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COLEGIO DE SAN JUAN DE LETRAN- CALAMBA

SCHOOL OF ENGINEERING
MACHINE DESIGN LAB 1

DESIGN : AN INSPIRATION BASED RIGHT EXECUTION STUDY AS THE


KEY FOR EFFECTIVENESS OF NEXT IN LINE LETRANITE
MECHANICAL ENGINEERS

RESEARCH WORK NO. 1

GRADE

BASTIAN, BIEN CARLO M.


4ME1
3130361

ENGR. JOSE R. FRANCISCO, PME


INSTRUCTOR

JUNE 23, 2016


DATE
OBJECTIVE:

“THIS REPORT, ENTITLED, DESIGN : AN INSPIRATION BASED


RIGHT EXECUTION STUDY AS THE KEY FOR EFFECTIVENESS OF NEXT
IN LINE LETRANITE MECHANICAL ENGINEERS, WAS DONE AS A
COMPRESSED AIDE FOR OUR CAPABILITY TO LEARN THE INITIAL
POINT OF THIS COURSE, MACHINE DESIGN 1 AND PRACTICALLY, FOR
US TO HAVE A GUARANTEE OF PASSING AFTERWARDS; AS IT IS
ORIGINALLY REQUIRED BY OUR HONORABLE INSTRUCTOR, ENGR.
JOSE R. FRANCISCO, PME.

AFTER READING THIS INSPIRATION AND REFERENCE-BASED


REPORT, A READER MUST HAVE LEARNINGS ABOUT THE FOLLOWING:

1. DESIGN
2. MECHANICAL ENGINEERING DESIGN
3. DESIGN OF MECHANICAL SYSTEMS
4. FUNDAMENTAL DESIGN CONSIDERATIONS
5. CODES AND STANDARDS
6. ECONOMICS IN DESIGN
7. COMPUTERS IN DESIGN

WITH THOSE INPUTS AND KNOWLEDGE TO BE APPLIED, AN


M.E. STUDENT WILL BE SURELY EFFECTIVE IN THE TRACK OF
HIS/HER CAREER, WHICH IS THE ROOT OBJECTIVE OF THIS REPORT.”

DISCUSSION PROPER

1. DESIGN –

BASED ON THE GATHERED INFORMATION FROM AN


SPECIFIC BOOK ENTITLED, FUNDAMENTALS OF MACHINE
ELEMENTS, IT IS SAID THAT DESIGN IS SUCH A DIFFERENT
THINGS IN MEANING TO DIFFERENT PEOPLE. FOR EXAMPLE, A
CLOTHING MANUFACTURING BELIEVES THAT INCORPORATING
DIFFERENT MATERIALS OR COLORS INTO A NEW TUXEDO
STYLE CONSTITUTES OR FORMS A DESIGN. A POTTER PAINTS
DESIGNS ONTO CHINA TO COMPLEMENT ITS SURROUNDINGS.
AN ARCHITECT DESIGNS ORNAMENTAL FACADES FOR
RESIDENCES. AND MOST OF ALL, AN ENGINEER, AS IT SAID IN
THE BOOK, CHOOSES A BEARING FROM A CATALOG AND
INCORPORATES IT INTO A SPEED-REDUCER ASSEMBLY.
THESE DESIGN ACTIVITIES, ALTHOUGH THEY APPEAR TO
BE FUNDAMENTALLY DIFFERENT, SHARE A COMMON THREAD:

AND THAT IS THEY ALL REQUIRE SIGNIFICANT


CREATIVITY, PRACTICE, AND VISION TO BE DONE WELL.

IN OTHER REFERENCE, DESIGN IS AN INNOVATIVE AND


HIGHLY ITERATIVE PROCESS. IT IS ALSO A DECISION-MAKING
PROCESS. DECISIONS SOMETIMES HAVE TO BE MADE WITH
TOO LITTLE INFORMATION, OCCASIONALLY WITH JUST THE
RIGHT AMOUNT OF INFORMATION, OR WITH AN EXCESS OF
PARTIALLY CONTRADICTORY INFORMATION. DECISIONS ARE
SOMETIMES MADE TENTATIVELY, WITH THE RIGHT RESERVED
TO ADJUST AS MORE BECOMES KNOWN. THE POINT IS THAT
THE ENGINEERING DESIGNER HAS TO BE PERSONALLY
COMFORTABLE WITH A DECISION-MAKING, PROBLEM –
SOLVING ROLE.

