Introduction to MACHINE

DESIGN PROJECT
Concepts and
methodologies of How To
design Machines
 Out line of the content
1. Classification of machine design
2. Phases of machine design
3. Considerations and document presentation
4. Project title descriptions
1.1. Introduction
Definition: Machine Design is the creation of new and better machines and
improving the existing ones which is more economical in the overall cost
of production and operation.
1.2. Classification of machine design
 Adaptive design; concerned with adaptation of existing designs, needs no
special knowledge or skill . The designer only makes minor alternation or
modification in the existing designs of the product.
 Development 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 so that the final
product may differ quite markedly from the original product
 New design. needs lot of research, technical ability and creative thinking.
Only those designers who have personal qualities of a sufficiently high
order can take up the work of a new design.
1.3.Design Considerations
Usually quite a number of characteristics must be considered and prioritized in a
given design situation.
Many of the important ones are as follows (not necessarily in order of
importance)
• Functionality Noise
• Strength/stress Styling
• Distortion/deflection/stiffness Shape
• Wear Size
• Corrosion Control
• Safety Thermal properties
• Reliability Surface
• Manufacturability Lubrication
• Utility Marketability
• Cost Maintenance
• Friction Volume
• Weight Liability
• Life
• Remanufacturing/resource recovery
 1.4. Design Tools and Resources
• Inexpensive microcomputers and robust computer software packages
provide tools of immense capability for the design, analysis, and of
mechanical components.
• The engineer always needs technical information, either in the form
of basic science/engineering behavior or the characteristics of
specific off-the-shelf components.
• The resources can range from science/engineering textbooks to
manufacturers’ brochures or catalogs. Here too, the computer can
play a major role in gathering information.
1.5. Acquiring Technical Information
It is extremely important to keep abreast of past and current
developments in one’s field of study and occupation by gathering
information from different sources.
Cond… Technical informations
• Some sources of information are:
• Libraries (community, university, and private). Engineering
dictionaries and encyclopedias, textbooks, monographs,
handbooks, indexing and abstract services, journals, translations,
technical reports, patents, and business
sources/brochures/catalogs.
• Government sources. Departments of Defense, Commerce, Energy,
and Transportation; National Technical Information Service; and National
Institute for Standards and Technology.
• Professional societies. American Society of Mechanical
Engineers, Society of Manufacturing Engineers, Society of
Automotive Engineers, American Society for Testing and Materials,
and American Welding Society.
• Commercial vendors. Catalogs, technical literature, test data,
samples, and cost information.
• Internet. The computer network gateway to websites
associated with most of the categories listed above
 Chapter Two
2. PHASES IN MACHINE DESIGN
• To cope with this wide variety of tasks, designers
have to adopt different approaches, use a wide
range of skills and tools, have broad design
knowledge and consult specialists on specific
problems.
• This becomes easier if designers master a general
working procedure, understands generation and
evaluation methods and are familiar with well-
known solutions to existing problems.
 The activities of designers can be roughly classified into the
following phases.:
• 2.1. Conceptual Design: is the phase of identifying the essential problems
through abstraction, establishing function structures, searching for appropriate
working principles and combining these into a working structure— the basic
solution path is laid down through the elaboration of a solution principle.
 Conceptual design specifies the principle solution
• The purpose of this decision is to answer the following questions based on the
requirements list agreed upon during task clarification

• Has the task been clarified sufficiently to allow the development of a solution in
the form of a design?
• Is a conceptual elaboration really needed, or do known solutions permit direct
progress to the embodiment and detail design phases?
• If the conceptual stage is indispensable /essential, how and to what extent
should it be developed systematically?
Contd…. Conceptual design
 2.1. Embodiment design
 is the part of the design process in which, starting from the principle solution or
concept of a technical product, the design is developed in accordance with
technical and economic criteria and in the light of further information
2.1 Steps of Embodiment Design
i. Starting with the principle solution, and using the requirements list, identify
those requirements that have a crucial bearing on the embodiment design:
where those requirements can be; size determining, arrangement
determining, material determining requirements, etc.
ii. the spatial constraints determining or restricting the embodiment design must
be identified (for instance clearances, axle positions, installation
requirements, etc.).
iii. a rough layout, derived from the concept, is produced with the emphasis on the
overall embodiment-determining main function carriers, that is, the assemblies
and components fulfilling the main functions.
iv. Preliminary scale layouts and form designs for the embodiment-determining
main function carriers must be developed; that is, the general arrangement,
component shapes and materials must be determined provisionally.
 Steps in embodiment Cont’d…….
v. One or more suitable preliminary layouts must be selected in accordance with the
procedure described earlier
vi. Preliminary layouts and form designs must now be developed for the remaining
main function carriers that have not yet been considered because known
solutions exist for them or they are not embodiment-determining until this stage.
vii. Next, determine which essential auxiliary functions (such as support, retention,
sealing and cooling) are needed and, where possible, exploit known solutions
(such as repeat parts, standard parts, catalogue solutions).
viii. Detailed layouts and form designs for the main function carriers must now be
developed in accordance with the embodiment design rules and guidelines,
paying due attention to standards, regulations, detailed calculations and
experimental findings, and also to the problem of compatibility with those
auxiliary functions that have been realized.
x. Evaluate the layouts against technical and economic criteria.
xi. Fix the preliminary overall layout. The overall layout describes the complete
construction structure
xii. Optimize and complete the form designs for the selected layout by eliminating
the weak spots that have been identified during the course of the evaluation.
 2.3. Detail Design
 is that part of the design process which completes the embodiment of technical
products with final instructions about the shapes, forms, dimensions and surface
properties of all individual components, the definitive selection of materials, and
a final scrutiny/inspection of the production methods, operating procedures and
costs.
 Another—and perhaps the most important—aspect of the detail design phase is
the elaboration of production documents, including detailed component
drawings, assembly drawings, and appropriate parts lists.
 These activities are increasingly undertaken using CAD software. This allows the
direct use of product data for production planning and the control of CNC
machine tools.
 Depending on the type of product and production schedule (one-off, small batch,
mass production), the design department must also provide the production
department with assembly instructions, transport documentation and quality
control measures and the user with operating, maintenance and repair manuals.
 Chapter Three
3. Special considerations and Report Documentation
3.1. special considerations
 Here, we need to know that whenever we go through all the above
procedures there are some possibilities of considering the utilization of
different standards, codes, economics, etc.
i. Standards and Codes

