Machine Design- MEC

3004
Knowledge shared by
Dr. Santosh Kumar Sahu
Design procedure
Design:

Deciding what to make and how it should work.

Example:
It is also a decision-making process. Designing a fan — decide number of blades, blade
shape, material, motor speed, airflow required.

Making a detailed sketch or diagram to show how to

build it.
Example:
Drawing the fan’s front view, side view, dimensions of
blades, positions of holes, materials, and assembly
instructions.

Design = Idea + Function + Planning

Drawing = Visual details to manufacture the design
 Standardization

Standardization is defined as obligatory BIS — Bureau of Indian Standards

norms, to The BIS is India’s national standard body,
which various characteristics of a product responsible for formulating, maintaining, and
should promoting quality and safety standards for goods
and services in India.
conform.
The characteristics include
• Materials,
• Dimensions and shape of the component,
• Method of testing and
• Method of marking,
• Method of packing and storing

A standard is defined as a set

of specifications for parts,
materials or processes.
The following standards are used in
mechanical engineering design:

(i)Standards for Materials, their

Chemical
Compositions, Mechanical Properties
and Heat
Treatment

(ii) Standards for Shapes and

Dimensions of
Commonly used Machine Elements

(iii) Standards for Fits, Tolerances and

Surface
Finish of Component
•ASTM: American Society for Testing and Materials
•ISO: International Organization for Standardization
(iv) Standards for Testing of Products •JSME: Japan Society of Mechanical Engineers
•EU: European Union regulations
•BIS: Bureau of Indian Standards
(v) Standards for Engineering Drawing
of
Components
 There are three types of standards:

(i) Company standards They are used in a particular

company or a group of sister concerns.

(ii) National standards These are the IS (Bureau

of Indian Standards), DIN (German), AISI or SAE
(USA) or BS (UK) standards.

(iii) International standards These are prepared

by
the International Standards Organization (ISO).
ADVANTAGES of STANDARDIZATION ???
Interchangeability of Parts: Standard parts can be replaced easily without custom modifications.
Reduces Cost: Mass production of standard parts reduces manufacturing and inventory costs.
Simplifies Design and Manufacturing: Designers can use existing standard parts, saving time and effort.
Ensures Quality and Reliability: Standardized materials and processes ensure consistent quality.
Simplifies Maintenance and Repair: Standard parts are easily available and replaceable.
Improves Communication: Clear specifications and codes reduce misunderstandings between designer,
manufacturer, and customer.
Facilitates International Trade: Products made to international standards can be sold and used globally.
Reduces Waste: Better control over sizes, tolerances, and processes leads to less material waste.

Bolts and Nuts are standardized — so a bolt of M10 size from one company will fit an M10 nut from another
company anywhere in the world.
 SELECTION OF PREFERRED
SIZES

In engineering design, many a times, the designer

has to specify the size of the product.

The ‘size’ of the product is a general term,

Parameters like

• power transmitting capacity,

• load carrying capacity,
• speed,
• Dimensions (such as height, length and
width, and volume or weight of the product).
 Preferred numbers
The system is based on the use of geometric a manufacturer of lifting tackles who wants to introduce
progression to develop a set of numbers. five different models of capacities ranging from about
There are five basic series 15 to 100 kN.
R5,
R10,
R20,
R40
R80, Renard series

Series increase in steps of

58%, 26%, 12%, 6%, and 3%, respectively.

