Ref: 4.

Lebanese International University

School of Engineering
Department of Mechanical Engineering

Spring 2016-2017

MENG560 Machine Design I Section C

Instructor:Mehdi Chouman
Office:School of Engineering - Block F 2d floor
E-Mail: mehdi.chouman@liu.edu.lb
Campus Beirut Lectures time:M 17:00-19:45 - classroom 401-F

Office Hours: M 16:00 -17:00

Note: If these hours are not convenient, please make an appointment at a mutually agreeable
time. It is best to make an appointment or you can send an e-mail message.

Course Description
Philosophy of machine design safety factor/reliability relationships. Contemporary fatigue design
analysis, including low-high cycle fatigue (S-N diagrams and fracture mechanics), tri-axial state
of non-reversed stress and fatigue damage, surface failure with applications on design case
studies of relatively simple machine parts.

Course Performance Criteria (PCs)

A student who successfully fulfills the course requirements will have demonstrated:
Develop an understanding of the general design process and the fundamentals of a good
PC-1.
design.
PC-2. Develop an understanding of the fundamental principles of failure theories.
Develop an understanding of static and dynamic modes of failure of machine parts exposed
PC-3.
to uniaxial and multiaxial stresses.
PC-4. Develop an understanding of the fundamental principles of surface fatigue.

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PCs mapping to PSOs: 1 (Weak), 2 (Medium), 3 (Strong), or blank (None).

Program Students Outcomes
(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k)
PC-1 2 2
PC-2 2 2
PC-3 2 3 2
PC-4 2 3 2
PC-5
PC-6
PC-7
PC-8

Course Learning Outcomes

(a) An ability to apply knowledge of mathematics, science, and engineering.
(c) An ability to design a system, component, or process to meet desired needs within realistic
constraints such as economic, environmental, social, political, ethical, health and safety,
manufacturability, and sustainability.
(e) An ability to identify, formulate, and solve engineering problems.

Program Students Outcomes (PSOs)

Student outcomes describe what students are expected to know and be able to do by the time of
graduation. These relate to the knowledge, skills, and behaviors that students acquire as they
progress through the program.
(a) An ability to apply knowledge of mathematics, science, and engineering.
(b) An ability to design and conduct experiments, as well as to analyze and interpret data.
(c) An ability to design a system, component, or process to meet desired needs within realistic
constraints such as economic, environmental, social, political, ethical, health and safety,
manufacturability, and sustainability.
(d) An ability to function on multidisciplinary teams.
(e) An ability to identify, formulates, and solves engineering problems.
(f) An understanding of professional and ethical responsibility.
(g) An ability to communicate effectively.
(h) The broad education necessary to understand the impact of engineering solutions in a global,
economic, environmental, and societal context.
(i) Recognition of the need for, and an ability to engage in life-long learning.
(j) Knowledge of contemporary issues.
(k) An ability to use the techniques, skills, and modern engineering tools necessary for
engineering practice

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Topics Covered
1. Introduction to Design
2. Materials and Processes
3. Load Determination
4. Stress, Strain, and Deflection
5. Static Failure Theories
6. Fatigue Failure Theories
7. Surface Failure

Prerequisites
N/A

Co-requisites
N/A

Textbook and Recommended Material

Textbooks

Machine Design: An Integrated Approach. Robert L. Norton. Pearson International Edition,

Fourth Edition..

References

Shigley's Mechanical Engineering Design. Richard G. Budynas and J. Keith Nisbett. Eighth
Edition. McGrawHill, 2008.

Course Schedule

Week Textbook/Reference Topic

Chapter 1: Introduction to Design

1.1 Design
1.2 A Design Process
1.3 Problem Formulation and Calculation
1 Norton
1.7 Factors of Safety and Design Codes
Chapter 2: Materials and Processes
2.1 Material-Property Definitions
2.6 General Properties of Metals

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Week Textbook/Reference Topic

