Elements of Machine Design IE326

Module 1 - Introduction

Dr. Iyas Khader

German-Jordanian University – Department of Industrial Engineering IE326

Introduction
What is des ign
To formulate a plan for the satisfaction of a specified need. Mechanical
engineering design involves all the disciplines of mechanical
engineering
The process requires innovation, iteration, and decision-making and is
communication-intensive
The product should be
 Functional
 Safe
 Reliable
 Competitive
 Usable
 Possible to manufacture
 Marketable

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Introduction
Des ign proces s

3 Shigley’s Mechanical Engineering Design, 10th Ed., McGraw-Hill Education

German-Jordanian University – Department of Industrial Engineering IE326

Introduction
Des ign proces s
Some characteristics that influence the design are:

4 Shigley’s Mechanical Engineering Design, 10th Ed., McGraw-Hill Education

German-Jordanian University – Department of Industrial Engineering IE326

Introduction
Machine elem ents

5 http://www.autobild.de

German-Jordanian University – Department of Industrial Engineering IE326

Introduction
Materials s election charts : As hby ’s m ethod

6 Wiley’s Online Support Module: Mechanical Engineering

M. F. Ashby, Materials Selection in Mechanical Design, 2002
German-Jordanian University – Department of Industrial Engineering IE326
Introduction
Materials s election criteria: perform ance index
Consider the cylindrical shaft of length 𝐿 and radius 𝑟

The application of twisting moment (or torque), 𝑀𝑡 produces an angle of

twist 𝜙. Shear stress 𝜏 at radius 𝑟 is defined by the equation:
𝑀𝑡 𝑟
𝜏=
𝐽
1
𝐽 is the polar moment of inertia, which for a solid cylinder is 𝐽 = 2 𝜋𝑟 4 , thus
2𝑀𝑡
𝜏= 3
𝜋𝑟
A safe design calls for the shaft to be able to sustain some twisting
moment without fracture

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Introduction
Materials s election criteria: perform ance index
In order to establish a materials selection criterion for a strong and light
material
2𝑀
 Strong: we replace the shear stress in 𝜏 = 𝜋𝑟 3𝑡 with the shear strength of
the material 𝑆𝑠𝑦 divided by a factor of safety 𝑛
𝑆𝑠𝑦 2𝑀𝑡
= 3
𝑛 𝜋𝑟
 Light: the mass needs to be taken into consideration: 𝑚 = 𝜌𝑉 (𝜌: density,
𝑉: volume) = 𝜋𝑟 2 𝐿𝜌; hence, the radius of the shaft in terms of its mass is:
𝑚
𝑟=
𝜋𝐿𝜌
𝑆𝑠𝑦 2𝑀𝑡 𝜋𝐿3 𝜌3
 = 3 = 2𝑀𝑡 ; solving for the mass yields:
𝑛 𝑚 𝑚3
𝜋
𝜋𝐿𝑃

2Τ3
𝜌
𝑚 = 2𝑛𝑀𝑡 𝜋 1Τ3 𝐿 Τ
2 3
𝑆𝑠𝑦
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Introduction
Perform ance index
2 Τ3
𝜌
𝑚 = 2𝑛𝑀𝑡 𝜋 1 Τ3 𝐿 Τ
2 3
𝑆𝑠𝑦

Safe functioning
Geometry
Materials properties
The best materials to be used for a light shaft that can safely sustain a
𝜌
specified twisting moment are those having low 2Τ3
𝑆𝑠𝑦

Performance index - in this case, defined in terms of strength:

2Τ3
𝑆𝑠𝑦
𝑃=
𝜌

Apply to materials selection charts (log 𝑆𝑠𝑦 vs. log 𝜌) by defining design
guidelines
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Introduction
Perform ance index

Design guidelines for performance

indices of P = 3, 10, 30, and 100
MPa2/3m3/Mg all having a slope of
3/2

10 Wiley’s Online Support Module: Mechanical Engineering

M. F. Ashby, Materials Selection in Mechanical Design, 2002
German-Jordanian University – Department of Industrial Engineering IE326
Introduction
Des ign factors for m aterials
Setting constraints on:
 Mechanical behavior: strength, hardness, toughness, ductility, brittleness,
fracture toughness, etc.
 Physical behavior: density, electrical, thermal, magnetic, optical
properties, surface adhesion, etc.
 Chemical behavior: reactivity, toxicity, flammability, biocompatibility,
compatibility with lubricants, etc.
 Deteriorative behavior: fatigue, creep, corrosion, wear behavior, etc.
 Cost: price (per-unit mass) and price of fabrication

