MDP 1 Lecture 1 Design Methods Revised

Mechanical Design Practice MENG 2004
Topic 1 Design methods design factor static methods, factor, failure mechanisms and balanced design
(Shigleys Mechanical Engineering Design - Chapter 1)
John Fielke Associate Professor School of Advanced Manufacturing and Mechanical Engineering
MD Week 1, Slide No. 2
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John Fielke course coordinator Fielke,

BEng (Mechanical), BESc (Ag Eng), PhD (Soil Science) g( ), ( g g), ( ) CPEng, SMIEAust Tillage tool design Dried grape processing Agricultural equipment design a. Research b. Consulting b C lti c. Expert Witness

Other courses Computer Techniques CADD CAM Principles and Practice Product Design Communication Final year p j y projects PhD supervision ( x 5)

Other interests Family, gardening Travel Learning rock and roll dancing

Learning expectations g p Attend lectures, interact and ask questions. Look at sections in text book (great background information) Use the weekly quizzes to revise lecture material. Attempt tutorial questions before tutorial (reviewed one week after lecture). Work on assignment as group meeting both at tutorials and in own time during the week. Use discussion forum to ask course related questions. Try to grasp topics weekly and seek help early. If you are having difficulties/issues please let me know. Provide feedback where you can see improvements can be made Make this best course in program.
Course Objectives
At the end of the course students should b able t th d f th t d t h ld be bl to:a. apply an appropriate design methodology and appreciate the legal implications of the design process. b. select appropriate materials to satisfy design requirements. c. explain material behaviour and simple failure mechanisms and design for these situations. d. design mechanical components f strength and d d i h i l t for t th d deflection with regard to safety standards. e. e correctly select standard components from manufacturer's catalogues.
http://www.ntn.co.jp/english/products/pdf/ball/pdf/Bearing_en_all.pdf DO NOT REMOVE THIS NOTICE. Reproduced and communicated on behalf of the University of South Australia pursuant to Part VB of the copyright Act 1968 (the Act) or with permission of the copyright owner on (24/709) Any further reproduction or communication of this material by you may be the subject of copyright protection under the Act. DO NOT REMOVE THIS NOTICE.
Course Teaching & Learning Arrangements

Course information booklet Course website (LearnOnline) Weekly lectures and tutorials Weekly quiz (10% grade) Two assignments ( g (20% g grade each) ) Three hour exam (50% grade) Must achieve at least 40% in exam and an overall pass grade to pass the course. There will be no supplementary assessment.
Course Teaching & Learning Arrangements
Any questions?
Intended Learning Outcomes

At the end of this lecture, students will be able to: Explain the engineering design process and the importance of an appropriate design. List the requirements to document a design in a professional and responsible manner. Recall the range of static failure modes. Explain the difference between stress & strength strength. Select an appropriate design factor ( (factor of safety). y) Undertake a balanced design.
http://takemeiamyours.files.wordpress.com/2008/02/roller coaster.jpg
DO NOT REMOVE THIS NOTICE. Reproduced and communicated on behalf of the University of South Australia pursuant to Part VB of the copyright Act 1968 (the Act) or with permission of the copyright owner on (22/6/10) Any further reproduction or communication of this material by you may be the subject of copyright protection under the Act. DO NOT REMOVE THIS NOTICE.
Mechanical Design
Products created must be: 1. 2. 2 3. 4. 5. 6. 7. Functional Safe S f Reliable Competitive Usable Manufacturable Marketable
Design is an innovative and highly iterative process Decisions must sometimes be made with: 1. Too little information 2. 2 Just the right amount of information 3. Excessive and often contradictory information
Design Process
Mechanical Engineering Design, 9th Edition. (2011) Budynas, R.G. and Nisbett, J.K.
Page 6
Professional Responsibility
Responsibility rests with the Engineer Engineer. When i j Wh injury, f il failure or poor performance occurs:f - Legal proceedings will examine design reports, notes and calculations. - Your work will be presented in court. Courts will be looking for p g professional negligence and apportioning g g pp g blame for payment of damages/prosecution.
When things goes wrong

