UNIT 1 INTRODUCTION TO MECHANICAL

DESIGN
Structure
I. I Introduction
Object~ves
1.2 The Procedure of Design
I .3 The Machine and its Designer
1.4 Engineering Materials
1.5 Mechanical Properties
1.6 Tension Test
1.7 Stress Strain Diagram of Mild Steel
1.8 Compression Strength
1.9 Torsional Shear Strength
1.10 Elastic Constants
I . 1 1 Hardness
1 .I2 Fatigue
I . I3 Creep
1.14 Impact Strength
1.15 Engineering Materials
1.16 Steel
1.17 Alloy Steel
1.18 Heat Treatment
1.19 Stainless Steel
1.20 Cast Iron
1.2 1 Non-ferrous Materials
1.22 Bearing Materials
1.23 Plastic
1.24 Manufacturing Considerations
1.25 Summary
1.26 Key Words
1.27 Answers to SAQs

1.1 INTRODUCTION
Design is a process that ends in creation of something which will satisfy some need of a
person, group of persons or society. The homes and buildings in which we reside, the
dams which store water for irrigation or generation of electricity, an engine which is
used for pumping water or a hoist for lifting loads are the things that are designed before
they are made. The design does not pertain to a single device, structure or product or
even something which can be seen to exist. The process of design can achieve a system,
which can be identified by its physical entity or by service, which is rendered by the
system.
Fundamentals of The process of design will take into consideration all the fdctors that would likely to
Engineering Design affect the performance of the end system. The constraints in respect of materials to be
used, the processes for changing shapes and size, the personnel to employed, the cost of
components and personnel, transportation of final product or establishment of final
system, etc. will be brought under consideration in the design process. If the end result is
the product then its disposal after it has served its purpose is also to be considered during
design.
Mechanical design is one of several design processes, which ends in systems that
provide for doing certain mechanical work or creating certain desired motion and often
both. Such devices will need enough strength or capacity to bear forces, which result in
doing work and creating motion. The possibility of adopting most economic and
convenient process of shaping material to build the device or system will always be the
priority of design. Keeping the cost low at every step to make end product most
economic will also be the central consideration. Creating such designs will require
designer to have some specified knowledge and experience. In this text we will try to
generate requisite knowledge. Some experience may be gained through solving
problems.
Objectives
After studying this unit, you should be able to
explain what is design?
describe the machine and its designer,
illustrate the procedure of design,
know material used in mechanical design, and
understand the considerations for manufacturing.

1.2 THE PROCEDURE OF DESIGN

The process of design which encompasses design of mechanical systems or machines
consists of a few steps to be followed in order. The discrete steps are :
Recognition
The first step is to recognize the need, i.e. what is the need to be fulfilled. All
designs require that the need should be properly and fully defined and described.
This description may become the statement of the problem.
Synthesis
This step involves identifying all possible solutions and making a list. In case of
mechanical design the step may consist in selecting mechanism or group of
mechanisms which will result in desired motion or group of motions and
transmission of forces.
Analysis
The best solution is chosen based upon knowledge and experience. The chosen
solution is analysed to see the effects of all factors. In case of mechanical design
in which each elemept is required to transmit some force and have definite motion
will be analysed to determine force to be transmitted and size of element. The
motion will also be Analysed.
Material Selection
The analysis will be based upon important information of capacity of material,
which wil1,be used to transmit force. The capacity may be described in terms of
forces, stresses, strains, type of forces or stress, environment in which the machine
 or element has to work, etc. the material is selected upon the basis of such Introduction to
Mechanical Design
capacities, and also its ability to undergo process of manufacture.
Calculation
The limits or permissible values of forces or stresses are immediately known if
material is selected. The background knowledge of stress analysis or relationship
between forces and deformations are used to determine the sizes which could be
cross-sectional dimension, length and changes in cross-sectional dimensions. At
this stage connections between the elements may also enter the considerations.
Revision and Modification
The availability of material in certain sizes and shapes, and joining of elements for
perfect fit has resulted into standardizations. Such standards are available from
professional institutions, government organisations and manufactures of standard
elements. Therefore, the results of calculations are to be checked against
information from the relevant source or sources. The dimension may be modified
to suit standard.
Report
After a design process has been completed the outcome may be a system which
would satisfy the needs as described in the first step. If the design is mechanical,
the sizes of and connection between the elements would have been decided. The
materials would be known and the type of manufacturing methods would have
been arrived at. A complete report on the problem has to be prepared. The
mechanical designs are best reported by drawings and standard methods for
specifying material and special manufacturing process on the drawing are well
known practices.

1.3 THE MACHINE AND ITS DESIGNER

A machine is understood to be a device which transmits motion and force in a controlled
manner. A machine is made up of several elements in such a way that each element will
move in coherence with other and force will be transmitted from element to element.
The motion and force at various points will constitute mechanical work or energy.
Hence, the prime function of machine can also be regarded as receiving energy at input
point and transmitted it to some other body at output point. Between the input and output
points the form of energy may or may not change. For example, an internal combustion
engine is a machine. It receives thermal energy at the top of piston in the cylinder and
delivers kinetic energy at the crank shaft. A milling machine or a lathe machine receives
mechanical energy and transmits mechanical energy to work piece through removal of
material at cutting point very close to machines are the structures which are also made up
of elements and are subjected to forces but they differ from machines in that they do not
have elements moving in relation to each other. In fact all their elements are stationary.
Many of them can be designed as machines.
In fact. in machine designing we divide activity in the separate steps. One in which only
motion is considered and analyzed without considering forces that may be the cause of
motion. For this step the elements of machines are regarded as rigid or non-deforming.
In the second step the elements are regarded as stationary and forces that are transmitted
from connecting link or created due to motion are consider to be acting on the element.
The element is supposed to be deforming and hence internal resistance called stress is
considered for calculating the size of the element. The subject of Machanical Design,
Design of Machine Elements, Machine Design or Mechanical Engineering Design
after deals with second step. The first step as included in design procedure at steps 2 and
3 is often taken separately which is outside the purview of the subject of Machine
Design. On the other hand design of structures (several of them) in included in this
subject.
Fundamentals of Designing will appear as a decision making process in which the sizes of various
Engineering Design elements will be decided. In simpler designs, enough background information and
knowledge are available by way of which a particular element may be regarded to be
loaded purely axially, as a beam or as a shaft. Some may be under combined leading
when all three or two of these load conditions may exist. A designer's capability is tested
by the fact that he creates a similarity between a machine element and any of the
standard loading conditions. For examples treating a gear tooth, as a cantilever beam can
be an example of ingenuity of the designer or regarding belt to be bent like a beam over
pulley could another such example. In the present we will be considering several such
examples in which similarity between a machine member and another loaded in a
standard fashion (i.e. axially, bending, torsion or combination thereof) will be brought
out. And then the standard formulae of the subject of Strength of Materials or
Mechanics of Solids may be used. The designer will have to be sensitive to
determination of forces that may arise from any source. For example, a steam turbine is
designed thermodynamically for its major purpose of converting thermal energy into
mechanical energy or design of a hydraulic turbine will use principles of Fluid
Mechanics but a designer of machine will be concerned with the forces that arise from
flow of steam or water upon the elements like blades and rotors. Needless to say that
designer will find it difficult to visualise all the forces comprehensively if he does not
possess comprehensive knowledge of thermodynamics and Fluid Mechanics. We may
end up by collecting various characteristics a designer must possess.
(a) He should have sound and comprehensive knowledge in particular field of
engineering to which the design belongs (like Thermodynamics, Fluid
Mechanics, Refrigeration, etc.)
(b) He invariably should be conversant with Mechanics, Mechanisms,
Structures, Engineering Materials and Manufacturing Processes.
(c) Comprehensive knowledge of Mechanics of solids for correlating sheers,
deformation, forces (loads) and geometry is a must but in certain cases
where the elemeqt may not find a parallel in any of standard strength of
Material solution the designer may be required to use advanced techniques
of Theory of elasticity. The expertise in this area is an added feature.
(d) Some situations which are out of the purview of Strength of Material may
require experimental methods like Strain Gauge Survey or Photo-elasticity.
With the advent of fast computers the Numerical Techniques of Finite
Elements has beoome a handy and strong tool in the hands of designer of
machines.
(e) The national and'international standards and professional codes make the
job of designing much easier. Many times they are essentially to be
followed under orders of government or by law. Such standards are helpful
in infusing safety of operation and economy. It is thus imperative that a
designer is well versed with standards and codes.
(f) A designer must be able to use his knowledge and experience and must
always be ready to learn from his own experiences and those of others.
Thus, a constant touch with current literature is required. However, the
designer should be cautious that his experience of past does not become an
obstacle in innoviation.
(g) The ease of operation, safety during operation and convenient repairs and
maintenance along with the cost of equipment are such factors, which are
related to ultimate user. The designer, must make himself aware of human
nature and preferences so that his design may be acceptable and remains
safe in all aspects of operation, repair, maintenance and final disposal.
(h) The appearance of the product should be attractive to buyers with whose
needs in mind the design was made. The designer should have
understanding ofiaesthetics to make the product attractive.
 Introduction to
1.4 ENGINEERING MATERIALS Mechanical Design

There may be an endless list if we want to tabulate all those materials that are used in
engineering practice. They may be identified by their properties and compositions which
will again be too many for description for a text. The materials that are used for making
machines could form a shorter list and properties that are considered at the design stage
may be narrowed down to only essential. We will first describe and define properties of
materials and describe a few important materials to reduce burden on the reader.

