What is Design?

Design is a creative planning process that

leads to useful products and systems.
There is no perfect design.

Requirements
of
a
design
are made up of criteria and
constraints.

Why Design???
Only true wealth a country can
create is through manufactured
goods and technology!!
Innovation and technology brought
to life thru Design (improve quality
of life).

Traditional Design
Craft Evolution
Trail & Error- Costly, One change at a time
No medium to record design influence on
product.

Design by drawing
Dimensions are known earlier
Manufacturing are divided into stages
Trail & Error.

What is the Design Process?

The design process is a purposeful
method of planning practical solutions to
problems.
The design process is never final; there
are always multiple solutions to a problem.
The design process is influenced by
requirements
called
criteria
and
constraints.

Design is an Iterative Process

Begins
with
a
recognition of need for
a product, service, or
system
During the idea phase
encourage
a
wide
variety of solutions
through brainstorming,
literature search, and
talking to users
Best
solutions
are
selected for further
refinement

Models or prototypes
are
made
and
problems that arise
may
require
new
ideas to solve and a
return to an earlier
stage in the process
Finally drawings are
released
to
manufacturing
for
production.

Phases of Design

Phases of Design:
(similar to Mott, F 111)

Recognize the Need

Definition of Problem

(function, requirements, and evaluation

criteria)

Synthesis

Analysis & Optimization

Evaluation
ITERATION
From:

Presentation

Shigley, Mechanical Engineering

Design, 2nd Ed, McGraw-Hall,
1972

Design Process

Communicate
Results

Define the
Problem

Define the Problem

Brainstorm

Improve
Design

Design
Process

Test and
Evaluate

Model or
Prototype

Research

Develop
Ideas

Choose
Best Idea

Defining the problem is like

conducting detective work. You
must examine the evidence and
form some conclusions.

Examples:
Design
a
vehicle
that
can
communicate with other vehicles to
prevent accidents.
Design an athletic shoe that decreases
the amount of sprained ankles when
worn on hardwood gym floors.

Communicate
Results

Brainstorm

Define the
Problem

Brainstorm

Improve
Design

Design
Process

Test and
Evaluate

Model or
Prototype

Research

Develop
Ideas

Choose
Best Idea

Brainstorming
involves
bringing a group of people
together to generate many
different ideas.

Examples:

Make the athletic shoe out of plastic.

The shoe needs to grip the floor; the
bottom should be made of rubber.
The ankle support should be stiff.
Dont forget the air vents.

All ideas are considered none are criticized!

Communicate
Results

Research

Define the
Problem

Brainstorm

Improve
Design

Design
Process

Test and
Evaluate

Model or
Prototype

Research

Develop
Ideas

Choose
Best Idea

Research may require going to the

library, using computer databases,
writing
letters,
performing
experiments, and asking questions.

Examples:
Read books and magazines
View films or videos
Search the Internet
Ask questions of the experts

Create and analyze a survey

Communicate
Results

Define the
Problem

Brainstorm

Improve
Design

Design
Process

Test and
Evaluate

Model or
Prototype

Research

Develop
Ideas

Choose
Best Idea

Develop Ideas
Develop multiple ideas that will
solve the problem and meet the
requirements. The alternatives
may all be quite diverse.

Criteria:
How will the solution actually work?
What materials should I use?
What should the product look like so
that people will buy it?

Constraints:
Will it be completed by the deadline?
What size should it be?

Communicate
Results

Define the
Problem

Brainstorm

Improve
Design

Design
Process

Test and
Evaluate

Model or
Prototype

Research

Develop
Ideas

Choose
Best Idea

Choose Best Idea

Decide on an idea that best meets the
criteria, fits within the constraints, and
has the least amount of negative
characteristics.

List the strengths and weaknesses of

each alternative.

Optimization Making improvements

to the design idea for better
performance or increased safety
Trade-off Giving up one desirable
trait for another (i.e., giving up on using
a certain material so that the object is
more affordable)

Communicate
Results

Define the
Problem

Brainstorm

Improve
Design

Design
Process

Test and
Evaluate

Model or
Prototype

Research

Develop
Ideas

Choose
Best Idea

Model or Prototype
Model building is used to gather
additional information and test
design ideas.

Examples:
Realistic drawings or renderings help you
visualize what the solution will look like in real
life.
Scale models or mock-ups are small,
accurate representations of the final product.

3D CAD (computer aided designs) can show

objects in action.
A prototype is a working model; it looks and
functions just like the finished product.

