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AENG 60
Machine Design I
Machine Design
Process
ENGINEERING
“a profession concerned primarily with
the application of a certain body of
knowledge, set of skills, and point of
view in the creation of devices,
structures, and processes used to
transform resources to forms which
satisfy the needs of society”
-Standard Handbook of Machine Design
KINEMATIC CHAIN
- is an assemblage of links, or rigid
bodies, that are connected by joints.
(Tsai, 2000)
What is Machine Design?
First, we must define:
-ENGINEERING
-ENGINEERING DESIGN
-KINEMATIC CHAIN
-MECHANISM
-MACHINE
ENGINEERING DESIGN
- ‘design’ comes from the Latin
‘designare’, which means to designate or
mark out. (Childs, 2004)
- “It is the process of applying the
various techniques and specific
principles for the purpose of defining a
device, a process or a system in
sufficient detail to permit its physical
realization.” (Norton, 2004)
MECHANISM
- system of elements arranged to
transmit motion in a predetermined
fashion (Norton, 2004)
- a kinematic chain in which at least one
link has been ‘grounded’ or ‘attached’ to
the frame of reference (which itself may
be in motion). (Tsai, 2000)
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When we design,
MACHINE We specify
- combination of mechanisms and other -Configuration / shape / arrangement
components that transforms, transmits,
or uses energy, load, or motion for a
specific purpose.

- “assemblage of several components for

the purpose of transforming external
energy into useful work” (Tsai, 2000)

When we design, When we design,

We specify We specify
-Size / dimension -Materials

Budynas-Nisbett,
2008

e.g. Diameter, length, thickness, height, gauge number, etc

e.g. Metals, plastics, wood, ceramics, etc

When we design, TALENTS AND BODIES OF KNOWLEDGE

We specify NEEDED BY A DESIGNER
-Manufacturing
• Knowledge, ability, talent to generate
processes to be used
ideas and/or possibilities
• Knowledge of how to evaluate and sort
“good” from “bad” ideas
• Knowledge of the structure of design
and how to tailor the process to the task
at hand
e.g. Welding/joining, machining, drilling, forming, etc

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THE DESIGN PROCESS (Shigley)
Budynas-Nisbett, 2008
THE DESIGN PROCESS (SCREW DRIVER)
DEFINITION OF PROBLEM
-More specific than identification of the need
-ALL specifications for the object to be
designed must be included
(input, output, characteristics, dimensions,
limitations)
THE DESIGN PROCESS (SCREW DRIVER)
SYNTHESIS
-“invention of the concept or concept design”
- concepts or ideas can be generated from
imagination or experiences
-Research is very useful in this stage
e.g.: review or survey of mechanisms for driving
screws or existing designs of screw drivers
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THE DESIGN PROCESS (SCREW DRIVER)
IDENTIFICATION OF NEED
-often constitute a highly creative act
-existence of a potential market for a
product, device or process
-re-engineering an existing machine
NEED: A device for tightening and/or
loosening screws easily and safely
THE DESIGN PROCESS (SCREW DRIVER)
DEFINITION OF PROBLEM
-Enumeration of design considerations
Problems for the SD:
-dimensions of the parts
-materials to be used
-intended users
-range of screw sizes that can be used
-type of screw tip
-color and configuration of the handle
-standards to be met
- etc...
THE DESIGN PROCESS (SCREW DRIVER)
ANALYSIS AND OPTIMIZATION
- Performed to assess whether the idea is
satisfactory, and if satisfactory, how well it
performed
-Concepts that do not survive analysis are
revised, improved, or discarded.
e.g.: computations of bit diameter, stress
analysis, etc
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THE DESIGN PROCESS (SCREW DRIVER)
ANALYSIS AND OPTIMIZATION
-Construction of mathematical models to
simulate the real physical system
-Prototyping can be done to aid in analysis
and optimization
e.g.: generation of equations to simulate
the screw tightening process, fabrication
of prototype
THE DESIGN PROCESS (SCREW DRIVER)
EVALUATION
- final proof of a successful design
- performed to confirm if the design really
satisfied the specifications
e.g.: actual testing of the product
THE DESIGN PROCESS (Shigley)
(Budynas-Nisbett, 2008)
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THE DESIGN PROCESS (SCREW DRIVER)
ANALYSIS AND OPTIMIZATION
- competing ideas are compared so that the
path leading to the most competitive product
can be chosen.
- compromises between and among the
desired criteria are made to arrive at the
optimum product
e.g.: comparison among different handle
designs
THE DESIGN PROCESS (SCREW DRIVER)
PRESENTATION
- a selling job
- written, oral, graphical
*Design is a communication-intensive activity
“You may be the cleverest person in the world but no one
will know that if you cannot communicate your ideas
clearly and concisely.” (Norton, 2004)
Typical Design Problem
Sison, 2008
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Typical Design Problem Characteristics of the Design Process

