Chapter 1

Winter 2023
Mechanical Engineering Department
College of Engineering
Imam Mohammad Ibn Saud Islamic University
 Machine Design I (Winter 2023)

Engineering Design Process

Test and
evaluate

Identify Brainstorm Build a

solutions Select a Report
the (conceptual
model or the result
design
problem design) prototype

Optimize
the
design

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Identify the Problem

 The problem/issue is general or in some cases particular e.g.

environmental pollution, organ transplant, prosthetic leg, electric
car
 It could be the new or existing problem

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Conceptual Design: Brainstorming

 The conceptual design must fulfil the functionality of the

need
 There could be many conceptual design to fulfil the
design need
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Conceptual Design: Brainstorming

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Conceptual Design: Brainstorming

Qinghua Liu, Jiadui Chen, Weixing Wang, and Qing Qin, Conceptual
Design Evaluation Considering Confidence Based on Z-AHP-TOPSIS
Method, Applied Sciences, 2021, 11(16), 7400
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Design Selection: Maximum Points Criterion

Maximum points are 5

Criteria Design 1 Design 2 Design 3
Cost 2 3 1
Weight 4 2 2
Volume 4 4 4
Material availability 4 3 2
Design for
3 4 5
manufacturing
Ergonomics 3 3 3
Aesthetic behavior 2 3 3
Safety 4 3 2
Environmentally
4 3 4
friendly
summation 30 28 26
Design 1 wins, so it is considered as the most optimum design
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Modeling or Prototyping
Model is the mathematical or physical (prototype) representation
of a real or conceptual design or system
𝑀𝑦
𝜎=
𝐼
Mathematical models
𝜔 =

Prototypes
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Design Requirements



.  .







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There could be many other and unseen factors!!

FACTOR OF SAFETY
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Failures

Disaster of Fukhushima Nuclear Crane Disaster in Makkah

Power Plant (2012)

Columbia space shuttle disaster (2003)

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Types of Failures

1. Design failure: due to improper design

consideration
2. Material failure: due to the selection of
improper material/manufacturing processes

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Design Failures

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Material Failures

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The Design Engineer’s Professional Responsibilities

 Satisfy
.. the needs of the customer in a
competent, responsible, ethical, and professional
manner
 Some key advise for a professional engineer
 Be competent
 Keep current in field of practice
 Keep good documentation
 Ensure good and timely communication
 Act professionally and ethically
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Standards and Codes

Why we
_ need
standards?
 Standards
 A set of specifications for parts, materials, or processes
 Intended to achieve uniformity, efficiency, and a specified
quality
 Codes
 A set of specifications for the analysis, design, manufacture,
and construction of something
 To achieve a specified degree of safety, efficiency, and
performance or quality

Various organizations establish and publish standards and

codes for common and/or critical industries

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American Society of Mechanical Engineers (ASME)

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ASME

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American Society of Metals (ASM)

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American Society of Metals (ASM)

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Saudi Arabia Standards Organization

The Saudi Standards, Metrology and Quality Organization (SASO) is a
technical government body in Saudi Arabia was established in 1972 and
governs tasks related to standards, metrology, and quality

https://e.saso.gov.sa/content/wasif-service/external-wassif?culture=ar
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Saudi Arabia Standards Organization

https://e.saso.gov.sa/content/wasif-service/external-wassif?culture=ar
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Standards and Codes
Some organizations that establish standards and codes of
particular interest to mechanical engineers:

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Tolerances
Close tolerances generally
increase cost
 Require additional
processing steps
 Require additional
inspection
 Require machines
with lower production
rates

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Breakeven Points
 A cost comparison between two possible production methods
 Often there is a breakeven point on quantity of production
EXAMPLE
 Automatic screw machine
 25 parts/hr
 3 hr setup
 $20/hr labor cost
 Hand screw machine
 10 parts/hr
 Minimal setup
 $20/hr labor cost
 Breakeven at 50 units

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Safety and Product Liability

 Strict Liability concept generally exists in all

over the world including KSA.
 Manufacturer is liable for damage or harm that
results because of a defect.
 Negligence must be avoided.
 Calls for good engineering in analysis and
design, quality control, and comprehensive
testing.

