EMT 303:

Engineering
Design I
by
Joshua Charana
Course Outline

1. The design functions of an organization. Design

methodology. Phases of design, product life cycle.
2. Ergonomics; anthropometrical data, the man-machine
relationship. Decision-making in design, reliability and
optimization.
3. Design factors: material selection, manufacturing and
assembly methods; force estimation, strength calculation,
material selection, weight economy; design safety factor.
4. Standardization; interchangeability; economics
consideration in design. Features, design principles for
various types of machine elements: screws, fasteners,
rivets, couplings, keys and keyways, shafts and axles,
clutches, cams, bearings and bearing housings. Use of
catalogues and standard design handbooks.
Course Outline cont….

5. Writing design reports; cost estimation (BOQs).

Design project. Shafts and axles; keys and
keyways; standards. Splines and serrations; hub
shaft mountings, Couplings; types, hubs and
driving flanges collar and coupling designs.
6. Clutches; types and characteristics; dog, plate
centrifugal, overrun and slip clutches; inspection,
assembly, adjustment and torque testing.
7. Belts and belt drives; types of belts.
Classification of vee-belts.
8. Transmission chains: Roller chains, sprockets,
design procedures.
Course Outline cont….

9. Bearings: designs; materials; types and selection;

bearing housing, removal, clearing, inspection and
assembly, lubrication, alignment and pre-lading. Seals:
gaskets and rings; dynamic and fluid seals; dirt
excluders; removal and fitting.
10. Cams and ratchets; type, variable cam and ratchet
feeds.
11. Gears; types and applications.
12. Adhesives and sealants: Bonding adhesives, retaining
compounds, thread locking. O-rings: functions,
composition and selection and standards.
Topic 2.: Ergonomics;

Ergonomics is the study of how tools and

machines can best be fitted to human
capabilities and limitations. In developing an
initial product design proposal, industrial
designers must consider not only broad
functional requirements and marketing goals,
but also aesthetics, style, ergonomics,
company image, and corporate identity. The
result of this effort is usually termed as
product marketing concept.
Cont……….
 The activity of designing user-friendly
machines for safe, easy, productive use is
called ergonomics or human factors
engineering. A key concept in ergonomic
design is that human operators exhibit a
wide variation in stature, weight, physical
strength, visual acuity, hearing ability,
intelligence, education, judgment,
endurance, and other human attributes.
Cont……….
 Itbecomes necessary, therefore, to provide
machine system features that match potential
user attributes, and protect operators against
injury resulting from operator error or machine
malfunction.
 Because most products and systems are
designed for use by an array of people, rather
than for use by one specific individual, it
becomes necessary to accommodate the whole
range of strengths and weaknesses of the
potential user population
To accomplish this objective, a designer must
be well informed about anthropometrics, about
the psychology of human behavior, and about
how to integrate these factors with technical
requirements in order to achieve a safe,
productive machine.
to properly design a machine for efficient
human interaction, anthropometric data on
human body size, posture, reach, mobility,
force, power, foot strength, hand strength,
whole-body strength, response speed, and/or
response accuracy may be required
2.1 Decision-making in design
Anticipating potential operator errors, and
designing a machine or system to accommodate
them without serious consequences, is also an
important part of effective ergonomic design.
Guidelines for avoiding serious consequences
resulting from operator errors include:
1. Survey the machine system to identify potential
hazards, then design the hazards out of the
product.
2. Design equipment so that it is easier to use
safely than unsafely.
3. Make design decisions that are compatible
with stereotypical human expectations e.g.
clockwise rotation of rotary control knobs
should respond to increased output.
4. Locate and orient controls in such a way
that the operator is unlikely to accidentally
strike them, or inadvertently move them, in
a normal operational sequence.
5. Where needed, recess or shield controls, or
provide physical barriers to avoid
inadvertent act.
6. Provide extra resistance when a control
reaches a hazardous range of operation, so
that an unusual human effort is required for
further actuation.
7. Provide interlock between or among controls
so that prior operation of a related control
is required before the critical control can be
activated.
8. When consequences of inadvertent
actuation are potentially grave, provide
covers, guards, pins, or locks that must be
removed or broken before the control can
be operated.
2.2. Reliability and Optimization
A guiding principle followed by effective designers is
to utilize as much available quantitative
information as possible in making design
decisions.
Therefore, if probabilistic descriptions are available
in the form of statistical data for describing
strength distributions, loading distributions, or
variations in environment, manufacturing,
inspection, and/or maintenance practices, these
data should be utilized to keep the probability of
failure low.
Cont…Reliability and Optimization
to keep the reliability above a prescribed level of
acceptability.
Therefore, reliability is the probability that a
machine or machine part will perform its intended
function without failure for its prescribed design
lifetime.
If the probability of failure is denoted by P(failure),
the reliability, or probability of survival, is R=1-
P(failure). Thus reliability is a quantitative
measure of survival success, typically based on
distribution functions verified by experimental
data.
Cont…Reliability and Optimization
Implementation of the probabilistic design
approach requires that the distribution function
(probability density function) be known or
assumed for both the stress at the critical point
(and all factors influencing stress) and the
strength at the critical point (and all factors
influencing strength).
If the probability density function for stress, f(σ),
and the probability density function for strength,
f(S), are known as shown in fig 2.3.
Cont…Reliability and Optimization
By definition, the reliability is the probability that
the strength exceeds the stress, or
R = P{S > σ} = P{S - σ > 0}
The area in Figure 2.3, that lies outside the shaded
interference area. The shaded area represents
probability of failure, that is, P { σ ≥ S }. The
probability of failure is sometimes called
unreliability.
Fig. 2.3 Probability density functions for stress
and strength, showing interference area (failure
region).
Normal Distribution
 Three probability density functions of particular
interest to a designer are; the normal, the log-
normal, and the Weibull distribution functions.
 Theprobability density function f(x) for the
normal distribution is
where x is a random variable such as stress or strength, û is the
estimated population mean, and σ is the estimated population standard
deviation, where
n equals the number of items in the population.
As a matter of interest, the square of the
standard deviation, is defined as the variance.
Example
An axially loaded, straight, cylindrical bar of
diameter d =12 mm is made of 2024-T4 aluminum.
With experimental data for the material tested
under conditions that closely correspond to actual
operating conditions indicate that the yield
strength is normally distributed with a mean value
of 330 MPa and standard deviation of 34 MPa.
 The static load on the bar has a nominal value of
30 kN, but due to various operational procedures,
and excitations from adjacent equipment, the
load has been found to actually be a normally
distributed random variables with standard
deviation of 2.2 kN.

 a.Find the existing factor of safety for the bar,

based on yielding as a failure mode.
 b. Find the reliability level of the bar, based on
yielding as a failure mode