2014

Fundamental of Mechanical Components in

Engineering Design

Hasanul Hadi bin M. Saleh

Polytechnic of Sultan Haji Ahmad
Shah

~ hereby notes prepared for POLISAS Mechanical Students as easy learning

book for Mechanical Engineering Design course. This book introduces the
fundamental of design process. It also covers the basic knowledge of
designing simple component of mechanical joint such as rivet and welds,
keys, gear and bearing. This book is not recommended as main reference
as it just notes compiled from other various sources. All references are
stated in bibliography section in each chapter. Hopefully, this kindly effort
will contribute to the reader or user of this book.

Design Process

Introduction
Mechanical engineering design involves all the disciplines of
mechanical engineering that applies the principles of engineering,
physics and materials science for analysis, design, manufacturing,
and maintenance of mechanical systems.
As a branch of engineering field, it requires an understanding of
core concepts including mechanics, kinematics, thermodynamics,
materials science, structural analysis, and electricity. Mechanical
engineers use these core principles along with tools like computeraided engineering, and product lifecycle management to design and
analyze manufacturing plants, industrial equipment and machinery,
heating and cooling systems, transport systems, aircraft, watercraft,
robotics, medical devices, weapons, and others.

Engineering design
The engineering design process is the formulation
of a plan to help an engineer build a product with
a specified performance goal. This process
involves a number of steps, and parts of the
process may need to be repeated many times
before production of a final product can begin.
Simple word: To create or designing a new product
or modifying existing product to fulfill human
need

Models of Engineering Design Process

PRIME design process adapted from MathieuC

website

PRIME
Problems: identifying needs, demand, necessity based on human

problems. Also goods in the future.

Research: find information on existing product that cause the
problems and any products that solve the problems. Well state in
literature.
Ideas: study how to overcome the problems by brainstorming
ideas in details of sketch, numerical supported data.
Make/modification: process of realizing the ideas from paper to
real product. Usually begin with prototype and end with
commercial product.
Evaluation: involves the testing of a prototype before finalize and
release to productions. Allow clients to give opinions in
presentation stage.

Factors that effects a design

The type and number of factors you have is unique for each project. That means everyone will have
their own set of design considerations specific to their problem statement. Some of design
considerations are as follows:
Functionality & marketability
Size, weight, shape & styling
Mechanical failure factors (ex: strength/stress/deflection/stiffness)
Cost, volume & manufacturability
Mechanical subdivision (ex: thermal/ friction/ lubrication)
Safety, reliability & liability
Life & maintenance
Noise & vibration
Material durability
Electricity
Standards and codes

A design constraint is limitation of your project due to the purpose or factors that cannot be
fulfilled. Some projects may be constrained by physical space or budget. Some limited by the choice
of materials or colors. Constraint will affect the product, and to overcome it requires challenge.

Concept Evaluation and selection

Evaluation and selection are analyzed by
comparing the concept with the reference
concept (Datum).
This is done by awarding points to the value of
each concept in order to determine the best
concept.
The result is determined in the form of the
advantages and disadvantages.
Thus, any weaknesses determined in the selected
design concept can be improved.

Example: Electric Furnace

Example: Electric Furnace

No.

Criteria

Interest criteria

Concept 1

Concept 2

Concept 3

1.

Efficiency

2.
3.
4.

5.

Commercial
design
Cost
Heating
mechanism
Heat chamber
shape

Concept
reference

D
A

T
U

6.

Combustion flow

7.

Mobility

8.

Total +

9.

Total

10.

Total overall

-1

-2

11.

Total actual

-4

-9

17

Design Specification
A technical specification is a document that
defines a set of requirements that a product or
assembly must meet or exceed.
A product or assembly that does not meet all of
the specifically expressed requirements does not
meet the specification, and often is referred to as
being out of specification or "out of spec."
Specifications are used when a contract for
technical products or services is issued.
The technical specification defines the
requirements to fulfill the contract.

Design Specification
MY SPECIFICATION

MY SIGNATURE:
CLIENT SIGNATURE:
PRODUCT: EASY/ ROCKING CHAIR
My product specification is written below. It is a check list that will help me develop my product. It
has been checked and agreed with my client/ customer
TARGET MARKET: The target market will be the customers of my clients furniture company. The
customers are mainly home/flat owners.
FUNCTIONS: The chair will be simple, effective and modern looking. It will create a sense of rest and
comfort which will enable the user to relax. The chair will be supplied as a flat pack, for ease of
distribution and to reduce transport/ distribution costs. It will be an interesting piece of furniture.
MATERIALS: The rocker rails will be manufactured from Aeroply which can be form easily into a variety
of shapes. The rest of the chair will be manufactured from beech, which can be machined
effectively. Also, beech is quite easy to cut and shape by hand. It is an attractive natural wood.
ERGONOMICS/ OVERALL SIZES: I will use measurements derived from my ergonomics research. The
chair will be comfortable to use as it will be designed to support the lower back. The overall sizes
will be approximately height 750mm, width 550mm, depth 650mm.