JIMMA UNIVERSITY

JIMMA INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING

ENGINEERING DESIGN OF MECHANICAL

SYSTEMS DMS6034
ASSIGNMENT-2
GROUP-1
MEMBERS ID NUMBER
1. ABEL ERMIAS( REPRESENTAT IVE) RM7512/11
2. KEYRU SALIA RM7519/11
3. BILILIGN FREHUN RM7515/11
4. BRHANU HAILE RM7516/11

SUBMISSION DATE-JAN13,2019
SUBMITTED TO-DR.SEUNGWON YOUN
 Embodiment
1.1.Introduction

The detailed analysis is begun in the embodiment stage. It connects the concept selection
stage and the detail design stage of a design process. The input of an embodiment process is
developing an outline sketch which is dictated by PDS or other design requirement. Its output
is a well-defined scheme drawing which has an additional documentation such as
calculations, required tolerances and suggested material and manufacturing process, which
can be used as input to the detail design.

Input
-Outline sketch
-associated project controlling document

Embodiment

Process

Output
-Scheme drawing
-Documentation

Fig.1. Embodiment Process

The 3D representation is replaced by scheme drawing in the embodiment stage. This scheme
drawing is used during the detail analysis stage since the detail analysis stage does not need a
3D model. The embodiment stage involves a compromise between conflicting requirements.
This is because many actions must be performed simultaneously and the decisions made in
one area have a knock on effect elsewhere.

It is essential to make sure that the design proposal is optimum by checking it up periodically
and by eliminating the weak point of the design. The embodiment process is cyclic and
iterative in nature. It begins with making decisions during an overall layout and then it is
modelled, analyzed, synthesized and optimized. The layout is revised again and again or
more detail is added to the original layout and the embodied design is evaluated in a reference
to the functions and constraints in the PDS. The entire process is repeated over and over
again until the best compromise solution is maintained in the consideration of manufacturing
and assembly processes and material selection.
The embodiment process must contain the following elements:

 Constraint check  Form design

 Functions check  Provisional processes
 Provisional materials

Modelling

Evaluation Analysis

Embodiment
Process

Layout Synthesis

Optimization

Fig.2. The cyclic nature of embodiment process

The information from the value engineering is crucial to embodiment stage since it provides
information about cost and performance of alternative proposals to the design team. The
information is synthesized and leads to the development of optimum design proposal.

1.2.Steps of embodiment process:

 Size and Strength
 Scheme Drawing
 Form Design
 Provisional materials and process determination
 Design for assembly and manufacture
1.2.1. Size and Strength

It is required to explore the PDS in a relation to the function and constraints which have a
direct influence on the overall size and strength of a product.

1.2.2. Scheme Drawing

Scheme drawing includes all known parameters and all relative motions and a document of
tolerance and materials. Based on Standard and bought out parts and other influencing factor
more decision is made and more information is added to the scheme, so that the scheme is
frequently updated. As the scheme drawing is continually updated it helps to control the
knock on effect. The update is happening because the embodiment process needed to add
every new idea in each cycle. The scheme drawing is drawn with a scale and only very tight
tolerance dimensions are included.

1.2.3. Form Design

After having a required size and strength of a component and before beginning the modelling,
analysis and synthesis process, the shape and form must be determined to further analyze the
stress flow at any joint. While doing this the primary functions considered first and it is
needed to take in to account the manufacturing and assembly processes.

1.2.3.1.Factors to be considered in defining shape and form:

 Manufacturing process
 Assembly process
 Size of component

Considering manufacturing process is very important in form design because each

manufacturing process has its own advantage and disadvantage to the component. This may
be a variation of cost which may influence the overall cost of the design process. It is
required for the component to be assembled in such a way that no part is damage during the
assembling process. The size also has an influence on a form design. It greatly determines the
strength and clearance between mating parts.

