2014-09-17

BASICS
MECHANICAL ENGINEERING DEPARTMENT
PALESTINE POLYTECHNIC UNIVERSITY

DR. MOMEN SUGHAYYER

2014-09-17

ME 351: Machine Design I

What is Engineering?
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Engineering is the art of applying scientific and

mathematical principles, experience, judgment, and
common sense to make things that benefit people.
In other words, engineering is the process of
producing a technical product or system to meet a
specific human need.

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Who are Engineers?

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Engineers are people who use their training in

mathematics, physics, and chemistry to understand
the physical world and develop creative solutions to
societies complex needs.
They are
designers,

planners, managers,
analysts, researchers, consultants,
sales specialists, and more
ME 351: Machine Design I - Dr. Momen Sughayyer

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What is Design?
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Design is an interplay between what we want to achieve and

how we want to achieve it.
The designers (mechanical engineer, electrical engineer, etc)
must do the following.

Know or understand their customers needs.

Define the problem they must solve to satisfy the needs.

Conceptualize the solution through synthesis.

Perform analysis to optimize the proposed solution (Adequacy

assessment).

Check the resulting design solution to see if it meets the original

customer needs.

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Mechanical Engineering Design

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Mechanical engineering design involves all the disciplines of

mechanical engineering;

It involves fluid flow, heat transfer, friction, energy transport,

material selection, thermomechanical treatments, statistical
descriptions, and so on.

Mechanical design concentrates mostly on loading, stress

analysis, and material mechanical properties.

ME 351: Machine Design I - Dr. Momen Sughayyer

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Design process
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The phases of the

design process
acknowledge the
many feedbacks and
iterations.

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Adequacy of Design
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Design product should be

Functional: satisfy the intended need and customer expectation.

Safe: not hazardous to the user, bystanders, or surrounding
property with appropriate directions or warnings provided.

Reliable: perform its intended function satisfactorily or without

failure at a given age.
Competitive: product survival.

Usable: user friendly product.

Manufacturable: suited to mass production with a minimum

number of parts (minimum information).
Marketable: purchasable with repair available.
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ME 351: Machine Design I - Dr. Momen Sughayyer

Design Considerations
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Functionality

Noise

Strength/stress

Styling

Distortion/deflection/stiffness.

Shape

Wear

Size

Corrosion

Control

Safety

Thermal Properties

Reliability

Surface

Manufacturability

Lubrication

Utility (electricity, gas. etc)

Marketability

Cost

Maintenance

Friction

Volume

Weight

Liability

Life

Remanufacturing/resource recovery

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Design Tools and Resources

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Computational Tools

CAD (Computer-aided design) software:

Aries, AutoCAD, CadKey, I-deas/Unigraphics, ProEngineer, etc.

CAE (Computer-aided engineering):

Finite element analysis/method (FEA or FEM):
Algor, ANSYS, MSC/NASTRAN, ABAQUS, etc.
Computational fluid dynamics:
CFD++, FIDAP, Fluent, etc.
Dynamic force and motion in mechanics:
ADAMS, DADS, Working Model, etc.

Acquiring Technical Information

Libraries, Government sources, Professional societies, commercial vendors,
internet.

ME 351: Machine Design I - Dr. Momen Sughayyer

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Engineers Professional Responsibilities

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The design engineer is required to satisfy the needs of

customers (management, clients, consumers, etc.) and is
expected to do so in a competent, responsible, ethical, and
professional manner.
Success in engineering (achievements, promotions, raises, etc.)
may in large part be due to competence but if you cannot
communicate your ideas clearly and concisely, your technical
proficiency may be compromised.
The design engineers professional obligations include
conducting activities in an ethical manner.

