UNIT-I

CHAPTER-1
Introduction
Meaning of design with special reference to machine
design- Definition and understanding of several types
of designs. Concept of design

Veeresh R. K., Associate Professor

Robotics and AI Enginnering.
NMAM Institute of Technology
Nitte, Karkala, India
27-07-2023 1
 Machine:
Definition: A machine may be defined as combination of moving and stationary parts constructed
for the useful purpose for generating, transforming or utilizing mechanical energy.

A machine is a device that converts mechanical energy into useful work. It is necessary to have a
good knowledge of many subjects such as Mathematics, Engineering mechanics, Strength of
materials, Theory of machines, Workshop process and Engineering drawing.

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Classification of machine design:

A machine design may be classified as follows

1. Adoptive design: This type of design needs no special knowledge or skills and can be attempted by designers of ordinary
technical training. The designer only makes minor alteration or modification of existing designs of the product.

2. Development design: This type of design needs considerable scientific training and design ability in order to modify the
existing designs into a new idea by adopting a new material or different method of manufacture.

In this case though the designer starts from the existing design but the final product may differ quite markedly from the original
product.

3. New design: This type of design needs lot of research, technical ability and creative thinking. Only those designers who
personal qualities of a sufficiently high order can take up the work of new design.
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 Depending upon the method this can be classified as
1. Rational design: depends upon the mathematical formula of principle of mechanics.
2. Empirical design: this type design depends upon empirical formulae based on the practice and post
experience.
3. Industrial design: depends upon the production aspects to manufacture any machine component in the
industry.
4. Optimum design: It is best design for the given objective function under the specified constraints. It
may be achieved by minimizing the undesired effects.
5. Element design: It is the design of any element of mechanical system like a piston, crankshaft,
connecting rod etc.
6. Computer Aided design: this type of design is depends upon the use of computer system to assist in
the creation, modification, analysis and optimization of design.
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General procedures in machine designing
General procedures in machine designing - Explained in detail
In designing a machine element/components there is a rigid rule. The problem may attempt in many
ways.

However the general procedure to solve a design problem is as follows

Recognition of Need:
First, we need to make a complete statement of the problem, indicating the need, aim or purpose for
which the machine is to be designed.

Synthesis (Mechanism):
Select the possible mechanism or group of mechanism, which will give the desired motion.

Analysis of forces:
Find the forces acting on each member of the machine and the energy transmitted by each member.

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General procedures in machine designing
Material selection:
Select the material best suited for each member of the machine. Following factors are
to be considered while selecting the material.
1. Availability of the material.
2. Suitability of the materials for working conditions in service.
3. Cost of the material.

Design of elements (size and stress):

Find the size of each member of the machine considering the forces acting on the
member and the permissible stress for the material used. It should be kept in mind
that each member should not differ or deform from the permissible limit.
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General procedures in machine designing
Modification:
Modify the size of the member to agree with the past experience and judgment
to facilitate manufacture. The modification may also be necessary by
consideration of manufacturing to reduce overall cost.

Detailed drawing:
Draw the detailed drawing of each component of the assembly of the machine
with complete specification for the manufacturing process

Production:
The final product / the component as per the drawing is manufactured in the
workshop.
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General design considerations
1. Types of load and stress caused by the load

Load: load is defined by external force acting upon a machine part.

Load on a machine component may act in several ways due to which the internal stresses are set up.

The various types of load are

a) Static load: It is stationary force acting on a machine member, It is applied gradually to a member and do not vary in
magnitude, point of application and the direction after the load has been applied.
b) Dynamic load: A dynamic load is one which is not static either initially on application or during the time it acts on a member.
Dynamic load on a machine part vary in magnitude, direction or both magnitude and direction.
c) Impact load: It is one which is applied suddenly to a member at high velocity.
d) Altering or cyclic load: A load is said to be altering one when the maximum and minimum loads are opposite side but
magnitude may or may not be same.
e) Repeated load: Load is said to be repeated one when the maximum load is zero or constant.
f) Steady or dead load: when the load on a machine element is constant during its life time is called steady or dead load.
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2. Motion of the parts or kinematics of the machine

