Engineering Design

Engineering Design

Industry relevance

This module fundamentally focusses on various aspects of engineering design namely, design process, design space, material selection, loads, obvious and unobvious failure modes hence stress and vibration margin and basic lifing practices in great detail. Enough discussion is provided to physics of vibration to bring about clarity for young engineers. Wherever relevant technological aspects of product lines are also discussed.

The module also addresses the modern best practices such as sensitivity analysis, probabilistic design, reliability assessment and basic introduction to digital twin technology.
Module incepts with interviewer’s expectations that sets the ideal direction of discussion of design
A special module is included to give fundamental literacy in composite mechanics.

Learning outcomes
  •  Appreciation for loads (mechanical, aerodynamic, electromagnetic and thermal) stress margin, best practices
    (aero and auto components)
  •  Material selection scope and challenges
  •  Best practices to address transient thermal loading and design remedies
  •  Vibration margin, excitation agencies, construction and interpretation of Campbell diagram, dynamic stress and damping
  •  Sensitivity analysis
  •  Familiarity with Probabilistic design philosophy and basic application
  •  Elementary idea about random vibration fatigue

Related Videos

Course Content

Component Design

  • Why phase 1
  • Introduction to engineering design
  • Engineering Design process: from concept sketching to component design

Design fundamentals

  • FOS
  • Specific material properties
  • Material utilisation factor
  • Vibration margin
  • Bearing support structure
  • Torsional excitation of crank shaft
  • Use of Goodman diagram
  • Safe life and Fail safe
  • Thermal loading
  • Off design failure example
  • Plates vs Shells

Various loadings

  • Mechanical loading
  • Inertial loading (Gyroscopic loading)

Centrifugal loading a detailed account (shaft design and disc burst analysis)

  • Consequences of CF loading
  • CF loading Quizzes
  • Effect CF load turbine clearance
  • Effect on Boundary condition
  • Stress stiffening
  • Flow over curved surfaces
  • Effect on bolted joint and interference fit
  • HP spool speed determination
  • Disc burst analysis based on plasticity theory
  • Disc burst analysis based on AWMH
  • Shaft design analysis
  • Material selection challenge.
  • Design summary for CF loading

Basic Introduction

  • Digital twin
  • Electromagnetic bearing

Design best practices

  • Sensitivity analysis
  • Probabilistic design
  • Reliability

OEM expectations of a designer

  • Example situation for designer and analyst
  • University examples vs real time examples

Learning best practices

  • Engineering wheel
  • Memory map

Physics Webinars Case Studies

  • Case Study 1: Mechanism efficiency vs Friction.
  • Case Study 2: Effect of axial thrust on gear transmission
  • Case Study 3: Stress discontinuity effect and design best practices
  • Case Study 4: Construction and interpretation of Campbell diagram, for various influences and variability in natural frequency
  • Case Study 5: Rotodynamic effect of rotor tilt and quantification of unbalance.
  • Case Study 6: Effect of elevated temperature on joint integrity
  • Case Study 7: How FEM practices affect design prediction: Mass lumping

 

Course Features
Lectures : Pre-recorded
webinars on all modules
Quizzes : Summary and quizzes
after each sub-module.
Language : English
Assessments : 7 physics assessments
after physics webinars
Certificate of Completion : yes
Reference : A text book on
Engineering Critical thinking
Mini : A mini project definition
(participants could buy the full solution)
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