Chapter 3: Load Determination

3.1 Loading Classes
2 Norton 3.3 Load Analysis
3.9 Beam Loading (Singularity Function)
4.10 Deflections in Beams

Chapter 3: Load Determination

3 Norton 4.10 Deflections in Beams
4.15 Stress Concentration

Chapter 4: Stress, Strain, and Deflection

4 Norton 4.15 Stress Concentration
4.17 Stresses in Cylinders

Chapter 5: Static Failure Theories

5 Norton 5.1 Failure of Ductile Material Under Static Loading
5.3 Fracture Mechanics

Chapter 5: Static Failure Theories

6 Norton 5.1 Failure of Ductile Material Under Static Loading
5.3 Fracture Mechanics

Chapter 6: Fatigue Failure Theories

6.1 Mechanism of Fatigue Failure
7 Norton
6.2 Fatigue-Failure Models
6.4 Fatigue loads

Chapter 6: Fatigue Failure Theories

8 Norton 6.5 Measuring Fatigue Failure Criteria
6.6 Estimating Fatigue Failure Criteria

Chapter 6: Fatigue Failure Theories

6.7 Notches and Stress Concentration
9 Norton
6.8 Residual Stresses
6.9 Designing for High-Cycle Fatigue

Chapter 6: Fatigue Failure Theories

10 Norton 6.10 Designing for Fully Reversed Uniaxial Stresses
6.11 Designing for Fluctuating Uniaxial Stresses

Chapter 6: Fatigue Failure Theories

11 Norton 6.10 Designing for Fully Reversed Uniaxial Stresses
6.11 Designing for Fluctuating Uniaxial Stresses

Chapter 6: Fatigue Failure Theories

12 Norton 6.12 Designing for Multi-axial Stresses in Fatigue
6.13 A General Approach to High-Cycle Fatigue

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Week Textbook/Reference Topic

Chapter 6: Fatigue Failure Theories

13 Norton 6.12 Designing for Multi-axial Stresses in Fatigue
6.13 A General Approach to High-Cycle Fatigue

Chapter 7: Surface Failure

7.1 Surface Geometry
14 Norton 7.2 Mating Surfaces
7.3 Friction
7.4 Adhesive Wear

Chapter 7: Surface Failure

7.4 Adhesive Wear
15 Norton
7.5 Abrasive Wear
7.6 Corrosion Wear

Method of Instruction
A mix of passive and active techniques will be adopted, primarily:
1. Instructor Lecture
2. Class discussion
3. Problem Based Learning

Course Requirements

1. Each student will read the chapters/sections assigned in the textbook according to
instructions, previously stated sections and announced sections during class.
Additionally, each student will attempt to answer all Study Questions and Study
Problems before class.
2. Class discussion will take place in the form of Question and Answer based on
instructor presentations and Study Problems.
3. Each Student will answer all Study Questions and Study Problems after class and
compare the answers given before class. Additionally, each student will complete all
homework as assigned in class.
4. Students are expected to attend all classes except in very extenuating circumstances as
indicated under "Attendance Policy" below. Students are also expected to actively
participate in class as described in "Class Participation" below.

Class Participation, Professionalism and Attention to Detail

1. This course requires that you participate in class discussions. In order for the discussions
to be meaningful, each student must come to class fully prepared to discuss the assigned
reading and to make meaningful comments. Since participation plays a role in your final
grade, it is essential that you have not only read the assignment, but have answered all
Study Questions and solved (or explained why you cant solve) Study Problems.

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2. Your class participation is tied to your attendance since you can't participate in class
discussions if you are not in class. Class discussions and in-class exercises can't be
duplicated so if you are not in class, you miss out on the experience.
3. Please note that merely showing up for class is not sufficient for this class. Unless you
make a conscientious effort to attend every class and actively participate in discussions.
4. All students are expected to conduct themselves in a professional manner. Unprofessional
behavior such as, but not limited to, repeated disruption of class (including habitually
walking in after class has started), sleeping in class, doing other course work in class,
reading a newspaper in class, a ringing cell phone, frequent side conversations with other
students and/or rudeness toward any person will be considered a serious violation of this
standard and will lower your grade accordingly. Please be sure to turn off your cell phone
before the start of class.
5. Attention to detail entails being prepared for class. This would include, but is not limited
to; having a pencil/pen, note pad, calculator; reading and following the course syllabus,
etc.

