒏),
Material Strength (𝑺)
𝒏= ≥𝟏 P
Allowable Stess (𝝈 𝒐𝒓 𝝉)
Example:
𝑷
▪ Rod under tension with cross-sectional area 𝐴 = 𝜋𝑑 /42
𝝈=
𝑨
▪ Axial force 𝑃 = 2000 𝑁 and Material strength 𝑆 = 24 𝑀𝑃𝑎
▪ Use a factor of safety ≥ 3, determine the rod diameter? 𝑺
𝒏= =𝟑
Solution: 𝝈
𝑆 24 𝑃 2000
𝜎≤ = = 8 𝑀𝑃𝑎 , thus 𝐴 = = ≥ 250 𝑚𝑚2 .
𝑛 3 𝜎 8
P
𝜋 4
But 𝐴 = 𝑑2 , then 𝑑 ≥ 250 × = 17.8 𝑚𝑚 ≅ 18 𝑚𝑚 (preferred size)
4 𝜋
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Mechanical Engineering Design
Uncertainty in Machine Design (Design Factor & Factor of Safety):
▪ A factor of safety is always unitless and greater than one. By how much greater than
one?

▪ A factor of safety increases with high uncertainties (low level of confidence) in the
design data (static or dynamic loads, material properties, stress analysis, or the
environment).

▪ Often the value of the factor of safety is governed by codes and standards (e.g., ASME
Boiler and Pressure Vessel Code).

▪ Examples:
o Commercial aircrafts, 𝑛 = 1.2 𝑡𝑜 1.5 (weight saving)
o Military aircrafts, 𝑛 = 1 𝑡𝑜 1.1 (pilots wear parachutes)
o Missiles, 𝑛 = 1 (short life)
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Mechanical Engineering Design
Reliability and Probability of Failure:
▪ The probability of failure, 𝑝𝑓 , is given by the number of instances of
failures per total number of possible instances.

▪ The probability of failure, 𝑝𝑓 , is obtained from the probability density

function (PDF) of a continuous Gaussian (normal) distribution (𝜇𝑥 : Bearing
mean & 𝜎ො𝑥 : standard deviation):

▪ Integrating the above equations gives 𝑝𝑓 . The results are given in

tables as a function of Belt

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Mechanical Engineering Design
Reliability and Probability of Failure:
Example: In a shipment of 250 connecting rods, the mean tensile strength is found to be
𝜇𝑆 = 45 MPa and has a standard deviation of 𝜎ො𝑆 = 5 MPa.

▪ How many rods can be expected to have a strength less than 𝑆 = 39.5 MPa?

𝒙−𝝁𝒔 𝟑𝟗.𝟓−𝟒𝟓
𝒛𝟑𝟗.𝟓 = ෝ𝑺
= = −𝟏. 𝟏, 𝝓 𝒛𝟑𝟗.𝟓 = 𝟎. 𝟏𝟑𝟓𝟕
𝝈 𝟓

Normal (Gaussian) Distribution Tables

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Mechanical Engineering Design
Reliability and Probability of Failure:
▪ The number of rods (𝑆 < 39.5) = 250 (0.1357) ≅ 34 rods

▪ If the 250 rods are subjected to a stress of 39.5 MPa or higher, then the probability of
failure is:
𝒑𝒇 = 𝟎. 𝟏𝟑𝟓𝟕 (13.57%)

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Mechanical Engineering Design
Reliability and Probability of Failure:
▪ Reliability is defined as the probability that a system or a product will perform in a
satisfactory manner for a given period of time when used under specified operating
conditions.

▪ The reliability 𝑅 can be expressed by

𝑹 = 𝟏 − 𝒑𝒇 , 𝟎≤𝑹≤𝟏

▪ A reliability of 𝑅 = 0.90 means there is a 90 % chance that the part will perform its
proper function without failure.

▪ For the previous example (𝑝𝑓 = 0.1357),

𝑹 = 𝟏 − 𝟎. 𝟏𝟑𝟓𝟕 = 𝟎. 𝟖𝟔𝟒𝟑

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Mechanical Engineering Design
Reliability (Series Configuration):
▪ If a mechanical system fails when any one component fails, the system is said to be a
series system.