Communicate
Results

Define the
Problem

Brainstorm

Improve
Design

Design
Process

Test and
Evaluate

Model or
Prototype

Research

Develop
Ideas

Choose
Best Idea

Test and Evaluate

Models of design solutions must
be
tested
and
important
questions must be answered
during the evaluation.

Is it safe for people and the environment?

Is it comfortable?
Is it affordable?
Is it aesthetically pleasing (does it look
good)?
Will it last as long as it needs to?
Does it meet the criteria and constraints?
Does it work?

Communicate
Results

Define the
Problem

Brainstorm

Improve
Design

Design
Process

Test and
Evaluate

Model or
Prototype

Research

Develop
Ideas

Choose
Best Idea

Improve Design
After studying all test data and
evaluating design solutions, you
may need to make changes.

Now is the time to improve a design

before production begins.
During the improve design phase, you
may consider new ideas.

Communicate
Results

Define the
Problem

Brainstorm

Improve
Design

Design
Process

Test and
Evaluate

Model or
Prototype

Research

Develop
Ideas

Choose
Best Idea

Communicate Results
Share your design ideas with
others to prove the design is
worthy of manufacturing.

Examples:
Poster
Drawings
Charts
Prototypes
PowerPoint presentation
Reports
Discussion

Skills needed in mechanical

design?? Sect 1-3)

What is a Machine?
Machine is the devise that comprises of
the stationary parts and moving parts
combined together to generate, transform
or utilize the mechanical energy.

All the machines are made up of elements

or parts and units.

Some examples of the machines

Lathe: It utilizes mechanical energy to cut the metals.
The other types of machine tools also perform the same
task.
Turbines: They produce mechanical energy.
Compressors: They use mechanical energy to compress
the air.
Engines: They consume the fuel and produce
mechanical energy.
Refrigerators and air-conditioners: They use mechanical
engineering to produce cooling effect.
Washing machines: They use mechanical energy to
wash the clothes.

Classification of Machines
Machines generating mechanical energy: I.C
engine in which the chemical energy of the fuel is
converted into heat energy which in turn is
converted into mechanical work in the form of the
rotation of the wheels of the vehicle.
Machines transforming mechanical energy:
they convert mechanical energy into other form of
energy like electricity, hydraulic energy etc.
Machines utilizing mechanical energy: These
machines receive mechanical energy and utilize it
for various applications. E.g.Lathe

What are Machine Elements?

All the machines are made up of elements
or parts and each element may have to be
designed separately and in assembly.
The machines elements are classified into
two main types:
general purpose elements like nuts, bolts,
bearings, couplings and
special purpose elements like piston,
crankshaft ,gears rope,chain, etc.

What is Machine Design

The process by which resources or energy is
converted into useful mechanical forms, or the
mechanisms so as to obtain useful output from
the machines in the desired form as per the
needs of the human beings.
Machine design can lead to the formation of the
entirely new machine or it can lead to upgradation or improvement of the existing
machine

The Purpose of Machine Design

To understand the fundamentals of designing the most
commonly used parts, elements and units of various
machines.
The knowledge of machine design helps the designers
as follows:
1) To select proper materials and best suited shapes,
2) To calculate the dimensions based on the loads on
machines and strength of the material,
3) Specify the manufacturing process for the
manufacture of the designed component of the machine
or the whole machine.

Classification of Machine Design

ADAPTIVE DESIGN: Adaptation of existing Design.

The designer only makes minor alternation or

modification in the existing designs of the product.
DEVELOPMENT DESIGN: Designer starts from the

existing design, but the final product may differ

quite markedly from the original product.

New Design: The designs, depending upon the methods

used, may be classified as follows:
(a) Rational design. This type of design depends
mathematical formulae of principle of mechanics.

upon

(b) Empirical design. This type of design depends upon

empirical formulae based on the practice and past experience.

(c) Industrial design. This type of design depends upon the

production aspects to manufacture any machine component in the
industry.
(d)Optimum design. It is the best design for the given objective
function under the specified constraints. It may be achieved by
minimizing the undesirable effects.

(e) System design. It is the design of any complex

mechanical system like a motor car.
(f) Element design. It is the design of any element
of the mechanical system like piston, crankshaft,
connecting rod, etc.
(g) Computer aided design. This type of design
depends upon the use of computer systems to
assist in the creation, modification, analysis and
optimisation of a design.

Mechanical Design Markets:

1.

Consumer Products lawnmowers, household appliances, et.

Cost and safety major issues .

2.

Manufacturing systems/ general industrial equipment machine

tools, conveyers, test machines, inspection machines, et.

