MENG 303

Machine Design

Course Introduction &

Overview
Dr. Ahmed Asker
 Course Grading

 The total course grade is comprised of :

◦ Assignments 10%.
◦ Quizzes: 10%
◦ Midterm exam: 20%
◦ Project: 20%
◦ Final Exam: 40%
 Despite that no grade are earned for the attendance, University
attendance policy needs to be followed.

Nile University MENG 303 Machine Design Dr. Ahmed Asker 2

 Course Description

 Introduction to design concepts.

 Engineering materials used for design of mechanical components.
 Stress concentrations.
 Design for Different Types of Loading (steady and cyclic loadings).
 Design of Fasteners, connections, and power screws.
 Design of Spur gears. Helical gears. Design of shafts.
 Selection of bearings.
 Design of helical compression springs.
 Design of columns and struts.
 Utilization of interactive computer programs for design of
mechanical components and assembly.

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 Course contents

 Course Introduction & Overview

 Review of Strength of Material.
 Static Failure Theories.
 Design Based on Fatigue Stress.
 Design of Shafts and Shaft Components.
 Selection of Ball and Roller Bearings.
 Screws, Fasteners, and the Design of Nonpermanent Joints

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 Recommended readings

Norton, Robert L. "Machine design: an Budynas, Richard Gordon, and J. Keith

integrated approach“, 6th edition, Prentice- Nisbett. Shigley's “mechanical engineering
Hall Inc, 2020. design”, 11th edition, McGraw-Hill, 2021.

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Design

 To formulate a plan for the satisfaction of a specified need

 Process requires innovation, iteration, and decision-making
 Communication-intensive
 Products should be
◦ Functional
◦ Safe
◦ Reliable
◦ Competitive
◦ Usable
◦ Manufacturable
◦ Marketable

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Mechanical Engineering Design

 Mechanical design is a complex process, requiring many skills.

 Extensive relationships need to be subdivided into a series of
simple tasks.
 Design is an iterative process with many interactive phases.
 Many resources exist to support the designer, including many
sources of information and an abundance of computational design
tools.
 There are roles to be played by codes and standards, ever-present
economics, safety, and considerations of product liability.

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Mechanical Engineering Design

 In mechanical design, other considerations include dimensions

and tolerances, units, and calculations.
 Mechanical engineering design involves all the disciplines of
mechanical engineering.
 Example
◦ Journal bearing—fluid flow, heat transfer, friction, energy transport,
material selection, thermomechanical treatments, statistical
descriptions, etc.

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 The Design Process

 Iterative in nature
 Requires initial
estimation, followed
by continued
refinement

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Mechanical Engineering Design

 Think about the many fields in which you can use mechanical
design.
◦ Consumer products.
◦ Manufacturing systems.
◦ Construction equipment.
◦ Agricultural equipment.
◦ Transportation equipment.

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Design Considerations

 Some characteristics that influence the design

▪ Functionality
▪ life
▪ Strength/stress
▪ noise
▪ Wear
▪ style
▪ Corrosion
▪ Maintenance
▪ Safety
▪ Reliability ▪ Liability

▪ Manufacturability ▪ Volume
▪ Utility ▪ weight
▪ friction ▪ control
▪ Marketability ▪ Lubrication
▪ Distortion/deflection/stiffness
▪ Weight

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Computational Tools

 Computer-Aided Engineering (CAE)

◦ Any use of the computer and software to aid in the engineering
process Includes
 Computer-Aided Design (CAD)
◦ Drafting, 3-D solid modeling, etc.
 Computer-Aided Manufacturing (CAM)
◦ CNC toolpath, rapid prototyping, etc.
 Engineering analysis and simulation
◦ Finite element, fluid flow, dynamic analysis, motion, etc.
 Math solvers
◦ Spreadsheet, procedural programming language, equation solver, etc.

