LESSON 1.
INTRODUCTION TO MACHINE DESIGN
1.1 What is Design?
The word ‘design’ can either be a noun or a verb. As a noun,
‘Design’ can be referred to an object’s aesthetic appearance as
well as its function. For example, ‘a beautifully designed dress’
refers to its appeal to our visual perception, and ‘a nicely
designed car engine that gives very good mileage and
performance’ refers to the concept of function. As a verb,
‘Design’ is the act of formalizing an idea or concept into
concrete information. It includes the processes of conception,
invention, visualization, calculation, refinement and
specification of details that determine the form of a product.
Design may be defined as an iterative decision making process
to formulate a plan by which resources are optimally converted
into systems, processes or devices in order to solve a specific
problem or to fulfill a specific need. It begins with a need, a
problem, an idea or a concept and ends with concrete
information, in the form of drawings, computer representation or
in any other form, which helps in manufacturing and utilization
of a product.
1.2 Phases of Design Process
The design process begins with identification of a need and a
decision to do something about it. After a number of iterations,
the process ends with the presentation of the plans for satisfying
the need. Depending on the nature of the design task, several
phases may be repeated before the design is finalized. Complete
design process can be explained with the help of Figure1.1,
which shows the phases of design process and iterations.
1.2.1 Identification of Need
Design process generally starts with the identification of need, a
problem or with the recognition of a potential market for a
product, device or process. Recognition of the need requires a
lot of imagination and creativity, because the need is generally
not clear and evident and can be vague. It can be just a feeling of
uneasiness or a sensing that something is wrong. For example,
there is a need to do something about the design of a motor
vehicle may be indicated by its low efficiency, lesser maximum
speed or high noise and vibration levels. Then the need
statement may say that the design of the motor vehicle needs an
improvement.
1.2.2 Definition of Problem
Need statement is generally brief and doesn’t include the details.
The definition of problem is more specific and includes all the
specifications for the object to be designed, which include the
input i.e. resources to be utilized, expected output, cost
limitations, quantity required, expected life and reliability,
temperature limitations, maximum range and expected
variations in the variables, dimensional & weight limitations,
manufacturing limitations etc. Anything that limits the
designer’s freedom of choice is a constraint and all the
constraints should be clearly defined in the problem definition.
Background information on all the relevant aspects of the
problem should also be gathered. It includes the study to find out
whether this, or a similar problem, has been solved before. If a
ready-made solution is available in the market, it can be used.
Or even if something new is to be done, the study of existing
similar technologies, products, relevant patent literature and
technical publications can be very helpful.
1.2.3 Synthsis
Synthesis is the process of concept generation, the purpose of
which is to develop as many ideas as possible to offer potential
solutions to the problem defined in previous phase. Primary
need is identified for initial focus and then all feasible design
alternatives are developed. Different proposed alternatives
should not be compared with each other, in this phase, and each
alternative should be separately evaluated on the basis of
established criteria.
1.2.4 Analysis and Optimization
After synthesis, different proposed solutions are analyzed to
assess their performance and can be ranked. Alternatives having
unsatisfactory performance can either be revised and improved
or discarded. It is always advisable to select two or three design
concepts and develop them instead of selecting presumably the
best one only. Concepts, with potential, are optimized to further
increase their performance. Optimization is the repetitive
process of refining a set of criteria, which are often conflicting,
to achieve the best compromise. These competing design
concepts can finally be compared again so that the path leading
to the most competitive product can be chosen. For analysis and
optimization, mathematical models are prepared to simulate the
real physical system.
Synthesis, analysis and optimization go hand in hand.
Identification of any kind of deficiency or inadequacy in the
proposed solution, in the analysis and optimization phase, may
require synthesis of some new solution and process keeps on
repeating until an adequate and optimum solution is obtained.
1.2.5 Evaluation
In this phase, prototype model of the design is generally made
and tested, which is the final evaluation of the design to make
sure that it satisfies the original requirements. In addition to this,
design is evaluated for its reliability, competitiveness, economic
viability, maintenance requirements, profitability and so on.
1.2.6 Presentation
Final phase of the design process is to communicate the design
to others. This presentation can be in the form of drawings,
computer models on in any other form that would help in
manufacturing and utilization of the product.
1.3 Machine Design
Machine is a combination of linkages having definite motion
and capable of performing useful work. Machine Design is
creation of plans for the machine to perform the desired
functions. Machine design can be defined as creation of right
combination of correctly proportioned moving and stationary
components so constructed and joined as to enable the
liberation, transformation and utilization of energy. Scientific
principles, technical knowledge and imagination are used to
develop a machine or mechanical system to perform specific
functions with maximum economy and efficiency. It includes
the creation of new better machines or improving the existing
ones. Machine Design requires the knowledge of basic and
engineering sciences such as Physics, Mathematics, Engineering
Mechanics, Strength of Materials, Theory of Machines,
Thermodynamics and Heat Transfer, Vibrations, Fluid
Mechanics, Metallurgy, Manufacturing Processes and
Engineering Drawing.
In machine design, the designer’s task is to determine the
motion, forces and energy transfer involved so as to determine
the sizes, shapes and materials for each element of the machine.
When any component of machine ceases to perform its intended
function, machine element or machine is said to have failed.
Generally the machine elements are designed on the basis of
strength and rigidity so that they are able to withstand the
applied load with permissible deformation or stress. In addition
to strength and stiffness, other factors that are considered in
design of machine element are weight, cost, wear, safety,
reliability etc. Design work may involve concentrating on one
component at a time, but it is very important to simultaneously
consider its relation with the other components and the product
as a whole.
In machine design, as in any other kind of design, no standard
procedure or rigid rules can be specified for the designer, but the
following steps are generally followed:
1. Problem to be solved or desired purpose of the machine
is completely and clearly stated.
2. Possible mechanisms that will provide the desired
motion or set of motions are selected.
3. Forces acting on and energy transmitted by each
element of the machine are determined.
4. Best suitable material is selected for each of the
machine element.
5. Allowable values of stress and deflection are
determined for each machine element, depending upon
its material and functional requirements.
6. Size and shape of each machine element is determined
so that it can withstand the applied loads without failure.
7. Dimensions of the machine elements are modified
considering manufacturing aspects.
8. Assembly and detailed drawings of the machine are
made with complete specification of materials and
manufacturing methods.
1.4 Design Considerations
As discussed in the previous article, strength and stiffness are
very important factors that are considered in machine design but
there are a number of other considerations that the designer has
to keep in mind while designing any product. Some of the
important factors considered in design are listed below:
1. Functionality
2. Strength
3. Stiffness
4. Wear
5. Corrosion
6. Thermal Properties
7. Surface Finish
8. Lubrication
9. Friction
10. Weight
11. Noise
12. Shape
13. Size
14. Safety
15. Reliability
16. Manufacturability
17. Utility
18. Maintenance
19. Liability
20. Cost
21. Life
22. Styling
23. Control
24. Volume
25. Marketability
26. Remanufacturing
References
1. Design of Machine Elements by VB Bhandari
2. Mechanical Engineering Design by J.E. Shigley
3. Analysis and Design of Machine Elements by V.K. Jadon
4. Machine Design by R.S. Khurmi
5. Mechanical Design by Peter Childs
6. Engineering Design by G.E. Dieter
7. Machine Design by PC Sharma & DK Aggarwal