Ride owners also had to pay out some $3 million last year after the Spin Dragon ride collapsed when 44 of its gondola s gondola's 48 bolts snapped, injuring 42 at the Royal Adelaide Show in southern Australia in 2000. Victims received up to $400,000 each as part of the settlement. settlement
http://goliath.ecnext.com/coms2/gi_01996858449/Scary-rides-scary-risks-more.html 6858449/Scary-rides-scary-risks-more html http://news.bbc.co.uk/2/hi/asia-pacific/908310.stm
DO NOT REMOVE THIS NOTICE. Reproduced and communicated on behalf of the University of South Australia pursuant to Part VB of the copyright Act 1968 (the Act) or with permission of the copyright owner on (24/709) Any further reproduction or communication of this material by you may be the subject of copyright protection under the Act. DO NOT REMOVE THIS NOTICE.
When design g g goes wrong g
The Age, 2 March 2009 Age
http://media.photobucket.com/image/southern%20 star%20observation%20wheel/rustyhawkbf/TheW heel2171008.jpg
http://business.theage.com.au/business/design-fault-tokeep-ailing-wheel-shut-20090301-8lh8.html
When design g g goes wrong g

Annually in Australia 650,000 occupational injuries and illnesses Costs at least $20 billion a year In Australia Jan 2000 to June 2002: > 77 workplace deaths can be attributed to poor design, (37% of all workplace fatalities)
Source: The Role of Design Issues in Work Related Injuries in Australia 1997-2002, Work-Related 1997 2002 NOHSC July 2004)
Professional Responsibility
Each design must have a design report/file which includes: includes: Assumptions Calculations C l l ti Decision reasoning Calculations Drawings and sketches Design history
Manufacturers are governed by product liability laws
Mechanical Failures - DATABASE

Look t for L k out f mechanical f il h i l failures Upload an image/URL to the course FAILURES DATABASE Have a look at what others have uploaded and place a comment
Product Recall- DATABASE Recall

Look t for L k out f product recall notices d t mechanical d i i d t ll ti due to h i l design issues Upload an image/URL to the course RECALL DATABASE Have a look at what others have uploaded and place a comment
Design Procedure 1 Define Problem 1.

Firstly Assume nothing and ask questions questions. Often the real need is not always evident to all. Decide with confidence what is the problem.
Design Procedure 2 Define Constraints 2.

Constraints may include: include:1. Performance (force, power, speed, volumes) 2. Dimensions (size and weight) 2 Di i ( i d i ht) 3. Shape/layout 4. Strength 5. Manufacturing process 6. Environment 7. Safety 8. Costs
Design Procedure 3 Material Selection 3.

Material selection will depend upon: upon:1. Strength and dimensions 2. Production 2 P d ti methods th d 3. Standard size availability 4. Weldability and machinability 5. Corrosion, heat and wear resistance 6. Reliability (e.g. castings and welds may have porosity or inclusions which can lead to premature failure)
Design Procedure 4. Preliminary Designs g y g

Apply creativity Rarely is there only 1 correct solution Some solutions will be better than others, but you will need to develop them to see their potential. Select 3 to 6 preliminary designs and - Make approximate calculations for sizes/selections pp - Create sketches or CAD models - Develop a workable solution for each design - Gain costs of each design - Maybe undertake tests of the design using a proto-type/simulation
Design Procedure 5 Selection 5.

Do not include unworkable designs in the decision making process unworkable process. Use a structured decision making process to choose the best design. e.g. weighted scoring method 5A. Develop criteria for assessment (excluding cost as cost will be the final determinant after the weighting process) For example: Reliability - since it is to be used on remote sites Low maintenance unskilled users Uses standard components easy to get spare parts
Design Procedure 5B Selection 5B.

5B. 5B Develop relative weights for each criteria (from 1 to 10) and provide justification For F example l Reliability has a weight of 10 as it so important the machine will not break down when needed as the whole production line depends upon it. Low maintenance has a weight of 7 as it is expensive to stop the line and undertake maintenance and it can only be done on routine shut downs. downs Uses standard components has a weight of 6 as it is easier to get a local part than get a special replacement part part.
Design Procedure 5C Selection 5C.

5C. 5C Develop a table for each design and score each design for meeting the criteria
Criteria Weight g Design 1 g Score Reliability Low Maintenance Standard components Performance Low Energy consumption Ease of manufacture Corrosion resistance 10 7 6 5 4 2 1 6 10 3 10 2 1 10 Design 2 g Score 8 6 7 6 8 10 4 Design 3 g Score 10 2 10 1 10 5 1
Design Procedure 5D Selection 5D.

