ME3411E Machine Design

Course Outcomes:
• Understand the design process and basic theories of failure.
• Design the thread fasteners and joints for strength.
• Design the shafts using stress analysis and design standards.
• Design the spur gears based on bending, contact and wear
strength.
• Select rolling contact bearings for various applications, based on
standards and practices.
Course contents
Course contents…
Evaluation Policy:

• Mid Semester Exam : 30 Marks

• Assignments : 5 marks
• Class Test : 5 Marks
• Mini Project : 10 Marks

• End Semester Exam : 50 Marks

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• Total : 100 Marks

• Grading Criteria: Relative

• References:
• Shigley, J. E., and Mischke, C. R., 2003, Mechanical Engineering Design, 6th ed. Tata McGraw-Hill.
• Richard, G. B., and Nisbett, J. K., 2011, Shigley’s Mechanical Engineering Design, 9th ed. Tata McGraw-Hill.
• Siegel, M. J., Maleev, V. L, and Hartman, J. B., 1965, Mechanical Design of Machines, 4th ed. International
Textbook Company.
• Phelan, R. M., 2005, Fundamentals of Mechanical Design, 3rd ed. Tata McGraw-Hill.
• Juvinall, R. C., and Marshek, K. M., 2000, Fundamentals of Machine Component Design, 3rd ed. John Wiley &
Sons.
• Norton, R. L., 2013, Machine Design, 5th ed. Pearson Education, 2013.
• Maitra, G. N., 2001, Handbook of Gear Design, 2nd ed. McGraw-Hill.

Data Handbooks (allowed for reference during examinations):

• P.S.G. Tech., 2015, Machine Design Data Handbook, Kalaikathir Achchagam.
• Mahadevan, K., and Reddy, B., 2013, Design Data Handbook for Mechanical Engineers, 4th ed. CBS
Publishers and Distributors
• Bhandari, V. B., Machine Design Data Book, 2nd ed.
Introduction to Design:

• To design is either to formulate a plan for the satisfaction of a specified need or to solve
a specific problem.

• If the plan results in the creation of something having a physical reality, then the product
must be functional, safe, reliable, competitive, usable, manufacturable, and marketable

• Design is an innovative and highly iterative process

• The engineering designer has to be personally comfortable with a decision-making,

problem-solving role.

• A designer’s personal resources of creativeness, communicative ability, and problem

solving skill are intertwined with the knowledge of technology and first principles.
Steps in design
process
• Machine design is defined as the 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.
• A designer uses principles of basic and engineering sciences
Some examples
(a) Newton’s laws of motion
(b) D’ Alembert’s principle
(c) Boyle’s and Charles’ laws of gases
(d) Carnot cycle
(e) Bernoulli’s principle
• The designer has technical information of the basic elements of a machine.
Fastening devices, chain, belt and gear drives, bearings, oil seals and
gaskets, springs, shafts, keys, couplings,and so on.

A machine is a combination of these basic elements.

• The designer uses his skill and imagination to produce a configuration,
which is a combination of these basic elements.

• The final outcome of the design process consists of the description of the
machine.
• Drawings of assembly and individual components.

• A design is created to satisfy a recognized need.

• The need may be to perform a specific function with
maximum economy and efficiency.
BASIC PROCEDURE OF MACHINE DESIGN
Basic procedure for the design of machine elements
Design considerations

When we use the expression

design consideration, we are
referring to some characteristic
that influences the design of
the element or, perhaps, the
entire system.

Several characteristics may be interrelated, which affects the configuration of the total system.
Standards and Codes
• A standard is a set of specifications for parts, materials, or processes intended to achieve uniformity, efficiency,
and a specified quality.
• One of the important purposes of a standard is to limit the multitude of variations that can arise from the
arbitrary creation of a part, material, or process.
• A code is a set of specifications for the analysis, design, manufacture, and construction of something.
• The purpose of a code is to achieve a specified degree of safety, efficiency, and performance or quality.

• Examples:
• American National Standards Institute (ANSI)
• American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE)
• American Society of Mechanical Engineers (ASME)
• American Society of Testing and Materials (ASTM)
Economics
• Standard Sizes
• Large Tolerances
• Break even points and cost estimation
Engineering Materials- Families and classes
 Engineering Materials - Strength
• Metals and metal alloys
• Ceramics
• Polymers
• Elastomers
• Natural Materials
• Composite Materials
• Foams
Engineering Materials – Young’s Modulus

• Metals and metal alloys

• Ceramics
• Polymers
• Elastomers
• Natural Materials
• Composite Materials
• Foams
 Tension Test
• A tension test is one of the simplest and basic tests and determines values of number of
parameters concerned with mechanical properties of materials like strength, ductility and
toughness.
The following information can be obtained from a tension test:
• (i) Proportional limit
• (ii) Elastic limit
• (iii) Modulus of elasticity
• (iv) Yield strength
• (v) Ultimate tension strength
• (vi) Modulus of resilience The standard gauge length l0 is given by,

• (vii) Modulus of toughness

• (viii) Percentage elongation
• (ix) Percentage reduction in area

*The shape and dimensions of this specimen are standardized. They should conform to IS 1608 : 1972.
Engineering stress-strain diagram

