Course outline for Machine Design Project I

Wachemo University
Department of Mechanical Engineering
Wachemo University

Course Title Machine Design Project I

Course Number MEng 3161
Prerequisite Machine Elements II, Mechanisms of Machinery
ECTS/Credit Hours 5/3
Target Group 3rd year Mechanical Eng’g Students
Class room Design room
Lecturer *Muluneh Mengesha* ;
Office Room_______
Consultation hr Wednesday 10:00 AM-12:00 AM

Course Description

Machine Design project I, a course, is mainly focus on a study of a design process of machines and
equipment. Practical approach on conceptual design, embodiment design, and design for manufacturing
and assembly for a practical design for typical machine design will be exercised on projected based
machine design. Further, operational characteristics and design features associated with pressure vessel
and simple workshop machine will be given as project work.

Course Objectives

On completion of this course students will:

 Be familiar with machine design process and concepts
 be familiar with technical approach of synthesizing, analyzing and optimizing different
machine element for practical machine design.
 be familiar with guide line for machine element design for manufacturing and assembly
 gain experience and confidence in applying machine design concepts for other machine
element or product;
 prepare a report for design on pressure vessel and a simple workshop machine

Activities
Week(s
Activities Expected outcome and Assignment
)
Getting started Student will prepare a report on a one of a
st
1 and  Lecture on simple workshop machine like: press machine,
2nd  General principle of machine design lifting machine, puller, pipe bender.
 Design for manufacturing Report should incorporate
 Design for assembly and  the specification of the machine
 Selected projects, simple workshop  main component of the machine
machine, jacks and pressure vessel element
 Demonstration on simple work shop  functional advantage of the component
machines  free sketch of the machine, and

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 Course outline for Machine Design Project I
components
3rd  Distribution for simple workshop  Each student will have a design specification
machine specification to student. for its project on simple workshop machine.
3rd and Concept generation  Students will submit their own alternative
4th  Identifying the basic machine element for solution for their project which will be
given designed machine. derived from their concept generation.
 Preparing a general layout of the
machine, in free hand sketch,  Submission date: 4th week,
4th and Idea finding (narrowing of ideas toward  Student submit their design project overall
5th feasible solutions) from proposed alternative layout using free sketch
design  Submission date: 4th week,
6th Geometry analysis for the machine respect to Report on the geometric analysis of their
the given specification. machine
7th and  Force and strength analysis for basic  Report on the system force in the machine
8th machine element  Report on strength analysis of their machine
 Selection for materials for basic element elements
9th Design and selection for standard machine Report on selected standard machine elements
elements
10th Design for manufacturing and assembly
11th Finalizing Submission for final report on simple
workshop machine, part and assembly
drawing [70% of total]
12th  Distribution for pressure vessel  Each student will have a design specification
specification to student. for its project on simple workshop machine.
12th Geometry analysis for the machine respect to Report on given assignment is submitted
the given specification.
13th  Force and strength analysis for pressure  Report on the system force in the machine
vessel body and support.  Report on strength analysis of their machine
 Selection for materials for basic element elements
14th Design and selection for standard machine Report on selected standard machine elements
elements
15th Finalizing Submission for final report on pressure
vessel, part and assembly drawing [30% of
the total]
16th Presentation

Attendance 
Minimum of 75% attendance during lecture and tutorial hours
Requirement 
100% attendance during practical work sessions, except for some unprecedented
mishaps
Assessment / Project 1: Simple workshop machine Project 2: Pressure vessel design [30%]
Evaluation design [70%]
 Individual Assignment: 20%  Final reports & Presentation
 Progress report 20% 45%
 Assembly drawing 15%
Reference book J. E. Shigley, C. R. Mischke,& R. G. Budnas, Mechanical Engineering Design,7th

