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STUDY GUIDE · GKU 8

Mechanical design and analysis study guide (Mechanical Engineering)

Two parts, following the ETEC handout. Engineering drawing: reading and writing drawings to ISO, GD&T, projection, sections, solid modelling and CAD geometry. Design of machine elements: design factor and standards, stiffness and stress analysis, static and fatigue failure, shafts, screws and fasteners, springs, bearings, gears, belts, clutches and brakes, drive actuators, pressure vessels, joints, and limits, fits and reliability.

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Structured by the official ETEC subject standard for this topic: every listed topic and learning outcome, with formulas, figures and worked examples. The full sections are available to members in the app.

SKU 8.1 · Engineering drawing

  1. Reading a drawing: standards, dimensions, surface texture and GD&T

    The conventions that let a drawing be read the same way in any workshop: sheets, scales, lines, dimensioning, surface texture symbols, and geometric tolerances with the bonus tolerance at MMC.

  2. CAD and solid modelling: parts, assemblies and drawings

    How a CAD system represents a solid, how a parametric part is built from sketches and features, how mates assemble parts, and what a CAD workstation needs.

  3. Geometry inside CAD: transformations, curves and surfaces

    The mathematics a CAD system runs on: homogeneous transformation matrices in two and three dimensions, perspective projection, analytic and synthetic (Bézier, B-spline) curves, and the surfaces built from them.

  4. Orthographic, auxiliary and isometric views

    How multi-view drawings are projected (first and third angle), how true lengths and true shapes are found with auxiliary views, and how to move between orthographic views and isometric pictorials.

  5. Sectional views, intersections and developments

    How to cut a part to show its inside, which parts are never hatched, how the line where two solids meet is found, and how a surface is unrolled into a flat pattern for sheet-metal work.

  6. Working drawings: parts, assemblies, fasteners and standard elements

    What a complete drawing set contains, how assembly drawings and parts lists work, and how threads, fasteners, welds, bearings, gears and structural members are shown by convention instead of being drawn in full.

SKU 8.2 · Design of machine elements

  1. The design process: from a need to a working product

    The stages of the engineering design cycle, how concepts are generated and chosen against several objectives and constraints, and why prototypes and iteration are part of the method rather than a sign of failure.

  2. Engineering ethics and technical reporting

    The engineer's duty to public safety, how classic failures turned into ethics cases, how to reason through a dilemma, and how a technical report should be organised.

  3. Design fundamentals: design factor, codes, standard sizes and materials

    How a design factor is chosen from the uncertainties in load and strength, what codes and standards decide for you, why sizes are rounded to preferred numbers, and how a material is chosen for a stiffness or strength target.

  4. Deflection, stiffness, impact loading and buckling of machine elements

    Machine elements treated as springs: the stiffness of rods, shafts and beams, how springs combine, why a dropped load stresses a part far more than the same load placed gently, and when a compression member buckles before it yields.

  5. The finite element method and CAE

    How a finite element program turns a part into a set of springs, assembles and solves , and how to set up and check a CAE stress analysis so that its colours can be trusted.

  6. Static failure theories: ductile and brittle materials

    Which combination of stresses a tension test result can be compared with: distortion energy and maximum shear stress for ductile parts, maximum normal stress and Coulomb–Mohr for brittle ones.

  7. Fatigue: endurance limit, mean-stress criteria and finite life

    Why parts fail under repeated stress far below yield, how the endurance limit of a real part is estimated, how a mean stress is allowed for (Goodman, Soderberg, Gerber), and how finite life and cumulative damage are estimated.

  8. Shafts, keys and couplings

    Sizing a power-transmission shaft for static strength and for fatigue under rotating bending, sizing the key that drives the hub, and checking the critical speed.

  9. Power screws and threaded fasteners

    The torque to raise and lower a load with a power screw, self-locking and efficiency, then bolt preload, tightening torque and how an external load is shared between a preloaded bolt and the clamped parts.

  10. Mechanical springs

    Stress and rate of a helical compression spring, the curvature (Wahl or Bergsträsser) factor, solid and free length, buckling, springs in series and parallel, and a note on leaf and other springs.

  11. Rolling bearings and journal bearings

    Selecting a ball or roller bearing from its load rating and the required life, the equivalent load, and how a journal bearing works: lubrication regimes, the Stribeck curve, Petroff friction and the Sommerfeld number.

  12. Gears: spur, helical, bevel and worm

    Gear geometry and the law of gearing, gear trains, the forces on spur, helical, bevel and worm gears, interference, and the Lewis bending stress with a dynamic factor.

  13. Belt and chain drives

    Belt geometry, the capstan relation between tight and slack tensions, centrifugal tension and transmitted power, why V-belts carry more than flat belts, and the essentials of chain drives.

  14. Clutches and brakes

    Torque capacity of disc clutches under uniform wear and uniform pressure, band brakes, and the energy a brake must absorb and the temperature rise it causes.

  15. Drive components: hydraulic, pneumatic and electromechanical actuators

    Sizing a hydraulic or pneumatic cylinder for force and speed and its pump for power, and sizing an electric motor with a gearbox or a ball screw for a mechanical load.

  16. Pressure vessels, piping and press fits

    Thin-walled vessels and pipes, thick-walled cylinders (Lamé), the effect of a code on the wall thickness, and the contact pressure and torque capacity of an interference fit.

  17. Welded, riveted and bonded joints

    Throat stress in fillet welds; weld groups loaded in torsion and in bending (primary and secondary shear); the failure modes and efficiency of riveted joints; and how adhesive joints are designed.

  18. Limits and fits, tolerance stacks, quality and reliability

    ISO 286 tolerance grades and fundamental deviations, clearance, transition and interference fits, worst-case and statistical tolerance stacks, process capability, stress–strength reliability, and design for manufacture and assembly.

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