Design of Machine Elements

Course code: ME3L002

LTP: 3-0-0

Dr. Manas Ranjan Pattnayak

School of Mechanical Sciences (SMS)
Indian Institute of Technology (IIT) Bhubaneswar
Office: E-206/SMS
Contact No.: +91 9438289031
Email ID: mrpattnayak@[Link] 1
Evaluation scheme

Content Weightage

Mid semester : 30%

Assignments : 15%

Project : 15%

End semester : 40%

2
 Introduction

Do you know “worldwide about 70% researchers and companies do research and develop
the products for use of 30% rich people of society”. There is need to think and re-orient the
research for eradicating the poverty.

One of the objectives of engineering should be दरिद्र नािायण (one of the forms of god) की सेवा
3
Introduction

If the point of contact between the product and people

becomes a point of friction, then the industrial designer
has failed. On the other hand, if people are made safer,
more efficient, more comfortable-or just plain happier-
by contact with the product, then the designer has
succeeded.

Henry Dreyfuss

4
Blessings of Engineering

5
Journey from stone age to modern age
Detailed syllabus
1. Factor of Safety (Lecture - 1)

2. Selection of Rolling-element Bearings (Lecture - 1 to 3)

3. Design of Fluid-film Bearings (Lecture - 3 to 5)

4. Fatigue Failure Theories (Lecture - 6 & 7)

5. Design of Gears (Lecture - 8 & 9)

6. Design of Screw Jack (Lecture - 10)

7. Design of Levers(Lecture - 11)

8. Design of Brakes (Lecture - 12)

9. Design of Pressure Vessel (Lecture - 13) 6

Learning outcome of the course

1. To choose an appropriate Factor of Safety towards designing a particular

machine component.

2. To select an appropriate rolling-element bearing from manufacturer’s

catalogue for supporting and guiding a rotor

3. To determine dimensions and performances of various machine

components (fluid-film bearings, gears, screw jack, lever, brake, pressure
vessel) based on relevant failure theories for strength.

7
Machine Design
1. Adaptive design; 2. Developmental design; 3. New design

8
V. B. Bhandari (3rd edition)
Machine Design

9
Machine Design

10
Machine Design

11
Factor of Safety

Factor of safety is a factor introduced in design of machine

components due to uncertainty or ignorance.

It is used to reduce allowable strength/load (due to uncertainty

in material strength).

Or

It is used to increase the applied load/applied stress (due to

uncertainty in loading).

12
Factor of Safety

Allowable stress Syt Sut

Factor of safety = = or
Induced stress σ σ

ONLY VALID, when Force and Stress has a linear proportionality

relation.

Allowable load FAllowable

Factor of safety = =
Applied load FApplied

Major difficulty in design is to decide an appropriate factor of

safety. 13
Factor of Safety
Design of a ceiling fan hanging rod

14
Factor of Safety
Design of a ceiling fan hanging rod

A standard household ceiling fan weighs around 3 Kg. It is supported from the
ceiling by an Aluminum 6061-T6 (Sy = 276 MPa) solid rod of 10 mm diameter.
Will the rod fail?

15
Factor of Safety
Design of a ceiling fan hanging rod

A standard household ceiling fan weighs around 3 Kg. It is supported from the
ceiling by an Aluminum 6061-T6 (Sy = 276 MPa) hollow rod of OD 10 mm and
ID 9 mm. Will the rod fail?

16
Factor of Safety

Choosing proper factor of safety is one of the difficult and

challenging aspect of design which beginners face.

The question is what one should do. One way is to study

previous similar designs for similar application and take a
decision based on this.

It may be helpful, especially for a beginner/budding designer to

systematically determine total factor of safety as a function of
individual factor of safety.