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 Course outline for Machine Design Project I
edition, McGraw-Hill, 2004,
Joseph Shigley, Charles Mischke, and Thomas H. Brown, Standard Handbook of Machine
Design, Jun 25, 2004.
Robert L. Norton, Machine Design: An Integrated Approach,3rd Edition, May 10, 2005.
Avallon, E.A., Marks’ Standard Handbook for Mechanical Engineers, Tenth Edition,
McGraw-Hill, 1997
Coulson and Richardson’s , Chemical Engineering Design, Volume 6, Second Edition,
Butterworth Heinemann, 1996

Machine Design
Engineers mostly defines engineering design as ‘‘the process of devising a system, component or
process to meet desired needs.’’ And it emphasizes that design is an iterative decision-making
process, in which natural sciences, mathematics, and applied sciences (engineering) are applied
to meet a stated objective in an optimal manner.

I. Design Process

One engineer might say engineering design starts with a need directly communicated by
customer or with an innovation idea developed by a research team that would lead to an
incremental improvement on the state of the art, or a totally new product and end with solution.
To design a good product with an optimum solution, it should pass through some design
processes. Hence, it is necessary to follow a basic design process.

What is the design process?

How does it begin?
Does the engineer simply sit down at a desk with a blank sheet of paper and jot
down some ideas?
What happens next?
What factors influence or control the decisions that have to be made?
Finally, how does the design process end?

The complete design process, from start to finish, is often outlined as in Fig. 1. The process
begins with an identification of a need and a decision to do something about it. After much
iteration, the process ends with the presentation of the plans for satisfying the need. Depending
on the nature of the design task, several design phases may be repeated throughout the life of the
product, from inception to termination.

Identifying customer need Definition of a problem

Synthesis

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 Prototyping Evaluation Presentation
Course outline for Machine Design Project I

Fig. 1 The phases in design

i. Identification of need, or Problem formulation, generally starts the design process.

Recognition of the need and phrasing the need often constitute a highly creative act,
because the need may be only a vague discontent, a feeling of uneasiness, or a sensing
that something is not right.

For example, the need to do something about a automatic screw driver may be indicated
by the torque level, by a variation in joint features, or easy for handling as many as many
screw driver sets.

Note: The process of customer-need identification must be carried without attempting to

develop product specifications.

ii. The definition of problem is more specific and must include all the specifications for the
object that is to be designed. The specifications are the input and output quantities, the
characteristics and dimensions of the space the object must occupy, and all the limitations
on these quantities.

The specifications define the cost, the number to be manufactured, the expected life, the
range, the operating temperature, and the reliability and other, as per the interest of
design engineer or product design team members. Specified characteristics can include
the speeds, feeds, temperature limitations, maximum range, expected variations in the
variables, dimensional and weight limitations, etc.

Anything that limits the designer’s freedom of choice is a constraint; the capacity of
manufacturing process and labor skills can be taken as an example.

Example for a specification for a power transmission

 Power to be delivered: 20 hp
 Input speed: 1750 rev/min
 Output speed: 85 rev/min
 Targeted for uniformly loaded application, such as conveyor belts, blowers, and
generator

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 Course outline for Machine Design Project I
 Output shaft and input shaft are in-line
 Continuous operation
 6-year life, with 8 hour/day, 5 day/week
 Low maintenance
 Competitive cost

iii. The synthesis of a proposal/plan connecting possible system elements is sometimes

called the invention of the concept or concept design. This is the first and most important
step in the synthesis task. Various proposals must be proposed, investigated, and
quantified in terms of established metrics.

iv. Detail analysis must be applied for formulated idea from the synthesis of the design
process. It helps to assess whether the system performance is satisfactory or better, and, if
satisfactory, just how well it will perform. Here, a mathematical models which is
scientifically believed to simulate real problem used for analysis. System proposals/idea
that does not survive analysis should be revised, improved, or discarded.

v. Further, systems with potential are optimized to determine the best performance of
which the proposal is capable. Competing proposals are compared so that the path
leading to the most competitive product can be chosen.

