ILO1: Able to understand the philosophy, concept,

and the different types of machine design process.

ILO2: Able to recognize the skill needed to perform
competent mechanical designs.
ILO3: Able to understand the nature of a well-
presented design calculation criteria and establish a
set of criteria for evaluating proposed designs.
Design is an exacting profession, but highly fascinating
when practiced against broad background of
knowledge.
Machine design is engineering and only Mechanical
Engineers can perform this.
(a) A good background in strength of
materials.
(b) A good acquaintance with the
properties of materials used in
machines.
(c) A familiarity with the major
characteristics and economics of
various manufacturing processes.
(d) Specialized knowledge in various
circumstances, such as the
properties of materials in
corrosive atmosphere, at very low
(cryogenic) temperature.
(e) A preparation of deciding wisely:
i. when to use manufacture’s catalogs, buying stock or relatively
available items, and when custom design in necessary;
ii. when empirical design is justified;
iii. when the design should be tested in service tests before
manufacture starts:
iv. when special measure should be taken to control vibration and
sound (and others).
(f) Some aesthetic sense, “customer appeal.”
(g) A knowledge of economics and comparative costs.
(h) Inventiveness and creative instincts.
1. Sketching , technical drawing, and computer-aided design
2. Properties of materials, materials processing, and manufacturing processes
3. Application of chemistry such as corrosion protection, plating, and painting
4. Static, dynamics, strength of materials, kinematics, and mechanisms
5. Oral communication, listening, technical writing, and teamwork skills
6. Fluid mechanics, thermodynamics, and heat transfer
7. Fluid power, the fundamentals of electrical phenomena, and industrial controls
8. Experimental design and performance testing of materials and mechanical systems
9. Creativity, problem solving, and project management
10. Stress analysis
11. Specialized knowledge of the behavior of machine elements such as gears, belt
drives, chain drives, shafts, bearings, keys, splines, couplings, seals, springs,
connections (bolted, riveted, welded, adhesive), electric motors, linear motion devices,
clutches, and brakes
1. Adaptive Design

This classification is concerned with the adaptation of the existing

designs and create minor modifications or altercations as
improvements in the existing design of the product. This type of
design does not require special knowledge or skills and can be done
by the designers with ordinary technical training.
2. Development Design

This type requires considerable scientific training and design

ability in order to modify an existing design into a new idea by
integrating new materials or different way of manufacturing.
3. New Design
This type requires a lot of research, technical ability and
creative thinking. Only those designers who have personal
qualities of a sufficiently high order can take up the work of a
new design.

An early Wright Model B in flight.

Depending on the methods, the design may be classified as follows:
a) Rational Design. The type of design that depends upon
mathematical formulae of principle of mechanics.
b) Empirical design. The type of design that depends upon empirical
formulae based on the practice and experience.
c) Industrial design. The type of design that depends upon the
production aspects to manufacture any machine component in the
industry.
d) Optimum design. The type that 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. The type of design for any complex mechanical
system like a motor car.
f) Element design. The type of design for any element of the
mechanical system like piston, crankshaft, connecting rod, etc.
g) Computer aided design. The type of design that depends upon the
use of computer systems to assist in the creation, modification,
analysis and optimization of a design.
a) The type of load and stresses caused by the load.
The load, on a machine component, may act in several ways due to
which the internal stresses are set up. The external loads can cause
internal stressed to the system. These stresses must be determined
accurately since these will be used in determining the component size.
The system loading can be attributed to:
Energy transmission by a machine member.
❑Dead weight.
❑Inertial forces.
❑Thermal effects.
❑Frictional forces.
Loads can be classified either static (does not change in magnitude and
direction and normally increases gradually to a steady value) or
dynamic (changes due to magnitude or direction)
b) Motion of parts or kinematics of the machine.
The operation of any system depends on the simplest arrangement of the parts
which will give the motion required. The motion of the parts may be classified
as:
❑Rectilinear motion (either unidirectional and reciprocating motions)
❑Curvilinear motion (rotary, oscillatory, or simple harmonic)
❑Motion with constant velocity
❑Motion with constant or variable acceleration.