‘basic series’ and ‘derived series’,

 Man–Machine Closed-Loop
System
AESTHETIC CONSIDERATIONS
IN DESIGN

Scenario:
ERGONOMIC CONSIDERATIONS
A worker is operating a computer for long hours.
IN DESIGN
Ergonomic Problem:
If the chair is too low and the monitor is too high, the
Ergonomics is defined as the relationship between
worker has to tilt their neck upward for hours — causing
man and machine and the application of anatomical,
neck pain and fatigue.
physiological and psychological principles to solve
Ergonomic Solution:
the problems arising from man–machine relationship
Adjust the chair height, place the monitor at eye level,
and provide a wrist rest for the keyboard.
This setup respects the worker’s natural body posture
(anatomy), reduces physical strain (physiology), and
improves focus and comfort (psychology).
 Uncertainty in machinery design
Uncertainty comes from unpredictable
Uncertainties in machinery design abound. Examples of uncertainties concerning variations in material properties,
stress and strength include loading, processing, and
environment.
• Composition of material and the effect of variation on properties. Engineers must consider these
• Variations in properties from place to place within a bar of stock. unknowns to ensure safety and
• Effect of processing locally, or nearby, on properties. reliability.
• Effect of nearby assemblies such as weldments and shrink fits on stress Example: A shaft’s strength may
conditions. vary due to uneven heat treatment
• Effect of thermomechanical treatment on properties. or unexpected stress
• Intensity and distribution of loading. concentrations.
• Validity of mathematical models used to represent reality.
• Intensity of stress concentrations.
• Influence of time on strength and geometry.
• Effect of corrosion.
• Effect of wear.
• Uncertainty as to the length of any list of uncertainties.
Engineers must accommodate uncertainty. Uncertainty always accompanies
change.
Interchangeability

An interchangeable part is one which can be substituted

for similar part manufactured to. the same drawing. In
earlier times production used to be confined to small
number of units and the same.

Interchangeable parts are parts (components) that are,

for practical purposes, identical. They are made to
specifications that ensure that they are so nearly identical
that they will fit into any assembly of the same type. One
such part can freely replace another, without any custom
fitting, such as filing.
DESIGN FOR MANUFACTURE AND ASSEMBLY
(DFMA)
The design effort makes up only about 5% of the total cost of a
product. However, it usually determines more than 70% of the
manufacturing cost of the product.

Therefore, at best only 30% of the product’s cost can be

changed once the design is finalised and drawings are prepared.

The best strategy to lower product cost is to recognise the

importance of manufacturing early in the design stage.

These guidelines, although simple, are used to simplify design,

decrease assembly cost, improve product reliability and reduce
operation time required to bring a new product into the
market.

Design for manufacture and assembly are simple guidelines

formulated by Bart Huthwaite, Director of Institute for
Competitive Design, Rochester, USA
Fits and Tolerances
TOLERANCES

• Due to the inaccuracy of manufacturing methods, it is not

possible to machine a component to a given dimension.

• The components are so manufactured that their dimensions

lie between two limits—maximum and minimum.

• The basic dimension is called the normal or basic size,

while the difference between the two limits is called
permissible tolerance.

The two limits are sometimes called the

upper and lower deviations.

Tolerance is defined as permissible variation in the

dimensions of the component.
Terminology
• Nominal Size (Basic Size)/Actual Size

• Limits (lower/upper)

• Allowance

• Tolerance
 •Actual Deviation = Actual size − Basic size
• Upper deviation U=Upper Limit Size−Basic Size
•Upper Deviation = Upper limit − Basic size
• Lower deviation
•Lower Deviation = Lower limit − Basic size
• Mean Deviation
TYPES OF FITS

When two parts are to be assembled, the relationship

resulting from the difference between their sizes before
assembly is called a fit.

Clearance fit is a fit which always provides a positive clearance

between the hole and the shaft over the entire range of
tolerances.

Interference fit is a fit which always provides a positive

interference over the whole range of tolerances.

Transition fit is a fit which may provide either a clearance or

interference, depending upon the actual values of the
individual tolerances of the mating components.

There are two basic systems for giving tolerances to the shaft
and the hole, namely, the hole-basis system and the shaft-basis,
system.
 40H8/f7
Shaft of
Basic size grade 7
Hole of
Fundamental deviation grade 8
We know that the fundamental deviation (lower deviation) for hole H8, i.e EI = 0

Upper deviation

ES = 39 = 0.039 mm

V. B. Bhandari Data Book micron i.e 1 micron= 0.001 mm

We know that the fundamental deviation (upper
deviation) for shaft f7,

From Table 3.16

Upper deviation (es)= -25 = -0.025 mm

Lower deviation (ei)= -50 = -0.050 mm
V. B. Bhandari Data Book micron i.e
1 micron= 0.001 mm
Tolerance of shaft = -es-(-ei)
=-0.025- (-0.050) = 0.025 mm
 H8 hole
Zero Tolerance= -es- (-ei)
Upper deviation
Basic size

