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Chapter 1
Introduction to
Mechanical Engineering
Design
The McGraw-Hill Companies © 2012
Chapter Outline
Detailed Process:
https://www.sciencebuddies.org/science-fair-projects/engineeri
ng-design-process/engineering-design-process-steps
Computational Tools
Computer-Aided Engineering (CAE)
Any use of the computer and software to aid in the
engineering design process
Computer-Aided Design (CAD)
Drafting, 3-D solid modeling, etc. (AutoCAD, Solid
Edge, Solid Works)
Computer-Aided Manufacturing (CAM)
CNC toolpath, rapid prototyping, etc. (MasterCAM, Power
Shape)
Engineering Analysis and Simulation
Finite element, fluid flow, dynamic analysis, motion, etc. (ANSYS, ABAQUS)
Math solvers
Spreadsheet, procedural
programming language,
Shigley’s Mechanical Engineering Design
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, American Petroleum Institute etc.
Commercial Vendors
◦ Catalogs, technical literature, test data, etc.
Internet
Access to much of the above information
Shigley’s Mechanical Engineering Design
A Few Useful Internet Sites
www.globalspec.com
www.engnetglobal.com
www.efunda.com
www.thomasnet.com
www.uspto.gov
Standard Sizes
Use of standard sizes is a first principle of cost reduction.
Hot-rolled steel 53 mm square, Mobile chargers
Table A-17 lists some typical preferred sizes
Parts that are made and sold in large quantities usually
cost somewhat less than the odd sizes
Shigley’s Mechanical Engineering Design
Tolerances
When two or more design approaches are compared for cost, the
choice between the two depends on a set of conditions such as the
quantity of production, the speed of the assembly lines, or some other
condition
There then occurs a point corresponding to equal cost, which is
called the breakeven point
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
Shigley’s Mechanical Engineering Design
Safety and Product Liability
The designer must allow the maximum stress to be less than the
strength by a sufficient margin so that despite the uncertainties,
failure is rare (Factor of Safety)
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 (), Shear
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 Shigley’s
processing
Mechanical Engineering Design
Uncertainty
Design load is the maximum load the part should ever experience in service
So a structure with a FOS of exactly 1 will support only the design load and no more. Any
additional load will cause the structure to fail. A structure with a FOS of 2 will fail at twice
the design load. (Six Hitting in Cricket)
Difference b/w FOS & DF: The FOS or yield stress, is how much the designed part
actually will be able to withstand while DF or working stress, is what the item is required
to be able to withstand
Methods to Address Uncertainty
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
Solution
Answer
Answer
Solution
Answer
Answer
(1-5)
R Ri
n
i1
Example: A shaft with two bearings having reliabilities of
95% and 98% has an overall reliability of
R = R1 R2 = 0.95 (0.98) = 0.93 or
Parallel System
93% – In a parallel system at least one of the units
must succeed for the system to succeed (Gates of dams, support
cables in bridges)
Figure 1-4
Answer
Answer
Answer