Class 1

Today’s Class Objectives

REVIEW SYLLABUS CLASS GOALS INTRODUCTION

Instructional Format
• Attendance is important, and expected
• Lectures are recorded for later viewing
• Canvas LMS will be used for assignments, projects,
announcements.
Syllabus
• Students will be introduced to the mechanical design process.
• If you choose to pursue a career in Industrial Design, this course
will provide hands on training directly applicable to this field.
• Students should gain some practical experience in this field.
• This experience should include ;
1. Working in a design team;
2. Practical experience in the design process from inception
to completion.
3. Application of first principles to design of machine
elements
4. Writing technical reports describing design projects.
5. Act professionally and ethically.
Syllabus
• Homework:
• Homework will be due on the dates shown. Late
submissions will be accepted until the graded homework
is returned, subject to a penalty of 20%.
• Homework will be assigned on the date that a section is
completed
• Learning is to be acknowledged above timeline – open
to suggestions.
Syllabus
Grading
Homework 20%
Exams (2 in class exams) 15% ea.
Design Projects 15% ea.
Final Exam 20%
 Date Class No Subject Assignment

Mon, Jan 8 1 Introduction to the design process HW-1

Wed, Jan 10 2 Sections 2-1 thru 2- 8
Mon, Jan 15 MLK Holiday
Wed, Jan 17 3 Sections 2-9 thru 2-15
Mon, Jan 22 4 Sections 2-16 thru 2-22 HW-2
Wed, Jan 24 5 Sections 3-1 thru 3-5
Mon, Jan 29 6 Sections 3-6 thru 3-12
Wed, Jan 31 7 Sections 3-13 thru 3-18- HW-3
Mon, Feb 5 8 Sections 4-1 thru 4-5 Project 1
Wed, Feb 7 9 Sections 4-6 thru 4-11
Mon, Feb 12 10 Sections 4-12 thru 4-17 HW-4
Wed, Feb 14 11 Sections 5-1 thru 5-6
Mon, Feb 19 12 Exam 1 Chapters 1 - 4
Wed, Feb 21 13 Sections 5-7 thru 5-13 HW-5
Mon, Feb 26 14 Sections 6-1 thru 6-6
Wed, Feb 28 15 Sections 6-7 thru 6-12
Mon, Mar 4 16 Sections 6-12 thru 6-19 HW-6
Wed, Mar 6 17 Sections 7-1 thru 7-8 Project 1 Due
Mon, Mar 11 Spring Break
Wed, Mar 13 Spring Break
Mon, Mar 18 18 Sections 8-1 thru 8-6 HW-7 / Project 2
Wed, Mar 20 19 Sections 8-7 thru 8-12 HW-8
Mon, Mar 25 20 Sections 9-1 thru 9-5
Wed, Mar 27 21 Exam 2 Chapters 5-8
Mon, Apr 1 22 Sections 9-6 thru 9-9 HW-9
Wed, Apr 3 23 Sections 10-1 thru 10-8
Mon, Apr 8 24 Sections 10-8 thru 10-13
Wed, Apr 10 25 TBD Project 2 Due
Mon, Apr 15 26 Review
Wed, Apr 17 27 Review
Mon, Apr 22 Final Exam 1:30-4:00 pm
 Because learning changes everything. ®

Chapter 1
Introduction to Mechanical
Engineering Design

Lecture Slides

© 2020 McGraw Hill. All rights reserved. Authorized only for instructor use in the classroom.
No reproduction or further distribution permitted without the prior written consent of McGraw Hill.
 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.
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 The Design Process

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

Access the text alternative for slide images.

Fig. 1–1
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 Design Considerations

Some characteristics that influence the design

1 Functionality. 14 Noise.
2 Strength/stress. 15 Styling.
3 Distortion/deflection/stiffness. 16 Shape.
4 Wear. 17 Size.
5 Corrosion. 18 Control.
6 Safety. 19 Thermal properties.
7 Reliability. 20 Surface.
8 Manufacturability. 21 Lubrication.
9 Utility. 22 Marketability.
10 Cost. 23 Maintenance.
11 Friction. 24 Volume.
12 Weight. 25 Liability.
13 Life. 26 Remanufacturing/resource recovery.
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 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.

