ME 316-MACHINE ELEMENTS

Lecture 1: Introduction to Mechanical Engineering Design

Asst. Prof. Dr. Hakan KALKAN
2021-2022 Spring
 DEPARTMENT of
MECHANICAL ENGINEERING

Design
 To formulate a plan for the satisfaction of a specified need
 Process requires innovation, iteration, and decision-making
 Communication-intensive
 Products should be
◦ Functional
◦ Safe
◦ Reliable
◦ Competitive
◦ Usable
◦ Manufacturable
◦ Marketable

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MECHANICAL ENGINEERING

Mechanical Engineering Design

• Mechanical engineering design involves all the
disciplines of mechanical engineering.
• Example
– Journal bearing: fluid flow, heat transfer, friction,
energy transport, material selection,
thermomechanical treatments, statistical
descriptions, etc.

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The Design Process

• Iterative in nature
• Requires initial
estimation, followed
by continued
refinement

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Design Considerations
• Some characteristics that influence the design

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MECHANICAL ENGINEERING

Computational Tools
• Computer-Aided Engineering (CAE)
– Any use of the computer and software to aid in the
engineering process
– Includes
• Computer-Aided Design (CAD)
– Drafting, 3-D solid modeling, etc.
• Computer-Aided Manufacturing (CAM)
– CNC toolpath, 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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 DEPARTMENT of
MECHANICAL ENGINEERING

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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 DEPARTMENT of
MECHANICAL ENGINEERING

Standards 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
• Various organizations establish and publish standards and
codes for common and/or critical industries
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 DEPARTMENT of
MECHANICAL ENGINEERING

•
Standards and Codes
Some organizations that establish standards and codes of particular interest to
mechanical engineers:

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MECHANICAL ENGINEERING

Economics
• Cost is almost always an important factor in
engineering design.
• Use of standard sizes is a first principle of cost
reduction.
• Table A–17 lists some typical preferred sizes.
• Certain common components may be less
expensive in stocked sizes.

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 DEPARTMENT of
MECHANICAL ENGINEERING

Tolerances
• Close tolerances
generally increase
cost
– Require additional
processing steps
– Require additional
inspection
– Require machines
with lower
production rates

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 DEPARTMENT of
MECHANICAL ENGINEERING

Stress and Strength

• Strength
– An inherent property of a material or of a mechanical
element
– Depends on treatment and processing
– 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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 DEPARTMENT of
MECHANICAL ENGINEERING

Uncertainty
• Deterministic method
– Establishes a design factor, nd
– Based on absolute uncertainties of a loss-of-function
parameter and a maximum allowable parameter

◦ If, for example, the parameter is load, then

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 DEPARTMENT of
MECHANICAL ENGINEERING

Design Factor Method

 Often used when statistical data is not available
 Since stress may not vary linearly with load, it is more common to express
the design factor in terms of strength and stress.

• 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.
• The factor of safety is the realized design factor of the final design,
including rounding up to standard size or available components.

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 DEPARTMENT of
MECHANICAL ENGINEERING

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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 DEPARTMENT of
MECHANICAL ENGINEERING

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
• Fit – The amount of clearance or interference between mating parts
• GD&T – Geometric Dimensioning and Tolerancing, a comprehensive
system of symbols, rules, and definitions for defining the theoretically
perfect geometry, along with the allowable variation.

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MECHANICAL ENGINEERING

Choice of Tolerances
• The designer is responsible for specifying tolerances for
every dimension.
• Consideration is given to functionality, fit, assembly,
manufacturing process ability, quality control, and cost.
• Excessive precision is a poor design choice, in that it
limits manufacturing options and drives up the cost.
• Less expensive manufacturing options should be
selected, even though the part may be less than
perfect, so long as the needs are satisfactorily met.

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Power Transmission Case Study

Specifications

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MECHANICAL ENGINEERING

Power Transmission Case Study Specifications

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MECHANICAL ENGINEERING

Power Transmission Case Study

Specifications

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