Under Graduate Course

on

Machine Design
Design of Machine
Elements
Dr. S. S. Roy
Professor
Robotics & A.I Lab. (RAIL)
Department of Mechanical Engineering

Reference Books
1. V.B. Bhandari, “Design of Machine Elements ”, <Third edition>, Tata McGraw Hill.
2. J.E. Shigley, C.R. Mischke, “Mechanical Engineering Design”, Tata McGraw Hill.
3. M.F. Spotts & T.E. Shoup, “Design of Machine Elements”, Pearson Education.

Machine Design Handbook

1. “Design Data”, Compiled by Faculty of Mechanical Engineering, PSG College, Coimbatore
2. “CMTI Hand Book”, Compiled by Scientists of Central Manufacturing technology Institute, Bangalore

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 Design of Machine Element
Gear
Pressure vessel Clutch
Drive

IC engine
C-frame
parts

Brake
Coupling

Spring Bearing

Belt, Rope, chain Connecting rod

Drive

Cam Power Screw

Key Shaft & Axle

Crane hook Riveted

Welded Joint Bolted Joint
Joint

Introduction

 Design is the process of problem solving

 Design is a decision making process

 Design is an iterative process

 Design is an innovative or creative process

Machine Design

In Mechanical Engineering
Objective of a Designer is to design & develop a product (devices, machinery, mechanical system) or process
that is functional, safe, reliable, usable, manufacturable, competitive & marketable by using different
engineering tools [ like Mathematics, CAD-CAE etc.]

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 Mechanical Design
Energy Stem
Mechanical Engineering Systems
Structures & Motion Stem

Energy Stem in Mechanical Engineering  Design of heat exchangers

 Design of IC engines
 Design of boilers
 Design of air compressors, gas turbine etc…
They rely on the use of technical materials from thermodynamics, heat transfer, combustion etc.

Structures & Motion Stem in mechanical Engineering

 Design of gear box
 Design of belt drive, chain drive system
 Design of suspension systems
 Design of machine structure etc…
They draw on technical materials from solid mechanics, kinematics, dynamics etc.

Mechanical design applies to design in mechanical engineering systems where both stems can be involved
Machine Design is a sub-set of mechanical design where the focus is on Structures & Motion stem only

Mechanical Engineering Design/ Machine Design

the use of scientific principles, technical information, skill & imagination in the description of
configuration of a mechanical system/ machine to perform specific functions with maximum
economy & efficiency

Designer  uses principles of basic engineering sciences

 has technical information of basic elements of machine like fasteners,

gear, belt drive, bearing etc.
- Relative advantages & disadvantages of basic elements & their suitability
in different applications.

 uses skill & imagination to produce a configuration, which is a

combination of basic elements.
- Intellectual part of constructing a proper configuration is creative in nature

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 Machine Design transfers
Kinematic Link
Mechanism Motion

transforms
Kinematic Pair
Primary Objectives
Kinematic Chain Mechanism transfers
One link fixed

Machine Energy
Machine Tool Machine transforms

All Machines are Mechanism but all Mechanisms are not Machine

All Machine Tools are Machine but all Machines are not Machine Tool

Mechanism - assemblage of resistant bodies, connected by joints, to form a kinematic

chain with one link fixed & having the purpose of transmitting &
transforming motion.

Machine - Combination of resisting bodies having definite motions & capable of

performing useful work.
- Combination of resistant bodies with successfully constrained relative
motions which is used to transform, transmit & modify available energy to
do some useful work
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Machine Design
Design
Design Analysis Design Synthesis
 decision –making process
Inputs
Mechanism
Outputs
is given  process of creating new
configuration/ mechanism
determines the
Given Configuration, material & dimension  Selecting optimum/best
assume mode of failure configuration from no. of existing
mechanism
 Selecting materials from no. of
alternative materials
 Determination of optimum shape
& dimensions of the component
on the basis of design analysis

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 Type of Design

Adaptive Design Developmental Design New Design

- This is based on
- This is an entirely new
existing design. - Starts with an existing one but based on
design, but the final existing scientific
- Existing standard product may differ principles.
product or systems quite markedly from
with/ without minor the original product. - Needs lot of research,
modification, are
technical ability &
adapted for a new - A new model of a car creative thinking.
application.

Type of Design
based on Methods

Rational Design Empirical Design Industrial Design

- This depends upon - This is based on - These are based on

mathematical formulae empirical formulae industrial
of mechanics. which in turn is based considerations and
on experience and norms viz. market
- This is based on experiments. survey, external look,
determining the production facilities,
stresses and strains of low cost, use of
components and existing standard
thereby deciding their products.
dimensions.

