University of Santo Tomas​ ​ ​ ​ ​ Faculty of Engineering​

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MECHANICAL DESIGN
OVERVIEW

Mechanical design is a multifaceted and iterative process that blends creativity, technical
knowledge, and analytical skills. It aims to meet specific needs or solve problems by specifying
requirements and determining the best strategies to achieve them. This process involves a
broad range of disciplines, including material properties, mechanical analysis, structural
integrity, and adherence to established standards and codes. A successful design balances the
constraints of safety, reliability, and efficiency with the practicalities of cost and manufacturing
feasibility.

Helpful Videos: Engineering and Mechanical Engineering Profession

THE DESIGN PROCESS

The typical design process follows a series of interconnected phases, beginning with the
identification of a need. This phase involves recognizing and clearly articulating a specific
problem or gap that requires a solution. The problem is then defined with detailed specifications,
taking into account constraints such as material limitations, dimensions, costs, and expected
performance. From this point, the synthesis phase generates a range of possible solutions,
drawing on creativity and innovation. These solutions are then analyzed and optimized to
determine the most feasible and effective option. The evaluation phase follows, where
prototypes are tested to validate the performance against the defined criteria. Finally, the
process concludes with the presentation of the design, documenting the solutions and clearly
communicating the design’s strengths and results.

Basics of Mechanical Engineering Design

Understanding the principles of mechanical engineering design is essential, as it includes a

clear distinction between design and analysis. Key areas like material properties, stress
analysis, failure modes, and statistical reliability are emphasized to ensure robust and reliable
designs. Preventing failures is a crucial aspect of this process, which involves designing
components to avoid static load failures, fatigue, or time-varying stresses. Conservative safety
factors and redundant systems are often employed in critical design areas to enhance reliability.

Various analytical tools play a significant role in modern design. Computer-Aided Design (CAD)
software allows engineers to create detailed 3D models and simulations, facilitating visualization
and optimization. Computer-Aided Engineering (CAE) tools, including software for stress
simulations, fluid dynamics, and thermal analysis, provide deeper insights into the mechanical
behavior of components under various conditions. Finite Element Analysis (FEA) techniques are
particularly useful for predicting part reactions to real-world forces, vibrations, and temperature
changes, making them indispensable in complex mechanical design projects.

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Prepared by: Assoc. Prof. Anthony James C. Bautista, PME, MBA, PhD
2025
University of Santo Tomas​ ​ ​ ​ ​ Faculty of Engineering​
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Design decisions also involve several considerations, including the balance of strength, safety,
and cost. An effective design must meet the functional requirements while being economically
viable, and usability is a core focus to ensure the product satisfies user needs. Adherence to
industry standards, such as those set by ASME and ISO, is crucial to maintaining product safety
and reliability. Economic factors play a significant role in the design process, particularly when
choosing materials, manufacturing techniques, and determining the break-even point.
Standardizing dimensions can reduce costs, while understanding tolerances allows engineers to
control manufacturing precision and manage expenses effectively.

Professional Responsibilities in Engineering

The professional responsibilities of an engineer extend beyond technical competence. Ethical

standards are fundamental, prioritizing public safety and welfare in every design decision.
Effective communication and documentation are critical, enabling engineers to present their
ideas clearly and collaborate with colleagues and stakeholders. Lifelong learning is necessary to
stay current with technological advances and to remain effective in the ever-evolving field of
mechanical engineering. Moreover, respecting intellectual property, upholding confidentiality,
and adhering to industry codes of conduct are vital in maintaining the integrity of the engineering
profession.

Design Tools and Resources

Modern engineering heavily relies on advanced tools and resources. CAD software, for
example, is essential for visualizing and optimizing designs, while simulation tools allow for
virtual testing under various conditions, reducing the need for costly physical prototypes. Access
to technical libraries, research databases, and standards enables engineers to make informed
decisions and maintain best practices throughout the design process.

Ultimately, mechanical design is an iterative journey. It rarely follows a straight path, requiring
ongoing testing, analysis, and refinement. Engineers often revisit earlier phases to improve
designs based on feedback and new insights. The goal is to develop a product that is not only
functional but also reliable, safe, cost-effective, and capable of exceeding customer
expectations. This iterative approach ensures that the final product is finely tuned to meet both
technical specifications and practical market demands.

_____________________________________________________________________________________________________
Prepared by: Assoc. Prof. Anthony James C. Bautista, PME, MBA, PhD
2025
University of Santo Tomas​ ​ ​ ​ ​ Faculty of Engineering​
________________________________________________________________________________________________________

GENERAL CONSIDERATIONS IN MACHINE DESIGN

1.​ Type of Load and Stresses:

When designing a machine component, understanding the type of load it will encounter is
crucial. Loads may be static (constant), dynamic (changing with time), or impact loads (sudden
forces). For example, the shaft of a rotating motor experiences cyclic stresses due to the
continuous change in direction of forces acting on it. Similarly, bridges experience dynamic and
impact loads from vehicles passing over them. Knowing these stresses helps determine the
material and design shape to prevent failure, such as fatigue or buckling.

