1

Machine Design – I
Code: ME- 216
Credit Hours: 2
Lecture
INTRODUCTION TO MACHINE
DESIGN

Dr. Muhammad Imran

Mechanical Engineering Program
University of Engineering & Technology
Taxila
 What is OBE System

Outcome Based Education (OBE) is an

educational system focusing on what is learned
and not what is taught.

01/18/2025
 What is OBE System
 An education philosophy that focuses on
the Graduate Attributes or Outcomes
after completing an academic programme.
 Focuses on Empirically measuring student
performance.
 Does not specify or require any particular
style of teaching or learning.
 Requires that students demonstrate that
they have learned the required skills and
content.

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 OBE Questions

 What do you want the students to learn?

 Why do you want them to learn?
 How can you best make students learn
it?
 How will you know what they have
learnt?

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 What is OBE System

1. Program educational objectives (PEOs)

2. Program learning outcomes (PLOs)
3. Course learning outcomes (CLOs)
4. Bloom Taxonomy
i. Psychomotor
ii. Cognitive
iii. Affective

6
Learning Outcomes Bloom’s Taxonomy

Bloom’ Taxonomy Provides a way to organise thinking skills into six levels, from the 7most
basic to the more complex levels of thinking
 Course Contents in OBE System

Bloom
CLO CLO Statement PLO
Taxonomy

Understand the principles and the process for PLO-1

CLO-1 design of machine elements like keys, couplings, Engineering C2,
brakes, clutches, and fly wheels. Knowledge Comprehension
Analyze the machine design problems which is PLO-2
CLO-2 interrelated to fastening techniques and power Problem C4
transmitting shafts. Analysis Analysis

Present the design aspects effectively through

CLO-3 oral presentation.
PLO-10 A2
Communication Responding

Dr. Muhammad Imran MED, UET, Taxila

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 Machine Design-I
Evaluation Criteria Under OBE System

Through
Assignments
Quizzes 10%
Semester Project/Presentation 15%
Mid Semester Paper 25%
End Semester Paper 50%

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 Books
Text Book:
1. Machine Design BY: R. S. Khurmi
2. Mechanical Design an Integrated Approach By: Robert L.
Norton
3. Mechanical Engineering Design By: Joseph Edward Shigley
4. Machine Design By: Robert L. Mott
5. Design of Machine Elements, By M. F. Spotts
Reference Books:
1. Machine Design By: Dr. Anbdullah
2. Machine Design BY: MUBEEN
3. CAD/CAM/CIM BY P. Radhakrishnan
4. Automation, Production System & CIM by Mikell P.
Groover

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 Course Contents
 Introduction to Machine Design,
 Overview about basics of Mechanical Engineering,
 Criteria of the performance & Designing of Machine Parts.
 Mechanical Properties of Metals.
 Heat Treatment Processes.
 Analysis of Load ~ force diagram for Brittle & Ductile materials,
 Metals Fits, Tolerances & Surface Finish.
 Codes and Standards.
 Factor of Safety, its Criteria, Determination of F.O.S for different
cases, Role of Economics in Machining.
 Designing of Pin, Cotter Joints, Riveted Joints, Welded Joints &
Flywheel.
 Designing of Couplings
 Designing of Keys and Screws.
 Designing of Clutches and Brakes.
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 Machine Design
What is the importance of Machine Design for
Engineers?

What is Machine Design?

Creation of new and better machines AND

Improving existing ones

So that it is economical in the cost of production

and operation.
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 Machine Design
• The subject Machine Deisgn is the creation of new and better
machines and improving the existing ones. A new or better machine is
one which is more economical in the overall cost of production and
operation.
• The process of design is a long and time consuming one. From the
study of existing ideas, a new idea has to be conceived. The idea is
then studied keeping in mind its commercial success and given shape
and form in the form of drawings.
• In the preparation of these drawings, care must be taken of the
availability of resources in money, in men and in materials required for
the successful completion of the new idea into an actual reality.
• In designing a machine component, it is necessary to have a good
knowledge of many subjects such as Mathematics, Engineering
mechanics, Strength of Materials, Theory of Machines, Workshop
Processes and Engineering Drawing.
 INTRODUCTION

