Introduction

Piyush Shakya

405, Machine Design Section

Department of Mechanical Engineering
IIT Madras
email: pshakya@iitm.ac.in

August 1, 2019

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Contents

1 Why This Course

2 Importance of Following Standards

3 The Bigger Picture

4 Actual Design Cycle (Indian Industry)

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Encountered Mechanical Failures

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Why This Course ?? Losses Due to Failures

• Source: Salam I, Tauqir A, Haq A U, et al. (1998) An air crash due to

fatigue failure of a ball bearing Engineering Failure Analysis 5(4):
261-269.
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Why This Course ?? Losses Due to Failures

• Source: Gerdun V, Sedmak T, Inkovec VS, et al. (2007) Failures of

bearings and axles in railway freight wagons. Engineering Failure
Analysis 14: 884-894.
• Direct loss
• Indirect loss

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Why This Course ?? Economic Loss Numbers

• The overall cost of the gearbox, crane rental, labor, and revenue
losses for replacing a gearbox of 1-2 MW turbines was more than
|60 lakhs (Sankar et al., 2012 data).

• In a wind turbine, downtime due to bearing failure can lead to

lost revenue of up to $48,000 per month for a 1.5 MW turbine and
cost of repairing the bearing can go up to $50,000, excluding the
replacement logistics costs (William, 2009 data).

• Rolling element bearing failures account for outages amounting to

1.1% to 1.8% of power output and cost $150 million annually to the
utility industry (Pinkus, 1991 data).

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Why This Course ?? Economic Loss Numbers
(References)

• S. Sankar, M. Nataraj, and V. Prabhuraja, Failure analysis of bearing

in wind turbine generator gearbox," Journal of Information Systems
and Communication, vol. 3, no. 1, pp. 302-309, 2012.

• W. Oh, Preventing bearing failure: Third time lucky at Oregon wind

farm." http://www.renewableenergyworld.com/rea/news/article/2009/
failure-third-time-lucky-at-oregon-wind-farm, June 2009.

• O. Pinkus, Manual of bearing failures and repair in power plant

rotating equipment," Tech. Rep. EPRI GS-7352, Electrical Power
Research Institute (EPRI), California, 1991.

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Types of Forces

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Types of Forces

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Suitability of Members for application

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Importance of Following Standards

• Mars climate orbiter was lost in 1999 due to non adherence to the
standard units. (cost: $327.6 millions)

• NASA used SI units.

• Lockheed Martin used non-SI units (British units).

• Source: https://en.wikipedia.org/wiki/Mars_Climate_Orbiter

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Importance of Following Standards

• Brake, Clutch, and Accelerator

• Driving Side, Time Zones, (India, Russia (11)).

• Volumes, Quality, Availability, Cost etc.

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Standards and Codes

• Standard is defined as a set of specifications for parts, materials or,

processes. The objective of a standard is to reduce the variety and
to limit the number of items to a reasonable level.
• Company standards: They are used in a particular company or a
group of sister concerns.
• National standards: These are the BIS (Bureau of Indian Standards),
DIN (German), AISI or SAE (USA) or BS (UK) standards.
• International standards These are prepared by the International
Standards Organization (ISO).
• Code is defined as a set of specifications for the analysis, design,
manufacture, testing, and erection of the product. The purpose of
a code is to achieve a specified level of safety.

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The Bigger Picture

• Manufacturing Considerations

• Aesthetics

• Cost Considerations

• Value Analysis and Value Engineering (VA/VE)

• Minimization of number of parts.

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The Bigger Picture
• Human Machine Interface

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The Bigger Picture

• Ergonomic Consideration (Motorcycles, Cockpit)

• Anthropometric data : The geometric properties of human âĂŞ
their height, reach, and seating requirements, the size of the holes
they can fit through, and so forth- (human measure data)

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The Bigger Picture
• Reliability, Maintainability, and Availability Considerations (ME6226)

• Reliability is a critical attribute of a product/item, expressed by

a probability that the product will perform its required function
under the given operating condition for a stated time interval. (as
per ISO 2382-9).

• Maintainability is the probability that a failed component or system

will be restored to a specified condition within a given period when
maintenance is performed in accordance with prescribed procedure
and resources.

• Availability is the probability that a component or system is per-

forming its required function at a given point of time when used
under stated operating condition.

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The Bigger Picture

• Stochastic loading conditions (Wind turbines)

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The Bigger Picture

• Quality (as per ISO 9001: 2005 definition) is the degree to which a
set of inherent characteristics fulfills requirement.

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The Bigger Picture

• Generative Design (New Trends)

• Design Optimization

• Selection of preferred sizes

• Concurrent Engineering

• NVH

• Design for Waste/ Disposal/ Environment (Canada Philippines Waste

Issue)
https://www.philstar.com/headlines/2019/04/24/1912211/canada-work
philippines-timely-resolution-waste-issue

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The Bigger Picture

• Tolerances
• Selective Assembly (Indian Industry)
• Others (legal etc.)

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Actual Design Cycle (Automobile Industry)
• Market Survey

• Use of statistics to quantify the significant wants (requirements)

• Rewriting/breaking down significant requirements into engineeing

specifications.

• Arrival of design specifications from market survey or by bench-

marking.

• Making first design by using as many parts of the previous products

as possible. (engine volume)

• Making stage 1 prototype (called α prototype in some industries).

Only R&D workshop is used to make 5-10 machines.

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Actual Design Cycle (Automobile Industry)
• Stage 1 prototype testing (parallel testing for all the aspects dis-
cussed earlier).

• Feedback loop and modification of design

• Making stage 2 prototype (called β prototype in some industries).

Limited supplier assistance to make 20-50 machines.

• Stage 2 prototype testing (parallel testing for all the aspects dis-
cussed earlier).

• Feedback loop and modification of design

• Making stage 3 prototype (called QP (Quatlity Proving) prototype

in some industries). Limited supplier assistance to make 50-100
machines.

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Actual Design Cycle (Automobile Industry)
• Stage 3 prototype testing (parallel testing for all the aspects dis-
cussed earlier).

• Feedback loop and modification of design (if any). Ideally machine

should have no change at this stage.

• Launch of the product

• Fire fighting (Infant mortality in the field)

• Warranty study for each subsystem.

• Design change to improve quality and to reduce warranty com-

plaints.

• Industry Software: Excel, Romax, Ansys

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Thank You

One must learn by doing the thing; for though you think you know it,
you have no certainty until you try. — (Sophocles)

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