MWU,COE

Department of Mechanical
Engineering

CH-1
INTRODUCTION TO
DESIGN OF MACHINE
ELEMENTS
 Machine Design
📌 Machine Design is the creation of new and better
machines or improving the existing ones.
📌 A better machine is one which is more economical
in the overall cost of production and operation.
📌 The process of design is a long and time consuming
one.
📌 From the study of existing ideas, a new idea has to
be conceived.
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General Procedure in Machine Design

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 Simple Stresses in Machine Parts
Load
📌 It is defined as any external force acting upon a machine
part.
Stress
📌 When some external system of forces or loads act on a body,
the internal forces (equal and opposite) are set up at various
sections of the body, which resist the external forces.
📌 This internal force per unit area at any section of the body is
known as unit stress or simply a stress. It is denoted by a Greek
letter sigma (σ). Mathematically,
Stress, σ = P/A 4
Where, P = Force or load acting on a body, and
A = Cross-sectional area of the body.

Pascal (Pa) such that 1 𝑃𝑎= 1 𝑁𝑚2 .

• In S.I. units, the stress is usually expressed in

• In actual practice, we use bigger units of stress

such that 1𝑀𝑃𝑎= 1×106𝑁𝑚2= 1 𝑁𝑚𝑚2

i.e. megapascal (MPa) and gigapascal (GPa),

and 1𝐺𝑃𝑎= 1 × 109𝑁𝑚2= 1𝑘𝑁𝑚𝑚2

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 Working Stress or Design Stress
📌 When designing machine parts, it is
desirable to keep the stress lower than the
maximum or ultimate stress at which failure of
the material takes place.
📌 This stress is known as the working stress
or design stress. It is also known as safe or
allowable stress.
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📌Note:

By failure it is not meant

actual breaking of the
material.
Some machine parts are said
to fail when they have plastic
deformation set in them, and
they no more perform their
function satisfactory.

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 Factor of Safety
• It is defined, in general, as the ratio of the maximum stress to the working

𝑀𝑎𝑥𝑖𝑚𝑢𝑚𝑠𝑡𝑟𝑒𝑠𝑠
or design stress. Mathematically,

𝐹𝑎𝑐𝑡𝑜𝑟𝑜𝑓𝑠𝑎𝑓𝑒𝑡𝑦=
𝑊𝑜𝑟𝑘𝑖𝑛𝑔𝑜𝑟𝑑𝑒𝑠𝑖𝑔𝑛𝑠𝑡𝑟𝑒𝑠𝑠
• In case of ductile materials e.g. mild steel, where the yield point is clearly
defined, the factor of safety is based upon the yield point stress. In such cases,

𝑌𝑖𝑒𝑙𝑑𝑝𝑜𝑖𝑛𝑡𝑠𝑡𝑟𝑒𝑠𝑠
𝐹𝑎𝑐𝑡𝑜𝑟𝑜𝑓𝑠𝑎𝑓𝑒𝑡𝑦=
𝑊𝑜𝑟𝑘𝑖𝑛𝑔𝑜𝑟𝑑𝑒𝑠𝑖𝑔𝑛𝑠𝑡𝑟
𝑒𝑠𝑠
• In case of brittle materials e.g. cast iron, the yield point is not well defined as for
ductile materials. Therefore, the factor of safety for brittle materials is based on
𝑈𝑙𝑡𝑖𝑚𝑎𝑡𝑒𝑠𝑡𝑟𝑒𝑠𝑠
ultimate stress.
𝐹𝑎𝑐𝑡𝑜𝑟𝑜𝑓𝑠𝑎𝑓𝑒𝑡𝑦=
𝑊𝑜𝑟𝑘𝑖𝑛𝑔𝑜𝑟𝑑𝑒𝑠𝑖𝑔𝑛𝑠𝑡𝑟𝑒𝑠𝑠
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Note: The above relations for factor of safety are for static loading.
Cont..
Example 1.1: A coil chain of a crane required to carry a maximum load of 50 kN, as shown in
figure below

a) Find the diameter of the link stock, if the permissible tensile stress in the link material is not to
exceed 75 MPa.
b) Determine the working or design stress of a coil chain, if its safety factor is 2.5

