Chapter Outline

Shigley’s Mechanical Engineering Design

 What is Design?
 To formulate a plan for the satisfaction of a specified need
 Process requires innovation, iteration, and decision-making
 Products should be

◦ Functional
◦ Safe
◦ Reliable
◦ Competitive
◦ Usable
◦ Manufacturable
◦ Marketable

Shigley’s Mechanical Engineering Design

 Mechanical Engineering Design
 Mechanical engineering design involves all the disciplines of
mechanical engineering.
 Example

◦ Journal bearing: fluid flow, heat transfer, friction, energy

transport, material selection, thermomechanical treatments,
statistical descriptions, etc.

Shigley’s Mechanical Engineering Design

 The Design Process

 Iterative
in nature
 Requires initial estimation,
followed by continued
refinement

Shigley’s Mechanical Engineering Design

 Identification of Need
 Understand the problem
 Carefully read, understand and refine the problem statement

Shigley’s Mechanical Engineering Design

 Definition of Problem
 Problem definition is most significant step in the engineering
design process
 Identify the known and unknown parameters.
 Formulate the refined problem statement

Shigley’s Mechanical Engineering Design

 Synthesis
 State what must be determine to arrive at a solution to the
problem.
 Sketch the components or system
 Create a flowchart of the steps necessary to reach the final
solution.
 The step may be: Free body diagram, Material properties,
equations from the text, etc.
 State all assumptions
 Conceptual design
 Alternate design

Shigley’s Mechanical Engineering Design

 Analysis
 Using your solution strategy, analysis the problem using exact
equation or numerical tools.
 References all sources of equations, tables, charts, software
results, etc.
 Analytical or numerical (FEA) analysis of design to meet
standards requirement
 If not meet standards, redesign the product
 If meet requirements, go for evaluation (prototype testing

Shigley’s Mechanical Engineering Design

 Evaluation

Prototype testing:
Actual test of the product to check whether it pass or fail

Presentation:
Present the product for marketing and production

Shigley’s Mechanical Engineering Design

 Design Considerations

 Some characteristics that influence the design

Shigley’s Mechanical Engineering Design

 Computational Tools
 Computer-Aided Engineering (CAE)
◦ Any use of the computer and software to aid in the
engineering process
◦ Includes
 Computer-Aided Design (CAD)
 Drafting, 3-D solid modeling, etc.
 Computer-Aided Manufacturing (CAM)
 CNC toolpath, rapid prototyping, etc.
 Engineering analysis and simulation
 Finite element, fluid flow, dynamic analysis, motion, etc.
 Math solvers
 Spreadsheet, procedural programming language, equation solver,
etc.

Shigley’s Mechanical Engineering Design

 A Few Useful Internet Sites

 www.globalspec.com
 www.engnetglobal.com
 www.efunda.com
 www.thomasnet.com
 www.uspto.gov

Shigley’s Mechanical Engineering Design

 The Design Engineer’s Professional Responsibilities

 Satisfy the needs of the customer in a competent, responsible,

ethical, and professional manner.
 Some key advise for a professional engineer

◦ Be competent
◦ Keep current in field of practice
◦ Keep good documentation
◦ Ensure good and timely communication
◦ Act professionally and ethically

Shigley’s Mechanical Engineering Design

 Ethical Guidelines for Professional Practice
 National Society of Professional Engineers (NSPE) publishes a
Code of Ethics for Engineers and an Engineers’ Creed.
 www.nspe.org/ethics
 Six Fundamental Canons
 Engineers, in the fulfillment of their professional duties, shall:
◦ Hold paramount the safety, health, and welfare of the public.
◦ Perform services only in areas of their competence.
◦ Issue public statements only in an objective and truthful
manner.
◦ Act for each employer or client as faithful agents or trustees.
◦ Avoid deceptive acts.
◦ Conduct themselves honorably, responsibly, ethically, and
lawfully so as to enhance the honor, reputation, and usefulness
of the profession.

Shigley’s Mechanical Engineering Design

 NSPE Engineers’ Creed
 As a Professional Engineer I dedicate my professional
knowledge and skill to the advancement and betterment of
human welfare.
 I pledge:

◦ To give the utmost of performance;

◦ To participate in none but honest enterprise;
◦ To live and work according to the laws of man and the highest
standards of professional conduct;
◦ To place service before profit, the honor and standing of the
profession before personal advantage, and the public welfare
above all other considerations.
 In humility and with need for Divine Guidance, I make this
pledge.