IT IS SAID ALSO THAT DESIGN IS A COMMUNICATION-


INTENSIVE ACTIVITY IN WHICH BOTH WORDS AND PICTURES
ARE USED, AND WRITTEN AND ORAL FORMS ARE EMPLOYED,
WHICH ENGINEERS HAVE TO COMMUNICATE EFFECTIVELY AND
WORK WITH PEOPLE OF MANY DISCIPLINES; AND THOSE
SKILLS ACQUIRED BY AN ENGINEER WHEN IT COMES TO
DESIGN IS THE BASIS WHERE HIS/HER SUCCESS DEPENDS.

THE PERSONAL RESOURCES OF A MAN TO BECOME


EFFECTIVE IN DESIGN ARE THE FOLLOWING:

1. CREATIVENESS
2. COMMUNICATIVE ABILITY
3. PROBLEM SOLVING SKILL

PROVIDING THAT THOSE SKILLS ARE INTERTWINED WITH


KNOWLEDGE OF TECHNOLOGY AND FIRST PRINCIPLES.

4.ENGINEERING TOOLS (SUCH AS MATHEMATICS,


STATISTICS, COMPUTERS, GRAPHICS, AND
LANGUAGES)THAT ARE COMBINED TO PRODUCE A PLAN
THAT, WHEN CARRIED OUT, PRODUCES A PRODUCT THAT
IS FUNCTIONAL SAFE, RELIABLE, COMPETITIVE,USABLE,
MANUFACTURABLE, AND ESPECIALLY, MARKETABLE,
REGARDLESS OF WHO BUILDS IT OR WHO USES IT.
2. MECHANICAL ENGINEERING DESIGN-

IT IS IN THE PRODUCTION AND PROCESSING OF ENERGY AND


PROVIDING THE MEANS OF PRODUCTION, THE TOOLS OF
TRANSPORTATION, AND THE TECHNIQUES OF AUTOMATION
WHICH MECHANICAL ENGINEERS ARE ASSOCIATED WITH. THE
SKILL AND KNOWLEDGE BASE ARE EXTENSIVE. AMONG THE
DISCIPLINARY BASES ARE MECHANICS OF SOLIDS AND FLUIDS,
MASS AND MOMENTUM TRANSPORT, MANUFACTURING
PROCESSES, AND ELECTRICAL AND INFORMATION THEORY. IN
DEFINITION, IT IS SIMPLY AS MECHANICAL ENGINEERING DESIGN
INVOLVES ALL THE DISCIPLINES OF MECHANICAL ENGINEERING.

REAL PROBLEMS RESIST COMPARTMENTALIZATION. A SIMPLE


JOURNAL BEARING INVOLVES FLUID FLOW, HEAT TRANSFER,
FRICTION, ENERGY TRANSPORT, MATERIAL SELECTION,
THERMOMECHANICAL TREATMENTS, STATISTICAL DESCRIPTIONS,
AND SO ON. A BUILING 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, TURBOMACHINERY 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. ALL OF THESE PHRASES ARE SOMEWHAT
MORE FOCUSED EXAMPLES OF MECHANICAL ENGINEERING
DESIGN. THEY ALL DRAW ON THE SAME BODIES OF KNOWLEDGE,
ARE SIMILARLY ORGANIZED, AND REQUIRE SIMILAR SKILLS.

3. DESIGN OF MECHANICAL SYSTEMS-

A MECHANICAL SYSTEM IS A SYNERGISTIC COLLECTION OF


MACHINE ELEMENTS. IT IS SYNERGISTIC BECAUSE AS A DESIGN
IT REPRESENTS AN IDEA OR CONCEPT GREATER THAN THE SUM
OF THE INDIVIDUAL PARTS.
EXAMPLE:

(A MECHANICAL WRISTWATCH, ALTHOUGH MERELY A


COLLECTION OF GEARS, SPRINGS, AND CAMS, ALSO REPRESENTS
THE PHYSICAL REALIZATION OF A TIME MEASURING DEVICE.
MECHANICAL SYSTEM DESIGN REQUIRES CONSIDERABLE
FLEXIBILITY AND CREATIVITY TO OBTAIN GOOD SOLUTIONS.)

CREATIVITY SEEMS TO BE AIDED BY FAMILIARITY WITH


KNOWN SUCCESSFUL DESIGNS, AND MECHANICAL SYSTEMS ARE
OFTEN COLLECTIONS OF WELL- DESIGNED COMPONENTS FROM A
FINITE NUMBER OF PROVEN CLASSES.

