ADVANCE MECHANICAL DESIGN
ME 78507

Course Objectives:

To make students able to

• Analyze the design failure on failed design or existing product failed due to design.
• Improve the performance of existing design from required modification.
• Introduce new materials in design.
• Realize the need on the benefits to product quality by production and industrial design.

1. Introduction
   (4 hours)
   1. The meaning of design for production
   2. Product development stage analysis
   3. Process type
   4. Product specification
   5. Cost and value analysis
   6. Cost and performance analysis
2. The meaning of Appreciable Product Design
   (4 hours)
   1. Criteria for Successful and Appreciable Design
   2. The basis for selection of best design – Function, Aesthetics, Appropriateness of Technology, Ergonomics, Innovation
      1. Value and Cost of the Product
3. Design against Different types of Failures
   (9 hours)
   1. Fatigue Failure – Introduction
      1. Fatigue Design Criteria
      2. Design against Failure
   2. Shock and Impact Failure – Introduction
      1. Impact Based Design
   3. Fracture and Failure Analysis
      1. Objectives of Fracture Mechanics Technology
      2. Energy Theory
      3. Critical Stress
4. Interaction of materials, manufacturing and design
   (5 hours)
   1. Design for manufacturability
   2. Selecting manufacturing process
   3. Design for casting, forging, sheet metal forming, machining, welding
   4. Design for assembly, corrosion resistance and environment
   5. Products after retirement
5. Designing for Substitute Materials
   (8 hours)
   1. Designing with Plastics – Introduction
      1. Plastic Properties
      2. Plastic Products
      3. Recycling of Plastics
   2. Designing with Rubber – Introduction
      1. Rubber Properties
      2. Rubber Products
      3. Recycling of Rubber
   3. Designing with Ceramics – Introduction
      1. Ceramic Properties
      2. Ceramic Products
      3. Recycling of Ceramics
   4. Designing with Wood – Introduction
      1. Wood Properties
      2. Wood Products
      3. Recycling of Wood
6. Designing for ‘X’ methodologies
   (9 hours)
   1. Safety and Reliability
      1. Design for Safety
      2. Defect Free and Fail Safe Design
   2. The Meaning of Reliability
      1. Design for Reliability
      2. Reliability Techniques
      3. Fault Tree Methods
      4. Failure Mode and Effective Analysis
      5. Approach to Reliable Design
   3. Elements of Integrating Reliability into Design Process
   4. Causes of Unreliability
   5. Methods of Assuring Reliability
   6. Factor of Safety and Reliability
   7. ‘K’ out of ‘N’ units Reliability Calculation
7. Human Engineering Considerations
   (6 hours)
   1. Ergonomics
      1. Objective of Ergonomics
      2. Advantages of Ergonomics
      3. Application of Ergonomics
      4. Approaches adopted by Ergonomics
      5. Scope of Ergonomics
   2. Human Engineering
      1. The man – machine system
      2. Potential capabilities of man and machine
      3. Man- machine system design comparison
   3. Design of controls
   4. Design of displays
   5. Population stereotypes and interaction between man and machine

Practical:

The laboratory work will be closely connected with lecture and classroom work, and should generally be of a qualitative nature.

1. Critic writing exercise on project thesis by undergraduate students
2. Convert a selected sketch to actual working component.
3. Development analysis and technical advancement study of selected product.
4. Concept development for design and decision making by pair comparison.
5. New product design and development.

References

1. Arther H. Burr and John B. Cheatham , “Mechanical Analysis and Design”, Prentice – Hall of India Pvt. Ltd.
2. Arun Shukla , “Practical Fracture Mechanics in Design” Publisher Dekkar.
3. A. K. Chitale, R. C. Gupta, “ Production Design and Manufacturing”, Prentice – Hall of India Pvt. Ltd.
4. Karl T. Ulrich, Steven D. Eppinger , “Production Design and Development” : Tata – McGraw Hill International Edition.

Evaluation Scheme:

The questions will cover all the chapters in the syllabus. The evaluation scheme will be as indicated in the table below:

*There could be minor deviation in mark distribution.