BDA 31203 Notes (Student Version - Printable) Sem II 2018_2019.pdf - FACULTY OF MECHANICAL AND MANUFACTURING ENGINEERING UNIVERSITI TUN HUSSEIN ONN

BDA 31203 Notes (Student Version - Printable) Sem II 2018_2019.pdf

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Unformatted text preview: FACULTY OF MECHANICAL AND MANUFACTURING ENGINEERING UNIVERSITI TUN HUSSEIN ONN MALAYSIA BDA 31203 - Mechanical Component Design (Lecture Slides) Semester II 2018 / 2019 Course Coordinator : MR. MOHD AZWIR BIN AZLAN Lecturers : 1) Mr. Mohd Azwir bin Azlan – (S1 & S2) 2) Dr. Koh Ching Theng (S3 & S4) (S9 & S10) 3) Mr. Mohd Nizam bin Katimon - (S5 & S6) 4) Dr. Ahmad Mubarak bin Tajul Arifin (S7 & S8) FACULTY : SEMESTER : SESION : COURSE : FACULTY OF MECHANICAL AND MANUFACTURING ENGINEERING (FKMP) 2 2018 / 2019 BDA 31203 - MECHANICAL COMPONENT DESIGN (MCD) TIME SCHEDULE DAY / TIME SUNDAY ITEMS MONDAY LOCATION ITEMS Library - BT9 [max - 60] BDA 31203 (S3 & S4) (Dr. Koh) LOCATION TUESDAY ITEMS LOCATION WEDNESDAY ITEMS LOCATION 8.00 - 8.50 9.00 - 9.50 10.00 - 10.50 11.00 - 11.50 12.00 - 12.50 1.00 - 2.00 2.00 - 2.50 3.00 - 3.50 4.00 - 4.50 5.00 - 5.50 6.00 - 6.50 7.00 - 8.00 8.00 - 8.50 9.00 - 10.00 10.00 - 11.00 BDA 31203 (S1 & S2) (En. Azwir) Library - BT9 [max - 60] BDA 31203 Library - BT9 BDA 31203 (S5 & S6) - (S7 & S8) Library - BT9 (En. Nizam) [max - 60] [max - 60] --------------- ------------- G3 - (Dr.Mubarak) (S9 & S10) BKB6 [max 60] (Dr Koh) THURSDAY ITEMS LOCATION FRIDAY ITEMS LOCATION Sem 2 Sesi 2018/2019 Borang Akuan Mengikuti Kuliah Ganti Kursus BDA 31203 - Rekabentuk Komponen Mekanikal Saya pelajar yang bernama dari seksyen no matrik , mengakui bahawa saya telah mengikuti kuliah ganti yang telah diajar oleh (Dr. Mubarak / Dr. Koh / / En. Azwir / En. Nizam ) pada bagi (Sila potong yang tidak berkenaan) menggantikan kuliah yang tidak dapat saya hadiri pada . Topik yang dipelajari adalah:Sila tandakan () bagi topik / kuliah ganti yang telah diikuti. Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11 Week 12 Week 13 Week 14 Week 15 Lesson Plan, Introduction To Design Process, Analysis And Synthesis Static Design Failure Of Theories Fatigue Design Failure Of Theories (Topic 4.1 ~ 4.7) Fatigue Design Failure Of Theories (Topic 4.8 ~ 4.11) Gear – Part 1 (Topic 5.1 ~ 5.13) Design Project (Project Briefing, Review on Best Example Project Report) & Gear – Part 2 (Topic 5.14 ~ 5.19) Gear – Part 2 (Example & Discussion) SEMESTER BREAK Shaft Design Bearing Non-Permanent Joints (Topic 8.1 ~ 8.5) Non-Permanent Joints (Topic 8.6 ~ 8.10) Non-Permanent Joints (Topic 8.11 ~ 8.13) Project Supervision Project Supervision Tandatangan Pelajar, Disahkan oleh, ........................................... ........................................... Tarikh : Nama Pensyarah : Tarikh : Lampiran A Faculty of Mechanical and Manufacturing Engineering (FKMP) LECTURE PLAN 1. Name of Course: MECHANICAL COMPONENT DESIGN Course Code: BDA 31203 2. Synopsis: This course consists of analysis, synthesis and design basic and complex mechanical component i.e. bearings, shafts, gears, and non-permanent joint such as screw and fastener with consideration of strength, rigidity, reliability, static and fatigue failure. 3. Name(s) of Academic Staff: Mr. Mohd Azwir bin Azlan (S1 & S2) – Coordinator Dr. Koh Ching Theng (S3, S4, S9 & S10) Mr. Mohd Nizam bin Katimon (S5 & S6) Dr Ahmad Mubarak bin Tajul Arifin (S7 & S8) 4. Semester and Session Offered: 5. Credit Value: 6. Semester Pre-requisite (if any): Session 2 20182019 Lecture (hour/week) 3 Tutorial (hour/week) 0 Practical (hour/week) 0 1) Technical Drawing & CAD 2) Solid Mechanics II 7. 