The motion of parts may be

a. Rectilinear: motion which includes unidirectional and reciprocating motions.

b. Curvilinear motion: which includes rotary oscillatory and simple harmonic.
c. Constant velocity:
d. Constant or Variable acceleration
3. Selection of materials: It is essential that a designer should have thorough knowledge of the properties of the material and
their behavior under working condition.
4. Form and size of the parts: form and size are based on judgment, the smallest practicable cross-section may used but it
may be checked that the stress included in the designed c/s area reasonably safe.
5. Fractional resistance and lubrication: There is always a loss of power due to frictional resistance and it should be noted
that the friction of starting is higher than that of running friction. It is therefore essential that a care full attention must be given to
the matter of lubrication of all the surfaces which moves in contact with others whether in rotating, rolling, slicing or bearing.

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6. Convenient and economical features: In designing the operating features of the machine should be
carefully studied. The starting, controlling and stopping levels should be located on the basis of convenient
handling.
7. Use of standard parts: The standard or stock parts should be used whenever possible. The use of
standard Parts is closely related to cost.
8. Safety of operation: Designer should always provide safety devices for the safety of the operator.
9. Workshop facilities: A design engineer should be familiar with the limitation of his employee’s
workshop, in order to avoid the necessary of having work done in some other workshop.
10. Assembling: Every machine or structure must be assembled as a unit before it can function. The final
location of any machine is important and the design engineer must anticipate the exact location.

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Codes and Standards:

A Standard is a set of specification of parts, materials to achieve uniformity,

efficiency and specified quality. One of the important purposes of the standard is to
place a limit on the number of items in a particular specification and to reduce
inventory.

A Code is a set of specifications for the analysis, design, manufacture and construction of parts.
The purpose of code is to achieve a specific degree of safety, efficiency, performance and quality.

There are several organizations who have established the specifications of standards and safety or
design codes. Some of the Codes and Standards are given below:

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SAE: Society of Automotive Engineering

ISO: International Standards Organization

JIS: Japan Industrial Standards

BIS: Bureau of Indian Standards

ASME: American Society of Mechanical Engineers

ASM: American Society for Metals

ASTM: American Society of Testing Metals

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 1. A hypothetical cantilever beam 350 mm long is subjected to a point load of 6 kN.
Factor of safety 3. Find the dimensions of the most economical cross section. σy=350
N/mm2 Assume circular, rectangular (Assume h=2b) and I section (Assume H=6t, h=3t,
B-b=t, b=2t).
y
350
 max = = 116.67 MPa
Factor of safety n= 3
 max
M FXl 6000 X 350
i) Assume circular cross section b = =
Z  d3
b = = 116.67 d=56.8mm
32  d3 A=2827mm2
32

M FXl FXl
ii) Assume rectangular cross section b = = 2 Assume h=2b b =
Z bh b(2b) 2
6 6
6000 X 350
116.67 = b=29.9mm=30mm
4b3
6 h=2X30=60mm
27-07-2023 A=1800mm2 13
iii) Assume I Section
Assume H=6t, h=3t, B-b=t, b=2t DDHB Table 10.1/136

BH 3 − bh3
I= 3tX (3t )3 − 2t (3 t)3 H 6t
12 I= = 49.5t 4 C = = = 3t
12 2 2
I 49.5t 4
Z= = = 16.5t 3
C 12

M 6000 X 350
b = = 4
= 116.67
Z 16.5t

t=10.29=11mm

Hence H=6X11=66, h=3 X11=33,, B-b=t, b=2X11=22

A=(55X11)+(33X11)+(55X11)=1573 mm4

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2. Determine the maximum normal stress and maximum shear stress at section A-A for
cranck shown in Fig.Q1 (c). When load of 10KN is assumed to be concentrated at the center
of crank pin