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 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.

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 Ethical Guidelines for Professional Practice

National Society of Professional Engineers (NSPE) publishes a

Code of Ethics for Engineers and an Engineers’ Creed.
www.nspe.org/ethics.
Six Fundamental Canons.
Engineers, in the fulfillment of their professional duties, shall:
• Hold paramount the safety, health, and welfare of the public.
• Perform services only in areas of their competence.
• Issue public statements only in an objective and truthful manner.
• Act for each employer or client as faithful agents or trustees.
• Avoid deceptive acts.
• Conduct themselves honorably, responsibly, ethically, and lawfully so
as to enhance the honor, reputation, and usefulness of the profession.
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 Standards and Codes 1

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.
• 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.
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 Standards and Codes 2

Some organizations that establish standards and codes of particular

interest to mechanical engineers:
Aluminum Association (AA). ASM International.
American Bearing Manufacturers Association British Standards Institution (BSI).
(ABMA). Industrial Fasteners Institute (IFI).
American Gear Manufacturers Association Institute of Transportation Engineers (ITE).
(AGMA).
Institution of Mechanical Engineers (IMechE).
American Institute of Steel Construction (AISC).
International Bureau of Weights and Measures
American Iron and Steel Institute (AISI). (BIPM).
American National Standards Institute (ANSI). International Federation of Robotics (IFR).
American Society of Heating, Refrigerating and International Standards Organization (ISO).
Air-Conditioning Engineers (ASHRAE).
National Association of Power Engineers
American Society of Mechanical Engineers (NAPE).
(ASME).
National Institute for Standards and
American Society of Testing and Materials Technology (NIST).
(ASTM).
Society of Automotive Engineers (SAE).
American Welding Society (AWS).

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 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.

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 Tolerances

Close tolerances
generally increase cost.
• Require additional
processing steps.
• Require additional
inspection.
• Require machines
with lower production
rates.

Access the text alternative for slide images. Fig. 1–2

© McGraw Hill Source: From Ullman, David G., The Mechanical Design Process, 3rd ed., McGraw-Hill, New York, 2003. 18
 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.
Access the text alternative for slide images. Fig. 1–3
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 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.

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 Uncertainty 1

Common sources of uncertainty in stress or strength.

• Composition of material and the effect of variation on properties.
• Variations in properties from place to place within a bar of stock.
• Effect of processing locally, or nearby, on properties.
• Effect of nearby assemblies such as weldments and shrink fits on stress
conditions.
• Effect of thermomechanical treatment on properties.
• Intensity and distribution of loading.
• Validity of mathematical models used to represent reality.
• Intensity of stress concentrations.
• Influence of time on strength and geometry.
• Effect of corrosion.
• Effect of wear.
• Uncertainty as to the length of any list of uncertainties.
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 Uncertainty 2

Stochastic method.
• Based on statistical nature of the design parameters.
• Focus on the probability of survival of the design’s function
(reliability).
• Often limited by availability of statistical data.

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 Uncertainty 3

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

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 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 2000 lbf, 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, from Equation (1–1), should be
1 0.85
Answer =nd = 1.4
1 1.2
From Equation (1–2), the maximum allowable load is found to be
2000
Answer Maximum allowable =
load = 1400 lbf
1.4
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 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.
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 Example 1–2

A rod with a cross-sectional area of A and loaded in tension with an axial force of P =
2000 lbf undergoes a stress of σ = P∕A. Using a material strength of 24 kpsi 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∕4, σ = P∕A, and from Equation (1–3), σ = S ∕ nd, then
P P S
σ= = =
A π d 2 4 nd
Solving for d yields
12
 4 Pnd 
12
 4 ( 2000) 3 
Answer =d =
 π S   π ( 24= 0.564 in
000) 
From Table A–17, the next higher preferred size is 85 in = 0.625 in. Thus, when nd is
replaced with n in the equation developed above, the factor of safety n is
π Sd 2 π ( 24 000) 0.6252
Answer =n = = 3.68
4P 4 ( 2000)
Thus, rounding the diameter has increased the actual design factor.
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 Reliability Method of Design

Reliability method of design – A method of design that relates the

distribution of stresses with the distribution of strengths to achieve
an acceptable success rate.
Reliability, R – The statistical measure of the probability that a
mechanical element will not fail in use.