The design process is

Trans-disciplinary
e.g.
1. Large machines or systems require the collaborative efforts of
professionals of different backgrounds
2. To successfully design a rice mill, engineers should have
backgrounds in mechanical eng’g, agriculture, etc

Characteristics of the Design Process Characteristics of the Design Process

The design problems are, Sometimes ...

Almost always, open-ended. Design = “T A E”

- They do not have a unique or ‘‘correct’’
solution
- Some solutions will clearly be better than
others
Trial and Error
Ashby, 2005
Design is an iterative process.

Characteristics of the Design Process Design Considerations

-characteristics that influence the design of the
element or, perhaps, the entire system.
The design process is a
Functionality Utility Properties
Strength/ Stress Cost Surface
Decision-Making Process Distortion / Processing Lubrication
Deflection / Weight Marketability
-required in every step of the design process Stiffness Life Maintenance
-involves compromises among competing Wear Noise Volume
choices Corrosion Styling Liability
Safety Shape Scrapping /
-largely influenced by design considerations Reliability Size Recycling
Friction Control etc . . .
Usability Thermal (Budynas-Nisbett, 2008)

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Design Considerations

The
best
bolt
array
is ...

Design
Considerations Childs, 2004

Design Design Considerations

Considerations

VS.
VS.

Engine

Bolted Joint Welded Joint

Electric Motor

Design
Design
Considerations
Considerations
Hopper Design

Belt and Pulley VS. VS.

Gears
Galvanized Iron (GI) Sheet Black Iron (BI) Sheet

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Design Considerations Design Considerations

VS. VS.

SMAW OA Welding Painted GI/BI sheet Stainless sheet

Design Considerations Design Criteria

Functional – the product must perform to fill
its intended need and customer expectations
Safe – the product is not hazardous to the
VS. user, bystander, or surrounding properties
Reliable – the product must perform its
intended function satisfactorily or without
failure at a given age
Stainless Knapsack Sprayer Plastic Knapsack Sprayer
Competitive – the product is a contender in
QUIZ #2. Which is better? Justify your its market
answer.

Design Criteria Useful Rules in Design

Usable – the product is “user-friendly”,
accommodating to human size, strength, 1. “QUANTIFY WHEREVER POSSIBLE”
posture, reach, force, power, and control
Childs, 2004
Manufacturable – the product has been
reduced to a “minimum” number of parts,
suited for mass production, with dimension, 2. “KISS”
distortion, and strength under control Keep It Simple, S2p!d
Marketable – the product can be bought, and
service (repair) is available MDShrock, AENG 160, 2006

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Engineer’s 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. (National Society of Professional Engineers)
ENGR. RALPH KRISTOFFER B. GALLEGOS
INSTRUCTOR-IN-CHARGE
OFFICE: Agricultural Machinery Division
IAE, CEAT, UPLB
CONTACT: (049) 536-2792
09157703713
rkbgallegos@yahoo.com
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References
AMD-IAE. 2010. AENG 60 Handouts. CEAT, UP Los Banos.
Ashby, MF. 2005. Material Selection in Mechanical Design. United
Kingdom: Elsevier, Ltd.
Budynas-Nisbett. 2008. Shigley’s Mechanical Engineering Design, 8th
ed. USA: McGraw Hill Companies, Inc.
Childs, PRN. 2004. Mechanical Design, 2nd ed. United Kingdom:
Elsevier, Ltd.
Hurst, KS. 1999. Engineering Design Principles. New York: Elsevier, Ltd.
Norton, RL. 2004. Design of Machinery, 3 rd ed. New York: McGraw Hill.
Shigley, JE and CR Mischke. 1996. Standard Handbook of Machine
Design, 2nd ed. New York: McGraw Hill.
Sison, L. 2011. Innovating ERDT. Powerpoint Presentation. Iligan City:
Engineering Research and Development for Technology.
Tsai, LW. 2000. Mechanism Design: Enumeration of Kinematic
Structures According to Function. Florida, USA: CRC Press.