(i) Bending stress due to the bending moment

Due to applied load the section A-A is subjected to
(ii) Shear stress due to twisting moment
M Bending Moment at Mb 9 X 105
b = b = = 21.73 N
Z section A-A is M b = FXl M b = (10 X 10 )(25 + 25 + 40) = 9 X 10 N − mm
3 5
 d 
3 3
75 mm2
32 32
dT T
T = =
= r
Twisting Moment at  d4 2  d3
J
section A-A is T = FXR T = (10 X 103 ) X 125 = 125 X 104 N − mm 32 16
125 X 104
= = 15.09 N
27-07-2023  3
75 mm 2 15
16
   
2
Maximum Normal Stress  max = +   + 2 DDHB 1.5 (a)/3
2 2

2
21.73  21.73 
 max = +   + 15.09 2
= 29.46 N 2
2  2  mm

 
2
Maximum Shear Stress
 max =   + 2
DDHB 1.5 (b)/3

2

2
 21.73 
 max =   + 15.09 2
= 18.60 N 2
 2  mm

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3. Determine the cross sectional dimensions of the wall bracket shown in Fig Q
(3), if the maximum stress in the material of the bracket is limited to 120MPa.
Take depth of the section equal to three times width

Horizontal Component of the load FH = F cos  = 10 X 103 X cos30 FH = 8660.25 N

Vertical Component of the load FV = F sin  = 10 X 103 X sin 30 Fv = 5000 N
Bending Moment Due to Horizontal load M bH = FH Xl M bH = 8660.25 X 600 = 5196150 N − mm

Bending Moment Due to Vertical load M bV = FV Xl M bv = 5000 X 1200 = 6 X 106 N − mm

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27-07-2023 18
Total stress on the cross section  = b +d
 = ( bH +  bV ) +  d
A bracket shown in figure is
 M bH M bV  FH made of 30C8 steel with σy=350
 = + + N/mm2subjected to a load 5.5kN.
 Z Z  A Using h=3t find the dimensions of
h and t. where‘t’ is thickness of
 
 M bH M bV  + FH bracket.
= + 2
 bh 2 bh  bh
 6 6 
(Given h=3b)

 
 5196150 6 X 10  8660.25
6
 = 2
+ 2  + bX 3b
 b (3b ) b (3b )  By trial error method
 6 6 
b=40mm
7464100 2886.75
120 = 3
+ h=3X40=120mm
b b2
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4. Determine the maximum principal stress and maximum shear stress at section A-A of the
member shown in figure Q12. Neglect transverse shear

Bending Moment due to horizontal load M bH = 1000 X 250 = 250 X 103 N − mm

Bending moment due vertical load M bV = 2500 X 200 = 500 X 103 N − mm

M bH 250 X 103 250 X 103
Bending Stress due to horizontal load  bH = = =
Z  d 3  503
32 32
 bH = 20.37 MPa
M bV 500 X 103 500 X 103
Bending Stress due vertical load  bV = = =
Z  d 3  503
32 32
 bV = 40.74 MPa

Resultant Bending Stress  b =  bH

2
+  bV
2
= 20.37 2 + 40.742

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 FV FV 2500
Direct Stress d = = d = = 1.273MPa
A  d2  50 2
4 4

At section A-A maximum Principal stress

 =  b +  d = 45.55 + 1.273 = 46.82 MPa (Compressive Stress)

Torque due to horizontal load T = 1000 X 200 = 200 X 103 N − mm

T 200 X 103 50
Maximum Shear Stress  = r= X = 8.1487 MPa
J  50 4
2
32

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5. A steel link subjected to a tensile load has a cross section 15mmX15mm. It is required to
replace this link by an offset link as shown in figure Q13. Determine the dimension ‘b’ of the
link, so that the offset link will have the same strength as original link
P P
Direct Link d = =
15 X 15 225
P M
Offset link  = d +b = +
50 Xb Z

P PX (20 + 25) P 0.108 P

= + 2
= +
50 Xb bX 50 50b b
6 Strength of the both link is equal
P P 0.108P
= +
225 50b b