17
Factor of Safety
1. Material Properties (FOSM)

2. Stress (FOSS) FOS = FOSM * FOSS * FOSG * FOSFA

3. Geometry (FOSG) * FOSR * FOSE * FOSD * FOSEI

4. Failure Analysis (FOSFA)

5. Desired Reliability (FOSR)

6. Environmental Factors (FOSE)

7. Danger to Personnel (FOSD)

8. Economic Impact (FOSEI) 18

 Factor of Safety
1. Contribution due to material properties (FSM)

2. Contribution due to incomplete knowledge of loads / stresses (FSS)

3. Contribution due to geometry resulting from tolerances (FSG)

4. Contribution due to accuracy of failure analysis and the confidence

one has in it (FSFA)

5. Contribution because of reliability desired (FSR)

6. Contribution due to environment effect (FSE)

7. Factor to consider danger to personnel (FSD)

8. Factor to consider economic impact (FSEI) 19

Guidelines for choosing Factor of Safety

Contribution of the material:

FSM = 1.0 Material properties are well known. (e.g.,

designer conducts test on material)
FSM = 1.1 – 1.5 Material properties from a handbook or are
manufacturer's values.
FSM = 1.5 – 2.2 Material properties are not well known.

20
Guidelines for choosing Factor of Safety

Contribution of the load/stress:

FSS = 1.0 – 1.2 Load is well defined

FSS = 1.2 – 1.4 Overload of 20 – 40 %
FSS = 1.4 – 1.7 Load is not well known or the stress analysis
method is of doubtful accuracy
FSS = 1.2 – 3.0 Shock loading (depends on rate of load
application)

21
Guidelines for choosing Factor of Safety

Contribution of the geometry:

FSG = 1.0 – 1.2 Tolerances are fine

FSG = 1.2 – 1.4 Tolerances are average
FSG = 1.4 – 1.7 Dimensions are slack

22
Guidelines for choosing Factor of Safety

Contribution of failure analysis:

FSFA = 1.0 – 1.3 Used failure theory is accurate

FSFA = 1.3 – 1.6 Used failure theory is inappropriate
FSFA = 1.6 – 2.5 Failure analysis theory is not well developed

23
Guidelines for choosing Factor of Safety

Contribution of reliability:

FSR = 1.0 – 1.2 Reliability is less than 90%

FSR = 1.2 – 1.6 Reliability is in the range 92 – 98%
FSR = 1.6 – 2.0 Reliability greater than 99%

24
Guidelines for choosing Factor of Safety

Contribution of environmental factors:

FSE = 1.0 – 1.6 Temperature, Corrosion, Humidity, etc.

25
Guidelines for choosing Factor of Safety

Contribution of danger to personnel and economic impact:

FSD
Characteristics
Not Serious Serious Very Serious
Not Serious 1.0 – 1.2 1.2 – 1.3 1.3 – 1.5
FSEI Serious 1.2 – 1.4 1.3 – 1.5 1.5 – 1.8
Very Serious 1.4 – 1.6 1.7 – 2.0 1.8 – 2.2

26
Design problem
Design of a ceiling fan hanging rod

Design the rod to support a ceiling fan weighing 30 N (even the weight might
not be provided and the Designer will have to figure it out)

Note:
• Size is not stated but required to be found
• Shape is not stated but to be decided
• Material is not specified but to be selected
• Manufacturing process not mentioned but to be decided

27
Design problem
Design of a ceiling fan hanging rod
Designer required to take major decisions
1. Length of rod
2. Type of cross section
3. Cross sectional area of rod
4. Material and treatment to be used
5. Aesthetic considerations
6. Cost etc.

Note:
All the above aspects might not be important or more aspects might have to
be added – the decision has to be taken by the Designer after a well thought
out process.
More experienced the Designer, easier it would be design.

So, design has to be learnt and cannot just be studied from a book. 28
Design problem
Decide appropriate factor of safeties to design a ceiling fan
hanging rod and evaluate the overall factor of safety.
1. Material Properties (FOSM)

2. Stress (FOSS)
3. Geometry (FOSG)

4. Failure Analysis (FOSFA)

5. Desired Reliability (FOSR)

6. Environmental Factors (FOSE)
7. Danger to Personnel (FOSD)

8. Economic Impact (FOSEI) 29

Thank you

30