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ENME353

Machine Design I

Syllabus

  1. Introduction (2 hours)
    1. Fundamental concept of machine design
    2. Basic steps in the design and synthesis process: identification of need, problem definition, collection of relevant information and functional requirements, concept development, evaluation of design alternatives, design communication, feedback from manufacturers and users
    3. Communicating the design: engineering drawings and CAD, graphs and charts
  2. Material Selection for Design (2 hours)
    1. Materials properties
    2. Economics of materials
    3. Evaluation criteria for materials selection
    4. Cost versus performance relations
    5. Cost and value analysis
  3. New Product Design (2 hours)
    1. Feasibility studies and assessment
    2. Preliminary design development
    3. Detailed design and engineering analysis
    4. Planning for manufacturing, distribution and product usage
    5. Planning for product retirement and end-of-life handling
  4. Problem Solving and Decision Making (2 hours)
    1. Problem-solving process and techniques
    2. Invention and ideation methods
    3. Brainstorming
    4. Problem definition: needs, goals, constraints, compromises, conditions and evaluation criteria
    5. Problem-solving stages: preparation, incubation, inspiration and verification
    6. Decision matrix method and decision tree analysis
  5. Design of Shafts (12 hours)
    1. Shafts and fatigue failure
    2. Stress-life method and the S-N diagram
    3. Design for static loads
    4. Endurance limit and modifying factors
    5. Stress concentration and notch sensitivity
    6. Characterizing fluctuating stresses: completely reversed stress, fluctuating stress between unequal values, fluctuating stress in the same sign
    7. Combination of loading modes (axial, bending and torsion)
    8. Failure criterion (Gerber, Soderberg and Goodman)
  6. Rolling Contact Bearings (6 hours)
    1. Bearing types and their classification
    2. Bearing life, load-life relationship and reliability-life relationship using the Weibull distribution
    3. Combined radial and thrust loading in bearings
    4. Bearings under variable loading conditions
    5. Selection of ball and cylindrical roller bearings
    6. Selection of tapered roller bearings
  7. Lubrication and Journal Bearings (4 hours)
    1. Types of lubrication, viscosity and viscosity charts
    2. Petroff's law and stable lubrication (thick film lubrication)
    3. Hydrodynamic lubrication theory
    4. Design considerations for journal bearings
    5. Minimum film thickness, coefficient of friction, lubricant flow, film pressure and temperature rise
  8. Design of Flexible Mechanical Elements (10 hours)
    1. Flat belts
    2. V-belts
    3. Timing belts
    4. Chain and sprocket drive
    5. Wire rope
  9. Force Analysis of Gears (5 hours)
    1. Basic concepts of gears: types, nomenclature, involute properties, conjugate action, contact ratio, interference, gear tooth formation, tooth systems and gear trains
    2. Force analysis
    3. Spur gearing
    4. Helical gearing
    5. Bevel gearing
    6. Worm gearing

Practicals

  1. Problems related to the design of shafts (iterative design problems), covering shaft layout using computational tools
  2. Problems related to the design of rolling contact bearings (iterative design problems) using computational tools
  3. Problems related to the design of journal bearings (iterative problems concerned with temperature rise) using computational tools
  4. Problems related to the design of flexible mechanical elements (multi-options design problem) using computational tools
  5. Problem on a simple power transmission system design comprising shafts, bearings and flexible mechanical elements

Evaluation

Final exam questions cover all chapters. Approximate marks distribution (total 60 marks over 45 hours):

  1. Introduction and Material Selection for Design: 6 marks
  2. New Product Design and Problem Solving and Decision Making: 6 marks
  3. Design of Shafts: 16 marks
  4. Rolling Contact Bearings: 8 marks
  5. Lubrication and Journal Bearings: 5 marks
  6. Design of Flexible Mechanical Elements: 12 marks
  7. Force Analysis of Gears: 7 marks