Basics of Mechanical Design Engineering (2022)

Explore the product designing process from research to launch, and differentiate related terms. Learn standard design procedures, concurrent engineering, design for excellence, voc, and essential design documents and tools.

Define mechanical designing as sizing elements, assessing stresses, and selecting materials, and cover two pathways: machining element design with analysis, and creative mechanism design focused on functionality.

Master the two phases of product design and development, balancing functionality, mechanism, and appearance with manufacturing methods, production planning, ISO standards, and thorough documentation.

Industrial design blends arts and engineering to create products that balance functionality, durability, quality, and attractive appearance. Designers use symmetry, color, and shapes to influence buyers and appraisers.

Basics of mechanical design engineering (2022) introduces new product development (NPD) in manufacturing, covering how to select materials, optimize production cycles, and balance price, quality, and variety to beat rivals.

Learn how R&D improves existing products through blueprints, testing, manufacturing, packaging, and marketing, guided by market feedback and root-cause analysis with a scientific approach.

Explore reverse engineering as a systematic process: analyze a product, identify critical features, build a 3d model, determine material and specifications, and select appropriate manufacturing methods.

Identify the product need through surveys and market feedback, define design factors like force, time, target audience, and cost, and guide development toward feasible production and packaging.

Explore the product designing process within the designing procedure, from gathering information and creating specifications to conceptual design, embodiment and detail design, evaluation, prototyping, and continuous improvement.

Adopt concrete engineering to reduce design time and complete production within a year, enabling simultaneous work and new communication methods, while requiring a larger team with powerful information skills.

The lecture outlines lifecycle designing, from development to end-of-life, and shows how PLM and system engineering coordinate reuse, recycling, and environment-friendly materials.

Explore design for X (DFX) and its techniques, including live performance analysis, design for manufacturing, design for assembly, and lifecycle cost analysis to optimize product lifecycle design.

Master design for cost by aligning design quality with efficient manufacturing to reduce costs. Explore direct and indirect costs, fixed and variable costs, and pricing elements like margins and MRP.

Explore design for value (dfv) and value engineering to add value to a product with minimal cost, evaluating the value board and maximizing value delivery.

Design for manufacturing emphasizes making products manufacturable by reducing operations and costs, using standardized materials and common parts. Prioritize open tolerances, simple joining, and easy assembly to speed production.

Explore design for assembly (DFA/DFMA) principles that minimize parts and fasteners, enable self-locating and modular subassemblies, and streamline retrieval, insertion, and handling for efficient product assembly.

Design for testing and maintenance (dft & dfm) emphasizes accessible covers and testing provisions to identify faults and ensure quality before packaging.

Apply design for the environment by reducing raw material use, reusing components, selecting alternative materials, and recycling within a lifecycle approach.

explores how design for sustainability integrates manufacturability, environmental impact, remanufacturability, and economy with packaging, assembly, and social health factors.

Explore ergonomics in design as a human factors approach that reduces stress on arms, wrists, and eyes. Learn seating considerations and ergonomic techniques to create sturdy, user-centered products.

Explore designing tools, instruments, software, 3D printers, and testing machines and how they help determine exact sizes, coating thickness, radius, diameter, and prototype feasibility through simulation.

Master essential measuring instruments for design engineers, from vernier calipers and micrometers to bevel protector, height and dial gauges, thickness gauges, scanners, and radius gauges for internal and external measurements.

Explore software tools for mechanical design, including 3d modeling and drafting with SolidWorks and Creo, analysis with Simulink and MATLAB, manufacturing with Mastercam, and data management with Teamcenter.

Explore polymer based and metal based 3D printing, including SLA stereolithography, selective laser sintering, deposition modeling, and DLP, comparing speed, energy use, strength, accuracy, and post-processing for rapid prototyping.

Explore polymer and metal additive manufacturing methods, including multijet fusion and laser sintering, discuss post-processing, and learn 3d modeling with open source tools and photogrammetry for rapid prototyping.

Master detailed mechanical drawing concepts for aspiring mechanical design engineers, including deep drawing groups, features, projections, views, and symbols, plus tolerances, geometric tolerances, surface finish, and balancing.

Define mechanical drawing as technical or engineering drawing, a vital communication tool that conveys size, material, surface finish, and the manufacturing process and sequence for part production, including assembly.