1.5 MECHANICAL PROPERTIES

Properties are quantitative measure of materials behaviour and mechanical properties
pertain to material behaviours under load. The load itself can be static or dynamic. A
gradually applied load is regarded as static. Load applied by a universal testing machine
upon a specimen is closet example of gradually applied load and the results to tension
test from such machines are the basis of defining mechanical properties. The dynamic
load is not essentially a gradually applied load - then how is it applied. Let us consider a
load P acting at the center of a beam, which is simply supported at its ends. The reader
will feel happy to find the stress (its maximum value) or deflection or both by using a
formula from Strength of Materials. But remember that when the formula was derived
certain assumptions were made. One of them was that the load P is gradually applied.
Such load means that whole of P doest not act on the beam at a time but applied in
instalments. The instalrnent may be, say PI100 and thus after the 1 Ooth instalment is
applied the load P will be said to be acting on the beam. If the whole of P is placed upon
the beam, then it comes under the category of the dynamic load, often referred to as
Suddenly Applied Load. If the load P falls from a height then it is a shock load. A
fatigue load is one which changes with time. Static and dynamic loads can remain
unchanged with time after first application or may alter with time (increase or reduce) in
which case, they are fatigue load. A load which remains constantly applied over a long
time is called creep load.
All Strength of Material formulae are derived for static loads. Fortunately the stress
caused by a suddenly applied load or shock load can be correlated with the stress caused
by gradually applied load. We will invoke such relationships as and when needed. Like
stress formulae, the mechanical properties
. . are also defined and determined under
gradually applied loads because such determination is easy to control and hence
economics. The properties so determined are influenced by sample geometry and size,
shape and surface condition, testing machines and even operator. So the properties are
likely to very from one machine to another and from one laboratory to another.
However, the static properties carry much less influence as compared to dynamic
(particularly fatigue) properties. The designer must be fully aware of such influences
because most machines are under dynamic loading and static loading may only be a
dream.
It is imperative at this stage to distinguish between elastic constants and mechanical
properties. The elastic constants are dependent upon type of material and not upon the
sample. However, strain rate (or rate of loading) and temperature may affect elastic
constants. The materials used in machines are basically isotropic (or so assumed) for
which two independent elastic constants exist whereas three constants are often used in
correlating stress and strains. The three constants are Modules of Elasticity (E), Modulus
of Rigidity (G) and Poisson's Ratio (v). Any one constant can be expressed in terms of
other two.
An isotropic material will have same value of E and G in all direction but a natural
material like wood may have different values of E and G along fibres and transverse to
fibre. Wood is non-isotropic. Most commonly used materials like iron, steel, copper and
its alloys, aluminum and its alloys are very closely isotropic while wood and plastic are
non-isotropic. The strength of material formulae are derived for isotropic materials only.
Fundamentals of The leading mechanical properties used in design are ultimate tensile strength. yield
Engineering Design
strength, percent elongation, hardness, impact strength and fatigue strength. Before we
begin to define them, we will find that considering tension test is the most appropriate
beginning.

1.6 TENSION TEST

The tension test is commonest of all tests. It is used to determine many mechanical
properties. A cylindrical machined specimen is rigidly held in two jaws of universal
testing machine. One join is part of a fixed cross-head, while other join to the part of
moving cross-head. The moving cross-heads moves slowly, applying a gradually applied
load upon the specimen.

Figure 1.1 : Tension Test Specimen

The specimen is shown in Figure 1. I. The diameter of the specimen bears constant ratio
with the gauge length which is shown is Figure 1.I as distance between two gauge points
1
marked at the ends of uniform diameter length. In a standard specimen - = 5 . The
d
diameter, d, and gauge length, 1, are measured before the specimen is placed in the
machine. As the axial force increases upon the specimen, its length increases, almost
imperceptibly in the beginning. But if loading continues the length begins to increase
perceptibly and at certain poiht reduction in diameter becomes visible, followed by great
reduction in diameter in the lbcal region of the length. In this localised region the two
parts of the specimen appear to be separating as the machine continues to operate but the
load upon the specimen begins to reduce. Finally at some lesser load the specimen
breaks, with a sound, into two pieces. However, the increase in length and reduction of
load may not be seen in all the materials. Specimens of some materials show too much of
extension and some show too little. The reader must be conversant with the elastic
deformation, which is recoverable and plastic deformation, which is irrecoverable. Both
type of deformations occur during the test. The appearance of visible decrease in the
diameter in the short portion of length (called necking) occurs when the load on the
specimen is highest. The maqhines of this type have arrangement (devices) for the
measurement of axial force, P,and increase in length, 6. The values of force, P and
extensions, 6 can be plotted on a graph. Many machines have x-y recorder attached to it
P
and direct output of graph is obtained. The stress is denoted by o and calculated as -
A
where A is the original area of cross-section. Although the area of cross-section of
specimen begins to change as the deformations goes plastic, this reduction is seen at and
after the maximum load. The separation or fracture into two pieces can be seen to have
occurred on smaller diameter. Yet, the stress all through the test, from beginning to end,
D
is represented by o = f- . The strain is defined as the ratio of change in length at any
A
6
load P and original length 1 and represented by E, i.e. E = - at all loads. Since A and 1
1
are constants hence nature of graph between P and 6 (load-extension) or between o and E
(stress-strain) will be same. Figure 1.2 shows a stress-strain diagram, typically for a
material, which has extended much before fracture occurred.
At first we simply observe yhat this diagram shows. In this diagram o is the starting
point and oa is straight line.!~longline oa, stress (o) is directly proportional to strain (E).
Point b indicates the elastic limit, which means that if specimen is unloaded from any
point between o and b (both inclusive) the unloading curve will truly retrace the loading
curve. Behaviour of specimen material from point b to c is not elastic. In many materials Introduction to
Mechrnicnl Design
all three points of u, b and c may coincide. At c the specimen shows deformation without
any increase in load (or stress). In some materials (notably mild or low carbon steel) the
load (or stress) may reduce perceptibly at c, followed by considerable deformation at the
reduced constant stress. This will be shown in following section. However, in most
materials cd may be a small (or very small) region and then stress starts increasing as if
the material has gained strength. Of course the curve is more inclined toward E axis. This
increase in stress from d to e is due to strain hardening. Also note again that ob is elastic
deformation zone and beyond h the deformation is elastic and plastic - meaning that it is
part recoverable and part irrecoverable. As the deformation increases plastic deformation
increases while elastic deformation remains constant equal to that at b. If the specimen is
unloaded from any point in the plastic deformation region the unloading curve will be
parallel to elastic deformation curve as shown in Figure 1.3.

Figure 1.2 : Typical a - s Diagram

4 r

Figure 1.3 :a - E Diagram for n Ductile Material

Percent Elongation
From any point g the unloading will be along gi where gi is parallel to oa. oi is the
strain which remains in the specimen or the specimen is permanently elongated by
I E~ The total strain at g when the specimen is loaded is oj = E, + E, where E,, is
recoverable part. At fracture, i.e. at point5 if one is able to control and unload the
specimen just before fracture, the unloaded will follow f k. The strain ok is an
important property because deformation is defined as percent elongation. Hence,
ok = % elongationI100. Percent elongation is important property and is often
measured by placing two broken pieces together and measuring the distance
between the gauge points. You can easily see that after the fracture has occurred,
the specimen is no more under load, hence elastic deformation (which is equal to
km) is completely recovered. However, in a so-called ductile material km << om.
lfthe distance between gauge points measured on two broken halves placed
together is I, then
I, - I
% Elongation = -x 100
I
Fundamentals of The gauge length has pronounced effect on % elongation. Since the major amourit
Engineering Design of deformation occurs locally, i.e. over very small length smaller gauge length will
1
result in higher % elongation. After - > 5 the % elongation becomes independent
d
of gauge length. % elongation is an indication of very important property of the
material called ductility. The ductility is defined as the property by virtue of
which a material can be drawn into wires which means length can be increased
and diameter can be reduced without fracture. However, a ductile material
deforms plastically before it fails. The property opposite to ductility is called
brittleness. A brittle material does not show enough plastic deformation. Brittle
materials are weak under tensile dress, though they are stronger than most ductile
materials in compression.

Figure 1.4 : a - E Diagram for a Brittle Material

A typical diagram for a brittle material is shown in Figure 1.4. The definitions like
too much and too small % elongation fail to give numerical indication. Hence
engineers regard all those materials as brittle, which show a % elongation less
than 5% other are regarded as ductile. Most steels in carbon and medium carbon
range are ductile by this definition. Cast iron is a typical brittle material. Concrete
is another example of a brittle material. The failures in engineering structures and
machine elements always take place due to tensile stress and hence brittle
materials are not used for making such elements. Such components like beds of
machines and foundations can be made in cast iron. If tensile stress carrying
members have to be made in c.1 then they have to be made heavy for making
stress very low.
Ultimate Tensile Strength, Yield Strength and Proof Stress
The maximum stress reached in a tension test is defined as ultimate tensile
strength. As shown in Figure 1.3 the highest stress is at point e and ultimate
tensile stress (UTS) is represented by a,. Some authors represent it by ti,,.The
point C marks the beginning whiled marks the end of yielding. The C is called
upper yield point whiled is called the lower yield point. The stress corresponding
to lower yield point is defined as the yield strength. For the purposes of
machines. the part has practically fail if stress reaches yield strength, (a,), for this
marks the beginning of the plastic deformation. Plastic deformation in machine
parts is not permissible. Hence one may be inclined to treat o, as failure criterion.
We will further discuss this later in the unit.
It is unfortunate to note that many practical materials show a - E diagrams which
do not have such well defined yielding as in Figures 1.2 and 1.3. Instead they
show a continuous transition from elastic to plastic deformation. In such cases
yield strength (o,)becomes difficult to determine. For this reason an alternative,
called proof stress, is defined which is a stress corresponding to certain predefined
strain. The proof strevs is denoted by a,. A a - E diagram for a material, which
 shows no distinct yield is shown in Figure 1.5. The proof stress is determined introduction to
Mechanical Design
corresponding to proof strain a,, which is after called offset by laying a,, on strain
axis to obtain a point q on a axis and drawing a line parallel to elastic line to cut
the o - a curve at p. Then o, is measured on stress axis. The values of proof strain
or offset have been standardized for different materials by American Society for
Testing and Materials (ASTM). For example, offset for aluminum alloys is 0.2%,
same in for steels while it is 0.05% for cast iron (Cl) and 0.35 for brass and
bronze.

Figure 1.5 : Proof Stress (q)

Corresponding to Offset E~

Toughness and Resilience

Since the force, which pulls the tension test specimen, the force is causing
movement of its point of application hence the work is done. This work is stored
in the specimen and can be measured as

W= I pdl= A1 I -.P dl
- = (vol.)
A 1
o da

Apparently the quantity ) o d a is the energy stored in the specimen per unit
volume and is nothing but the area under the o - a curve, up to any point
toughness is regard as ability of a material to absorb strain energy during elastic
and plastic deformation. The resilience is same capacity within elastic range. 'The
maximum toughness will apparently be at fracture, which is the area under entire
o - a diagram. This energy is called module of toughness. Likewise the
maximum energy absorbed the specimen within elastic limit is called modulus of
resilience. This is the energy absorbed the tension specimen when the
deformation has reached point a in Figure 1.2. But since in most materials the
proportional limit, elastic limit (points a and b in Figures 1.2 and 1.3) seem to
coincide with yield stress as shows in Figure 1.3, the modules of resilience is the
area of triangle as shown in Figure 1.6.