3.

Construction Equipment/ Agriculture Equipment loaders, scrapers,

vibratory rollers, pavers, tractor, harvester, et.

4.

Aerospace Industry commercial airliners, helicopters, military jets,

etc.

Performance, safety, weight major issues (ohead helicopter

rotor)

5.

Transportation truck, bus and automotive

Factors to be considered during

Machine Design:
Cost
High output and efficiency
Strength-strong enough to sustain all the forces
it is designed for
Stiffness or rigidity- no deformation of the
machine or machine elements beyond the
specified limits.
Wear resistance:
Lubrication
Operational safety:

Ease of assembly
Ease and simplicity of disassembly
Ease and simplicity of servicing and control
Light weight and minimum dimensions
Reliability
Durability
Processability
Economy of repairs and maintenance
Use of standard parts
Use of easily available materials
Appearance of the machine
Number of machines to be built

Introduction-Materials
Material Science- The study of the properties of
solid materials and how those properties are
determined by a materials composition and
structure.

Materials -Materials are used to produce Product

Materials for Engineering-To selecting the correct
materials for the application in which the engineered
part is being used

30

Classification of Engineering Materials

Materials in Manufacturing

Fundamental properties
Characteristic

Behavior

Property

Units

Strength

strong, weak

ultimate strength

MPa (ksi)

Elastic strength

elastic then plastic

yield strength

MPa (ksi)

Stiffness

flexible, rigid

modulus of elasticity

MPa (Mpsi)

Ductility

draws, forms easily

% elongation,
% area reduction

dimensionless

Hardness

resists surface
indentation

Brinell No.

MPa (ksi)

Corrosion resistance

resists chemicals,
oxidation

galvanic series

activity
number

Selection of Material
Choosing materials for a component, we take into account
many different factors.
Material Properties
The expected level of performance from the material
Material Cost and Availability
Material must be priced appropriately
Material must be available
Processing
Casting Machining Welding
Environment
The effect that the service environment has on the part
The effect the part has on the environment
The effect that processing has on the environment

Materials Selection Charts

In identifying a material, approach the task in three

stages:
List the material requirements for the design. Rank the requirements in importance to the designs
success.

Select and evaluate candidate materials.

Choose the most economical material.

Material Selection in Mechanical Design

Translation: express design requirements as
constraints and objectives.
Screening: eliminate materials that cannot do the
job.
Ranking: find materials that best do the job.
Supporting Info: handbooks, expert systems,
web, etc.

Translation
Function: What does the component do?
Objective: What essentials conditions must be
met?
Constraints: What is to be maximized or
minimized?
Free Variables: Identify which design variables
are free?

Screening
Methods to evaluate large range of materials
Material Bar Charts
Material Property Charts (density vs. Youngs
Modulus)
Screen on Constraints
Rank on Objectives

Application of Most Commonly Used Materials

Component

Material

41

Application of Most Commonly Used Materials

Component

Ken Youssefi

Material

SJSU, ME dept.

42

Application of Most Commonly Used Materials

Component

Ken Youssefi

Material

SJSU, ME dept.

43

SIMPLE STRESSES
Machine parts are subjected to various
forces due to:

Weight of the machine.

Friction between moving parts.
Imbalance of moving parts.
Temperature change.

Any external forces acting on a body is

called as LOAD.

Stress- Strain

Sign convention
> 0 Tensile (member is in tension)
< 0 Compressive (member is in compression)
Unit SI:
N/m2 = Pa (Pascal)
kN/m2 = kPa
MPa, GPa, etc.

Stress-Strain Diagram

Yielding Region
Begins at yield stress Y
Slope rapidly decreases
until it is horizontal or
near horizontal
Large strain increase,
small stress increase
Strain is permanent

Linear region
Stress-strain response is linear
Slope = Modulus of Elasticity (Youngs modulus) = E
E has units of N/mm2
We get a relation between stress and strain known as
Hookes Law.

Strain Hardening
After undergoing large
deformations, the metal has
changed its crystalline structure.
The material has increased
resistance to applied stress
(it appears to be harder).

Necking
The maximum supported stress
value is called the ultimate
stress, u.
Loading beyond u results in
decreased load supported and
eventually rupture.

E for commonly used materials

What is Shear Stress?

Normal stress (), which acts perpendicular/normal
to the cross-section. Shear stress () acts
tangential to the surface.

Shearing stresses are commonly found in bolts, pins, and

rivets.

