MENG 356

Mechanical Design I

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Course Description

Instructor	Dr. Maher Younan
Office	New Falaki Building, room 526
Phone	797-5336
Email	myounan@aucegypt.edu
Class Hours	TR 8:00-850 am
Required Text	Norton, R., “Machine Design”, 2^nd ed. Prentice Hall, 2000.
Reference	Mott, R.L. “Machine Elements in Mechanical Design”, 3^rd ed, Prentice Hall, 2000

Course Prerequisites

Students entering this course should understand and be able to apply:

• The principle of static equilibrium
• The fundamental laws and techniques of elastic strength of materials: Hooke’s Law, Stress/Strain relations, Mohr’s Circle, Shear-Bending Diagrams, and thin pressure vessels.
• Principles of Materials Behavior
• The mathematical techniques learned in differential and integral calculus.

Meeting these prerequisites is demonstrated by having successfully completed the AUC courses: MENG355, ENGR214 and MATH231

Goals

1. Set suitable design criteria for machine elements
2. Design several power transmission elements (shafts and couplings), flexible load carrying elements (springs) and mechanical joints.
3. Use the computer to assist in the design calculations and construction drawings.

Expected Outcomes

After completing this course, students should be able to:

• Represent a physical model with a schematic and a free body diagram and solve for the unknown reactions.
• Apply the appropriate failure theory and factor of safety to static and dynamic systems.
• Determine suitable dimensional tolerances for different applications
• Use the computer to model, analyze and design different machine elements.
• Design the following components

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• Beams
• Shafts
• Keys and couplings
• Springs
• Welds
• Bolted and riveted connections
• Design and analyze a real engineering system involving one or more of the above-mentioned components.

Course Philosophy

This course is a design-oriented course. Thus, many of the problems you will confront will be open-ended and will have more than one correct solution. This will be true on homework and exams.

In this course, it is expected that you will apply the material learned in other courses to engineering problems. It is your responsibility to make sure that your understanding of this previous course material is adequate. Throughout the semester, we will review techniques learned in ENGR229 and MENG355 in order to apply them to design situations. These reviews will be fairly quick, so that the majority of lecture time can be devoted to design practice and design considerations. To facilitate efficient use of class time, it is expected that students will complete the assigned readings prior to class and independently review this material as needed.

Course Content

Beyond reading and lectures, students will be expected to complete weekly homework assignments, project, two exams, and a final exam.

Topics

1. Fundamentals of Mechanical Design, Materials, stress analysis, standards and codes. (4 classes)
2. Design of Power Transmission Elements: shafts, load analysis, stress concentration, fits and tolerances, keys and splines, rigid and flexible couplings (14 classes)
3. Flexible Load Transmission Elements (Springs) (6 classes)
4. Joining of Materials, Bolted connections, riveted connections, welded connections (6 classes)

Lab Projects: (Problem solving and Design sessions)

1. Beam design (strength and rigidity) (2 sessions)
2. Shaft Design (3 sessions)
3. Fits and Tolerances (2 sessions)
4. Keys and Couplings (2 sessions)
5. Springs (2 sessions)
6. Design of Welds (1 session)
7. Bolted and Riveted connections (1 session)

Design Project

Students should submit projects on design of realistic components using the available facilities and software or by developing their own general-purpose design packages for classes of problems. Students may work in groups of 2-3 and the projects may involve one or more of the following:

1. Using I-DEAS modeling package
2. Developing general purpose software (e.g. shaft design, ..)
3. Using other packages like Toolkit (TK solver) and some of the available packages.
4. Construct a real model

Course Policies

Attendance

Attendance and participation is expected in the lecture portions of the course. However, attendance will not be taken or directly included in calculating your grade.

Late homework will only be accepted for extraordinary circumstances and only with prior arrangement.

Grading

The course components will have the following weighting:

Homework*	20%
Projects	15%
Two Exams	35%
Final	30%

* The homework provides the primary opportunities for you to practice and apply what you are learning in this course and are critical to mastery of this material. The homework is also used to extend the course coverage beyond what is covered in class. Therefore, failure to complete all assignments and receive a grade of at least 70% on the portion of this course will result in failure of the course.

An essential skill of a design engineer is the ability to communicate. Communicating your design is essential for it to be manufactured and used properly. Therefore, grades will be severely reduced for failure to prepare clear designs, drawings and technical communication.

Homework will be collected at the beginning of class one week after it is assigned. Homework assignments must be completed neatly on engineering paper and multiple pages stapled. Sloppy, incomplete work will be immediately returned to the student for resubmission with a 25% reduction in grade.

Academic Integrity

A high degree of professionalism is expected of you by the instructor and by your fellow students. Acts of academic dishonesty will not be tolerated and will result in academic and/or disciplinary sanctions. Situations warranting sanctions include but are not limited to:

• Forgery and Alteration: such as submitting another student’s work as yours. Working together on homework is encouraged; however, work submitted for grading MUST be your own work.
• Misrepresentation: such as having another student take your exams.
• Cheating During Exam: such as assisting another student on an exam.
• Providing Misleading Information: such as providing false information for missing a class assignment.
• Plagiarism: Presenting, as one’s own an idea derived from an existing source without crediting the source.

Sanctions may include actions that affect a student’ grade (including course failure) and/or warnings, probation, dismissal, or expulsion. If you have any questions about the ethics of a situation please discuss it with the instructor as soon as possible.

Course Schedule

Week	Topic	Chapter
1	A) Fundamentals of Design of Machine Elements: 1. Codes and standards, safety and reliability	1,3
2 and 3	2. Internal reactions, load stress relations, transformation of stress	4
4	3. Materials properties and designation 4. Failure criteria a. Static failure	2 5
5	b. Fatigue failure Review	6
6	Exam 1 B) Design of Mechanical Components Power transmission elements a. Shafts and axles	9
7&8	a. Shafts and axles b. Keys and couplings	9
9	c. Tolerances and fits	Notes
10	d. Machine construction	Notes
11	Load transmission elements a. Compression springs	13
12	b. Tension and other types of springs	13
13	Review and Exam 2
14	3. Joining of materials a. Bolted connections	14
15	b. Welded connections Review	Notes