Unit No 1.

Concepts of Machine Design

Prepared by,
Mrs. Rajendra Pawar
Asst. Professor
Department of Mechanical Engineering,
R. I. T., Rajaramnagar
1
 Design of Machine Elements

Content of Unit 1: Concept of Machine Design

 Introduction: Engineering Design and classification
 Basic design procedure
 Requirement of machine elements,
 Standards and codes, selection of preferred sizes,
 Engineering material and classification
 Manufacturing considerations and their selection
 Design for manufacture and assembly,
 Theories of failures
 Selection of failure theories
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 Design of Machine Elements

Engineering Design
 It is a creative, iterative process directed towards the
fulfilment of human needs by using scientific knowledge.
 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
 Common series of steps that engineers use in creating
functional products and processes.

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 Design of Machine Elements

Classifications of Engineering Design

Engineering design can have different forms, but they all include a common attribute:
any type of engineering design is a process.
The main types of engineering design are:
 Original or innovative design generates an original concept for solving a specific
need.
 Adaptive design adapts an existing engineering solution to a new problem.
 Redesign improves an existing design.
 Selection design is based on a selection of off-the-shelf components with the needed
properties.
 Industrial Designs are used to design products for the market.

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 Design of Machine Elements

Classifications Original , or innovative, design

A. Rational design: This type of design depends upon mathematical formulae of principle of
mechanics.
B. Empirical design: This type of design depends upon empirical formulae based on the
practice and past experience.
C. Industrial design: This type of design depends upon the production aspects to manufacture
any machine component in the industry.
D. Optimum design: It is the best design for the given objective function under the specified
constraints. It may be achieved by minimizing the undesirable effects.
E. System design: It is the design of any complex mechanical system like a motor car.
F. Element design: It is the design of any element of the mechanical system like piston,
crankshaft, connecting rod, etc.
G. Computer aided design: This type of design depends upon the use of computer systems to
assist in the creation, modification, analysis and optimization of a design.
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 Design of Machine Elements

General Considerations in Machine Design

 Types of load and stresses caused by the load
 Motion of the parts or kinematics of the machine
 Selection of materials
 Form and size of the parts
 Friction resistance and lubrication
 Convenient and economical features
 Use of standard parts
 Safety of operation
 Workshop Facilities
 Number of machines to be manufactured
 Manufacturing and Assembling
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 Design of Machine Elements

Design of Machine Element

 Designing individual components of the machine.
 Considering the forces and motion that need to be
transmitted.
 Determines the dimensions of the part or element.

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 Design of Machine Elements

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 Design of Machine Elements

Basic Requirements of Machine Elements

 Strength – Sufficient strength
 Rigidity – Should not deflect or bend
 Wear Resistance – Reduces useful life of the
component
 Minimum Dimension & Weight - Optimum
 Manufacturability - Ease of fabrication &
Assembly
 Safety
 Conformance to Standards
 Reliability
 Min. Life Cycle Cost

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 Design of Machine Elements

Use of Standards in Design

The obligatory norms, to which various characteristics of a product should conform.

• Standards: Set of specifications for

parts, materials or processes.
• Codes: Set of specifications for analysis,
design, testing.
• The characteristics include materials,
dimensions and shape of the
component, method of testing and
method of marking, packing and storing
of the product.

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 Design of Machine Elements

Use of Standards in Design

 Standards for materials, their chemical compositions, Mechanical properties and
Heat Treatment.
 FG 150, FG 200, FG 220- (IS 210): Strength
 55Cr3- (IS 570 Part 4): Chemical composition
 Standards for shapes and dimensions of commonly used machine elements.
 Dimension and cross-section of V belts (IS 2494)
 Standards for fits, tolerances and surface finish of the component
 Fit IS 2709 (Guide for selection of fits)
 Tolerances IS 919 (Recommendations for limits and fits for engineering)
 Surface texture IS 10719

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 Design of Machine Elements

Use of Standards in Design

 Standards/codes for testing of products
 Testing of pressure vessels IS 2825
 Cranes and hoists IS807
 Standards for engineering drawing of components
 SP46 by BIS for engineering drawings
 The Standard Parts category contains mechanical blocks
grouped into 4 subcategories:
 Fasteners, such as bolts, nuts, and washers.
 Machine Parts, such as bearings, and sprockets.
 Piping, such as pipes, elbows, and flanges.
 Structural Shapes, such as beams, channels, and bars.

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 Design of Machine Elements

Standardization: Advantages
 Reduction in types and dimensions of
identical components
 Reduced manufacturing facilities required
for individual organization
 Easy replacement and availability

 Reduced designer tasks

 Improved quality and reliability

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 Design of Machine Elements

Selection of Preferred sizes

 The Preferred Series Number is a designed for
Preferred Reducing
machine component that needs Sizes Number
standardization to avoid variations.
 It implies that the product’s important Basic Derived
parameters should be common in nature. Series Series
 French balloonist and Engineer Charles Renard
R5 5
10 1.58 Increasing
suggested the method to specify the sizes of Number
R10 10
10 1.26
the product to satisfy the needs of the
R20 20
10 1.12
customers.
R40 40
10 1.06
 It is based on the geometric progression to R80 80
10 1.03
develop a set of numbers.
 Each series has its own series factor.

