Module

DESIGN & ENGINEERING

(Reference)

2 hours lecture and 2 hour practical per week (Cre

Reference Books (T):

1.

Exploring Engineering - An Introduction to Engineering and Design:

Balmer, R. T., Keat W. D., Wise, G., and Kosky P., Third Edition; (ISBN13: 978-0124158917ISBN-10: 0124158919) .

2.

Engineering Design - A Project based introduction:

Dym, C. L., Little, P. and Orwin E. J. Wiley; (ISBN-978-1-118-32458-5).

3.

Design for X Concurrent engineering imperatives:

Eastman C. M., Springer 1996; (ISBN 978-94-011-3985-4).

4.

Engineering Design Process:

Haik, Y. And Shahin M. T., Cengage Learning; (ISBN-13: 978-0-495-66816-9).

DESIGN & ENGINEERING

(Reference)

2 hours lecture and 2 hour practical per week (Cre

Reference Books (T):

4.

Engineering Design: A Systematic Approach:

Pahl, G., Beitz, W., Feldhusen J. and Grote, K. H., 3rd ed. 2007; (ISBN
978-1-84628-319-2).

6.

Engineering by Design:
Voland, G., Pearson India; (ISBN 978-93-325-3505-3).

7.

A Textbook of Design & Engineering:

Subin P George & Arun K Varghese., Pentex.

8.

Engineering by Design:
Dieter & Schmidt, McGraw Hill Education ( India) Edition 2013.

DESIGN & ENGINEERING

(Reference)

2 hours lecture and 2 hour practical per week (Cre

E References (E):
i.

http://opim.wharton.upenn .edu/ ulrich/designbook.html.

E-Book (Free download).

ii.

http://www2.warwick.ac.uk/fac/sci/wmg/ftmsc/modules/modulelist/peu
ss/designforx/design_for_x_notes_s ection_5.pdf.
E-Resources (Free download).

DESIGN & ENGINEERING

02 (Course Plan)
2 hours lecture and 2 hour practical per week (Credits
Module 2 (Detailed) (2+3 hrs. Theory & 4 hrs. Practice); Mark Weightage: 15%

Theory:
Design

process

Different

stages

in

design

and

their

significance:
Defining the design space; Analogies and "thinking outside of the
box"; Quality function deployment- meeting what the customer wants;
Evaluation and choosing of a design..
Design Communication:
Realization of the concept into a configuration, drawing and model.
Concept of "Complex is Simple". Design for function and strength.
(Contd)
5

DESIGN & ENGINEERING

02 (Course Plan)
2 hours lecture and 2 hour practical per week (Credits
odule 2 (Contd) (Detailed) (2+3 hrs. Theory & 4 hrs. Practice); Mark Weightage: 15%

Theory:
Design detailing:
Material selection, Design visualisation - Solid modelling; Detailed 2D
drawings
. Tolerancing:
Use of standard items in design; Research needs in design; Energy
needs of the design, both in its realization and in the applications

Practice:
An exercise in the detailed design of two products:
Stapler/ door/clock.
6

Dimensions

Ref:T8,
Ch8.6/Pg338

o Dimensions are used on engineering drawings to

o specify size, location, and orientation of
o features of components.

o Since the objective of product design is to market

o a

profitable

product,

the

design

must

be

described
o in detail with engineering drawings.
o Dimensions are as important
o as the geometric information that is
o conveyed by the drawing.
10/24/16 10:17:10 AM

Dimensions

o Each

drawing

must

Ref:T8,
Ch8.6/Pg338

contain

the

following

information:
o The size of each feature
o The relative position between features
o The required precision (tolerance) of
o sizing and positioning features
o The type of material, and how it should be
o processed to obtain its
o expected mechanical properties
10/24/16 10:17:10 AM

Ref:T8,
Tolerance
Ch8.6/Pg338
o A tolerance is the acceptable variation in the

dimension.
o Tolerances must be placed on a dimension or geometric
feature of a part to limit the permissible variations in
size because it is impossible to repeatedly manufacture
a part exactly to a given dimension.
o A small (tight) tolerance results in greater ease of
interchangeability of parts and improved functioning.
o Tighter tolerances result in less play or chance for
vibration in moving parts.
10/24/16 10:17:10 AM

Tolerance

Ref:T8,
Ch8.6/Pg338

o A tolerance is the acceptable variation in the dimension.

o Tolerances must be placed on a dimension or geometric feature of a part to limit
the permissible variations in size because it is impossible to repeatedly
manufacture a part exactly to a given dimension.
o A small (tight) tolerance results in greater ease of interchangeability of parts
and improved functioning.
o Tighter tolerances result in less play or chance for vibration in moving parts.
o However, smaller (tighter) tolerances are achieved at an increased cost of
manufacture.
o Larger (looser) tolerances reduce the cost of manufacture and make it easier to
assemble components, but often at the expense of poorer system performance.
o An important responsibility of the designer is to make an intelligent choice of
tolerances considering the trade-off between cost and performance.
10/24/16 10:17:10 AM

10

Tolerance

Ref:T8,
Ch8.6/Pg338

o A tolerance is the permissible variation from the

specified dimension. The designer must decide
how much variation is allowable from the basic
dimension of the component to accomplish the
desired function. The design objective is to make
the tolerance no tighter than necessary, since
smaller tolerances increase manufacturing cost
and make assembly more difficult.
10/24/16 10:17:10 AM

11

Tolerance

Ref:T8,
Ch8.6/Pg340

o The tolerance on a part is the difference between the upper

and lower allowable limits of a basic size dimension. Note that

so long as the dimension falls within the tolerance limits the
part is acceptable and in spec. The basic size is the theoretical dimension, often a calculated size, for a component. As a
general rule, the basic size of a hole is its minimum diameter,
while the basic size for its mating shaft is the maximum
diameter. Basic size is not necessarily the same as nominal
size. For example, a in. bolt has a nominal diameter of
inch, but its basic size may be dif- ferent, e.g., 0.492 in.
10/24/16 10:17:10 AM

12

Tolerance

Ref:T8,
Ch8.6/Pg340

o Tolerances may be expressed in several ways.

o Bilateral

tolerance.

