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Design
What is Design?
Aesthetic
marketability
Ease of
Requirement handling
Safety
Availability of
Creation FUNDS
Economical
Model Available
(Rough idea) material Recyclability
Manufacturing
resources
Machine Material/s
Analysis Force/stress Sizes
Design used
What is the basic knowledge required for
Machine Design?
Mechanical Design
•Mathematics
Mathematics
• Mechanics of Machines
•Engineering
EngineeringMechanics
Mechanics • Mechanics of Materials
• Fluid Mechanics & Thermodynamics
•Strength
Strengthof
ofMaterials
Materials
•Workshop
WorkshopProcesses
Processes
•Engineering
EngineeringDrawing
Drawing
• Computing
• Thermal stresses
Steady loads
Variable loads
• Torsional stresses
Find the simplest arrangement that would give the most efficient motion
that is required.
3. Selection of MATERIALs
Synthesis Select the mechanism that would give the desired motion
and form the basic model with a sketch etc
Material selection
Force
Area
Unknown dimensions
needs to be calculated
Factor of Safety
The load which any member of a machine
carries is called working load, and stress
produced by this load is the working stress.
Obviously, the working stress must be less
than the yield stress, tensile strength or the
ultimate stress.
This working stress is also called the
permissible stress or the allowable stress or
the design stress.
Factor of Safety Contd.
Some reasons for factor of safety include the
inexactness or inaccuracies in the estimation
of stresses and the non-uniformity of some
materials.
U
ltimateoryieldstress
F
acto
rofsa
fe
ty=
D
esignorw orkingstress
Note: Ultimate stress is used for materials e.g. concrete which do not
have a well-defined yield point, or brittle materials which behave in a
linear manner up to failure. Yield stress is used for other materials e.g.
steel with well defined yield stress.
Factor of safety
Effect of Failure
Type of load
Degree of accuracy in force analysis
Material of component
Reliability
Cost
Service conditions
ENGINEERING DESIGN
Design
- a plan or drawing produced to show the look
and function or workings of a
building, garment, or other object before it is
made
- the form, parts, or details of something
according to a plan
Design establishes and defines solutions to and
pertinent structures for problems not solved
before, or new solutions to problems which
have previously been solved in a different way.
ENGINEERING DESIGN
• Engineering design is the method that engineers use to
identify and solve problems.
Imagine
Choose a Possible
solution solutions
Click on a “slice” of the Engineering Design Process cycle to learn more about its parts
Define problem and goal
• Consider:
– What do you want to accomplish?
– What are the requirements?
– Are there any limitations?
– Who is the customer?
Research
• Gather information and investigate existing
technologies related to the problem
• Talk to individuals who share this problem and could
benefit from possible solutions
Best
(2)
http://www.sciencebuddies.org/engineering-design-process/engineering-design-prototypes.shtml
Improve
• Share results and continue
to seek how your team
could make the solution
better.
• Iterate your design to Image taken from:
http://www.rubymarketer.com/improve-search-engine-ranking/
make the product the best
it can be.
– Iterate - to repeat an already
completed task to
incorporate new information (3)
Ulrich K., Eppinger S. 2000. Product Design and Development. 2 nd Edition. Irwin
(3)
McGraw-Hill, Boston.
Innovation vs. Invention
Invention Innovation
A device or process originated A new improvement to an
after study and experiment existing device or process
Invention
Innovations
Image taken from: http://www.novuslight.com/led-market-phasing-in_N239.html
Invention
Innovations
Image taken from: http://lexpower.wordpress.com/2010/07/21/chronological-order-show-me-the-timeline/1000px-bicycle_evolution-en-svg/
Types of Design
Original Design:
•An original, innovative concept to achieve a need
• Successful original designs occur rarely, but when they
do occur they usually disrupt existing markets
e.g. Development of microprocessor
Development of Engine
Types of Design
Adaptive design :
• The design team adapts a known solution to satisfy a
different need
• To produce a novel application
• Relatively common in design
• e.g. User interface adapted to different screen sizes
Types of Design
Redesign :
• Engineering design is employed to improve an
existing design
• The task may be to redesign a component in a
product that is failing in service, or to redesign a
component so as to reduce its cost of manufacturing
• Does not affect working principle of original design
• e.g. Change in shape to reduce stress concentration
Types of Design
•Selection Design : -
•The design task consists of selecting the
components with the needed performance,
quality, and cost from the catalogs of potential
vendors
e.g. Selection of motors, bearings, etc.