Engineering Design:
 Engineering design is a process of applying
various scientific principles and techniques for purpose
of defining in detail a product (or) a process (or) a
system to its realization.
 In simpler words design is formulation of a plan,
for execution towards satisfying a needs.
 Machine Design is defined as to fix dimension for
machine components.
General procedure in Machine Design…
Need or aim Recognize and specify the problem
Select the mechanism that would
Synthesis give the desired motion and form
the basic model with a sketch etc
Analysis of the FORCES

Material selection
Determine the stresses and thereby
Design of elements the sizes of components, failure or
deformation does not occur

Modification Modify sizes to ease construction & reduce

overall cost
Detailed
drawing Production
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VARIOUS STEPS IN DESIGN PROCESS
Recognition of a need:
Identifying the customer needs through market research.
Definition of the problem:
Preparation of complete list of technical specifications.
Synthesis:
Collection of new ideas (or) modifying the existing Ideas.
Analysis:
 The forces acting on the component are determined.
 The material for the component is selected.
 The geometric dimensions of the component are
determined.
 CONTINUE…
Evaluation:
The possible success of the proposal should be
verified from technical and economical stand points.
Detailed Design:
It’s the actual sizing and dimensioning all individual
components in the part.
Proto-type & Testing:
Proto-type testing may lead to some modification.
Production:
Actual component manufactured at shop floor.
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 TYPES OF MACHINE DESIGN

Adaptive design:
The designer only makes minor alteration (or)
modifications in the existing designs of the product.
Development design:
Modifying existing designs into a new idea by
adopting a new material or different method of
manufacture.
New design:
This type of design needs lot of research, technical
ability and creative thinking.
 Further classification of design

Rational design:
This type of design depends upon mathematical formulae
of principle of mechanics.
Empirical design:
This type of design based on empirical formula based on
practice and past experience.
Industrial design:
Depends upon the production aspects to manufacture.
Optimum design:
It’s the best design for the given objective function under
the specified constraints.
 Continue…

System design:
To develop a system that will meet expected needs
within realistic constraints such as economical
environmental, social, political, ethical, safety and
sustainability
Element design:
Design of machine elements such as piston, crank
shaft, gear,etc.
Computer aided design:
Use of computer systems to assist in the creation,
modification, analysis and optimization of a design.
 Stages of Design
Mechanical design activity in an industrial
setting embodies a continuum effort from
initial concept to development and field
service.
1. Preliminary design,
2. Intermediate design,
3. Detail design, and
4. Development and
field service 22
1.Preliminary Design
, or conceptual design, is primarily concerned with synthesis,
evaluation, and comparison of proposed machines or system
concepts. A “black-box” approach is often used, in which
reasonable experience based performance characteristics are
assigned to components or elements of the machine or system.

Overall system analyses, including force analyses, deflection

analysis, thermodynamic analysis, fluid mechanic analysis,
heat transfer analysis, electro- mechanic analysis, or control
system analysis may be required at the preliminary design stage.
The result of the preliminary design stage is the proposal of a
likely-successful concept to be designed in depth to meet
specified criteria of performance, life, weight, cost, safety, or
others.
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2. Intermediate Design
embraces the spectrum of in-depth engineering design of
individual components and subsystems for the already
preselected machine or system. Intermediate design is vitally
concerned with the internal workings of the black boxes, and
must make them work as well or better than assumed in the
preliminary design proposal. Material selection, geometry
determination, and component arrangement are important
elements of the intermediate design. Effort, and appropriate
consideration must be given to fabrication, assembly,
inspection, maintenance, safety, and cost factors, as well.
The result of the intermediate design stage is establishment of all
critical specifications relating to function, manufacturing,
inspection, maintenance, and safety.

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3. Detail Design
is concerned mainly with configuration, arrangement,
form, dimensional compatibility and completeness, fits
and tolerances, standardization, meeting specifications,
joints, attachment and retention details, fabrication
methods, assimilability, producibility, inspectability,
maintainability, safety, and establishing bills of material
and purchased parts.
 The result of the detail design stage is a complete set of drawings
and specifications, including detail drawings of all parts, or an
electronic CAD file, approved by engineering design, production,
marketing, and any other interacting departments, ready for
production of a prototype machine or system.

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4. Development and Field Service
activities follow in sequence after the production of a
prototype machine or system. Development of the
prototype from a first model to an approved production
article may involve many iterations to achieve a product
suitable for marketing.

 Field service information, especially warranty service data on

failure rates, maintenance problems, safety problem, or other
user-experience performance data, should be channeled back to
the product design team for future use in product improvement
and enhancement of life cycle performance.

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 Factor influencing machine design

1. Safety
2. Reliability
3. Quality
4. Productivity
5. Cost
6. Ecological consideration
7. Availability of men, material & machines
8. Working environment
9. Energy conservation
10. Space constraints
General considerations in machine design

1. Type of load and stresses caused by the load

2. Motion of the parts or kinematics of the machine
3. Selection of materials
4. Form and size of the parts
5. Frictional resistance and lubrication
6. Convenient and economical features
7. Use of standard parts
8. Safety of operation
9. Workshop facilities
10. Number of machines to be manufactured
11. Cost of construction
 Design rules

1. Design should aim at the best with the least

expenditure
2. The component should have adequate strength, wear
resistance and corrosion resistance
3. The assembly should be backlash free
4. Resonance is to be avoided
5. The design should be simple, fool proof, easy to
operate and should reduce operator’s fatigue.
6. The design should need only a minimum maintenance
7. Whenever possible, dimensions of the components
should be rounded off to standard values.
 How a design is born
Market
survey
Aesthetic
marketability
Ease of
Requirement handling
Availability of Safety
Creation FUNDS
Economical
Model Available
(Rough idea) material Recyclability
Manufacturing
resources
Material/s
Analysis Force/stress Sizes
used
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 Mechanical Engineering Design
• Mechanical engineering design involves all the
disciplines of mechanical engineering
• Example: Fluid Flow, Heat Transfer, Friction
(Tribology), Energy, Transport, Material Selection,
Thermo Mechanical Treatments, Statistical
Descriptions…
• Phases- Machine design, machine-element design,
machine-component design, systems design, and fluid-
power design

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 What is Machine Design?

• Core of mechanical – Stress Concentrations

engineering – Fracture Mechanics
– Stress and strain – Optimization
– Designing for safety – Composite Materials
– Static failure theories – Manufacturing Processes
– Fatigue failure theories – Computer Aided Machine
– Machine elements Design and Analysis
– Mechanical material – Measuring Stress and Strain
properties

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What is the basic knowledge required for
Machine Design?
• Mathematics
Mathematics
• Mechanics of Machines
• Engineering
EngineeringMechanics
Mechanics • Mechanics of Materials
• Fluid Mechanics & Thermodynamics
• Strength
Strengthof
ofMaterials
Materials

• Workshop
WorkshopProcesses
Processes

• Engineering
EngineeringDrawing
Drawing

• Computing

• Finite Element Analysis, Computational Fluid Dynamics etc

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Important considerations in Machine Design
1. Type of LOAD and STRESS caused by the load

• Dead loads • Stress and strain

(Tensile, compressive, shear)
• Live loads

Steady loads • Thermal stresses

Variable loads
• Torsional stresses
• Shock loads (suddenly)
• Bending stress

• Impact loads (applied

with some velocity)
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 Loads
• Mechanical  forces, moments…
• Thermal
• Chemical changing in place/ time
• …
static cyclic dynamic

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 Effect of Varying Load
Fatique limits
σv σr

 min cycle assymetry m cycle mean stress

r v
 max ratio  max ratio 01/18/2025
Loads & Stresses

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 Direct Stress
Load:
Any external force acting upon a machine member
Types of load:
(i) Dead (or) Steady (or) Static load:
The load which does not change in magnitude
and direction.
Ex. Self weight
(ii) Live (or) Varying load:
The load which is continuously changing.
Ex. Vehicle pass over a bridge
 Continue…
(iii) Suddenly applied load (or) shock load:
The load which is applied suddenly
Ex: Blows of a hammer

(iv) Impact load:

The load which is applied with some initial
velocity (or) The load which is dropped from certain
height.
Ex: forging
 Continue…
Stress:
The internal resistance of force per unit area is called
stress.
σ =P/A
Where P = Load or force acting on the body
A = Cross- sectional area of the body
Strain:
The rate of change of deformation (or) It’s the ratio of
change in dimension to the original dimension.
e =δl/l
Relationship between σ,e,E, δl
Deformation, ( δl ) =pl/AE
 TYPES OF STRESSES AND
STRAINS
Tensile Stress: The stress induced in a body, when subjected to two equal
and opposite pulls as result of which there is an increase in length, is
known as tensile stress. The ratio of increase in length to the original
length is known as tensile strain.
P
Tensile stress σ = Resisting force = A
Cross sectional area l
and tensile strain, ε = Increase length = l
Original length
 Compressive Stress
The stress induced in a body, when subjected to
two equal and opposite pushes as a result of
which there is a decrease in length of the body,
is known as compressive stress. The ratio of
decrease in length to the originalP length is
known as compressive strain. A

Compressive stress, σ = Resisting force

l =
l
Cross sectional area

Compressive strain, ε = Decrease in length =

Original length
 Shear Stress:
The stress induced in a body, when subjected to
two equal and opposite forces which are acting
tangentially across the resisting section as a
result of which the body tends to shear off
across the section, is known as shear stress.
The corresponding strain is known as shear
strain.
P
Shear stress, q = Shear resistance =
A
Shear area
l
Shear strain Φ = Transverse displacement = l
 FACTOR OF SAFETY AND LATERAL
STRAIN
FACTOR OF SAFETY:
It is defined as the ratio of the ultimate stress to
the working stress of the material.
Factor of Safety = Ultimate Stress
Working Stress

LATERAL STRAIN:
The strain at right angles to the direction of
applied load is known as lateral strain.
Lateral Strain = Increase or Decrease in Lateral
Dimension
Modulus of Elasticity (Young’s Modulus (E):
According to Hooke’s law, the stress in a material is proportional to the
strain upto the elastic limit. Therefore within the elastic limit, the
ratio of the axial stress to the corresponding axial strain is found to
be a constant. This constant is called Modulus of Elasticity or
Young’s Modulus. It is denoted by E.
Modulus of Elasticity or Young’s Modulus = Axial Stress
Axial Strain

E=

Modulus of Rigidity or Shear Modulus (G):
The ratio of shear stress to the corresponding shear strain is found to be
a constant upto the elastic limit of the material. This constant is
called Modulus of Rigidity or Shear Modulus of the material. It is
denoted by G.
q
Modulus of Rigidity or Shear Modulus = Shear Stress = G =
Shear Strain 
Poisson’s Ratio (μ) or (1/m):
It has been experimentally found, that if a body is stressed within its
elastic limit, the lateral strain bears a constant ratio to the linear
strain. Mathematically,
Lateral strain = A constant
Linear strain

This constant is known as poisson’s ratio and is denoted by 1/m or μ.

Strain Energy (or) Resilence:

When a body is loaded with in the elastic limit the work done on the
body is stored in the form of energy . The strained body is now
capable of doing some external work on removal of the load. The
energy stored in the body due to internal strain is called strain
energy or resilience.
Strain energy = (σ2/2E) ×A×l------------- N.mm
 Hooke’s Law
It states that, “ Within elastic limit the stress
induced in the material is directly proportional to
strain”.
σαe
σ = E e.
E=σ
e
Where, σ – Stress; e – Strain; E – Young’s Modulus
 Stress Strain Diagram
Ultimate
Strength
Yield
Breaking
Point Elastic Limit
Limit
Proportional
STRESS/
LOAD