DESIGNING A MECHANICAL SYSTEM IS A DIFFERENT TYPE OF


PROBLEM THAN SELECTING A COMPONENT. OFTEN, THE
DEMANDS OF THE SYSTEM MAKE EVIDENT THE FUNCTIONAL
REQUIREMENTS OF A COMPONENT. HOWEVER, DESIGNING A
LARGE MECHANICAL SYSTEM, POTENTIALLY COMPRISING
THOUSANDS OR EVEN MILLIONS OF MACHINE ELEMENTS, IS
MUCH MORE OPEN, UNCONSTRAINED PROBLEM.

TO DESIGN SUPERIOR MECHANICAL SYSTEMS, AN ENGINEER


MUST HAVE A CERTAIN SOPHISTICATION AND EXPERIENCE
REGARDING MACHINE ELEMENTS. STUDYING THE DESIGN AND
SELECTION OF MACHINE ELEMENTS AFFORDS AN APPRECIATION
FOR THE STRENGTHS AND LIMITATION OF CLASSES OF
COMPONENTS. THEY CAN THEN BE MORE EASILY AND
APPROPRIATELY INCORPORATED INTO A SYSTEM. FOR EXAMPLE,
A MECHANICAL SYSTEM CANNOT INCORPORATE A WORM GEAR
OR A BELLEVILLE SPRING IF THE DESIGNER DOES NOT REALIZE
THAT THESE DEVICES EXIST.

A TOOLBOX ANALOGY OF PROBLEM SOLVING CAN BE


SUCCINCTLY STATED AS, “IF YOUR ONLY TOOL IS A HAMMER,
THEN EVERY PROBLEM IS A NAIL” THE PURPOSE OF STUDYING
MACHINE ELEMENT DESIGN IS TO FILL THE TOOLBOX SO THAT
THE PROBLEM- SOLVING AND DESIGN SYNTHESIS ACTIVITIES
CAN BE FLEXIBLE AND UNCONSTRAINED.
4. FUNDAMENTAL DESIGN CONSIDERATIONS –

SOMETIMES THE STRENGTH REQUIRED OF ELEMENT IN A


SYSTEM IS AN IMPORTANT FACTOR IN THE DETERMINATION OF
THE GEOMETRY AND THE DIMENSIONS OF THE ELEMENT. IN
SUCH A SITUATION WE SAY THAT STRENGTH IS AN IMPORTANT
DESIGN CONSIDERATION. WHEN WE USE THE EXPRESSION
DESIGN CONSIDERATION, WE ARE REFERRING TO SOME
CHARACTERISTIC THAT INFLUENCES THE DESIGN OF THE
ELEMENT OR, PERHAPS, THE ENTIRE SYSTEM. USUALLY QUITE A
NUMBER OF SUCH CHARACTERISTICS MUST BE CONSIDERED AND
PRIORITIZED IN A GIVEN DESIGN SITUATION. MANY OF THE
IMPORTANT ONES ARE AS FOLLOWS (NOT NECESSARILY IN
ORDER OF IMPORTANCE) :

A. FUNCTIONALITY
B. STRENGTH/ STRESS
C. DISTORTION/DEFLECTION/STIFFNESS
D. WEAR
E. CORROSION
F. SAFETY
G. RELIABILITY
H. MANUFACTURABILITY
I. UTILITY
J. COST
K. FRICTION
L. WEIGHT
M. LIFE
N. NOISE
O. STYLING
P. SHAPE
Q. SIZE
R. CONTROL
S. THERMAL PROPERTIES
T. SURFACE
U. LUBRICATION
V. MARKETABILITY
W. MAINTENANCE
X. VOLUME
Y. LIABILITY
Z. REMANUFACTURING/RESOURCE RECOVERY
SOME OF THESE CHARACTERISTICS HAVE TO DO DIRECTLY
WITH THE DIMENSIONS, THE MATERIAL, THE PROCESSING,
AND THE JOINING OF THE ELEMENTS OF THE SYSTEM.
SEVERAL CHARACTERISTICS MAY BE INTERRELATED, WHICH
AFFECTS THE CONFIGURATION OF THE TOTAL SYSTEM.

5. CODES AND STANDARDS-

A STANDARD IS A SET OF SPECIFICATIONS FOR PARTS,


MATERIALS, OR PROCESSES INTENDED TO ACHIEVE
UNIFORMITY, EFFICIENCY, AND A SPECIFIED QUALITY. ONE OF
THE IMPORTANT PURPOSES OF A STANDARD IS TO PLACE A
LIMIT ON THE NUMBER OF ITEMS IN THE SPECIFICATIONS SO
AS TO PROVIDE A REASONABLE INVENTORY OF TOOLING,
SIZES, SHAPES, AND VARIETIES.