Types of Design
• Industrial Design
• This form of design deals with improving the appeal of a
product to the human senses, especially its visual appeal
• Consideration of how the human user can best interface
with the product
• It is a vital aspect of many kinds of design
Design for Manufacturing
Design for Manufacturing
Design for Manufacturing is the process
of designing parts, components or
products for ease of manufacturing with
an end goal of making a better product
at a lower cost.
This is done by simplifying, optimizing
and refining the product design.
Integration of designing and
manufacturing
Design for Manufacturing
• General Guidelines
1. Minimize total number of parts
- Reduces cost of the product and increases reliability of product
- This can be achieved by combining two or more parts during
design, using snap/ press fit to replace / reduce fasteners
Minimize total number of parts
Minimize total number of parts
Design for Manufacturing
2.Minimize variety of parts
- Reduces the manufacturing cost and
inventory, improves quality of parts
Variety
- Variety in product range so that customer requirements can be satisfied e.g. Fridge
volumes
- Variety with colors and shapes
• The type and size of the control devices selected depends upon
the following number of factors, the principle ones are
Types of Controls
1.Hand wheel –
Torque corresponding to tangential force as 300 to 400 N if the rim of the wheel grasped
firmly by both hands.
2. Small Crank –
Can be operated at high speeds with load of the order of 10 to 20 N, maximum speed of
crank 200 rpm, handle length 40 mm and grip diameter 10 mm
Control Elements Design Considerations
3. Round knob –
Be operated by hand.
Diameter – 10 mm to 150 mm max. suitable
Diameter – 50 mm , torque – 25 Nm
4. Joysticks –
It is a lever with two degree of freedom and used to control two independent variable
simultaneously e.g. gear box operating lever of automobile and selector switches.
Control Elements Design Considerations
5. Push buttons –
These are used for controlling two state parameters and can be biased to return to the
un-operated condition when not presses (car horn) or may require second pressure to
release them (T.V. on/off switch).
Layout Design
Sequence of Operations
Functional Grouping
Frequency of use
Ease of Identification
Layout Design
Examples
Working Environment
• Light
Standard codes about light system at work space should be strictly
followed
Intensity, color, brightness, glare, etc should be monitored and
maintained
• Noise
Standard industrial norms should be followed
Noise results in annoyance, hearing loss and less work efficiency
It can be reduced by proper maintenance, isolators and use of silencers
Working Environment
• Temperature
Proper temperature results in enhanced work efficiency
Temperature at work space depends on nature of work
Upper limit = 28 . 2
Zero line
Hole
Different Types of limit
Unilateral Limit: In this
method of presenting the
limits, both the limits of size
are on the same side of the
zero line.
Upper limit of shaft is less than the lower limit of the hole.
2. Interference fit
Upper limit of the hole is less than the lower limit of shaft.
3. Transition fit
Diameter of the largest permissible hole is greater than the diameter of
the smallest shaft.
• Neither loose nor tight like clearance fit and interference fit.
• Tolerance zones of the shaft and the hole will be overlapped between
the interference and clearance fits.
Systems used to Indicate Fits
types of fits
For Shaft
For Hole
Maximum metal limit
(MML) = 44.95 mm
Least metal limit (LML) =
45.05 mm
Geometric Relations
Tolerance Stack
Last Button not
entering in the shirt
slot
Can you read this Drawing?
And…
Benefits
of
GD&T
G e o m et r i ca l t o l e r a n c e s vs
size t o l e r a n c e s
Precision &
Accuracy
Reduced
re w o r k cost
Reduced
Defects
Increased
understanding
Upper Deviation
Deviation:- It is the algebraic
difference between actual size,
to its corresponding basic size.
Hole
Min.dia.
Max.dia.
Shaft
60 H7 f8
Tolerance
grade for
Tolerance Shaft
grade for
Hole
ISO System of Limits and Fits
ISO System of Limits and Fits
Grades of Tolerance
It may be noted that the value of IT6 Grade is taken as 10i and
values of the subsequent grades are obtained by multiplying
earlier grade by 5 10
Grades of Tolerance
• IT01 = 0.3 +0.008D
• IT0 = 0.5 +0.0012D
• IT1 = 0.3 +0.02D
• The value of IT2 is selected properly by scaling
in between the values of other tolerance
grade.
Fundamental deviations
Grades of Tolerance
Symbolic Representation of Tolerance
Few Definitions
• Shaft and Hole: These terms are used to designate all the
external and internal features of any shape and not
necessarily cylindrical.
