ME 332 Machine Design and Cad I

Jawadullah

Lecturer

Mechanical Engineering Department

Chenab college of Engineering and Technology

Fall Semester 2017

 Machine Design

Machine Design
is an iterative process that has as its primary objective
the synthesis of machines in which the critical problems
are based upon material sciences and engineering
mechanics sciences.
This synthesis involves the creative conception of Increasing Stress

mechanisms, and optimization with respect to

performance, reliability and cost.
Machine design does not encompass the entire field
of mechanical engineering. Design where the critical
problems involve the thermal/fluid sciences fall under
the broader category of mechanical engineering
Finite element model of a pickup
design. truck floorpan assembly

The primary objective of machine design is synthesis,

or creation, not analysis. Analysis is a tool that serves
as a means toward an end.
The Traditional Design Process
 Preliminary Design Phase

Often the first step in which a designer becomes involved,

and may not involve intense iteration. In this phase, we
deal with the entire machine:
Define function
Identify constraints involving cost, size, etc. Concept 1 Two longitudinal members, one trans-verse
split-end cross member, small transverse member in
transmission tunnel, rear transverse member similar to

Develop alternative conceptions of original, gauge reduction.

mechanism/process combinations that can satisfy the

constraints
Perform supporting analyses (thermodynamic, heat
transfer, fluid mechanics, kinematics, force, stress,
life, cost, compatibility with special constraints)
Select the best mechanism Concept 6 Two integrated, split transverse cross
members, rear transverse member similar to original,
reduced sheet thickness in cross members.

Document the design

Alternative design concepts for cross members
in a light-duty truck floorpan assembly
 Intermediate Design Phase

Generally occurs after preliminary design, but the two

phases may overlap. Intermediate design always involves
iterations. In this phase, we deal with individual
components of the machine:
Identify components
Define component functions
Front

Identify constraints involving cost, size, etc. Reinforcement

Develop tentative conceptions of the components

mechanism/process combinations using good form Corner
Reinforcement
synthesis principles
Perform supporting analyses (including analyses at A-pillar component geometries
each critical point in each component)
Select the best component designs
Document component designs; prepare a layout
drawing
 Detail Design Phase

Subsequent to intermediate and. In this phase,

we deal with individual components of the
machine and the machine as a whole:
Select manufacturing and assembly
processes
Specify dimensions and tolerances
Prepare component detail drawings
Prepare assembly drawings Line rendering of a pickup box assembly showing
geometric details such as wheel well openings,
cross members, and bed corrugation

Lecture material in this course focuses on the preliminary and intermediate

phases. The design projects will involve elements of detail design
 Design Considerations

The design of a component or system may be influenced by a number of requirements.

If a requirement affects design, it is called a design consideration. For example, if the
ability to carry large loads without failure is important, we say that strength is a design
consideration. Most product development projects involve a number of design
considerations:

- Strength/stress - Cost - Thermal properties

- Distortion/stiffness - Processing requirements - Surface finish
- Wear - Weight - Lubrication
- Corrosion - Life - Marketability
- Safety - Noise - Maintenance
- Reliability - Aesthetic considerations - Volume
- Friction - Shape - Liability
- Usability/utility - Size - Scrapping/recyclability
 Standards and Codes

Standards and codes represent a prescriptive approach to design that may be

incorporated into a design process.
Standards
A set of technical definitions and guidelines for designers and manufacturers.
Standards are written by experts and are considered voluntary. ASME
groups develops and maintains standards using committees.
Code
A set of standards that has been adopted by one or more governmental
bodies or incorporated into a contract. Essentially, a code is a set of standards
with the force of law behind it.
According to its web site, ASME maintains and distributes 600 codes and
standards used around the world for the design, manufacturing and installation of
mechanical devices.
 ASME Standards and Codes Related to Standardization

A112 Plumbing Materials and Equipment

B1 Screw Threads
B5 Machine Tools - Components, Elements, Performance, and Equipment
B18 Standardization of Fasteners
B29 Chains, Attachments and Sprockets for Power Transmission and Conveying
B32 Metal and Metal Alloy Wrought Mill Product Nominal Sizes
B40 Standards for Pressure and Temperature Instruments and Accessories
B46 Classification and Designation of Surface Qualities
B47 Gage Blanks
B73 Chemical Standard Pumps
B89 Dimensional Metrology
B94 Cutting Tools, Drivers, and Bushings
B107 Hand Tools and Accessories
B133 Gas Turbine Procurement
HST Overhead Hoists
MFC Measurement of Fluid Flow in Closed Conduits
MH1 Pallets, Slip Sheets, and Other Bases For Unit Loads
SRB Slew Ring Bearing
STS Steel Stacks
Y14 Engineering Drawing and Related Documentation Practices
 ASME Standards for Screw Threads (1)

