Engineering design is the process of devising a system,

component, or process to meet desired needs. It is a

decision making process in which basic sciences,
mathematics, and engineering sciences are applied to
convert resources optimally to meet stated objective

 Identification of need generally starts the design

process. Recognition of the need and phrasing the need

often constitute a highly creative act, because the need
may be only a vague discontent, a feeling of
uneasiness, or a sensing that something is not right.
The need is often not evident at all; recognition is
usually triggered by a particular adverse circumstance
or a set of random circumstances that arises almost
simultaneously

 The definition of problem is more specific and must

include all the specifications for the object that is to be

designed. The specifications are the input and output
quantities, the characteristics and dimensions of the
space the object must occupy, and all the limitations
on these quantities. We can regard the object to be
designed as something in a black box. In this case we
must specify the inputs and outputs of the box,
together with their characteristics and limitations.

 The synthesis of a scheme connecting possible system

elements is sometimes called the invention of the

concept or concept design. This is the first and most
important step in the synthesis task. Various schemes
must be proposed, investigated, and quantified in
terms of established metrics.

 As the fleshing out of the scheme progresses, analyses

must be performed to assess whether the system

performance is satisfactory or better, and, if
satisfactory, just how well it will perform.
System schemes that do not survive analysis are
revised, improved, or discarded. Those with potential
are optimized to determine the best performance of
which the scheme is capable. Competing schemes are
compared so that the path leading to the most
competitive product can be chosen.

 Evaluation is a significant phase of the total design

process. Evaluation is the final proof of a successful

design and usually involves the testing of a prototype
in the laboratory. Here we wish to discover if the
design really satisfies the needs.

 Communicating the design to others is the final, vital

presentation step in the design process. Undoubtedly,

many great designs, inventions, and creative works
have been lost t0 posterity simply because the
originators were unable or unwilling to explain their
accomplishments to others.

 characteristic that influences the design of the

element or, perhaps, the entire system.

1 Functionality
2 Strength/stress
3 Distortion/deflection/stiffness
4 Wear
5 Corrosion
6 Safety
7 Reliability
8 Manufacturability
9 Utility
10 Cost
11 Friction
12 Weight
13 Life

14 Noise
15 Styling
16 Shape
17 Size
18 Control
19 Thermal properties
20 Surface
21 Lubrication
22 Marketability
23 Maintenance
24 Volume
25 Liability

 The consideration of cost plays such an important role

in the design decision process that we could easily

spend as much time in studying the cost factor as in
the study of the entire subject of design.
The cost of manufacturing a single product will vary
from city to city and from one plant to another because
of overhead, labour, taxes, and freight differentials and
the inevitable slight manufacturing variations.

 A code is a set of specifications for the analysis, design,

manufacture, and construction of something. The

purpose of a code is to achieve a specified degree of
safety, efficiency, and performance or quality. It is
important to observe that safety codes do not imply
absolute safety

 A standard is a set of specifications for parts,

materials, or processes intended to achieve uniformity,

efficiency, and a specified quality. One of the
important purposes of a standard is to place a limit on
the number of items in the specifications so as to
provide a reasonable inventory of tooling, sizes,
shapes, and varieties.

 The organizations of interest to mechanical engineers are:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

Aluminium Association (AA)

American Gear Manufacturers Association (AGMA)
American Institute of Steel Construction (AISC)
American Iron and Steel Institute (AISI)
American National Standards Institute (ANSI)5
ASM International6
American Society of Mechanical Engineers (ASME)
American Society of Testing and Materials (ASTM)
American Welding Society (AWS)
American Bearing Manufacturers Association (ABMA)7
British Standards Institution (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)8
Society of Automotive Engineers (SAE)

 The strict liability concept of product liability generally

prevails in the United States. This concept states that

the manufacturer of an article is liable for any damage
or harm that results because of a defect. And it doesnt
matter whether the manufacturer knew about the
defect, or even could have known about it.
The best approaches to the prevention of product
liability are good engineering in analysis and design,
quality control, and comprehensive testing
procedures.

 The word ergonomics implies the study of man at

work while the word human factors implies the study

of ma n in relation to equipment and environment.

 Design

and performance parameter that

contribute to achieving customer requirements

can

Refer to detail description of the completed design,

including all dimensions, material properties and

fabrication instructions

Power to be delivered: 20 hp
Input speed: 1750 rev/min
Output speed: 85 rev/min
Targeted for uniformly loaded applications, such as conveyor
belts, blowers,
and generators
Output shaft and input shaft in-line
Base mounted with 4 bolts
Continuous operation
6-year life, with 8 hours/day, 5 days/wk
Low maintenance
Competitive cost
Nominal operating conditions of industrialized locations
Input and output shafts standard size for typical couplings

Power to be delivered: 20 hp
Power efficiency: >95%
Steady state input speed: 1750 rev/min
Maximum input speed: 2400 rev/min
Steady-state output speed: 8288 rev/min
Usually low shock levels, occasional moderate shock
Input and output shaft diameter tolerance: 0.001 in
Output shaft and input shaft in-line: concentricity 0.005 in, alignment
0.001 rad
Maximum allowable loads on input shaft: axial, 50 lbf; transverse, 100 lbf
Maximum allowable loads on output shaft: axial, 50 lbf; transverse, 500 lbf
Base mounted with 4 bolts
Mounting orientation only with base on bottom
100% duty cycle
Maintenance schedule: lubrication check every 2000 hours; change of lubrication
every 8000 hours of operation; gears and bearing life >12,000 hours;
infinite shaft life; gears, bearings, and shafts replaceable
Access to check, drain, and refill lubrication without disassembly or opening of
gasketed joints.

 Materials Selection
The designer of any product, other than software must

get involved with material selection.

Only occasionally will the exact grade of material be
specified by the customer.
Even then the designer must understand the material to
be able to design the product.

 So many materials, so much information.

How do we decide?
How do we begin to choose?

First we need to look at the function of the product

 Product Analysis
Just what it says analyse the product!
What does it do?
How does it do it?
Where does it do it?

Who uses it?

What should it cost?

 What is the function of a bike obvious?

How does the function depend on the type

of bike?
Racing
Touring
Mountain bike
Commuter
Childs

 How is it made to be easily maintained?

What should it look like (colours etc.)?

What should it cost?
How has it been made comfortable to ride?

How do the mechanical parts work and interact?

 Textbooks

Manufacturers literature
Internet Sites

 Modulus spans 5 orders of magnitude 0.01 GPa for

foams to 1000 GPa for diamond

The charts therefore use logarithmic scales, where
twice the distance means ten times.
This makes it possible to show the full range on one
chart

 Allow easy visualisation of properties

Show lots of different materials

Can be drilled down to specifics
Show balances of properties e.g. strength v cost

Ideal for a first rough cut selection

 1. Think about the design from ergonomic and

functional viewpoint.
2. Decide on the materials to be used.
3. Choose a suitable process that is also economic
4. Is the product performance driven or cost driven?
This makes a huge difference when choosing materials

Although we usually choose materials first sometimes

it is the shape and process which is the limiting factor

 Drink Container

What are the requirements

 Provide leak free environment for storing liquid.

Comply with food standards & protect liquid from

health hazards.
For fizzy drinks, withstand pressure.
Brand image & identity
Easy to open
Easy to store & transport
Cheap for high volumes

 Steel

Aluminium
Glass
Plastic