Course Number and Title
ME 35400: Machine Design
Course Description and Credit Hours
Design, analysis, and selection of machine components for fluctuating loading. Application of design
fundamentals to mechanical components and integration of components to form systems. Open-ended design
projects reinforce the design process. 3 credit hours.
Prerequisites
ME 26300: Introduction to Mechanical Engineering Design, Innovation, and Entrepreneurship
ME 27400: Basic Mechanics II
ME 32300: Mechanics of Materials
Meeting Times, Instructional Modality, CRN, Instructors, and Resources for
Course Assistance
Course Supervisor: Prof. Fu Zhao, ME 2194, fzhao@purdue.edu
ME 35400-001 (CRN 23730)
MWF 1:30 pm – 2:20 pm
Face-to-Face
WALC 1132
ME 35400-002 (CRN 23731)
MWF 3:30 pm – 4:20 pm
Face-to-Face
WALC 1087
ME 35400-003 (CRN 23733)
MWF 12:30 pm – 1:20 pm
Face-to-Face
WALC 1132
Satish Boregowda, Ph.D.
Senior Lecturer
Mechanical Engineering
Office: POTR 322A
Phone: 765-496-0128
sboregow@purdue.edu
ME 35400-004 (CRN 69527)
MWF 2:30 pm – 3:20 pm
Face-to-Face
WALC 1132
Steven Lorenz, Ph.D.
Visiting Assistant Professor
Mechanical Engineering
slorenz@purdue.edu
ME 35400-005 (CRN 69528)
MWF 11:30 am – 12:20 pm
Face-to-Face
WALC 1132
Benxin Wu, Ph.D.
Professor
Mechanical Engineering
Office: 2550NW
Phone: 765- 496-0391
wu65@purdue.edu
ME 35400-006 (CRN 69529)
MWF 9:30 am – 10:20 am
Face-to-Face
WALC 1087
Steven Lorenz, Ph.D.
Visiting Assistant Professor
Mechanical Engineering
slorenz@purdue.edu
Satish Boregowda, Ph.D.
Senior Lecturer
Mechanical Engineering
Office: POTR 322A
Phone: 765-496-0128
sboregow@purdue.edu
Fu Zhao, Ph.D.
Professor
Mechanical Engineering
Office: ME 2194
Phone: 765-494-6637
fzhao@purdue.edu
A schedule of instructor and TA office hours will be posted on Brightspace. You can also contact the course
instructors via e-mail if needed. However, it is recommended that you utilize office hours first.
Learning Resources, Technology and Texts
Required Textbook:
Shigley’s Mechanical Engineering Design, Eleventh Edition, R.G. Budynas and J.K. Nisbett. McGraw-Hill
Education, New York, 2020. [ISBN: 978-1-264-08776-1].
The publisher offers several formats for purchase. You can also purchase from other venues.
Additional Readings/Resources: Additional resources will be posted on Brightspace. You may also be asked to
utilize other technology during lectures in order to facilitate questions and discussion (e.g., HotSeat, Slack,
Piazza). In particular, we will use Piazza as the Q&A platform for homework, the term project, and exams.
Instructors and TAs will moderate the discussion on Piazza.
Software/web resources: Purdue has licensed Office 365 from Microsoft to make it available for free on an
individual basis to students, faculty and staff, including use on their personally owned machines.
Use of artificial intelligence (AI) or Large Language Models (LLM): Use of AI tools by students during the learning
process for non-assessed work is allowed. No AI tool is allowed for assessed work.
Tutoring support:
The Academic Success Center, located in Wiley Hall, Room C215, provides a variety of proactive, practical and
approachable academic support services for undergraduate students.
Visit Ask a Librarian to connect with helpful resources and services provided by the Purdue Libraries and School
of Information Studies for course assignments and projects.
Brightspace learning management system (LMS)
Access the course via Purdue’s Brightspace learning management system. Begin with the Start Here tab, which
offers further insight into the course and how you can be successful on it. It is strongly suggested that you
explore and become familiar not only with the site navigation, but also with the content and resources available
for this course. See the Student Services widget on the campus homepage for resources such as Technology
Help, Academic Help, Campus Resources, and Protect Purdue.
Learning Outcomes
By the end of the course, you will be able to:
1. Apply fundamental concepts from statics, dynamics, and mechanics of materials to the design of
machine components and/or systems.
