MNE 3010 Mechanical Design

Fundamentals
Dr. Lawrence Li
Room Y6713
Tel 3442-8406
mekyli@cityu.edu.hk
 Content
— Introduction to design, mechanical properties of materials (10
hrs)
— Design of shafts for power transmission: Combined bending,
torsion and axial loading. Critical speed.
— Design of keys and keyways, and couplings: Bending, torsion and
combined loads, stresses in keyed shafts; rigid and flexible
couplings.
— Design of brakes and clutches (4 hrs)
— Design of pulleys and belts: Flat-belt and V-belt
drives. Centrifugal tension
— Design of gears and gear trains (4 hrs)
— Design of bearings: Journal bearings. Anti-friction
bearings. Bearing life prediction. Selection of ball bearings and
roller bearings.
— Design of spring: Types of springs. Analysis of stiffness. Spring wire
size, number of coils, pitch, overall dimensions etc.

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 Recommended Books
— Hamrock, Schmid, Jacobson, “Fundamentals of Machine
Elements”, McGraw-Hill (Textbook)
— Shigley’s Mechanical Engineering Design, 8th edition in SI
units, McGraw-Hill (Reference)

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 What is design?
— Means different things to different people
— Common thread: they all require a lot of creativity, practice and the vision/desire to do well

“The art of directing the great resources of power in nature for the use and convenience of man”
Thomas Tregold (1987)

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 What is famous in Holland?

Courtesy of Lawrence Li

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 Windmills in Kinderdijk

Courtesy of Lawrence Li

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 Windmills in Kinderdijk

Courtesy of Lawrence Li

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 Saw-mill (exterior)

Courtesy of Lawrence Li

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 Saw-mill (the machinery)

Courtesy of Lawrence Li

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 Saw-mill (gear – power transmission)

Courtesy of Lawrence Li

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 What MNE3010 is about?
— The design context in this course is the transformation of concepts and ideas into useful
machinery.

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 What is a machine?
— A combination of mechanisms and other components that transforms, transmits or uses energy,
load, or motion for a specific purpose
— E.g. Heart pump

Mohawk Innovative Technology, Inc, (MiTi®)

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 Fundamental decision makings in mechanical design
— Loading
— Kinematics
— Materials
— Strength
— Reliability
— Deformation
— Tribology (friction, wear and lubrication)
— Cost
— Space requirement
Mohawk Innovative Technology, Inc, (MiTi®)

Engineer should hold paramount the safety, health and welfare of the public in performing
their professional duties.
1st Fundamental Canon in the Code of Ethics for Engineers ASME (1997)

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 Mechanical System
— Mechanical system is a synergistic collection of machine elements. (e.g. mechanical watch are
made of gears, springs and cams.)
— To design a good mechanical system, an engineer must have a certain level of sophistication and
commands regarding different machine elements.
— “If your only tool is a hammer, then every problem you face is a nail!”

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 Design is a multidisciplinary (cooperative) endeavour
— Tradition design approach, compartmentalized (over the wall, OTW)
— Take a long time
— Everyone concentrate on his own things
— Sequential operation (i.e. you have to wait!)
— Concurrent approach, different approaches involved simultaneously (altogether, could be a
mess in the beginning!)
— Effort (redundant) is minimized
— Quick to product
— Don’t work alone, group discussion, design review meetings, require communication skills
— Need to know other disciplines, at least their language (technical terms, names) (e.g. Heart
pump)
— Material science, law, finance, marketing, go-green (e.g. Inco)

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 Design Approaches

From Hamrock, Fundamentals of Machine Elements

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 Failure
— When we have selected/designed a machine element, the next big question we should ask is
whether it will fail in service.
— Kinds of failure:
— It becomes completely inoperable.
— It still operate but it is unable to give desirable performance.
— Serious deterioration has made it unreliable or unsafe for continued use; immediate removal for repair or
replacement is required.
— Which kind of failure is better?!

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 Safety in mechanical design

— Safety factor: ns = ((yield)ultimate stress) / (working stress)

When ns > 1 , safe

When ns < 1, back to the drawing board
— Safety factors varies from about 3 (for dead load accurately known) to 12 (for shock loads of
indefinite magnitude).

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 Pugsley method for safety factor
Pugsley Equation: ns = nsxnsy
Where nsx is calculated from A,B &C;
nsy is from D & E

From Hamrock, Fundamentals of Machine Elements

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 Pugsley safety factor
— A wire rope is used on an elevator to transport people in a
building, the elevator design can be 50% overloaded before the
safety switch shuts off the motor. What is the safety factor?
Item Your Why?
Judgment

A Vg, g, f, p

B Vg, g, f, p

C Vg, g, f, p

D ns, s, vs

E ns, s, vs
Courtesy of Lawrence Li

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 Product liability

Read Hamrock pp 11-16

From Owner’s Manual, No37 CD Transport, Mark Levinson, Madrigal Audio Laboratory

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 Design’s twin - Manufacturing
— Design for manufacturing (DFM)
— Easy to fabricate, assemble, construct, maintain (service)
— Environment, green index
— Legal consideration, IP rights
— Marketing; Will it attract buyers?(iPhone)
— Serviceability; Can it be repaired quickly, locally?
— Quality, TQE, Zero defect manufacturing