8. Course Learning Outcomes (CLO): At the end of the course, students will be able to: Example: Explain the basic principles of risk management (C2, PLO1) CLO 1 Engineering Knowledge: Calculate factor of safety by using static and fatigue failure of theories. (C3, LO1) CLO 2 Design/ Development of Solution: Evaluate several machine components (i.e. gears, shafts and bearing) that function in one mechanical system or machine. (C5, LO10) CLO 3 Life Long Learning: Seek for the most appropriate information source for component selection in the design project. (A3, LO6) CLO 4 Modern Tool Usage: Produce model and simulate by using engineering software for project design validation. (C4, LO2) Mapping of Course Learning Outcomes (CLO) to Programme Learning Outcomes (PLO), Delivery and Assessment Methods: Course Learning Outcomes (CLO) Programme Learning Outcomes (PLO) PLO1 CLO 1 PLO2 PLO6 CLO 3 CLO 4 Assessment Method KPI Lecture, Assignment 1&2. 100% pass Lecture, Case Study, PO-PBL Test 1, Test 2, Project - Report. 100% pass PLO10 CLO 2 Delivery Method PO-PBL Project - Soft Skill. 100% pass PO-PBL Project - Drawing. 100% pass Indicate the relevancy between CLO and PLO by ticking “ / ” at the appropriate relevant box. 9. Transferable Skills (if applicable): (Soft skills learned in the course which can be utilized in student development) 1 2 3 n Edisi : 5 / No. Semakan : 1 Lampiran A Faculty of Mechanical and Manufacturing Engineering (FKMP) 10. Distribution of Student Learning Time (SLT): Week Course Content Outline CLO Teaching and Learning Activities Guided Learning (F2F) L W1 Present Lesson Plan 17th ~ 1.0 INTRODUCTION TO DESIGN PROCESS 23rd Feb 1.1 Design Definition 2019 1.2 Mechanical Engineering Design 1.3 Design Process 1.4 Design Tools and Resources 1.5 Design Engineer’s Professional Responsibilities 1.6 Standards and Codes 1.7 Economics 2.0 ANALYSIS AND SYNTHESIS 2.1 Material Strength and Stiffness 2.2 Equilibrium and FBD 2.3 Types of Load 2.4 Stress 2.5 Principle Stress for Plane Stress 2.6 Mohr’s Circle for aPlane Stress 2.7 General 3 Dimensional Stress 2.8 Uniformly Distributed Stresses 2.9 Normal Stress for Beam in Bending 2.10 Shear Stress for Beam in Bending 2.11 Torsion 2.12 Stress Concentration T P SLT Guided Independent Learning Learning (NF2F), eg. (NF2F) e-learning O 0.5 0.5 0.5 0.5 1 2 2(R) + 1(TP) 5 3.0 STATIC DESIGN FAILURE OF THEORIES 3.1 Introduction 24th Feb nd 3.2 Why Need Failure ~ 02 Theories Mac 3.3 Static Failure Theories 2019 3.4 Maximum Shear Stress Theory 3.5 Distortion Energy Theory 3.6 Column-Mohr Theory 3.7 Maximum Normal Stress Theory 3.8 Modification of Mohr Theory 1 3 3(R) + 3(AP) + 1(TP) 10 W3 & 4.0 FATIGUE DESIGN FAILURE W4 OF THEORIES 4.1 Introduction to Fatigue 4.2 Fatigue Load and Failure 03rd ~ 4.3 Life and Fatigue Strength 16th Mac 4.4 S-N Diagram 2019 4.5 Endurance Limits 4.6 Endurance Limit Modifying Factors 1 6 6(R) + 3(AP) + 2(RP) + 2(TP) 19 W2 Edisi : 5 / No. Semakan : 1 Lampiran A Faculty of Mechanical and Manufacturing Engineering (FKMP) 4.7 Stress Concentration and Notch Sensitivity 4.8 Fatigue Strength 4.9 Characterizing Fluctuating stressess 4.10 Combination of Loading Modes 4.11 Safety Factor 5.0 GEAR – PART 1 5.1 Introduction: terminology, types of gears and its 17th ~ application 23rd Mac 5.2 Construction of gears 2019 5.3 Tooth systems 5.4 Gear ratio 5.5 Gear train 5.6 Gear Tooth Analysis W5 2 3 3(R) + 2(RP) + 1(TP) DESIGN PROJECT Project Briefing – Project Title & Theme, Planning Schedule, Report Format, Report & Soft Skill Assessment Discussion and Review on Best Example Project Report Group Registration 3 5.0 GEAR – PART 2 6.7 Gear Tooth Bending Analysis 6.8 Gear Tooth Wear Analysis 6.9 Factor of Safety 2 5 5(R) + 5(RP) + 3(TP) 18 W9 2 3 3(R) + 4(RP) + 2(TP) 12 W10 2 3 3(R) + 3(RP) + 1(TP) 10 W6 & W7 24th Mac ~ 06th Apr 2019 W8 1 9 1 MID SEMESTER BREAK 07th ~ 13th Mac 2019 6.0 SHAFT DESIGN 6.1 Introduction 6.2 Shaft Materials 14th ~ 6.3 Shaft Layout 20th Apr 6.4 Shaft Design for Stress 