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 Design of Machine Elements

Selection of Preferred sizes

 The series is established by taking the first number
and multiplying it by a series factor, to get the
second number, and so on…..
 This procedure is continued until the complete
series is built up.
 Example: The manufacturer of lifting tackles wants
to introduce nine different models of capacities
ranging from about 15 to 100KN.
 Answer: R10 series needs to follow = 1.26
Capacities of the different models are 16, 20, 25,
31.5, 40, 50, 63, 80 and 100 kN

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 Design of Machine Elements

Engineering Materials and its Classification

 Engineering materials are substances
used to construct machines and
structures
 The primary function of an engineering
material is to withstand applied loading
without breaking and without
exhibiting excessive deflection.
 Depending up on the service condition
and the functional requirement,
different mechanical properties are
considered and a suitable material is
selected.
 Availability, Cost and Weight
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 Design of Machine Elements

Mechanical Properties of Engineering Materials

 Strength: It is the property of a material which opposes the deformation or breakdown
of material in the presence of external forces or load.
 Elasticity: The property of a substance by which it regains its original shape and size
when the deforming force is removed.
 Plasticity: It is a mechanical property of a material and is defined as the quality of
material when it undergoes non-reversible deformation under the effect of an external
force.
 Toughness: It is also a mechanical property and is defined as the ability of a material to
absorb energy and undergo plastic deformation without undergoing fracturing.
 Ductility: Ductility is a property of a solid material which indicates that how easily a
material gets deformed under tensile stress.
 Hardness: It is the ability of a material to resist to permanent shape change due to
external stress.
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 Design of Machine Elements

Mechanical Properties of Engineering Materials

 Resilience: It is the ability of a material to absorb the energy when it is deformed
elastically by applying stress and release the energy when stress is removed.
 Malleability: It is a property of solid materials which indicates how easily a material
gets deformed under compressive stress.
 Resilience: It is the ability of a material to absorb the energy when it is deformed
elastically by applying stress and release the energy when stress is removed.
 Fatigue: It is the weakening of a material due to repeated loading cycles.
 Stiffness: It is determined by materials capacity to withstand deformation when
stressed.
 Creep: is a slow and irreversible deformation, if it is exposed to a steady tension at a
high temperature over a protracted length of time.
 Wear Resistance: Material's capacity to withstand degradation and wear when in touch
with other surfaces
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Mechanical Component Reason for Material Selection
Material Design Application
of Machine Elements
Alloy Steel High strength, wear resistance, Automotive, industrial
Gears (e.g., EN24) toughness, and machinability machinery
SAE-783 Low friction, good wear resistance, and Journal bearings,
Bearings (Bronze Alloy) ability to handle high loads Crankshaft bearing
Spring Steel High elasticity, fatigue strength, and Suspension systems,
Springs (e.g., 65Mn) durability mechanical assemblies
Aluminum Lightweight, high thermal conductivity, Internal combustion
Pistons and good strength-to-weight ratio engines
Alloy
High strength, fatigue resistance, and Automotive engines,
Crankshafts Forged Steel ability to withstand cyclic loads marine engines
Inconel (Nickel High-temperature resistance, corrosion Jet engines, power
Turbine Blades Alloy) resistance, and strength generation turbines
Stainless Steel Corrosion resistance, strength, and Construction, machinery,
Bolts and Fasteners (SS304) durability marine environments
Good wear resistance, vibration Automotive engines
Engine Blocks Cast Iron damping, and machinability
High strength-to-weight ratio, Aerospace, marine
Propeller Shafts Titanium Alloy corrosion resistance, and durability industries
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Material Standard Composition Key Properties Applications
Design of Machine Elements
EN8 BS 970: Carbon: 0.35-0.45%, Manganese: High tensile strength, good Shafts, gears, bolts,
(Medium 080M40 0.6-1%, Silicon: 0.05-0.35%, Iron: machinability, moderate wear and forgings
Carbon Steel) Balance resistance
EN31 (High BS 970: Carbon: 0.90-1.20%, Chromium: 1- High hardness, excellent wear Ball bearings, dies,
Carbon Steel) 535A99 1.6%, Iron: Balance resistance, high tensile strength and tools
SS304 ASTM A240 Chromium: 18-20%, Nickel: 8-10.5%, Excellent corrosion resistance, good Food processing,
(Stainless Carbon: 0.08% max, Iron: Balance mechanical properties, non- chemical equipment,
Steel) magnetic in annealed state pipelines
Aluminum ASTM B209 Aluminum: ~97%, Magnesium: 0.8- Lightweight, corrosion-resistant, Aerospace,
(6061 Alloy) 1.2%, Silicon: 0.4-0.8%, Iron: 0.7% good weldability, high strength-to- automotive parts,
max weight ratio marine structures
Aluminum ASTM B209 Aluminum: ~90%, Zinc: 5.1-6.1%, Very high strength, moderate Aerospace, defense,
(7075 Alloy) Magnesium: 2.1-2.9%, Copper: 1.2- corrosion resistance, lightweight and high-
2%, Iron: 0.5% performance
vehicles