5D. 5D Multiply the score by its weight and sum up the total for each design design.
Criteria Weight g Design 1 g Score Reliability Low Maintenance Standard components Performance Low Energy consumption Ease of manufacture Corrosion resistance Totals 10 7 6 5 4 2 1 6 10 3 10 2 1 10 Total 60 70 18 50 8 2 10 218 Design 2 g Score 8 6 7 6 8 10 4 Total 80 42 42 30 32 20 4 250 Design 3 g Score 10 2 10 1 10 5 1 Total 100 14 60 5 40 10 1 230
Design Procedure 5E Selection 5E.

5E. 5E Add rankings and finally add in cost to help choose the final design design.
Criteria Weight g Design 1 g Score Reliability Low Maintenance Standard components Performance Low Energy consumption Ease of manufacture Corrosion resistance Totals Design ranking Estimated cost 3 $150,000 10 7 6 5 4 2 1 6 10 3 10 2 1 10 Total 60 70 18 50 8 2 10 218 1 $170,000 Design 2 g Score 8 6 7 6 8 10 4 Total 80 42 42 30 32 20 4 250 2 $120,000 Design 3 g Score 10 2 10 1 10 5 1 Total 100 14 60 5 40 10 1 230
Design Procedure 5F Proposal 5F.

5F. 5F Document your findings and conclusion in a design proposal report that includes: Details of all alternative designs Justification of selection scores (weights and scores) Calculations Sketches Drawings Costs A discussion on why the preferred design is recommended
Design Procedure 6 Final Design Report 6.

The design final design report should include: include:A statement of the design brief A summary of the fi l outcomes, i l di a d f th final t including drawing i A step-by-step record of the design evolution, including - All assumptions made - Diagrams, sketches etc of all alternative designs - Selection procedure for final design - Sample calculations - Results of all calculations - Material selection criteria and data - Reference used, especially Standards - Standard product or component drawings - Final design details and drawings Recommendations for proving or testing the design, including test procedures.
Design Procedure 7 Prototype Checks 7.

To validate assumptions and check performance testing of a proto type assumptions, proto-type should be carried out The Th results of proto-type testing must b added to the D i R lt f t t t ti t be dd d t th Design Report. t
Kverneland (plough manufacturer), Norway note hydraulic cylinders used to create a cyclic l d t t t for t li load to test f fatigue
Design Procedure 7 Prototype Checks 7.

Drop tests on forklift to Australian Standard The timber block was 45 kg dropped from 1.5 metres. The Timber bundle was 1600 kg dropped from 1.4 metres.
Class question
How have you seen companies test proto-types?
Design Procedure 8. Release for production d ti

Further detailed design work Specifications are written Production drawings are created Bills of materials finalised and structuring of assemblies
Details for manufacturing/tooling, p g g purchasing and p g production p planning g Required quality checks Performance specifications Operators Manuals Parts books The above is done for medium to large projects, but smaller projects may not need full j y justification. All projects will need assumptions and calculations to be documented.
Getting the design right early saves time and money ti d
Relative cost of a design change
Time Change Made At time of preliminary design Checking Process planning Following tooling d jigs have b F ll i t li and ji h been made d Once production has commenced Field retrofit/recall
Relative cost $1 $10 $100 $1,000 $1 000 $10,000 $100,000 $100 000
Break
Design for strength considers

Maximum stress (shock and start up loads) Component strength (yield or UTS) Design Factor (Factor of Safety)
Actual Maximum Stress

Stress is a state property at a specific point Normal stress () Shear stress () Only by knowing the actual forces acting on the component will the stress be known known. Loads may be maximum on stopping, starting y g g or jamming. A shock f t (Ksh) i applied t th static l d h k factor is li d to the t ti load.
Typical Values Shock Factors
Source : unknown
Component Strength
Strength is a material property property. Yield Strength ( y) g (S Ultimate tensile strength (Sut) Shear Strength (Ss) Strength may vary from point to point within a component of the same material due to work hardening, g, heat treatment, surface finish, inclusions etc.
Design Margin
In order to have a safe design the Component Strength must be greater than the Actual Maximum Stress Stress. In many cases there is a great deal of uncertainty on both the values for the strength and the stress and these are accounted for using a Design Factor or Factor of Safety
Design Factor N Factor,

