NHẬP MÔN KỸ

THUẬT CƠ KHÍ
INTRODUCTION TO MECHANICAL ENGINEERING
CHƯƠNG 2. THIẾT KẾ CƠ KHÍ
Mechanical Design
2.1. OVERVIEW

u The National Academy of Engineering (NAE) has identified 14 so-called Grand

Challenges facing the global engineering community and profession in the
twenty-first century:

• Make solar energy economical • Engineer better medicines

• Provide energy from fusion • Reverse-engineer the brain
• Develop carbon sequestration methods • Prevent nuclear terror
• Manage the nitrogen cycle • Secure cyberspace
• Provide access to clean water • Enhance virtual reality
• Restore and improve urban infrastructure • Advance personalized learning
• Advance health informatics • Engineer the tools of scientific discovery
 2.1. OVERVIEW

Relationship of
the topics
emphasized in
this chapter
(shaded boxes)
relative to an
overall program
of study in
mechanical
engineering
2.2. THE DESIGN PROCESS

u Although a mechanical engineer might specialize in a field such as materials

selection or fluids engineering, the day-to-day activities will often focus on
design.
u A designer will start from scratch and have the freedom to develop an original
product from the concept stage onward.
u Smart phones and hybrid vehicles are examples of how technology is changing
the way people think about communication and transportation. In other cases,
an engineer’s design work will be incremental and focus on improving an existing
product.
2.2. THE DESIGN PROCESS
Where does the life of a new product begin?
u First, a company will identify new business opportunities and define requirements
for a new product, system, or service.

u engineers exercise their creativity and develop potential concepts, select the
top concept using the requirements as decision criteria, develop details (such as
layout, material choice, and component sizing), and bring the hardware to
production
2.2. THE DESIGN PROCESS
Will the product meet the initial requirements, and can it be
produced economically and safely?

u Mechanical engineers are mindful that the level of precision needed in any
calculation gradually grows as the design matures from concept to final
production.

u Resolving specific details (Will a grade 1020 steel be strong enough? What must
the viscosity of the oil be? Should ball or tapered roller bearings be used?)
doesn’t make much sense until the design gets reasonably to its final form.

u After all, in the early stages of a design, the specifications for the product’s size,
weight, power, or performance could change
2.2. THE DESIGN PROCESS

 Everyone can learn to become more innovative.

 Innovation, a familiar concept to industrial designers, artists, and marketers, is
becoming a critical topic in the development of strategies around the world to
solve complex social, environmental, civic, economic, and technical challenges
2.2. THE DESIGN PROCESS
2.2. THE DESIGN PROCESS
2.2. THE DESIGN PROCESS

Flowchart of the
prototypical mechanical
design process:

 • Requirements
development
 • Conceptual design
 • Detailed design
 • Production
2.2. THE DESIGN PROCESS
Requirements Development

 Engineering design begins when a basic need has been identified.

Initially, a design engineer develops a comprehensive set of system
requirements considering the following issues:

 • Functional performance: What the product must accomplish

 • Environmental impact: During production, use, and retirement
 • Manufacturing: Resource and material limitations
 • Economic issues: Budget, cost, price, profit
 • Ergonomic concerns: Human factors, aesthetics, ease of use
 • Global issues: International markets, needs, and opportunities
 • Life cycle issues: Use, maintenance, planned obsolescence
 • Social factors: Civic, urban, cultural issues
 2.2. THE DESIGN PROCESS
Conceptual Design

 In this stage,
design engineers
collaboratively
and creatively
generate a wide
range of potential
solutions to the
problem at hand
and then select
the most promising
one(s) to develop.
 2.2. THE DESIGN PROCESS
Conceptual Design

 the process
is guided by
divergent
thinking - a
diverse set of
creative
ideas is
developed
 Once a rich set of concepts has been generated, the
process is guided by convergent thinking, as
engineers begin to eliminate ideas and converge on
the best few concepts.
2.2. THE DESIGN PROCESS
Detailed Design

 At this point in the design process, the team has defined, innovated,
analyzed, and converged its way to the best concept.
 In the detailed design of the product, a number of issues must be
determined:

ü • Developing product layout and configuration

ü • Selecting materials for each component
ü • Addressing design-for-X issues (e.g., design for reliability, manufacturing, assembly, variation,
costing, recycling)
ü • Optimizing the final geometry, including appropriate tolerances
ü • Developing completed digital models of all components and assemblies
ü • Simulating the system using digital and mathematical models
ü • Prototyping and testing critical components and modules
ü • Developing the production plans
2.2. THE DESIGN PROCESS
Detailed Design