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Acquiring Technical Information

 Libraries
◦ Engineering handbooks, textbooks, journals, patents, etc.
 Government sources
◦ Government agencies, U.S. Patent and Trademark, National Institute
for Standards and Technology, etc.
 Professional Societies (conferences, publications, etc.)
◦ American Society of Mechanical Engineers, Society of Manufacturing
Engineers, Society of Automotive Engineers, etc.
 Commercial vendors
◦ Catalogs, technical literature, test data, etc.
 Internet
Access to much of the above information

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Standards and Codes

 Standard
◦ A set of specifications for parts, materials, or processes.
◦ Intended to achieve uniformity, efficiency, and a specified quality
◦ Limits the multitude of variations
 Code
◦ A set of specifications for the analysis, design, manufacture, and
construction of something.
◦ Intended to achieve a specified degree of safety, efficiency, and
performance or quality
◦ Does not imply absolute safety
 Various organizations establish and publish standards and codes
for common and/or critical industries

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Standards and Codes

 Some organizations that establish standards and codes of

particular interest to mechanical engineers:
◦ American Bearing Manufacturers Association (ABMA)
◦ American Gear Manufacturers Association (AGMA)
◦ American Institute of Steel Construction (AISC)
◦ American Iron and Steel Institute (AISI)
◦ American National Standards Institute (ANSI)
◦ American Society of Mechanical Engineers (ASME)
◦ American Society of Testing and Materials (ASTM)
◦ American Welding Society (AWS)
◦ National Association of Power Engineers (NAPE)
◦ National Institute for Standards and Technology (NIST)
◦ Society of Automotive Engineers (SAE)

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 The Design Engineer’s Professional Responsibilities

 Satisfy the needs of the customer in a competent, responsible,

ethical, and professional manner.
 Some key advise for a professional engineer
◦ Be competent
◦ Keep current in field of practice
◦ Keep good documentation
◦ Ensure good and timely communication
◦ Act professionally and ethically

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Skills Needed in Mechanical Design

 Sketching, technical drawing, and computer-aided design.

 Properties of materials, materials processing, and manufacturing
processes.
 Applications of chemistry such as corrosion protection, plating,
and painting.
 Statics, dynamics, strength of materials, kinematics, and
mechanisms.
 Oral communication, listening, technical writing, and teamwork
skills.
 Fluid mechanics, thermodynamics, and heat transfer

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Skills Needed in Mechanical Design

 Fluid power, the fundamentals of electrical phenomena, and

industrial controls
 Experimental design and performance testing of materials and
mechanical systems
 Creativity, problem solving, and project management
 Stress analysis
 Specialized knowledge of the behavior of machine elements such
as gears, belt drives, chain drives, shafts, bearings, keys, splines,
couplings, seals, springs, connections, electric motors, linear
motion devices, clutches, and brakes.

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Economics

 Cost is almost always an important factor in engineering design.

 Use of standard sizes is a first principle of cost reduction.
 Table A-17 lists some typical preferred sizes.
 Certain common components may be less expensive in stocked
sizes.

Table A–17- Preferred Sizes

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Tolerances

 Close tolerances generally

increase cost
◦ Require additional processing
steps
◦ Require additional inspection
◦ Require machines with lower
production rates

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Breakeven Points

 A cost comparison between two possible production methods

 Often there is a breakeven point on quantity of production

EXAMPLE
 Automatic screw
machine
 25 parts/hr
 3 hr setup
 $20/hr labor cost
 Hand screw machine
 10 parts/hr
 Minimal setup
 $20/hr labor cost
 Breakeven at 50 units
Nile University MENG 303 Machine Design Dr. Ahmed Asker
 Stress and Strength

 Strength
◦ An inherent property of a material or of a mechanical element
◦ Depends on treatment and processing
◦ May or may not be uniform throughout the part
◦ Examples: Ultimate strength, yield strength
 Stress
◦ A state property at a specific point within a body
◦ Primarily a function of load and geometry
◦ Sometimes also a function of temperature and processing