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Attendance Policy
1. Attendance in all classes is required. There are no exceptions to this policy except in very
extenuating circumstances (sickness of such severity that it prevents the student from
attending classes, serious illness or death in the family). Please note that if you schedule a
doctor's or dentist's appointment during class hours, this is NOT an excused absence.
Athletic students (As identified by the University) will also be excused for documented
games/matches/tournaments etc. It is incumbent on the student to provide acceptable
documentation to substantiate all absences or the absence will be considered unexcused.
Acceptable documentation for excused absences must be provided no later than one week
following the student's return to school. Documentation submitted after this time will not
be considered. It is incumbent on the student to provide the documentation, the instructor
will not ask for it. Please note that the documentation must state that the student was
unable to attend class during specific dates.
2. Roll will be called in the very beginning of each class. If you arrive after roll has been
called, you will be marked as half present.
3. In any regular semester or summer term, students may miss no more than the equivalent
of five weeks (15 class sessions for courses offered 3 times a week, 10 for courses
offered twice a week, and 5 for courses offered once a week.) of instructions in any
registered course and still receive credit for that course. The number of absences in
summer modules is 8 class sessions for courses offered 4 times a week, and 4 class
sessions for courses offered twice a week. It should be well noted that attendance is taken
for all class sessions, i.e. from the 1st to the last, and that excuses of any nature do NOT
eliminate an absence whatsoever. Students who exceed the above limits are automatically
given an (AW) grade in the course by the UMS, and consequently not be allowed to
attend class any longer.
4. If the number of absences exceeds the limits spelled out in item 3 after the withdrawal
deadline, the student will not receive an AW grade, therefore, the final examination must
be written, otherwise, an F grade will be granted.

Make-Up Examination Policy

As per university council decision, a student is eligible for a mid-term or final examination
make-up if and only if he/she had the following incidents:

a. Sickness; proved by hospitalization report; that is; a discharge summary is

necessary.
b. Death in the family proved by a death certificate or equivalent and personal
identification.
c. Accidents proved by an expert report.

1. The last day to submit a petition for a make-up examination is on the first Monday after
the date of the last examination which is usually takes place on Saturday. The decisions
for approval/disapproval by the campus committee should take place on first Tuesday
after the date of the last examination.

2. Regarding the mid-term examination, if approved, either the student writes a mid-term or
the weight of the mid-term would be credited toward the following mid-term or the final.

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3. For the midterm, the student must appeal to the school directly; the approval of the
Dean/Associate Dean is a must.

4. Final Make-up examinations take place always on the Wednesday prior to starting the
next semester. All grades must be approved on the Friday prior to starting the spring or
summer semester.

5. As for summer semester, all approved make-up final exams will be held on the first
Wednesday following end of summer Final Examination period.

6. All grades of approved make-up final exams must be approved by the Deans and send by
mail to the registrars Office of each relevant Campus, the Deans are also required to cc
the Academic Director, Provost and Vice President. This procedure is only applicable to
Make-Up examination Policy.

Supplementary Examinations Policy

1. A student is eligible for a supplementary examination if and only if the student has one
failed course to complete his/her graduation requirements and his/her GPA is 2.0 and
above; that is, the process takes place upon clearance. Therefore, supplementary
examination is granted to students who failed in the last year of graduation and could not
re-take the course in the same year.
2. The supplementary examination is only written for courses with F grades. A student who
received either W or AW is ineligible to be granted a supplementary examination.
3. The course of the supplementary examination must be registered in the same term as
(Supplementary Examination) and the received grade must be shown in the
aforementioned same semester. The original F grade of the course must be left intact. The
GPA should be calculated based on the supplementary examination grade.
4. Supplementary examination is comprehensive and is only granted once. The
examinations weight is one hundred percent.

Directed Study (DS) Course Policy (offered as SP Courses)

Regardless of GPA statues a student is eligible for DS courses under the following conditions:

1. The number of DS courses is limited to two.

2. The courses statuses are either F or D, D+ (To raise GPA provided that only a
maximum of two courses are needed to raise GPA).

3. The two courses were failed in the year of graduation and the courses were not offered
in the subsequent semester in which the courses were failed. That is the courses must be
either 400 level or 600 level courses.

4. A course can be offered as DS only if the course is not offered in the main campus or
nearby campuses. Nearby campuses are grouped as (Beirut, Saida, Nabatieh), and (Beirut
& Jeddeih). However, Bekaa and Tripoli are considered remote campuses.

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5. DS courses should be treated like any other normal courses in which grade distribution
along with the examination dates are immediately entered to UMS so that students know
their examination dates.

Probations rules
The duration of finishing a BS degree is three years. However, the school allows the student to
stay for four and a half years excluding summer semesters to earn his/her degree. Hence, a
student must pass a minimum of 12 credits in each semester so that he/she can finish in four and
half years. Consequently, a student who is on probation must pass at least 12 credits in every
semester since he/she joined the university.