I n ~ e d i u r C Steel
n

Figure 1.6 : Resilience and Toughness for Two Materials

It can be seen that modulus of resilience is greater for medium carbon steel than
for mild steel, whereas modules of toughness of two materials may be closely
same. Medium carbon steel apparently has higher UTS and YS but smaller percent
elongation with respect to mild steel. High modules of resilience is preferred for
such machine parts, which are required to store energy. Springs are good
example. Hence, springs are made in high yield strength materials.
Fundamentals of SAQ 1
Engitteering Design
(a) Discuss the procedure of Design.
(b) What characteristics a designer must possess?
(c) Sketch a stress-stain diagram. What properties you can define with the help
of this diagram?
i
(d)
k
Distinguish between a brittle nd ductile material. Why is a brittle material
not favoured for use as machi e element?
(e) Define modulus of resilience kind modules of toughness.

1.7 STRESS STRAIN DIAGRAM FOR MILD STEEL

Mild steel as steel classification is no ,no& a popular term. It was in earlier days that
group of steel used structural purposes wqs called mild steel. Its carbon content is low
and a larger group of steel, named low carbon steel, is now used for the same purposes.
We will read about steel classification latlr. Mild steel was perhaps developed first out
of all steels and it was manufactured from Bessemer process by blowing out carbon from
iron in a Bessemer converter. It was made from pig iron. The interesting point to note
that this steel was first studied through o - E diagram and most properties were studied
with respect to this material. The term yield strength (YS) is frequently used whereas
yield behaviours is not detectable in most steel varieties used today. It is mild steel,
which very clearly show a yield behaviour and upper and lower, yield points. Figure 1.7
shows a typical o - E diagram for mild steel.

Figure 1.7 : o - E Diagram for M i l d Steel

The proportional limit, elastic limit and upper yield point almost coincide. d is lower
yield point and deformation from c to d is at almost constant stress level. There is
perceptible drop in stress from c to c'. The deformation from c' to d is almost 10 times
the deformation, etc. It can be seen effectively if strain is plotted on larger scale, as
shown on right hand side in Figure 1.7, in which the E scale has been doubled.
The mechanism of yielding is well understood and it is attributed to line defects,
dislocations. The readers are already exposed to this defect in the subject of Material
Science. This defect in materials is also responsible for effect of strain rate on
mechanical properties like UTS, YS and percent elongation.
The UTS normally increases with increasing strain rate and decreases with increasing
temperature. Similar trend is shown by yield strength, particularly in low carbon steel.
I
I

I 1.8 COMPRESSION STRENGTH Introduction to

Mechanical Design

Compressio~ztest is often performed upon materials. The compression test on ductile

material reveals little as no failure is obtained. Brittle material in compression shows
specific fracture failure, failing along a plane making an angel greater than 45' with
horizontal plane on which compressive load is applied. The load at which fracture occurs
divided by area of X-section is called compressive strength. For brittle material the
stress-strain curves are similar in tension and compression and for such brittle materials
as CI and concrete modules of elasticity in compression is slightly higher than that in
tension.

1.9 TORSIONAL SHEAR STRENGTH

Another iinportant test performed on steel and C1 is torsion test. In this test one end of
specimen is rigidly held while twisting moment or torque is applied at the other end.
The result of test is plotted as a curve between torque (0 and angle of twist or angular
displaceinent 0. The test terminates at fracture. The T- (3 curves of a ductile inaterial is
very much similar to load extension or o - E curve of tensile tzst except that the torque
does not reduce after attaining a maximum value but fracture occurs at maximum torque.
It is because of the fact that there is no reduction in the sectional area of the specimen
during the plastic deformation. The elastic limit in this case can be found as the point
where straight line terminates and strain hardening begins, marked as point b in
Figure 1.8. Mild steel will show a marked yielding while other ductile materials show a
smooth transition froin elastic to plastic deformation. The plastic deformation zone in
torsion is much larger than in tension because the plastic deformation beginning from
outer surface spreads inside while in tension the stress being uniform over the X-section
the plastic deformation spreads over entire section at the same time.

Figure 1.8 : Torque-twist Diagram in Torsion

The rnodulus ofrapture or ultirnare torsional shear strength is calculated form

where T,,,, is maximum torque, j is polar moment of inertia of the specimen section of
diameter d. From the T - 0 diagram the slope of linear region can be found as
proportional to modulus of rigidity, which is ratio of shearing stress to shearing strain.

1.10 ELASTIC CONSTANTS

Witltin elastic lintit tlre stress is directly proportional to strain. This is the statement of
Hooke's law and is true for direct (tensile or compressive) stress and strain as well as for
shearing (including torsional shearing) stress and strain. The ratio of direct stress to
direct strain is defined as modulus ofelasticity (E) and the ratio of shearing stress and
shearing strain is defined as modulus ofrigidity (g).Both the moduli are called elastic
constants. For isotropic material E and G are related with Poisson's ratio
Fundamentals of
Engineering Design

Poisson's ratio which is the ratio of transverse to longitudinal strains (only magnitude) is
yet another elastic constant. If stress o acts in three directions at a point it is called
volumetric stress and produces volumetric strain. The ratio of volumetric stress to
volumetric strain according to Hooke's law is a constant, called bulk modulus and
denoted by K. It is important to remember that out of four elastic constants, for an
isotropic material only two are independent and other two are dependent. Thus K can
also be expressed as function of any two constants.

It may be understood that elastic constants E and G are not determined from tension or
torsion test because the machines for these tests undergo adjustment of clearance and
also some deformation, which is reflected in diagram ordinarily. The constants are
determined from such devices, which show large deformation for comparatively smaller
load. For example, E is determined by measuring deflection of a beam under a central
load and G is determined by measuring deflection of a close-coiled helical spring under
an axial load. Poisson's ratio is normally not measured directly but is calculated from
above equation. The elastic constants remain fairly constant for a class of material and
are independent of specimens.

1.11 HARDNESS
Hardness of a inaterial is its ability to resist indentation or scratching. This property is
the measure of resistance to wear and abrasion. Both scratch and indention methods are
used for determining this property. For engineering purposes indentation method is used.
The load that is used to cause inde~tationon a flat surface by an indenter is divided by
surface area of indentation to obtain a number that is called hardness number. A ball of
10 mm diameter made in hardened steel is used as an indenter under a load of 30000 N
and kept applied for 30 sec. There of indentation is

with D as diameter of the ball and d as the diameter of impression on flat surface.
Different loads are used for different materials. Brinell hardness number is the ratio of
load P and area of indented surface as given above. Instead of using the area of surface
of indentation of divide the load P to obtain harness number one can use the area of
circular impression on the surface or the projected area or the depth of indentation
directly can be used as an indicator of hardness. The former is used to determine Meyer
hardness number while latter is used with a different (conical) indentor for Rockwell
hardness number. Rockwell hardness uses different loads and indentors for having
different Rockwell scales. Rockwell C is commonly used for steels. Rockwell method is
generally preferred over Brinell because it does not require a finished surface, it can be
determined on a finished part without spoiling the surface and it gives the reading of
hardness directly. Rockwell method measures the depth of the indentation and hardness,
called Rockwell hardness number is inversely proportional to the depth of indentation.
It is no wonder that a relationship exists between hardness of a material and its strength
because both are related to bonding forces at atomic level. Because of nature of stress in
a hardness test being complex (triaxial) and effect of friction creeping in due to contact
between the indentor and the specimen such relationship is difficult to establish.
However, empirically the ultimate tensile strength and Rockwell c hardness are related
as
 I t is also interesting to note that techniques, which increase the ultimate tensile strength Introducliun lo
hlechanical Design
of material also increase the hardness. Increase in strength and hardness is associated
with decrease in ductility (%age elongation), increase in yield or proof strength and
consequent increase in ~nodulusof resilience. For this reason hardness is often used in
lieu of elaborate tension test for characterizing a material or checking effectiveness of
any treatment. Hardness is also used for calculating UTS (o,,) in design.
It may also be mentioned here that while the treatments given to material may alter yield
strength ultimate tensile strength, hardness and %age elongation. the module of elasticity
will remain unchanged. That's why the constants of material are to be differentiated
from mechanical properties.

1.12 FATIGUE
Fatigue is not the property but the behaviour of material under stress which changes with
time. Most interesting thing about fatigue is that a stress level which is below yield or
elastic limit is safe if applied once, but if same level is applied repeatedly upon a
specimen then it will fail. Such a failure under repeated stressing is called fatigue failure
and has discernible characteristics.
The most important characteristic of fatigue failure is that it is without perceptible
plastic deformation in the region of fracture. Even if the specimen is loaded under axial
tensile stress which reverses and whose magnitude is below yield strength, the fatigue
failure will occur and there will be no necking or elongation in the specimen. The
fracture surface has a characteristic appearance with rings (under magnification) and
rough surface (Figure 1.9).
Smooth region
rlngs can be seen
under magnification

Rough zone

Figure 1.9 :Characteristic Fatigue Fracture

Figure 1.10 : A Typical Fatigue Curve

The number of cycles after which the specimen fails is failed the fatigue life at the
applied stress. If stress level is plotted against In of number of cycles at failure the
characteristic fatigue curve is obtained (Figure 1.10). The curve indicates that at lower
I stress level the specimen tends to have longer life or even may not fail. All fatigue tests
are stopped at lo7 cycles and a specimen surviving 10 million cycles is regarded survival
or non-failure. The stress level at which specimen survives 10 million cycles is called
fatigue strength or endurance l i n ~ i (former
t denoted by o,is preferably used). Fatigue
life at given stress level and fatigue strength are two fatigue properties and they are
influenced by several factors such as specimen size, surface finish, stress concentration,
temperature, frequency, etc. A smooth polished specimen at frequency less than
1000 cycleslmin. and room temperature will have
Fundanlentals of o, = 0.5 o,(steels)
E~rgineeringDesign
o, = 0.4 o,,(non-ferrous)
The fatigue strength is affected by several variables :
(a) Fine finished surfaces result in high fatigue strength.
(b) Stress concentration reduces fatigue strength but not as much as stress
concentration factor.
(c) All treatments that improve static strength also improves fatigue strength.
(d) Under-stressing is process of stress cycling below fatigue strength. It
improves fatigue strength. Gradually increasing cyclic stress up to fatigue
strength is coaxing.
(e) Small size specimen (6 to 12 mm dia) have higher fatigue strength than
larger size specimen (> 6, mm dia), but after 100 mm dia, this effect levels
off.
(f) Corrosive atmobphere, high temperature cause reduction in fatigue strength.

