RSKIRAN Advanced Engineering Design nOTES

Advanced Engineering Design

Course Objectives

1. To introduce design philosophy, various design models, and the process of product design, including creativity, need analysis, and strength considerations.

2. To understand failure theories and their applications in design, including static failure theories, fatigue mechanisms, and the design for fatigue strength and life.

3. To analyze surface failures, their causes, and the effects of surface geometry, wear, corrosion, and dynamic contact stresses on the performance of materials.

4. To evaluate the economic factors influencing design, including break-even analysis, ergonomics, and modern approaches like value engineering.

5. To study the importance of fits, tolerances, and surface finish in design, and their impact on load transmission and the selection of materials and processes.

6. To promote teamwork and ethical considerations in engineering design, emphasizing the importance of collaboration and responsible decision-making in product development.

7. To explore the process of product design, including strategy development, concept generation, planning, testing, and design for manufacturing techniques.

Syllabus:

Design philosophy: Design process, Problem formation, Introduction to product design, Various design models-Shigley model, Asimov model and Norton model, Need analysis, Strength considerations -standardization. Creativity, Creative techniques, Material selections, Notches and stress concentration, design for safety and Reliability

Failure theories: Static failure theories, Distortion energy theory, Maximum shear stress theory, Coulomb-Mohr’s theory, Modified Mohr’s theory, Fracture mechanics theory., Fatigue mechanisms, Fatigue failure models, Design for fatigue strength and life, creep: Types of stress variation, design for fluctuating stresses, design for limited cycles, multiple stress cycles, Fatigue failure theories ,cumulative fatigue damage, thermal fatigue and shock, harmful and beneficial residual stresses, Yielding and transformation

Surface failures: Surface geometry, mating surfaces, oil film and their effects, design values and procedures, adhesive wear, abrasive wear, corrosion wear, surface fatigue, different contacts, dynamic contact stresses, surface fatigue failures, surface fatigue strength.

Economic factors influencing design: Economic analysis, Break-even analysis, Human engineering considerations, Ergonomics, Design of controls, Design of displays. Value engineering, Material and process selection in value engineering, Modern approaches in design.

Importance of Fits and Tolerance influencing design: Tolerance from process and function, interchangeability and selective assembly, selection of fits for different design situations, surface finish. Load transmission, load equalization light weigh and rigid constructions.

Team work and Ethics in engineering design: Team formation, functioning, discharge, team dynamics, Ethical issues considered during engineering design process

Product Design: Product strategies, Product value, Product planning, product specifications, concept generation, concept selection, concept testing.

Design for manufacturing: Forging design, Casting design, Design process for non metallic parts, Plastics, Rubber, Ceramic, Wood, Glass parts. Material selection in machine design.

Course Outcomes

1. Demonstrate the application of various design models and the design process, considering factors such as creativity, material selection, and safety.

2. Apply failure theories to assess design strength and durability, considering static and dynamic failure mechanisms, including fatigue and creep.

3. Analyze surface failure mechanisms such as wear and corrosion, and apply this knowledge to improve material performance in real-world applications.

4. Conduct economic analysis in design, including break-even analysis and ergonomics, to optimize product design and functionality.

5. Apply principles of fits, tolerances, and surface finish to ensure proper functioning, load transmission, and manufacturing efficiency.

6. Understand the role of teamwork and ethics in the engineering design process, fostering collaboration and responsible decision-making.

7. Design products with a focus on value, product planning, and effective selection of manufacturing methods, including considerations for materials such as plastics, rubber, and ceramics.

References:

1. Machine Design An Integrated Approach by Robert L. Norton, Prentice-Hall New Jersey, USA.

2. Mechanical Engineering Design by J.E. Shigley and L.D. Mitchell published by McGraw- Hill International Book Company, New Delhi.

3. Fundamentals of machine elements by Hamrock, Schmid and Jacobian, 2nd edition, McGraw- Hill International edition.

4. Product design and development by Karl T. Ulrich and Steven D. Eppinger. 3rd edition, Tata McGraw Hill.

5. Product Design and Manufacturing by A.K. Chitale and R.C....