Chapter 1: Introduction

BAE 417-Design of Machine Systems 417Fall 2005

Design


A design must be:

  

  

FunctionalFunctional- fill a need or customer expectation SafeSafe- not hazardous to users or bystanders ReliableReliable- conditional probability that product will perform its intended function without failure to a certain age. CompetitiveCompetitive- contender in the market UsableUsable- accommodates human size and strength ManufacturableManufacturable- minimal number of parts and suitable for production MarketableMarketable- product can be sold and serviced

To design is either to formulate a plan for the satisfaction of a specified need or to solve a problem.

Design Process Actions

 

 

Conceive alternative solutions Analyze, test, simulate, or predict performance of alternatives Choose the best solution Implement design

Design is
  

An innovative and iterative process A communication intensive activity Subject to constraints

Steps to Design

Design Considerations
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Strength Stiffness Wear Corrosion Safety Reliability Friction Usability Utility Cost Processing Weight Life

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Noise Styling Shape Size Control Thermal Properties Surface Lubrication Marketability Maintenance Volume Liability Recovery

Codes and Standards



CodeCode- a set of specifications for the analysis, design, manufacture, and construction of something StandardStandard- a set of specifications for parts, materials, or processes intended to achieve uniformity, efficiency, and a specified quality

Organizations
       


Aluminum Association (AA) American Gear Manufacturers Association (AGMA) American Institute of Steel Construction (AISC) American Iron and Steel Institute (AISI) American National Standards Institute (ANSI) American Society for Metals (ASM) American Society of Mechanical Engineers (ASME) American Society of Testing Materials (ASTM)
American Welding Society (AWS)

        

American Bearing Manufacturers Association (ABMA) British Standards Institute (BSI) Industrial Fasteners Institute (IFI) Institution of Mechanical Engineers (I. Mech. E.) International Bureau of Weights and Measures (BIPM) International Standards Organization (ISO) National Institute for Standards and Technology (NIST) Society of Automotive Engineers (SAE) American Society of Agricultural and Biological Engineers (ASABE)

Economics


 

Cost plays an important role in design decision process  No matter how great the idea may be, if its not profitable it may never be seen The use of standard sizes and large manufacturing tolerances reduce costs Evaluating design alternatives with regard to cost  Breakeven Points  Cost Estimates

Product Liability


Strict liability concept prevails in the U.S.



Manufacturers are liable for any damage or harm that results from a defect.

Uncertainty
 

Roman Method- repeat designs that are proven MethodFactor of Safety Method of Philon- separate the loss-ofPhilonloss-offunction load and the impressed load using a ratio

Loss of Function nd ! Impressed Load



Permissible Stress- fraction of significant material Stressproperty (i.e., strength)

Uncertainty


Design Factor Method- factor of safety is increased with Methodrounding error to achieve nominal size (5.3 mm designed bolt size is increased to 6.0 mm) Stochastic Design Factor Method- uncertainty in stress Methodand strength is quantified for linearly proportional loads

s Average Strength nd ! ! Average Stress W

Measures of Strength
    

S Strength Ss Shear Strength Sy Yield Strength Su Ultimate Strength S - Mean Strength

Measures of Stress
     

X Shear Stress W Normal Stress W W Principal Stress Wy Stress in y-direction yWr Radial Stress Wt Tangential Stress

Stress Allowable (AISC)

   

Tension: 0.45 Sy Wall 0.60 Sy Shear: Xall = 0.40 Sy Bending: 0.60 Sy Wall 0.75 Sy Bearing: Wall = 0.90 Sy

Loads Used to Obtain Stresses

F ! Wd  Wl  kFl  Fw  Fmisc


Where:
Wd- dead loads Wl- live loads k- service factor Fw- wind load Fmisc- locality effects (earthquakes)

Service Factors
Applications Elevators Traveling Crane Supports Light Machinery Supports Reciprocating Machinery Supports Floor and Balcony Supports k 2 1.25 1.20 1.50 1.33

Factor of Safety


Design factors (nd) are defined as:

and

strength nd ! stress

n d ! n sn z
where ns-accounts for uncertainty of strength nd-accounts for uncertainty of loads

Realized Factor of Safety

S nr ! W
Ss nr ! X

Reliability


 

Probability that a mechanical element will not fail in use 0R1 Reliability approach to design: judicious selection of material, processes, and geometry to achieve reliability goal Factor of Safety Method- time proven, widely Methodaccepted Reliability Approach- new, requires data Approach-

Homework Assignment


Do problems1-6, 1-9, and 1-14 for next problems1- 11Tuesday.