A Lecture

on

Unit –I
Mechanical Engineering Design Process
By

Dr. Khizar Ahmed Pathan

Ph.D. (Mech.), M.Tech (Machine Design), BE (Mech.)

Professor and Dean - Academics

Machine Elements

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 Course Structure

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Course Structure

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 Course Structure

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Course Syllabus

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 Course Syllabus

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Types of Loads & Stresses

Tension

Compression

Shearing

Bending

Torsion

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 Machine Design
Use of Scientific principles, Technical information and Imagination to
define Machine or System to perform specific function with maximum
economy and efficiency.

OR

Creation of new and better machine and improving the exiting ones for
better economy.

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Lecture by Dr. K.N. Pathan, CSCOE

Machine Design
Scientific Principles includes Physics, mathematics, Statics and
Dynamics, Thermodynamics and Heat Transfer, Vibrations and Fluid
Mechanics.

Some examples are:

Newton’s Law of Motion
D’ Alembert’s Principle
Boyle’s and Charle’s Laws of gases
Bernoullis Principle

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 Traditional Design Methods
1. Craft-evolution Method

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Lecture by Dr. K.N. Pathan, CSCOE

Traditional Design Methods

1. Craft-evolution Method 2. Design by Drawing Method

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 General Industrial Design Procedure

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General Industrial Design Procedure

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 General Industrial Design Procedure

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General Industrial Design Procedure

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 Design of Machine Elements Procedure

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Design of Machine Elements Procedure

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 Design of Machine Elements Procedure

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Lecture by Dr. K.N. Pathan, CSCOE

Design of Machine Elements Procedure

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 Design of Machine Elements Procedure

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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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 Design Considerations
Types of Loads and Stresses caused by load
Motion of Parts:
Curvilinear: Rotary, Oscillatory, SHM
Rectilinear: Unidirectional and Reciprocating Motion
Selection of Material
Lubrication
Safety of Operation
Manufacturing Cost
Convenient Handling
Method of Manufacturing
Ease of Maintenance and servicing

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Design Considerations
Strength Use of Preferred Series

Rigidity Factor of Safety

Manufacturing Service Factor

Assembly and Cost

Standards and Codes

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 Design Considerations
Strength
Strength is the capacity of an object or
substance to withstand force or
pressure.
Rigidity

Inability to be to bent or be forced out of

shape.

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Design Considerations
Manufacturing
The process through which raw
materials are transformed into a
final product.

Assembly and Cost

A Machine element or product
should be designed such that it
facilitates to minimize the
assembly cost and time.

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 Design Considerations
Factor of Safety
Material Strength may be
Yield Strength in case of Static loading of ductile material
Ultimate Strength in case of Static loading of Brittle material
Endurance Limit in case of Fatigue loading
Factors to be Considered while selecting FOS
The Design Engineer has to select FOS by balancing Cost and Safety
Factors:
1. Degree of Uncertainty about loading
2. Degree of Uncertainty about Material
3. Uncertainties in applied load and material strength
4. Human Safety
5. Economy

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Lecture by Dr. K.N. Pathan, CSCOE

Design Considerations
Service Factor/ Application Factor

Service Factor=Maximum load/Average load

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 Use of Standards in Design
Standards and Codes
Norms to which the characteristics of the product should confirm.
Standards: Set of Specification for Parts, Materials and Process.
Codes: Set of Specification for Analysis, Design, