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Design Consideration & Material Designation

This document provides an introduction to machine design and discusses key considerations in the machine design process. It outlines the 10 steps of the design procedure, from defining the problem to preparing design reports. It also discusses factors to consider like strength, cost, manufacturability. The document reviews material properties and heat treatments. It provides guidelines for various manufacturing processes like casting, forging, welding. Finally, it discusses standardization and preferred series for machine components.

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mutthudarur
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219 views22 pages

Design Consideration & Material Designation

This document provides an introduction to machine design and discusses key considerations in the machine design process. It outlines the 10 steps of the design procedure, from defining the problem to preparing design reports. It also discusses factors to consider like strength, cost, manufacturability. The document reviews material properties and heat treatments. It provides guidelines for various manufacturing processes like casting, forging, welding. Finally, it discusses standardization and preferred series for machine components.

Uploaded by

mutthudarur
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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INTRODUCTIONTO

MACHINE DESIGN
• Machine design is defined as the use of
scientific principles, technical information and
imagination in the description of a machine or
a mechanical system to perform specific
functions with maximum economy and
efficiency.
• Example: The process of design of a belt
drive.
DESIGN
PROCEDURE
1. Definition of 7.Determination of
problem dimensions
2. Synthesis
8.Modification of
3. Analysis of
dimensions
forces
4. Selection of 9.Preparation of
material drawings
5. Determination of 10.Preparation of
mode of failure design report
6. Selection of factor
of safety
DESIGN CONSIDERATIONS
 Strength  Friction and wear
 Rigidity  Life
 Reliability  Vibrations
 Safety  Thermal considerations
 Cost  Lubrication
 Weight  Maintenance
 Ergonomics  Flexibility
 Aesthetics  Size and shape
 Manufacturing  Stiffness
 Corrosion
considerations  Noise
 Assembly  Environmental
considerations
 Conformance considerations
AESTHETIC CONSIDERATIONS
IN DESIGN
• Appearance is an outwardexpression of
quality of the product and is the
communication of product with the user.
first
• Aesthetics is defined as the set of principles of
appreciation of beauty. It deals with the
appearance of the product.
ASPECTS OF AESTHETIC DESIGN
 Form(shape)  Contrast
 Symmetry and shape  Impression and
 Color purpose
 Continuity  Style
 Variety  Material and surface
 Proportion finish
 Noise  Tolerance
ERGONOMICS CONSIDERATIONS
IN DESIGN
• Ergonomics is defined as the study of the man
- machine - working environment relationship
• It aims at decreasing the physical and mental stresses to
the user
 Areas covered under ergonomics
• Communication between man (user) and machine
• Working environment
• Human anatomy and posture while using the machine
• Energy expenditure in hand and foot operations
MANUFACTURING
CONSIDERATIONS IN DESIGN
 Minimum total number of parts in a product
 Minimum variety of parts
 Use standard parts
 Use modular design
 Design parts to be multifunctional
 Design parts for multiple use
 Select least costly material
 Design parts for ease of manufacture
 Shape the parts for minimizing the
operations
DESIGN CONSIDERATIONS
FOR CASTINGS
 Design parts to be in compression then in tension
 Strengthen parts under tension by use of external devices
 Shape the casting for orderly solidification
 Avoid abrupt change in cross-section
 Provide more thickness at the boss
 Round off the corners
 Avoid concentration of metal at junctions
 Avoid thin sections
 Make provision for easy removal of pattern from
the mould
DESIGN CONSIDERATIONS
FOR FORGINGS

 Keep fibre lines parallel to tensile and


compressive forces and perpendicular to shear
forces
 Avoid deep machining cuts
 Keep vertical surfaces of forged parts tapered
 Keep the parting line in one plane
 Provide adequate fillet and corner radii
 Avoid thin sections
DESIGN
CONSIDERATIONS
IN WELDING
 Use the minimum possible number of welds
 Select the same thickness for the parts to be
welded together
 Locate the welds at the areas in the design where stresses
and/or deflections are not critical
 Effect of shrinkage and distortion should be minimized by
post welding annealing and stress relief operations
 Decide proper welding sequence
 Design welding in the flat or horizontal position and not in
the overhead position
 Use only the amount of weld metal that is
absolutely required
STANDARDIZATION
• It is the process of establishing the set of norms to
which a specified set of characteristics of a
component or a product should conform
• Example: Standardizing the shaft consists of
specifying the set of shaft diameters and material