Indian Standard System of Limits and Fits
Indian Standard System of Limits and Fits
System of Limits and Fits
The selection of letter freezes one
limit of hole / shaft
Representation of
Tolerance
(how much away from Basic size)
1) Letter Symbol
Basic Size
45 E8/e7
GD&T
Types o f G e o m e t r i c a l t o l e r a n c e s
F o r m To l e r a n c e s
O r i e n t a t i o n To l e r a n c e s
• Parallelism • Angularity
• Perpendicularity
Location to le r a n c e s
• Position • Concentricity
• Symmetry • Coaxiality
runout tolerances
• Circular ru n o u t • To t a l r u n o u t
Simple Drawing
Problem was
GD&T
Symbols
Symbols
Feature Control Frame
Details o f
To l e r a n c e s
Form
To le ra n ce s
Straightness
Straightness tolerance
T h e t o l e r a n c e z o n e , in t h e c o n s i d e r e d p l a n e , is l i m i t e d b y
t w o parallel s t r a i g h t l i n e s a d i s t a n c e a p a r t a n d in t h e
specified d i r e c t i o n o n l y
GEOMETRIC DIMENSIONING AND TOLERANCING
(GD&T)-STRAIGHTNESS
FLATNESS
flatness tolerance
The e x t r a c t e d ( a c t u a l ) s u r f a c e s h a l l be c o n t a i n e d b e t w e e n t w o
parallel p l a n e s DISTANCE T a p a r t .
GEOMETRIC DIMENSIONING AND TOLERANCING
(GD&T)- FLATNESS
Ro u n d n e s s
roundness tolerance
The t o l e r a n c e zone, in t h e c o n s i d e r e d c r o s s - s e c t i o n , is l i m i t e d b y
two c o n c e n t r i c c i r c l e s w i t h a d i ff e r e n c e in r a d i i o f t
GEOMETRIC DIMENSIONING AND TOLERANCING
(GD&T)-ROUNDNESS
CYLINDRICITY
cylindricity tolerance
The t o l e r a n c e z o n e is l i m i t e d b y t w o c o a x i a l c y l i n d e r s w i t h a d i f f e r e n c e
in r a d i i o f T
GEOMETRIC DIMENSIONING AND TOLERANCING
(GD&T)
Details o f
To l e r a n c e s
O r i e n t a ti o n
To le ra n ce s
PARALLELISM
• Pa ra l l e l i s m t o l e r a n c e o f a line
r e l a t e d t o a d a t u m system
Dir e c t i o n
• s p e c i f i eTdh e t o l e r a n c e z o n e i s l i m i t e d b y t w o p a r a l l e l p l a n e s a d i s t a n c e
a p a r t . The pl anes a r e p a r a l l e l t o t h e d a t u m s a n d in t h e
d i r e c ti o n s p e c i fi e d
Parallelism
Prependicularity
Per p en d icu lar ity t o l e r a n c e o f a line r e l a t e d t o a d a t u m
line
The t o l e r a n c e z o n e is l i m i t e d b y t w o p a r a l l e l p l a n e s a d i s t a n c e a p a r t
and perpendicular t o t h e datum
GD&T Perpendicularity
• The examples below give different applications of perpendicularity geometric tolerance.
– Figure 1 is the application of perpendicularity to a surface.
– Figure 2 is the application of perpendicularity to an axis.
– Figure 3 is the application of perpendicularity to a center plane.
– Figure 4 is the application of perpendicularity of line elements.
Perpendicularity to an Axis
Perpendicularity to a
Perpendicularity to a Surface
Center Plane
Perpendicularity to Line
Elements
174
Perpendicularity
Angularity
Angularity t o l e r a n c e o f a line r e l a t e d t o a d a t u m line
a ) Line a n d d a t u m l i n e i n t h e s a m e p l a n e :
The t o l e r a n c e z o n e is l i m i t e d b y t w o p a r a l l e l p l a n e s a d i s t a n c e t
apart and inclined a t t h e specified angle t o t h e datum.
Angularity (example)
b) The t o l e r a n c e z o n e is l i m i t e d b y t w o p a r a l l e l p l a n e s a d i s t a n c e t
apart a n d inclined a t t h e specified a n g l e t o t h e d a t u m. The c o n s i d e re d
line and
t h e d a t u m l i n e a r e n o t in t h e same p l a n e
Details o f
To l e r a n c e s
L o c a ti o n To le ra n ce s
Po s i ti o n
Position tolerance of a point
The t o l e r a n c e z o n e is l i m i t e d b y a s p h e r e o f d i a m e t e r t i f t h e t o l e r a n c e
v a l u e i s p r e c e d e d b y t h e s y m b o l SØ. T h e c e n t e r o f t h e s p h e r i c a l t o l e r a n c e
z o n e is f i x e d b y t h e o r e t i c a l l y e x a c t dimensions w i t h r e s p e c t t o t h e
datums A, B a n d C
GD&T – Datum Surfaces and Features
Po s i ti o n
Position t o l e r a n c e o f a line
The t o l e r a n c e z o n e is l i m i t e d b y t w o p a r a l l e l p l a n e s a d i s t a n c e t a p a r t
a n d s y m m e t r i c a l l y d i s p o s e d a b o u t t h e c e n t e r line. The c e n t e r l i n e is f i x e d
by t h e o r e t i c a l l y e x a c t d i m e n s i o n s w i t h r e s p e c t t o d a t u m s A a n d B. T h e
t o l e r a n c e i s s p e c i f i e d i n o n e d i r e c t i o n o n l y.