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Introduction
Perform ance index and cons traints
P = 10 MPa2/3m3/Mg

Materials within the shaded region

are acceptable candidates for a solid
cylindrical shaft that has a mass-
strength performance index in
excess of 10 MPa2/3m3/Mg and a
strength of at least 300 MPa

12 Wiley’s Online Support Module: Mechanical Engineering

M. F. Ashby, Materials Selection in Mechanical Design, 2002
German-Jordanian University – Department of Industrial Engineering IE326
Introduction
Ex am ple on cons traints
1. Brittleness (fracture toughness) – eliminates glasses and ceramics
2. Strength > 300 MPa – eliminates wood, polymers, some alloys (e.g., Mg
and some Al alloys), and some engineering composites

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Introduction
Ex am ple on cons traints
3. Taking material cost into consideration (on a per-unit mass basis)

This provides a comparison of these materials on the basis of the cost of

materials for a cylindrical shaft that would not fracture in response to the
twisting moment 𝑀𝑡

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Introduction
Econom ics of the des ign problem
The consideration of cost plays such an important role in the design decision
process that we could easily spend as much time in studying the cost factor
as in the study of the entire subject of design:
 Use of standard sizes is a first principle of cost reduction
 Tolerances, surface finish, and treatments are perhaps the most
significant design incurred costs due to:
 additional processing steps
 additional inspection
 lower production rates
 Often there is a breakeven point on quantity of production

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Introduction
Econom ics of the des ign problem

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Introduction
Econom ics of the des ign problem
Example: fabrication of a component using an automatic screw machine
versus a hand screw machine

 Automatic screw machine

 25 parts/hr
 3 hr setup
 $20/hr labor cost
 Hand screw machine
 10 parts/hr
 Minimal setup
 $20/hr labor cost
 Breakeven at 50 units

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Introduction
Com putational tools
Computer Aided Engineering (CAE): any use of the computer and software
to aid in the engineering process

CAE includes:

 Computer-Aided Design (CAD)

Drafting and geometrical modeling, etc.
 Computer-Aided Manufacturing (CAM)
CNC toolpath, rapid prototyping, etc.
 Engineering analysis and simulation
Finite element method (FEM), computational fluid dynamics (CFD),
multibody and dynamic analysis, etc.
 Math solvers
Spreadsheet, procedural programming language, equation solver, etc.

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Introduction
S tandards and codes
 Standard
 A set of specifications for parts, materials, or processes
 Intended to achieve uniformity, efficiency, and a specified quality
 Limits the multitude of variations
 Code
 A set of specifications for the analysis, design, manufacture, and
construction of something
 To achieve a specified degree of safety, efficiency, and performance
or quality
 Does not imply absolute safety

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Introduction
Ins titutions /organizations

Various organizations establish and publish standards and codes for

common and/or critical industries, e.g.:

American Iron and Steel Institute (AISI)

American National Standards Institute (ANSI)
American Society of Mechanical Engineers (ASME)
American Society of Testing and Materials (ASTM)
National Institute for Standards and Technology (NIST)
Society of Automotive Engineers (SAE)
German Institute for Standardization (DIN)
International Standards Organization (ISO)

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Introduction
Uncertainty
Common sources of uncertainty in stress or strength:
 Composition of material and the effect of variation on properties
 Variations in properties from place to place within a bar of stock
 Effect of processing locally, or nearby, on properties
 Effect of nearby assemblies such as weldments and shrink fits on stress
conditions
 Effect of thermomechanical 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
 Effect of wear
 Uncertainty as to the length of any list of uncertainties
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Introduction
Uncertainty
Mathematical models to address uncertainties:

A. Deterministic method (classical method of design)

 Establishes a design factor, 𝑛𝑑
 Based on absolute uncertainties of a loss-of-function parameter and a
maximum allowable parameter
B. Stochastic method
 Based on statistical nature of the design parameters
 Focuses on the probability of survivals (reliability)
 Often limited by the availability of statistical data