Explore machine drawing, board drawing, production drawing, and machine shop drawing, detailing basic dimensions, orientation, tolerances, materials, finishes, coatings, and quality checks per ISO standards.

Analyze assembly drawings, instruction manuals, exploded assemblies, schematic assembly drawings, and catalog drawings to understand dimensions, part numbers, material details, assembly sequence, and user guidance for accurate product construction.

Explore the elements of a mechanical drawing, including drawing sheets, size scales like a1 to a4, grid references, orientation marks, center marks, the title and revision blocks, and assembly tables.

Explore drawing projections, including isometric and orthographic projections used in drawings, and oblique and perspective projections, with one-, two-, and three-point perspectives that aid size estimation and spacing in paintings.

Explore isometric projections, including the three types, and learn to convert iso views to orthographic views using the isometric scale, with lines drawn at 30 and 45 degrees.

Explore orthographic projections, converting 3D objects into 2D views using horizontal and vertical planes. Compare first-angle and third-angle projections, observer positions, and notation with solid and hidden lines.

Explore drawing symbols and line types, including continuous, projection, center, hidden, and section lines, and learn how they convey edges, dimensions, and surfaces in mechanical design.

Explore drawing symbols and their meanings for conveying dimensions, diameters, depths, and radii in mechanical design drawings. Apply conical and square symbols with notes for quality checks.

Learn to read drawing notes by identifying node representations, diameters, hole counts and spacing, and applying symbols for temper, hardening, and grinding.

Learn welding symbols in drawings, focusing on base metal, route opening for edge preparation, groove details, welding face, and thickness and length indicators guiding accurate assembly.

Learn welding symbols and their four major parts, including arrows side and reference line, and compare ISO and EWR system styles, plus how dimensions and wording placement affect symbol interpretation.

Learn welding symbols in building drawings, including the four parts, all-around and field weld symbols, root opening, groove, and finishing designators.

Explore welding symbols for joints such as groove, bevel, and fillet welds, including backing, root opening, spot welds, and dimensioning conventions with practical examples.

Explore surface finish symbols for surface roughness, learn to measure readings, compute the mean roughness value, and use charts to select machining operations like grinding.

Present the surface finish symbol and its four types, including machining without specified roughness, a circle for no material removal, and lines indicating machining or coating with parameters A–E.

Explore fits and tolerances in mechanical design by comparing shaft and hole sizes, understanding basic size and limits, and outlining four tolerance methods: limited, bilateral, single limit, and unilateral.

Explore selecting tolerances and basic sizes for holes and shafts, using the zero line to understand clearance, transition, and interference fits.

Explore selecting fits with the basic hole and shaft system, analyzing clearance fits, MMC, and minimum and maximum clearances, and applying RC1–RC9 and related running fits for bearings.

Explain interference fits, where shaft diameter exceeds hole, requiring force to assemble and disassemble. It distinguishes minimum, maximum, true interference and locational interference for high-accuracy assemblies.

Explore transition fit, lying between clearance and interference fits, with three types defined, where shaft and hole diameters are nearly equal, offering little play.

Learn about eight to nine types of dimensioning, including aligned and unidirectional, parallel, chain, and coordinate dimensions, and how datum and table methods organize design data.

Explore geometric dimensioning and tolerancing (GD&T) concepts, focusing on position symbols, tolerances, and datum references to ensure precise fits for multi-component assemblies and material condition modifiers M and L.

Explore GD&T drawing elements by analyzing form based tolerances—straightness, flatness, circularity, and cylinder city—along with location, orientation, and profile tolerances and measurement methods.

Master GD&T concepts for drawing alignment of two cylinders and holes using positioning and symmetry symbols, with CMM measurements and datum references.

Explore the application of geometric dimensioning and tolerancing, including pillars, flatness, parallelism, perpendicularity, angularity, datum planes, and diameter tolerances, with practical gear and shaft examples.

Explore profile based geometric dimensional tolerances and surface profiles, including line versus surface profile distinctions, tolerance zones, and datum references in GD and T-5 drawings.

Explore manufacturing processes essential to the design engineer, covering casting, drying, machining, sheet metal, metal length, and other operations, plus heat treatment methods like hardening, tempering, and quenching.