2019 6.5 Limits and Fits 7.0 BEARING 7.1 Introduction 7.2 Bearing Types 21st ~ th 7.3 Bearing Mounting and 27 Apr Enclosures 2019 7.4 Bearing Life 7.5 Bearing Load, Life at Rated Reliability 7.6 Relating Load, Life and Reliability 7.7 Combined Radial and Thrust Loading 7.8 Lubrication Edisi : 5 / No. Semakan : 1 Lampiran A Faculty of Mechanical and Manufacturing Engineering (FKMP) W11 – 8.0 NON-PERMANENT JOINTS 8.1 Introduction W13 8.2 Thread standard and definition 28th Apr 8.3 The mechanic of power ~ 18th screw May 8.4 Threaded fasteners 2019 8.5 Joints: Fastener stiffness 8.6 Joints: Member stiffness 8.7 Bolt strength 8.8 Tension joints : The external load 8.9 Relating bolt torque to bolt tension 8.10 Statically loaded tension joint with preload 8.11 Gasketed joints 8.12 Fatigue loading of tension joints 8.13 Bolted and riveted joints loaded in shear 2 W14 – W15 19th ~ 30th May 2019 3 DESIGN PROJECT Project Supervision 9 9(R) + 3(TP) 6 21 6 Total 112 *(R)= Revision, (AP)=Assignment Preparation, (RP)=Report Preparation, (TP)=Test Preparation CLO Percentage (%) 1 1st Continuous Assessment F2F NF2F SLT Assignment – Start after finish Chapter 3 in Week 2. Submit 1 week after or before 07/03/2019 ; 3:30 pm 1 5.0 2 2nd Assignment – Start after finish Chapter 4 in Week 4. Submit 1 week after or before 21/03/2019 ; 3.30 pm) 1 5.0 3 1st TEST --- (1.5 hours) (19/03/2019 ; 8:00 – 9:30 pm) 1 10.0 1.5 1.5 4 2nd TEST --- (2.5 hours) 2 20.0 2.5 2.5 2.0 2.0 2.0 2.0 (24/04/2019 ; 8:00 - 10:30pm 5 3rd TEST --- (2.0 hours) (21/05/2019 ; 8:30 - 10:30pm 2 20.0 6 PROJECT (Report) Submit before 30th May 2019; 3:30 PM (Thursday) 2 32.5 7 PROJECT (Drawing) 4 2.5 8 PROJECT (Lifelong Learning / Progress) 3 5.0 Total 8.0 * L = Lecture, T = Tutorial, P = Practical/Laboratory, O = Others, F2F = Face to Face, NF2F = Non Face to Face. Edisi : 5 / No. Semakan : 1 Lampiran A Faculty of Mechanical and Manufacturing Engineering (FKMP) Final Assessment CLO Percentage (%) F2F NF2F SLT 1 2 Total GRAND TOTAL SLT 120.0 11. Special Requirement to deliver the course: For example, software, nursery, computer lab, simulation room etc. 12. References (including required and further readings): 1. BDA 31203 Lecturer Notes 2. Richard. G. Budynas, J. Keith Nisbett, (2015), “Shigley’s Mechanical Engineering Design”, Tenth Edition in SI Units, McGraw Hill Education. (ISBN: 978-981-4595-28-5) 3. Robert L. Mott, (2014), “Machine Elements in Mechanical Design”, New Jersey: Pearson. (ISBN: 978-013-3349-07-8) 13. Other Additional Information: 14. Attendance and Regulations: 15. Prepared by: Name: Hj. MOHD AZWIR BIN AZLAN Verified by: Name: Assoc. Prof. Dr. SUFIZAR BINTI AHMAD Position: Lecturer Position: Assoc. Professor Date: 10th February 2019 th Date: 10 February 2019 Edisi : 5 / No. Semakan : 1 1. Students must attend not less than 80% of contact hours for each course including Compulsory Attendance Course (Hadir Wajib - HW) and Attendance Only Course (Hadir Sahaja - HS). 2. Students who do not fulfil item (1) of the above are not allowed to attend further lectures and are not allowed to sit for any further assessment. Zero marks (0) will be given to student who fails to comply with item (1). As for Compulsory Attendance Course (Hadir Wajib - HW), student who fails to comply with item (1) will be given Failure Attendance (Hadir Gagal - HG). 3. Students must observe University dress code and must conduct themselves in appropriate manner to avoid any disciplinary action. 