Copper ASTM B152 Copper: 99.9% Excellent electrical and thermal Electrical wiring,
(Pure) conductivity, good corrosion heat exchangers
resistance
Brass ASTM B36 Copper: 68.5-71.5%, Zinc: Balance Good corrosion resistance, Plumbing, decorative
(C26000) excellent machinability, moderate items, fittings
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Material Standard Composition Key Properties Applications
Design of Machine Elements
Titanium (Ti- ASTM B348 Titanium: 90%, Aluminum: 6%, High strength-to-weight ratio, Aerospace, medical
6Al-4V) Vanadium: 4% excellent corrosion resistance, implants, marine
biocompatible components
Inconel 718 ASTM B637 Nickel: 50-55%, Chromium: 17-21%, High-temperature strength, Jet engines, power
Molybdenum: 2.8-3.3%, Iron: excellent corrosion resistance, good turbines, nuclear
Balance weldability reactors
Cast Iron ASTM A48 Carbon: 2.5-4%, Silicon: 1-3%, Iron: Excellent vibration damping, good Engine blocks,
(Gray) Balance wear resistance, machinability machine bases
EN24 (Alloy BS 970: Carbon: 0.36-0.44%, Chromium: 1- High tensile strength, toughness, Aircraft components,
Steel) 817M40 1.4%, Nickel: 1.3-1.7%, good wear resistance gears, shafts
Molybdenum: 0.2-0.4%, Iron:
Balance

Mild Steel ASTM A36 Carbon: 0.15-0.30%, Manganese: Ductile, weldable, moderately Structural
(Low Carbon 0.7%, Silicon: 0.2%, Iron: Balance strong, low cost applications,
Steel) automotive parts
AISI 4340 ASTM A29 Carbon: 0.38-0.43%, Nickel: 1.65- High strength, toughness, fatigue Aerospace,
(Alloy Steel) 2%, Chromium: 0.7-0.9%, resistance automotive, heavy
Molybdenum: 0.2-0.3%, Iron: machinery
Balance

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 Design of Machine Elements

Design for Manufacturing and Assembly

 Design for Manufacturing: It is the method of design for ease of manufacturing of
the collection of parts that will form the product after assembly.
 Concerned with reducing overall part production cost
- Minimizes the complexity of manufacturing operations
- Uses common datum features and primary axes

 Design for Assembly: DFA is the method of design of the product for ease of
assembly.
 Concerned only with reducing product assembly cost
- Minimizes number of assembly operations
- Minimize the number of components and time required for assembley

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 Design of Machine Elements

Principles of DFM (DFM Guidelines)

 Minimize part variation  Open tolerance as much as possible
 Simplify and reduce the number of  Avoid special tooling and frequent tool
manufacturing operations changes
 Standardize materials and use  Select materials for best
common parts manufacturability
 Design parts to be multifunctional  Specify ‘acceptable’ surface finish for
 Design parts for multiuse functionality
 Design parts for ease of fabrication  Minimize assembly direction
 Avoid separate fasteners  Minimize handling in assembly

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 Design of Machine Elements

Design for Manufacturing

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 Design of Machine Elements

Design for Manufacturing

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 Design of Machine Elements

Design for Machining

Deep, small diameter Blind holes should not have

holes should be avoided a flat bottom. Flat bottomed Drills should enter and
holes cause problems with exit surfaces
subsequent operations perpendicular to the
hole’s centreline.

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 Design of Machine Elements

Design for Machining Avoid partial holes as there

are high chances that drill
Holes should not will wander if a large
Specify standard hole
intersect a cavity. portion of the hole is outside
sizes as they can be
created using a standard the material.
drill.

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 Design of Machine Elements

Principles of DFA (Guidelines for Assembly)

 Minimize part count
 Design parts with self-locating features
 Design parts with self-fastening features
 Minimize reorientation of parts during assembly
 Emphasize ‘top-down’ assemblies
 Standardize parts
 Ensure adequate access & unrestricted vision
 Ensure parts are easily handled from bulk
 Minimize reorientation (assemble in Z axis) & secondary
operations during assembly
 Make parts symmetrical or obviously asymmetrical

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 Design of Machine Elements

Design for Assembly

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 Design of Machine Elements

Design for Assembly

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 Design of Machine Elements

Design for Assembly

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 Design of Machine Elements

Design for Assembly

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 Design of Machine Elements

Theories of Failure
The common most theories are
 Maximum principal stress theory (Rankine’s theory)

 Maximum shear stress theory (Coulomb, Tresca and Guest’s theory)

 Distortion energy theory (Huber von Mises and Hencky’s theory)

 Maximum strain theory (St. Venanat’s theory)

 Maximum total strain energy theory (Haigh’s theory)

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 Design of Machine Elements

Stress-Strain Curve

Ductile Material Brittle Material

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 Design of Machine Elements

Theories of Failure
 Types

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 Design of Machine Elements

Theories of Failure
 Types

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 Design of Machine Elements

Thank You!!!!

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