Analysis and Design of Machine

Components
L-T-P : 4-0-0
Instructors:
Sanjeevi
Poornesh K
Abhilash Singh
Department of Mechanical Engineering
What is Design?

Design is the process of deciding what to make, how to make it, so that
it performs its intended function under given conditions

Design is the process of deciding what to make, how to make it, and how
safe and reliable it must be so that it performs its intended function
under given conditions
What is Mechanism
• A device which transforms motion to some desirable pattern
• May contain linkages, cams, gears, belts and chain

Examples ??
What is Machine?
• typically contains mechanisms
• designed to provide significant forces and transmit significant power

A system of elements arranged to transmit motion and energy in a pre

determined fashion
Basic Procedure
1. Product Specifications

2. Selection of Mechanism

3. Layout of Configuration

4. Design of Individual Components

5. Preparation of Drawings
Design of Machine Elements
It is the most important step in the complete procedure of machine design. In order to ensure the
basic requirements of machine elements, calculations are carried out to find out the dimensions of
the machine elements.
Example: Bolt
A bolt must:
• Hold two plates together
• Carry a certain load
• Not break, bend, or loosen
• Be economical and manufacturable
Design involves:
• Choosing material (steel grade)
• Calculating diameter (strength)
• Checking failure modes (shear, tension, fatigue)
• Applying a factor of safety
• Ensuring standard sizes and ease of manufacture
Now what is Machine Design?

It is defined as, “use of scientific principles, technical information and

imagination in the description of a machine or a mechanical system to
perform specific functions with maximum economy and efficiency”
Materials
• Design
- made out of some material
- able to manufacture that material
• Through understanding of
- material properties
- treatments
- manufacturing process
Material Property (How to determine?)
• Determined through destructive testing of samples under controlled loading

• Test loading do not accurately duplicate actual service loading

• There will be some statistical variation in the strength of any particular sample compared
to the average tested properties for that material

• Many of the published data are given as minimum values

• The best material-data will be obtained from destructive or nondestructive testing under
actual service loadings of prototypes of actual design, made from actual materials by the
actual manufacturing process.
Tensile Test
• The bar is stretched slowly in tension until it breaks, while the load and the distance
across the gauge length (or alternatively the strain) are continuously monitored. The
result is a stress-strain curve
Stress – Strain Curve
Tensile Test
• Parameters measured are load and deflection but those plotted are
stress and strain.
• Stress (σ) is defined as the load per unit area, (σ) = P/A,
here P - Applied load at any instant, and
A - original cross section area of the specimen.
• Strain is the change in length per unit length ϵ = (l−lo)/lo
where lo- original gauge length and l- gauge length at any load P.
• Modulus of Elasticity E = σ/ ϵ.
E is a measure of the stiffness of the material in its elastic range.
Tensile Test
• Elastic Limit: The point beyond which the material will take a permanent plastic deformation.
Boundary between elastic-behavior and plastic-behavior region of the material.
Tensile Test
• Yield strength At a point y slightly above the elastic limit, the material begins to yield more readily
to the applied stress, and its rate of deformation increases (note the lower slope).
This is called the yield point, and the value of stress at that point defines the yield
strength, Sy of the material.
Tensile Test
• Ultimate Tensile Strength The stress in the specimen continues to increase non-linearly to a peak
value at point u. This is considered to be largest tensile stress the
material can sustain before breaking.
Specific Strength
• In comparing the properties of different materials it is quite useful to
express those properties normalized to the material’s density.
• Since light weight is nearly always a goal in design, we seek the
lightest material that has sufficient strength and stiffness to withstand
the applied loads.
• The specific strength of the material is defined as the strength
divided by the density.
• The strength-to-weight ratio is another way to express the specific
strength
Ductility
• Ductility- tendency for a material to deform significantly before fracturing.
• Figure shows a test specimen of ductile steel after fracture.

The distortion called necking-down can clearly seen at the break. The fracture surface appears torn and is laced
with hills and valleys
Brittleness
• Absence of significant deformation before fracture.
• Figure shows a test specimen of cast iron after fracture.

The break shows no evidence of necking and has the finer surface contours.
Compression Test
• Tensile test machine can be run in reverse to apply a compressive load to a specimen.
• The ductile sample will not fracture in compression. If enough force is available from
the machine, it could be crushed into a pancake shape
• Brittle materials will fracture when compressed. Note the rough, angled fracture
surface. Brittle materials have much greater strength in compression than in tension.
Bending Test
• A thin rod, is simply supported at each end as beam and loaded transversely in the
center of its length until it fails.
• If the material is ductile, failure is by yielding. If the material is brittle, the beam
fractures.
Torsion Test
• The shear properties of a material are more difficult to determine than its tensile
properties. A specimen similar to the tensile test specimen is made with non circular
details on its ends so that it can be twisted axially to failure.
• The helical twist in the ductile specimen’s line after failure shows that it wound up for
several revolutions before breaking in ductile case.
• The brittle, torsion-test specimen’s line is still straight after failure as there was no
significant plastic distortion before fracture.
Torsion Test
• The stress-strain relation for pure torsion is defined by
𝐺𝜃𝑟
𝜏=
𝑙
𝐸
• The shear modulus 𝐺 =
2(1+𝜇)

• The breaking strength in torsion is called the ultimate shear strength or modulus
𝑇𝑟
of rupture Sus and it is calculated from 𝑆𝑢𝑠 = , where T is the applied torque
𝐽
necessary to break the specimen, J is polar moment of Inertia.
Torsion Test
• In the absence of available data for the ultimate shear strength of a material, a
reasonable approximation can be obtained from tension test data

Steel: Sus = 0.8Sut

Other ductile materials: Sus ≃ 0.75 Sut

Sys = 0.8Sy
 Contents Faculty
Introduction to Design, Engineering Materials, Simple Dr. Sanjeevi
Stresses, Compound Stresses in machine parts, Review Nakka
of Failure theories, Design for static and dynamic
loading, Stress Concentration, Curved Beams, Cotter and
Knuckle Joint
Design of shafts, keys, and coupling, Variable and Impact Dr. Poornesh Kumar K
loading, Design of springs, Spring nomenclature, Design
of helical spring for static and fatigue loads, Collar and
Pivot friction, Design of coupling
Design of power screws, Lubrication, Design of Journal Dr. Abhilash Singh
Bearing, Design/Selection of Ball Bearings and
Roller Bearings
Evaluation Plan

• Insem (Quiz/Assignment/Project) = 30 %

• Mid Sem Exam = 20 %

• End Sem = 50 %
Reference books
• V.B. Bhandary - Design of Machine Elements, Tata McGraw Hill.

• RL Norton – Machine Design, An integrated approach, Pearson Education Asia

• J.E. Shigley and Mische Mech. Engineering Design , Tata McGraw Hill

• Hall, Holowenko, Laughlin- Machine Design, Schaum’s Outline Series.

• V. L. Maleev and Hartman; Machine Design ; CBS Pbl. New Delhi.