Accounts for uncertainties concerning stress and strength: Composition of materials Variations in properties within a bar of stock Effect of local processing on properties Effect of nearby welds, shrink fits Effect of heat treatment Intensity and distribution of loading Validity of loading model to represent reality Intensity of stress concentration Influence of time on strength and geometry Effect of corrosion Effect of wear Uncertainty of other factors
Design Factor N for aircraft Factor,

Design Factors (Uncertainty) must be managed by engineers For example aircraft use Materials with high certainty of properties (certified) Known loads from study and measurement Testing to verify all assumptions High quality control Routine testing to detect signs of failure Hence they can use small design factors of 1.05 to 1.15 ( (otherwise the plane will be too heavy to fly) p y y)
Design Factor N - selection guide Factor,

The uncertainties can be broken down into:Material reliability (Nm) Workshop Accuracy (Nw) Design load accuracy (Na) Consequence of Failure (Ncf) The design factor N = Nm x Nw x Na x Ncf If N > 6 you should re-evaluate and manage the re evaluate uncertainties.
Calculating Design Factor, N

N = Nm x Nw x Na x Ncf
Material Reliability Nm = 1.0 Nm = 1.1 Nm = 1.5 to 2.0 Nm = 3.0 Workshop and inspection accuracy Nw = 1.0 Nw = 1.05 to 1.1 Nw = 1.15 to 1.2 Design accuracy Na = 1.05 Na = 1.2 to 1.5 Na = 2.0 to 3.0 Consequence of failure Ncf = 1.2 Ncf = 1.4 to 2.0 Ncf = 2.0 to 3.0 Ncf = 3.0 30 Ncf = 4.0 Certified Sut or Sy Ductile materials Brittle material using Suc Brittle material using Sut Machined surfaces Forged and die cast surfaces Sand cast surfaces For precise, well defined situations If theory uses unproved assumptions y p p Rough, preliminary calculations
If no danger to persons and replacement is no problem For general applications When replacement means material losses When failure endangers operating personnel When failure is disastrous
Source : unknown
Design Factor N - typical values Factor,

1.25 < N < 1.5 low weight is necessary and exceptional certainty exists. 1.5 < N < 2.5 2.5 < N < 3.0 3.0 < N < 4.0 4.0 < N < 6.0 ductile materials, known constant load brittle materials, known loads uncertain loads dangerous or disastrous consequence of failure
Allowable Stress Ductile (normal stress)

For ductile materials and normal stress, stress Failure is based on permanent deformation i.e. yield (Sy)
For tension/compression
For bending, g
Allowable Stress Ductile (shear stress)

For ductile materials and shear stress, stress Failure is based on permanent deformation i.e. yield (SS) However, torsion tests show for ductile materials Ss = 0.6Sy
For direct shear
For t i F torsion
Allowable Stress Brittle

For brittle materials materials, There is no yield prior to ultimate failure (strain at failure < 5%) Hence Suc or Sut is used for material strength
Balanced Design (steps 1-7) 1 7)

1. 1 Select material (find value for Sy) ). 2. Calculate the Design Factor for each component N = Nm x Nw x Na x Ncf 3. Determine the allowable stress for each component = Sy/N (for normal stresses) = 0.6Sy/N (for shear stresses) 4. Trace the force through the assembly, splitting the force where there is more than one path (e.g. if the load is carried by 5 rivets, force per rivet = Force/5). f i t F /5) 5. Explode the assembly and show forces acting on each part. 6. 6 Determine the stress associates with each failure mode (tension (tension, compression/bearing, shear, bending, torsion). 7. Write the equation for each mode of failure as follows Allowable stress Actual Stress Sy/N or 0.6Sy/N F/A or Mc/I or Tr/J
Balanced Design (steps 8-11) 8 11)

8. 8 Write all the equations involving all the unknown dimensions (one equation per failure mode). 9. Solve the equations (look for equations with least no. of unknowns) 10. Round up the sizes to preferred sizes (see next slide). This has provided a balanced design. 11. Consider reducing the size of the part you desire to have fail first in the th event of an overload. Ch t f l d Choose the easiest part to replace or th th i t tt l the cheapest so as to provide protections to the other parts from failure. A balanced design minimises the use of material and will look dimensionally correct. correct
Preferred Sizes
Millimeters 0.05, 0.06, 0.08, 0.1, 0.12, 0.16, 0.2, 0.25, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, , , , , , , , , , , , , 1.0, 1.1, 1.2, 1.4, 1.5, 1.6, 1.8, 2.0, 2.2, 2.5, 2.8, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 8.0, 9.0, 10, 11, 12, 14, 16, 18, 20, 22, 25, 28, 30, 32, 35, 40, 45, 50, 60, 80, 100, 120, 140, 160, 180, 200, 250, 300
Source: Shigley Table A-17, pp 1035.
Example: Design of a Mechanism