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 Manufacturer Customer

Identification of Need
General Procedure
in Machine Design Collecting relevant design
information & feasibility study

Problem definition, Design specification

Design Conceptualization/ Design

Preliminary design i.e. Synthesis
Mechanism synthesis

Modeling & Simulation

Engineering Analysis
CAD/CAE Design
Analysis
Design Optimization

Design Evaluation

Detail Design of
Components

Design Communication & Documentation

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Basic Procedure of Design of

Machine Element
Specify functions of element

Determine loads acting on element

Select suitable material for element

Determine failure mode (s) of element

Determine geometric dimensions of element

based on above failure mode

Check & modify dimensions for assembly & manufacture

Check design at critical cross-sections

Prepare detail engineering drawing of element

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 Basic Requirements of Machine Elements
Broad objective of designing a machine element is to ensure that it preserves its operating capacity
during the stipulated service life with minimum manufacturing & operating costs.

In order to achieve these objectives, the machine element should satisfy following basic requirements.

Strength - should have sufficient strength to avoid failure (fracture/ general yielding) due to force.

Rigidity - should not deflect or bend beyond permissible limit due to forces/moments.

Wear Resistance - Machine components like gear, cam should have sufficient wear resistance.
Wear leads to the loss of accuracy, puts the part out of order.

Minimum Dimensions & - Machine part should be sufficiently strong, rigid & wear resistant & at the
Weight same time, with minimum possible dimensions & weight.

Manufacturability - ease of fabrication & assembly.

- shape & material of the m/c part should be selected in such a way that it can
be produced with minimum manufacturing cost
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Basic Requirements of Machine Elements

Safety - shapes & dimensions of the machine parts should ensure safety to the user/operator.

Reliability - is probability that a machine part will perform its intended functions under desired
operating conditions over a specified period of time.
- machine part should be reliable i.e. it should perform its function satisfactorily over its
lifetime.

Maintainability - ease with which a machine part can be serviced or repaired.

- machine part should be maintainable

Conformance to - machine part should confirm to the National or International standard.

Standards

Minimum Life Cycle cost - Total cost to be paid by the purchaser for purchasing the part and
operating & maintaining it over its life span.

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 “Standards” in Machine Design
Standardization Standardization is defined as obligatory norms, to which various characteristics of a product
should conform.
The characteristics include materials, dimensions and shape of the component, method of testing and
method of marking, packing and storing of the product.

Standard
Standard is defined as a set of specifications for parts, materials or processes

Purpose of Standard to reduce the variety & limit the no. of items to a reasonable level

Code
Code is defined as a set of specifications for the analysis, design, manufacture, testing and
erection of the product

Purpose of Code to achieve a specified level of safety

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“Standards” in Machine Design

Advantages of Standardization
 The reduction in types & dimensions of identical components, to a rational number, makes it
possible to manufacture the standard component on mass scale in a centralized process.

 Standard parts are easy to replace when worn out due to interchangeability.
 The application of standard machine elements & especially the standard units reduce the time &
effort needed to design a new machine.
Standardization results in substantial saving in Designer’s effort
 The standards of specifications & testing procedures of machine elements improve their quality &
reliability.
In designing, the aim is to use as many standard components as possible for a given machine

Company Standards
I.S / B.I.S India
B.S UK
Types of Standards National Standards
A.I.S.I / S.A.E USA
D.I.N German

International Standards
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 “Standards” in Machine Design
Indian Standards in Mechanical Engineering Design

SP 46 Bureau of Indian Standards on “Engineering Drawing Practice for Schools & Colleges
I.S. 210 Seven grades of grey cast iron
I.S. 1570 Chemical composition of various grades of alloy steel
I.S. 733 : 1983 Mechanical Properties of wrought Al. & Al alloy Bars, Rods for general purposes
I.S. 736 : 1986 Mechanical Properties of wrought Al. & Al alloy Plates for general purposes
I.S. 919 Recommendations for Limits & Fits for Engineering
I.S. 2709 Guide for selection of fits
I.S. 8000 Geometrical tolerancing on technical drawings
I.S. 4218 : 1996 Designation & Dimension of screw threads, bolts & nuts

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Aesthetic Considerations in Machine Design

When there are a number of products in the market, having the same qualities of efficiency, durability and cost, the
customer will naturally attracted towards the most appealing product.

The external appearance is an important feature, which not only gives grace and luster to the product but also
dominates the sale in market.

Automobiles Household Appliances Audio Visual Equipments

The job of an Industrial Designer is to create new forms & shapes, which are aesthetically
Industrial Design pleasing.

The external appearance of the products is a cumulative effects of number of factors :

Form Step Colour Surface finish & Tolerances Materials Manufacturing Methods
Stream
Taper
Shear
Sculpture

Relationship between Functional requirement & Appearance of the Product

 In many cases, functional requirements result in shapes, which are aesthetically pleasing. The evolution of the
streamlined shape of the boeing is the result of studies in aerodynamics for effortless speed.
 Chromium plating on the household appliances is for corrosion resistance rather than for pleasing appearance
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 Ergonomic Considerations in Machine Design

Ergonomics is defined as the relationship between Man & Machine and the application of anatomical, physiological
and psychological principles to solve the problems arising from Man-Machine relationship.

