ME 122 - MACHINE DESIGN 7.

SPACE SYSTEMS – satellite systems, space

shuttle, and launch systems which contain numerous
TOPIC 1 - THE NATURE OF MECHANICAL mechanical systems (antennas, robotic arms, cargo
DESIGN securing devices and propulsion systems).

MECHANICAL ENGINEERING - is the branch of II. THE MECHANICAL DESIGN PROCESS

engineering that is concerned with the conversion
of energy and with the design of machines. The The chief objective of an enterprise that produces a
designer of machines is a versatile person, not a product is to satisfy the customer. It is essential
specialist, because he must have knowledge of that you know your customer’s desires before
science, “to know”, and a knowledge of beginning a product design.
engineering, “to produce”.
III. PRP (PRODUCT REALIZATION PROCESS)
For instance, the design of the machinery for missile FACTORS TO CONSIDER.
launching requires, in part, considerable knowledge
of (1) physics, (2) mechanics, (3) aerodynamics, 1. Marketing functions to assess customer
(4) performance of materials in high-intensity, (5) requirements.
short time use, (6) electronics and (7) safety 2. Research to determine the available technology
requirements. that can reasonably be used in the product.
3. Availability of the materials and components that
Design of machine elements is an integral part of the can be incorporated into the product.
larger and more general field of mechanical design. 4. Product design and development
Designers and design engineers create devices or 5. Performance Testing
systems to satisfy specific needs. 6. Documentation of the design
7. Vendor relationships and purchasing functions
MECHANICAL DEVICES typically involve moving 8. Consideration of global sourcing of materials and
parts that transmit power and accomplish specific global marketing
patterns of motion. 9. Work-force skills
10. Physical plant and facilities available
MECHANICAL SYSTEMS are composed of several 11. Capabilities of manufacturing systems
mechanical devices. 12. Production planning and control of production
systems
I. CONSIDER THE FOLLOWING FIELDS WHERE 13. Production support systems and personnel
MECHANICAL PRODUCTS ARE DESIGNED AND 14. Quality systems requirements
PRODUCED. 15. Operation and maintenance of the physical plant
16. Distribution systems to get products to the
1. CONSUMER PRODUCTS – household customer
appliances (can openers, food processors, mixers, 17. Sales operations and time schedules
toasters, vacuum cleaners, clothes washers), lawn 18. Cost targets and other competitive issues
mowers, chain saws, power tools, garage door 19. Customer service requirements
openers, air conditioning systems. 20. Environmental concerns
21. Legal requirements
2. MANUFACTURING SYSTEMS – material 22. Availability of financial capital
handling devices, conveyors, cranes, transfer
devices, industrial robots, machine tools, automated IV. TYPES OF DESIGN
assembly systems, forklift trucks and packaging
equipment. 1. ADAPTIVE DESIGN - This is based on existing
design, for example, standard products or systems
3. CONSTRUCTION EQUIPMENT – tractors with adopted for a new application. Conveyor belts,
front-end loaders or backhoes, mobile cranes, power control system of machines and mechanisms or
shovels, dump trucks, road pavers, concrete mixers, haulage systems are some of the examples where
compressors and many others. existing design systems are adapted for a particular
use.
4. AGRICULTURAL EQUIPMENT – tractors,
harvesters (for corn, wheat, tomatoes, cotton, fruit 2. DEVELOPMENTAL DESIGN - Here we start with
and many other crops), rakes, plows, cultivators, and an existing design but finally a modified design is
conveyors. obtained. A new model of a car is a typical example
of a developmental design.
5. TRANSPORTATION EQUIPMENT – automobiles,
trucks, and buses (which include hundreds of 3. NEW DESIGN - This type of design is an entirely
mechanical devices), aircraft(which include new one but based on existing scientific
retractable landing gears, actuators, cargo handling principles. No scientific invention is involved but
devices, and many others. requires creative thinking to solve a problem.
Examples of this type of design may include
6. SHIPS – cargo handling cranes, rotating radar designing a small vehicle for transportation of men
antennas, drive gearing and drive shafts and others. and material on board a ship or in a desert. Some
research activity may be necessary.
V. TYPES OF DESIGN BASED ON METHODS 1. Identify the machine element being designed and
the nature of the design calculation.
1. RATIONAL DESIGN - This is based on 2. Draw a sketch of the element, showing all features
determining the stresses and strains of that affect performance or stress analysis.
components and thereby deciding their dimensions. 3. Show in a sketch the forces acting on the element
(the free-body diagram), and provide other drawings
2. EMPIRICAL DESIGN - This is based on to clarify the actual physical situation.
empirical formulae which in turn is based on 4. Identify the kind of analysis to be performed, such
experience and experiments. For example, when as stress due to bending, deflection of a beam,
we tighten a nut on a bolt the force exerted or the buckling of a column, and so on.
stresses induced cannot be determined exactly but 5. List all given data and assumptions
experience shows that the tightening force may be 6. Write the formulas to be used in symbol form, and
given by P=284d where, d is the bolt diameter in mm clearly indicate the values and units of the variables
and P is the applied force in kg. There is no involved. If a formula is not well known to a potential
mathematical backing of this equation but it is based reader of your work, give the source. The reader may
on observations and experience. want to refer to it to evaluate the appropriateness of
the formula.
3. INDUSTRIAL DESIGN - These are based on 7. Solve each formula for the desired variable.
industrial considerations and norms viz. market 8. Insert data, check units, and perform
survey, external look, production facilities, low cost, computations.
use of existing standard products. 9. Judge the reasonableness of the result.
10. If the result is not reasonable, change the design
VI. SKILLS NEEDED IN MECHANICAL DESIGN decisions and recompute.
11. When a reasonable, satisfactory result has been
Designers use wide range of skills and knowledge in achieved, specify the final values for all important
their daily work. design parameters, using standard sizes, convenient
dimensions, readily available materials, and so on.
1. Technical drawing and computeraided design
(CAD)
Example:
1. AutoCAD softwares, Inventor,
Mechanical Desktop etc.
2. Pro-Engineer
3. Solidworks
4. Others
2. Properties of materials
2. Manufacturing processes
3. Statics, dynamics and strength of materials.
4. Kinematics and mechanics

VII. CRITERIA FOR EVALUATING MACHINE

DESIGN DECISIONS

1. Safety
2. Performance ( the degree to which the design
meets or exceeds the design objectives)
3. Reliability ( a high probability that the device will
reach or exceeds its design life)
4. Ease of manufacture
5. Ease of service or replacement of components
6. Ease of operation
7. Low initial cost
8. Low operating and maintenance costs
9. Small size and low weight
10. Low noise and vibration, smooth operation
11. Use of readily available materials and purchased
components
12. Careful use of both uniquely designed parts and
commercially available components
13. Appearance that is attractive and appropriate to
the application

VIII. DESIGN CALCULATIONS

To prepare a careful design record, you

should take the following steps.