27-07-2023 b=28.8mm 22
Steel Link

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6. A 50mm diameter steel rod supports a 9kN load and in addition is subjected to a torsional
moment of 100N-m as shown in Figure Q6. Determine the maximum tensile and the
maximum shear stress
The critical stress at point A
Normal Stress  =  d +  b
F M 9000 9000 X 28
= + = +
A Z  50 2  503
4 32
 = 25.118MPa
T 100 X 103 50
Maximum Shear Stress
Shear stress due torque  = r= X = 4.074 MPa
J  4
2
 
50 2
32
 max =   +  2
2
  
2

Maximum Normal Stress  max = +   + 2

2 2 2
 25.118 
 max =   + 4.074 = 13.20MPa
2

25.118
2
 25.118   2 
 max = +   + 4.074 2
= 25.76MPa
 2 
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2
7. A Z-Bracket is supported and loaded as shown in Fig Q 1 (b). Determine the maximum
shear stress at section A-A and at Section B-B
Consider the Section A-A Consider the Section B-B
Normal Stress  =  d +  b M 45000 X 225
 = = b =
Z 125 X 502
F M −45000 45000 X (150 + 25) 6
= + = −
A Z 50 X 125 125 X 502
6
 = 194.4MPa
 = −158.4MPa Maximum Shear stress

(Tension at C and Compression at D)

 
2 2
 194.4 
 max =   + = 
2
 +0
2  2 
   −158.4 
2 2

 max =   +  2 =   +0
2  2 
 max = 97.2MPa
 max = 79.2MPa
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27-07-2023 26
8. A circular rod of diameter 50mm is subjected to load as shown in Fig
Q. Determine the nature and Magnitude of stress at critical Points
(Tensile
F Fa 15 X 103
Direct stress due to axial load d = a = d = = 7.64MPa at A
A  d2  502 and B)
4 4
A
3
M b 3 X 10 X 250 15kN
Bending stress due to bending load b = =  b = 61.115MPa
Z  503
32 B

(Tensile at A and Compressive at B)

T 1X 106 50
Shear stress due torsion load  = r= X = 40.75MPa
J  504 2
32

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(i) Consider the point at A (Tensile at (ii) Consider the point at B (Tensile at B due to
direct load and
Normal Stress at A  = d +b
A due to Normal Stress at B  = d −b Compression at B due
direct load
and Tensile  = 7.64 − 61.115 = −53.47MPa to bending load)
 = 7.64 + 61.115 = 68.75MPa at A due to Shear Stress  = 40.75MPa
bending
 = 40.75MPa   
2
Shear Stress load) Maximum Normal Stress  max = +   + 2
2 2
  
2
Maximum Normal Stress
 max = +   + 2
−53.47  −53.47 
2
2 2  max = +  + 2
= 21.99 MPa
 40.75
2 2  2 
68.75  68.75 
 max = +   + 40.75 2
= 87.68MPa
 2    
2
2
Minimum Normal Stress  min = −   + 2
Minimum Normal Stress  =  −    +  2
2

min  
2 2
2 2
−53.47  −53.47 
2

68.75  68.75 
2  min = −   + 40.75 = −75.47 MPa
2

 min = −   + 40.75 = −18.93MPa

2 2  2 
2  2 
 
2

   max =   +  2
2
Maximum Shear Stress
Maximum Shear Stress  max =   + 2
2 2
2
 68.75   −53.47 
2

 max27-07-2023
=   + 40.75 2
= 53.31MPa  max =   + 40.75 = 48.73MPa28
2

 2   2 
9. A steel member is loaded as shown in Fig. Q14. Determine the magnitude
of (i) Maximum normal stress (ii) Minimum normal stress (iii) Maximum
shear stress.

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 Review Questions
1. What are the basic steps in the machine design process?
Or
2. Discuss the design process
Or
3. Explain the basic procedure of machine design

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 THANK YOU
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