The

variation

occurs

in

both

directions from the basic

o dimension. That is, the upper limit exceeds the basic
value and the lower limit falls 8
o below it.
o Balanced bilateral tolerance: The variation is equally
distributed around the ba- sic dimension. 2.500 0.005.
This is the most common way of specifying toler- ances.
10/24/16 10:17:10 AM

13

Tolerance

Ref:T8,
Ch8.6/Pg340

o Unbalanced bilateral tolerance: The variation is

not equal around the basic di- mension:

10/24/16 10:17:10 AM

14

Tolerance

Ref:T8,
Ch8.6/Pg340

o Unilateral tolerance: The basic dimension is taken

as one of the limits, and varia- tion is in only one
direction.

10/24/16 10:17:10 AM

15

Tolerance

Ref:T8,
Ch8.6/Pg340

o Each manufacturing process has an inherent ability to maintain a

certain range of
o tolerances, and to produce a certain surface roughness (finish).To
achieve tolerances outside of the normal range requires special
processing that typically results in an exponential increase in the
manufacturing cost. For further details refer to Sec. 13.4.5 Thus, the
establishment of the needed tolerances in embodiment design has an
impor- tant influence on the choice of manufacturing processes and the
cost. Fortunately, not all dimensions of a part require tight tolerances.
Typically those related to critical-to- quality functions require tight
tolerances. The tolerances for the noncritical dimen- sions should be set
at values typical for the process used to make the part.
10/24/16 10:17:10 AM

16

Tolerance

Ref:T8,
Ch8.6/Pg340

o A second use for tolerance information is to set the upper and lower limits for
o quality control of the manufacturing process. Figure 8.20 shows a quality
control
o chart for the machining of shafts on a CNC lathe. Every hour the diameter of
four samples made that hour is measured and their average is plotted on the
chart. The upper and lower control limits are based on the tolerances
adjusted by a statistically relevant multiplier. When a sample mean exceeds
one of the control limits it tells the operator that something is out of control
with the process, perhaps a worn cutting tool, and that an adjustment must
be made. This procedure helps to produce a product having minimum
variability, but it is never a substitute for designing quality into the product
with robust design

10/24/16 10:17:10 AM

17

Tolerance

Ref:T8,
Ch8.6/Pg340

o An engineering drawing must indicate the required

tolerance for all dimensions. Usually, only the
critical dimensions have labeled tolerances. The
other dimensions gain their tolerance from a
general (default) tolerance statement like All
dimensions have a tolerance of 0.010 unless
otherwise specified. Often this information is
given in the title block of the drawing.
10/24/16 10:17:10 AM

18

Tolerance

o There

are

generally

Ref:T8,
Ch8.6/Pg340

two

classes

of

issues

in

parametric design associated with tolerances on

parts when they must be assembled together. The
first deals with fit, how closely the tolerances should
be held when two components fit together in an
assembly. The second is tolerance stackup, the
situation where several parts must be assembled
together

and

interference

occurs

because

the

tolerances of the individual parts overlap.

10/24/16 10:17:10 AM

19

Fit

Ref:T8,
Ch8.6/Pg340

o A typical mechanical assembly where fit is of

concern is a shaft running in a bearing or a piston
sliding in a cylinder. The fit between the shaft and
the bear- ing, as expressed by the clearance, is
important to the functioning of the machine

10/24/16 10:17:10 AM

20

Fit

Ref:T8,
Ch8.6/Pg340

o A typical mechanical assembly where fit is of

concern is a shaft running in a bearing or a piston
sliding in a cylinder. The fit between the shaft and
the bear- ing, as expressed by the clearance, is
important to the functioning of the machine
o the tolerances on the components, this will have
an upper limit and a lower limit

10/24/16 10:17:10 AM

21

Stackup

Ref:T8,
Ch8.6/Pg342

o Tolerance stackup occurs when two or more parts must be

assembled in contact. Stackup occurs from the cumulative

effects of multiple tolerances. This is called a stackup because
as the dimensions and their tolerances are added together they
stack up to add to the possible total variation. A stackup
analysis typically is used to prop- erly tolerance a dimension
that has not been given a tolerance or to find the limits on a
clearance (or interference) gap. Such an analysis allows us to
determine

the

maximum

possible

variation

between

two

features on a single component or between compo- nents in an

assembly.
10/24/16 10:17:10 AM

22

Worst-Case Tolerance Design

Ref:T8,
Ch8.6/Pg344

o In the worst-case tolerance design scenario the

assumption is made that the dimension of each
component is at either its maximum or minimum
limit of the tolerance. This is a very conservative
assumption, for in reality when a manufacturing
process is running in control many more of the
components will be closer to the basic dimension
than will be close to the limits of the tolerance.
10/24/16 10:17:10 AM

23