4. Students must follow safety regulations during learning and teaching. Lampiran A MATRIK HASIL PEMBELAJARAN KURSUS DAN HASIL PEMBELAJARAN PROGRAM MATRIX OF COURSE LEARNING OUTCOMES AND PROGRAMME LEARNING OUTCOMES Fakulti (Faculty) : FACULTY OF MECHANICAL AND MANUFACTURING ENGINEERING Program (Programme) : BACHELOR OF MECHANICAL ENGINEERING WITH HONOURS Kod Kursus (Course Code) : BDA 31203 Nama Kursus (Course Title) : MECHANICAL COMPONENT DESIGN Matrik ini perlu digunakan bersama: (This matrix is to be used together with) 1. Objektif Pendidikan Program (PEO) (Programme Educational Objectives (PEO)) 2. Hasil Pembelajaran Program (PLO) (Programme Learning Outcomes (PLO)) 2 3 4 C1 C2 C3 C4 C5 C6 PLO13 PLO12 PLO11 PLO10 PLO9 PLO8 PLO7 PLO6 PLO5 C5 PO-PBL Project - Soft Skill. PO-PBL Project - Drawing. A3 C4 1 Kognitif (Cognitive) Pengetahuan (Knowledge) Pemahaman (Comprehension) Aplikasi (Application) Analisis (Analysis) Sintesis (Synthesis) Penilaian (Evaluation) RPP-04 / Prosedur Pelaksanaan Kuliah Edisi: / No. Semakan: Lecture, Case Study, PO-PBL Kaedah Pentaksiran (Method of Assessment) Assignment 1, Assignment 2, Project – Report, Test 1. Test 2, Test 3, Project - Report. Kaedah Penyampaian (Method of Delivery) Lecture, Case Study, C3 Evaluate several machine components (i.e. gears, shafts and bearing) that function in one mechanical system or machine. (C5, LO10) Seek for the most appropriate information source for component selection in the design project. (A3, LO6) Produce model and simulate by using engineering software for project design validation. (C4, LO2) Jumlah (Total) PLO4 Calculate factor of safety by using static and fatigue failure of theories. (C3, LO1) PLO3 1 PLO2 Hasil Pembelajaran Kursus (Course Learning Outcomes) PLO1 Pemetaan kepada PLO (Mapping to PLO) Bil. (No.) 1 P1 P2 P3 P4 P5 P6 P7 1 1 Taksonomi Pembelajaran (Learning Taxonomy) Psikomotor (Psychomotor) Persepsi (Perception) A1 Set (Set) A2 Respons Berpandu (Guided Response) A3 Mekanisme (Mechanism) A4 Respons Ketara Kompleks (Complex Overt Response) A5 Adaptasi (Adaptation) Lakuan Tulen (Origination) KPI* 100% students pass 100% students pass 100% students pass 100% students pass *KPI – Petunjuk prestasi utama (Key performance indicator) Afektif (Affective) Menerima (Receiving) Memberikan Maklum Balas (Responding) Menilai (Valuing) Mengorganisasi (Organising) Menghayati Nilai (Internalising) BDA 31203 – Mechanical Component Design CHAPTER 1 – Introduction to Engineering Design Learning Outcomes Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. At the end of this topic, the students would be able to apply and appreciate the knowledge to: BDA 31203 Notes – Mechanical Component Design • understand the basic principles of mechanical engineering and its applications in engineering design. Week 1 • recognize the approach and the process of engineering design. Chapter 1 Introduction to Engineering Design • practice standards and codes, ethics and professionalism of mechanical engineer. Prepared by: Mohd Azwir Bin Azlan 2 Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. BDA 31203 – Mechanical Component Design CHAPTER 1 – Introduction to Engineering Design What you will be learn here? • 1.1 - Design Definition • 1.2 - Mechanical Engineering Design • 1.3 - Design Process • 1.4 - Design Tools and Resources • 1.5 - Design Engineer’s Professional Responsibilities • 1.6 - Standards and Codes • 1.7 - Economics Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. BDA 31203 – Mechanical Component Design CHAPTER 1 – Introduction to Engineering Design 1.1 – Design Definition • Word design is derived from the Latin designare, which means “to designate, or mark out.” • Webster’s gives several definitions, “to outline, plot, or plan, as action or work… to conceive, invent – contrive.” • To design is either to formulate a plan for satisfaction of a specified need or to solve a problem. • Design is an innovative and highly iterative process. It is also a decision making process. 3 Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. 