Modelling: models (types, role in engineering design, mathematical modeling, similitude and scale models), finite element modeling and analysis
Optimization techniques: differential calculus, search methods, multivariable search methods; linear and geometric programming, multifactor objective functions
Product Design Considerations (6 hours)
Design for Manufacture and Assembly
Design for Reliability and Safety
Design for Quality and Robustness
Design for Testing
Design for Sustainability
Risk, reliability and safety: risk and society, probabilistic approach to design, reliability theory (failure rates, system reliability), hazard analysis and fault tree analysis
Design of Springs (8 hours)
Stresses in a helical spring
Deflection of a helical spring
Extension and compression springs
Spring materials: estimation of tensile strength and torsional yield strength
Design of helical spring: critical frequency
Fatigue loading
Belleville spring
Helical torsion spring
Leaf spring
Energy storing capacity of a spring
Design of Spur and Helical Gears (12 hours)
Lewis's bending equation
Surface durability
AGMA stress and strength equations
Geometry factors, elastic coefficient and various factors affecting gear performance (dynamic, overload, surface condition, size, load distribution, hardness ratio, stress-cycle, reliability, temperature and rim-thickness factors)
Safety factors
Design of gear mesh
Design of Clutches and Brakes (10 hours)
Internal expanding rim clutches and brakes
External expanding rim clutches and brakes
Band-type clutches and brakes
Frictional contact axial clutches
Cone clutches and brakes
Energy consideration and temperature rise
Frictional material
Design of Power Screws (5 hours)
Power screws, forms of threads, multiple threaded screws, terminology
Torque requirement for lifting and lowering loads, self-locking of screws
Efficiency of power screws, collar friction torque, overall efficiency and coefficient of friction
Practicals
Solving problems related to the design of springs using computational tools
Computing problems related to the design of gear mesh (spur and helical) using computational tools
Computing problems related to the design of clutches and brakes using computational tools
Computing problems related to the design of power screws using computational tools
Evaluation
Final exam questions cover all chapters. Approximate marks distribution (total 60 marks over 45 hours):
Modelling and Optimization, Product Design Considerations: 14 marks