2. Apply static and fatigue failure theories to the design of machine components and/or systems.
3. Select standard machine components and materials.
4. Apply problem-solving and communication skills through design projects.
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Assignments
Homework assignments will be posted on Brightspace in accordance with the course schedule. Homework will
NOT be collected. Solutions to homework will be posted after one week. A term project will be assigned which is
to be worked in individually. There will be 2 checkpoints where progress on your project will be checked, and
feedback will be provided.
There are two midterm exams and one final exam. Exam dates and times are specified on the course schedule.
Exams will be closed-book and closed-note, but an equation sheet will be provided. Each student is allowed to
bring a single 8.5” x 11” crib sheet to the exam. Both sides of the crib sheet may be utilized. A calculator is the
only electronic resource that is allowed on exams and will be in accordance with the ME calculator policy
(https://engineering.purdue.edu/ME/Undergraduate/calculatorPolicy). Additional use of electronic equipment
must be approved by the DRC.
The lowest exam score will be dropped. If you are unable to take one of the exams at the specified time due to
an excused absence, a university-sponsored activity, or a religious observation, or other circumstances allowed
by university policy, you will have the option to take a make-up exam. If you choose NOT to take a make-up
exam, the scores from the other two exams will be used to calculate your final grade. You must take at least two
exams in order to pass the course.
Project progress report and the final report will be submitted via Gradescope. Exams will be scanned into
Gradescope and graded. You can find your scores on reports and exams on Gradescope.
Re-grade requests for all graded assignments will be accepted. Re-grade requests must be submitted via
Gradescope within one week of assignment return. A re-grade may result in a grade increase, decrease, or no
change.
Grading Scale
Final grades will be calculated using the following weighting:
Term Project: 20%
Highest Scoring Exam: 40%
Second Highest Scoring Exam: 40%
Lowest Scoring Exam: 0%
If needed, your total points will be rounded to an integer. The grade cutoffs will not be more stringent than the
following.
A+
B+
C+
D+
F
96 – 100
86 – 89.99
76 – 79.99
66 – 69.99
below 60
A
B
C
D
93 – 95.99
83 – 85.99
73 – 75.99
63 – 65.99
3
ABCD-
90 – 92.99
80 – 82.99
70 – 72.99
60 – 62.99
It is possible for, depending on the class averages at the end of the semester, the grade cutoffs to be adjusted.
However, the grades in this course are not curved with an intent of satisfying particular preset grade distribution
goals.
The final date to withdraw from a course with a W for Spring 2024 is Friday, April 12.
You are expected to comply with the guidelines for academic integrity as specified by university policy. Failure to
do so will result in a notification to the Office of the Dean of Students (ODOS). In addition to notifying ODOS,
potential consequences of a lapse in academic integrity include, but are not limited to, the following.
o Earning a zero (0) for the assignment.
o Earning an F in ME 35400.
Attendance Policy
This course follows the University Academic Regulations regarding class attendance, which state that students
are expected to be present for every meeting of the classes in which they are enrolled. When conflicts or
absences can be anticipated, such as for many University-sponsored activities and religious observations, you
should inform the instructor of the situation as far in advance as possible. For unanticipated or emergency
absences when advance notification to is not possible, contact the instructor as soon as possible by email or
phone. For absences that do not fall under excused absence regulations (see below), this course follows the
following procedures:
1.
Do not come to class if you are feeling ill but make sure you catch up with the missed class lectures and
the materials. If it is an emergency, email your instructor and follow the University regulations on emergent
medical care (see below).
2.
Unless it falls under the University excused absence regulations (see below) or DRC accommodations,
any work due should be submitted on time.
3.
If that day’s class involves assessed work such as a test or presentation, you and the instructor will plan
if and how you can make up the work, following the assignment guidelines. This plan must be done before the
next class period, so again, email the instructor immediately when you know that you will miss class.
4.
The most important consideration in any absence is how it will affect your achievement of the
assignment objectives and the course learning outcomes.
For cases that fall under excused absence regulations, you or your representative should contact or go to the
Office of the Dean of Students (ODOS) website to complete appropriate forms for instructor notification. Under
academic regulations, excused absences may be granted by ODOS for cases of grief/bereavement, military
service, jury duty, parenting leave, or emergent medical care. The processes are detailed, so plan ahead.
Academic Integrity
Academic integrity is one of the highest values that Purdue University holds. Individuals are encouraged to alert
university officials to potential breaches of this value by either emailing integrity@purdue.edu or by calling 765494-8778. While information may be submitted anonymously, the more information is submitted the greater
the opportunity for the university to investigate the concern. More details are available on our course
Brightspace under University Policies and Statements.