1.13 CREEP
Yet another important behaviour of material arises when the material is subjected to a
constant load over a long time. It is found that a body of material subjected to a load
which causes stress less than yield strength, over a long period of time. undergoes a
deformation which increases as time possess. The strain so created may ultimately cause
the failure. The behaviour of material is termed creep and the strain is known as creep
strain. The rate at which strain increases will decide after what time the material will
fail. At higher stress the strain rate will be higher and vice-versa. It may be noted from
the definition given here that the temperature is not a requirement for creep deformation
to occur. Creep occurs at all temperatures. However, the creep rate is accelerated with
increasing temperature and at temperature which is close to half of melting point
temperature on absolute scale, creep becomes an important consideration in design. Thus
theoretically though higher temperature is not an essential condition for creep yet at
higher temperature it is a real problem. The creep rate at constant temperature increases
with increase in stress and qt constant stress it increases with increase in temperature.
The characteristic creep curve is plotted between creep strain and time and is
characterised by three stages as shown in Figure 1 . I 1. A designer would prefer to load a
machine part in such a way that only secondary creep having a constant creep rate sets
in. Tertiary creep is characterized by increasing creep rate and fast ends in fracture.
Creep becomes an important consideration in gas turbine blading design because
temperature is high. The higher limit oftemperature in gas turbine is limited because of
creep of blading material.

Secondary
Steady State
Tert~ary
1

Figure 1.11 : Creep Curve : Three Stages of Creep are Depicted

Sometime a quantity like creep srrength is defined as a stress at a given temperature lntroductiun to
Mechanical Design
which will produce minimum creep rate of a certain amount usually 0.000 1 %/hour.
Creep rupture strength is a stress at given temperature, which will cause rupture after a
predefined life in number of hours say I000 or 10,000 hours. Rupture is theoretically a
fracture occurring with X-sec. reduced to zero. Both creep strength and creep rupture
strength are arbitrary and not used in design but for comparing two materials.
A consequence of creep is a phenomenon called stress relaxarion, which refer to
decrease of stress at constant strain. Problem of stress relaxation is common in bolts used
to clamp two parts at higher temperature. For example, bolts used to clamp cover on a
pressure vessel, at high temperature may lose stress after some time and thus clamping
force gets reduced.
Addition of 1.25% cr and 0.5% Mo in 0.1 % C steel improves creep resistance. Addition
of Cr in varying proportion along with Mo in steel help improve creep resistance. Nickel
base alloys like Inconel (C-0.04, Fe- 7.0, Cr-I 5.5, Ni-76) have high creep resistance.
Cobalt base super alloys are also used for various purposes against creep.

1.14 IMPACT STRENGTH

lmparr is a rapidly applied load. A notched specimen is broken under impact loading in
an impact test. The state of stress at notch is complex, in fact triaxial and impact load
causes a high strain rate. The combination of these two make the material to behave in a
brittle manner and raises the yield strength. Thus the fracture occurs before yielding. It is
often difficult to calculate the stress at notch and hence the energy absorbed in fracturing
the specimen is measured as the material property and is given a name as impact
strength. Such a value cannot be used for designing but it is an indicator of the fact as to
how much tendency the material has to behave as brittle material. The machine for such
a test consists of a swinging hammer, which through a free fall is allowed to strike a
notched specimen in a way to stress notch in tension. The potential energy of hammer
before striking (i.e. in its raised position) can be calculated and also the potential energy
of the hammer after striking and causing the fracture of the specimen can be calculated
from the height reached by hammer at the end of its swing. The difference of two
potential energies minus loss of energy in moving through air is the energy absorbed by
the specimen in fracturing. The energy is the impact strength of material of specimen.
Two configuration of notched specimen are in common use and they are shown in
Figure 1.12. Charpy test uses the specimen is simply supported beam while Izod test
uses the specimen as cantilever. In both the cases the load is so applied that notch is in
tension. A 10 mm x 10 mm x-section bar supported over a span of 40 mm an carrying a
Y-notch of depth equal to 113 of the depth of section is a common Charpy test specimen.
To compare results from different sources standardization of specimens is necessary. An
Izod specimen may be rectangular or circular in section.

h
lrnpact Load

Nolch

ta
(a) Chary test

Impact load

(b)lzod test

Figure 1.12 : Impact Test Configuration

Apart from two worst condition, viz. of impact and notch, which render specimen brittle
a third condition to be explored is temperature. The material tends to become brittle at
Fundamentals of low temperature and hence performing impact tests on notched specimens at different
Engineering Design temperature is imperative. The results of such a test are depicted in Figure 1.13 wherein
the impact strengths are plotted as function of temperature. The results apparently centre
on a temperature T, showing that for T > T, the impact strength increase fast but for
T < T, it reduces fast. Such a temperature is called transition temperature as it represents
the transition from ductile to brittle nature as temperature reduces. The operation of a
machine part or structural component near transition temperature on higher side carries
the risk that if temperature reddces slightly the material may start behaving in a brittle
manner. Impact tests are often useful in establishing transition temperature. The purpose
could be to avoid such a temperature or to select a material whose transition temperature
is higher than the operating temperature. The material most susceptible to this transition
is mild steel and this material is largely used for structures. The non-ferrous material like
alloys of Cu and A1 do not show such transition from ductile to brittle. For evaluating
performance of welded mild steel such tests are often performed because the milk steel
welded structures are often used in ship building. The ships have to operate in warm and
cool climates.

Temperature

Figure 1.13 :Influence o f Temperature on Notched B a r Impact Energy

I

1.15 ENGINEERING MATERIALS

The materials used for structures, tools, machines and other durable goods are generally
regarded as engineering materials. These materials are variously classified. Organic and
inorgunlc materials are close to scientific division. Materials of both types are used for
engineering purposes. Organic substances are mostly derived from living organisms and
necessarily contain carbon as one constituent. Animal hides (leather), wood, oil
(petroleum), several chemicals, paints, man made polymers and natural resins are
examples of organic materials, All elemqnts including metals and their alloys, acids not
having carbon as its constituent, ceramic, non living natural materials like sand the rock
are regarded as inorganic materials. Both types are found in gaseous, liquid and solid
states.
Composites are combination of materials in which neither solution nor chemical reaction
occurs but properties improves for engineering purposes purely because of mechanical
interaction between the constituents. All constituents may be organic or inorganic or
both. Reinforced concrete is a common example while reinforced plastics, cemented
carbide tools are also composites. Reduction in weight couple with high strength and
stiffness have opened possibilities of development of newer composites.
Because of ductility, malleab(lity, electrical conductivity and strength the metals have
become very common and dependable engineering martial. Though most metals are
elements (like Fe, A l , Cu, Zn3 very few are used in practice. Their properties improve by
alloying. The most commonly used alloy is steel which has Fe as most important
constituent and C and Si as alloying elements in very small proportion. Alloys like steel
have become very dependable inaterials because their properties can be altered by heat
treatment.
High temperature application requires the materials to remain sufficiently strong over a Inrroducrion to
3lechanical Design
wide range of temperature. The oxides, borides, nitrides and carbides of several metallic
elements have high wear resistance, high strength at elevated temperatures but have
marked brittleness. Such materials are described as ceramics.
Polyniers orplastic have acquired a great deal of popularity for making parts of
complicated shapes but not subjected to high loads. These are organic compounds made
by chemical processes and are used in form of fibres, sheets and in various other shapes.
Most composites are made using plastics. The composites and plastics have good
resistance against corrosion.
Perhaps the most common engineering materials after bricks and concrete are alloys.
Steel is the foremost example. The elemental metals are mixed in liquid state or heated to
liquid state where they may have total or partial solubility and on cooling the solids may
have total or partial solubility. Combination of two or more metals produce alloys in
solid state in most cases they posess properties better than the constituents. Equilibrium
diagrams drawn between temperature (ordinate) and % age composition of one of the
two constituents give great deal of information about alloys. Number of phases at any
temperature and their chemical composition cab be found from phase or equilibrium
diagrams.
Pure Iron may contain 99.99% iron. which could be produced by very costly electrolytic
process. Though not good for much strength, pure iron is used for research transformer
cores. Commercial iron may 99.99% pure. While bring expensive it is used for special
purposes for high corrosion resistance and electrical conductivity. Wrought iron contains
about 3% slag particles distributed unifor~nlyin iron matrix. 'The presence of slag is
helpful in increasing resistance against fatigue and corrosion. This material is used for
stream. oil and water pipelines. The alloys of iron containing upto 2% carbon along with
small amounts of S, Si. P and Mn are classified as steel. Cost iron is yet another alloy of
iron containing more than 2% of carbon.

1.16 STEEL
By far the colnmonest engineering materials, after brick and concrete, is steel. Steel is
known for its several favourable properties. It has strength and ductility, good electrical
and thermal conductivity, it is amenable to machining and other manufacturing processes
and it is comparatively easily produced.
A Steel containing C in the range of 0.04 to 1.2% along with Mn (0.3 to 1.04%), Si (upto
0.3%), S (max 0.04%), P) lnax 0.05%) is classified as plain carbon steel. Another group
is called alloy steel. C steel is further divided into three groups. They are described here.
Low C Steel
Carbon less than 0.27%. It is marked by high ductility, low strength, good
machinability and formability. They are weldable but do not respond to heat
treatment.
Medium C Steel
Carbon varies between 0.27 and 0.57%. This steels is heat treatable and good
strength is achievable after treatment. This steel is stronger and tougher than low
carbon steel and machines well.
High C Steel
They contain more than 0.57% C. The high C steel responds readily to heat
treatment. In heat-treated state they develop very high strength and hardness and
thus become less machinable. They also lose ductility and in the high carbon range
may become very brittle. The higher C content makes these steel difficult to weld.
Funda~nentalsof Following table describes applications, the properties required for applications and the
Engineering Design steel which can provide such properties.

