MEC531: ENGINEERING DESIGN 1

PART A: MECHANICAL DESIGN PROCESS

1. Introduction to Mechanical Design Process
1.1 The Phases of Design
1.2 Problem identification and defination
1.3 Product design specifications
1.4 Concept development, evaluation and selection

PART B: DESIGN FOR STRENGTH

2. Design for Strength
2.1 Static Strength
2.2 Failure theories
2.3 Stress Concentration
2.4 Fatigue Strength
2.5 Introduction to fracture mechanics

PART C: DESIGN OF MECHANICAL ELEMENTS

3. Design of Mechanical Joints
4. Design of Power Transmission Elements
5. Design of Flexible Mechanical Elements
6. Design of Rolling Bearing

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√ PART A: MECHANICAL DESIGN PROCESS
1. Introduction to Mechanical Design Process
1.1 The Phase of Design
1.2 Problem identification and defination
1.3 Product design specifications
1.4 Concept development, evaluation and selection

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 IMPLEMENT
CONCEIVE DESIGN
(MEC532) OPERATE
(MEC531) (MEC531)
(MEC532)

CDIO

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 Design
safe
functional
reliable marketable
competitive
usable

manufacturable

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What is Engineering
Design?

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• Engineering design is a creative and
comprehensive process.
• Integrates mathematics, basic sciences,
engineering sciences, engineering
economics and other subjects for the creation of
components, systems, products and processes to satisfy
specific needs and constraints.
• i.e. constraints include economic, safety, health,
environmental and social factors, the requirements of
standards and legislation, and other considerations such as
maintainability, serviceability, and manufacturability.
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Engineering Design
Engineering Design Process

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The Phases of Design
Phase I. Conceptual Design
Phase II. Embodiment Design
Phase III. Detail Design
Phase IV. Planning for Manufacture
Phase V. Planning for Distribution
Phase VI. Planning for Use
Phase VII. Planning for Retirement

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1st Three Phases of the Engineering Design
Process
Conceptual Design

Define Gather Concept Evaluation of

Problem Information Generation Concepts

Parametric Configuratio Product

Detail Design
Design n Design Architecture

Embodiment Design
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 Phase 1: Conceptual Design Phase
• a.k.a Feasibility Study.
• Requires greatest creativity, involves the most uncertainty and requires
coordination among many functions in the business organization.
• Discrete activities to be considered:
− Identification of customer needs
− Problem definition
− Gathering information
− Conceptualization
− Concept selection
− Refinement of the PDS
− Design review

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 Problem Definition
• Most important steps in the engineering design process is
identifying customer needs.
• The customer needs can be gained from:
– Interviewing customers
– Focus group
– Customer survey
– Customer complaints

• Tools to achieve this:

– Benchmarking
– QFD
– PDS

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• Benchmarking
– Method for measuring company operation against the best
company inside and outside of the industries.
– Select the product, process, or functional area that is to be
benchmark.
– Identify the performance metrics that will be measured and
used for comparison.
– Compare the best in class product or process with the in house
equivalent using the performance metrics.
– Specified program and actions to meet an exceed the
competition.

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• QFD – Quality Function Deployment
– A planning and problem solving tool that is finding growing
acceptance for translating customer requirements into
engineering characteristics of a product.
– A largely graphical method that systematically looks at all the
elements that go into the product definition.
– Helps organizations seek out both spoken and unspoken
needs.
– QFD links the needs of the customer (end user) with design,
development, engineering, manufacturing, and service
functions.
– Also known as ‘House of Quality’.

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Cross, 1998 NRNR_MEC531_2020
• PDS – Product Design Specification
– A statement of what a product to be designed is intended to do.
– Its aim is to ensure the development of a product meets the
need of the users.
– The PDS is a specification of what is required but not the
specification of the product itself.

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• Example PDS –
Product Design
Specification

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 Gather Information
• Information from Internet
– Engineering URLs

• Patent Literature
– Intellectual Property
– Patents

• Handbook

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 Concept Generation
• Brainstorming
• Functional decomposition
• Morphological chart

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 Kerusi Kereta

Ubahsuai Ubahsuai Ubahsuai Keselamatan Memuatkan

Tempat duduk Penyandar Penyandar Pengguna System
Kepala Pengesan Sel
Beban

●Pergerakan ke ●Pergerakan ●Pergerakan ke ●Jenis ●Bentuk

depan & bersudut atas dan bawah ●Titik ubahsuai ●Pergerakan
belakang ●Bentuk ●Bentuk
●Bentuk ●Titik ubahsuai ●Titik ubahsuai
●Titik ubahsuai

Rajah 3.3: Penguraian Fungsi Pokok

NFAM, 2007
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• Morphological chart
– Chart arranges a functions and sub-functions in a logical order
– Each sub-function list the possible how
– Purpose to uncover combinations of ideas that comprise
design concepts that might not ordinarily be generated

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 Evaluation of Concepts
• Comparison Based on Absolute Criteria
• Pugh’s Concept Selection Method
• Weighted Decision Matrix

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kahoot

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Pugh’s Concept Selection Method​

Kriteria Konsep 1 Konsep 2 Konsep 3 Kerusi

Standard

Tempat duduk:
Mekanisme yang mempunyai
banyak pilihan titik rehat dan
+ - - D
pergerakan yang lancar
Penyandar :
Keselesaan, mudah untuk diubah- + S - A
suai
Penyandar kepala:
Pergerakan yang mudah dan tidak S - + T
memenuhi ruang
Keselamatan pengguna:
Ringkas dan selamat
S - - U

Lokasi pengesan:
Pergerakan yang mudah dan + + - M
kestabilan pengesan terjamin
∑+ 3 1 1
∑- 0 3 4
∑S 2 1 0

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 Weighted Decision Matrix
Example (Crane hook)
 Proposed concepts :
 Concept 1 : Steel plates welded together
 Concept 2 : Steel plates riveted together
 Concept 3 : Cast-steel hook (monolithic)

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 Weighted Decision Matrix

• Step 1 – Identify the design criteria :

– Material cost
– Manufacturing cost
– Time to produce
– Durability
– Reliability
– Reparability
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 Weighted Decision Matrix
• Step 2 – Determine the weighting factor for each design
criteria
Construct hierarchical objective tree
Crane hook

Cost Quality in service

Mat. Manuf. Reparability Durability Reliability Time to

Cost Cost produce

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 Weighted Decision Matrix

O1= 1.0

O11= 0.6 O12= 0.4

O111= 0.3 O112= 0.5 O113= 0.2 O121= 0.6 O123= 0.1
O122= 0.3
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 Step 3 - Form the decision matrix
Concept 1 Concept 2 Concept 3

Weight
Design Criterion Units
factor

Magnitude Score Rating Magnitude Score Rating Magnitude Score Rating

Mat cost 0.18 RM/kg 60 8 1.44 60 8 1.44 50 9 1.62

Manuf. Cost 0.3 RM 2500 7 2.1 2200 9 2.7 3000 4 1.2

Reparability 0.12 Experience Good 7 0.84 Excellent 9 1.08 Fair 5 0.6

Durability 0.24 Experience High 8 1.92 High 8 1.92 Good 6 1.44

Reliability 0.12 Experience Good 7 0.84 Excellent 9 1.08 Fair 5 0.6

0.04 Hours 40 7 0.28 25 9 0.36 60 5 0.2

Time to prod.

          7.42     8.58     5.66

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Today’s reflections

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