Copyright
See the University Policies and Statements section of Brightspace for guidance on Use of Copyrighted Materials.
Effective learning environments provide opportunities for students to reflect, explore new ideas, post opinions
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openly, and have the freedom to change those opinions over time. Students and instructors are the authors of
the works they create in the learning environment. As authors, they own the copyright in their works subject
only to the university’s right to use those works for educational purposes. Students may not copy, reproduce, or
post to any other outlet (e.g., YouTube, Facebook, or other open media sources or websites) any work in which
they are not the sole or joint author or have not obtained the permission of the author(s).
Nondiscrimination Statement
Purdue University is committed to maintaining a community which recognizes and values the inherent worth
and dignity of every person; fosters tolerance, sensitivity, understanding, and mutual respect among its
members; and encourages each individual to strive to reach their potential. In pursuit of its goal of academic
excellence, the University seeks to develop and nurture diversity. The University believes that diversity among
its many members strengthens the institution, stimulates creativity, promotes the exchange of ideas, and
enriches campus life. A link to Purdue’s full Nondiscrimination Policy Statement is included in our course
Brightspace under University Policies.
Accessibility
Ensuring that Purdue students have access to equitable learning experiences is a University-level commitment
and is the responsibility of all members of the Purdue community. The Disability Resource Center (DRC) is a key
partner in this work and is a resource for students and instructors. The Student Services widget on Brightspace
links to the DRC. You are also encouraged to contact the Disability Resource Center at: drc@purdue.edu or by
phone: 765-494-1247.
Mental Health/Wellness Statement
If you find yourself beginning to feel some stress, anxiety and/or feeling slightly overwhelmed, try
Therapy Assistance Online (TAO), a new web and app-based mental health resource available courtesy of
Purdue Counseling and Psychological Services (CAPS). TAO is available to students, faculty, and staff at any
time.
If you need support and information about options and resources, please contact or see the Office of the
Dean of Students. Call 765-494-1747. Hours of operation are M-F, 8 a.m.- 5 p.m.
If you find yourself struggling to find a healthy balance between academics, social life, stress, etc., sign up
for free one-on-one virtual or in-person sessions with a Purdue Wellness Coach at RecWell. Student coaches
can help you navigate through barriers and challenges toward your goals throughout the semester. Sign up
is free and can be done on BoilerConnect.
If you’re struggling and need mental health services: Purdue University is committed to advancing the mental
health and well-being of its students. If you or someone you know is feeling overwhelmed, depressed, and/or in
need of mental health support, services are available. For help, such individuals should contact Counseling and
Psychological Services (CAPS) at 765-494-6995 during and after hours, on weekends and holidays, or by going to
the CAPS office on the second floor of the Purdue University Student Health Center (PUSH) during business
hours.
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Basic Needs Security
Any student who faces challenges securing their food or housing and believes this may affect their performance
in the course is urged to contact the Dean of Students for support. There is no appointment needed and Student
Support Services is available to serve students 8 a.m.-5 p.m. Monday through Friday.
Emergency Preparation
In the event of a major campus emergency, course requirements, deadlines and grading percentages are subject
to changes that may be necessitated by a revised semester calendar or other circumstances beyond the
instructor’s control. Relevant changes to this course will be posted onto the course website or can be obtained
by contacting the instructors or TAs via email or phone. You are expected to read your @purdue.edu email on a
frequent basis.
A link to Purdue’s Information on Emergency Preparation and Planning is located on our Brightspace under
“University Policies and Statements.” This website covers topics such as Severe Weather Guidance, Emergency
Plans, and a place to sign up for the Emergency Warning Notification System. You are encouraged to download
and review the Emergency Preparedness for Classrooms document (PDF) or (Word).
During the first day of class we will review the Emergency Preparedness plan for our specific classroom,
following Purdue’s required Emergency Preparedness Briefing. Please make note of items like:
•
•
•
The location to where we will proceed after evacuating the building if we hear a fire alarm.
The location of our Shelter in Place in the event of a tornado warning.
The location of our Shelter in Place in the event of an active threat such as a shooting.
Course Schedule
Week
1
2
3
4
5
6
Lecture
Date
Topic
Reading
1
M
Jan 8
Introduction to Machine Design.
Chapter 1
2
W
Jan 10
Factor of Safety.
Chapter 1
3
F
Jan 12
Combined Stress and Critical Elements
3-4 to 3-12
M
Jan 15
No class – Martin Luther King Jr. Day
4
W
Jan 17
Failure Due to Static Loading.