c) Selection of materials.
The designer should be knowledgeable of the properties of the materials and
their characteristics under working conditions. Some of the important
characteristics of materials that are needed to be considered are: strength,
durability, flexibility, weight, resistance to heat and corrosion, ability to cast,
welded or hardened, machinability, electrical conductivity, etc.
d) Shape, size, and space requirements
The shape and size of the machine parts are based on judgment. To design
any machine part for form and size, the forces which the part must sustain
must be known. It is also necessary to anticipate any suddenly applied or
impact load that may cause failure of parts. For non-standard element, the
shapes and space requirements depend in the available space in a
particular machine assembly that it will be used.

e) Manufacture.
The designer should ensure that the designed elements can be
manufactured with ease and can be produces within the available facilities
at low cost.

f) Operational parameters.
The designer should ensure that machines can be operated with ease. The
sequence of operation should be simplified and must not be complicated
or would require an excessive force.
g) Reliability and safety
The designer should take the reliability of its work as an important factor.
Reliability is defined as the probability of the element or a machine not to fail
when exposed to operation. To ensure a high reliability, attention to detail
should be done in every stages of the design process.
Safety should also be of paramount importance in designing. Machines must
be designed to address and serve the needs of mankind and not to harm them.
In some cases, the designer must include in the design of the machine the
necessary safety devices for the safety of the operator.

h) Maintenance, cost, and aesthetics

The safety and reliability of the machine should be served with high quality
maintenance to ensure the optimum running condition. Regular scheduled
maintenance should be done to moving and loaded parts to avoid catastrophic
failures. The designer should give careful attention to the matter of lubrication
of all surfaces that interacts with other parts whether in rotating, sliding, or
rolling bearings.
The cost of the manufacturing and additional cost due to aesthetic should also
be considered in the design. Although in many cases, aesthetic is not an
essential aspect of machine design.
In the design process, it is established that the needs
and expectations of the customers are identified
before starting the design of mechanical device. It is
done by formulating clear and complete statements
of functions, design requirements, and evaluation
criteria.
 Functions.
Functions would tell what the device is capable of and in general, it uses non-
quantitative statements that employ action phrases including to support a
load, to lift a crate, to transmit power, or to hold two structural members
together.

Design requirements.
The design requirements are detailed and usually quantitative statements of
expected performance levels, environmental conditions in which the device
must operate, limitations on space or weight, or available materials and
components that may be used.
 Evaluation criteria
The evaluation criteria are statements of desirable qualitative characteristics
of a design that assists the designer in deciding which alternative design is
optimum or the design that maximizes the benefits while minimizing the
disadvantages.
Achieving a high overall performance should also be a high priority. Certain
design concepts may have desirable features not present on others:
• Safety (the relative inherent safety over and above stated requirements)
• Performance (the degree to which the design concept exceeds
requirements)
• Ease of manufacture
• Ease of service or replacement of components
• Ease of operation
• Low initial cost
• Low operating and maintenance costs
• Small size and low weight
• Low noise and vibration; smooth operation
• Use of readily available materials and purchased components
• Prudent use of both uniquely designed parts and commercially available
components
• Appearance that is attractive and appropriate to the application
The design calculation is an integral part of the mechanical design process to
ensure the reliability and accuracy of the outcomes. Therefore, it is important
to conduct the calculations neatly, completely, and in an orderly fashion.
There will be cases wherein the designer will have to explain to others the
approached used in the design, which data used, and which assumptions and
judgments are made.
 Figure shows a sample design
calculation of a beam that subjected to
concentrated loading. 2050 pounds (lb).
The design assumes that a rectangular
shape is to be used for the cross section
of the beam. Other practical shapes
could have been used. The objective is
to compute the required dimensions of
the cross section, considering both
stress and deflection. A material for the
beam is also chosen.
 Stress
The word stress as used in all through the semester shall always be
understood to mean unit stress, s, 𝜎, or any symbol, measured in lbs
per square inch or kips per square inch (psi or ksi) in English system
and Newton per square meter or kilo-newton per square meter (𝑁/𝑚2
or k𝑁/𝑚2 ).
𝐹
𝑠=
𝐴
where: F is load, A is the cross-sectional area that offers resistance to
the load.
Types of stress
 Analysis of Simple Stresses
When the body is acted upon by some external forces or loads, the internal
forces (equal and opposite) are set up at various sections of the body, which
resist the external forces. This internal force per unit area at any section of the
body is known as unit stress or simply a stress.