The duration of finishing an MS degree is two years. However the school allows the student to
stay for three years excluding summer semesters to earn his/her degree. Hence, a student must
pass a minimum of 9 credits in each semester so that he/she can finish in three years.
Consequently, a student who is on probation must pass at least 9 credits in every semester since
he/she joined the university.

1. A BS student is considered for being ousted from school if the student had been on probation
for three consecutive semesters; summer semester is not counted. The Total GPA should be
cumulative and hence the number of probations is based on cumulative GPA not on
semester GPA.

2. An MS student is considered for being ousted from the school if the student had been on
probation for two consecutive semesters; summer semester is not counted. The consecutive
probations are counted after the student attempts a minimum of twelve credits. The Total
GPA should be cumulative and hence the number of probations is based on cumulative
GPA not on semester GPA.

3. The student will be ousted from school and offered to join another school at LIU if item 1 is
met or the student did not pass the required number of credits since he/she joined LIU. That
is an average of 12 credits per semester, for BS student, since the student joined LIU, and 9
credits per semester for MS student, since he/she joined LIU.

4. A BS student cannot register for the senior project course while being on probation.

5. An MS student cannot register for the thesis course while being on probation.

Course Assessment
This course will be assessed by two main instruments:

1. Online student evaluation construct of 15 questions with Likert scale (5 answers)

2. Class visitation

These instruments will be reviewed by the department each term. In addition, the School of
Engineering Council will review the recommendation of the department at the end of each
academic year.

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Marking Profile:

Evaluation Date Time Room Weight Chapters Covered

Quizzes N/A% N/A
Test N/A N/A N/A N/A% N/A
Midterm April 20, 2017 17:00- Room 40% Chapters 3, 4, 5 and
19:00 6
Assignments 15% All Chapters
Project N/A N/A% N/A
Final TBA 3 Hours 45% All Chapters

*Final exam includes all materials covered in the course with emphasis on the materials covered
after the midterm.
* All examinations must contain questions that are based on literal interpretation and
competence. The cores of the questions are profoundly related to direct reading from assigned
textbooks and references. The weight of the questions will be at least 15 % and at most 25 % of
the total percentage of the mark.
* A student cannot write any examinations without valid university identification. Failing to
have valid university identification will result in assigning a zero mark to the relevant
examination.

Equivalent Lettering Grades

Final Grade Letter Grade

90.0-100 A
85.0-89.99 B+
80.0-84.99 B
75.0-79.9 C+
70.0-74.99 C
65.0-69.99 D+
60.0-64.99 D
0.0-59.0 F

Homework
Homework should be clearly presented i.e.:
1. It should be written on A4 paper. The problem number should be clearly shown, and the
problems must be organized in the ascending order. One problem is allowed on each side
of the paper, that is, do not write two or more problems on one face of the sheet.
2. Each necessary figure that is part of the solution of the problem must be neatly drawn,
that is, use your compass, protractor, ruler, and any other mean to perform task.
3. It should include a title page (Course Name, Semester, Date, Name).
4. The homework papers should be stapled together.

Notes
1. Photocopied books are not allowed in classroom

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2. Deadline for volunteer withdrawal is on Sunday, May 28, 2017

3. Exam dates are subject to change
Assignments:

Assignment Chapter/Subject Assignment details Due date

1 Chapter 2: Problems : 2.9 2.14- March 2, 2017
Materials and 2.21
Processes
2 Chapter 3: Load Problems :3.25 (a) March 9, 2017
Determination 4.23(a)
Chapter 4: Stress,
Strain, and
Deflection
3 Chapter 4: Stress, Problems : 4.41 4.76 (a) March 16, 2017
Strain, and 4.78(a)
Deflection
4 Chapter 5: Static Problems : 5.37 5.51 April 6, 2017
Failure Theories 5.53

5 Chapter 6: Problems : 6.1- 6.51- April 20, 2017

Fatigue Failure 6.53
Theories
6 Chapter 6: Problems : 6.4 6.55 April 27, 2017
Fatigue Failure 6.57
Theories
7 Chapter 6: Problems : 6.15(a) 6.59 May 4, 2017
Fatigue Failure 6.63
Theories
8 Chapter 6: Problems : 6.20 6.26 May 11, 2017
Fatigue Failure 6.29
Theories
9 Chapter 6: Problems : 6.25 6.38 May 18, 2017
Fatigue Failure 6.62
Theories
10 Chapter 7: Problems : 7.13 - 7.25 May 24, 2017
Surface Failure 7.26

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