Engineering Strain
True stress-true strain diagram

Incremental elongation divided by the

current gauge length
 Stress-Strain diagram
• Deformation of gauge length, is measured by
an extensometer.
• The procedure of measuring the tension
force and corresponding deformation is
continued till fracture.
• The tensile force divided by the original
cross-sectional area of the specimen gives
stress.
• The deformation divided by gauge length
gives the strain in the specimen.
• (i) Proportional Limit: The term proportional limit is defined as the
stress at which the stress-strain curve begins to deviate from the straight
line.
• (ii) Modulus of Elasticity:The modulus of elasticity or Young’s
modulus (E) is the ratio of stress to strain up to the point P.
• (iii) Elastic Limit: The elastic limit of the material is defined as
the maximum stress without any permanent deformation.
• (iv) Yield Strength: The yield strength is defined as the maximum
stress at which a marked increase in elongation occurs without
an increase in the load
• (v) Ultimate Tensile Strength: The stress corresponding to the
point U is called the ultimate strength. The ultimate tensile
strength is the maximum stress that can be reached in the
tension test.
• (vi) Percentage Elongation: The percentage elongation is defined
as the ratio of the increase in the length of the gauge section of
the specimen to the original gauge length, expressed in percent.
• (vii) Percentage Reduction in Area: The ratio of decrease in
the cross-sectional area of the specimen after fracture to the
original cross-sectional area, expressed in percent.
• If the loading is stopped at point Y, at a stress level slightly
higher than the elastic limit E, and the specimen is unloaded and
readings are taken, the curve would follow the dotted line, and a
permanent set or plastic deformation will exist.
• The strain corresponding to this permanent deformation is
indicated by OA.
• For such materials, that do not exhibit a well-defined yield point,
the yield strength is defined as the stress corresponding to a
permanent set of 0.2% of gauge length.
• In such cases, the yield strength is determined by the offset
method.
• The point of intersection of this line and the stress–strain curve
is called Y or the yield point and the corresponding stress is
called 0.2% yield strength.
• Proof Strength: 0.1% Proof strength, denoted by symbol Rp0.1, is
defined as the stress that will produce a permanent extension of 0.1%
in the gauge length of the test specimen.
• The proof load is the force corresponding to proof stress.
• Proof Strength is used in the design of fasteners.
Mechanical Properties of Engineering Materials
• Strength: Material’s resistance to external forces.
• Elasticity: Ability to regain shape after deformation when external
load is removed.
• Plasticity: Ability to retain permanent deformation.
• Stiffness: Resistance to deformation under external load.
• Modulus of Elasticity is the measure of Stiffness.
• Resilience: Absorption and release of energy in elastic deformation.
• Toughness: Energy absorption before fracture.
• Malleability: Ability to deform under compressive force.
• Ductility: Ability to deform under tensile force.
• Brittleness: Brittleness is the property of a material which shows
negligible plastic deformation before fracture takes place.
• Hardness: Resistance to penetration or permanent deformation.

• Understanding these properties helps in selecting materials for

different applications, considering factors like strength, deformation,
and resistance to wear.
• The selection of a material for a machine part or structural member is
one of the most important decisions the designer is called on to
make.
• The selection process can be as involved as any design problem with
the evaluation of the many material physical, economical, and
processing parameters.
• There are systematic and optimizing approaches to material selection.
• Here, for illustration, we will only look at how to approach some
material properties.
Material selection method
• One basic technique is to list all the important material properties
associated with the design, e.g., strength, stiffness, and cost.
• Prioritize by using a weighting measure depending on what properties are
more important than others.
• For each property, list all available materials and rank them in order
beginning with the best material
• Once the lists are formed, select a manageable amount of materials from
the top of each list.
• From each reduced list select the materials that are contained within every
list for further review.
• The materials in the reduced lists can be graded within the list and then
weighted according to the importance of each property.
Stress Analysis

• Simple stresses in beams

• Compound stresses in beams

• Strength and stiffness considerations

• Theories of failure
 Simple stresses in beams
• Types of loadings

• Axial tension and compression loads

• Torsional loads

• Bending loads

*[Link]
Equilibrium and Free-Body Diagrams
• The word system will be used to denote any isolated
part or portion of a machine or structure—including all
of it if desired—that we wish to study.
• If we assume that the system to be studied is
motionless or, at most, has constant velocity, then the
system has zero acceleration. Under this condition the
system is said to be in equilibrium.
Buckling of columns
Buckling of columns
Values of end fixity coefficients
Stress Concentration Factor
Shaft design
 Stress concentration factor
• In the development of the basic stress equations for tension, compression, bending, and torsion,
it was assumed that no geometric irregularities occurred in the member under consideration.
• But it is quite difficult to design a machine without permitting some changes in the cross sections
of the members.
• Any discontinuity in a machine part alters the stress distribution in the neighborhood of the
discontinuity so that the elementary stress equations no longer describe the state of stress in the
part at these locations.
• Such discontinuities are called stress raisers, and the regions in which they occur are called areas
of stress concentration.
Examples:
• Rotating shafts must have shoulders designed on them so that the bearings can be properly
seated and so that they will take thrust loads

• The shafts must have key slots machined into them for securing pulleys and gears.

• A bolt has a head on one end and screw threads on the other end, both of which account for
abrupt changes in the cross-section.

• Other parts require holes, oil grooves, and notches of various kinds.
• A theoretical, or geometric, stress-concentration factor Kt or Kts is used to relate
the actual maximum stress at the discontinuity to the nominal stress.
Solution:
Stress Analysis
 Stress

In general, a complete state of stress is defined by nine stress components

Stress transformation

Plane stress transformation equations

Principal stresses
Maximum shear stress
Mohr’s Circle
Example
Mohr’s Circle for 3D stress
Theories of failure