mechanical design process

1. Introduction to
Mechanical
Design Process(3)
Created by
Ahmed Ashraf Gebril

2. contents
1. Introduction
2. Types of Mechanical Design
3. Mechanical Design Process
4. Key considerations in mechanical design

3. Mechanical
Design Process
Section 3

4. Structural Requirements
and Constraints
1. Minimum mass requirements
2. Volume requirements
3. Strength requirements
4. Stiffness requirements
5. Requirements for dimensional accuracy and
stability
6. Requirements for Production and
Processing Facility
7. Unification requirements

5. Mechanical Design
Process
The process begins with an identification of a need and a
decision to do something about it. After many iterations,
the process ends with the presentation of the plans for
satisfying the need.
Depending on the nature of the design task, several design
phases may be repeated throughout the life of the
product, from inception to termination.

6. Mechanical Design
Process
In the typical mechanical design process, there are 7 steps
involved:
1. Problem Definition
2. Conceptual Design
3. Preliminary Design
4. Detailed Design
5. Prototyping, Testing & Validation
6. Production & Implementation
7. Post-Launch Evaluation

7. Mechanical Design
Process
 Goal: Define the design challenge.
 Activities:
• Understand user needs and market gaps.
• Gather functional, performance, and regulatory
requirements.
• Research existing solutions and constraints (cost,
materials, time).
 Output: Clear problem statement and design
specifications.
1.Problem Definition

8. Mechanical Design
Process
2. Conceptual Design
 Goal: Generate and evaluate broad solutions.
 Activities:
• Brainstorming (e.g., sketches, mind maps).
• Develop multiple concepts (e.g., mechanisms,
configurations).
• Use tools (like decision grids or scoring tables) to
compare ideas and choose the best one(trade-off
analysis).
 Output: 2–3 viable conceptual designs.

9. Mechanical Design
Process
2. Conceptual Design
Decision matrix:
A tool used to compare ideas against one
another using specific criteria

10. Mechanical Design
Process
 Goal: Refine concepts into workable layouts.
 Activities:
• Select materials, rough dimensions, and basic
geometries.
• Analyze forces, motions, and load paths.
• Consider manufacturability and assembly (DFMA).
 Output: 3D CAD models, rough calculations, and
prototype plans.
3. Preliminary Design

11. Mechanical Design
Process
 Goal: Finalize all specifications for production.
 Activities:
• Precise dimensions, tolerances, and surface finishes.
• Stress analysis (FEA), thermal, or fluid dynamics
simulations.
• Optimize for cost, weight, and performance.
 Output: Detailed drawings, BOM (Bill of Materials), and
CAD files.
4.Detailed Design

12. Mechanical Design Process
5. Prototyping, Testing & Validation
 Goal: Validate the design.
 Activities:
• Build physical or digital prototypes.
• Test functionality, durability, and safety (e.g., fatigue
tests).
• Identify failures and iterate.
 Output: Test reports and design improvements.

13. Mechanical Design
Process
 Goal: Transition to manufacturing.
 Activities:
• Select production methods (e.g., machining,
injection molding).
• Design tooling and jigs.
• Quality control planning (e.g., ISO 9001).
 Output: Final product ready for market.
6. Production & Implementation

14. Mechanical Design
Process
 Goal: Improve future designs.
 Activities:
• Monitor field performance and user feedback.
• Identify wear/failure patterns.
 Output: Lessons learned for next-gen designs.
7. Post-Launch Evaluation

15. Example on the Mechanical Design
Process for a Gearbox
1.Problem Definition 2. Conceptual Design
 Need: Design a compact,
high-torque gearbox for
an industrial conveyor.
 Requirements: 50 Nm
torque, 1000 RPM input,
90% efficiency, IP54
protection.
 Brainstorm gear types (spur,
helical, planetary).
 Select helical gears (smoother,
quieter operation).

16. Example on the Mechanical Design
Process for a Gearbox
3. Preliminary Design 4.Detailed Design
 Layout: 2-stage reduction,
steel gears, aluminum
housing.
 Rough sizing: Gear ratios
(5:1 each stage), shaft
diameters.
 CAD model with exact
dimensions, tolerances, and
bearings.
 FEA validation for stress on
gears/shafts.

17. Example on the Mechanical Design
Process for a Gearbox
5. Prototyping,
Testing & Validation
6. Production &
Implementation
 3D-print prototype; test
under load for noise,
heat, efficiency.
 Fix issues (e.g., gear tooth
wear).
 Finalize molds for housing,
CNC gear machining.
 Outcome: A durable, efficient
gearbox meeting specs..

18. Tools & Technologies in Modern
Design
 CAD Software: For 2D/3D modelling (e.g., SolidWorks,
Inventor, Fusion 360).
 Simulation Tools: Finite Element Analysis (FEA),
Computational Fluid Dynamics (CFD) (like Ansys ).
 Prototyping: 3D printing, CNC machining.

19. Thank you for attention