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Uncertainty

 Common sources of uncertainty in stress or strength

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Uncertainty

 Deterministic method
◦ Establishes a design factor, 𝑛𝑑
◦ Based on absolute uncertainties of a loss-of-function parameter and a
maximum allowable parameter

𝑙𝑜𝑠𝑠 − 𝑜𝑓 − function parameter

𝑛𝑑 = (1-1)
maximum allowable parameter
◦ If, for example, the parameter is load, then

𝑙𝑜𝑠𝑠 − 𝑜𝑓 − function load

Maximum allowable load = (1-2)
nd

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Example 1-1

 Consider that the maximum load on a structure is known with an

uncertainty of ±20 percent, and the load causing failure is known
within ±15 percent.
 If the load causing failure is nominally 9 kN, determine the design
factor and the maximum allowable load that will offset the
absolute uncertainties.
Solution
 To account for its uncertainty, the loss-of-function load must
increase to 1/0.85, whereas the maximum allowable load must
decrease to 1/1.2. Thus, to offset the absolute uncertainties the
design factor should be
𝑤𝑜𝑟𝑠𝑡 − 𝑐𝑎𝑠𝑒 𝑎𝑝𝑝𝑙𝑖𝑒𝑑 𝑙𝑜𝑎𝑑 1.2
𝑛𝑑 = = = 1.4
𝑤𝑜𝑟𝑠𝑡 − 𝑐𝑎𝑠𝑒 𝑙𝑜𝑎𝑑 𝑡𝑜 𝑓𝑎𝑖𝑙 0.85
9
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑙𝑜𝑎𝑑 = = 6.4 𝑘𝑁
1.4
Nile University MENG 303 Machine Design Dr. Ahmed Asker
 Design Factor Method

 Often used when statistical data is not available

 Since stress may not vary linearly with load, it is more common to
express the design factor in terms of strength and stress.
𝑙𝑜𝑠𝑠 − 𝑜𝑓 − function strength 𝑆
nd = = (1-3)
allowable stress 𝜎 𝑜𝑟 𝜏
 All loss-of-function modes must be analyzed, and the mode with
the smallest design factor governs.
 Stress and strength terms must be of the same type and units.
 Stress and strength must apply to the same critical location in the
part.
 The factor of safety is the realized design factor of the final design,
including rounding up to standard size or available components.

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Example 1-2

A rod with a cross-sectional area of A and loaded in tension with an axial force
of 𝑃 = 9 kN undergoes a stress of 𝜎 = 𝑃 ∕ 𝐴. Using a material strength of 170
MPa and a design factor of 3.0, determine the minimum diameter of a solid
circular rod. Using Table A–17, select a preferred fractional diameter and
determine the rod’s factor of safety.
SOLUTION
Since 𝐴 = 𝜋𝑑2 Τ4 , 𝜎 = 𝑃Τ𝐴 , and from Equation (1–3), 𝜎 = 𝑆Τ𝑛𝑑 , then
𝑃 𝑃 𝑆
𝜎 = = 2 =
𝐴 𝜋𝑑 Τ4 𝑛𝑑
Solving for 𝑑 yields
1 1
4𝑃𝑛𝑑 24 9000 3 2
𝑑= = 6
= 14.22 𝑚𝑚
𝜋𝑆 𝜋 170 10
From Table A–17, the next higher preferred size is 16 mm. Thus, when 𝑛𝑑 is
replaced with 𝑛 in the equation developed above, the factor of safety 𝑛 is
𝜋𝑆𝑑2 𝜋 170 106 16 × 10−3 2
𝑛= = = 3.798
4𝑃 4 9000
 Thus, rounding the diameter has increased the actual design factor.
Nile University MENG 303 Machine Design Dr. Ahmed Asker
 Dimensions and Tolerances

 Nominal size – The size we use in speaking of an element.