1.2.3.2.Rules in defining form design

 Optimum manufacturing method is chosen in a consideration of quantities to be
manufactured, strength requirements, weight restrictions and any other relevant
factors.
 Apply the load in the axis of the material
 Maintain smooth stress flow due to load through components
 Compromise between size and shape & form design
1.2.4. Provisional materials and process determination

Engineering decision making process should consider material and process selection as large
number of materials and processes are evolving which have a direct impact on industry.
There may be a number of material and process that can fulfils the requirement set by the
specification, so selection may seem difficult but if main criteria is identified it is possible to
use elimination process that can minimize the number of material and process needed.
Approximately half of the cost of the manufactured product is due to the material cost. The
optimum use of material results in increased product performance, greater efficiency and
reduced cost which increase the competitiveness of the company. The specification of a
material must be thorough and complete which may be done as a ratio of cost/unit volume,
cost/weight or weight/strength ratios.

The main criteria used to select the combination of materials and processes are:

 Availability  Density
 Quantity required  Surface roughness
 Vibration damping  Ease of machining
  styling possibilities  Wear resistance
 Friction coefficients  Speed of delivery
 Electrical properties  Corrosion resistance
 Cost  Operating environment
 Tolerances required  Chemical resistance
 Environmental impact  Mechanical properties
 Density
1.2.5. Design for assembly and manufacture

Suggestions from manufacturing engineers are crucial and must be utilized by engineering
designer. In the case of interferences in an assembly, the design should be suitable for
machining and assembly if the following are critically appraised:

 Ease of machining  Avoidance of redundant fits

 Economy  Accessibility
 use of existing machinery and  Ease of assembly
tooling
The manufacturing process should be considered in addition to the functionality when ease of
machining is needed. Providing undercuts and placing features which are easier to machine
and inspect are used for simplifying the machining process. The manufacturing process is
chosen after careful cost analysis of the alternatives. It is recommended to use simple shapes
(cylindrical and flat surfaces) as much as possible to lower a cost.

Fewer numbers of components are required to avoid excessive fits and make the assembly
easier. It is required to make the assembly optimum rather than possible because the least
number of components increase the complexity of manufacturing. The symmetric nature of
an assembly is not desirable.

1.3.Industrial Design

Design is about achieving a technical optimum solution which has an ergonomic and
aesthetic value. The unlimited need and the competitive nature of the market make the design
more complex in order to fully address the whole nature of the product. This needs experts
which work in a team for common goal providing that each member must be aware of the
ability and aim of his colleagues.

The broad covering areas of design activity are: Technical, Ergonomics and Aesthetics.

The general distinction between engineering and industrial design is:

 The engineering designer is biased towards producing goods which have use.
 The industrial designer is biased towards ensuring useful products satisfy and appeal
to their users.

The basic aims of industrial design are: to satisfy ergonomic and aesthetic value.
1.3.1. Ergonomics

In any design whether engineering or industrial it is essential to make sure that the design of
the machine operation or work environments are in accordance with human capability and
limitations. This is done by introducing a new concept called ergonomics. This will establish
a guide line to check the fitting of a design to human ability. Even though many machines are
designed for automation, it is impossible to avoid human interaction completely. It is possible
only to decrease the degree of interaction.

The problems related to human interaction in the development of complex system are:

 Those which complement the capabilities and limitations of human operators

 Those concerned with procurement, selection classification, training and promotion of
operators.

The questions must be considered during the design of products and processes which involve
human interaction are:

 What role is the operator expected to play?

 Will optimum use be made of inherent human capacities?
 How will the equipment fit the operator?
 Will the operator sit or stand?
 Will the operator's posture be satisfactory?
 Is the section of population likely to operate the equipment clearly defined?
 What information does the operator need to perform the task?
 Should this information be visual, auditory or tactile?
 What type of display will give quick information with minimum ambiguity?
 What type of controls will be optimum?
 How much force can the operator be reasonably expected to apply?
 What form of communication is appropriate between operators?
 What physical and mental work will the operator be required to do?
 What are the ambient conditions likely to be?
1.3.2. Aesthetics

During identification some irrational factors arise from human perception which will lead to
some doubt. This irrationality cause confusion of visual form and attribute attached. Some
knowledge of the working of the eye is helpful for the designer to avoid this doubt, which can
help a customer to increase his confident recognition.