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Introduction
Uncertainty
Mathematical models to address uncertainties:

A. Deterministic method (classical method of design)

 Establishes a design factor, 𝑛𝑑
 Based on absolute uncertainties of a loss-of-function parameter and a
maximum allowable parameter
𝑙𝑜𝑠𝑠 − 𝑜𝑓 − 𝑓𝑢𝑛𝑐𝑡𝑖𝑜𝑛 𝑝𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟
𝑛𝑑 =
𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑝𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟
e.g., if the parameter is load, then the maximum allowable load 𝐹𝑎𝑙𝑙𝑜𝑤 can
be found from
𝐹𝑙𝑜𝑠𝑠−𝑜𝑓−𝑓𝑢𝑛𝑐𝑡𝑖𝑜𝑛
𝐹𝑎𝑙𝑙𝑜𝑤 =
𝑛𝑑

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Introduction
Uncertainty
Example 1
Consider that the maximum load on a structure is known with an
uncertainty of ±20 percent, and the load causing failure is known within
±15 percent. If the load causing failure is nominally 2000 N, determine the
design factor and the maximum allowable load that will offset the absolute
uncertainties

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Introduction
Factor of s afety
The factor of safety has the same definition as the design factor, but
generally differs numerically

 Often used when statistical data is not available

 Since stress may not vary linearly with load, hence the safety factor relies
on the stress instead of load (force)

𝑙𝑜𝑠𝑠 − 𝑜𝑓 − 𝑓𝑢𝑛𝑐𝑡𝑖𝑜𝑛 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑆

𝑛= =
𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝜎 𝑜𝑟 𝜏

 All loss-of-function modes must be analyzed, and the mode with the
smallest design factor governs
 Stress and strength terms must be of the same type and units
 Stress and strength must apply to the same critical location in the part

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Introduction
Factor of s afety
Example 2

A rod with a cross-sectional area of A and loaded in tension with an axial

force of 𝑃 =8900 N undergoes a stress of 𝜎 = 𝑃Τ𝐴. Using a material strength
of 165 MPa and a design factor of 3.0, determine the minimum diameter of
a solid circular rod.
Using Table A–17, select a preferred fractional diameter and determine the
rod’s factor of safety

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Introduction
Uncertainty
B. Stochastic method
 Based on statistical nature of the design parameters
 Focuses on the probability of survivals (reliability)
 Often limited by the availability of statistical data
 The reliability method of design is one in which we obtain the
distribution of stresses and the distribution of strengths and then relate
these two in order to achieve an acceptable success rate
 The reliability is related to the probability of failure, 𝑝𝑓 , which is obtained
from the probability density function
The two most important continuous probability distributions for our use are:
 Gaussian (normal) distribution
 Weibull distribution

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Introduction
§ Uncertainty
To obtain values of 𝑝𝑓 , integration of 𝑓 𝑥 is necessary. This can come easily
from a table if the variable 𝑥 is placed in dimensionless form. This is done
using the transform:
𝑥 − 𝜇𝑥
𝑧=
𝜎ො𝑥

The value of the normal density function is given by Φ 𝑧

The transform variant 𝑧 has a mean value of zero and a standard deviation
of unity
The probability of an observation less than 𝑧 is Φ 𝑧 for negative values of 𝑧
and 1 − Φ 𝑧 for positive values of 𝑧

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Introduction
§ Uncertainty
 Reliability, 𝑅 – the statistical measure of the probability that a mechanical
element will not fail in use
 Probability of failure, 𝑝𝑓 – the number of instances of failures per total
number of possible instances
𝑅 = 1 − 𝑝𝑓

The value of 𝑅 falls in the range 0 ≤ 𝑅 ≤ 1

Example 3

If 1000 parts are manufactured, find the reliability if 6 of the parts failed

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Introduction
§ Uncertainty
 Series System – a system that is deemed to have failed if any component
within the system fails
 The overall reliability of a series system is the product of the reliabilities
of the individual components
𝑛

𝑅 = ෑ 𝑅𝑖
𝑖=1
The value of 𝑅 falls in the range 0 ≤ 𝑅 ≤ 1

Example 4

Consider a shaft with two bearings having reliabilities of 95 percent and 98

percent, what is the overall reliability?

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