Text

Book: Richard G. Budynas and J. Keith Nisbett, Shigleys

Mechanical Engineering Design, Ninth Edition,
McGraw Hill 2011 ( )
Evaluation: Homework 10%
Project 15%
Three Exams 25% each
Syllabus:
1. Steady Failure
2. Fatigue Failure
3. Mechanical Springs
4. Rolling Contact Bearings
5. Lubrication and Journal Bearings
6. Clutches, Brakes, Couplings, and Flywheels
Shigleys Mechanical Engineering Design

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Shigleys Mechanical Engineering Design

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3.
: 6
3-D printer

Shigleys Mechanical Engineering Design

Lecture Slides

Chapter 1
Introduction to
Mechanical Engineering
Design
The McGraw-Hill Companies 2012

Chapter Outline

Shigleys Mechanical Engineering Design

Thermodynamics, Faraday law

Engine, Motor, Transmission

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

Shigleys Mechanical Engineering Design

Mechanical Engineering Design

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.

Shigleys Mechanical Engineering Design

The Design Process

Iterative

in nature
Requires initial estimation,
followed by continued
refinement

Shigleys Mechanical Engineering Design

Design Considerations
Some

characteristics that influence the design

Green Product, most important

Shigleys Mechanical Engineering Design

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.
Shigleys 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,
etc.
Commercial vendors
Catalogs, technical literature, test data, etc.
Internet
Access to much of the above information
Shigleys Mechanical Engineering Design

A Few Useful Internet Sites

www.globalspec.com
www.engnetglobal.com
www.efunda.com
www.thomasnet.com
www.uspto.gov

Shigleys Mechanical Engineering Design

The Design Engineers 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

Shigleys Mechanical Engineering Design

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.
Shigleys Mechanical Engineering Design

NSPE Engineers Creed

As

a Professional Engineer I dedicate my professional

knowledge and skill to the advancement and betterment of
human welfare.
I pledge:
To give the utmost of performance;
To participate in none but honest enterprise;
To live and work according to the laws of man and the highest
standards of professional conduct;
To place service before profit, the honor and standing of the
profession before personal advantage, and the public welfare
above all other considerations.
In humility and with need for Divine Guidance, I make this
pledge.
Shigleys Mechanical Engineering Design

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
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
Shigleys Mechanical Engineering Design

Standards and Codes

Some

organizations that establish standards and codes of

particular interest to mechanical engineers:

Shigleys Mechanical Engineering Design

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.

Shigleys Mechanical Engineering Design

Tolerances
Close

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

Shigleys Mechanical Engineering Design

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
Shigleys Mechanical Engineering Design

Safety and Product Liability

Strict

Liability concept generally prevails in U.S.

Manufacturer is liable for damage or harm that results because
of a defect.
Negligence need not be proved.
Calls for good engineering in analysis and design, quality
control, and comprehensive testing.

Shigleys Mechanical Engineering Design

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

Shigleys Mechanical Engineering Design

Uncertainty
Common

sources of uncertainty in stress or strength

Shigleys Mechanical Engineering Design

Uncertainty
Stochastic

method
Based on statistical nature of the design parameters
Focus on the probability of survival of the designs function
(reliability)
Often limited by availability of statistical data

Shigleys Mechanical Engineering Design

Uncertainty
Deterministic

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

If, for example, the parameter is load, then

Shigleys Mechanical Engineering Design

Example 1-1

Solution

Answer

Answer

Shigleys Mechanical Engineering Design

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.

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.
Shigleys Mechanical Engineering Design

Example 1-2

Solution

Answer

Answer

Shigleys Mechanical Engineering Design

Reliability
Reliability,

R The statistical measure of the probability that a

mechanical element will not fail in use
Probability of Failure, pf the number of instances of failures
per total number of possible instances

Example:

If 1000 parts are manufactured, with 6 of the parts

failing, the reliability is
or 99.4 %

Shigleys Mechanical Engineering Design

Reliability
Series

System a system that is deemed to have failed if any

component within the system fails
The overall reliability of a series system is the product of the
reliabilities of the individual components.
n

R Ri

(1-5)

i 1

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 93%

Shigleys Mechanical Engineering Design

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.

Shigleys Mechanical Engineering Design

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

Shigleys Mechanical Engineering Design

Example 1-3

Figure 1-4

Shigleys Mechanical Engineering Design

Example 1-3 (Continued)

Solution

Answer

Answer

Answer
Shigleys Mechanical Engineering Design

Linked End-Of-Chapter Problems

Shigleys Mechanical Engineering Design

Power Transmission Case Study Specifications

Shigleys Mechanical Engineering Design

Power Transmission Case Study Specifications

Shigleys Mechanical Engineering Design

Power Transmission Case Study Specifications

Shigleys Mechanical Engineering Design