ME 3201: Design of Machine Element
August-November 2025
Dr. Manoj Pandey (mpandey@[Link])
411 Machine Design Section
Department of Mechanical Engineering
Phone Ext. : 4658
Introduction
Learning Resources Moodle
Shigley’s Mechanical Machine Design: An
Engineering Design: Richard Integrated Approach
Budynas and Keith Nisbett RL Norton
Course Logistics Assesment
Faculty & Rooms Quiz 1 15 %
• Dr. Anirudh Udupa @ room # MSB 242 Quiz 2 15 %
• Dr. Manoj Pandey @ room # MSB 243 End Sem 40 %
(ME23158-251) Tutorials (In class) 10 %
• Dr. Sourav Rakshit @ room # MSB 245 Assignment (3-4) 10 %
Project 10 %
Timings F-slot
Tutorial
Create study group of not more than 4 peers
(emails due August 7th).
In class tutorials (Mostly Friday) would be
done and submitted in groups.
The questions for the tutorial would be posted
before the slot.
Assignment would be submitted individually.
Lecture
Attendance
Attendance will be strictly enforced
• Attendance will be strictly enforced. Those with less than 75%
attendance cannot write the make up and grade improvement
exam and also cannot give the Teachers Feed Back.
• If you are late by more than five minutes you will not be given
attendance.
• Attendance will be taken by my TAs as the class progresses.
• Attendance will be available in a webpage and link will be given
for you to see your standing
How to Do Well in Design of Machine Elements
❑Read the assigned materials before coming to class·
❑ Take/make meaningful notes and comments.
❑ Be "in" and "active in" a study group
➢Work ,Tutorial Homework problems together, submit work that represents
your knowledge, understanding, efforts, etc.
➢ Solve similar problems, teach them to your study group members.
➢ Decide and resolve how similar problems could be presented on an exam.
➢Review the most important chapter concept, process, methods, etc.
Syllabus
Design of Machine Elements
• Failure theories (Recap), Design of shafts, keys and couplings,
• Design of Gears, Springs, Threaded fasteners
Prerequisite
• Strength of Materials
Introduction to Machine Design
Work is the product of force
and displacement
A machine is an arrangement of parts having the purpose of doing work.
Parts may also be referred to as machine elements or machine components.
Machines or machine components can fail in a variety of ways.
❑ Become obsolete
❑ Wear out
❑ Break (or permanently deform)
What is Failure?
Plastic deformation of Bumper
Plastic deformation of Fastner
Fracture of crank shaft
Local buckling of a beam
Plastic deformation of Plate
Roller Bearing Wear
Design
..is a decision-making process.
❑It is not inventing a new device.
❑It is defining the shape, size, and material of a part such that the
part will not fail under the conditions expected in service.
➢ The general concept, application, and shape of a part is often known at
the beginning of the design process.
➢ Failure is predicted when the factor of safety is 1.
Multidisciplinary Approach in Design
Design Considerations
Characteristics that influence the design
1. Functionality. 14. Noise.
2. Strength/stress. Many design
15. Styling.
factors must be
3. Distortion/deflection/stiffness. 16. Shape. considered and
4. Wear. 17. Size. prioritized
18. Control.
5. Corrosion.
19. Thermal properties.
6. Safety. 20. Surface.
7. Reliability. 21. Lubrication.
8. Manufacturability. 22. Marketability.
9. Utility. 23. Maintenance.
10. Cost. 24. Volume.
25. Liability.
11. Friction.
26. Remanufacturing/resource recovery.
12. Weight.
13. Life.
Failure Analysis Process
Design decision making process includes the following considerations.
Shape & Dimension
1. Geometry and kinematics
How the machine move
2. Loads Forces & Moments Load
3. Stress 𝐹 𝑀𝑐 𝑇𝑐 …
𝜎= 𝜎= 𝜏=
𝐴 𝐼 𝐽
4. Strength Geometry
Same units 5. Static failure
as Stress, Choose which theory
but Strength 6. Fatigue failure
is a Material
Property 7. Factor(s) of safety More on this in a minute
By the end of the course, you will be able to…
❑ Apply fundamental concepts from statics, dynamics, and mechanics of
materials to the design of machine components and/or systems.
❑ Apply static and fatigue failure theories to the design of machine
components and/or systems.
❑ Select standard machine components and materials.
Factor of Safety
❑The factor of safety (n) is always unitless and compares a loss-of-function parameter to the
maximum allowed, or predicted, value of that parameter.
loss − of − function parameter
n=
maximum allowed, or predicted,Highly Controlled
parameter value
Most Certain
The parameter can be load, stress, deflection, etc.
❑A part can have multiple factors of safety. Each factor of safety characterizes a potential
failure mode. The most likely failure mode is the one with the smallest factor of safety.
Leastcode
❑The choice of a factor of safety may be dictated by a design Controlled
or by a standard. More
Less certain
often, engineering judgement is required to choose a factor of safety.
❑Given the uncertainties involved, a factor of safety should not be specified to more than
1decimal place.
Factor of Safety
Rank the following in order from lowest You are designing a flywheel for an
factor of safety to highest factory of safety. Automobile application.
Estimate the factor of safety for each The factor of safety for the flywheel is
application. most likely:
5-10
_____A screwdriver
o 1.2
It depends 10-20
_____Cast-iron wheels o 2
o 5
It depends 1.2-5
_____Structural steel o 10
1.2-1.3
_____Aircraft components
Mechanical Engineering Design
Root of a gear
Failure Initiation
F Support of cantilever beam
Stress concentration location
Surface
Static Failure Analysis
• Combined Stress and Identification of Critical
Elements
• A critical element is a specific location within a
machine component where failure ismost likely to
occur.
What is the size/dimension of this critical element?
Critical Element
The recipe to identify the critical element(s) of a machine component is:
1. Draw the free body diagram of the machine component.
2. Solve for all reactions.
3. Determine, and sketch, the internal loads for each segment of the machine component.
✓ Axial
✓ Torsion
✓ Bending
✓ Transverse shear
4. Identify the location(s) in the machine component where the internal load(s) is/are extreme. The
location(s) identified are the machine component's critical cross-section(s).
5. For each internal load, determine the stress distribution at the critical cross-section.
6. Identify critical element(s) on each critical cross-section.
7. Represent the state of stress for each critical element on a stress element.
Example Critical Element
FAC 100lbf
0y 45°
0x
A B
shear
0 A B
bending
axial
22