B1.1-1989 Unified Inch Screw Threads (UN and UNR Thread Form)
B1.2-1983 (R1991) Gages and Gaging for Unified Inch Screw Threads
B1.3-1992 Screw Thread Gaging Systems for Dimensional Acceptability Inch and Metric
Screw Threads (UN, UNR, UNJ, M, and MJ)
B1.5-1997 Acme Screw Threads
B1.7M-1984 (R1992) Nomenclature, Definitions and Letter Symbols for Screw Threads
B1.8-1988 (R1994) Stub Acme Screw Threads
B1.11-1958 (R1994) Microscope Objective Thread
B1.12-1987 (R1998) Class 5 Interference-Fit Thread
B1.13M-1995 Metric Screw Threads M Profile
B1.15-1995 Unified Inch Screw Threads
B1.16M-1984 (R1992) Gages and Gaging for Metric M Screw Threads
B1.20.1-1983 (R1992) Pipe Threads, General Purpose (Inch)
B1.20.7-1991 (R1998) Hose Coupling Screw Threads (Inch)
B1.21M-1997 Metric Screw Threads MJ Profile
B1.22M-1985 (1992) Gages And Gaging Practice For "MJ" Series Metric Screw Threads
B1.30M-1992 Screw Threads Standard Practice for Calculating and Rounding Dimensions
 ASME Standards for Screw Threads (2)

B1.1-1989 Unified Inch Screw Threads (UN and UNR Thread Form)

Scope: This Standard specifies the thread form, series, class, allowance, tolerance,
and designation for unified screw threads. (In order to emphasize that unified screw
threads are based on inch modules, they may be denoted unified inch screw threads.)
Several variations in thread form have been developed for unified threads; however,
this Standard covers only UN and UNR thread forms.

For easy reference, a metric translation of this Standard has been incorporated as
Appendix C. Appendices A through C contain useful information that is supplementary
to the sections of this Standard.

Order No. M020889 $55.00

 ASME Standards for Screw Threads (3)

B1.7M-1984 (R1992) Nomenclature, Definitions and Letter Symbols for Screw Threads

Scope: The purpose of this Standard is to establish uniform practices for standard
screw threads with regard to the following:

a. Screw thread nomenclature, and

b. Letter symbols for designating features of screw threads for use on drawings, in
tables of dimensions which set forth dimensional standards and in other records,
and for expressing mathematical relationship.

This Standard consists of a glossary of terms, and illustrated table showing the
application of symbols, and a table of thread series designations. Many of the terms
and symbols specified in this Standard vary considerably from those of previous issues
because ISO terms and symbols have been adopted where the intended definition is
the same.

Order No. L00011 $32.00

 Economics

Strength, safety, reliability, and cost are perhaps the most important design
considera-tions. In general the design alternative that satisfies other design
considerations at the lowest costs is to be preferred. Issues affecting the
cost of a design include:

Product development costs

Material choice
Manufacturing processes involved
Economies of scale
Tolerances specified
Use of standard sizes and
components

Breakeven point for two different screw manufacturing processes

 Safety and Reliability

Safety is paramount, most importantly because it is an ethical issue. Safety is

also related to function. Safe designs tend to function well and perform
reliably.

The United States law recognizes the concept of strict reliability. The
manufacturer of a product is responsible for any damage or harm that arises
due to a defect in the product. It doesnt matter how long after manufacture
the damage occurs, or if the defect is due to a design flaw or manufacturing
error. Negligence does not have to be proven. A plaintiff only has to establish
that the product was defective and that the defect caused damage or harm.
 Uncertainty Inherent in Engineering Design

Sources of Uncertainty
Random variables associated with material processing result in strength
distributions that vary from sample to sample. Some samples will have
strengths greater than the specified value. Others hopefully a very few
will have strengths lower than the specified value.
Statistical scatter in critical dimensions specified into the design during
the detail design phase due to imperfections in manufacturing processes.
Approximations used in the analytical expressions used to perform
design calculations.
Inexact knowledge of the magnitude and tie history of external loads.
Effect of corrosion and wear on strengths.
 Dealing With Uncertainty (1)

Permissible Stress Method

Permissible stress in a design is based upon a fraction of material
strength. The actual fraction is based upon experience with successful
designs. Still used by civil engineers and for the design of weldments.
Design Factor Method
There is a difference between a design goal, which may be based upon
experience (often involving load) and design realization which is based
upon a specific failure criterion (often involving stress) quantified by a
strength value:

strength
all
nm
d
n design factor
m exponent in the load to strength relationsh ip
stress
 Dealing With Uncertainty (2)

Stochastic Design Factor Method

Stochastic means involving random variables, and uncertainty in strength
and stress can be statistically quantified.
The design factor equation can then be adapted to use to determine a
mean design factor. For a linear load stress relationship:

S
all
nd
n mean design factor
S mean strength
all mean allowable stress

Stochastic Method
Does not use a design factor. Based upon the concept of reliability, R:

0 R 1.0