Table 1.1 : Application of Plain C Steel

SI. No. Application Properties Steel

Nails. rivets. stampings High ductility. low Low C (AISI 1010).

strength 0.08/0.13,0.1 Max. 0.310.60

Beams. rolled sections High ductility, low Low C ( 1 020),

strength, toughness 0.1710.20,0.10/0.20.
I I 0,310.60

3. 1 Shafts and gears Heat treatable for good Med C (1030), 0.2710.35, 1
strength and ductility 0.2010.35, 0.510.80
I
Crank shaft, bolts, Heat treatable for good Med C (1040). 0.3610.45,
connecting rod. machine strength and ductility 0.2010.35,0.60/0.90
component

/ 1 Lock washers. valve

springs
Toughness High C (1060) 0.5410.066,
0.2010.35, 0.6010.90

Wrenches, dies, anvils High toughness and High C (1070), 0.6410.76,

hardness 0.2010.35,0.6010.90

7. Chissels, hammers, Retains sharp edges High C (1080)

shears

8. Cutters, tools, taps, Hardness, toughness. High C (1090), tool steel

1 hacksaw blades, springs heat treatable

* Composition In %of C, Si, Mn (in this order) with Max P-0.04% and Max S-0.05.

1.17 ALLOY STEEL

Plain C steels contain C in the range of 0.04 to I .2. Additionally they contain
Mn (0.3 to 1.04%), Si (up to 0.3%), S (0.04% Max) P (0.05% Max). Other than C no
element has significant effect on mechanical properties except that Mn may provide
some hardenability. S and P are undesirable elements.
Several advantages in terms of improved mechanical properties and corrosion resistance
are obtained by adding one or several alloying elements like Si, Mli, Ni, Cr, Mo, W, V,
Cu, B, A l , etc. The various advantages of alloy steel are :

(a) Higher hardness, strength and toughness, hardness on surface and over
bigger cross-section.

(b) Better hardenability and retention of hardness at higher temperatures (good

for creep and cutting tools).

(c) Higher resistance against corrosion and oxidation.

The alloying elements affect the properties of steel in 4 ways :

(a) By strengthening ferrite while forming a solid solution. The strengthening

effects of various alloying elements are in this order : Cr, W, V, Mo, Ni, Mn
and Si.

(b) By forming carbides which are harder and stronger. Carbides of Cr and V
are hardest and strongest against wear particularly after tempering. High
22 alloy tool steel use this effect.
 Ni and Mn lower the austenite formation temperature while other alloying ll~truductiolll o
(c) h.lechunicrl Design
elements raise this temperature. Most elements shift eutectoid composition
to lower C % age.
(d) Most elements shift the isothermal transformation curve- (TTTj to lower
temperature, thus lowering the critical cooling rate. Mn, Ni, Cr and Mo are
promznently ejyective in this respect.
Effects of individual alloying elements on properties of steel :
Sulfur
S is not a desirable element in steel because it interferes with hot rolling and
forging resulting in hot-shortness or hot embitterment. S, however, is helpful in
developing free cutting nature. S u p to 0.33% is added in,free cutting steel. If steel
is not free cutting S is restricted to 0.05% in open hearth or converter steel and to
0.025% in electric furnace steel.
Phosphorous
P produces cold shortness, which reduces impact strength at low temperature. SO
its %age is generally restricted to level of S. It is helpful in free cutting steels and
is added up to 0.12%. It also improves resistance to corrosion.

r Silicon
S, is present in all steels but is added up to 5% in steels used as laminates in
transformers, motors and generators. For providing toughness it is an important
constituent in steel used for spring, chisels and punches. It has a good effect in
heel that it combines with free O2 forming S,02increasing strength and soundness
of steel castings (up to 0.5%).
Manganese
12 to 14% of Mn produces extremely tough, wear resistant and nonmagnetic steel
called Hatjield Steel. It is important ingredient of free cutting steel upto 1.6%. Mn
combines with S, forming MnS. For this purpose Mn must be 3 to 8 times the S.
M, is effective in increasing hardness and hardenability.
Nickel
Ni is good in increasing hardness, strength and toughness while maintaining
ductility. 0.5% of Ni is good for parts subjected to impact loads at room and very
low temperature. Higher amounts of Ni help improve the corrosion resistance in
presence of Cr as in stainless steel. Nickel in steel results in good mechanical
properties after annealing and normalising and hence large forgings, castings and
structural parts are made in Ni-steel.
Chromium
Cr is common alloying element in tool steels. stainless steels, corrosion resistant
steels (4% Cr). It forms carbide and generally improves harness, wear and
oxidation resistance at elevated temperature. It improves hardenability of thicker
sections.
Molybdenum
Mo is commonly present in high-speed tool steel, carburising steel and heat
resisting steel. It forms carbide having high wear resistance and retaining strength
at high temperatures. Mo generally increases hardenability and helps improve the
effects of other alloying elements like M,, Ni and Cr.
Tungsten
W is important ingredient of tool steel and heat resisting steel and generally has
same effects as Mo but 2 to 3% W has same effect as 1% of Mo.
Fundrmentrls of Vanadium
Engineering Design
Like Mo, V has inhibiting influence on grain growth at high temperature. V
carbide possesses highest hardness and wear resistance. It improves fatigue
resistance. It is important constituent of tool steel and may be added to
carburising steel. Hardenability is markedly increased due to V.

Titanium
Addition of Ti in stainless steel does not permit precipitation of Cr carbide since
Ti is stronger carbide former and fixes the C.

Cobalt

It imparts magnetic property to high C steel. In the presence of Cr, Co does not
permit scale formation at high temperature by increasing corrosion resistance.
.
Copper
Atmospheric corrosion resistance of steel is increased by addition of 0.1
to 0.6% Cu.

Boron

Very small %age (like 0.001 to 0.005) of B is effective in increasing hardness

particularly in surface hardening boriding treatment.

Lead
Less than 0.35% Pb improves machinability.

Aluminum
Al in %age of 1 to 3 in nitriding steels is added to improve harness by way of
forming A1 nitride. 0.01 to 0.06% A1 added during solidification produces
fine-grained steel castings.
We may also correlate certain desired properties with alloying elements. They are
mentioned below.

(a) Hardenability is improved by addition any or more than one of the

following. Si, M,, Ni, Cr, Mo, W, B.

(b) Toughness, that is the capacity to absorb energy before fracture

increases with addition of Si and Ni.

(c) The presence, of Cr, Mo and W helps steel to retain strength at high
temperatures.

(d) Cr, Mo and W also help improve resistance against corrosion.

(e) Wear resistance of steel increases when alloyed with Cr, Mo, W and V.

(f) The impact strength at low temperature improves due to Ni.

(g) Cu helps steel achieve better resistance against atmospheric corrosion.

(h). Surface hardenability is improved by addition of Al

(i) V helps increase fatigue strength of steel.

('j) Steels with S, P and Pb have better machinability.

Table 1.2 describes application, desired properties and composition of several alloy
steels.
 Table 1.2 : Applications of Alloy Steels Introduction to
Mechanical Design
I I
'
SI. No. Application Desired Properties Composition
4
I
1 I Rail Steel Strength. ductility, impact and C-04% to 0.6% Mn
fatigue strength , and Cr- upto I% I
Spring steel (tension, Good elongation, high elastic limit (a) C-0.6. Mn-0.9
compression. torsion) (20 to 30%, 1200-1400 MPa)
Si-2.0
(b) C-0.5, Mn-0.8.
Cr-1 .O. V-0.15
(c) C-0.5, Mn-0.9
Cr-0.5. Ni-0.6
Mo-0.2
Structural steel High strength, toughness, high Wide range of alloy
(bridges building, temperature strength. corrosion steels containing
cars. gears, clutches, resistance several alloying
shafts) elements
Weldable steel for Weldability, high resistance to C-0.15 to 0.3% with
welded structures atmospheric corrosion, resistance some Cu and V
to brittle fracture
Concrete reinforcing Bend 90"- 180°, torsteel with ribs C-0.3 to 0.4%, Min
steel for grater surface area. 0.5 to 0.8%
Elong = 16%
UTS =500-650 Mpa
Y.S. = 35 MPa
High speed steel for Resist temperature upto 550- C-8%, W-18% Cr-4%.
cutting tools 600'~ V-1%
Cutting tools requiring high
hardness at working temperature
I C-8%, W-6%,
Mo-5%, Cr-4%. V-2%

Ii Ii 11 1 8 : 4 : 1 steeland
6 : 5: 4: 2 steel
I
i
Ii
Creep resisting steel Application in pipeline upto
400-550°C