SINGLE SHEAR

DOUBLE SHEAR

Shear Modulus or Modulus of rigidity

Within elastic limit, Shear
proportional to Shear Strain.

stress

is

directly

Bearing or Crushing Stress

A localized compressive stress at the
surface of contact between two parts.

Working Stress
When designing any machine component , the
stress induced should be kept lower than the
Maximum or Ultimate strength of the material.
Ratio of Max.stress to working stress is called as
Factor of Safety.

Volumetric Strain- Ratio of change in volume to

Original Volume.

Bulk Modulus- When the part is subjected to stresses in

three mutually perpendicular direction of equal intensity,
Ratio of Direct stress to Volumetric strain is called as
bulk modulus.

Relationship between
Youngs modulus

Bulk

and

Relation between Youngs Modulus and

Modulus of Rigidity

Impact Stress
The stress produced due to the falling
load is called impact stress.

Torsional Shear Stress

Stress due to Torsion is called
torsional shear stress.
It has zero value at centroidal axis and
maximum at outer surface.

Bending Stress in Straight Beams

Factor of Safety
It is used to provide reserve strength to the
component in case of an unavoidable
circumstances(Uncertainity in Force magnitude,
Variation in Mat Prop, Variation in Part Dim due to
improper workmanship) .
FOS = Failure load/ Working Load
Or
= Failure Stress /Working Stress.

BIS Designation of Steel

Plain Carbon Steel
xCy
x = Carbon
y = Mn
30 C 8
0.3 % of C,
0.8 % of Mn.

Alloy Steel
C- Major Constituents (0.13 0.17).
Si, Cr, Mn, Mo etc., - Minor ( 0.01-0.08)

35Mn 2 Mo 45
- 0.35 % of C,
- 0.002% of Mn,
- 0.45 % of Mo.

Principal Stresses
But it has been observed that at any point in a strained material, there
are three planes, mutually perpendicular to each other which carry
direct stresses only . These are called as Principal Stresses and
plane in which these stresses act is called Principal Plane.
Of these one is maximum and other is minimum.

Maximum Principal stress :

Minimum Principal Stress

Maximum Shear Stress

A shaft, as shown in Fig., is subjected to a

bending load of 3 kN, pure torque of 1000 N-m,
and an axial pulling force of 15 kN. Calculate
the
stresses
at
A
and
B.

THEORIES OF FAILURES

ECCENTRIC LOADING

Variable
Machine Parts

Stresses

COMPLETELY REVERSED STRESS

in

REPEATED STRESS

FLUCTUTATING STRESS

When a material is subjected to repeated stresses, it

fails at stresses below the yield point stresses. Such
type of failure of a material is known as fatigue.
The fatigue of material is effected by the size of the
component, relative magnitude of static and fluctuating
loads and the number of load reversals.

Endurance or Fatigue limit (e).

It is defined as maximum value of the completely reversed
bending stress which a polished standard specimen can
withstand without failure, for infinite number of cycles (usually
107 cycles).

Mean or average stress,

Reversed stress component or alternating or variable stress,

Stress ratio, R

Endurance limit for reversed bending load,

eb = e.Kb = e .( SINCE Kb = 1)

Endurance limit for reversed axial load,

ea = e.Ka
Endurance limit for reversed torsional or shear load,
e = e.Ks
Kb = Load correction factor for the reversed or rotating bending load.
Its value is usually taken as unity.
Ka = Load correction factor for the reversed axial load. Its value may
be taken as 0.8.
Ks = Load correction factor for the reversed torsional or shear load.
Its value may be taken as 0.55 for ductile materials and 0.8 for brittle
materials

Stress Concentration
Whenever a machine component changes the shape of its
cross-section, the simple stress distribution no longer holds
good and the neighbourhood of the discontinuity is different.
This irregularity in the stress distribution caused by abrupt
changes of form is called stress concentration.

It occurs for all kinds of stresses in the presence of fillets,

notches, holes, keyways, splines, surface roughness or
scratches etc.

Theoretical
or
Form
Concentration Factor

Stress

Defined as the ratio of the maximum stress in a member

(at a notch or a fillet) to the nominal stress at the same
section based upon net area.

Fatigue Stress Concentration Factor

NOTCH SENSITIVITY
Defined as the degree to which the theoretical effect of stress
concentration is actually reached. The stress gradient depends
mainly on the radius of the notch, hole or fillet and on the grain

size of the material.

Combined
Variable Stress

Steady

and

GERBER METHOD

Kf = STRESS CONC.FACTOR

GOODMAN METHOD

SODERBERG METHOD