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Engineering Systems Design
Engineering design is an iterative decision making process of creating plans used for the
optimal conversion of resources to systems, processes and devices used for satisfying human
needs. The purpose of an engineering design course is not main to teach new topics but to
inculcate the habit of thought by which the knowledge already acquired is being purposefully
and effectively applied in solving practical engineering problems.
Mechanical Engineering Design or Machine Design is one of the branches of engineering
design which deals with the systems that converts energy into useful mechanical forms.
Machine design acquaints the students with the fundamentals of designing individual
components of machine and creating of the right combination of them so as to enable optimal
liberation, transformation and utilization of energy.
Hence, a mechanical design course helps in inculcating the skill of selecting the best
suited materials and shapes, computing their dimensions on the strength and specifying
manufacturing requirements for a particular system or combination of systems.
Therefore, mechanical engineering design constitutes the application of mathematics,
mechanics, thermodynamics, engineering drawing, engineering materials,
manufacturing technology, electrical theories, social studies and humanities in
conjunction with past knowledge and experience etc.
In other words design of machine is based on past experience, factual knowledge and
engineer’s skill. Engineer’s skill includes inventiveness, good interdisciplinary
communication, measurement and decision making, simulation/optimization and social
abilities. Social skill is highly required so as to be sensitive to change in desired even it
has not been communicated.
Mechanical design may be broadly classified based on the nature of its final product into
three as new, development and adaptive designs. It can also be classified based on design
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methods as empirical, rational, functional, optimum, element, system, industrial, and computer
aided designs etc.
New designs (creative or inventive design) are created from scratch through the application of
scientific laws, technical ability and creative thinking.
Development design (innovative design) involves modification of an existing design, it starts
from an existing one, although the final product may differ from the initial one.
Adaptive design involves adaptation of an existing design in which only minor modifications
usually in product dimensions is possible due to substantial development has finally ceased in
the field concern.
Machine is a combination of stationary and moving elements constructed for the purpose of
generating, transforming or utilizing mechanical energy. Base on this definition a machine can
be an;
Energy generating machine or prime mover which converts other forms of energy to
mechanical work. E.g. I. C. engines, steam engines, turbines and electrical motors etc.
Energy transforming machine or converting machines which transforms mechanical
energy to other forms of energy e.g. electric generators, pumps etc.
Energy utilizing machine which receives, delivers and utilizes mechanical energy for
performing useful work e.g. lathe, grinding machines etc.
Machine Elements are separate parts of a machine which may either an integral unit or consisting
of several smaller units rigidly joined together. A machine is formed when two or more of machine
elements are grouped to work together. Machine elements are broadly classified into two, general
and specific purpose elements.
General purpose elements which may be fasteners or rotary motion drives are common to all
machine. Fasteners are used to join machine parts temporary so as not to destroy them
whenever the need to disassemble them arises such as nuts, bolts, keys etc. while rotary motion
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drives are power transmission elements such as belt, rope, chain, gear, worm, coupling,
bearing, axles and shaft.
Special purpose elements are main for a particular type of machine(s) such as piston,
connecting rod, camshafts, push rod, turbines blades etc.
Mechanical Design Procedure
1. Make a clear and precise statement of the problem which the machine to be designed will solve.
2. Determination of possible mechanisms which will give the desired motion or group of motion
required to achieve the machine- simple mechanism is most desired for easy maintenance of the
system when produced.
3. Determination of forces that will act on and energy to be transmitted by the mechanisms or
machine elements that makes up the mechanism. – Computing the allowable/design stress of
the elements considering factors that affects their strength e.g. temperature, loading methods,
impact, fatigue etc.
4. Selection of the best material and size of each machine element (with respect to standard
specifications) which will enable it to reset distortion under loading to enable easy manufacture
and maintenance. These require application of post experience and judgment with respect to the
following factors.
i. Availability
ii. Cost/economy of performance.
iii. Durability - Strength/weight, Light weight with high strength is preferred
iv. Processability, reliability and maintainability
v. Compliance with set standard and portability- use of minimum dimension possible
vi. Aesthetics- appearance/simplicity
5. Production of the detail and working drawings of the system i.e. orthographic, exploded
isometric components and assembly drawings with precise specifications of materials,
dimensions and manufacturing methods.
6. Development and evaluation of prototype to assess the functionality of the design.
7. Development of full scale product and its evaluation.
8. Production of the design report and commissioning.
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Recognition of needs
Specification and Requirement
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Feasibility study
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Creative design synthesis
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Preliminary design and development
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Detailed Design
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Production and testing of Prototype
Design for Production
Development of full scale product
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Product commissioning
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Fig. 1: Systems Design Cycle
Design Report Writing
1. Preliminary - Cover page, title page, abstract, and table of content.
2. Introduction – Background, objectives/scope and justification.
3. Literature Review – Review of previous designs in the area, indicating specific short coming of
the existing systems, the new design will address and theoretical frame work based on which
the new will be developed.
4. Design Methodology and Analysis- Design concepts and considerations base on which
mechanism and components were selected, material selection and force analysis of
components, selection of standard components, determination of the system’s power
requirement, production of the detailed drawings of the system with complete specification of
the manufacturing processes involved and its performance evaluation procedure.
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5. Result and Discussion -Presentation of results of the system performance and its comparative
analysis with respect to that of the latest and general adopted versions of the existing systems.
6. Conclusion and Recommendations.
7. Reference.
8. Appendices