◦ Is not required to match the actual dimension
 Limits – The stated maximum and minimum dimensions
 Tolerance – The difference between the two limits
 Bilateral tolerance – The variation in both directions from the basic
dimension, e.g. 1.005 ± 0.002 in.
 Unilateral tolerance – The basic dimension is taken as one of the
limits, and variation is permitted in only one direction, e.g.

10.0+0.01
−0.01 𝑚𝑚

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Dimensions and Tolerances

 Clearance – Refers to the difference in sizes of two mating

cylindrical parts such as a bolt and a hole.
◦ Assumes the internal member is smaller than the external member
◦ Diametral clearance – difference in the two diameters
◦ Radial clearance – difference in the two radii
 Interference – The opposite of clearance, when the internal
member is larger than the external member
 Allowance – The minimum stated clearance or the maximum
stated interference or mating parts

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Integration of Machine Elements into a Mechanical Design

 To illustrate how the design of machine elements must be

integrated with a larger mechanical design, let us consider the
design of a speed reducer for a small tractor.
 Suppose that, to accomplish the speed reduction, you decide to
design a double reduction, spur gear speed reducer. You specify
four gears, three shafts, six bearings, and a housing to hold the
individual elements in proper relation to each other.

Conceptual
design for a
speed reducer

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Integration of Machine Elements into a Mechanical Design

The primary elements of the speed reducer are:

 The input shaft (shaft 1) is to be connected to the power source, a
gasoline engine whose output shaft rotates at 2000 rpm. A flexible
coupling is to be employed to minimize difficulty with alignment.
 The first pair of gears, A and B, causes a reduction in the speed of
the intermediate shaft (shaft 2) proportional to the ratio of the
numbers of teeth in the gears. Gears B and C are both mounted to
shaft 2 and rotate at the same speed.
 A key is used at the interface between the hub of each gear and
the shaft on which it is mounted to transmit torque between the
gear and the shaft.

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Integration of Machine Elements into a Mechanical Design

 The second pair of gears. C and D, further reduces the speed of

gear D and the output shaft (shaft 3) to the range of 290 to 295
rpm.
 The output shaft is to carry a chain sprocket (not shown). The
chain drive ultimately is to be connected to the drive wheels of
the tractor.
 Each of the three shafts is supported by two ball bearings.
 The bearings are held in a housing that is to be attached to the
frame of the tractor.
 Seals are shown on the input and output shafts to prohibit
contaminants from entering the housing.

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 DESIGN CALCULATIONS

To prepare a careful design record, you will usually take the following
steps:
1. Identify the machine element being designed and the nature of
the design calculation.
2. Draw a sketch of the element, showing all features that affect
performance or stress analysis.
3. Show in a sketch the forces acting on the element (the free-body
diagram) and provide other drawings to clarify the actual physical
situation.
4. Identify the kind of analysis to be performed, such as stress due
to bending, deflection of a beam, buckling of a column, and so
on.

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 DESIGN CALCULATIONS

5. List all given data and assumptions.

6. Write the formulas to be used in symbol form, and clearly
indicate the values and units of the variables involved.
7. Solve each formula for the desired variable.
8. Insert data, check units, and perform computations.
9. Judge the reasonableness of the result.
10. If the result is not reasonable, change the design decisions and
re-compute. Perhaps a different geometry or material would be
more appropriate.
11. When a reasonable, satisfactory result has been achieved,
specify the final values for all important design parameters, using
standard sizes, convenient dimensions, readily available
materials, and so on.

Nile University MENG 303 Machine Design Dr. Ahmed Asker

 Course Project

 Design of a wood lathe for a

carpenter shop.
 Objective:
 The objective of this project
is to design a wood lathe
suitable for use in a
carpenter shop. This project
will help students formulate
design constraints, specify
design requirements, and
develop detailed
specifications for the
machine.