4 BDA 31203 – Mechanical Component Design CHAPTER 1 – Introduction to Engineering Design 1.2 - Mechanical Engineering Design BDA 31203 – Mechanical Component Design CHAPTER 1 – Introduction to Engineering Design 1.3 - Design Process • Mechanical engineering design involves all disciplines of mechanical engineering. • Examples: A simple journal bearing involves fluid flow, heat transfer, friction, energy transport, material selection, thermomechanical treatments, and so on. 5 Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. BDA 31203 – Mechanical Component Design CHAPTER 1 – Introduction to Engineering Design 1.3 - Design Process Recognition of need BDA 31203 – Mechanical Component Design CHAPTER 1 – Introduction to Engineering Design 1.3 - Design Process Recognition of Need Definition of Problem • Often consist highly creative act, because the need may be only a vague discontent, a feeling of uneasiness, or a something is not right. Definition of Problem 7 • Is more specific and must include all the specifications for the object that is to be designed. • The specifications are the input and output quantities, the characteristics and dimensions of the space the object must occupy, and all the limitations on these quantities. • Usually triggered by a particular adverse circumstance or a set of random circumstances that arises almost simultaneously. Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. 6 Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. 8 BDA 31203 – Mechanical Component Design CHAPTER 1 – Introduction to Engineering Design 1.3 - Design Process BDA 31203 – Mechanical Component Design 1.3 - Design Process Synthesis Analysis and Optimization • The combination of ideas into a complex whole. Synthesis • Construct or devise abstract models of the system that will admit some form of mathematical analysis. • Is sometimes called the invention of the concept or concept design. • Generate concept ⇒ variant concept ⇒ concept selection ⇒ concept improvement ⇒ detailing concept. 9 Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. BDA 31203 – Mechanical Component Design CHAPTER 1 – Introduction to Engineering Design 1.3 - Design Process Analysis and Optimization BDA 31203 – Mechanical Component Design 10 CHAPTER 1 – Introduction to Engineering Design 1.3 - Design Process Presentation • Presentation is a selling job. • Is the final proof of a successful design and usually involves the testing of a prototype in the laboratory. • When designers sell a new idea, they also sell themselves. If they are repeatedly successful in selling ideas, designs and new solutions to management, they begin to receive salary increases and promotions; in fact, this is how anyone succeeds in their profession. • Intent to discover if the design really satisfies the needs. • Is it reliable? Will it compete successfully with similar products? Is it economical to manufacture and to use? Is it environmental friendly? Presentation Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. • Carry out to simulate or predict real physical system very well. Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. Evaluation Evaluation CHAPTER 1 – Introduction to Engineering Design 11 Department of Material and Engineering Design, Faculty of Mechanical and Manufacturing Engineering, University of Tun Hussein Onn Malaysia (UTHM) Johor. • Undoubtedly, many great designs, inventions and creative works, have been simple lost because the originators were unable to explain their accomplishment to others. 12 BDA 31203 – Mechanical Component Design CHAPTER 1 – Introduction to Engineering Design BDA 31203 – Mechanical Component Design CHAPTER 1 – Introduction to Engineering Design 1.4 - Design Tools and Resources 1.5 - Design Engineer’s Professional Responsibilities Today engineer has a great variety of tools and resources available to assist in the solution of des...
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