Machine Design

2020 Spring semester

Prof. Jaehwan Kim

Email: [email protected]
Office: 2N 387
Tel: 032-860-7326
Songdo Center: 032-874-7325
Office Hour: Wed 13:00-15:00

Prof. J. Kim @ Inha U.

 Course Outline
 To foster a thorough understanding of the design process
 To learn and apply basic mechanical analysis techniques
 To develop insight from analysis and use it in design
 To fulfill specific functional requirement
 To reinforce:
- communication (oral, written and graphical)
- cooperative problem solving
- project management skills

Prof. J. Kim @ Inha U.

 Course Overview
 Principle of Design
 The Engineering Design Process
 Managing Design Projects
 Team Work, Ethics, Effective Presentation
 Optimization in Design and Reliability
 Linear Elasticity
 Calculus of Variations
 Elastic Foundations & Thin tubes
 Beams & Beam Strings
 Thin Plates

Prof. J. Kim @ Inha U.

 Related Topics
 Strength of Materials
 Advanced Machine Dynamics
 Optimal Design
 Computer Aided Design and Engineering

Prof. J. Kim @ Inha U.

 Text Books
 Atila Ertas & Jesse C. Jones, The Engineering Design
Process, John Wiley & Sons, 1996
 Irving H. Shames & Clive L. Dym, Energy and Finite
Element Methods in Structural Mechanics, Hemisphere
Pub. Co.1985.

 References:
 C. Lanczos, The variational Principles of mechanics, Dover
Pub., 1970
 S. Timoskenko & S. Woinowsky-Kreiger, Theory of Plates
and Shells, McGraw-Hill, 1959

Prof. J. Kim @ Inha U.

 Grading
 Attendance: 10%
 Homeworks:10%
 Class Exams: 60%
 Term Project: 20%

Prof. J. Kim @ Inha U.

 Term Project
 All students are mandated to resolve practical machine
design problems. Usually, redesign of mechanical product
requires design, analysis and evaluation of one or more
special purpose parts. In the beginning of the class, each
student should submit their Project Proposal with in a month
and final report is due at the end of the semester. All
reports are evaluated based on quality of contents, amount
of effort, challenge and opportunity.

 Project proposal: Two-pages to include member names, a

brief overview of your design and a sketch of actual parts or
assembly.
 Final Report:

Prof. J. Kim @ Inha U.

 Design Principle

 Drafting & Design CAD & Analysis

Prof. J. Kim @ Inha U.

 Engineering Design
 The process of devising a system, component, or process to
meet desired needs. Among the fundamental elements of the
design process are the establishment of objectives and criteria,
synthesis, analysis, construction, testing and evaluation.
 The engineering design component of a curriculum must
include some of the following features: development of
student creativity, use of open ended problems, development
and use of design methodology, formation of design problem
statements and specifications, consideration of alternative
solutions, feasibility considerations, and detailed system
descriptions.
 Variety of realistic constraints: economic factors, safety,
reliability, aesthetics, ethics and social impact.
ABET(Accreditation Board for Engineering & Technology)

Prof. J. Kim @ Inha U.

 The Design Process
Recognition
of Need Preliminary Design

Conceptualiz
Detailed Design
ation
Qualification Testing

Feasibility
Assessment Production Planning
Tooling Design
Decision:
Funding Approval
Production
Assignment of Group

Prof. J. Kim @ Inha U.

 Recognition of Need
 Requests for Proposals (RFP): formal requests for needs
 Informal requests: customer suggestions, assignments from
supervisors, etc.
 The need can be identified by an organization: government project
feasibility assessment prior to the issuance of an RFP
 Idea proceeded the identified need: Hula hoop
 Sensitive vs insensitive
 Without a thorough understanding of the Need,
it is impossible to identify the correct solutions

Prof. J. Kim @ Inha U.

 Conceptualization
 Identify viable solutions from which the optimum approach can
be selected

 Synthesis: A decision of the detail structure that satisfies the

specification of the problem
 Synthesis must be followed by Optimization and Analysis
 The system under design must be analyzed to determine
whether the performance complies with the specifications
 Mathematical Models are required

Prof. J. Kim @ Inha U.

 Creativity in
conceptualization
 Creativity could be taught. But engineering schools do not
 Personality to correlate with creativity:
- Good Guessing
- Risk Taking, - Challenging authority and procedure
- Preferring the complex and difficult
- Being sensitive emotionally, having a sense of beauty
- Having a vivid imagination
- Desiring honesty and frankness
- Being curious, - Having high self-esteem

Prof. J. Kim @ Inha U.