I Other parts upto 500°C

C-low carbon

Ball bearing steel Rolling element. inner and outer C-0.9 to 1.1% Cr-0.6
races. High hardness 61-65 R, to 1.6%, Mn-0.2 to
high fatigue strength 0.4%
Hadfield Mn steel Resistance to abrasion ad shock. C-I to 1.4% Si-0.3 to
excavating and high toughness, strength ad 1.0% Mn- I0 to 14%
crushing machine, ductility with Fe
railroad crossing, oil
well, cement, mining
industries. Used as
casting and hot rolled
High strength low
alloy steel (HSLA)
High strengthlweight ratio.
Balanced properties such as
C-0.07 to 1.3%. TI, V.
A1 Co less than 0.5% 1
i for automotive parts toughness, fatigue strength.
weldability and formability
I
:
i
Fundamentals o f
Engineering Design 1.18 HEAT TREATIMENT
Heat treatment is the process through controlled heating and cooling of metal to induce
desired properties. The process causes changes in the structural arrangements in the
structure of the metal. The structure of an alloy is made up of different phases, which
precipitate from molten mixture depending upon the rate of cooling. The reader may like
to improve familiarity with phakes by revising parts of Material Science and we will
ignore such details in this text. The medium carbon steel, high carbon steel and alloy
steel are especially sensitive to heat treatment. Several handbooks describe heat
treatments of several classes of steel. It will suffice here to give brief description.
Annealing
The steel is heated slightly above the critical temperature cooled slowly, often
keeping material in the furnace and shutting off heat. The annealing will result in
uniform grain structure, reduced strength and harness and increased ductility.
Internal stresses which might have resulted from previous treatment (mechanical
or thermal) are removed by annealing.
Normalising
The heating is same as in annealing but the metal is cooled faster by placing it out
of the furnace. This treatment removes effect of any previous heat treatment and
prepares the metal for further treatment.
Quenching
Quenching is rapid cooling at different rates. It is cheved by immersing the heated
metal from above critical temperature into cold water or any other cooling
medium. The quenching results in high hardness. Steels develop high hardness by
retaining iron carbide which forms at critical temperature and des not find time to
decompose as the cooling occurs very fast. Cooling media such as ice water. cool
water, oil, hot oil, molten salts and molten lead are used depending upon desired
cooling rate. The result of quenching is increased hardness and strength and
decreased ductility while improper quenching may result in surface cracks.
Tempering
Some of the lost ductility due to quenching is restored through tempering. In this
process the quenched metal is heated to some pre-decided temperature and metal
is soaked for some time. The range of temperature used for steel is generally from
200°C to 600°C and cooling is done in the furnace. The tempering treatment also
helps remove internal stresses, which are created due to hardening treatment. UTS,
Ys and hardness reduce while % elongation, impact strength increase due to
tempering at temperatures of 300°C and above. There is little effect on these
properties below 300°C.
Casehardening
Casehardening is a surface hardening process, often applied on low carbon steels
which do not responded to heat treatment. The process consists in packing the
steel piece in charcoal powder and covered from outside. The charcoal powder
cuts of air. When heated in a furnace the carbon from charcoal penetrates the
surface and on quenching the carburized surface retains hardness. 'The process is
also known as carburizing and steels containing 0.1 to 0.25% C are easily
carburized. The mechanism of hardening is two fold. Firstly the carbon of iron is
very hard and due to quenching it is retained in the surface. Secondly due to
increase in C in the surface layer, the residual compressive stress is produced.
Surface hardening is advantageous in case of gear teeth since the inner bulk
material still remains softer and tougher and thus combined advantage of harder
surface and tougher core mereases the life.
 It may be pointed out here that surface is the weakest region of the material in any I~itrotIuctionto
M e c l ~ a n i c aDesign
l
form. Fatigue cracks initiate late in hard surface and the wear resistance in also
better.
Besides carburizing by packing there are other methods of surface hardening of
steels. In gas carburizing the metal is heated in gas atmosphere in controlled
manner to avoid oxidation and permit absorption of the gas in the surface. The
gasses used for the purpose are natural gas, coke oven gas, butane or propane. In
the process called cyaniding the steel part is heated covered with the mixture of
potassium ferrocyanide and potassium bichromate. In some cases the mixture is
replaced by powdered potassium cyanide. A very hard case is produced by
cyaniding. A thin hardened layer is produced by immersion of part in the heated
cyanide solution. Natriding is yet another method of case hardening. It consists in
heating the part in the presence of dissociated ammonia in the range of 570°C to
61 0°C.
The surface hardness of 60 Rockwell C associated with core hardness of 33 to
38 RC is produced by carburizing. Nitriding can produce surface hardness upto
70 RC and core hardness of 27 to 47 RC. Natrided parts can be tempered. All
steels can be nitrided but those containing aluminum develop very high hardness.
Nitralloy 135 and 135 modified is a highly preferred material for gears. It contains
C-0.3510.41, Mn-0.55, Si-0.3, Cr-1.2011.60, AI-1.00, Mo-0.2010.35. This material
develops surface hardness of 65-70 and core hardness of 30-36 RC. AISI 4340
(C-0.40, Mn-0.70, Si-0.30, Cr-0.80, Mo-0.25, Ni-1.00) and AISI 4140 (C-0.40,
Mn-0.90. Si-0.30, Cr-0.95, Mo-0.20) are two other steels. which are nitrided and
used to make gears.
The high frequency current when passed through body of a part results in surface
heating. Once heated this way, the part is quenched in water. This treatment
resulting into hardened surface is called induction hardening for which steels
containing 0.4 to 0.5% C is good.
SAQ 2
(a) Sketch o - E diagram for mild steel and compare with o - E diagram of
other ductile material.
(b) Define elastic constants for isotropic material and give their correlation.
(c) Define hardness and state how is the hardness of metal measured. How is
UTS relatedto hardness?
(d) What do you understand by fatigue strength and enumerate factors that
affect fatigue strength?
(e) Describe three stages of creep.
(f) What is the use of information obtained from impact test?

1.19 STAINLESS STEEL

Stainless steel is an alloy steel but has become a class on its own because of widespread
applications. It also has several unique properties. Being steel all types of stainless steel
essentially contains C but they also contain chromium. Many of stainless steels also
contain nickel. The important properties of stainless steels are mentioned below :
(a) They have wide range of strength and hardness accompanied by ductility.
(b) Stainless steels resist corrosion because very thin hydrous oxide layer forms
on surface, which obstructs further penetration of oxygen.
Fundanlenrals of (c) They exhibit good creep resistance and resist oxidation at elevated
Engineering Design
temperatures.
(d) They have good thermal conductivity.
(e) Stainless steels are weldable and machinable.
(0 They can be worked hot and cold.
(g) Since the surface is not corroded, they maintain good surface appearance
andfini.
(h) It does not show a very steep transition (ductility to brittleness) under
impact.
Combination of these properties render stainless steels as the best possible material
against corrosion, chemical attacks, high temp. low temperature and for critical parts that
are required to be small in size. They are also capable to bear high stress concentration
as ductility help plastic deforrhation under increased stress at stress concentration. Gears.
shafts and springs are made in stainless steel to take advantage of high strength, ductility
and corrosion resistance if sizes have to be keeping smaller. Blades for compressors and
turbine chemical containers. surgical instruments are made in stainless steel to take
advantage of anti corrosive properties.
There are three major types of stainless steels
Ferritic Stainless Steel

This is the most abundantly used stainless steel and has ferritic structure because
which it cannot be heat-treated. It has high resistance against corrosion and
oxidation. It is used in furnace as container of acids and trims of alitomobiles.
Carbon content of ferritic steel varies from 0.08 to 0.2%, Cr from 12 to 20.
Mn from 1 to IS%, and Si is 1.0%.
Martensitic Stainless Steel

This steel has martensitic structure and hence hardness. It can be hardened by
quenching. It is used for table wear, surgical instruments, springs, blades of
turbines and tools like cutting blades. The composition is C-0.01 to 1.2%, Cr-I2 to
18%, Mn-l t3 1.2%, Si-0.05 to 1 .O, Ni-1 .O to 2.0%. For surgical instruments
0.75% Mo is added. Free machining quality achieved big additional of 0.75% S.
Austenitic Stainless Steels

This steel has austenitic structure. C is less than 0.2 whereas Cr varies between
16 and 24% while Ni from 8 to 22%. Ni helps stabilizing austenite. Mn and Si,
respectively vary between 2 to 10% and 1 to 3%. Addition of 0.15% makes this
steel free cutting. The most wideIy used verity is 18.8 stainless steel which
contains 18% Cr and 8% Ni. This steel can be easily cold worked and does not
strain harden. It is used for chemical plants, mainly with joints. It is, however,
susceptible to intergranular corrosion.

1.20 CAST IRON

Cast iron plays very important role in engineering practice, as it is one of the commonest
materials for manufacturing of machines and their parts. It is being used since fourteenth
century while steel came in use during 19th century. Casting is a process in which
molten metal is poured in a mould and on solidifying the casting of the shape of mould is
obtained. General properties of cast iron are :
(a) Cheap material.
(b) Lower melting point (1200°C) as compared to steel (1380-1 500°C).
 (c) Good casting properties, e.g. high fluidity, low shrinkage, sound casting, Introduction tn
Mechanical Design
ease of production in large number.
(d) Good in compression but CI with ductility are also available.
(e) CI is machinable is most cases.
(f) Abrasion resistance is remarkably high.
(g) V e ~ yimportant property of CI is its damping characteristic which isolates
vibration and makes it good material for foundation and housing.
(h) Alloy C1 may be good against corrosion.
CI is prepared from melting pig iron in electric furnace or in cupola furnace. Electric
furnace given better quality.
CI contains different elements in addition to Fe. The carbon content of CI is more than
2%. Si Varies between 0.5 to 3.0%. It is very important because it controls the form of C
in C1. S content in C1 varies between 0.06 to 0.12% and is largely present as FeS, which
tends to melt at co~nparativelylow temperature causing hot shortness. Mn inhibits
formation of FeS.
Though P increases fluidity of CI - a property helpful for pouring - it has to be restricted
to 0.1 to 0.3% because it reduces toughness. P is present in the form of FeP.
L. Mn in C1 varies from 0.1 to 1 .O% though such a small M,, does not affect properties of
CI. It certainly helps improve upon hot shortness by taking care of S.
Several other alloying elements like Ni, Cr, Mo, Mg, Cu and V may be added to C1 to
obtain several desirable properties.
CI containing C in form of cementite is called white cast iron. Microstructure of such CI
consists of pearlite, cementite and ledeburite. If C content is less than 4.3% it is
hypoeutectic CI and if C is greater than 4.3% it is hypereutectic C1. White cast iron has
high hardness and wear resistance and is very difficult to machine, it can be ground,
though. Hardness of white C1 varies between 350-500 BHN and LlTS between
140-180 Mpa. White CI is normally sand cast to produce such parts as pump liners, mill
liners, grinding balls. etc.
C1 containing carbon in form of graphite flakes dispersed in matrix of ferrite or pearlite
is classified as grey cast iron. The name is derived from the fact that a fracture surface
appears gray. Gray C1 differs in %age of Si from white cast iron while C %age is almost
same. The liquid alloy of suitable composition is cooled slowly in sand mould to
decompose Fe3C into Fe and C out of which C is precipitated as graphite flakes.
Addition of Si, A1 or Ni accelerates graphatisation. The graphite flakes vary in length
from 0.01 to 1.0 mm. Larger flakes reduce strength and ductility. The best properties of
gray CI are obtained with flakes distributed and oriented randomly. lnoculant agents
such as metallic A I, Ca, Ti, Zr and S i c and CaSi when added in small amount cause
formation of smaller graphite flakes and random distribution and orientation.
Grey CI is basically brittle with hardness varying between 149 to 320 BHN and UTS of
150 to 400 Mpa. Different properties are obtained by varying cooling rate and quantity
of inoculant agents. It has excellent fluidity, high damping capacity and machinability.
If grey CI is repeatedly heated in service to about 400°C, it suffers from permanent
expansion called growth. Associated with dimensional change are loss of ductility and
strength as a result of growth. When locally heated to about 550°C several times this
material develops what are called fire cracks resulting into failure.
Grey CI is used for clutchplates, brake drums, beds of machine tools and equipments,
counter weights in elevator and furnace, gear reducer casing, motor housing, pump
housing, turbine housing, engine frames, cylinders and pistons.
lron castings are sometimes cooled rapidly on the surface to obtain white CI structure
while inside is allowed to cool slowly to obtain gray C1 structure. Such a combination is
called chilled or mottled C1. Metal or graphite chillers are used to chill the casting on
Pundanlentalsof outer surface. High hardness and wear resistance on the surface and low hardness and
Engineering Design strength at the core are obtained in chilled CI. Railroad freight car wheels, gram niill
rolls, rollsfor crushing ores, hammers etc. are made in chilled Cl.
High strength grey C1 is obtained by addition of strong inoculating agent like CaSi to
liquid alloy before casting process. UTS in the range of 250 to 400 Mpa is obtained.
This C1 is called meehanite iron and can be toughened by oil quenching treatment to a
UTS of 520 Mpa.
If graphite in C1 is present in form of nodules or spherods in the matrix of pearlite or
ferrite the material is called nodular cast iron. The C1 has a marked ductility giving
product the advantage of steel and process advantage of C1. It is basically a grey C1 in
which C varies between 3.2 to 4.1%, Si between 1.O to 2.8% while S and P are restricted
to 0.03 and 0.1%, respectively. Ni and Mg are added as alloying elements. Crankshafts,
nietal working rolls, punch and sheet metal dies and gears are made out of nodular CI.
The defects like growth and fire cracks are not found in this class of iron. This makes it
suitable forfurnace doors, sand casting and steam plants. It also possesses good
corrosion resistance making it useful in chemrcalplans, petroleum industry and marine
upplicutions.
White CI containing 2.0 to 3.0% C, 0.9 to 1.65% Si, < 0.1 8% S and P, some Mn and
< 0.01 % Bi and B can be heat treated for 50 hours to several days to produce temper
carbon in the matrix of ferrite or pearlite imparting malleability to CI. This class is
known as malleable cast iron and can have a high as 100 MPs of UTS and 14%
elongation. Duet to such properties as strength, ductility, machinability and wear
resistance and convenience of casting in various shapes, malleable CI is largely used for
automotive parts such a crank and can? shafts, steering brackets, shaft brackets, brake
curriers and also in electrical industry as switch gear parts,fittings for high and low
voltage transmissions and dis~ibutronsystem for railway electrification.
Addition of alloying elements such as Ni and Cr provide shock and impact resistance
along with corrosion and heat resistance to CI. These are called alloyed CI 3 to 5% Ni
and 1 to 3% Cr produces Ni-hard CI with hardness upto 650 BHN and modlfied
Ni-hard CI with impact and fatigue resistance is produced by adding 4-8% Ni and
4-15% Cr. Ni-resist CI with 14 to 36% Ni and 1 to 5% Cr is alloy CI having good
corrosion and heat resistance.