▪ The reliability of a series system (𝑹𝒔 ) is given by:

𝑹𝟏 𝑹𝟐 𝑹𝟑
𝑹𝒔 = ς𝒏𝒊=𝟏 𝑹𝒊 Reliability Block Diagram (RBD)
𝑹𝒔 < 𝐦𝐢𝐧 (𝑹𝒊 )

▪ For example, consider a shaft with two bearings having reliabilities of 95 % and 98 %.
𝑹𝒔 = 𝑹𝟏 𝑹𝟐
𝑹𝟐 = 𝟎. 𝟗𝟓 × 𝟎. 𝟗𝟖 = 𝟎. 𝟗𝟑𝟏

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Mechanical Engineering Design
Reliability (Series Configuration):

Examples: Machine

▪ Motor-Coupling-Gearbox-Machine

▪ Joints of a Robotic arm

▪ Fluid filters in series (clogging failure)

Filter Filter
(1) (2)

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Mechanical Engineering Design
Reliability (Parallel Configuration):
▪ If a mechanical system fails when all components fail, the system is said to be a parallel
(redundant) system.
𝑹𝟏
▪ The reliability of a parallel system (𝑹𝒑 ) is given by:
𝑹𝟐
𝑹𝒑 = 𝟏 − [ς𝒏𝒊=𝟏(𝟏 − 𝑹𝒊 )]
Reliability Block
𝑹𝒑 > 𝐦𝐚𝐱 (𝑹𝒊 ) Diagram (RBD)
𝑹𝟑

▪ For example, consider two pumps connected in parallel having reliabilities of 95 %

and 98 %. Note: The system can operate with a single pump.
𝑹𝒑 = 𝟏 − 𝟏 − 𝑹𝟏 𝟏 − 𝑹𝟐
𝑹𝒑 = 𝟏 − 𝟏 − 𝟎. 𝟗𝟓 𝟏 − 𝟎. 𝟗𝟑 = 𝟎. 𝟗𝟗𝟔𝟓
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Mechanical Engineering Design
Reliability (Parallel Configuration):

Examples

▪ Multi V-belt drive

▪ A spare tire in the vehicle

▪ A generator in a hospital

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Mechanical Engineering Design
Reliability (Parallel Configuration):
▪ Connecting components in parallel adds Redundancy, which is a 𝑹𝟏
means to improve the reliability.
▪ Adding redundancy increases the cost and makes the system 𝑹𝟐
more complicated, but if the cost of failure is high, redundancy is
often an attractive option.

Types of Redundancy:
𝑹𝟏
▪ Active Redundancy: the redundant items operate
simultaneously in performing the same function.
𝑹𝟐
▪ Passive (Standby) Redundancy: the redundant items are only
activated when the primary item fails. An automatic or manual Switch
switch is required.

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Mechanical Engineering Design
Redundancy, System Function, and Modes of Failure:
Example: Consider a pipeline with two non-return valves.
▪ System function: allow flow in one direction and prevent back flow.
▪ Mode of Failure: “Fails Open” ▪ Mode of Failure: “Fails Closed”
▪ Physical connection to achieve ▪ Physical connection to achieve
redundancy (series redundancy): redundancy (parallel redundancy):

▪ In order to achieve a parallel reliability configuration (redundancy), the physical

connection depends on the mode of failure and the system function.
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Mechanical Engineering Design
Redundancy, System Function, and Modes of Failure:
Example: Consider a hydraulic system with two filters.
▪ System function: supply clean oil to the hydraulic system.
▪ Mode of Failure: “Bursting” ▪ Mode of Failure: “Clogging”
▪ Physical connection to achieve ▪ Physical connection to achieve
redundancy (series redundancy): redundancy (parallel redundancy):

▪ In order to achieve a parallel reliability configuration (redundancy), the physical

connection depends on the mode of failure and the system function.
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