 Feasibility Assessment
 Purpose: to ensure that the project proceeds into the design
phase on the basis of a concept that is achievable technically
and within cost constraints.
 People who have broad experience and good judgement: a
work ownership mentality

Prof. J. Kim @ Inha U.

 Decision:
Establishing the Objectives
 Design Requirements: A task that must be accomplished prior to
initiating the design and after the concept is selected.
 All project team members should have a complete
understanding of the requirements.
 Establish early and using excellent judgement with wide and in-
depth coordination among key members in the process.
 The objectives should be continuously reviewed during the
design process to ensure that they continue to reflect the goals
of the project.
 Coordination can be achieved from a common understanding of
the Design Requirements.

Prof. J. Kim @ Inha U.

 Decision: Organization
 Work Breakdown Structure(WBS): A family tree subdivision of
the effort that is used to provide a means for management of the
various work elements.
 WBS is developed by starting with the end objective and
subdividing it into manageable elements according to size and
complexity.
 WBS is compatible with the organizational structure to ensure
that management accountability is maintained and that diffusion
of responsibility across organizational line is minimized.
 Degree and level depend on: complexity, duration of the effort,
overall cost, organizational structure of the contractor and
customer, number of contracts and their relationships and needs
of contractor and customer management.

Prof. J. Kim @ Inha U.

 Preliminary Design
 Bridge between the design concept and the detailed design
 Design concept is further defined and if more than one concept
is involved, an evaluation leading to selection of the best overall
solution is conducted.
 As the design concept is refined, the overall cost will become
more realistic.
 Requirements established during this phase form the basis for
the component specifications.
stringent vs lax requirements
 This phase is performed by a small group who are eventually
involved in the detail design process.

Prof. J. Kim @ Inha U.

 Detailed Design
 Develop a system of drawings that completely describes a
proven and tested design.
 Various disciplinary organizations are actively involved in
synthesis/analysis, resolving the system design concept into
component parts, evaluating components to validate the
established requirements, specifying undefined design
requirements and assessing the effect of the component
requirements on the overall system requirements.
 Detailed drawings
 Assembly drawings, Bill of Materials (BOM)
 Engineering Order (EO), Change Order (CO)

Prof. J. Kim @ Inha U.

 Production Planning
 Production Planning: initiated by review of the design drawings
to identify the machines, tooling and machining operations.
 Production control: CIM, JIT,
 Production: Design group should continually support
manufacturing since problems usually surface during
production that need to be resolved by coordination between
design and manufacturing.

Prof. J. Kim @ Inha U.

 Example: Wiper
 Although many improvements have been made in the
manufacture of automobiles during the past 10 years, the
windshield wipers are limited in effectiveness during heavy rain,
and they pose a problem to further improvement in vehicle
aerodynamics.

 Use brainstorming techniques to

develop other solutions for
keeping the windshield clear
during inclement weather.

Prof. J. Kim @ Inha U.

Advanced Technology in Design
 Market pressure, limited economic life of products, need to
shorten the development time, need to improve product quality,
need to improve communication between design and
manufacturing engineers =>
 CAD/CAM: performs design and production engineering
concurrently.
 Advantages:
 shorten product design cycle
 improve quality of product
 reduce the number of test articles and mockups required
 Better communication between design and manufacturing
 Reduce engineering change order

Prof. J. Kim @ Inha U.

 CAD
 Solid Modeling:
 Boundary representation (Brep)
 Constructive Solid Geometry (CSG)
 Surfaces:
 Nonuniform Rational B-Spline Surfaces (NURBS)

 Initial Graphics Exchange Standard (IGES)

Prof. J. Kim @ Inha U.

 CAM
 Transfer information from the CAD drawing into a format usable
by the NC machines that manufacture parts.
 NC program links the part geometry and the machine tools used
in manufacturing the part.
 CAM Software: convert design data into NC codes.

Prof. J. Kim @ Inha U.

 CIM
 Key in improving the productivity, efficiency, profitability of the
industrial base and in maintaining a competitive position in market.
 Integration of all of the steps in the manufacturing process by
applying computer technology to control, organize, and distribute
the manufacturing process information.
 CAD/CAM/MRP

Prof. J. Kim @ Inha U.

 CAE for Design
 Engineering Analysis  Design Synthesis
 Physical Principles  Design Principle
 Trouble Shooting  Vital Few Design Parameters
 Design of Experimentation
 What if & Sensitivity Study
 Regression; Applications
 Optimization
 Statistical Control

 Design Guidelines
 Specification item

Prof. J. Kim @ Inha U.