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Codes and Standards

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Standard: a set of specifications for parts, materials, or processes

intended to achieve uniformity, efficiency, and a specified quality.
Code: a set of specifications for the analysis, design, manufacture,
and construction of something.
All of the organizations and societies have established
specifications for standards and safety or design codes.
AA, AGMA, AISC, AISI, ANSI, ASM, ASME, ASTM, AWS, ABMA,
BSI, IFI, I. Mech. E., BIPM, ISO , NIST, SAE, JIS, DIN

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Economics
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Standard sizes (Table A-17)

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Economics
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Large Tolerances

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Economics
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Breakeven points

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Economics
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Cost estimates:

Cost per weight

Number of parts
Area
Volume
Horsepower
Torque
Capacity
Speed
Various performance ratios

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Safety and Product Liability

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The strict liability concept of product liability generally

prevails in the United States (laws exist).

The manufacturer of an article is liable for any damage or

harm that results because of a defect. It does not matter
whether the manufacturer knew about the defect, or even
could have known about it.

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The Adequacy Assessment

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An adequacy assessment consists of the cerebral, empirical,

and related mathematical modeling steps that the designer
takes to ensure that a given specification set is satisfactory
(suitable, feasible, and acceptable).

The adequacy assessment draws from the analysis portions of

prior course work.

ME 351: Machine Design I - Dr. Momen Sughayyer

2014-09-17

Uncertainty in Mechanical Design

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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.

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Uncertainty in Mechanical Design

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Methods to address uncertainties:

(1) Deterministic

Design factor or safety factor

nd

Loss of Function Load (Failure Load)

Maximum Allowable Load

(2) Stochastic
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Example
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Stress and Strength Notations

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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.
Strength is an inherent property a part, a property built into the part
because of the use of a particular material and process.
S: Strength
Ss: shear strength
Sy: yield strength
Su: ultimate strength
s: normal stress
t: shear stress

ME 351: Machine Design I - Dr. Momen Sughayyer

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Allowable Stress and Strength

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The American Institute of Steel Construction has published the Manual of

Steel Construction Allowable Stress Design (ASD).
The relationship between allowable stresses and specified
minimum strengths:
Tension 0.45 Sy<sall <0.60 Sy
Shear

tall=0.40 Sy

Bending 0.60 Sy<sall <0.75 Sy

Bearing sall =0.90 Sy

The minimum strength is that at least 99% of the population of values

obtained from all standard material in size range meets. (ANSI-ASTM)
ANSI-ASTM: American National Standard Institute- American Society for
Testing and Materials.
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Loads and Forces

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The loads or forces are:

F = SWd + SWl + SKFl + Fw + SFmisc

SWd: Sum of the dead loads

SWl: Sum of the stationary or static live loads
Fl: Forces that may cause impact or dynamic loading
K: Service factors in Table 1.2.
Fw: Wind load on the structure
Sfmisc: The effects of earthquakes, hurricanes, or other
extraordinary conditions
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Design Factor and Factor of Safety

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The AISC method for relating stress and strength is also used in some
other specialized design areas. However, it is not general approach,
since it addresses only specific materials and loadings.

Three Categories of Design:

The product is made in large quantities justifying elaborate testing

of materials, components, and prototypes in the field.
The product is made in sufficient quantities to justify a modest
material test program, perhaps as small as ultimate tensile tests.
The product is made in such small quantities that no testing of
materials is performed at all.

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Deterministic Design Factor of Safety

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The general approach to the allowable load-loss of function load

problem is the deterministic design factor method.
Allowable load =loss of function load/nd
nd=S(loss of function)/s(allowable)=strength/stress
When the stresses are linearly proportional to the loads. For contact stress
problems where stresses are not linearly proportional to loads, the form
changes to
nd=(strength/stress)3 for spheres in contact
nd=(strength/stress)2 for cylinders in contact
ME 351: Machine Design I - Dr. Momen Sughayyer

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Reliability
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The reliability method of design is one in which we obtain the

distributions of stresses and the distribution of strengths and
then relate these two in order to achieve an acceptable
success rate.

