IPE 3717

Chapter 1
Engineering Design

FAISAL M AH M U D
L EC T U R ER , D EPART M EN T O F IPE ( D U ET )

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DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING, DUET,
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What is Design?
To design is either to formulate a plan for the satisfaction of a specified
need or to solve a specific problem.
If the plan results in the creation of something having a physical
reality, then the product must be functional, safe, reliable, competitive,
usable, manufacturable, and marketable.
Design is an innovative and highly iterative process also a decision
making process.
Decisions sometimes have to be made with too little information,
occasionally with just the right amount of information, or with an excess
of partially contradictory information.

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Phases in Design

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Phases in Design
Step 1: Identification of need generally starts the design process.
•The need may be only a vague discontent, a feeling of uneasiness, or a
sensing that something is not right.
•For example, the need to do something about a food-packaging machine
may be indicated by the noise level, by a variation in package weight, and
by slight but perceptible variations in the quality of the packaging or wrap.
Step 2:The definition of problem is more specific and must include all the
specifications for the object that is to be design.
•The specifications are the input and output quantities, the characteristics
and dimensions of the space the object must occupy, and all the limitations
on these quantities.
•The specifications define the cost, the number to be manufactured, the
expected life, the range, the operating temperature, and the reliability.

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 Phases in Design
Step 3:The synthesis of a scheme connecting possible system elements is
sometimes called the invention of the concept or concept design.
•Various schemes must be proposed, investigated quantified in terms of
established metrics.
Step 4: Analysis and Optimization
• As the fleshing out of the scheme progresses, analyses must be
performed to assess whether the system performance is satisfactory or
better, and, if satisfactory, just how well it will perform.
•Those with potential are optimized to determine the best performance of
which the scheme is capable
Step 5: Presentation

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Design Considerations
1 .Functionality 14 .Noise
2 .Strength/stress 15 .Styling
3.Distortion/deflection/stiffness 16. Shape
4 .Wear 17. Size
5 .Corrosion 18 .Control
6 .Safety 19 .Thermal properties
7 .Reliability 20 .Surface
8 .Manufacturability 21. Lubrication
9. Utility 22 .Marketability
10 .Cost 23 .Maintenance
11 .Friction 24 .Volume
12 .Weight 25 .Liability
13 .Life 26.Remanufacturing/resource
recovery

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 Concept of Stress and Strength
•Strength is a property of a material or of a mechanical element.
• Stress shows the resistance of a material to the external load and is not
a property.

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Uncertainty
• 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 weldmesh and shrink fits on stress conditions.
• Effect of thermo mechanical treatment on properties.
• Intensity and distribution of loading.
• Validity of mathematical models used to represent reality.
• Intensity 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

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Mathematical Method to Address Uncertainty
•Deterministic Method to address Uncertainty

loss of function parameter

𝑛𝑑 =
maximum allowable parameter
•If the parameter is load, then the maximum allowable load can be
found from
loss of function load
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑙𝑜𝑎𝑑 =
𝑛𝑑

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 Example
Consider that the maximum load on a structure is known with an
uncertainty of ±20 per cent, and the load causing failure is known
within ±15 per cent .If the load causing failure is nominally 2000 lbf.,
determine the design factor and the maximum allowable load that
will offset the absolute uncertainties.

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Safety Factor
loss−of−function strength S
nd= =
allowable stress σ(or τ )

A rod with a cross-sectional area of A and loaded in tension with an

axial force of P 2000 lbf undergoes a stress of σ = P/A. Using a
material strength of 24 kpsi and a design factor of 3.0, determine
the minimum diameter of a solid circular rod. Using Table A–17,
select a preferred fractional diameter and determine the rod’s
factor of safety.

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 Reliability
The statistical measure of the probability that a mechanical element will
not fail in use is called the reliability of that element. The reliability R
can be expressed by
R = 1 − pf
where pf is the probability of failure, given by the number of
instances of failures per total number of possible instances.
A reliability of R = 0.90 means that there is a 90 percent chance that
the part will perform its proper function without failure.

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Stress- Strain

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