A CODE IS A SET OF SPECIFICATIONS FOR THE ANALYSIS,


DESIGN, MANUFACTURRE, AND CONSTRUCTION OF
SOMETHING. THE PURPOSE OF A CODE IS TO ACHIEVE A
SPECIFIED DEGREE OF SAFETY, EFFICIENCY, AND
PERFORMANCE OR QUALITY. IT IS IMPORTANT TO OBSERVE
THAT SAFETY CODES DO NOT IMPLY ABSOLUTE SAFETY. IN
FACT, ABSOLUTE SAFETY IS IMPOSSIBLE TO OBTAIN.
SOMETIMES, THE UNEXPECTED EVENT REALLY DOES HAPPEN.
DESIGNING A BUILDING TO WITHSTAND A 190 KPH WIND
DOES NOT MEAN THAT THE DESIGNERS THINK A 220 KPH
WIND IS IMPOSSIBLE; IT SIMPLY MEANS THAT THEY THINK IT
IS HIGHLY IMPROBABLE.

ALL OF THE ORGANIZATIONS AND SOCIETIES LISTED BELOW


HAVE ESTABLISHED SPECIFICATIONS FOR STANDARDS AND
SAFETY OR DESIGN CODES. THE NAME OF THE ORGANIZATION
PROVIDES A CLUE TO THE NATURE OF THE STANDARD OR
CODE. SOME OF THE STANDARDS AND CODES, AS WELL AS
ADDRESSES, CAN BE OBTAINED IN MOST TECHNICAL
LIBRARIES. THE ORGANIZATIONS OF INTEREST TO
MECHANICAL ENGINEERS ARE :

ALUMINUM ASSOCIATION (AA)

AMERICAN GEAR MANUFACTURERS ASSOCIATION


(AGMA)
AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AMERICAN IRON AND STEEL INSTITUTE (AISI)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)^5

ASM INTERNATIONAL^6

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

AMERICAN SOCIETY OF TESTING AND MATERIALS (ASTM)

AMERICAN WELDING SOCIETY (AWS)

AMERICAN BEARING MANUFACTURERS ASSOCIATION


(ABMA)^7

BRITISH STANDARDS INSTITUTION (BSI)

INDUSTRIAL FASTENERS INSTITUTE (IFI)

INSTITUTION OF MECHANICAL ENGINEERS (I. MECH. E)

INTERNATIONAL BUREAU OF WEIGHTS AND MEASURES


(BIPM)

INTERNATIONAL STANDARDS ORGANIZATION (ISO)

NATIONAL INSTITUTE FOR STANDARDS AND TECHNOLOGY


(NIST)^8

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

6. ECONOMICS IN DESIGN-

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. HERE WE INTRODUCE ONLY A FEW GENERAL
CONCEPTS AND SIMPLE RULES.

SINCE MANUFACTURING HAS A GREAT CONTRIBUTION FOR


OUR ECONOMY, THIS THING WILL BE RELATED IN ECONOMICS
IN DESIGN.
WHEN IT COMES TO MANUFACTURING AND DESIGN, BOTH OF
THEM ARE DIFFICULT TO CONSIDER APART FROM EACH OTHER.
DESIGN FOR MANUFACTURABILITY (DFM) IS A WELL-
ESTABLISHED AND NEEDED TOOL FOR DESIGN ENGINEERS.
MANUFACTURABILITY PLAYS A HUGE ROLE IN THE SUCCESS OF
COMMERCIAL PRODUCTS. AFTER ALL, A BRILLIANT CONCEPT
THAT CANNOT BE MANUFACTURED CANNOT BE SUCCESSFUL
DESIGN. ALSO, BECAUSE MOST MANUFACTURING COSTS ARE
DETERMINED BY DECISIONS MADE EARLY IN THE DESIGN
PROCESS, MARKET SUCCESS DEPENDS ON MINIMIZING THESE
COSTS. INDIVIDUAL COMPONENTS SHOULD BE DESIGNED TO
BE EASILY FABRICATED, ASSEMBLED, AND CONSTRUCTED.
[DESIGN FOR ASSEMBLY (DFA)].

IN SIMPLEST MEANING, ECONOMICS IN DESIGN IS A


DECISION OR DECIDING WHETHER A PRODUCT WILL LEAD TO
CORPORATE PROFITABILITY IS OF UTMOST CONCERN.