Limit

EXTENSION/STRAIN
 Stress Strain Diagram
•Point P: Proportional Limit: Within Proportional Limit
stress is directly proportional to strain. Hence the material
will regain its original shape after unloading.
The stress corresponding to the load is known as Limit of
Proportionality.
•Point E represents the elastic limit. In the region PE, the
stress is not proportional to strain. It means the stress strain
diagram is not a straight line.
•Any loading beyond point E, will cause permanent
deformation. The stress corresponding to the load at E is
called at Elastic Limit.
•Yield Stress (Point Y) :The loading beyond E causes
extension much larger than the extensions observed earlier.
The material yields to a greater extent and the stress
corresponding to the load at Y is termed as Yield Stress
•Beyond Y, a much smaller increase in the load causes
considerable extension and the materials is said to be semi
• At U, the material yields at a particular point and a
neck is formed there. The stress corresponding to
that load at U is called maximum stress (Ultimate
stress)
• Beyond U, the extension governed by the time of
loading. The load required to cause extension is
smaller than the load at M.
•The area of cross section is considerable reduced.
• The elongation continues till the material breaks at
B.
•The stress corresponding to the load at B is called
Breaking stress.
 Continue…
• Percentage reduction in area:
% reduction in area = (A-A1)/A ×100
A – Original area of cross-section.m 2
A1 – Cross- sectional area after fructure at the
neck,m2

Percentage elongation:
% elongation in length= (l1-l/l × 100
l1 – Length of specimen after fracture, mm
l – original length, mm
 Torsional shear stress
• When a machine member is subjected to
the action of two equal and opposite couples
acting in parallel planes, then the machine
member is said to be subjected to torsion.
• The stress set up by torsion is known as
torsional shear stress.
• Consider a shaft fixed at one end and
subjected to a torque (T) at the other end.
• As a result of this torque every cross-section of
the shaft is subjected to torsional shear stress.
53
54
 Bending Stresses in Straight Beams

Bending Stress: In engineering practice, the machine parts of

structural members may be subjected to static or dynamic loads which
cause bending stress in the sections besides other types of stresses
such as tensile, compressive and shearing stresses.

55
A little consideration will show that when a beam is subjected
to the bending moment, the fibers on the upper side of the
beam will be shortened due to compression and those on the
lower side will be elongated due to tension. It may be seen that
somewhere between the top and bottom fibers there is a
surface at which the fibers are neither shortened nor
lengthened. Such a surface is called neutral surface. The
intersection of the neutral surface with any normal cross-
section of the beam is known as neutral axis. The stress
distribution of a beam is shown in previous Fig. The bending
equation is given by

56
57
 Impact and shock loading

The load acting on any machine component can be of either of

these two types
1. Gradual load
2. Suddenly applied (or) Impact (or) Shock
load.
Gradual load:
Gradual load is one which, goes on increasing over a
period of time till the maximum value is reached.
Suddenly applied (or) Impact (or) Shock load:
Impact (or) shock load which is applied suddenly (or)
with some initial velocity.
Ex: Punching presses, Hammer
 Principal Stress

• Principal plane is a plane in which the shear

stress is zero, and the direct stresses acting
along these planes are known as principal
stress.
• When shear stress is also acting in addition we
have to find out maximum and minimum
principal stresses.
 Eccentric loading

• An external load, whose line of action is

parallel but does not coinside with the
centroidal axis of the machine component, is
known as an eccentric load (P).
• The distance between the centroidal axis of the
machine component and the eccentric load is
called eccentricity.
• It is generally denoted by e.
Important considerations in Machine Design

2. KINEMATICS of the machine (Motion of the

parts)
Find the simplest arrangement that would give
the most efficient motion that is required.

3. Selection of MATERIALs

Knowledge of the properties of the materials

and their behaviour under working
conditions is required.

