Mechanical System Design (DE ZG525)

WILP Lecture Location and Timing: Online (Saturday, 5:50 pm to 7:50 pm)

By
Dr. Arnab Guha

Assistant Professor in Mechanical Engineering

BITS Pilani, Hyderabad Campus
[email protected]
 Course Instructor Background
B.E. (Hons), Mechanical Engineering
Bengal Engineering & Science University, Shibpur
India, 2012

M.Sc., Mechanical Engineering

University of Alberta, Canada, 2014

Ph.D., Acoustic Biosensors

Loughborough University, UK, 2018
Postdoctoral Research Associate in Healthcare Engineering
Loughborough University, UK, Jan 2019 – Nov 2019

Technical Manager (* Self Employed)

Nutech Calibrators & Engineers, Kolkata, India, Dec 2019 – Sep 2020

Assistant Project Officer

Indian Institute of Technology Guwahati, Oct 2020 – Jul 2021

Postdoctoral Research Fellow in microfluidics-based point-of-care biosensors

University College London (UCL), UK, Sep 2021 – Mar 2023

Assistant Professor in Mechanical Engineering

BITS Pilani, Hyderabad Campus, Mar 2023 – Present
DE ZG525, Mechanical System Design, 27.07.2024 2
 Learning Outcomes of DE ZG525
 Understanding of mechanical systems

 Comprehensive and clear approach for design of mechanical systems

 Relevant methodologies and steps for design of mechanical systems

 Study of concepts of reliability and optimization pertaining to mechanical system design

DE ZG525, Mechanical System Design, 27.07.2024 3

Image Courtesy: Google
 DE ZG525 Lecture Content
 Introduction to Mechanical system design

 Mechanical system characteristics and modelling

 Statistical consideration in mechanical system design

 Optimum design of mechanical systems

 Case Study: Design of Machine Tool Gear Box

Image Courtesy: Google

DE ZG525, Mechanical System Design, 27.07.2024 4
 Books and Consultation Hour
Text Books

 "Mechanical System Design”, A. Goel, Technical Publications, 1st Ed., 2020

 "Mechanical System Design", K.U. Siddiqui and M.K. Singh, New Age Publisher, 2 nd Ed., 2017

Reference Books

 "Mechanical System Design", S.P. Patil, JAICO Publisher, 2 nd Ed., 2012

 "Design Optimization using MATLAB and SOLIDWORKS", K. Suresh, Cambridge University Press
1st Ed., 2021

Consultation Hour: Through prior online appointments if needed

DE ZG525, Mechanical System Design, 27.07.2024 5
 Evaluation Components for DE ZG525
Evaluation Name Type Weight Duration Day, Date,
Component (Quiz, Lab, Project, Mid- (Open Session, Time
term exam, End semester book,
exam, etc.) Closed
book,
Online,
etc.)
Quiz -1 Online, 15% 11 days September 1-10,
Open 2024
Book
EC - 1
Situational Learning Online, 15% 11 days October 10-20,
Assignment Open 2024
Book
Mid-Semester Test Closed 30% 2 hours Saturday,
EC - 2 Book 21/09/2024
(Evening)
Comprehensive Exam Open 40% 2½ hours Saturday,
EC - 3 Book 30/11/2024
(Evening)

DE ZG525, Mechanical System Design, 27.07.2024 6

 Concept of Systems
 Origin : Greek word “Systema”

 Meaning : Organised relationship among functioning units/components

Examples of Systems Functioning Components

Transportation system Personnel, machines and organizations
School system Buildings, teachers, administrators and textbooks
Weapon system Equipment, procedures and personnel

DE ZG525, Mechanical System Design, 27.07.2024 Image Courtesy: Google 7

 Model of a mechanical system
 Simple System Model x

F
Input Process Output

Boundary

 System with multiple inputs and outputs

Input 1 Output 1
Input 2 Process Output 2
Input 3 Output 3
Input 4 Output 4

DE ZG525, Mechanical System Design, 27.07.2024 * Image Courtesy: Google 8

 Classification of Mechanical Systems by Loop
 Open Loop System No influence of system on output

Input Processing Unit Output

Metal cutting machine (Lathe)

 Closed Loop System Influence of system on output

Input Processing Unit Output

Sensing system
Feedback Thermostat

DE ZG525, Mechanical System Design, 27.07.2024 * Image Courtesy: Google 9

 Classification based on nature of mechanism
 Mechanistic system Fully mechanized with choice of system composition at user’s discretion

Guided missile Dial telephone

 Quasi-mechanistic system Some mechanical functions carried out by the user

* Image Courtesy: Google

Underwater fighter jets

Fighter plane DE ZG525, Mechanical System Design, 27.07.2024 10
 Classification based on nature of environment
 Physical system System that can be seen and felt

Traffic system

 Conceptual system System having no physical form and existing in user’s mind

e.g. Hour, Days, Weeks, Months, Year etc.