7. COMPUTERS IN DESIGN-

COMPUTER AIDED DESIGN (CAD) ALSO MEANS DIFFERENT


THINGS TO DIFFERENT PEOPLE, BUT IN THIS TEXT, IT IS THE
APPLICATION OF COMPUTER TECHNOLOGY TO PLANNING,
PERFORMING, AND IMPLEMENTING THE DESIGN PROCESS.
COMPUTERS ALLOW US TO VIRTUALLY INTEGRATE ALL PHASES
OF THE DESIGN PROCESS, WHETHER TECHNICAL OR
MANAGERIAL ACTIVITIES. WITH SOPHISTICATED HARDWARE
AND SOFTWARE, MANUFACTURERS CAN NOW MINIMIZE
DESIGN COSTS, MAXIMIZE EFFICIENCY, IMPROVE QUALITY,
REDUCE DEVELOPMENT TIME, AND MAINTAIN AN EDGE IN
DOMESTIC AND INTERNATIONAL MARKETS.

CAD ALLOWS THE DESIGN ENGINEER TO VISUALIZE


GEOMETRIES WITHOUT MAKING COSTLY MODELS, ITERATIONS
OR PROTOTYPES. THESE SYSTEMS CAN NOW ANALYZE
DESIGNS OF SIMPLE BRACKETS TO COMPLEX STRUCTURES
QUICKLY AND EASILY. DESIGNS CAN BE OPTIMIZED AND
MODIFIED DIRECTLY AND EASILY AT ANY TIME. INFORMATION
STORED BY COMPUTER CAN BE ACCESSED AND RETRIEVED
FROM ANYWHERE WITHIN THE ORGANIZATION.

ARTIFICIAL INTELLIGENCE (AI) STUDIES ATTEMPT TO


DUPLICATE HOW THE HUMAN MIND WORKS AND APPLY IT TO
PROCESSES ON THE COMPUTER.
EXPERT SYSTEMS ARE RULE-BASED COMPUTER PROGRAMS
THAT SOLVE SPECIAIZED PROBLEMS ON AN EXPERT LEVEL AND
PROVIDE PROBLEM-SOLVING SKILLS TO THE DESIGN
ENGINEER.

THE ADVENT OF COMPUTER NUMERICAL CONTROL (CNC)


HAS MADE GROUP TECHNOLOGY (GT) AND CELLULAR
MANUFACTURING (CM) INCREASINGLY VALUABLE. GT IS
EXTREMELY VALUABLE WHEN A DESIRED DESIGN IS MERELY AN
EXTENSION OR MODIFICATION OF AN EXISTING COMPONENT.
CM MANUFACTURING IS THE ORGANIZATION OF MACHINE
TOOLS SO THAT A WIDE VARIETY OF DESIGNS CAN BE
FABRICATED UNDER CNC WITH MINIMAL LAG TIME.

RAPID PROTOTYPING IS ANOTHER COMPUTER-DRIVEN


TECHNOLOGY THAT PRODUCES PARTS FROM COMPUTER
GEOMETRY DESCRIPTION FILES IN HOURS OR EVEN MINUTES.
IT HAS BEEN ESPECIALLY HELPFUL IN DESIGN VISUALIZATION
AND RAPID DETECTION OF DESIGN ERRORS.

FINITE ELEMENT ANALYSIS (FEA) IS THE MOST PREVALENT


COMPUTATIONAL METHOD FOR SOLID AND FLUID MECHANICS
ANALYSIS. FINITE ELEMENT COMPUTATIONAL METHOD SOLVES
COMPLEX SHAPES, SUCH AS THOSE FOUND IN MACHINERY,
AND REPLACES THE COMPLEX SHAPE WITH A SET OF SIMPLE
ELEMENTS INTERCONNECTED AT A FINITE SET OF NODE
POINTS. THE STIFFNESS OF EACH ELEMENT IS KNOWN AND IS
EXPRESSED IN TERMS OF STIFFNESS MATRIX FOR THAT
ELEMENT. BY COMBINING ALL THE STIFFNESS MATRICES,
APPLYING KINEMATIC AND STRESS BOUNDARY CONDITIONS,
AND SOLVING FOR UNKNOWN STRESSES OR DISPLACEMENTS,
COMPLICATED GEOMETRIES AND LOADING CONDITIONS CAN
BE EASILY ANALYZED.

-END OF REPORT-

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