 Objectives of standardization
• To make the interchangeability of the
components possible
• To make the mass production of components easier
PREFERRED SERIES AND
ITS SELECTION
• Preferred series are series of numbers obtained
by geometric progression and rounded off
• The four basic preferred series are designated as:

• The other series are called derived series and are


obtained by multiplying or dividing the basic sizes by
10, 100, etc.
MECHANICAL
PROPERTIES OF
MATERIALS
 Strength  Malleability
 Stiffness/Rigidity  Toughness
 Elasticity  Machinability
 Resilience
 Plasticity
 Creep
 Ductility
 Fatigue
 Brittleness
 Hardness
EFFECT OF
ALLOYING
ELEMENTS
 Chromium
 Nickel
 Manganese
 Silicon
 Molybdenum
 Vanadium
 Tungsten
STEELS DESIGNATED ON THE BASIS
OF MECHANICAL PROPERTIES
• These steels are carbon and low alloy steels where the main
criterion in the selection and inspection of steel is the tensile
strength or yield stress.
• According to Indian standard these steels are designated by
a symbol ‘Fe’ or ‘Fe E’ depending on whether the steel has
been specified on the basis of minimum tensile strength or
yield strength, followed by the figure indicating the minimum
tensile strength or yield stress in 𝑁/𝑚𝑚2
• For example ‘Fe 290’ means a steel having minimum tensile
strength of 290 𝑁/𝑚𝑚2 and ‘Fe E 220’ means a steel having
yield strength of 220 𝑁/𝑚𝑚 2.
STEELS DESIGNATED ON THE BASIS
OF CHEMICAL COMPOSITION
• According to Indian standard, steels are designated in the
following order :
• (a) Figure indicating 100 times the average percentage
of carbon content,
• (b) Letter ‘C’, and
• (c) Figure indicating 10 times the average percentage of
manganese content. The figure after multiplying shall be
rounded off to the nearest integer.
• For example 20C8 means a carbon steel containing 0.15
to
0.25 per cent (0.2 per cent on an average) carbon and
0.60 to
INDIAN STANDARD DESIGNATION OF
LOW AND MEDIUM ALLOY STEELS
• According to Indian standard, low and medium alloy steels
shall be designated in the following order :
1. Figure indicating 100 times the average percentage carbon.
2.Chemical symbol for alloying elements each followed by the
figure for its average percentage content multiplied by a factor as
given below :

• For example 40 Cr 4 Mo 2 means alloy steel having average


0.4% carbon, 1% chromium and 0.25% molybdenum.
INDIAN STANDARD DESIGNATION
OF HIGH SPEED TOOL STEEL
• According to Indian standard, the high speed tool steels
are designated in the following order :
1. Letter ‘XT’.
2.Figure indicating 100 times the percentage of carbon
content.
3.Chemical symbol for alloying elements each followed by
the figure for its average percentage content rounded off to
the nearest integer, and
4.Chemical symbol to indicate specially added element to
attain the desired properties.
• For example, XT 75 W 18 Cr 4 V 1 means a tool steel with
average carbon content 0.75 percent, tungsten 18 per cent,
chromium 4 per cent and vanadium 1 per cent.
HEAT TREATMENT OF STEELS
• A combination of operations involving the heating
and cooling of a metal or an alloy in the state for the
purpose of obtaining certain desirable conditions or
properties without change in chemical composition

 Various heat treatment processes are:


• Normalizing • Hardening
• Annealing • Tempering
• Spheroidising • Surface or case
hardening
AIM OF HEAT TREATMENT
• To increase the hardness of metals
• To relieve the stresses set up in the material after hot
or cold working
• To improve machinability
• To soften the metal
• To modify the structure of the material to improve its
electrical and magnetic properties
• To change the grain size
• To increase the qualities of a metal to provide better
resistance to heat, corrosion and wear
MATERIAL SELECTION PROCESS
• The different steps involved in the
material selection process are as follows:
 Analysis of desired material properties
 Screening of candidate materials
 Selection of most suitable material
THANK YOU 

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