ME F241:

Design of Machine Elements

Semester II, 2013-14

Introduction to

Mechanical Engineering Design

Instructor-In-Charge:
Dr. Srinivasa Prakash Regalla

What is Mechanical Engineering Design?

To design is to either formulate a plan for the

satisfaction of a specified need or to solve a
specific problem
Design is an innovative and highly iterative process
Design is a communication-intensive activity
PLAN

KNOWLEDGE OF TECHNOLOGY

Implementation

CREATIVENESS
COMMUNICATIVE ABILITY
PROBLEM SOLVING SKILL
Engineering Tools (mechanics of solids and fluids, mass and momenturm
transport, manufacturing processes, mathematics, statistics, electrical
and information theory, engineering graphics, computers, Languages)

Design

A PRODUCT
that is:
Functional,
safe,
Reliable,
Competitive,
Usable,
Manufacturable,
and
Marketable

The Mechanical Design Process: Different phases and interactions

DESIGN CONSIDERATIONS

READ: DESIGN FOR

DESIGN TOOLS AND RESOURCES

CAD (ProEngineer, AutoCAD, Unigraphics,

Solidworks) and Rapid Prototyping (SLA, LOM,
SLS, FDM, LENS, Objet-Polyjet)
CAE: Finite Element Analysis (Algor, Ansys,
MSC/Nastran,
LS-DYNA,
Hyperworks,
COMSOL, ABAQUS)
Non-engineering-specific computer tools: word
processing, spreadsheets (WORD, Excel, Lotus,
OpenOffice)
Mathematical
Solvers
(MathCad,
Maple,
MATLAB, Mathematica, TKSolver)

DESIGN ENGINEERS RESPONSIBILITY

PLEDGE (From National Society of Professional Engineers, USA):

STANDARDS AND CODES

ECONOMICS: cost of manufacturing, as can be affected at the design stage

Standard sizes
Preferred numbers

Large tolerances
Breakeven points
Cost estimation

Safety and Product Liability

The concept of strict liability (used in the USA)

Design engineers should review the
advertisements, make suitable amendments with
warnings, instructions etc.

Stress and Strength

Strength is a property of the material of a

mechanical component
Stress is a state property at a specific point within a
body, which is a function of:

Load
Geometry
Temperature
Manufacturing processing

Uncertainty and Design Factor

When yielding is treated as failure:

Maximum allowable load = Yield strength/nd

When rupture or fracture is treated as failure:

Maximum allowable load = Ultimate tensile strength/nd

Factor of safety, n, is another number calculated

using the same equation but after the preferred
numbers are chosen, hence n may differ from nd

Design Engineers Professional

Responsibilities: As important as anything
else in this course
Understand the problem
Identify the knowns
Identify the unknowns and formulate the solution
strategy
State all assumptions and decisions
Analyze the problem
Evaluate your solution
Present your solution

PRESENT YOUR SOLUTION

Your communication skills are important here

Here you are selling your technical abilities
All your work may be misunderstood unless you
skillfully present
Know you audience

The Designers Communication Skills

How to develop?
Keep a neat and clean log book of your activities of
the project/course
Enter frequently in the log book with dates
Separate logbooks should be used for different
projects/courses
Logbook is the only reference you have to explain
when questioned about your decisions

Materials

Material selection for a component while designing

is governed by:

Stress and deflection

Aesthetics
Merely to fill up the space
Corrosion resistance
Temperature concerns

Material Strength and Stiffness

Simple tension test to

determine E, y, u
fracture strain (f) and
percentage elongation.
The point a corresponds to the
0.2
percent
permanent
deformation. The strength is called
as proof strength.

True stress-strain diagram

Hardness

The resistance to penetration/indentation is called

as hardness
Hardness Tests: Brinell, Rockwell, Vickers, Knoop
All tests involve indentation but with different
types of indenters with different loads
For steels, minimum Sut for BHN between 200 and
450 is:
Sut = 3.41(BHN) MPa
For cast irons, minimum Sut is:
Sut = 1.58(BHN) 86

Impact Testing for Toughness

Charpy and Izod Tests

Toughness is desirable for taking tensile and
bending loads

Effect of strain rate on mechanical properties

Temperature effect on Strength

Effect of Manufacturing Process on Strength

MATERIAL FAMILIES AND CLASSES

MATERIAL FAMILIES AND CLASSES

YOUNGS MODULUS OF VARIOUS MATERIALS

MATERIAL INDEX

Load and Stress Analysis

Free-body
diagram
of
component and equillibrium
equation

SHEAR FORCE AND BENDING MOMENT