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Design
FunctionalFunctional- fill a need or customer expectation SafeSafe- not hazardous to users or bystanders ReliableReliable- conditional probability that product will perform its intended function without failure to a certain age. CompetitiveCompetitive- contender in the market UsableUsable- accommodates human size and strength ManufacturableManufacturable- minimal number of parts and suitable for production MarketableMarketable- product can be sold and serviced
To design is either to formulate a plan for the satisfaction of a specified need or to solve a problem.
Conceive alternative solutions Analyze, test, simulate, or predict performance of alternatives Choose the best solution Implement design
Design is
Steps to Design
Design Considerations
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Strength Stiffness Wear Corrosion Safety Reliability Friction Usability Utility Cost Processing Weight Life
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Noise Styling Shape Size Control Thermal Properties Surface Lubrication Marketability Maintenance Volume Liability Recovery
CodeCode- a set of specifications for the analysis, design, manufacture, and construction of something StandardStandard- a set of specifications for parts, materials, or processes intended to achieve uniformity, efficiency, and a specified quality
Organizations
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) American Society for Metals (ASM) American Society of Mechanical Engineers (ASME) American Society of Testing Materials (ASTM)
American Welding Society (AWS)
American Bearing Manufacturers Association (ABMA) British Standards Institute (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) Society of Automotive Engineers (SAE) American Society of Agricultural and Biological Engineers (ASABE)
Economics
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 Cost Estimates
Product Liability
Manufacturers are liable for any damage or harm that results from a defect.
Uncertainty
Roman Method- repeat designs that are proven MethodFactor of Safety Method of Philon- separate the loss-ofPhilonloss-offunction load and the impressed load using a ratio
Uncertainty
Design Factor Method- factor of safety is increased with Methodrounding error to achieve nominal size (5.3 mm designed bolt size is increased to 6.0 mm) Stochastic Design Factor Method- uncertainty in stress Methodand strength is quantified for linearly proportional loads
Measures of Strength
Measures of Stress
X Shear Stress W Normal Stress W W Principal Stress Wy Stress in y-direction yWr Radial Stress Wt Tangential Stress
Tension: 0.45 Sy Wall 0.60 Sy Shear: Xall = 0.40 Sy Bending: 0.60 Sy Wall 0.75 Sy Bearing: Wall = 0.90 Sy
Where:
Wd- dead loads Wl- live loads k- service factor Fw- wind load Fmisc- locality effects (earthquakes)
Service Factors
Applications Elevators Traveling Crane Supports Light Machinery Supports Reciprocating Machinery Supports Floor and Balcony Supports k 2 1.25 1.20 1.50 1.33
Factor of Safety
and
strength nd ! stress
n d ! n sn z
where ns-accounts for uncertainty of strength nd-accounts for uncertainty of loads
S nr ! W
Ss nr ! X
Reliability
Probability that a mechanical element will not fail in use 0R1 Reliability approach to design: judicious selection of material, processes, and geometry to achieve reliability goal Factor of Safety Method- time proven, widely Methodaccepted Reliability Approach- new, requires data Approach-
Homework Assignment