 Lưu ý:
ü An important general principle in the detailed design stage is simplicity. The simpler design
concept is better than a complex one, because fewer things can go wrong.
ü Engineers need to be comfortable with the concept of iteration in a design process. Iteration is
the process of making repeated changes and modifications to a design to improve and
perfect it.
ü The usability of a product can become particularly problematic as its technology becomes
more sophisticated. The engineers often collaborate with industrial designers and psychologists
to improve the appeal and usability of their products. So, the engineering is a business venture
that meets the needs of its customers.
2.2. THE DESIGN PROCESS
Detailed Design

 Lưu ý:
ü Engineers must be very diligent in documenting the design process’s engineering drawings,
meeting minutes, and written reports so that others can understand the reasons behind each of
the decisions. Such documentation is also useful for future design teams who will want to learn
from and build on the present team’s experiences.
ü Drawings, calculations, photographs, test data, and a listing of the dates on which important
ü milestones were reached are important to capture accurately how, when, and by whom the
invention was developed.
ü A design paten tis directed at a new, original, and ornamental design. A design patent is
intended to protect an aesthetically appealing product that is the result of artistic skill; it does
not protect the product’s functional characteristics.
2.2. THE DESIGN PROCESS
Detailed Design
 Lưu ý:
ü More commonly encountered in mechanical engineering, the utility patent protects
the function of an apparatus, process, product, or composition of matter. The utility
patent generally contains three main components:
 • The specification is a written description of the purpose, construction, and
operation of the invention
 • The drawings how one or more versions of the invention
 • The claims explain in precise language the specific features that the patent
protects
 2.2. THE DESIGN PROCESS
Detailed Design

The top ten countries ranked

by the number of patents
granted in the United States
in 2009
2.2. THE DESIGN PROCESS
Production
 if the product is technically superb but requires expensive materials and
manufacturing operations, customers might avoid the product and select one that is
more balanced in its cost and performance.
 even at the requirements development stage, engineers must take into account
manufacturing requirements for the production stage. After all, if you’re going to take
the time to design something, it had better be something that actually can be built,
preferably at a low cost.
2.2. THE DESIGN PROCESS

 Although manufacturing and rapid prototyping technologies continue to advance,

virtual prototyping is gaining acceptance as an effective decision support tool in
engineering design.
 Virtual prototyping takes advantage of advanced visualization and simulation
technologies available in the fields of virtual reality, scientific visualization, and
computer-aided design to provide realistic digital representations of components,
modules, and products
2.2. THE DESIGN PROCESS
 2.2. THE DESIGN PROCESS

Virtual prototyping
also capitalizes on
advanced hardware
that provides haptic
(tactile) feedback to
an engineer using
forces, vibrations, and
motions, as shown with
the PHANTOM® six-
degrees-of-freedom
interface from
SensAble Technologies
in use at Boeing
2.2. THE DESIGN PROCESS
2.3 MANUFACTURING PROCESSES
 Manufacturing technologies are so economically important
because they are the means for adding value to raw materials by
converting them into useful products.
 Engineers select processes, identify the machines and tools, and
monitor production to ensure that the final product meets its
specifications. The main classes of manufacturing processes are as
follows:
2.3 MANUFACTURING PROCESSES
2.3 MANUFACTURING PROCESSES
2.3 MANUFACTURING PROCESSES
2.3
MANUFACTURING
PROCESSES
2.3 MANUFACTURING PROCESSES
2.3
MANUFACTURING
PROCESSES
2.3
MANUFACTURING
PROCESSES
2.3 MANUFACTURING PROCESSES
2.3 MANUFACTURING PROCESSES
2.4 CASE STUDY IN CONCEPTUAL
DESIGN: MOUSETRAP-POWEREDVEHICLES
 • Vehicles must travel 10 m as quickly as possible
 • The vehicle must be powered by only a standard household mousetrap. Energy that is
incidentally stored by other elastic elements or obtained from a change in elevation of the
vehicle’s center of mass must be negligible
 • Each vehicle is to be designed, built, refined, and operated by a team of three students
 • Teams will compete against one another in head-to-head races during a tournament; so the
vehicles must be both durable and reusable
 • The mass of the vehicle cannot exceed 500 g. The vehicle must fit completely within a 0.1-
m3 box at the start of each race. Each vehicle will race in a lane that is 10 m long but only 1
m wide. The vehicle must remain in contact with the surface of the lane during the entire race
 • Tape cannot be used as a fastener in the vehicle’s construction