THE AMERICAN UNIVERSITY IN CAIRO

Department of Mechanical Engineering

MENG 3506 [Mechanical Design I]

Spring 2018
Mechanical Design I (3 cr.)
Instructor: Drs. Mohamed F. Aly and Ashraf Nassef
Lab Instructor: Eng. Mohamed Bakr
TA: Ibrahim Gharib
Offices: SSE 2020, SSE 2021
Email: mfawzyaly@aucegypt.edu and nassef@aucegypt.edu

Course Description:
Introduction to design concepts. Constructional details as affected by manufacturing, assembly,
and strength considerations. Engineering materials. Design for steady and cyclic loading, and for
rigidity and stability. Rigid and elastic connections. Bolts, rivets and welds. Design of shafts,
springs and couplings. Use of interactive computer programs for problem solving is illustrated
and encouraged. Design projects.

Prerequisites: ENGR 2104, MENG 2505 and MENG 3505

Textbook: Mott, R.L. "Machine Elements in Mechanical Design", 3rd ed, Prentice Hall, 2000.

Course Outcomes:
After completing this course, students should be able to:
1. Represent a physical model with a schematic and a free body diagram and solve for the
unknown reactions.
2. Apply the appropriate failure theory and factor of safety to static and dynamic systems.
3. Determine suitable dimensional tolerances for different applications.
4. Use the computer to model, analyze and design different machine elements.
5. Design the following components:
a. Beams
b. Shafts
c. Keys and couplings
d. Springs
e. Welds
f. Bolted and riveted connections
6. Design and analyze a real engineering system involving one or more of the above-mentioned
components.
Computer Usage:
Students should learn to use SolidWorks/MITCalc modeler to model, analyze and design
machine elements.

Topics:
1. Fundamentals of Mechanical Design, Materials, stress analysis, standards and codes. [2
weeks: 2 Lecture-hrs/week (4classes)]
2. Design of Power Transmission Elements: shafts, load analysis, stress concentration, fits and
tolerances, keys and splines, rigid and flexible couplings. [7 weeks: 2 Lecture-hrs/week (14
classes)]
3. Flexible Load Transmission Elements (springs) 3 weeks: [2 Lecture-hrs/week (6 classes)]
4. Joining of Materials, Bolted connections, riveted connections, welded connections. [3 weeks:
2 Lecture-hrs/week (6 classes)]

Lab Sessions: (Problem solving and Design sessions)

1. Free Body Diagrams (1 session)
2. Shaft Hub Connections/ Shaft Design/Tolerances (3 sessions)
3. Bolts and Couplings (1 session)
4. Springs (1 sessions)
5. Design of Frames and Welds (3 sessions)
6. Lab projects (4 sessions)

Lab Projects
Students should submit projects on design of realistic components using the available facilities
and software using SolidWorks/MITCalc modeling packages. Only projects with authorized
license by the university are considered. Installing an authorized copy on a student laptop is the
sole responsibility of the student.

Course contribution to meeting professional component Engineering Science 3 cr.

(Significant Design Component)

Grading Policy:
Grade 1: Assignments (**) 5% (Marked by Eng. Mohamed Bakr)
Grade 2: Mid-Term #1 (To be announced) 25% (Marked by Dr. Mohamed Aly)
Grade 3: Mid Term #2 (To be announced) 25% (Marked by Dr. Ashraf Nassef)
Grade 4: Group Project (***) 15% (Marked by Dr. Ashraf Nassef )
(Progress Marks by Eng. Mohamed Bakr)
Grade 5: Tolerancing (£) 5% (Marked by Dr. Ashraf Nassef)
Grade 6: Final Exam (*) 25% (Marked by Drs. Mohamed Aly and Ashraf Nassef)

(*) No past exams are allowed or given for the final exam. Further regulations will be
announced.
(**) Assignments follow a strict deadline policy. No assignments are accepted after the hard
deadline, However, the best 70% of the assignments are considered.
(***) Group Project of 3 participants.
(£) This mark is allocated to a special exam on Tolerancing conducted right after the final