 A standard is a set of specifications for parts, materials, or processes

intended to achieve uniformity, efficiency, and a specified quality. One of
the important purposes of a standard is to limit the multitude of
variations that can arise from the arbitrary creation of a part, material,
or process.

 A code is a set of specifications for the analysis, design, manufacture, and

construction of something. The purpose of a code is to achieve a specified
degree of safety, efficiency, and performance or quality. It is important to
observe that safety codes do not imply absolute safety.
 Sources of standards and codes
 Some of the standards and codes, as well as addresses, can be obtained in most technical libraries or on
the Internet
 The name of the organization provides a clue to the nature of the standard or code.
 The organizations of interest to mechanical engineers are:
• Aluminum Association (AA)
• American Bearing Manufacturers Association (ABMA)
• American Gear Manufacturers Association (AGMA)
• American Institute of Steel Construction (AISC)
• American Iron and Steel Institute (AISI)
• American National Standards Institute (ANSI)
• American Society of Heating, Refrigerating and Air-Conditioning Engineers
• (ASHRAE)
• American Society of Mechanical Engineers (ASME)
• American Society of Testing and Materials (ASTM)
• American Welding Society (AWS)
• ASM International
• British Standards Institution (BSI)
• Industrial Fasteners Institute (IFI)
• Institute of Transportation Engineers (ITE)
• Institution of Mechanical Engineers (IMechE)
• International Bureau of Weights and Measures (BIPM)
• International Federation of Robotics (IFR)
• International Standards Organization (ISO)
• National Association of Power Engineers (NAPE)
• National Institute for Standards and Technology (NIST)
• Society of Automotive Engineers (SAE)
 3.2.Report documentation
 Design reports are written to introduce and document engineering
and scientific designs. In general, these reports have two audiences.
One audience includes other engineers and scientists interested in
how the design works and how effective the design is.
 Another audience includes management interested in the
application and effectiveness of the design.

The commonly used organizations used for design

reports are; summary, introduction, discussion,
conclusion and appendices.
 A. Summary/ Abstract
• Is an executive summary of your work that consise synopsis
of the design itself.
• When you write the summary, you have to assume that the
reader has some knowledge of the subject, but has not read
the report.
• So, it should provide enough background that it stands on
its own.
B. Introduction
 to provide some background information on the overall
design problem domain
• This introductory information should come from your
literature search – Library, Internet, trade magazines, etc.
• Key points to cover: context, purpose, scope, objective
 Cont’d…
• Under this section you need to include the following
subsections :
i. Problem definition; a short paragraph explicitly stating
the problem to be solved.
ii. Design Requirements; here, you describe the most
important, measureable design requirements that drove
your solution to the problem.

you are also expected to provide the assembled drawing of

the machine you are about to design.
 D. Design analysis
 Sufficient and Correct Analysis for part sizing and material
selection to avoid failure; Simulations demonstrate
performance of major subsystems in critical operating
modes.)
 It is important here that every component of the machine
should be worked out separately with their respective
sketches and their purposes.
 Possible specifications and codes can be utilized here
E. Discussion and Conclusion
• Discussion should include a specifications table, showing all
specification requirements vs. actual values for the final
design followed by the effect of variation if exists
• Conclusion should include the results and its implication and
the necessary future works
 F. References and appendices
 Reference is a list of cited sources of materials we utilized
in our work.

 Appendix comes at the back of the report and are not part
of the main body. Appendices for a design report contain
additional detail about the design that would not fit into the
main body because of page limits or because including the
detail would distract the reader from understanding the
design.
 Projects summary
The topics of design project-I are
the following:
 Pressure vessels
 Jacks
 Cranes
 Conveyors
 Amusement rides
 Spur Gear Speed Reducer, Single-Reduction
 Pressure vessels
• A pressure vessel is defined as a container with a pressure
differential between inside and outside.
• Tanks, vessel and pipelines that carry, store or receive
fluids are called pressure vessel.
• Function: storage, heat exchanger, process vessel
• Geometry: cylindrical, conical, helical, horizontal/vertical
• Construction; monowall, multiwall, forged, cast
• Service; steam, lethal, vacuum, fired, stationery/ mobile
Jacks