mec 391-mechanical design

BY
ENGR. FAZLAR RAHMAN
Assistant Professor
ME Faculty, IUBAT
 aBOUT me
 MASTERS in ME from University of Texas at Arlington (UTA),
Arlington, TX, USA (Major: Structural analysis & Design); and
BSME from BUET.

 I worked more than 10 (ten) years in Aerospace Company in USA in

Stress Analysis, Finite Element (FE) Analysis & Design Support
(worked mainly in Boeing 747 & 737 Plane, NASA-SOFIA and
Black Hawk Helicopter MOD program).

 I have experienced in Finite Element (FE) tools: Nastran/Patran, Pro-

Mechanica & ANSYS; Design tools: CATIA, Pro-E and AutoCAD
and other tools: MathCAD, MatLab.

Fazlar Rahman; ME Faculty; MEC 391; LEC_1; 2

 aBOUT me
CONTACT NUMBER:
IUBAT EXT. 511; ROOM # 519.
Cell Number : 01798455193

Email: [email protected]; [email protected]

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mec -391 (mechanical design)
REFERENCE BOOKS:

 Mechanical Engineering Design by Joseph E.

Shigley; 9th edition; published by Mc Graw Hill
(TEXT BOOK)
 Mechanics of Materials by Beer and Johnston; 7th
edition; published by Mc Graw Hill (REF. BOOK)
 Strength of materials by William Nash; 6th edition;
published by Mc Graw Hill (REF. BOOK)

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mec -391 (mechanical design)
MARK DISTRIBUTION:
 ATTENDANCE & DBC 10 %
 ASSIGNMENT 10 %
 FIRST TERM EXAM 20 %
 QUIZ 5%
 MID TERM EXAM 20 %
 FINAL EXAM 35 %
(NOTE: INSTRUCTOR HAS RIGHT TO MAKE CHANGE IN MARKS
DISTRIBUTION)

 ATTENDANCE: CLASS WILL START AT ON TIME AND ATTENDANCE WILL

BE GIVEN AT THE END OF BREAK.
 PLEASE DON’T MAKE NOISE AND UNNECESSARY TALK IN THE CLASS.
 IF YOU NEED TO GO OUT DON’T ASK FOR PERMISSION.
 BEHAVE LIKE A MECHANICAL ENGINEER.

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mec -391 (mechanical design)
RULE TO SUBMIT ASSIGNMENT
 Submit all assignment on due time in a folder.
 Should be printed Top sheet; hand written Top sheet is
not allowed.
 Top sheet should include Assignment No., Name of
course & section, your name, ID, SL No. and date of
submission.
 Assignment/Report should be included the question in
the first page.
 Report should include: Objective, scope, given data, free
body diagram & necessary sketches, analysis, result and
discussion.
 Partial report will not be accepted.
 Finally all Reports should submit in the same folder.
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 mec -391 (mechanical design)
MECHANICAL DESIGN
The product as result of mechanical design must be
functional, safe, reliable, competitive, usable,
manufacturable and marketable.
Design Consideration
Some characteristics that influence the design are :
(1). Functionality; (2). Strength; (3). Distortion/Deflection;
(4). Wear; (5). Corrosion; (6). Safety; (7). Reliability;
(8). Manufacturability; (9). Utility; (10). Cost; (11). Friction;
(12). Weight; (13). Life; (14). Noise; (15). Styling;
(16). Shape; (17). Size; (18). Control; (19). Thermal
Properties; (20). Surface; (21). Lubrication;
(22). Marketability; (23). Maintenance; (24). Volume;
(25). Liability and (26). Remanufacturing.
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 mec -391 (mechanical design)
DESIGN TOOLS AND RESOURCES
Today, engineer has a great variety of tools and resources
available to assist in the solution of design problem.
Inexpensive microcomputers and robust computer software
packages provides tools for the design, analysis, and
simulation of mechanical components.
Computational Tools
 Computer-Aided Design (CAD): 3D modeling of parts.
Computer-Aided Manufacturing (CAM): CNC tool path,
rapid prototyping, etc.
 Engineering analysis and simulation: Finite element, fluid
flow, dynamic analysis, motion, etc.
 Math solvers: Spreadsheet, procedural programming
language, equation solver, etc.
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 mec -391 (mechanical design)
DESIGN TOOLS AND RESOURCES (CONT’D)
Acquiring technical information
 Libraries: Engineering handbooks, textbooks, journals,
patents, etc.
 Government sources: Government agencies, U.S. Patent
and Trademark, National Institute for Standards and
Technology, etc.
 Professional Societies (conferences, publications, etc.):
American Society of Mechanical Engineers, Society of
Manufacturing Engineers, Society of Automotive
Engineers, etc.
 Commercial vendors: Catalogs, technical literature, test
data, etc.
 Internet: Access to much of the above information
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 mec -391 (mechanical design)
Design Engineer’s Professional Responsibilities
 Satisfy the needs of the customer in a competent,
responsible, ethical, and professional manner.
 Some key advise for a professional engineer:
 Be competent
 Keep current in field of practice
 Keep good documentation
 Ensure good and timely communication
 Act professionally and ethically
 Understand the problem
 Identify the known and unknown
 State all assumptions and decision
 Analyze the problem and evaluate the solution
 Present the solution.
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 mec -391 (mechanical design)
Design Codes and Standards
Standard:
A standard is a set of specifications for parts, materials or
processes intended to achieve uniformity, efficiency, and a
specified quality.