* Image Courtesy: Google

DE ZG525, Mechanical System Design, 27.07.2024 11

 Classification based on nature of task performed
 Power generating systems

Car Engine Wind Turbine Electric Motor

 Power transmitting systems

Chain Drives * Image Courtesy: Google

Belt Drives Gear Boxes
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 Classification based on nature of task performed (Cont.)
 Power consuming systems

Centrifugal pump Air Blower Machine Tools

 Motion control systems * Image Courtesy: Google

Clutch Steering wheel

Disc Brake
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 Concept of Design
 Webster Dictionary Definition : “To fashion after a plan”

 Engineering Definition : “To establish and define solutions for problems not solved before or new
solutions to problems which have been previously solved in a different
way”

 Evolution of Design : Need for modification of the form of natural objects in stone age

* Image Courtesy: Google

DE ZG525, Mechanical System Design, 27.07.2024 14

 Basic Requirements of Design
 Problem Statement : Design of a Stone made axe

 Technical Requirement : Cutting capacity of axe

 Ergonomic Requirement : User’s ability to hold and manipulate the axe

 Aesthetic Requirement : Effect due to user’s inner feelings

 Problem Statement : Design of an office chair

 Material Requirement : Wood / Steel / Plastic

 Ergonomic Requirement : Adjustable height, armrests, reclining, seat adjustment, proportion

 Aesthetic Requirement : Shape, decoration

* Image Courtesy: Google

DE ZG525, Mechanical System Design, 27.07.2024 15

 Design Considerations for Mechanical Systems
 Money / Value Engineering

 Manufacturing Processes

 Materials

 Material Sciences / Strength Analysis

 Mechanics / Functionality

 Motive Power Requirement / Performance

 Manipulation / Operationability

 Man-machine interaction / Ergonomics

 Optimization
* Image Courtesy: Google
 Face value / Aesthetics
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 Characteristics of Mechanical Systems
 Linear System  Non-linear System

Y Y

Output y = mx y = kx3
Output
y2
y1

X X
x1 x2
Input Input

* Image Courtesy: Google

Linear spring F = kx Non-linear spring F = kx3

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 Characteristics of Mechanical Systems (Contd..)
 Static System : Output ant any instant depends upon the input at that instant

𝑽 𝟎 (𝒕)
𝑰 𝟎 ( 𝒕 )=
𝑹 𝟏+ 𝑹𝟐

Bridge Furnitures

 Dynamic System : Output is a function of time depending on both input and initial conditions

𝝋 =𝐭𝐚𝐧 − 𝟏 ( 𝒗𝟎
𝒙 𝟎 𝝎𝒏 )
=,
* Image Courtesy: Google
Initial conditions Moving car
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 Characteristics of Mechanical Systems
 Time Invariant System : Input and output characteristics of the system do not change with time

Spring-mass-damper System Series RLC Circuit

Resonance frequency 𝝎 𝟎=
√
𝒌
𝒎
 Parameters of the system remain constant over time
≈ 𝝎 𝟎=
√𝟏
𝑳𝑪

DE ZG525, Mechanical System Design, 27.07.2024 19

 Characteristics of Mechanical Systems (Contd..)
 Time Varying System : Input and output characteristics of the system change with time

x
(t) (t) (t)
(t)

F
(t)

(t)

Resonance frequency ≈

Quartz Crystal Resonator

* Image Courtesy: Google
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 Characteristics of Mechanical Systems (Contd..)
 Distributed Parameter System : System parameters are a function of time and one or more spatial variables

y
Heat Iron Slab
Source Temperature 𝐓 = 𝐓 ( 𝐭 , 𝐱 , 𝐲 )
x

 Lumped Parameter System : System parameters are a function of time alone

y
Heat Iron Slab
A B C D Temperature 𝐓 𝐀 =𝐓 ( 𝐭 )
Source
x
𝐓 𝐀 =𝐓 𝐁 =𝐓 𝐂= 𝐓 𝐃
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 Modelling of Mechanical Systems

Motor Cycle

• Figure adapted from Textbook:

Singiresu S. Rao. Mechanical Vibration, Pearson sixth edition DE ZG525, Mechanical System Design, 27.07.2024 22
Modelling of a cantilever beam with an attached mass

𝐏 𝟎 𝐜𝐨𝐬 𝛚 𝐭
EI
m X

(t)

𝟑 𝐄𝐈
𝐤=
𝐏 𝟎 𝐜𝐨𝐬 𝛚 𝐭 𝐋𝟑

DE ZG525, Mechanical System Design, 27.07.2024 23

Thank You