LECTURE# 01:

Introduction

Danish Hameed
Department of Mechanical Engineering
Mirpur University of Science &
Technology, Mirpur A.K.
Pakistan
04/03/2015

Danish Hameed

BREAKUP OF LECTURE
Machine
Load Use to Obtained
#
01
Design
Stresses
Engineering Design
Mechanical Engineering
Design
Step to Design
Design Consideration
Codes & Standards
Organizations
Economics
Product Liability
Uncertainty
Measure of Strength
Measure of Stress
Stress Allowance
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Service Factors
FOS
Realized Factor of Safety
Reliability

Danish Hameed

WHAT IS A
MACHINE

MACHINE : A device for

transforming or
transfering energy
An apparatus consisting of interrelated units
(machine elements)
A device that modifies force and
motion
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 A machine receives energy in some

available
form and uses it to do some particular
kind of
work
e.g.
A petrol engine is a machine, which
may use
the heat energy derived from the
combustion
of the fuel to propel a vehicle along
the road
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 A lathe is a machine which receives

mechanical energy from the line shaft
through
the belt or gears and uses that energy
to
remove metal from a bar or other
piece
LINK of
OR ELEMENT : Each part of a
machine
work
which has motion relative to some
other
part
STRUCTURES
: Made up of series of
members
of regular shape that have a
particular
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 STRESS : Internal reacting force per

unit area
due to the effects of external applied
forces

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DESIG
N

Formulate a plan for the

satisfaction of a
human need
Design problem have no unique
answer

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 A good answer today may well turn

out to be
a poor answer tomorrow, if there is a
growth
of knowledge during the period
A design is always subject to certain
problemsolving constraints
A design problem is not a
hypothetical
problem
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 Design has an authentic

purpose
the creation of an end result by
taking
definite action, or
the creation of something having
physical
reality

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ENGINEERING
DESIGN

The process in which scientific

principles and
the tools of engineering
mathematics,
computers, graphics and English are
used to
produce a plan which, when carried
out, will
satisfy a human need
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Danish Hameed

MECHANICAL ENGINEERING
DESIGN

Design of things and systems of

mechanical
nature, machines, products,
structures,
devices, and instruments
For the most part, mechanical design
utilizes
mathematics, the materials sciences,
and the
engineering mechanics sciences
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Danish Hameed

 The ultimate goal in machine

design is to
a) size and shape the parts
b) choose appropriate material
c) and
choose manufacturing
process
So that resulting machine can be
expected to
perform its intended/signified
function
without failure
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Danish Hameed

 An engineer/ designer should be able

to
calculate and predict the mode and
conditions
of failure for each element and then
design it
This requires stress and deflection
to prevent that failure
analysis for
each part

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Danish Hameed

 Stresses are functions of applied and

inertial
loads
An analysis of the forces, moments,
torques
and dynamics of system must be
done before
stresses and deflections can be
completely
calculated
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Danish Hameed

Desig
n

A design must
be: Functional- fill a need or customer expectation

Safe- not hazardous to users or bystanders

Reliable- conditional probability that product will
perform
its intended function without failure to a certain
age.
Competitive- contender in the market
Usable- accommodates human size and
strength
Manufacturable- minimal number of parts and
suitable for
production
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Design Process
Actions

Conceive alternative
solutions
Analyze, test, simulate, or
predict
performance of alternatives
Choose the best solution
Implement design

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Design
is

An innovative and iterative

process

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Steps to
Design

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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Design
Considerations
Strength
14. Noise
Stiffness
Wear
Corrosion
Safety
Reliability
Friction
Usability
Utility
Cost
Processin
g
Weight
Life

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15. Styling
16. Shape
17. Size
18. Control
19. Thermal
Properties
20. Surface
21. Lubrication
22. Marketability
23. Maintenance
24. Volume
25. Liability
26. Recovery

Danish Hameed

Codes and
Standards

Code- a set of specifications for the

analysis,
design, manufacture, and
construction of
something
Standard- a set of specifications for
parts,
materials, or processes intended to
achieve
uniformity, efficiency, and a specified
quality
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Organizatio
ns
Aluminum Association (AA)
American Bearing
American Gear Manufacturers Manufacturers
Association (AGMA)
Association (ABMA)
American Institute of Steel
British Standards Institute
Construction (AISC)
(BSI)
American Iron and Steel
Industrial Fasteners Institute
Institute
(IFI)
(AISI)
Institution of Mechanical
American National Standards
Engineers (I. Mech. E.)
Institute (ANSI)
International Bureau of
American Society for Metals
Weights
(ASM)
and Measures (BIPM)
American Society of
International Standards
Mechanical
Organization (ISO)
American (ASME)
Welding Society
Engineers
National Institute for
(AWS)
American Society of Testing
Standards
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Materials (ASTM)
and Technology (NIST)

Economi
cs
Cost plays an important role in design
decision
process
No matter how great the idea may be,
if its
not profitable it may never be seen
The use of standard sizes and large
manufacturing tolerances reduce costs
Evaluating design alternatives with
regard to cost

Breakeven
Points
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Product
Liability

Strict liability concept prevails in

the
U.S.
Manufacturers
are liable for any damage
or harm
that results from a defect.

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Uncertain
ty
Roman Method- repeat designs that are
proven
Factor of Safety Method of Philon- separate
the lossof-function load
the impressed load
Lossand
of Function
using a ratio
nd =

Impressed Load
Permissible Stress- fraction of significant
material
property (i.e., strength)
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Uncertain
ty
Design Factor Method- factor of safety is
increased
with rounding error to achieve nominal size
(5.3 mm
designed bolt size is increased to 6.0 mm)
Stochastic Design Factor Method- uncertainty
in stress
and strength
linearly
nd is quantified
Averagefor
Strength
proportional
Average Stress
loads
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Measures of
Strength
S Strength
Ss Shear
Strength
Sy Yield Strength
Su Ultimate
Strength
S - Mean Strength

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Measures of
Stress

t Shear Stress
s Normal Stress
s1 Principal Stress
sy Stress in ydirection
sr Radial Stress
st Tangential Stress

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Stress
Allowable
(AISC)
Tension: 0.45 Sy ? sall ?

0.60 Sy
Shear:
tall = 0.40 Sy

Bending: 0.60 Sy ? sall ?

0.75 Sy
Bearing: sall = 0.90 Sy

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Engr.Uqab Munir
Butt

Loads Used to Obtain

Stresses
F = W + W + kF + F + F
d

Where:
Wd- dead loads
Wl- live loads
k- service factor
Fw- wind load
Fmisc- locality effects
(earthquakes)
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Engr.Uqab Munir
Butt

misc

Service
Factors
Applications
Elevators
Traveling Crane
Supports
Light Machinery
Supports
Reciprocating
Machinery
Supports
Floor and Balcony
Supports
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k
2
1.25
1.20
1.50

1.33

Danish Hameed

Factor of
Safety
Design factors (nd) are
defined as:

strength
nd =
and
stress

n d = n sn z
where
ns-accounts for uncertainty of
strength
nd-accounts for uncertainty of
loads
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Danish Hameed

Realized Factor of
Safety

nr =
S

nr
=Ss
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Reliabilit
y
Probability that a mechanical element
will not
fail in use
0?R?1
Reliability approach to design:
judicious
selection of material, processes, and
geometry
to achieve reliability goal
Factor of Safety Method- time proven,
widely
04/03/2015

Danish Hameed