Explore manufacturing processes that transform materials into useful products through labor, power, and time, and identify economical methods for production engineering that help design engineers grow in industry.

Learn casting, forging, and molding processes, with emphasis on sand casting, patterns, drag boxes, and risers, and understand when casting suits aluminum parts and hard-to-machine components.

Explore the investment casting process for complex shapes requiring precision and tight tolerances, where molten metal is poured and, after cooling, yields a complex product.

Explore how the die casting process injects molten metal into dies to form complex structures, using the mould and ejector to manage tolerances.

Explore gravity die casting, a gravity-based casting process for large, complex parts that delivers a superior surface finish and enables intricate geometries beyond conventional casting.

Explore low pressure and vacuum die casting techniques, including alloy wheel manufacture and complex structures, and see how squeeze casting delivers superior surface finish and strength.

Use centrifugal casting to create larger hollow metal parts by applying centrifugal force. Rotate the pattern with a motor while molten metal forms the outer walls.

Explain the continuous casting process used to produce metal blocks, where molten metal is poured and moved over rollers to form the final blocks.

Explore how casting enables easy fabrication of complex structures, and recognize there is no size limit from very large to very small parts using diverse casting processes.

Forge parts by applying heat and force to shape raw material, performing operations such as adding, upset, blocking, trimming, and machining to yield a strong final product.

Discover how hot forging uses heat to shape a workpiece into a final forged part, aided by machines through repeated shaping steps.

Explore cold forging, a heat-free shaping process, featuring multiple operations and machining steps with dies and tools to achieve the final object shape.

Forging delivers superior strength with tightly packed grain structure, enabling heavy, large parts and precise shapes using dies and machines.

Explore the molding process, which uses heat and force to shape non-metallic materials and plastics through injection molding, detailing equipment, molten plastic, cooling, and final products.

Learn how compression molding uses two-part upper and lower molds and compression force to shape a part, then eject the finished piece with an ejector.

Explore the blow molding process used to make bottle-shaped plastics, from processing plastic granules into moulds to shaping with airflow and finishing.

Rotational molding creates hollow, non-metallic tanks with enhanced strength by filling a vessel with powder, closing it, then rotating in two planes while heating; thickness depends on powder amount.

The molding process offers advantages for manufacturing, notably faster production than casting, and enables design flexibility to create complex structures and various tank sizes.

Explore the drying process that uses tensile force to shape objects by reducing diameter, and compare rolling and extrusion, noting rolling’s tensile or compression force versus extrusion’s normal force.

Explore the flat rolling process that turns raw blocks into metal sheets using rollers, heat, and force. Understand how different rolls size sheets and shape various forms.

Discover the thread rolling process within drawing processes, and understand why lubrication is very important.

Observe the ship rolling process: a metallic sheet enters the shape rolling machine, is rolled by rollers, welded to final shape, and different rollers yield various shapes to meet requirements.

Explore how the ring rolling process manufactures large rings with heating to shape them and rulers to set the final size.

Explore the transverse rolling process, also called the gross rolling process, and how heating and longer lengths or distances shape the rolling outcomes.

Compare the scrolling process with the transfer rolling process, focusing on the roller configuration relative to the object and its applications for metal and nonmetals.

Explore the roll bending process, a common sheet metal method for forming cylindrical shapes, demonstrated in the video.

Discover the advantages of the rolling process, including fast production rates and high quality. See how passing through different rollers yields a precise piece of quality.

Explore hot extrusion by heating the raw material and forcing it through dies to shape final products, using short and cold extrusion variants.

Discover the cold extrusion process and how tools and dies shape objects in extrusion operations. The video also covers how sheet milling relates to extrusion and forms the final product.

Explore how the wire drawing process reduces a wire's diameter to meet the required size, using applied force to transition from the initial large diameter to the final size.

Explore the rod drawing process, similar to the wire drawing process, using dies to reduce a rod’s diameter to the required size and yield the final product.

Explore the tube drawing process and its dual brewing approach, analyzing how redesign steps influence internal and external diameters and alter the grain structure of the product.

Drying processes are fast and flexible, similar to rolling processes. They recreate the green structure of a product, increasing strength and improving quality—two major advantages.

Explore the three metal joining processes—welding, lifting, and threading—from a design engineer’s perspective, gaining an overview of their applications and practical considerations.