5-4 to 5-11
5
F
Jan 19
Shape Synthesis.
Notes
6
M
Jan 22
Shape Synthesis.
Notes
7
W
Jan 24
Crack Nucleation and Propagation. Fatigue-Life Methods.
6-1 to 6-4
8
F
Jan 26
Stress-Life Method. S-N Diagrams.
6-7, 6-8, 6-19
9
M
Jan 29
Endurance Limit Modifying Factors.
6-9, 6-19
10
W
Jan 31
Stress Concentration and Notch Sensitivity.
5-2, 6-10, 6-19
11
F
Feb 2
Characterizing Fluctuating Stresses. Fluctuating-Stress Diagram.
6-11, 6-12, 6-19
12
M
Feb 5
Fatigue Failure Criteria for Ductile Materials.
6-13, 6-19
13
W
Feb 7
Combinations of Loading Modes.
6-16, 6-19
14
F
Feb 9
Cumulative Fatigue Damage.
6-17
15
M
Feb 12
Fatigue Failure Criteria for Brittle Materials.
6-15
16
W
Feb 14
Shaft Design.
7-1 to 7-6
6
HW
1
2
3
4
5
6
Week
Lecture
Date
9
10
11
12
13
14
15
16
Reading
7-7
17
F
Feb 16
Design of Keys.
18
M
Feb 19
Review.
T
Feb 20
–
19
W
Feb 21
Exam 1 – covering Lectures 1-15 (HW 1-5 + part of HW 6) – 810 pm
No class due to Exam 1
20
F
Feb 23
Limits and Fits.
7-8
21
M
Feb 26
Surface Fatigue Strength.
3-19, 6-18
22
W
Feb 28
Rolling Element Bearings: Life, Load, and Reliability.
11-1 to 11-5
23
F
Mar 1
Rolling Element Bearings: Combined Loading.
11-6
24
M
Mar 4
Lubrication.
12-1 to 12-6
25
W
Mar 6
Journal Bearings.
12-7 to 12-12
26
F
Mar 8
Journal Bearings.
12-7 to 12-12
7
8
Topic
–
M
Mar 11
No class – Spring Vacation
W
Mar 13
No class – Spring Vacation
F
Mar 15
No class – Spring Vacation
27
M
Mar 18
Material Properties.
2-1 to 2-8
28
W
Mar 20
Material Processing. Material Selection.
2-9 to 2-22
29
F
Mar 22
Gear Geometry.
13-1 to 13-12
30
M
Mar 25
Gear Loads.
13-13 to 13-17
31
W
Mar 27
Review.
Th
Mar 28
Exam 2 – covering Lectures 16-28 (HW 6-9) – 8-10 pm
32
F
Mar 29
No class due to Exam 2
33
M
Apr 1
Gear Mesh Design.
14-9
34
W
Apr 3
Spur Gear Bending.
Chapter 14
35
F
Apr 5
Spur Gear Wear.
Chapter 14
36
M
Apr 8
Compression Springs: Stresses and Spring Rates.
10-1 to 10-6
37
W
Apr 10
Compression Springs: Static and Fatigue Loading.
10-7 to 10-10
38
F
Apr 12
Extension Springs.
10-11
39
M
Apr 15
Torsion Springs.
10-12
40
W
Apr 17
Thread Standards. Threaded Fasteners.
8-1, 8-3
41
F
Apr 19
Bolted Joints. Bolt Stiffness.
8-4
42
M
Apr 22
Member Stiffness. Joint Constant.
8-5
43
W
Apr 24
Bolt Strength. Factors of Safety.
8-6 to 8-9, 8-11
44
F
Apr 26
Review.
–
TBD
Final Exam – covering Lectures 29-43 (HW 10-13)
Project Schedule
Release of Problem Statement: Feb 14, 2024
1st Project Progress Check: March 6, 2024 (Not graded but feedback provided)
2nd Project Progress Check: April 3, 2024 (Not graded but feedback provided)
Final Report Due: April 19, 2024
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HW
7
8
9
–
10
11
12
13
Notes:
a) Reading assignments are from the text: Shigley’s Mechanical Engineering Design, Eleventh Edition,
R.G. Budynas and J.K. Nisbett. McGraw-Hill Education, New York, 2020. [ISBN: 978-1-264-08776-1].
b) Homework assignments will be available on Brightspace on the Wednesday of the week they are
assigned. For example, HW 1 will be available on Wednesday, January 10. Solutions will be posted on
Brightspace one week after the release of the assignment.
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