𝐹
𝑠𝑡 = 𝜎 =
𝐴
 Tensile strength and Yield strength

When a member is subjected to the action of a force, it is

deformed, no matter how small the force. A test specimen
subjected to increasing stress will undergo increasing
strain.
By strain (tensile or compressive), we mean the
deformation per unit gage length, in per in.
 Shearing stress
Forces parallel to the area
resisting the force cause shearing
stress. It differs to tensile and
compressive stresses, which are
caused by forces perpendicular to
the area on which they act.
Shearing stress is also known as
tangential stress.
𝑽
𝒔𝒔 = 𝝉 =
𝑨
where V is the resultant shearing
force which passes which passes
through the centroid of the area A
being sheared.
 Torsional Shear Stress
When a machine member is subjected to the action of two equal
and opposite couples acting in parallel planes (or torque or
twisting moment) as shown in the figure, then the machine
member is said to be subjected to torsion. The stress set up by
torsion is known as torsional shear stress.
Where, T is the applied torque or twisting moment, ss is a
𝑠𝑠 𝐽 shearing (torsional) stress, which in designing is the
𝑇= design stress, J is the centroidal polar moment of inertia of
𝑐 the section, and c if the distance from the neutral axis to
the point where the stress ss is desired (usually the
maximum stress on an external fiber).
In many situations, the design of a part is defined by the permissible
deformations, rather than by some safe stress. The angle of twist θ of
the shaft within the section I is given by,

𝑇𝐿
𝜃=
𝐽𝐺

Where, T is the twisting moment, L is the distance of the studied

section, J is the polar moment of inertia of the section, and G is the
Modulus of Rigidity of the material (often, G = 11.5 x 106 psi or 12 x
106 psi, for steel).
 Factor of Safety-Design Factor
Factor of Safety also known as design factor, is a number that is
divided into a criterion of strength in order to obtain a design criterion.
𝒔𝒖 𝒔𝒚
𝒔𝒅 = and 𝒔𝒅 =
𝑵 𝑵
where 𝑠𝑑 in psi (N/𝑚2 ) is the design stress, also known as safe stress
or working stress and allowable stress; N is the design factor.
Inasmuch as the stress used in design is the significant number, the
best design stress is a particular number that depends upon the
criterion used for design.

Suppose 𝑠𝑢 =80 ksi, 𝑠𝑦 =50 ksi, and that a good 𝑠𝑑 = 20 𝑘𝑠𝑖. Calculate
the design factor based on ultimate strength; and based on yield
strength.
 Factor of Safety for Wire Ropes
(SI Units)
The factor of safety for wire ropes
based on the ultimate strength are
given in the following table. These
values are used to calculate the
design load by taking a factor of
safety 2 to 2.5 times the factor of
safety given in the table below.
 More on factor of safety and design stress
In general way, the greater the uncertainties the greater the design
factor, and the lower the design stress should be. Uncertainties and
other factors that affect the magnitude of the design stress are as
follows.
(a) Material (f) The Chance of an Accidental
(b) Size effect Load
(c) Loading (g) The Danger to Life or Property
(d) Computed Stress Environment (h) The Price Class in Which the
(e) Inspection Machine Is to Sell
Conduct research activities by visiting the e-library resources of our
university if necessary. Your research output should answer the
following questions below. Write your answers on short size bond
paper and observe proper margin and grammar.

1. A hollow steel tube with an inside diameter of 100 mm must

carry a tensile load of 400 kN. Determine the outside diameter
of the tube if the stress is limited to 120 MN/𝑚2 . Refer to
figure 1.
2. What force is required to punch a 20-mm-diameter hole in a
plate that is 25 mm thick? The shear strength is 350 MN/m2.
Refer to figure 2
3. What is transmission shaft?
4. What are the materials used for shafts? Identify each property
of each material in SI and English units.
5. Derive the torsional shear stress, 𝜏 acting upon the solid shaft.
16𝑇
𝜏=
𝜋𝑑 3