Positio n
Position tolerance of a
line
Po s i ti o n
Position t o l e r a n c e o f a line
The t o l e r a n c e z o n e is l i m i t e d b y a c y l i n d e r o f d i a m e t e r t i f t h e
tolerance v a l u e i s p r e c e d e d b y t h e s y m b o l Ø. T h e a x i s o f t h e t o l e r a n c e
c y l i n d e r is f i x e d b y t h e o r e t i c a l l y e x a c t dimensions w i t h r e s p e c t t o t h e
d a t u m s C, A a n d B
Po s i ti o n
Position t o l e r a n c e o f a f l a t s u r f a c e o r a median p la n e
The t o l e r a n c e z o n e is l i m i t e d b y t w o p a r a l l e l p l a n e s a d i s t a n c e t a p a r t
and symmetrically disposed a b o u t t h e t h e o r e t i c a l l y e x a c t position fixed
by t h e o r e t i c a l l y e x a c t dimensions w i t h r e s p e c t t o t h e d a t u m s A a n d B
C o n c e nt r i c i t y
Concentricity tolerance of a point
The t o l e r a n c e z o n e is l i m i t e d b y a c i r c l e o f d i a m e t e r t ; t h e t o l e r a n c e
value s h a l l be p r e c e d e d b y t h e symbol . The c e n t e r o f t h e c i r c u l a r
tolerance zone coincides w i t h t h e d a t u m p o i n t
Concentricity
The t o l e r a n c e z o n e is l i m i t e d b y a c y l i n d e r o f d i a m e t e r t ; t h e
tolerance v a l u e s h a l l be p r e c e d e d b y t h e symbol Ø . The axis o f t h e
cylindrical t o l e r a n c e zone coincides w i t h t h e d a t u m
Symmetry
Symmetry t o l e r a n c e o f a median
plane
The t o l e r a n c e z o n e is l i m i t e d b y t w o p a r a l l e l p l a n e s a d i s t a n c e t a p a r t ,
s y m m e t r i c a l l y disposed a b o u t t h e median plane, w i t h r e s p e c t t o t h e d a t u m .
Symmetry of Size Features
8.8
A 8.2
0.4 A
20.5
20.0
To l e r a n c e s
Runout
To le ra n ce s
Circular r u n o u t
Circular run-out tolerance —
radial
The t o l e r a n c e z o n e is l i m i t e d w i t h i n a n y c r o s s - s e c t i o n p e r p e n d i c u l a r t o
t h e d a t u m a x i s b y t w o c o n c e n t r i c c i r c l e s w i t h a d i ff e r e n c e in r a d i i o f
t, t h e c e n t e r s o f w h i c h coincides w i t h t h e d a t u m
Circular r u n o u t
Circular run-out tolerance —
axial
The t o l e r a n c e z o n e is l i m i t e d t o a n y c y l i n d r i c a l s e c t i o n b y t w o c i r c l e s
w i t h a d i s t a n c e t a p a r t l y i n g in t h e c y l i n d r i c a l section, t h e a x i s o f
which coincides w i t h t h e d a t u m
To t a l r u n o u t
To t a l r a d i a l r u n - o u t t o l e r a n c e
The t o l e r a n c e z o n e is l i m i t e d b y t w o c o a x i a l c y l i n d e r s w i t h a d i f f e r e n c e
in r a d i i o f t , t h e a x e s o f w h i c h coincide w i t h t h e d a t u m
RunOut
Note that the
CAUSE of the
RunOut is NOT
Known
Circular • In CIRCULAR
Case Could
be some
Total
Combo of
Circularity &
Concentricity
• In TOTAL
Case add
Straightness
to the list
To t a l r u n o u t
To t a l a x i a l r u n - o u t t o l e r a n c e
The t o l e r a n c e z o n e is l i m i t e d b y t w o p a r a l l e l p l a n e s a d i s t a n c e t a p a r t a n d
perpendicular t o t h e datum
How to read GD & T ?
- Location, Form, Profile, Run out or an
Orientation Tolerance
- Value of tolerance
- Bonus tolerance
- Size of feature – MMC to LMC
- Datum s
Thank you