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Units and Preferred Units

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Newtons second law, F = ma

(1) U.S. Customary foot-pound-second system (fps) and inchpound-second system (ips)
In fps system, the unit of mass is kip = 1000 lbf or 1000 lb

The weight of 1 slug is W= mg = 1 slug 32.2 ft/s2=32.2 lbf

The unit of pressure and stress is lbf/in2 = psi (6890 Pa)

ME 351: Machine Design I - Dr. Momen Sughayyer

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Units and Preferred Units

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Newtons second law, F = ma

(2) The International System of Units (SI: Systeme Internaional
dUnites) with the base units of kg, m, s. The force is
expressed as

The weight of 1 kg is W= mg = 1 kg 9.81 m/s2=9.81 N

The unit of pressure and stress is N/m2 = Pa

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Units and Preferred Units

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192 423.618 50 : correct notation, but should be expressed

as 1.924 105.
Use of prefixes G, M, k, m, micro (m), n, p
Prefixes should not be used in the denominators of derived unit
such as N/mm2 MN/m2.
Double prefixes should not be used such as mmm mm.

ME 351: Machine Design I - Dr. Momen Sughayyer

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Calculations and Significant Figures

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Usually three or four significant figures are necessary for

engineering accuracy.
Make all calculations to the greatest accuracy possible and
reports the results within the accuracy of the given input.
To display 706 to four significant figures:
706.0, 7.060102, 0.7060103
To display 91600 to four significant figures: 91.60103
When d=0.40 in
pd=3.1(0.40)=1.24in=1.2 in
pd=3.141592(0.40)=1.256in=1.3 in

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Power Transmission Case Study

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Assume that a company wishes to provide off-the-shelf speed

reducers in various capacities and speed ratios to sell to a wide
variety of target applications. The marketing team has determined
a need for one of these speed reducers to satisfy the following
customer requirements.
Notice that the list of customer requirements includes some numerical
specifics, but also includes some generalized requirements, e.g., low
maintenance and competitive cost.
These general requirements give some guidance on what needs to
be considered in the design process, but are difficult to achieve with
any certainty. In order to pin down these nebulous requirements, it is
best to further develop the customer requirements into a set of
product specifications that are measurable.

ME 351: Machine Design I - Dr. Momen Sughayyer

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Design Requirements
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Power to be delivered: 20 hp
Input speed: 1750 rev/min
Output speed: 85 rev/min
Targeted for uniformly loaded applications, such as conveyor belts, blowers,
and generators
Output shaft and input shaft in-line
Base mounted with 4 bolts
Continuous operation
6-year life, with 8 hours/day, 5 days/wk
Low maintenance
Competitive cost
Nominal operating conditions of industrialized locations
Input and output shafts standard size for typical couplings

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Design Specifications
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Power to be delivered: 20 hp

Power efficiency: >95%

Steady state input speed: 1750 rev/min

Maximum input speed: 2400 rev/min

Steady-state output speed: 8288 rev/min

Usually low shock levels, occasional moderate shock

Input and output shaft diameter tolerance: 0.001 in

Output shaft and input shaft in-line: concentricity 0.005 in, alignment
0.001 rad

Maximum allowable loads on input shaft: axial, 50 lbf; transverse, 100 lbf

Maximum allowable loads on output shaft: axial, 50 lbf; transverse, 500 lbf

Base mounted with 4 bolts

ME 351: Machine Design I - Dr. Momen Sughayyer

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Design Specifications
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Mounting orientation only with base on bottom

100% duty cycle

Maintenance schedule: lubrication check every 2000 hours; change of

lubrication every 8000 hours of operation; gears and bearing life
>12,000 hours; infinite shaft life; gears, bearings, and shafts replaceable
Access to check, drain, and refill lubrication without disassembly or opening
of gasketed joints.

Manufacturing cost per unit: <$300

Production: 10,000 units per year

Operating temperature range: 10 to 120F

Sealed against water and dust from typical weather

Noise: <85 dB from 1 meter

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