SAN JOSE STATE UNIVERSITY

Mechanical and Aerospace Engineering Department

ME 157 - Mechanical System Design

Instructor:
Class room:
Class time:
Class code:
Final Exam:

Dr. Ken Youssefi

E 331
Lecture - MW 10:30 - 11:45
41772
Friday Dec. 11, 9:45 - 12:00

Fall 2009
Office: IS106, phone: (510) 642-4483
Office hrs. : MW - TBA
Email: kyoussefi@aol.com
Course website: www.engr.sjsu.edu/mae

Sept. 3 (Th.) - Last day to drop, Sept. 11(Fri.) last day to add
COURSE OBJECTIVES:
Introduction to the mechanical design process: Design specification development, conceptual design, and
product design process. Application of the fundamentals from statics, dynamics, strength of materials, static and
fatigue failure theories are applied to specific machine components. Emphasis will be placed on the integration
of the mechanical engineering disciplines and systematic integrated approach to design of machine elements
and systems. Plastics and composite materials in design will be introduced. Also Introduction to fracture
mechanics will be covered in this course. The required group design project will increase the students'
understanding of the design process and dynamics of team work . 3 units.
Prerequisite: ME154, Co-requisite: ME110 and ME147
Required Textbooks:
1 Norton, R.L., Machine Design, 3rd ed., Prentice Hall, 2006
2 Ullman, D.G., The Mechanical Design Process, 3th edition, McGraw-Hill, 2003
3 Lecture notes (PowerPoint, see the website)
References:
Baumeister, Avallon, et al, Marks Handbook for Mechanical Engineers.
American Society for Metals, Metals Handbook, Vols. 8 & 10.
Juvinall and Marshek, Fundamentals of Machine Components Design, Wiley, 2001.
Roark, Formulas for Stress and Strain, 6th ed, McGraw Hill, 1996.
Rolfe and Barsom, Fracture and Fatigue Control in Structure, Prentice Hall, 1996.
Dudley, W.D., Practical Gear Design, McGraw Hill, 1984
Ertas, Atila and Jones, Jesse, The Engineering Design Process, Wiley, 1993.
Shigley, Mischke, and Budynas, Mechanical Engineering Design, 7th Edition, McGraw Hill, 2004.
Homework: homework problems are assigned a week before due date. Homework must meet a reasonable
standard of clarity and neatness. No late homework will be accepted without the consent of the instructor.
Homework problems will be reviewed in the class and the solution will be posted on the Mechanical and
Aerospace Engr. (mae) website (www.engr.sjsu.edu/mae, select faculty and then faculty web pages).
Design Project: students, working in groups, are responsible for a design project, see the separate handout.
Grading: 1st midterm 15%, 2nd exam 20%, Final Exam 25%, Project 25%, Homework 15%
Final course grade is determined using a normal distribution curve. Grade distribution:
Grade A
average plus one standard deviation and higher
Grade B
average plus standard deviation
Grade C+
average
Grade Caverage minus standard deviation
Grade F
average minus one standard deviation and lower

Academic Integrity Statement (University Policy)

Your own commitment to learning, as evidenced by your enrollment at San Jose State University and the
Universitys Integrity Policy, requires you to be honest in all yur academic course work. Faculty members are
required to report all infractions to the Office of Judicial Affairs. All students should review the Academic
Integrity Policy on cheating and plagiarism, copy of the policy can be found on the website at
http://sa.sjsu.edu/judicial_affairs/index.html
Campus policy in compliance with the Americans with Disabilities Act
If you need course adaptations of accommodations because of a disability, or if you need special arrangements
in case the building must be evacuated, please make an appointment with me as soon as possible, or see me
during office hours. Presidential Directive 97-03 requires that students with disabilities register with DRC to
establish a record of their disability.
College and Department Policy
You are responsible for understanding the policies and procedures for add/drop, academic renewal,
withdrawals, incomplete grade, classroom behavior, and other policies described in the catalog. Please read
your catalog thoroughly.
Course Objectives:

To introduce the Mechanical Engineering Process, design flow chart, identification of a need,
specification and requirements, conceptual design, evaluation of concepts, product design, human factor.
To design and select (from catalogs) various machine components such as: mechanical springs, contact
bearings, brakes and clutches, gears, shafts.
To introduce linear elastic fracture mechanics and design based on fracture toughness.
To have students work as a team to design a mechanical system and prepare a technical report.