Code:
A code is a set of specifications for the analysis, design,
manufacture, and construction of something.

The purpose of code is to achieve a specified degree of

safety, efficiency, performance and quality.

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 mec -391 (mechanical design)
Design Codes and Standards
Some organizations that establish standards and codes of
particular interest to mechanical engineers:
 Aluminum Association (AA)
 American Gear Manufacturing Association (AGMA)
 American Institute of Steel Construction (AISC)
 American National Standards Institute (ANSI)
 American Society of American Engineers (ASME)
 American Society of Testing and Materials (ASTM)
 International Standards Organization (ISO)
 Industrial Fasteners Institute (IFI)
 American Welding Society (AWS)
 American Bearing Manufactures Association (ABMA) etc.

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 mec -391 (mechanical design)
Cost and Economics in Engineering Design
 Cost is almost always an important factor in engineering
design.
 Use of standard sizes is a first principle of cost reduction.
 Certain common components may be less expensive in
stocked sizes.
 Close tolerances generally increase cost.
 Sometimes two or more design approaches are compared
for cost and choice between them depends on quantity of
production.
 Often there is a breakeven point on quantity of production.

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 mec -391 (mechanical design)
Cost and Economics in Engineering Design
Cost Vs Tolerance:

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Cost and Economics in Engineering Design
Cost Vs Quantity:

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 mec -391 (mechanical design)
Safety and Product Liability

 Strict Liability concept generally prevails in U.S.

 Manufacturer is liable for damage or harm that results
because of a defect.
 Negligence need not be proved. It does not matter
whether manufacturer knew about the defect or even
could have known about it.
 Calls for good engineering in analysis and design, quality
control, and comprehensive testing for prevention of
engineering liability.

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 mec -391 (mechanical design)
Stress and Strength
Strength:
 Strength is a property of a material or of a mechanical
element. The strength of an element depends upon the
choice, the heat treatment and processing of the
materials.
 May or may not be uniform throughout the part.
 Examples: Ultimate strength, yield strength
Stress:
 A state property at a specific point within a body.
 Primarily a function of load and geometry.
 Sometimes also a function of temperature and
processing.

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 mec -391 (mechanical design)
Uncertainty in Mechanical Design
The common sources of uncertainty in stress or strength are:
 Composition of material and the effect of variation on
properties.
 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 and wear.
 Effect of processing locally or nearby within a bar of stock.
 Effect of nearby assemblies such as welding and shrink fits
on stress conditions.

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 mec -391 (mechanical design)
Minimizing of Uncertainty in Mechanical Design
Uncertainty in Mechanical design can be evaluate or
minimize by Stochastic method, establishing of Factor of
safety, Design factor and Margin of safety.
Stochastic Method:
 Based on statistical nature of the design parameters.
 Focus on the probability of survival of the design’s
function (reliability).
 Often limited by availability of statistical data.
Factor of safety:
 It is a ratio of absolute strength (structural capacity) to
actual applied load, this is a measure of the reliability of a
particular design.

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 mec -391 (mechanical design)
Minimizing of Uncertainty in Mechanical Design (Cont’d)
Factor of Safety (Continue):

 Design load being the maximum load the part should ever
see in service.
Design Factor:
 The design factor is what the item is required to be able to
withstand (second "use").
 The design factor is defined for an application (generally
provided in advance and often set by regulatory code or
policy) and is not an actual calculation.

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 mec -391 (mechanical design)
Minimizing of Uncertainty in Mechanical Design (Cont’d)
Design Factor and Safety factor:
The difference between the safety factor and design factor
(design safety factor) is as follows:
 The safety factor is how much the designed part actually
will be able to withstand (first "use" from above).
 The design factor is what the item is required to be able to
withstand (second "use").
Margin of Safety:
 It is the ratio of the strength of the structure to the
requirements.
 In effect, this is a measure of excess capacity. If the margin
is 0, the part will not take any additional load before it
fails.
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 mec -391 (mechanical design)
Minimizing of Uncertainty in Mechanical Design (Cont’d)
Margin of Safety (Cont’d):

 Factor of safety (FS):

 In aircraft industry uses margin of safety instead of factor

of safety.

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 mec -391 (mechanical design)
Dimensions and Tolerances
 Nominal size: The size we use in speaking of an element. Is
not required to match the actual dimension.
 Limits: The stated maximum and minimum dimensions.
 Tolerance: The difference between the two limits.
 Bilateral tolerance: The variation in both directions from
the basic dimension, e.g. 1.005 ± 0.002 in.
 Unilateral tolerance: The basic dimension is taken as one
of the limits, and variation is permitted in only one
direction, e.g.

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 mec -391 (mechanical design)
Dimensions and Tolerances
 Clearance: Refers to the difference in sizes of two mating
cylindrical parts such as a bolt and a hole.
 Assumes the internal member is smaller than the
external member.
 Diametral clearance – difference in the two diameters.
 Radial clearance – difference in the two radii.
 Interference: The opposite of clearance, when the
internal member is larger than the external member.
 Allowance: The minimum stated clearance or the
maximum stated interference or mating parts.

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