Note: Figure 1 shows that synthesis and analysis and optimization are thoroughly and
iteratively related. Thus, we may synthesize several components of a system, analyze and
optimize them, and return to synthesis to see what effect this has on the remaining parts
of the system.

vi. Evaluation is a significant phase of the total design process. Evaluation is the final proof
of a successful design and usually involves the testing of a prototype in the laboratory.
Here we wish to discover if the design really satisfies the needs. Is it reliable? Will it
compete successfully with similar products? Is it economical to manufacture and to use?
Is it easily maintained and adjusted? Can a profit be made from its sale or use? How
likely is it to result in product-liability lawsuits? And is insurance easily and cheaply
obtained? Is it likely that recalls will be needed to replace defective parts or systems?

vii. Communicating the design to others is the final, vital presentation step in the design
process. Undoubtedly, many great designs, inventions, and creative works have been lost
to posterity simply because the originators were unable or unwilling to explain their
accomplishments to others. Presentation is a selling job.

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 Course outline for Machine Design Project I
II. Design Consideration

Sometimes the strength required for an element in a system is an important factor in the
determination of the geometry and the dimensions of the element. In such a situation we say that
strength is an important design consideration.

Besides, when we use the expression design consideration, we are referring to some
characteristic that influences the design of the element or, perhaps, the entire system. Usually
quite a number of such characteristics must be considered and prioritized in a given design
situation. Many of the important ones are as follows

 Functionality  Safety  Life  Thermal

properties
 Strength/stress  Reliability  Noise  Surface
 Distortion/deflection/stiffne  Manufacturabil  Styling  Lubrication
ss ity
 Wear  Utility  Shape  Marketability
 Corrosion  Cost  Size  Maintenance
 Weight  Friction  Control  Liability

III. Allowable Stress and Safety Factor

The survival of many products depends on how the design adjusts the maximum stresses in
component to be less than the component’s strength at specific location of interest. The designer
must allow the maximum stress to be less than the strength by a sufficient margin so that despite
the uncertainties, failure us rare. Where the uncertainties might rose due to

 Composition of material and the effect of variation on properties

 Variations in properties from place to place within a bar of stock
 Effect of processing locally, or nearly by, on properties
 Effect of nearby assemblies such as weldments and shrink fits on stress conditions
 Effect of thermo mechanical treatment on properties
 Intensity and distribution of loading
 Validity of mathematical models used to represent reality
 Intensity of stress concentration
 Influence of time on strength and geometry
 Effect of corrosion
 Effect of wear

Suggested safety factors for uncomplicated work

A 1.25- for exceptional reliable materials used under controllable conditions and subjected
1.5 to loads and stresses that can be determined with certainty

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 Course outline for Machine Design Project I
B 1.5-2 For well know materials under reasonable constant environmental conditions
subjected to loads and stresses that can be determined readily
C 2-2.5 For average materials operated in ordinary environments and subjected to lads and
stress that can be determined
D 2.5-3 For less tried materials or for brittle materials under average condition of
environment, load and stress
E 3-4 For untried materials used under average condition of environment, load and stress
F Repeated loads: the factor established in items 1 to 6 are acceptable but must be
applied to the endurance limit rather than to the yield strength of the material
G Impact load: the factors given in terms 3 to 6 are acceptable

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 Course outline for Machine Design Project I
IV. Material Selection

The choice of the material to be used for component /product depends on many things. The most
important thing is to know and understand the properties of engineering materials so that we can
search for suitable one for our designed or developed component or product. Herewith, a list of
materials properties that we might require to be familiar with