Basic size

=
f7 shaft
Upper limit
SELECTION OF FITS
The guidelines for the selection of clearance fits are The general guidelines for the selection of
as follows: interference fits are as follows:
(i) The fits H7-d8, H8-d9 and H11-d11 are loose running fits, (i) The fit H7-p6 or H7-p7 results in interference,
and are used for plumber-block bearings and loose pulleys. which is not excessive but sufficient to give non-ferrous
parts a light press fit. Such parts can be dismantled
(ii) The fits H6-e7, H7-e8 and H8-e8 are loose clearance fits, easily as and when required, e.g., fitting a brass bush in
and are used for properly lubricated bearings, requiring the gear.
appreciable clearances. The finer grades are used for heavy-
duty, high-speed bearings and large electric motors. (ii) The fit H6-r5 or H7-r6 is a medium drive fit on
ferrous parts, which can be easily dismantled.
(iii) The fits H6-f6, H7-f7 and H8-f8 are normal running fits,
widely used for grease or oil lubricated bearings having low (iii) The fits H6-s5, H7-s6 and H8-s7 are used for
temperature rise. They are also used for shafts of permanent and semi-permanent assemblies of steel and
gearboxes, small electric motors and pumps. cast iron parts. The amount of interference in these fits
is sufficiently large to provide a considerable gripping
(iv) The fits H6-g5, H7-g6 and H8-g7 are expensive from
manufacturing considerations. They are used in precision
equipment, pistons, slide valves and bearings of accurate Link
mechanisms.
The general guidelines for the selection of
interference fits are as follows:
(i) The fit H7-p6 or H7-p7 results in
interference, which is not excessive but
sufficient to give non-ferrous parts a light
press fit. Such parts can be dismantled easily
as and when required, e.g., fitting a brass bush
in the gear.

(ii) The fit H6-r5 or H7-r6 is a medium drive

fit on ferrous parts, which can be easily
dismantled.

(iii) The fits H6-s5, H7-s6 and H8-s7 are

used for permanent and semi-permanent
assemblies of steel and cast iron parts. The
amount of interference in these fits is
sufficiently large to provide a considerable
gripping.
The main bearing of an engine is shown in Fig.

Calculate the maximum and minimum diameters

of the bush and crank pin; and the maximum and
minimum clearances between the crank pin and
bush.
The exhaust valve of an IC engine
is shown in Fig. There is a
clearance fit between the valve
stem and its guide and an
interference fit between the valve
seat and its housing.
Determine

(i) upper and lower limit

diameters of the valve stem

(ii) inner diameters of guide for

valve stem

(iii) the clearances between the

stem and guide

(iv) diameters of the valve seat

(v) inner diameters of housing of

the valve seat
Maximum clearance = Largest guide (hole) - Smallest stem (shaft)
(vi) the interferences between
the valve seat and its housing Minimum clearance = Smallest guide (hole) - Largest stem (shaft)
For the following cases calculate
• Tolerances,
• Fundamental deviations &
• Limits
for hole and shaft
Engineering Materials

A tension test is one of the simplest and basic tests and

determines values of number of parameters concerned with
mechanical properties of materials
MECHANICAL PROPERTIES OF ENGINEERING
MATERIALS •Strength: The ability of a material to withstand an applied
(1) Strength load without failure or plastic deformation.
•Elasticity: The property of a material to return to its
(2) Elasticity original shape and size after the removal of a deforming
(3) Plasticity force.
(4) Stiffness •Plasticity: The ability of a material to undergo permanent
deformation without rupture when subjected to a force.
(5) Resilience •Stiffness: The resistance of a material to elastic
(6) Toughness deformation under an applied force.
(7) Malleability •Resilience: The ability of a material to absorb energy
(8) Ductility when deformed elastically and release it upon unloading.
•Toughness: The ability of a material to absorb energy and
(9) Brittleness
plastically deform without fracturing.
(10) Hardness •Malleability: The ability of a material to be deformed into
thin sheets under compressive stress without cracking.
•Ductility: The ability of a material to be stretched into a
wire or elongated without breaking under tensile stress.
•Brittleness: The tendency of a material to fracture or
break with little or no plastic deformation.
•Hardness: The resistance of a material to localized plastic
deformation, typically by indentation or scratching.
MODES OF FAILURE

