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FundamentalsofMechanicalDesign

Mechanicaldesignmeansthedesignofthingsandsystemsofamechanicalnature—machines,products,structures,devices,andinstruments.Forthemostpartmechanicaldesignutilizesmathematics,thematerialssciences,andtheengineering-mechanicssciences.

Thetotaldesignprocessisofinteresttous.Howdoesitbegin?

Doestheengineersimplysitdownathisdeskwithablanksheetofpaper?

And,ashejotsdownsomeideas,whathappensnext?

Whatfactorsinfluenceorcontrolthedecisionswhichhavetobemade?

Finally,then,howdoesthisdesignprocessend?

Sometimes,butnotalways,designbeginswhenanengineerrecognizesaneedanddecidestodosomethingaboutit.Recognitionoftheneedandphrasingitinsomanywordsoftenconstituteahighlycreativeactbecausetheneedmaybeonlyavaguediscontent,afeelingofuneasiness,ofasensingthatsomethingisnotright.

Theneedisusuallynotevidentatall.Forexample,theneedtodosomethingaboutafood-packagingmachinemaybeindicatedbythenoiselevel,bythevariationsinpackageweight,andbyslightbutperceptiblevariationsinthequalityofthepackagingorwrap.

Thereisadistinctdifferencebetweenthestatementoftheneedandtheidentificationoftheproblem.Whichfollowsthisstatement?

Theproblemismorespecific.Iftheneedisforcleanerair,theproblemmightbethatofreducingthedustdischargefrompower-plantstacks,orreducingthequantityofirritantsfromautomotiveexhausts.

Definitionoftheproblemmustincludeallthespecificationsforthethingthatistobedesigned.Thespecificationsaretheinputandoutputquantities,thecharacteristicsofthespacethethingmustoccupyandallthelimitationsonthesequantities.Wecanregardthethingtobedesignedassomethinginablackbox.Inthiscasewemustspecifytheinputsandoutputsoftheboxtogetherwiththeircharacteristicsandlimitations.Thespecificationsdefinethecost,thenumbertobemanufactured,theexpectedlife,therange,theoperatingtemperature,andthereliability.

Therearemanyimpliedspecificationswhichresulteitherfromthedesigner'

sparticularenvironmentorfromthenatureoftheproblemitself.Themanufacturingprocesseswhichareavailable,togetherwiththefacilitiesofacertainplant,constituterestrictionsonadesigner'

sfreedom,andhenceareapartoftheimpliedspecifications.Asmallplant,forinstance,maynotowncold-workingmachinery.Knowingthis,thedesignerselectsothermetal-processingmethodswhichcanbeperformedintheplant.Thelaborskillsavailableandthecompetitivesituationalsoconstituteimpliedspecifications.

Aftertheproblemhasbeendefinedandasetofwrittenandimpliedspecificationshasbeenobtained,thenextstepindesignisthesynthesisofanoptimumsolution.Nowsynthesiscannottakeplacewithoutbothanalysisandoptimizationbecausethesystemunderdesignmustbeanalyzedtodeterminewhethertheperformancecomplieswiththespecifications.

Thedesignisaniterativeprocessinwhichweproceedthroughseveralsteps,evaluatetheresults,andthenreturntoanearlierphaseoftheprocedure.Thuswemaysynthesizeseveralcomponentsofasystem,analyzeandoptimizethem,andreturntosynthesistoseewhateffectthishasontheremainingpartsofthesystem.Bothanalysisandoptimizationrequirethatweconstructordeviseabstractmodelsofthesystemwhichwilladmitsomeformofmathematicalanalysis.Wecallthesemodelsmathematicalmodels.Increatingthemitisourhopethatwecanfindonewhichwillsimulatetherealphysicalsystemverywell.

Evaluationisasignificantphaseofthetotaldesignprocess.Evaluationisthefinalproofofasuccessfuldesign,whichusuallyinvolvesthetestingofaprototypeinthelaboratory.Herewewishtodiscoverifthedesignreallysatisfiestheneedorneeds.Isitreliable?

Willitcompetesuccessfullywithsimilarproducts?

Isiteconomicaltomanufactureandtouse?

Isiteasilymaintainedandadjusted?

Canaprofitbemadefromitssaleoruse?

Communicatingthedesigntoothersisthefinal,vitalstepinthedesignprocess.Undoubtedlymanygreatdesigns,inventions,andcreativeworkshavebeenlosttomankindsimplybecausetheoriginatorswereunableorunwillingtoexplaintheiraccomplishmentstoothers.Presentationisasellingjob.Theengineer,whenpresentinganewsolutiontoadministrative,management,orsupervisorypersons,isattemptingtosellortoprovetothemthatthissolutionisabetterone.Unlessthiscanbedonesuccessfully,thetimeandeffortspentonobtainingthesolutionhavebeenlargelywasted.

Basically,thereareonlythreemeansofcommunicationavailabletous.Therearethewritten,theoral,andthegraphicalforms.Thereforethesuccessfulengineerwillbetechnicallycompetentandversatileinallthreeformsofcommunication.Atechnicallycompetentpersonwholacksabilityinanyoneoftheseformsisseverelyhandicapped.Ifabilityinallthreeformsislacking,noonewilleverknowhowcompetentthatpersonis!