Strength, hardness, durability, flexibility, weight,

resistance to heat and corrosion, electrical
conductivity, machinability, etc.
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 Engineering materials
a) Metals
b) Non-metals
Metals:
Ferrous – Which contains iron as the major constituent
Ex. Steel, Cast Iron
Non-ferrous – materials don't contains Iron.
Ex. Copper, Aluminium
Non-Metals:
(i) Ceramic materials – oxides, carbides and nitrides of various
metals. Ex. Glass, Brick, Concrete, Cement etc.
(ii) Organic materials – Polymeric materials composed of
carbon compounds. Ex: Paper, fuel, rubber, paints, etc.
Factors to be considered for the selection of
materials
1. Availability
2. Cost
3. Physical properties
4. Mechanical Properties
5. Manufacturing process
Physical properties:
 Colour Electical conductivity
 Shape Thermal conductivity
 Size
 Density
 Material selection based
on Mechanical properties
• Strength  ability to resist external forces
• Stiffness  ability to resist deformation under stress
• Elasticity  property to regain its original shape
• Plasticity  property which retains the deformation produced under load
• Ductility  property of a material to be drawn into wire form with using tensile force
• Brittleness  property of breaking a material without any deformation
• Malleability  property of a material to be rolled or hammered into thin sheets
• Toughness  property to resist fracture under impact load
• Machinability property of a material to be cut
• Resilience  property of a material to absorb energy
• Creep  material undergoes slow and permanent deformation when subjected to constant stress
with high temperature
• Fatigue  failure of material due to cyclic loading
• Hardness  resistant to indentation, scratch
Important considerations in Machine Design
65
4. Form and size of the parts

Use I-beam or Angle-iron?

The size will be determined by the
forces/torques applied (stresses on the
object) and the material used such that
failure (fracture or deformation) would not
occur

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 Designer Responsibilities

• Understand the problem

• Identify the known
• Identify the unknown and formulate
• State all assumptions and decisions
• Analyze the problem
• Evaluate solution
• Present solution

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Fail Safe and Safe Life Design Concepts
Catastrophic failures of machines or system that
result in loss of life, destruction of property, or
serious environmental degradation are simply
unacceptable to the human community, and, in
particular, unacceptable to the designers of such
failed machines or systems.
A designer can never provide a design of 100 percent
reliability, that is, she or he can never provide a
design absolutely guaranteed not to fail. There is
always a finite probability of failure.

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Fail Safe and Safe Life Design Concepts
68
The Fail Safe Design technique provides unnecessary
load paths in the structure so that if failure of a primary
structural member occurs, a secondary member is
capable of carrying the load on an emergency basis until
failure of the primary structure is detected and repair can
be made.
The Safe Life Design technique is to carefully select a
large enough safety factor and establish inspection
intervals to assure that the stress levels, the potential
flaw sizes, and the governing failure strength levels of
the material combine to give such a slow crack growth
rate that the growing crack will be detected before
reaching a critical size for failure.
Both fail safe life design depend upon inspectability.
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 Failure Criteria 69
• Any change in the size, shape, or
material properties of a machine or
machine part that renders it incapable of
performing its intended function must
be regarded as a mechanical failure.

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 Modes of Mechanical Failure 70
1. Force- and/or temperature-induced elastic deformation
2. Yielding
3. Brinnelling
4. Ductile rupture
5. Brittle fracture
6. Fatigue:
a. High cycle fatigue
b. Low-cycle fatigue
c. Thermal fatigue
d. Surface fatigue
e. Impact fatigue
f. Corrosion fatigue
g. Fretting fatigue

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 Modes of Mechanical Failure 71
7 Corrosion:
a. Direct chemical attack
b. Galvanic corrosion
c. Pitting corrosion
d. Intergranular corrosion
e. Selective leaching
f. Erosion corrosion
g. Cavitation corrosion
h. Hydrogen damage
i. Biological corrosion
j. Stress corrosion
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 Modes of Mechanical Failure 72
8 Wear:
a. Adhesive wear
b. Abrasive wear
c. Corrosive wear
d. Surface fatigue wear
e. Deformation wear
f. Impact wear
g. Fretting wear
9 Impact:
a. Impact fracture
b. Impact deformation
c. Impact fretting
d. Impact fatigue 01/18/2025
 Modes of Mechanical Failure 73
10. Fretting:
a. Fretting fatigue
b. Fretting wear
c. Fretting corrosion
11. Creep
12. Thermal relaxation
13. Stress rupture
14. Thermal shock
15. Galling and seizure
16. spalling

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 Modes of Mechanical Failure 74
17. Radiation damage
18. Buckling
19. Creep bucking
20. Stress corrosion
21. Corrosion wear
22. Corrosion fatigue
23. Combined creep and fatigue

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Machine Elements 75

75
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