1.21 NON-FERROUS MATERIALS

A typical jet turbine is made up of several metallic materials. It consists of 38% Ti,
12% Cr. 37% Ni, 6% Co, 5% A l , 1% Nb and 0.02% Ta, and others. All of them are
non-ferrous and example only goes to show that in engineering practice, the non-ferrous
materials are finding increasing applications. They represent, in contain cases, the
advantages of high strength and low weight while in some other cases they surpass the
mechanical strength of ferrous materials. In certain cases metals like copper and
aluminum have not alternative from the wide range if steel and cast iron. Electric
conductor and aircraft bodies are the examples. The aluminium alloys are exclusively
used for cooking utensils, as building materials and for aircraft bodies. Copper alleys are
used as conductor in electric machine, as transmission cables and tubing in heat
exchangers. The non-ferrous'alloys also show creep resistance and resistance to
oxidation at high temperatures. However, steel may continue to dominate the seen for its
strength, heat treatability and cost. The cost ratios on per weight basis bekGeen other
materials and steel are: Ti a1Ihys-62, Cu alloys-8, Mg alloys-1 3, A1 alloys-80, low alloy
steel-2.4, stainless steel-5.5 1, gray castiron- 1.22.
A large variety of alloys of Al, Cu, Mg, Ni are used for making several parts of machine.
They offer varied advantages of lightweight, favourable weight to strength ratio,
machinability, castability and formability. A.1 alloys are used for their high electrical
conductivity, corrosion resistance, good strength, etc. in such applications as electrical
conductors, storage tanks, marine parts and air craft parts, etc. Cu and Ti alloys are Introduction to
hl echanical Design
similarly used in automotive radiators, heat exchanger, electrical machines, condenser,
builder's hardware. There are innumerable uses of non-ferrous materials which may
include man made plastic materials along with metallic alloys and readers are advised to
find uses and corresponding composition of a particular alloy form numerous sources.
We take up material requirement of a particular machine element, called bearing. We
will take up design of bearings in one of units as we move ahead in our studies but
description of materials for one type of two bearings, viz. - sliding contact bearing is
taken up in next section.

1.22 BEARING MATERIALS

Bearing is a very important part of machines and materials used for bearings assume
great importance. In general it can be said that a good bearing material should possess
following characteristics :
(a) It should be strong enough to sustain bearing load,
(b) It should not heat rapidly,
(c) It should show a small coefficient of friction,
(d) It should wear less, having long service life, and
(e) It should work in foundry.
Generally it is expected that the journal and bearing would be made of dissimilar
materials although there are examples where same materials for journals and bearings
have been used. When the two parts are made in the same material the friction and hence
the wear are high.
Cast iron has been used as bearing material with steel shafts in several situations.
I-Iowever, the various non-ferrous bearing alloys are now being used largely as bearing
materials because they satisfy the conditions outlined above more satisfactorily.
Bronzes, babbitts and copper-lead alloys are the important bearing materials that are
widely used in service. Certain copper zinc alloys, that is brasses, have been used as
bearing materials, but only to limited extent. Since brass in general is cheaper, it has
replaced bronze in several light duty bearings.
Table 1.3 describes some bearing bronzes.
Table 1.3 : Bearing Bronzes

Bronze and
SAE Number
/ omp position
Mechanical Properties
U TS
MPa
YS
MPa
olO

Elong.
Applications

Leaded gun Cu. 86-89; 200 80 10 Bushing

metal?63 Sn: 9-1 1; Pb, 1-2.5; P,
0.25 max, impurities,
0.5 max
- -

Phosphor Cu, 78.5-81.5; Heavy loads

bronze, 64 Sn, 9-11?Pb. 9-11; P,
0.05-0.25;
Zn, 0.75 rnax
imvurities. 0.25 max
B~.onze CU,83-86; 167 Bronze backed
backing for Sn, 4.5-6.0; bearings
lined I'b, 8-10; Zn, 2.0; imp,
bearings, 66 0.25 max.
Semi-plastic Cu, 76.5-79.5: Soft and good
bronze, 67 Sn, 5-7; Pb, 14.5-17.5; antifriction
Zn, 4.0 max; properties
Sb, 0.4 max; Fe, 0.4
Fundrn~cl~frls
of Bearing bronzes are the cooper-tin alloys with small additions of other constituents.
Engineering Design Under conditions of heavy load and severe service conditions, bronzes are especially of
great advantages. They possess a high resistance to impact loading and, therefore, are
particularly used in locomotives and rolling mills bearings. However, they get heated up
fast as compared to other bearing materials, such as babbits. Bronze lined bearings are
easily removed and finished bushings are generally available in stocks.
The alloys of tin, copper, lead and antimony are called babbitts. The tin provides the
hardness and compressive strength to babbitts, copper makes them tough, antimony
prevents shrinkage while lead contributes to ductility. Bearing liners are extensively
made in babbitts for their better antifriction properties than bronzes.
When babbitt is backed up by a solid metal of high compressive strength it gives good
service under high speeds, heavy pressure. impact loads and vibrations. The backing
material could be bronze or steel. A thin layer of high-tin babbitt thoroughly fused to a
tinned bronze or steel has exceptional load carrying capacity and impact strength. In
case of cast iron bearings the babbitt is anchored in place by dovetail slots or drilled
holes because babbitt does not h s e with cast iron. Babbitt bearing linings of dependable
strength and life are made by pouring molten material into bearing, allowing to solidify
and fuse thoroughly and then machining to finished sizes. While the melting point of
babbitt varies between 180 and 24S°C, depending upon compos;tion, the pouring should
be done when metal is in fully fluid state. For example, SAE I0 babbitt has a melting
point of 22j°C, it should not be poured below 440°C. Some Babbitt materials are
described in Table 1.4.
Table 1.4 : Babbitts (White-bearing Metals)
SAE No. Composition % Application
Sn, 90; Cu, 4-5, Sb, 4-5; Pb, 0.35 max. Thin liner on bronze backing
10.
Fe, 0.08 max; As, 0.1. Max; Bi, 0.08 rnax
Sn,86,Cu,5-6.5,Sb,6-7.5,Pb,0.35 Hard babbitt good for heavy
Max: Fe. 0.08 max As, 0.1 max; Bi. 0.08 rnax pressures
Sn, 59.5: Cu. 2.25-3.75; Sb. 9.5-1 1.5; Cheap babbitt, good for large
Pb, 26.0 max; Fe, 0.08 max, Bi, 0.08 max. bearings under moderate loads

I 13. 1 Sn. 4.5-5.5, Cu, 0.5 max; Sb, 9.25-10.75;

Pb. 86.0. max; As. 0.2 max
Cheap babbitt for large bearing
under light load.

Copper-lead alloys, containing a larger percentage of lead have found a considerable use
as bearing material lately. Straight copper-lead alloys of this type have only half the
strength of regular bearing bronzes. They are particularly advantageous over babbitt at
high temperature as they can retain their tensile strength at such temperatures. Most
babbitt have low melting point and lose practically at tensile strength at about 200°C.
Typical copper-lead alloys contain about 75% copper and 25% lead and melt at 980°C.
The room temperature tensile strength of copper-lead alloy is about 73 Mpa and reduces
to about 33 Mpa at about 200°C.
Other Bearing Materials
An extensively hard wood of great density, known as lignum vitae, has been used
for bearing applications. With water as lubricant and cooling medium its
antifriction properties and wear are comparable with those of bearing metals.
Lignum vitae has been used with satisfactory results particularly in cases of step
brings of vertical water turbine, paper mill machinery, marine service and even
roll neck bearing of rolling mills.
More recently, in such cases where use of water as lubricant is necessary,
especially if sand and grit are present soft vulcanized rubber bearings have been
used. A soft, tough, resilient rubber acts as a yielding support, permitting grit to
pass through the bearing without scoring the shaft or the rubber.
 Graphite. which is a form of carbon, has been used as lubricant in bronze bearing Introduction to
Mechanical Ilesign
but bearing made entirely of carbon are being used. At low speeds carbon bearings
can carry pressure as high as 6.8 MPa.
Synthetic and natural composite materials, plastic and reinforced plastic are being
used as bearing material. However. their characteristics are not well established as
yet. Powder metallurgy bushing permits oil to penetrate into the material because
of its porosity.