During designing the choice of light and colour density has influence on human ability to
perceive detail and also influence both mind and emotion.

During designing the designer has to find interesting combination of shape to produce high
aesthetic satisfaction. The designer should select clean and simple lines with good proportion.
Shapes like ellipse, hyperbola, parabola, the cycloid and involute are capable of leading
strength and beauty appearance for the form. Generally, Aesthetics has to do with human
perception.
 Modelling
2.1 Introduction
It is always hard to specify the stage where modelling takes place because of its
progressive properties. It becomes more advanced and complex as the design proceeds.
Most designers put modelling between concept selection and detail design stages.
Modelling can be classified in to three broad classifications.The mathematical model,the
physical scale model and simulation.Generally modelling can be defined as the simple
representation of a product which is used to investigate a specific criterion of the real
product. After all the best quality of a model is its approximation to reality.
Theoretically every product being designed would be produced and tested. But this would
take time and cost. In order to be competitive with others time and cost are not cheap
thrown parameters. The time spent on developing the full sized product for testing
purpose will let the other competitors to gain market value. There are some exceptions,
notably in electronic circuit design, where prediction of the behaviour of a complex
circuit is impossible and circuits are cheap to build.

2.2 Mathematical modelling

Quotation by Ashley Perry reads “The product of an arithmetical computation is the
answer to an equation . It is not the solution to the problem.” This quotation has clearly
put that mathematical modelling equations must be realistic enough to solve a problem.
At the initial stages of design overall calculations are performed to verify working
principles and to make sure whether or not further work is justified. The analysis starts
with simple and becomes complex as the design progresses.
As the design process continues it is important to decrease the number of assumptions for
more accurate calculations. The more realistic models are made with fewer assumptions.
In some situations the form of the model is dictated . For example the selection of
bearings is governed by guidances in the manufacturers’ catalogues .
Mathematical modelling always starts with a simple one. This model is accomplished by
familiar simplifying assumptions like:
Linear springs F  kx
PV
Perfect gases  const
T
F
Uniform stress stress 
A
Ohm’s Law V  IR
After the simple model is formed the next step will be idealizing the input data.
Simplifying assumptions. For example during a cyclic load the shape of the curve is
minimized by only considering the number of times the maximum and minimum points
are reached. But the real shape of the curve is very complex.
Four stages are recommended in this chapter to form a mathematical model. Considering
the mathematical modeling of the column for a pillar drill shown in Fig2.1 each steps
could be explained.
1.Draw three separate diagrams, one showing the intended geometry Fig.2.1(a),a second
indicating the applied forces and moments Fig.2.1(c) and a third indicating the resultant
forces and moments on the critical section(s),Fig.2.1(c).

(a) (b) (c)

Figure 2.1 Pillar drill modelling.

2.State all assumptions.

-The drill is rotating in constant speed.
-The rate of feed into the workpiece is constant.
-There is no deflection in the drill arm.
-There is no sideways loading.
-There is no friction in the bearings.
-The pillar above the critical section is weightless.

3.Develop mathematical equations for the resultant forces and moments at the critical
section(s) in terms of the applied loading and the geometry.
Vertical force Fv  F  Mg  mg
Horizontal force Fh  F
Bending moment t  Fh  MgR  mgr  FR
Twisting moment T  M

4.State the failure criteria.

-The maximum principal stress occurring at the cross-section must not exceed the yield
stress of the material. These stresses will be caused by a combination of
compression(tension),bending and torsion.
-The column must not buckle.
-deflection should always be within acceptable limits. Any inaccuracies caused by the
column bending will affect drill accuracy.
-The natural frequency of vibration should be well away from the operating frequency of
the drill.
-Since the loading is cyclic ,fatigue life should be estimated.
The above procedures need to be repeated in order to find the worst case of loading,in
this case the application of the load F in the vertical direction will increase compressive
loading on the column. The critical sections in most structures are on areas of joints
because of the high concentration of stress in these areas.
Since the model is established mathematical and computer analysis could be carried on.