2.​ Motion of Machine Parts:

The motion of machine parts dictates the overall functionality of the machine. For instance, a
piston in an engine performs a rectilinear motion, while gears in a gearbox exhibit rotary motion.
Other machines, like conveyor belts, require constant velocity for smooth operation, while
cranes may need variable acceleration to lift and lower heavy loads safely. Understanding these
motions ensures that the components align with the desired mechanical behavior, optimizing the
system's efficiency and reliability.

3.​ Material Selection:

The choice of material directly affects the durability and performance of the machine. For
example, aluminum is lightweight and corrosion-resistant, making it ideal for aircraft parts, while
steel is preferred in building bridges due to its high tensile strength. In the case of marine
propellers, materials like bronze or stainless steel are chosen for their resistance to seawater
corrosion. Engineers must consider factors such as strength, weight, heat resistance, and
machinability when selecting materials for specific applications.

4.​ Form and Size:

The form and size of a part should be adequate to withstand the applied loads without
unnecessary material usage. For instance, the I-beam used in construction is shaped to provide
maximum strength with minimum weight. Similarly, the diameter of a bolt must be sufficient to
handle tensile forces without failure. Oversized parts increase material costs and weight, while
undersized parts may fail prematurely under stress. Judicious design ensures both safety and
cost-efficiency.

5.​ Friction and Lubrication:

Friction can cause significant energy losses and wear in machine components. For instance, the bearings
in a car wheel must be properly lubricated to reduce friction and improve efficiency. Without lubrication,
the friction during startup is higher than during regular operation, potentially leading to overheating or
wear. Proper selection of lubricants, such as oil for high-speed engines or grease for slow-moving gears,
is essential to extend the life of machine parts and improve performance.

_____________________________________________________________________________________________________
Prepared by: Assoc. Prof. Anthony James C. Bautista, PME, MBA, PhD
2025
University of Santo Tomas​ ​ ​ ​ ​ Faculty of Engineering​
________________________________________________________________________________________________________

6.​ Convenient and Economic Features:

Machines should be designed with user convenience and cost-efficiency in mind. For example,
the levers of a lathe machine are positioned ergonomically to reduce operator fatigue. Similarly,
modular designs in modern equipment, such as agricultural tractors, allow easy replacement of
parts like blades or wheels. Economical designs also minimize waste during production and
focus on reusable or recyclable materials, ensuring both cost savings and environmental
sustainability.

7.​ Use of Standard Parts:

Utilizing standard parts, such as screws, nuts, and bearings, reduces production costs and
simplifies assembly. For example, gears used in bicycles are often standard sizes, making them
easy to replace. Custom parts may be unavoidable in specialized applications, but standard
components are generally preferred as they shorten manufacturing lead times and ensure
compatibility with existing tools and systems.

8.​ Safety of Operation:

Machines should be designed to prevent accidents and ensure operator safety. For example,
modern elevators have safety brakes to stop the cabin in case of cable failure. Similarly,
interlocks in washing machines prevent the lid from opening while the drum is spinning. Safety
devices, such as emergency stop buttons and guards around moving parts, protect users from
injuries and ensure compliance with safety regulations.

9.​ Workshop Facilities:

Designers must be familiar with the manufacturing facilities available. For instance, a workshop
with CNC machines can produce parts with higher precision compared to traditional manual
tools. Understanding these constraints allows engineers to create designs that can be efficiently
produced using the available tools and equipment, avoiding delays and additional costs for
outsourcing.

10.​Production Quantity:

The number of units to be manufactured influences the design process. For mass production,
like car manufacturing, designs should prioritize automation and cost efficiency. On the other
hand, for custom or low-volume products, like specialized medical devices, the design should
focus on precision and customization. For instance, injection molding is ideal for
mass-producing plastic parts, whereas 3D printing suits prototyping or low-volume production.

_____________________________________________________________________________________________________
Prepared by: Assoc. Prof. Anthony James C. Bautista, PME, MBA, PhD
2025
University of Santo Tomas​ ​ ​ ​ ​ Faculty of Engineering​
________________________________________________________________________________________________________

11.​Cost of Construction:

The cost of constructing a machine or component plays a critical role in its design. A high-cost
design may be impractical or non-viable for production. For example, if an engineer designs an
agricultural machine but the cost of materials and manufacturing is too high, farmers may not be
able to afford it. To ensure economic viability, the design process must minimize unnecessary
expenses while maintaining functionality. For mass production, like in the automobile industry,
investments in automated production lines are justified because large-scale production reduces
the cost per unit, making it commercially viable.

12.​Assembling:

The assembly process should be considered during the design phase. Each component of the
machine must be easily assembled to form the final product. For example, car assembly lines
are designed for maximum efficiency, where components are manufactured separately, tested,
and later assembled at the final production site. In large-scale machinery like wind turbines,
parts are often manufactured and tested in workshops before being transported and assembled
on-site. Engineers must anticipate challenges such as transportation constraints and local
assembly facilities to ensure seamless integration and operation.

_____________________________________________________________________________________________________
Prepared by: Assoc. Prof. Anthony James C. Bautista, PME, MBA, PhD
2025