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Chapter 1 - Introduction

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10 views

Chapter 1 - Introduction

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Furkan Tanrıverdi
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© © All Rights Reserved
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MECH 313

Machine Element
Design
Dr. Başar YAVUZ
SYLLABUS
Basic design philosophy, material selection for engineering purposes
Design of couplings and keys
Design of belts and chains
Design of clutches and brakes
Design of gears (spur, helical, bevel and worm gears)
Design of springs
Design of nonpermanent joints (screws, bolts, fasteners, gaskets)
Design of permanent joints (welds and other adhesive bonding techniques)
Design of rolling contact bearings (ball and roller bearings)
Design of journal bearings
Design of shafts
Mechanical vibrations – damping and neutralization
Principles of material selection
Textbooks:

1. Shigley’s Mechanical Engineering Design, 9th Ed.


Budynas, R.G., Nissbet, J.K.
Mc Graw-Hill Book Company, 2011

2. Machine Elements in Mechanical Design, 4th Ed,


Mott, R.L., 2004
Pierson-Prentice Hall

3. Mechanical Design, 2nd Ed.


Childs, P.R.N.
Butterworth-Heinemann, 2004

4. Machine Design
Levinson, I.J.
Reston Publishers, Prentice-Hall Book Company,1978
5. Mechanical Engineering Design, Parts 1 and 2
Uğural, A.C.
McGraw-Hill Book Comp., 2004

5. Theory and Problems of Machine Design


Hall, A.S., Holowenko, A.R., Laughlin, H.G.
Schaum’s Outline Series, McGraw-Hill Book Comp.

6. Makine Elemanları, 3. Baskı


Yazıcıoğlu, O., Güngör, C., Yazıcıoğlu, R.
Nobel Yayın Dağıtım, 2006
To design is either to formulate a plan for the satisfaction of a specified need
or to solve a specific problem. If the plan results in the creation of something
having a physical reality, then the product must be functional, safe, reliable,
competitive, usable, manufacturable, and marketable.

Design is an innovative and highly iterative process. It is also a decision-making


process. A designer – almost always – has to come to a compromise between
conflicting requirements. (Safety versus weight, selection of the lightest available
material versus cost, simplicity versus marketability, functionality versus
manufacturability, etc.)
A designer’s personal resources of creativeness, communicative ability, and
problem solving skill are intertwined with the knowledge of technology and first
principles.
Engineering tools (such as mathematics, statistics, computers, graphics, and
languages) are combined to produce a plan that, when carried out, produces a
product that is functional, safe, reliable, competitive, usable, manufacturable,
and marketable, regardless of who builds it or who uses it.
Mechanical engineering design involves all the disciplines of mechanical
engineering. However, real problems resist compartmentalization. A simple
journal bearing involves fluid flow, heat transfer, friction, energy transport,
material selection, thermo-mechanical treatments, statistical descriptions, and so
on. A building is environmentally controlled. The heating, ventilation, and air-
conditioning considerations are sufficiently specialized that some speak of
heating, ventilating, and air-conditioning design as if it is separate and distinct
from mechanical engineering design. Similarly, internal-combustion engine
design, turbo-machinery design, and jet-engine design are sometimes considered
discrete entities. Here, the leading string of words preceding the word design is
merely a product descriptor. Similarly, there are phrases such as machine design,
machine-element design, machine-component design, systems design, and fluid-
power design.
Stages of a design process
DESIGN CONSIDERATIONS
When you are working on a design problem, it is important that you develop a
systematic approach. Careful attention to the following action steps will help you
to organize your solution processing technique.

• 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.

A designer has to work in an environment of uncertainity, related to material


properties, quality of manufacture, environmental degradation (corrosion,
errosion, wear, fatigue, etc.), loads, environmental effects (temperature, humidity,
vibration, dynamic loads, etc.) and their combined effects.
NO CHAIN IS STRONGER THAN ITS
WEAKEST LINK !

A designer is responsible from the safety of


his/her design. There cannot be anything
like
“NOTHING HAPPENS BRO”
(“Bİ ŞİY OLMAZ ABİ “ )
approach for a designer.
Design Factor and Factor of Safety
The simplest way to address the uncertainities in the design is to use a deterministic
“design factor” and a “factor of safety”, although these terms can be used
interchangeably.

Design factor relates to the external “forces” expected to be acting on the body,
while “factor of safety” relates to the strength of the body. For example, if the
torque expected to be carried by a shaft is 10 kN-m, a design factor of 4 means that
the calculations related to the sizing of the shaft is to be made taking the maximum
torque to be equal to 40 kN-m.

Factor of safety is defined as the ratio of the ultimate strength to the assumed
strength of the material:
u u
n or n
 
If the shaft to be designed shall be made of a material whose ultimate stress is 400 MPa, then
a factor of safety of 4 means that we should take  = 400/4 = 100 MPa.

Both the design factor and the factor of safety are to be taken to be larger than unity,
although due to incertainities and various effects the condition n1 does not preclude failure.
Failure can be either breaking of the machine part or excessive deformation such
that it does not perform the desired function.
Usually n = ni . For example, for a machine part under the action of
different loads, n = ns  n1  n2

ns is used to thake the uncertainties related to the material strength into account,
n1 can be due to uncertainties associated with load 1, n2 for load 2.

Usually it is more convenient to express factor of safety as:

p = C  f (x1 , x2 , x3 , ........ , xi) F (n1 F1, n2 F2, n3 F3 , ..... , nj Fj)

where:
C : A constant,
f : A function of geometry
xi : Dimensions of the part to be designed
F : A function of the loads, usually force and moment loads
Fj : External forces applied on the part
nj : Design factors related to variations in individual loads
Machine elements (screw sizes, plate thicknesses, shaft diameters, ball bearing
sizes, etc) are manufactured in standard sizes. In case that the calculation yields a
number like 14.238 mm, next largest standard size (for example, 15 mm) is
selected for application.

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