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 Project Phases

 Research and Analysis:

◦ Study existing wood lathes and their components.
◦ Identify the key features and specifications of a wood lathe.
◦ Analyze the needs of a typical carpenter shop.
 Formulating Design Constraints:
◦ Define the constraints based on the carpenter shop’s requirements.
◦ Consider factors such as budget, space, power supply, and safety. (You need
to select based on intended customers)
 Specifying Design Requirements:
◦ List the essential requirements for the wood lathe (e.g., motor power, speed
range, bed length, tool rest, etc.).
◦ Include ergonomic and safety considerations.
 Conceptual Design:
◦ Develop multiple design concepts.
◦ Evaluate the concepts based on the defined constraints and requirements.
◦ Select the most feasible concept for further development.
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 Project Phases

 Detailed Design:
◦ Create detailed drawings and specifications for the selected design.
◦ Include dimensions, materials, and manufacturing processes.
◦ Perform necessary calculations (e.g., motor selection, stress analysis).
 Prototyping and Testing (Optional extra points for working
prototype):
◦ If resources allow, build a prototype of the wood lathe.
◦ Test the prototype to ensure it meets the design requirements.
 Documentation and Presentation:
◦ Document the entire design process, including research, analysis,
design iterations, and final design.
◦ Prepare a presentation to showcase the design to the class.

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 Project Evaluation Criteria

 Research and Analysis: Depth and relevance of research.

 Design Constraints and Requirements: Clarity and completeness.
 Conceptual Design: Creativity and feasibility of concepts.
 Detailed Design: Accuracy and thoroughness of drawings and
specifications.
 Prototype (Optional): Functionality and quality of the prototype.
 Documentation and Presentation: Quality and clarity of
documentation and presentation.

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 Deliverables

 D1-Design Constraints and Requirements Report: Detailed list of

constraints and requirements.
 D2-Conceptual Design Report: Description and evaluation of
design concepts.
 D3-Detailed Design Report: Detailed drawings, specifications, and
calculations.
 D4-Prototype (Optional): Physical prototype of the wood lathe.
 D5-Research Report: Summary of the research and analysis phase.
 D6-Final Presentation: Presentation of the design process and final
design.

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 Project Team

 Teams of 5-6 students

 List of team members and the first deliverable (D1) has to be
submitted by week 4.

 Any team submission after this date will be

capped at 60% of the total project points.

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 Proposed Timeline

 Week 1-2: Team formation and Research and Analysis

 Week 3-4: Formulating Design Constraints and Specifying Design
Requirements
 Week 5-8: Conceptual Design
 Week 9-10: Detailed Design
 Week 11-12: Prototyping and Testing (Optional)
 Week 13: Documentation and Presentation Preparation
 Week 14: Final Presentation

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 Course Project

Learning objectives of the project

The student need to be able to deal with:
 Group Formation: Group are formed by the students.
 Project Management: Teams have limited time to complete the
conceptualization and assembly of their project.
 Creative Project: The project is an open-ended design problem where
students define the theme of their choice. That should provide the
opportunity to develop innovation and originality.
 Design Objectives and Constraints: Students should identify the
design objectives and design constraints of their own concepts.
 Troubleshooting: Design is an iterative process. Students will learn to
solve problems that were not originally envisioned.
 Reflection: Students need to analyze their work and present a reflection
of how their project can be improved. This diagnostic analysis is part of
the iteration process carried out in the design process.
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 Project Evaluation Criteria Course Project

 Design Conceptualization: Creative thinking, collection of design

requirement and proper selection of concept.
 Final Design: fulfilment of the function and design requires.
 Documentation and Reflection: detailed and clear documentation
of the design and its analysis throughout the semester.
 Presentation: Team presentation skills.

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 Project Assessments

 Project deliverables (15%)

1. Team formation and selection of the project title, W3. (hand-in)
2. Design specification and requirements, W4. (Moodle)
3. Preliminary idea and conceptual design, W9. (Moodle)
4. Final Report, W12. (Moodle)
5. Project prototype, video or simulation, W14. (Hand-in)
 Project Presentation, W14. (Moodle & Lecture theatre) (5%)

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