EMT 303:

Engineering
Design I
Topic 3: Design
Factors
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 3

3.0: Design factors:

The term design factor, N, is a measure of the

relative safety of a load-carrying component. In
most cases, the strength of the material from which
the component is to be made is divided by the
design factor to determine a design stress. Then
the actual stress to which the component is
subjected should be less than the design
stress.
Cont……….
 For some kinds of loading, it is more convenient to set
up a relationship from which the design factor, N, can
be computed from the actual applied stresses and the
strength of the material.
 The designer must determine what reasonable
value for the design factor should be in any
given situation
 Alldesign approaches must define the
relationship between the applied stresses on a
component and the strength of the material
from which it is to be made, considering the
conditions of service.
3.1 Factor of safety
 The strength basis for design can be yield strength in
tension, compression, or shear; ultimate strength in
tension, compression, or shear; endurance strength; or
some combination of these.
 The goal of the design process is to achieve a suitable
design factor. N, (sometimes called a factor of safety)
that ensures the component is safe.
 That is, the strength of the material must be greater than
the applied stresses.
 Factor of safety or design factor can be computed in
several ways depending on the failure condition to which
the designed material or product is exposed to; such
methods includes;
Examples of Design factor load analysis
Design factors, N. are useful for determining design
stresses for shaft design.
1. Geometry of the component and the loading are
known: We apply the desired design factor, N. to the
actual expected stress to determine the required
strength of the material. Then a suitable material
can be specified.
2. Loading is known and the material for the
component has been specified: We compute a design
stress by applying the desired design factor, N. to
the appropriate strength of the material.
 This is the maximum allowable stress to which any part of
the component can be exposed. We can then complete the
stress analysis to determine what shape and size of the
component will ensure that stresses are safe.
3. Loading is known, and the material and the complete
geometry of the component have been specified: We
compute both the expected maximum applied stress and the
design stress. By comparing these stresses, we can determine
the resulting design factor, for the proposed design and
judge its acceptability. A redesign may be called for if the
design factor is either too low (unsafe) or too high (over
designed).
4. Material selection; Material availability must be checked.
5. Manufacturing and assembly methods; Manufacturing
considerations may affect final specifications for overall
geometry, dimensions, tolerances, or surface finish
6. Force estimation; surface finishes should only be as smooth as
required for the function of a particular area of a component,
considering appearance, effects on fatigue strength, and
whether or not the area mates with another component.
7. Strength calculation;
8. Weight economy; In general, components should be as small as
practical unless operating conditions call for larger size or
weight.
8. Design safety factor; committed to production,
tolerances on all dimensions and acceptable surface
finishes must be specified so the manufacturing
engineer and the production technician can specify
suitable manufacturing processes.
9. Standardization; After computing the minimum
acceptable dimension for a feature of a component,
standard or preferred sizes should be specified using
normal company practice or tables of preferred sizes
10. Interchangeability;
11. Economics consideration in design; Each design
decision should be tested against the cost of achieving
it