One f th O of the 2 support columns (A) t l of a 50 tonne (500kN) press is shown in the diagram. Each column is attached to the press platen (B) by split rings (C) and each column is under a tension due to the 250kN down force from the press (B) through to the column (A) (A). Determine the dimensions shown for the following materials: A:Sut = 780 MPa, Syt = 590 MPa B:Sut = 340 MPa, Syt = 240 MP. C:Sut = 950 MPa, Syt = 810 MP Use a design factor of N = 4
Example Problem
Solution: Dis assemble components to analyse failure modes of each Dis-assemble
Example Problem
Preferred Size = 50 mm
Example Problem
50 68.2 68 2
Preferred size = 80 mm
Example Problem
802)
108 mm Preferred Size = 120 mm
Example Problem
8.2 mm Preferred size = 9 mm
Example Problem
D2 Pref. Size 50 mm
D3 80 mm
D4 120 mm
t 9 mm
Design Factors C l Column T i = 4 6 Tension 4.6 Bearing on column = 7.2 Bearing on platten = 6 0 6.0 Shear of ring = 4.4
Reference: Safe Design for Engineering St d t E i i Students
http://www.safeworkaustralia.gov.au/NR/rdonlyres/DD7E1 415-A581-404E-94A239F13A8A50ED/0/SafeDesignEngineering.pdf
Assignment 1
See Assignment Brief Due last Friday before Teaching Break
Quiz 1
See Course Homepage
Tutorial
See Course Homepage
Thank Th k you

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Mechanical Design Practice MENG 2004

MD Week 1, Slide No. 2

MD Week 1, Slide No. 3

John Fielke course coordinator Fielke,

MD Week 1, Slide No. 4

John Fielke course coordinator Fielke,

MD Week 1, Slide No. 5

John Fielke course coordinator Fielke,

MD Week 1, Slide No. 6

John Fielke course coordinator Fielke,

MD Week 1, Slide No. 7

MD Week 1, Slide No. 8

Course Teaching & Learning Arrangements

MD Week 1, Slide No. 9

Course Teaching & Learning Arrangements

MD Week 1, Slide No. 10

Intended Learning Outcomes

MD Week 1, Slide No. 11

MD Week 1, Slide No. 12

MD Week 1, Slide No. 13

MD Week 1, Slide No. 14

When things goes wrong

MD Week 1, Slide No. 15

When design g g goes wrong g

The Age, 2 March 2009 Age

http://media.photobucket.com/image/southern%20 star%20observation%20wheel/rustyhawkbf/TheW heel2171008.jpg

MD Week 1, Slide No. 16

When design g g goes wrong g

MD Week 1, Slide No. 17

Manufacturers are governed by product liability laws

MD Week 1, Slide No. 18

Mechanical Failures - DATABASE

MD Week 1, Slide No. 19

Product Recall- DATABASE Recall

MD Week 1, Slide No. 20

Design Procedure 1 Define Problem 1.

MD Week 1, Slide No. 21

Design Procedure 2 Define Constraints 2.

MD Week 1, Slide No. 22

Design Procedure 3 Material Selection 3.

MD Week 1, Slide No. 23

Design Procedure 4. Preliminary Designs g y g

MD Week 1, Slide No. 24

Design Procedure 5 Selection 5.

MD Week 1, Slide No. 25

Design Procedure 5B Selection 5B.

MD Week 1, Slide No. 26

Design Procedure 5C Selection 5C.

MD Week 1, Slide No. 27

Design Procedure 5D Selection 5D.

MD Week 1, Slide No. 28

Design Procedure 5E Selection 5E.

MD Week 1, Slide No. 29

Design Procedure 5F Proposal 5F.

MD Week 1, Slide No. 30

Design Procedure 6 Final Design Report 6.

MD Week 1, Slide No. 31

Design Procedure 7 Prototype Checks 7.

MD Week 1, Slide No. 32

Design Procedure 7 Prototype Checks 7.

MD Week 1, Slide No. 33

How have you seen companies test proto-types?

Design Procedure 8. Release for production d ti