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 Probability of Failure

Probability of Failure, pf – the number of instances of failures per

total number of possible instances.
Probability Density Function, PDF – the distribution of events
within a given range of values.
Two common PDFs.

• Gaussian (normal) distribution.

• Weibull distribution.

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 Gaussian (Normal) Distribution 1

The probability density function (PDF) of the Gaussian distribution

is expressed in terms of its mean, µx, and its standard deviation σˆ x
1  1  x − µx  
2

f ( x) exp  −    (1 - 4)
σˆ x 2π  2  σˆ x  

small σˆ x large σˆ x

Fig. 1–4 Typical plots of the Gaussian distribution

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 Cumulative Distribution Function for Gaussian Distribution 2

A sketch of the standard normal distribution, showing the z

transform is given below.
The normal cumulative density function is labeled Φ(zα).

Fig. 1–5

zα 1  u2 
Φ ( zα )
= ∫ exp  −  du
−∞ 2π  2
α zα ≤ 0
=
1 − α zα > 0
Access the text alternative for slide images.

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 Reliability 1

The reliability is related to the probability of failure by

R= 1− p f (1 - 8)

Example: If 1000 parts are manufactured, with 6 of the parts

failing, the reliability is
6
1−
R= 0.994
= or 99.4%
1000

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 Relating Design Factor to Reliability 1

Reliability is the statistical probability that machine systems and

components will perform their intended function satisfactorily
without failure.
Deterministic relations between stress, strength, and design factor
are often used due to simplicity and difficulty in acquiring
statistical data.
Stress and strength are actually statistical in nature.

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 Probability Density Functions 1

Stress and strength are statistical in nature.

Plots of probability density functions shows distributions.
Overlap is called interference of σ and S, and indicates parts
expected to fail.

Fig. 1–7 (a)

Access the text alternative for slide images.

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 Probability Density Functions 2

Mean values of stress and strength

= are σ µ=
σ and S µS
“Average” design factor is
µS
nd = (a )
µσ
Margin of safety for any value of stress σ and strength S is
m= S − σ (b)
The overlap area has negative margin of safety

Fig. 1–7(a)
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 Margin of Safety

Distribution of margin of safety is dependent on distributions of

stress and strength.
Reliability R is area under the margin of safety curve for m > 0.
Interference is the area 1–R where parts are expected to fail.

Fig. 1–7 (b)

Access the text alternative for slide images.

© McGraw Hill 35
 Dimensions and Tolerances 1

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, for example, 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, for example,
+0.004
1.005 −0.000 in

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 Dimensions and Tolerances 2

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.
Fit – The amount of clearance or interference between mating parts.
GD&T – Geometric Dimensioning and Tolerancing, a comprehensive
system of symbols, rules, and definitions for defining the theoretically
perfect geometry, along with the allowable variation.
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 Choice of Tolerances

The designer is responsible for specifying tolerances for every

dimension.
Consideration is given to functionality, fit, assembly,
manufacturing process ability, quality control, and cost.
Excessive precision is a poor design choice, in that it limits
manufacturing options and drives up the cost.
Less expensive manufacturing options should be selected, even
though the part may be less than perfect, so long as the needs are
satisfactorily met.

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 Choice of Dimensions 1

Dimensioning a part is the designer’s responsibility.

Include just enough dimensions.
Avoid extraneous information that can lead to confusion or multiple
interpretations.
Example of over-specified dimensions. With +/– 1 tolerances, two
dimensions are incompatible.

Fig. 1–8
Access the text alternative for slide images.

© McGraw Hill 39
 Choice of Dimensions 2

Four examples of which dimensions to specify

Fig. 1–9
Access the text alternative for slide images.

© McGraw Hill 40
 Tolerance Stack-up

The cumulative effect of individual tolerances must be allowed to

accumulate somewhere. This is known as tolerance stack-up.
Chain dimensioning allows large stack-up of many small tolerances
in series.

Baseline dimensioning minimizes large tolerance stack-up.

Access the text alternative for slide images.

© McGraw Hill 41