2.3 Optimization
In a design process there are always conflicting requirements. This is where optimization
comes in.
Optimization is the process of determining the values of variables of contrasting effect on
a desired criterion. It is finding a way to have both the variables in a state where the
desired criterion is in a more or less sufficient level. An optimization problem usually
involves three types of functional relationships among the specifications and design
parameters . These are:
Criterion function: this is the mathematical expression of the quantity whose maximum
or minimum is to be found as a function of the design parameters. This maybe a single or
ratio of several characteristics and there can only be one of it.
Functional constraints:Equations which are the physical laws involved in the proposed
design. The number of equations in this set must be less than the number of design
parameters.
Regional constraints:there is no limits to their number and are always expressed in
inequalities. These functions are mathematical statements of the limits which design
parameters must lie.
Of the many methods of optimization linear programming and differential calculus are
covered in this chapter.

Optimization by linear programming

This method is useful for case where the criterion function and the constraints are in a
linear function of the variables. If three or less variables exist it can be solved graphically.
The main target will be finding a feasible region. It is found by plotting the extremes of
satisfaction of the equations. The optimum point lies along the boundary of the feasible
region and which point is dictated by the slope of the line of criterion function.

Figure 2.2 Graphical solution

If four or more variables exist algebraic solution is necessary and it is beyond the
capacity of graphical solution.
Optimization by differential calculus

In cases where there are no functional constraints and regional constraints can be
temporarily ignored,we can assume the criterion function to be differential equation and
determine the optimum values. Setting the derivatives of the criterion function with
respect to zero and solving the resulting simultaneous equations give the optimum values.

2.4 Scale models

Although mathematical models are an important first step,the development and use of
two- and three-dimensional scale models has the value of verifying the likely behaviour
of the design before the commitment to continue with detail design is made.
Mannequins for assessing improvements in working conditions,models for assessing the
behaviour of linkage mechanisms,photoelastic models for see and quantify stress and
strains,are some of the two-dimensional models.
Modern flight simulators are examples of mannequins used to asses ergonomics and
much more. Mannequins are used as general guide to asses suitability of a machine for
manual manipulation.
Linkage mechanisms are required to identify if the mechanism works or not and how
much space it requires for it’s moving links.

Figure2.3 Chebyshev straight line mechanism(example of linkage mechanism)

Another advantages of the model are for better visualization of a mechanism than scheme
drawing and for assessing effects of changing geometry.
Photoelastic models are models prepared by polariscope when a photoelastic material is
strained and viewed with it. The result shows a distinctive coloured fringe patterns. The
pattern shows the overall strain distribution while the fringe indicate areas of constant and
relatively high stress. As a result decisions like strengthening the high stress
concentration areas can be made and quantifying both stress and strain by counting the
fringe as the load is increased is possible.
 Figure 2.4 Star shape undergoing photoelasticity analysis

Three-dimensional models are also very useful in assessing information which could
otherwise only be found trough many sketches,drawings or the full size manufacturing of
the product.
Scale models are much cheaper than prototypes. The main assessments made by using
scale models can be divided into three broad categories,technical,ergonomic and visual.

2.5 Simulation
Simulations are computer aided analysis and their main use is to identify high stress
concentration areas even some show dynamic analysis. Obvious example is the finite
element analysis.
Finite element analysis is a concept of simplifying the complicated problems by treating
the solid as an integration of small interconnected regions called finite elements and
computing approximate solution for each elements which will give the condition for the
equilibrium of the structure. It can be applied to heat transfer and fluid problems also.
The more recent category of modeling will be synthesis. What makes synthesis different
from design analysis is that in design analysis the designer is trying to find out how his
already made design will function in the real world by establishing stress levels,strains
etc... But synthesis is development of something which didn't exist before by the use of
different materials and different size settings.

Figure 2.5 Finite element analysis of garden hoe