Introduction to Design
Reference: Chapter # 1; Norton, Shigley
Design: to outline, plot or plan as action or work, to conceive, to invent
(Websters dictionary)
Design
Engineering
Artistic
Engineering design: Process of applying various techniques and scientific principles for the
purpose of defining a device, a process or a system in sufficient details to permit its
realization.
e.g.: Machine design: deals with the creation of machinery that works safely, reliably and well
Q: What is a machine?
An apparatus consisting of interdependent parts (also called as machine elements)
A device that modifies force or motion [Transfer of energy/useful work]
It is the task of an engineer to calculate these motions, forces and energy transferred to
determine the size, shapes and materials needed for each of the element of machine.
These forms the core of machine design.
1
Design Process Steps
Identification of need
Ill-defined and vague problem statement
Definition of problem
Problem restatement with details like input, output,
limitations, operating conditions, cost, reliability
Synthesis
Many alternate design options are sought
Analysis and optimization
Evaluation
o All possible solutions are studied and based on their
performance are either accepted, modified or rejected
o Most promising option is selected
Selection
Detailed Design
Prototyping & testing
Production
Every aspect is taken care, drawings are made,
manufacturing specifications are fixed and vendors
identified
Actual construction of design
Construction in large quantities
2
Problem formulation and calculation
Engineering/Mathematical model:
Its a idealization that describes the physical behavior of the intended system as an
assembly of parts signifying the various machine elements
Each part is represented using sketches/drawings denoting its geometry and equations are
set up to determine the response of parts once input is applied
Almost always the starting model is basic one to capture the essential phenomenon with
hand drawn sketches and back of the envelope calculations
The model can be enhanced in steps through inclusion of details and subsequently use of
computers
Computer aided design and engineering (CAD, CAE)
Highly iterative process
For mechanical problems:
Based on the expected loading, using free body diagram (F.B.D), forces, moments and
torques on individual elements are calculated
Using the material behavior of the machine components, stress and deflection is evaluated
to ensure safety/reliability of the component during usage
Analysis can be either based on Strength of Materials approach or detailed Theory of
Elasticity based stress calculations carried out using Finite element method (FEA) through
softwares like ANSYS, ABAQUS
3
Uncertainty
1.
2.
3.
4.
Examples:
Inhomogeneity
Influence of time on strength and geometry
Composition of material and effect of variation on properties
Effect of wear
Deterministic techniques must be modified by stochastic methods
Factor of safety/ Safety factor (F.O.S) :
Ratio of two quantities having same unit
e.g.: F.O.S = Strength/(Maximum Stress) Maximum stress Strength/F.O.S
F.O.S = Critical Load/Applied Load;
F.O.S = Critical speed/Applied Speed
Numerator is a material property obtained experimentally, while denominator is the
either based or decides the operating conditions
Value of F.O.S is decided based on the knowledge of uncertainties, level of confidence
in the mathematical model, experience, type of application
Standards and codes
Standards: is a set of specifications for parts, materials or processes intended to achieve
uniformity, efficiency and a specified quality
Codes: Set of specifications for the analysis, design, manufacture and construction
Organizations:
Bureau of Indian Standards (BIS: http://www.bis.org.in/)
American Society of Testing and Materials (ASTM: http://www.astm.org/)
American Society of Mechanical Engineers (ASME: http://www.asme.org/)
British Standards Institution (BSI: www.bsigroup.com/)
Units: We will be following SI (Systeme Internationale: http://physics.nist.gov/cuu/Units/units.html)
Quantity
Name
Symbol
Length
metre/meter
Mass
kilogram
kg
Time
second
Temperature
Kelvin
Electric current
ampere
Amount of substance
mole
mol
Luminous intensity
candela
cd
Calculations and significant figures
Output calculations should be expressed using the same number of significant digits as the
given input data
All intermediate calculations should be carried out using maximum possible accuracy to
minimize round-off error