1.23 PLASTIC
Plastic have gained immense popularity as engineering materials. These organic
materials. also know as polymers lack strength of metals and can not stand temperature
higher than 150°C yet they offer the advantages of convenient manufacturing into several
shapes and sizes right from molten state. They can be machined but cannot be formed
from solid state as metals can be done. The plastics have good surface finish; they are
not corroded and are not biodegradable. Due to the last property the plastics are difficult
to dispose off. These materials do not conduct electricity hence are used for making
electrical fittings. They are also bad conductors of heat. hence are used as insulators in
and housing for instruments and equipment, which produce heat inside. The low density
, is a strong property of plastic. Heaviest plastic has specific gravity of 2.3 against 7.8 of
steel and 2.7 of aluminum. The plastic content of automobile has gradually increased
from 12 kgf in 1960 to 100 kgf in 1980 and to 150 kgf in nineties. The plastic replaces
several times its weight in metals and automobiles thus become lighter. The plastics
offer advantages like low cost, elimination of finishing processes, simplified assembly,
reduction of noise and vibration.
P6lymers are classified into three broad divisions, viz. plastics, fibres and elastomers.
Thermoplastic resins are usually revised to as plastics and have the property of
increasing plasticity, i.e. ability to deform plastically with increasing temperature. They
have long chain structure. Thermosetting resins on the other hand have three-
dimensional network of primary bonds. They do not soften on heating, they become
harder due to completion of any left over polymerization reaction on heating.
Thermoplastics in colnmon use are low density and high density polyethylene, rigid
chlorinated polyvinyl chloride (PVC), polyproylene. ABS, Acrylic and
polytetrafluoroethylene (PTFE). Most of them have maximum use temperature of about
100°C. Only PTFE can be used at higher temperature upto 250°C. This material is used
for bearing. Polyethylene is used in automobile interiors. ABS is acronym for a family of
ther~noplasticsmade of acrylonitrile, butadiene and styrene. ABS is used for making
body of business machine, telephone housing and pipe and fitting in drain waste.
Thermosetting plastics in large number are made and used in industry. They can resist
little higher temperature than thermoplastics have higher insulation against heat and
electricity and have better dimensional stability. Malamine is very popular in consumer
items -particularly dinner sets. Most of these plastics like phenolic, epoxy and
rl;'
malainin: are used as bonding agents in plywood and particle boards. Epoxy is also
favoured coating surfaces for prevention of corrosion, improving surfaces and as primer
on automobile body.
Elastomers are the materials, which deform from double the length to ten times original
length. Rubber is an elastomer, which is obtained in liquid form trees but converted into
solid by process of vulcanisation. The use of rubber as shock absorber or vibration
dampner is well known styrenebutadiene is an artificial rubber.

1.24 MANUFACTURING CONSIDERATIONS

he subject concerns with the designer's intimate understanding of methods of
manufacturing. Any designed object can be given required shape by different methods of
 of
F'und;~~~~entals manufacturing and therefore the designer will have to speciQ the methods wherever he
Engineering Design
prefers a particular method. The selected material will have to be given a renewed
consideration for manufacturing. For example, from stress consideration a gear wheel
made in stainless less steel may be better and smaller but its machining and teeth cutting
will cost more as compared to medium carbon steel. The change of tools during
machining operation may cost. Even in modern computer numerically controlled
machines bringing required tool in position will not be cost free besides adding cost at
programming stage. It is therefore, to be considered by the designer if the radit of fillets
and shoulders may be kept same or they must be different. If the keyways can be cut in
one setting in more than one location the cost may be reduced for shaft manufacturing.
The pulleys can be cast or fabricated. The process needs to be examined on the basis of
weight and cost. Sometimes in increased cost may be tolerated if weight is reduced.
Similarly a welded structure from mild steel for the housing of a gear reducer may have
to be compared with the cast structure either in cast iron or steel.
Casting in sand mould or permanent may be a question before designer in many cases.
Although a permanent mould may appear to be a better choice for large number yet the
use of pressure and conditions of melting from batch to batch and high initial cost may
be prohibitive. Casting in general may pose several problems concerning rate of cooling,
change of thickness, intricate nature of product and any subsequent machining need to be
considered. The designer must consider that in casting metal at every location (i.e. a flat
wall and a corner) do not cool at the same rate. If material in adjacent location cools
differentially residual stressed are produced. They may even cause cracking. Such
consideration may require baSing thicknesses and radii not only on strength but also
upon rate of cooling. 'The residual stress may not only cause reduction of strength but
may result into undesirable deformation during subsequent machining. Large thicknesses
or diameter in casting solidify over a much longer period and hence are prone to have
coarse structure and lesser strength. The designer may have to assign a proper heat
treatment to refine internal grain structure.
The designer ought to take note of the fact that in forging the deformation is
concentrated more on the surface and inner material is not worked. In hot forging
process therefore the structure of material is more liable to be refined on the surface
creating non-uniformity of smucture in the entire body. The refinement is often
advantageous with improved strength, though defects are also some times created in
severely worked mater. On the other hand process like rolling, extruding and pressing
are not confined to only surface in their effects. They result in uniform structure in the
end. Cold processes are performed on softer alloys but stronger materials like steel are
often worked hot. Cooling will eventually follow which if not controlled and slow can
result in residual stresses. Anticipating the cooling stresses the designer may recommend
the rate of cooling.
Plastic parts are often cast in poulds made individually or in pressure die case. The
design must keep minimum thickness within limit, not below 4.5 mm. The pressure die
case plastic may not require finishing by machining but cast parts need machining and
hence proper thicknesses are to be provided. Very few parts of plastic are made by
machining but designer must take care of temperature rise during cutting process. Slight
rise in temperature may cause material to join by the side of machine surface. Internal
threading has to be performed much more carefully. They can be better made during
casting 13 threat per cm can be cast easily. The colour of casting is difftcult to maintain
which created problem in assembling parts. To avoid mismatch the surfaces may be
spotted as streaked.
SAQ 3
(a) Classify steel and state application of stainless steel.
(b) Why is mediumcarbon steel preferred for making machine parts?
(c) What heat treatments are given to medium carbon steel? What are the
benefits from swh treatments?
 Differentiate between steel and CI. Contrast properties of plain C steel and I~~rruduct~ tu~ ) n
&lcchanical Design
CI and state use of CI.
How could you make CI ductile?
Classify CI and mention uses of each type.
Mention non-ferrous materials, which are used in machines and structures.
What are bearing materials?
Mention compositions of phospher bronze, semi-plastic bronze and a babbit
metal, which used on bronze backing.
Describe non-metallic materials that are used as bearing materials.
Distinguish between two classes of plastic. Mention advantages of plastics
as engineering material and describe at least five uses.
What manufacturing consideration a designer has to make? Give examples
of cutting, casting and forging processes in respect of metals. Which of
these processes will be applicable to parts made in plastics?

1.25 SUMMARY -

Design is a decision making process in which a designer formulates the problem in clear
terms, finals several alternatives. selects the best solution, analyzes the best solution,
selccts material and determines dimensions. The process allows for modification to
achieve improvement at each step. The results are presented in form of a report which
will necessarily contain drawings. instructions for heat treatment, special processes, etc.
The designer of machine is required to have comprehensive knowledge of mechanical
engineering so that he understands clearly the various forces that act upon several parts
of machines and circumstances in which the machine and its parts have to perform. The
designer must be conversant with methods of analyzing stress through theoretical,
experimental and numerical methods. He may depend upon one or two of them so that he
can analyze a part con~pletely.The designer should be sensitive to human needs,
capabilities and sensibilities so that his design fulfills the objective, can be operated and
maintained by common person and pleases him to possess.
The engineering materials are used to make machine parts and there exist several of
them. They are all used to serve specific purpose based upon properties. The properties
that designer of machine will use will be related to strength and material behaviour under
load. The properties normally needed by machine part are yield strength. ultimate tensile
strength, percent elongation, toughness and residence. They are determined from tension
test on universal testing machine. 'The hardness and impact strength, though not used
indirect calculation are used for selecting materials for specific purposes. Fatigue and
creep are behaviours and conditions of varying load and constant load acting over a long
period respectively. While latter is a condition to be considered only in case of higher
temperatures, fatigue is the type of loading to which all machines, machine parts and
structure are subjected. Fatigue strength, which is defined as the stress at which material
will never fail, no matter how many times that stress varies, then appears to be the only
important property on the basis of which machine parts must be designed. However,
while on one hand its determination is difficult, on the other hand it has a definite
relationship with ultimate tensile strength (UTS). Hence UTS can be used as design
basis after fully understanding several factors that intluence fatigue strength.
b undarnentals of Out of several metallic lnaterials steel is the most common choice because such reasons
Engineering Design as easy availability, good strength, workability, ductility and heat treatability. Cast iron
is another good ferrous material preferred to.produce casting for its availability.
hardness, compressive strength and damping properties. Plain carbon steel, containing
Mn, Si, S and P in addition to carbon with large proportion iron is divided into three
types. viz. low carbon (0.08 to 0.27% C), medium carbon (0.28-0.57% C) and high
carbon (0.58 to 1.2% C) steels. Additionally Cr, Mo, Ni, V, Co, Al. Cu. etc. may be
added to obtain series of alloy steels which have better mechanical properties with
increased cost. Three types of stainless steels (ferritic. austenitic mortensitic) are in
common use for their corrosion and oxidation resistances. Each alloying element imparts
particular characteristic to steel. Steel of all types are heat treatable except low carbon
steel. They, however, can be case hardened like medium carbon and some alloy steels.
Plastic are being used for making parts of machines because they are light in weight.
However, they cannot compete with metals in strength. Non-ferrous metals which are
mainly alloys of aluminum, copper, zinc, magnesium, nickel, etc. are used for specific
reasons of weight and properties. They are invariably used in sliding bearings.
The design has to consider the available manufacturing processes and effects of such
processes on final product.

1.26 KEY WORDS

Mechanical Properties : Mechanical properties of the metals are those
which are associated with the ability of the
material to resist mechanical .forces and load.
Strength : It is the ability of a material to resist the externally
applied forces without breaking or yielding.
Stiffness : It is the ability of a material to resist deformation
under stress.
Elasticity : It is the property of a material to regain its original
shape after deformation when external forces are
removed.

1.27 ANSWERS TO SAOs

Refer the preceding text for all the Answers to SAQs.