Explore welding processes as a common method for permanent metal joining. Learn the five main welding types—gas welding, arc welding, electro logistic welding, solid-state welding, and other miscellaneous methods.

Explore how gas welding uses acetylene and oxygen to create a flame for heating and joining metals, and observe the final welded joint produced.

Examine metal joining processes by electrode type, including consumable-electrode methods such as shielded metal arc welding and gas augmenting, versus non-consumable-electrode methods like plasma welding.

Explore the shielded metal arc welding process using a consumable electrode coated with flux, where current passes through the electrode and workpiece to create the weld.

Explore gas metal arc welding (GMAW), using a bare electrode wire and shielding gas to protect the weld, delivering a high-quality, strong finish at a higher cost.

Explore gas tungsten arc welding, using tungsten electrodes and shielding gas with a consumable electrode for joining dissimilar metals.

Describe plasma welding, which uses two gases—shielding and plasma-creating—and a tungsten electrode, and its similarities to TIG welding, emphasizing the smooth surface finish and suitability for large, durable pieces.

Discover electric resistance welding, where electricity generates heat to join two parts with filler metal, then trim excess material to yield the final welded product.

Explore resistance welding, where applying force between two objects generates heat to join them, illustrating how two workpieces are forced together to form a weld.

Explore ultrasonic welding as a solid-state joining method that uses ultrasonic waves to create resistance and heat at the interface to join objects.

Explore diffusion welding, a metal joining process that uses heat to join parts, review the expected results, and discuss its applications.

Explore engineering materials, their classifications, and selection procedures, including various selection methods, the chemistry of materials, and the roles of engineers and designers in material choice.

Explore engineering materials used for manmade structures, including metals, polymers, ceramics, and composites, and learn how to select materials that withstand loads and life expectancy in design.

Classify solid engineering materials into crystalline and amorphous types, and explain how their structures drive properties such as hardness, with crystalline examples like Galena, Juarez, and White Oak.

Explore simple classifications of engineering materials, separating metals from non-metals and ferrous from non-ferrous, with examples like iron and steel. Include polymers, ceramics, glasses, and composites.

Explore the six classifications of engineered materials, focusing on metals and aluminum alloys such as 6061 and 6000 series, and how alloying alters properties to meet design requirements.

Explore the physical properties of engineering materials, including density, weight, appearance, and surface texture, and examine how shape (solid, liquid, or gas) affects material selection.

Explore thermal properties in mechanical design, including thermal conductivity, thermal resistivity, and thermal expansion, with formulas and real-world applications like heat transfer and material choice.

Explore chemical properties of materials in mechanical design, focusing on electro positivity and corrosion; learn how coating and base metals interact to ensure ferrous durability in natural environments.

Explore the electrical properties of materials, focusing on conductivity and resistivity, their reciprocal relationship, and how resistivity scales with length and cross-sectional area, important for electrical equipment.

Explore how optical properties of materials affect product appearance and customer perception, including color effects, classifying materials as transparent, translucent, or opaque, and noting uses for light transmission or blocking.

Learn how mechanical properties guide material choice in design, covering hardness tested with Rockwell and Brunel machines, brittleness, ductility, and malleability for forming and processing.

Examine toughness, stiffness, and elasticity as key properties, including plasticity and stress-strain behavior, with polymers and metals and implications for extrusion and forging.

Assess how machining ability and material properties guide milling and turning operations, emphasizing stress, strain, and modulus to predict material behavior under live milling and boring turning.

Examine standard-based material selection, predefined materials, and the adoption of new materials, with property-driven evaluation to design safer, cost-effective products.

Explore how engineers select materials using property charts, including thermal conductivity vs electrical resistivity and toughness vs Young's modulus, to shortlist washing machine components.

Develop an engineering perspective by exploring mechanical principles, stress, mechanisms, machines, and machine elements, and practice imagining a machine's workings to foster innovation in design.

Designing conceptualization uses a perception mindset to view products as parts with movements and stresses. Validation considers geometric shape, conditions, and material for each part in the overall assembly.

Explore how elastic materials resist external forces through deformation and stress, defined as force per unit area, and classify forces such as compression, tension, bending, shear, and torsion.

Explore basic concepts of designing by analyzing strain as the change in length over original length. Compare materials under the same load using stress–strain and Young's modulus to predict behavior.