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Cont..
Solution.
a) Given: 𝑃= 50𝑘𝑁= 50 × 103𝑁; 𝜎𝑡= 75𝑀𝑃𝑎= 75𝑁𝑚𝑚2
Let 𝑑= Diameter of the link stock in mm.
Area, 𝐴=𝜋4× 𝑑2 = 0.7854 𝑑2 we know that stress 𝜎= 𝑃𝐴, =50×103𝑁
0.7854 𝑑2,
75 𝑁𝑚𝑚2 50 × 103𝑁
𝑑2= 75𝑁𝑚𝑚2× 0.7854 = 850 𝑚𝑚2,𝑑= 29.13 𝑚𝑚

b) Given: Maximum stress = 75 𝑁𝑚𝑚2 ; 𝐹𝑎𝑐𝑡𝑜𝑟𝑜𝑓𝑠𝑎𝑓𝑒𝑡𝑦𝑠𝑓= 2.5,

𝑀𝑎𝑥𝑖𝑚𝑢𝑚𝑠𝑡𝑟𝑒𝑠𝑠
𝐹𝑎𝑐𝑡𝑜𝑟𝑜𝑓𝑠𝑎𝑓𝑒𝑡𝑦𝑠𝑓=
𝑊𝑜𝑟𝑘𝑖𝑛𝑔𝑜𝑟𝑑𝑒𝑠𝑖𝑔𝑛𝑠𝑡𝑟𝑒𝑠𝑠
𝑤𝑜𝑟𝑘𝑖𝑛𝑔𝑜𝑟𝑑𝑒𝑠𝑖𝑔𝑛𝑠𝑡𝑟𝑒𝑠𝑠= = 30𝑁𝑚𝑚2
𝑀𝑎𝑥𝑖𝑚𝑢𝑚𝑠𝑡𝑟𝑒𝑠𝑠𝑓𝑎𝑐𝑡𝑜𝑟𝑜𝑓𝑠𝑎𝑓𝑒𝑡𝑦= 75 𝑁𝑚𝑚2

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 Selection of Factor of Safety
Before selecting a proper factor of safety, a design engineer should consider the
following points :
1. The reliability of the properties of the material (such as; physical, chemical and
mechanical) and change of these properties during service ;
2. The reliability of test results and accuracy of application of these results to
actual machine parts ;
3. The reliability of applied load ;
4. The certainty as to exact mode of failure ;
5. The extent of simplifying assumptions;
6. The extent of localised stresses;
7. The extent of initial stresses set up during manufacture ;
8. The extent of loss of life if failure occurs ; and
9. The extent of loss of property if failure occurs.

Each of the above factors must be carefully considered and evaluated.

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Selection of Materials for Engineering Purposes
• The selection of a proper material, for engineering purposes, is one of
the most difficult problem for the designer.
• The best material is one which serve the desired objective at the
minimum cost.
• The following factors should be considered while selecting the material :
Availability of the materials,
Suitability of the materials for the working conditions in service, and
The cost of the materials.
• The important properties, which determine the utility of the material
are physical, chemical and mechanical properties.
• We shall now discuss the physical and mechanical properties of the
metals material in the following articles. 13
Physical Properties of Metals
• The physical properties of the metals include luster, colour, size and shape,
density, electric and thermal conductivity, and melting point.
• The following table shows the important physical properties of some pure metals.

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Mechanical Properties of Metals
• The mechanical properties of the metals are those which are associated with the
ability of the material to resist mechanical forces and load. These mechanical
properties of the metal include strength, stiffness, elasticity, plasticity, ductility,
brittleness, malleability, toughness, resilience, creep and hardness.
Strength:- It is the ability of a material to resist the externally applied forces
without breaking.
Stiffness:- It is the ability of a material to resist deformation under stress. The
modulus of elasticity is the measure of stiffness.
Elasticity:- It is the property of a material to regain its original shape after
deformation when the external forces are removed.
Plasticity:- It is property of a material which retains the deformation produced
under load permanently. This property of the material is necessary for forgings, in
stamping images on coins
Ductility:- It is the property of a material enabling it to be drawn into wire with
the application of a tensile force. 15
 Cont..
Brittleness:- It is the property of breaking of a material without giving any
sensible compression or elongation. Cast iron is a brittle material.
Malleability:- It is a special case of ductility which permits materials to be rolled
or hammered into thin sheets.
Toughness:- It is the property of a material to resist fracture due to high impact
loads like hammer blows.
Resilience:- It is the property of a material to absorb energy and to resist shock
and impact loads.
Creep:- When a part is subjected to a constant stress at high temperature for a
long period of time, it will undergo a slow and permanent deformation called
creep.
Hardness:- It embraces many different metals properties such as resistance to
wear, scratching, deformation and machinability etc. It also means the ability of a
metal to cut another metal.

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