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Reliability Method of Design

 Reliability, R – The
statistical measure of the
probability that a
mechanical element will
not fail in use
 Reliability method of
design – A method of
design where the success
rate of designed part is
measured through the
probability analysis
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Reliability Method of Design

The curve could be in between number of failures and magnitude of load

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Probability of Failure

 Probability of Failure, pf – the number of instances of

failures per total number of possible instances
 Example: if the sample size is 20, at most 5 parts are
failed during testing. This means the maximum
probability of failure is 25%.
 Probability Density Function, PDF – the distribution
of events within a given range of values.
 Two common PDFs
 Gaussian (normal) distribution
 Weibull distribution

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Gaussian (Normal) Distribution

The probability density function (PDF) of the Gaussian
distribution is expressed in terms of its mean, μx, and its
standard deviation ˆ x

large ̂ x
small ̂ x

Typical plots of the Gaussian distribution

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Reliability

 The reliability is related to the probability of failure by

Pf is calculated by integrating above equation

 Example: If 1000 parts are manufactured, with 6 of

the parts failing, the reliability is
or 99.4 %

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Reliability

 Series System – a system that is considered to have failed if any

component within the system fails e.g. car axle, connecting rod
of an engine, wing of an aeroplane
 The overall reliability of a series system is the product of the
reliabilities of the individual components.

 Example: A shaft with two bearings having reliabilities of 95%

and 98% has an overall reliability of
R = R1 R2 = 0.95 (0.98) = 0.93 or 93%

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Dimensions and Tolerances

Nominal size – The size we use in speaking of an element.

Limits – The stated maximum and minimum dimensions
Tolerance – The difference between the two limits
Bilateral tolerance – The variation in both directions from the
basic dimension, e.g. 1.005 ± 0.002 in.
Unilateral tolerance – The basic dimension is taken as one of
the limits, and variation is permitted in only one direction, e.g.

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Dimensions and Tolerances

R=R
1
R Clearance – Refers to the difference in sizes of two mating
2 cylindrical parts such as a bolt and a hole.
Assumes
= 0.95 (0.98) = the
0.93internal member is smaller than the external
or 93%
member
Diametral clearance – difference in the two diameters
Radial clearance – difference in the two radii
 Interference – The opposite of clearance, when the internal
member is larger than the external member
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Dimensions and Tolerances

 Allowance – The minimum stated clearance or the

maximum stated interference of mating parts

 Fit – The amount of clearance or interference between

mating parts

 GD&T – Geometric Dimensioning and Tolerancing, a

comprehensive system of symbols, rules, and definitions
for defining the theoretically perfect geometry, along
with the allowable variation.

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Geometric Tolerancing

GD&T Symbols | GD&T Basics (gdandtbasics.com)

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 Maximum Material Condition or for short, MMC, is a

feature of size symbol that describes the condition of a
feature or part where the maximum amount of material
(volume/size) exists within its dimensional tolerance.
 If you want to ensure that two parts never interfere or
limit the amount of interference between the parts when
they are at their worst tolerances, MMC can be called out.
Take a shaft that must go through a hole with clearance
between the two
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GD&T Symbols Reference Guide from Sigmetrix

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Choice of Tolerances

 The designer is responsible for specifying tolerances

for every dimension.
 Consideration is given to functionality, fit, assembly,
manufacturing process ability, quality control, and
cost.
 Excessive precision is a poor design choice, in that it
limits manufacturing options and drives up the cost.
 Less expensive manufacturing options should be
selected, even though the part may be less than
perfect, so long as the needs are satisfactorily met.

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Computer Aided Designing

Computer-Aided Engineering (CAE)
◦ Any use of the computer and software to aid in the
engineering process
◦ Includes
 Computer-Aided Design (CAD)
 Drafting, 3-D solid modeling, etc.
 Computer-Aided Manufacturing (CAM)
 CNC toolpath, rapid prototyping, etc.
 Engineering analysis and simulation
 Finite element, fluid flow, dynamic analysis, motion, etc.
 Math solvers
 Spreadsheet, procedural programming language,
equation solver, etc.
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