Thecompetentengineershouldnotbeafraidofthepossibilityofnotsucceedinginapresentation.Infact,occasionalfailureshouldbeexpectedbecausefailureorcriticismseemstoaccompanyeveryreallycreativeidea.Thereisagreattobelearnedfromafailure,andthegreatestgainsareobtainedbythosewillingtoriskdefeat.Inthefindanalysis,therealfailurewouldlieindecidingnottomakethepresentationatall.

IntroductiontoMachineDesign

Machinedesignistheapplicationofscienceandtechnologytodeviseneworimprovedproductsforthepurposeofsatisfyinghumanneeds.Itisavastfieldofengineeringtechnologywhichnotonlyconcernsitselfwiththeoriginalconceptionoftheproductintermsofitssize,shapeandconstructiondetails,butalsoconsidersthevariousfactorsinvolvedinthemanufacture,marketinganduseoftheproduct.

Peoplewhoperformthevariousfunctionsofmachinedesignaretypicallycalleddesigners,ordesignengineers.Machinedesignisbasicallyacreativeactivity.However,inadditiontobeinginnovative,adesignengineermustalsohaveasolidbackgroundintheareasofmechanicaldrawing,kinematics,dynamics,materialsengineering,strengthofmaterialsandmanufacturingprocesses.

Asstatedpreviously,thepurposeofmachinedesignistoproduceaproductwhichwillserveaneedforman.Inventions,discoveriesandscientificknowledgebythemselvesdonotnecessarilybenefitpeople;

onlyiftheyareincorporatedintoadesignedproductwillabenefitbederived.Itshouldberecognized,therefore,thatahumanneedmustbeidentifiedbeforeaparticularproductisdesigned.

Machinedesignshouldbeconsideredtobeanopportunitytouseinnovativetalentstoenvisionadesignofaproductistobemanufactured.Itisimportanttounderstandthefundamentalsofengineeringratherthanmemorizemerefactsandequations.Therearenofactsorequationswhichalonecanbeusedtoprovideallthecorrectdecisionstoproduceagooddesign.Ontheotherhand,anycalculationsmademustbedonewiththeutmostcareandprecision.Forexample,ifadecimalpointismisplaced,anotherwiseacceptabledesignmaynotfunction.

Gooddesignsrequiretryingnewideasandbeingwillingtotakeacertainamountofrisk,knowingthatisthenewideadoesnotworktheexistingmethodcanbereinstated.Thusadesignermusthavepatience,sincethereisnoassuranceofsuccessforthetimeandeffortexpended.Creatingacompletelynewdesigngenerallyrequiresthatmanyoldandwell-establishedmethodsbethrustaside.Thisisnoteasysincemanypeopleclingtofamiliarideas,techniquesandattitudes.Adesignengineershouldconstantlysearchforwaystoimproveanexistingproductandmustdecidewhatold,provenconceptsshouldbeusedandwhatnew,untriedideasshouldbeincorporated.

Newdesignsgenerallyhave“bugs”orunforeseenproblemswhichmustbeworkedoutbeforethesuperiorcharacteristicsofthenewdesignscanbeenjoyed.Thusthereisachanceforasuperiorproduct,butonlyathigherrisk.Itshouldbeemphasizedthatifadesigndoesnotwarrantradicalnewmethods,suchmethodsshouldnotbeappliedmerelyforthesakeofchange.

Duringthebeginningstagesofdesign,creativityshouldbeallowedtoflourishwithoutagreatnumberofconstraints.Eventhoughmanyimpracticalideasmayarise,itisusuallyeasytoeliminatethemintheearlystagesofdesignbeforefirmdetailsarerequiredbymanufacturing.Inthisway,innovativeideasarenotinhibited.Quiteoften,morethanonedesignisdeveloped,uptothepointwheretheycanbecomparedagainsteachother.Itisentirelypossiblethatthedesignwhichultimatelyacceptedwilluseideasexistinginoneoftherejecteddesignsthatdidnotshowasmuchoverallpromise.

Psychologistsfrequentlytalkabouttryingtofitpeopletothemachinestheyoperate.Itisessentiallytheresponsibilityofthedesignengineertostrivetofitmachinestopeople.Thisisnotaneasytask,sincethereisreallynoaveragepersonforwhichcertainoperatingdimensionsandproceduresareoptimum.

Anotherimportantpointwhichshouldberecognizedisthatadesignengineermustbeabletocommunicateideastootherpeopleiftheyaretobeincorporated.Initiallythedesignermustcommunicateapreliminarydesigntogetmanagementapproval.Thisisusuallydonebyverbaldiscussionsinconjunctionwithdrawinglayoutsandwrittenmaterial.Tocommunicateeffectively,thefollowingquestionsmustbeanswered:

（1）Doesthedesignreallyserveahumanneed?

（2）Willitbecompetitivewithexistingproductsofrivalcompanies?

（3）Isitecon