Shigley’s Mechanical Engineering Design

 Standards and Codes
 Standard

◦ A set of specifications for parts, materials, or processes

◦ Intended to achieve uniformity, efficiency, and a specified
quality
◦ Limits the multitude of variations
 Code

◦ A set of specifications for the analysis, design, manufacture,

and construction of something
◦ To achieve a specified degree of safety, efficiency, and
performance or quality
◦ Does not imply absolute safety
 Various organizations establish and publish standards and codes
for common and/or critical industries

Shigley’s Mechanical Engineering Design

 Standards and Codes
 Some organizations that establish standards and codes of
particular interest to mechanical engineers:

Shigley’s Mechanical Engineering Design

 Economics
 Cost is almost always an important factor in
engineering design.
 Use of standard sizes is a first principle of cost
reduction.
 Table A-17 lists some typical preferred sizes.
 Certain common components may be less expensive
in stocked sizes.

Shigley’s Mechanical Engineering Design

 Tolerances
 Close tolerances generally
increase cost
◦ Require additional
processing steps
◦ Require additional
inspection
◦ Require machines with
lower production rates

Shigley’s Mechanical Engineering Design

 Breakeven Points
 A cost comparison between two possible production methods
 Often there is a breakeven point on quantity of production

EXAMPLE
 Automatic screw
machine
 25 parts/hr
 3 hr setup
 $20/hr labor cost
 Hand screw machine
 10 parts/hr
 Minimal setup
 $20/hr labor cost
 Breakeven at 50 units

Shigley’s Mechanical Engineering Design

 Stress and Strength
 Strength

◦ An inherent property of a material or of a mechanical element

◦ Depends on treatment and processing
◦ May or may not be uniform throughout the part
◦ Examples: Ultimate strength, yield strength
 Stress

◦ A state property at a specific point within a body

◦ Primarily a function of load and geometry
◦ Sometimes also a function of temperature and processing

Shigley’s Mechanical Engineering Design

 Uncertainty
 Common sources of uncertainty in stress or strength

Shigley’s Mechanical Engineering Design

 Uncertainty
 Stochastic method
◦ Based on statistical nature of the design parameters
◦ Focus on the probability of survival of the design’s function
(reliability)
◦ Often limited by availability of statistical data

Shigley’s Mechanical Engineering Design

 Uncertainty
 Deterministic method
◦ Establishes a design factor, nd
◦ Based on absolute uncertainties of a loss-of-function
parameter and a maximum allowable parameter

◦ If, for example, the parameter is load, then

Shigley’s Mechanical Engineering Design

 Design Factor Method
 Often used when statistical data is not available
 Since stress may not vary linearly with load, it is more common
to express the design factor in terms of strength and stress.

 All loss-of-function modes must be analyzed, and the mode with

the smallest design factor governs.
 Stress and strength terms must be of the same type and units.
 Stress and strength must apply to the same critical location in
the part.
 The factor of safety is the realized design factor of the final
design, including rounding up to standard size or available
components.

Shigley’s Mechanical Engineering Design

 Example 1-2

Solution

Answer

Answer

Shigley’s Mechanical Engineering Design

 Reliability
 Reliability,R – The statistical measure of the probability that a
mechanical element will not fail in use
 Probability of Failure, p – the number of instances of failures
f
per total number of possible instances

 Example: If 1000 parts are manufactured, with 6 of the parts

failing, the reliability is
or 99.4 %

Shigley’s Mechanical Engineering Design

 Reliability
 Series System – a system that is deemed to have failed if any
component within the system fails
 The overall reliability of a series system is the product of the
reliabilities of the individual components.
n
R   Ri (1-5)
i 1

 Example: A shaft with two bearings having reliabilities of 95%

and 98% has an overall reliability of
R = R1 R2 = 0.95 (0.98) = 0.93 or 93%

Shigley’s Mechanical Engineering Design

 Dimensions and Tolerances
 Nominal size – The size we use in speaking of an element.
◦ Is not required to match the actual dimension
 Limits – The stated maximum and minimum dimensions
 Tolerance – The difference between the two limits
 Bilateral tolerance – The variation in both directions from the
basic dimension, e.g. 1.005 ± 0.002 in.
 Unilateral tolerance – The basic dimension is taken as one of
the limits, and variation is permitted in only one direction, e.g.

Shigley’s Mechanical Engineering Design

 Dimensions and Tolerances
 Clearance – Refers to the difference in sizes of two mating
cylindrical parts such as a bolt and a hole.
◦ Assumes the internal member is smaller than the external
member
◦ Diametral clearance – difference in the two diameters
◦ Radial clearance – difference in the two radii
 Interference – The opposite of clearance, when the internal
member is larger than the external member
 Allowance – The minimum stated clearance or the maximum
stated interference or mating parts

Shigley’s Mechanical Engineering Design