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 Physical units

From Hamrock, Fundamentals of Machine Elements

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 Conversion

Loss of the NASA Mass Climate Orbiter, 1999

… short essay
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From Hamrock, Fundamentals of Machine Elements
 sEe T ION 2.2 • An Error of Units on the Way to Mars 33

spacecraft weighed some 1387 pounds and was part of a 125 million-dollar planetary
exploration program. The spacecraft was designed to be the first orbiting weather
satellite for the planet Mars. Remote exploration of Mars is an important scientific
endeavor. Besides the Earth, Mars is the planet in our solar system that has the
most hospitable climate, including a landscape that has been shaped by landslides,
wind, volcanism, and water. In addition to gathering information about Martian
weather, data from the spacecraft would have been u eful to help scientists answer
such profound questions as, What caused drastic change in the climate of Mars and
Were the conditions necessary for primitive life ever present?
The Mars Climate Orbiter (MCa) was launched aboard a Delta II rocket from
Cape Canaveral, Florida. The spacecraft was to arrive at Mars on September23, 1999,
and it was scheduled to complete its primary science mission about five years later.
As the MCa approached the northern hemisphere of Mars, the spacecraft was to fire
its main engine for 16 minutes and 23 seconds at a thrust level of 640 N. The engine
burn would slow down the spacecraft and place it into an elliptical orbit. During
subsequent passes around the planet, thrusters on the MCa would further lower the
spacecraft into the more circular orbit that was needed for its science mission.
However, following the first main engine burn, the National Aeronautics and
Space Administration ( AS A) uddenly i sued the following statement:
Mars Climate Orbiter is believed to be lost due to a suspected navigation
error. Early this morning at about 2 A.M. Pacific Daylight Time the orbiter
fired its main engine to go into orbit around the planet. All the information
coming from the spacecraft leading up to that point looked normal. The
engine burn began as planned five minutes before the spacecraft passed
behind the planet as seen from Earth. Flight controllers did not detect a
signal when the spacecraft was expected to come out from behind the planet.

The following day, it was announced that

Flight controllers for NASA's Mars Climate Orbiter are planning to abandon
the search for the spacecraft at 3 P.M. Pacific Daylight Time today. The team
has been using the 70-meter-diameter (230-foot) antennas of the Deep Space
Network in an attempt to regain contact with the spacecraft.

What went wrong? A close look at the spacecraft's flight trajectory revealed that
during its final approach to the planet, the Mars Climate Orbiter apparently passed
only 60 km above the Martian surface, rather than the planned closest approach of
between 140 km and 150 km. Flight engineers had considered 85 km as the minimum
safe altitude for the spacecraft's flyby. The implication of the unexpectedly low
altitude as the spacecraft approached Mars was that either the spacecraft burned up
and crashed, or it skipped off the thin Martian atmosphere like a stone on the surface
of a lake and began to orbit the sun. Either way, the spacecraft was lost.
ASA thoroughly investigated the cause behind the spacecraft's loss. The Mars
Climate Orbiter Mishap Investigation Board found that the primary problem was
an error that occurred when information was transferred between two teams that
were collaborating on the spacecraft's operation and navigation. As it turns out, in a
segment of the ground-based computer software for navigating the spacecraft, those
PT ER 2 • Problem-Solving and Communication Skills

teams failed to convert a quantity properly between the United States Customary
System and the International System of Units.
The engineering quantity in question is called the engine's impulse, and it rep-
resents the net effect of the rocket engine's thrust over the time that the engine
bums. In order to steer the spacecraft and make changes to its velocity, NASA's sci-
entists and engineers needed to know the engine's impulse accurately. Impulse has
the dimensions of (force) x (time), and mission specifications called for it to have
been given in the units of newton-seconds. Numerical values for the impulse were
reported by one team without indicating the dimensions, and the data were mistak-
enly interpreted by a second team as being given in the units of pound-seconds. One
group of scientists and engineers working on the spacecraft's navigation thought that
the impulse was specified in the International System of Units, and the other group
understood the numerical values to be given in the United States Customary System.
This error resulted in the main engine's effect on the spacecraft's trajectory being
underestimated by a factor of 4.45, which is precisely the conversion factor between
newtons and pounds.
The proper accounting of units is not necessarily "rocket science," but it is im-
portant. In the following sections, we begin developing good practices for keeping
track of units in your calculations and for reporting them with your numerical an-
swers. Those are important skills for solving engineering problems and for making
sure that others have confidence in your work and can clearly understand it.
 Significant figures?
— Which is easier to read?
—820000 or 8.2×105
—0.000082 or 8.2×10-5

— Which shaft is more expensive to make?

1. A shaft of diameter 10 mm and length of
50mm
2. A shaft of diameter 10.0 mm and length of
50mm

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 Significant figures & uncertainty
A car of mass 1502 kg is accelerated by a force of 14.0N.
What is the acceleration and answer with significant
figures?
Answer
Acceleration = Force/Mass
= 14.0/1502 = 0.0093209054 m/s2 ???

From Hamrock, Fundamentals of Machine Elements

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