Mechanical Property Thermal properties

i. Modulus i. Melting point,
a. Elastic(E) ii. Thermal expansion
b. Shear(G) iii. Maximum services temperature
ii. Poisson’s ratio iv. Processing temperature
iii. Ductility - % elongation and area v. Deterioration at high temperature
reduction Electrical Property
iv. Strength ii. Resistivity
a. Tensile iii. Permittivity
b. Compressive Suitable for method of manufacturing
c. Shear i. Machine ability
v. Hardness ii. Weld ability
a. Brinell iii. Ability to be hot an d cold rolled
b. Rockwell iv. Ability to be drawn
vi. Malleability v. Ability to be forging
vii. Impact strength vi. Ability to be cast
a. Brittleness vii. Surface finish and appearance
b. Toughness
c. Notch sensitivity
viii. Fatigue properties
ix. Creep properties
x. Density
xi. Porosity
xii. Coefficient of friction
xiii. Corrosion resistance
xiv. Resistance to oxidation
xv. Stability of properties when in services
Design Consideration for Material Selection

The design engineer has a very large say in the choice of materials. Some of the things that
should be considered in the design process are outline below.

Strength: the component/product must not fail under the action of expected stress and forces
during its intended life span. Strength can mean many things and care should be given for cases
like fatigue, corrosion and their like that had an influence of weakening material strength.

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 Course outline for Machine Design Project I
Elasticity: the elasticity of a component depends on its modulus and attention for the
relationship between elastic, shear and bulk modulus along with Poisson’s ratio fir design
component material should be given.

Degradation: the material must not become degraded due to service or environmental factors
because it will reduce its intended life span. There are many thing that cause a material to
degrade such as corrosion, wear, and chemical attach and radiation.

Wear: it is a form of degradation due to surface rubbing together. The designer needs to
understand Tribology(friction and wear of rubbing surface). He must select materials with
suitable compatibility and wear resistance.

Surface finish:

The final treatment of manufactured parts is called the finishing process. These processes
enhance the physical properties of the surface material. Some machining processes shot lasting,
place the surface into compression and so prevent the propagation of crack. Polishing for
example remove fine surface cracks and improves the fatigue life of the components. Coating,
chrome panting, the surface may produce a hard surface. In general, surface finishing process
able to

 Protect the component/product surface from corrosion and other chemical attacks
 To enhanced physical surface properties
 To produce an attractive appearance

Choice of manufacturing: the cost of producing the components is always a big factor and the
designer must consider how the components/ product is manufactured. To large extent, the
manufacturing process is governed by the material. Beside, size, shape and quantity also had an
influence on selection of manufacturing process.

The mechanical properties of the finished component are affected by the manufacturing method.
For example a crankshaft is better than turning one because it produces a grain flow that makes it
stronger and more resistance to fatigue failure. Grinding and polishing also produce better
fatigue strength.

Here are list of manufacturing processes

With material removal Without removing material

 Turning, milling, drilling, shaping,  Casting, forging, drawing, bending,
broaching, etc pressing, etc

The tolerance on the finished size also governs the method. Casing and moulding does not
produce a high tolerance and generally materials removal is the best way to produce an accurate
size or fit. Eg. Grinding the outer and inner ring of a bearing race

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 Course outline for Machine Design Project I
Weldability: clearly any structured design for welding must be suitable for that process and the
weldability of the materials is an important consideration. Arc resistance may be also be
consideration.

Cost: the cost of the product depends on the design and manufacturing as covered in the
preceding work. In addition costs depend on the following.

 Raw material: when more than one material meets the required specifications, the
cheapest materials would be logically chosen and these depend largely on the price of the
raw material. For example copper us expensive as related with Aluminum, hence
tendency to make electrical conductor from Aluminum increase even though the cable
diameter has to be increased to meet the resistance criteria.
 Availability: again if more than one material meets the required specification, the final
choice of material may depend on the availability and the one most readily available
would be chosen.
 Quantity: the price of materials may well depend on contractual arrangement with
discount for quantities and regularity of orders.
 Storage: the material to be used and the end product may have to be stored and
transported so that material must not degrade whilst in storage.