A static load is defined as a force, which is gradually applied to

a mechanical component and which does not change its
magnitude or direction with respect to time, whereas a
dynamic load changes its magnitude or direction or both with
respect to time

A mechanical component may fail, that is, may be unable to

perform its function satisfactorily a result of any one of the
following three modes of failure:

(i) failure by elastic deflection;

(ii) failure by general yielding; and
(iii) failure by fracture.
FACTOR OF SAFETY
A machine component is subjected to a working
sufficient reserve strength in case of an accident. load of 12 kN. The component is made of a material
with a yield strength (failure load) of 60 kN.
The factor of safety is defined as Find the factor of safety (fs) for the component.

The magnitude of factor of safety depends upon the following

factors:

(i) Effect of Failure The component can theoretically withstand 5 times

(ii) Type of Load the working load before it reaches the failure (yield)
(iii)Degree of Accuracy in Force Analysis point.
(iv)Material of Component
(v) Reliability of Component
(vi)Cost of Component
(vii) Testing of Machine Element
(viii) Service Conditions
(ix)Quality of Manufacture
THEORIES OF ELASTIC FAILURE

• Theories of elastic failure provide a relationship between

the strength of machine component subjected to complex
state of stresses with the mechanical properties obtained in
tension test.

• With the help of these theories, the data obtained in the

tension test can be used to determine the dimensions of the
component, irrespective of the nature of stresses induced in
the component due to complex loads.

The principal theories of elastic failure are as follows:

(i) Maximum principal stress theory (Rankine’s theory)
(ii) Maximum shear stress theory (Coulomb, Tresca and Guest’s)
(iii) Distortion energy theory (Huber von Mises and Hencky’s)
(iv) Maximum strain theory (St. Venant’s theory)
(v) Maximum total strain energy theory (Haigh’s theory)
 i. MAXIMUM PRINCIPAL STRESS THEORY

The theory states that the failure of the mechanical component

subjected to bi-axial or tri-axial stresses occurs when the
maximum principal stress reaches the yield or ultimate strength
of the material.

• The theory considers only the maximum of principal

stresses and disregards the influence of the other Principal
stresses.

• The dimensions of the component Are determined by using a

factor of safety.
Region of Safety

Boundary for Maximum Principal

Stress Theory under Bi-axial Stresses
ii. MAXIMUM SHEAR STRESS THEORY

The theory states that the failure of a mechanical Suppose σ1, σ2, σ3,are the three principal stresses at a
component subjected to bi-axial or tri-axial stresses point on the component, the shear stresses on three
occurs when the maximum shear stress at any point in different planes are given by
the component becomes equal to the maximum shear
stress in the standard specimen of the tension test,
when yielding starts.

Therefore, the maximum shear stress theory predicts that the

yield strength in shear is half of the yield strength in tension,
i.e.,
Region of Safety

For bi-axial stresses,

iii. DISTORTION-ENERGY THEORY

The theory states that the failure of the mechanical component

subjected to bi-axial or tri-axial stresses occurs when the strain
energy of distortion per unit volume at any point in the
component, becomes equal to the strain energy of distortion
per unit volume in the standard specimen of tension-test, when
Region of Safety
yielding starts
iv. Maximum total strain energy theory ( Beltrami’s
theory)
v.
Comparison of Theories of Failure

[Link]
A bolt is subjected to an axial force of 10 kN with a
transverse shear of 5 kN. Find the diameter of the bolt
required according to

I. M.P. Stress. Theory

II. MSST
III. MDT
IV. M. P. Strain Theory
V. Max. Strain energy theory

It is assumed that permissible stress in tension is 100 Mpa

and the poission’s ratio is =0.3
A bolt is subjected to an axial force of 10 kN with a
transverse shear of 5 kN. Find the diameter of the bolt
required according to

I. M.P. Stress. Theory

II. MSST
III. MDT
IV. M. P. Strain Theory
V. Max. Strain energy theory

It is assumed that permissible stress in tension is 100 Mpa

and the poission’s ratio is =0.3
(Use maximum shear stress theory)