Topics of Ergonomic studies in Machine Design

 Anatomical factors in design of driver’s seat.

 Layout of instrument dials & display panels for accurate perception by the operators

 Design of hand levers & hand wheels.

Ergonomists have carried out experiments to determine the best dimensions of driver’s seat, the most convenient
hand or foot pressure or dimensions of levers and hand wheels.

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Manufacturing Considerations in Machine Design

Design Considerations of Castings

General Principles :

 Round all external corners

 All sections in a casting should be designed of uniform thickness, as far as possible. If
variation is unavoidable, it should be done gradually
 Avoid very thin section : Minimum thickness for CI component in sand casting is about 6 mm.
 The cast components should be designed in such a way that it will require a simpler pattern &
its moulding is easier.
 In designing a casting, the various allowances must be provided in making a pattern.
 The casting should be designed as simple as possible, but with a good appearance.

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 Design Considerations of Machined
Components
 Machining is basically secondary & finishing manufacturing process.
Dimensional Accuracy Dimensional Tolerance
Geometric / Form Accuracy Geometric Tolerance
Surface finish Surface roughness

General Principles :

 Avoid sharp corners

 Avoid too many shoulders & undercuts
 Avoid hard materials.

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Sequential Engineering Approach Vs. Concurrent Engineering Approach

Sequential Design Process Prototype Development Stage

Customer

Marketing Department

Design Office

Production Department

Sales & Service

Department

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 Sequential Engineering Approach Vs. Concurrent Engineering Approach

Concurrent Engineering Concurrent Engineering is defined as the design

process/approach that brings together a wide spectrum of
expert/specialist from several functional areas (like R & D,
Engineering, Manufacturing, Quality control, Marketing,
sales & service etc.) during the early phases of the design
process in new product development.

The team reviews the design from different aspects

 design for Manufacturing & Assembly (DFx)
 quality assurance & standardization
 aesthetics & ergonomics
 maintenance
 reliability & safety
 process, facility, capacity planning
 tool design
 functional / performance testing
 cost
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Sequential Engineering Approach Vs. Concurrent Engineering Approach

Concurrent Engineering Any possible bottleneck/mistake is thoroughly studied &
rectified. This results in small nos. of modification in the design
at a later stage & reduce time interval from conceptual stage
to marketing stage.

Customer’s
Simultaneous Engineering requirement

Cross Functional Team Approach

Manufacturability
Parallel Engineering Assembly &
Cost, Testability
Sales &
servicing
Design Engineering
: Concurrent Engineering
Approach

Reliability,
Maintainability &
Ergonomics
safety
&
Appearance
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Motivation
Most Economic Successful entry of a product into the market
can best occur if it can complete the above
Requirements Most Productive cycle in the shortest possible time & at the
lowest cost while maintaining very high
product quality & reliability
Improved Quality

CAD Computer Aided Design

CAE Computer Aided Engineering
CAM Computer Aided Manufacturing
VP & VR Virtual Prototyping & Virtual Reality
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 Scope of CAD-CAM-CAE
Design & Analysis
Theories
(FEM, CFD)

Automation
Geometric (Robot, FMS, CAPP)
Modeling

CAD-CAM-CAE

Manufacturing
Computer
Process
Graphics (RP&T, CNC)

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CAD-CAM-CAE Software
CAD/CAM/CAE software Purpose
CATIA ( CATIA PLM Express )
NX ( Siemens PLM ) 3-D modeling, Analysis & Simulation etc.

PRO-ENGINEER
SOLID WORKS
SOLID EDGE
INVENTOR
Mechanical DESKTOP
MasterCAM
SolidCAM 3-D modeling & Manufacturing Simulation

SmartCAM

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 CAD-CAE Software
CAE software Purpose
ADAMS Multi-body dynamic analysis & simulation

SimDESIGNER Motion with CATIA Multi-body dynamic analysis & simulation

Working Model Multi-body dynamic analysis & simulation

ANSYS Finite Element Analysis

NASTRAN Finite Element Analysis

ABAQUS Finite Element Analysis

LS-DYNA Finite Element Analysis, Crash simulation

DEFORM Finite Element Analysis, Crash simulation

PAMCRASH Finite Element Analysis, Crash simulation

FLUENT Computational Fluid Dynamics

Altair Hyper Mesh Meshing for Finite Element Analysis

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Computational Tools
Software Purpose
MATLAB Design calculation, dynamic analysis & simulation, design
optimization, control
Mathematica
Design calculation
MathCAD
Maple
TK Solver
Excel

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 Assignment # 1
1. Explain with example, the different steps involved in machine design process & in design of machine elements?
What are the basic requirements of machine elements?
2. Distinguish between design synthesis and design analysis.

3. What is Standardization & what are the advantages of standardization? Give examples of Indian standards for
commonly used engineering materials.

4. What is an industrial design? What is the relationship between functional requirement and external appearance of
the product.
5. Define ergonomics. What is the scope of ergonomics in machine design?

6. Distinguish between sequential design and concurrent engineering.

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