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 Course outline for Machine Design Project I

Addis Ababa University

Institute of Technology
Department of Mechanical Engineering

Course Title Machine Design Project II

Course Number MEng 4131
Prerequisite Machine Design Project I
ECTS/Credit Hours 5/3
Target Group 4th year Mechanical Eng’g Students
Class room 310 and design room
Lecturer Muluneh Mengesha
Office Room 348
Consultation hr Friday 9:30AM-11:30AM

Course Description

Machine Design project II, a course, focus on a study of an operational characteristics and design features
associated with power transmission mechanism which mostly used in industrial, Agro construction and
their like machineries. Further, it is project based course supported with a workshop practice on assembly
and disassembly of power transmission product and educational visit.

Course Objectives

On completion of this course students will:

 understand important machine design concepts
 be able to examine the functional requirements of selected transmission mechanism of
machinery and understand the role of the engineer in design of this products and their likes;
 be able to examine and analyze specific element and/or components of transmission
mechanism machinery;
 gain experience and confidence in applying machine design concepts for other machine
element or product;
 complete a design and prepare a report for design of transmission mechanism of machine to
gain an understanding and appreciation for the conceptualization, synthesis, analysis, and
evaluation steps of the design process.

Activities
Week( Activities Expected output; assignment
s)
1st Getting started An individual report on vehicle gear
 Lecture on box(VGB):
 General principle of machine Report should have an entities of
design  cover page
 Design for manufacturing  introduction/background
 objective
 Design for assembly and
 discussion on type of VGB,
 Vehicle gear box, a power
difference and similarities,
transmission system

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 Course outline for Machine Design Project I
working mechanisms,
identification of main components,
procedure of vehicle gear box
design
 conclusion and reference
2nd  Exercise eon assembly and  Students are expected to form group
disassembly of an industrial gear which compose maximum of four
box model members to do the set design
 Distribution of student project specification on vehicle manual
design specification, for grouped transmission gear box project.
member  Team will have a design
specification for its project.
3rd Concept generation
 Identifying the basic machine Students will submit their alternative
element of a given power solution derived from their concept
transmission design project. generation for their project.
 Preparing general layout for the
given design project with set Submission date: 3rd week, 2nd class
specification using free hand
sketch.
4th Idea finding (narrowing of ideas toward Student submit their design project overall
feasible solutions) from proposed layout using free sketch
alternative design Submission date: 4th week, 2nd class
5th Gear geometry analysis
 5th week 1st class :- individual work
on post given assignment from set Report on given assignment is submitted
project
 5th week 2nd class :- Group work
on the project
6th Force and strength analysis for basic
and element
7th Selection for materials for basic element
8th Design and selection for standard
machine elements
9th Designing housing, lubricant and cooling
system
10th Design for manufacturing and assembly
11th Finalizing and presentation Submission for final report, part and
assembly drawing

Attendance  Minimum of 75% attendance during lecture and tutorial hours

Requirement  100% attendance during practical work sessions, except for some unprecedented
mishaps
 Presence during industrial visit session/sessions
Assessment /  Individual Assignment:  Final report 30

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 Course outline for Machine Design Project I
Evaluation 10 %, %.
 Assembly and disassembly exercise  Part and assembly drawing 20%
5%  Presentation 10%
 Educational visit report :
5%
 Progress report
20%
Reference book Robert C. Juvinall and Kurt M. Marshek, Fundamentals of Machine Component Design,
Aug 2, 2005
Joseph Shigley, Charles Mischke, and Thomas H. Brown, Standard Handbook of Machine
Design, Jun 25, 2004.
Robert L. Norton, Machine Design: An Integrated Approach (3rd Edition), May 10, 2005.
Arthur H. Burr & John B. Cheatham, Mechanical Analysis and Design (2nd Edition), Mar
2, 1995
Avallon, E.A., Marks’ Standard Handbook for Mechanical Engineers, Tenth Edition,
MacGraw-Hill, 1997

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 Course outline for Machine Design Project I

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