Student Learning Objectives

The students should be able to:
Select a project to design a new product or modify an existing product, based on market research, and
carry it through the design process up to building the CAD prototype and evaluation for function.
Determine the location and magnitude of the maximum stress on a component.
Estimate the value of the stress concentration factor and apply it correctly to the stress component.
Design a machine component to guard against yielding or fracturing under static load using the
appropriate failure criteria and safety factors.
Design a machine component to guard against fatigue failure, either using the classical approach or the
fracture toughness approach.
Identify factors that have an influence on the design and selection of different machine components.
Design a spring, given the applied load and desired deflection, and select it from catalogs.
Select a suitable bearing from catalogs by knowing the bearing loads (radial and thrust), bearing life and
reliability.
Design a gear reducer (planetary or conventional) to obtain a certain output speed and use AGMA code
to determine the allowable load and select a suitable gear from catalogs.
Aware of the choices they have when it comes to material selections: metals as compared to composites
or plastics.

COURSE SCHEDULE
Week/Date
1
8/24
8/26
2
8/31
9/2
3
4

9/7
9/9
9/14
9/16

9/21
9/23

6
7

9/28
9/30
10/5
10/7
10/12
10/14

11

10/19
10/21
10/26
10/28
11/2

12

11/4
11/9

10

13
14
15

16

Subject
Reading Assign.(chapter) & HW
Introduction, course organization
(1,2) - Ullman
Design project discussion
An overview of Design Process and Concurrent Engineering
(5,6) Ullman, Notes
Product development planning, identification of a need,
Understanding customer needs design group formation
HW 1 (ideas)
Monday, Holiday Labor Day
(6) Ullman, Notes
Benchmarking (case studies) and Engineering Specifications
Conceptual Design phase; concept generation (intuitive and logical
(7) Ullman, Notes
methods), brainstorming and brain-writing.
Concept selection; estimating technical feasibility, Pughs method
(8) Ullman, Notes
Design project discussion project idea
HW 2 (mission stmt)
Design for manufacturing and assembly; concept of theoretical
(12) Ullman, Notes
minimum number of parts, design guidelines
Physical prototype building and testing, human factors in design
Notes
Design project specifications and requirements
HW 3 (specs)
Review; fatigue failure theories, example and design considerations
(5,6) Norton, Notes
Midterm exam 1
Gears; fundamental law, standard tooth specification,
(11,12) Norton
kinematics of gear tooth
Gear trains: conventional, planetary, and harmonic drives
HW 4 (fatigue)
Gears; force and stress analysis, AGMA code, design considerations
(11,12) Norton
Bearings: Journal and rolling contact type, ball, roller, tapered,
(10) - Norton
and thrust bearings.
Conceptual design due date (after presentation)
HW 5 (gear trains)
Furlough day no class
Bearings; bearing life and reliability, selecting bearing from catalog.
HW 6 (gear stress)
Flexible elements; belt and chain drives
Notes
Flexible elements; wire rope and flexible shafts, design consideration.
HW 7 (bearings)
Design of mechanical springs; tension, compression,
(13) - Norton
and specially design springs
Stresses, buckling and surging
Fatigue design using fracture mechanics approach,
Notes
Fracture toughness and crack propagation rate
Wednesday, Holiday Veterans Day
Design project discussion and exam review
Midterm Exam 2
Thanksgiving week no classes

11/11
11/16
11/18
11/23
11/25
11/30 Design using plastics; design considerations
Notes
Design using composite materials; structure, properties, applications and design considerations
12/2 Design project presentation
12/7 Design project presentation
12/8 Tuesday last day of instruction

Holiday and Furlough days (no class): Monday Sept 7, Monday Oct. 19, Wed. Nov. 11,
Monday-Friday, Nov23-27 (thanksgiving)

ky