Lecture Slides

Chapter 1
Introduction to
Mechanical Engineering
Design
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Shigleys Mechanical Engineering Design

Chapter Outline

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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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Design Considerations
Some

characteristics that influence the design

Focu
s

on

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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.
Malaysia: MySET (Malaysian Society for Engineering and
Technology), IEM (Institute of Engineers Malaysia).
Commercial vendors
Catalogs, technical literature, test data, etc.
Internet
Access to much of the above information
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A Few Useful Internet Sites

www.globalspec.com
www.engnetglobal.com
www.efunda.com
www.thomasnet.com
www.uspto.gov

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NSPE Engineers Creed

As

a Professional Engineer I dedicate my professional

knowledge and skill to the advancement and betterment of
human welfare.
I pledge:
To give the utmost of performance;
To participate in none but honest enterprise;
To live and work according to the laws of man and the highest
standards of professional conduct;
To place service before profit, the honor and standing of the
profession before personal advantage, and the public welfare
above all other considerations.
In humility and with need for Divine Guidance, I make this
pledge.
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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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Standards and Codes

Some

organizations that establish standards and codes of

particular interest to mechanical engineers:

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Economics
Cost

is almost always an important factor in

engineering design.
Use of standard sizes is a first principle of cost
reduction.
Table A17 lists some typical preferred sizes.
Certain common components may be less expensive
in stocked sizes.

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Tolerances

Close

tolerances generally
increase cost
Why? Give three reasons

Fig. 12
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Tolerances
Close

tolerances generally
increase cost
Require additional
processing steps
Require additional
inspection
Require machines with
lower production rates

Fig. 12
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Breakeven Points
A cost

comparison between two possible production methods

Often there is a breakeven point on quantity of production
EXAMPLE
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
Fig. 13
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Stress and Strength

Strength

a
<<M

ls
a
i
r
te

ring
e
e
ngin

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
nics
a
h
ec
M
Stress
olid
S
<
<
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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Uncertainty
Common

sources of uncertainty in stress or strength

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Uncertainty
Stochastic

method
Based on statistical nature of the design parameters
Focus on the probability of survival of the designs function
(reliability)
Often limited by availability of statistical data

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Uncertainty
Deterministic

Without considering
standard size or available
component

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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Example 11

Based on
experimental data

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Example 11

Solution
Answer

Answer

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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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Reliability Method of Design

Reliability

method of design A method of design that relates

the distribution of stresses with the distribution of strengths to
achieve an acceptable success rate.
Reliability, R The statistical measure of the probability that a
mechanical element will not fail in use

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Probability of Failure
Probability

of Failure, pf the number of instances of failures

per total number of possible instances
Probability Density Function, PDF the distribution of events
within a given range of values.
<<Sta
Two common PDFs
tistics
for En
gineer
Gaussian (normal) distribution
s
Weibull distribution

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Gaussian (Normal) Distribution

The

probability density function (PDF) of the Gaussian

distribution is expressed in terms of its mean, x, and its
standard deviation x

small x

large x

Fig. 14 Typical plots of the Gaussian distribution

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Gaussian (Normal) Distribution

pf is

obtained by integrating Eq. (14).

The

variable x is placed in dimensionless form using the

transformation variate

The

transformation variate is normally distributed, with a mean

of zero and a standard deviation and variance of unity.

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Cumulative Distribution Function for Gaussian Distribution

Integration

of the Gaussian distribution to find the cumulative

density function F(x) is accomplished numerically.
To avoid the need for many tables for different values of mean
and standard deviation, the z transform is used.
The integral of the transform is tabulated in Table A10.

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Cumulative Distribution Function for Gaussian Distribution

A sketch

of the standard normal distribution, showing the z

transform is given below.
The normal cumulative density function is labeled (z)

Fig. 15

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(partial)

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Example 14

Solution

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Example 14 (continued)

Answer

Fig. 16
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Example 14 (continued)

Answer

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Discrete Mean and Standard Deviation

xi

is the value of an event (i = 1, 2, k)

fi

is the class frequency, or number of times the event xi occurs within

the class frequency range
The discrete mean is

The

discrete standard deviation is

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Reliability
The

reliability is related to the probability of failure by

Example:

If 1000 parts are manufactured, with 6 of the parts

failing, the reliability is
or 99.4 %

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Reliability
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.

Example:

A shaft with two bearings having reliabilities of 95%

and 98% has an overall reliability of
R = R1 R2 = 0.95 (0.98) = 0.93
or 93%

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Relating Design Factor to Reliability

Reliability

is the statistical probability that machine systems and

components will perform their intended function satisfactorily
without failure.
Deterministic relations between stress, strength, and design
factor are often used due to simplicity and difficulty in acquiring
statistical data.
Stress and strength are actually statistical in nature.

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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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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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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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Power Transmission Case Study Specifications

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Power Transmission Case Study Specifications

Shigleys Mechanical Engineering Design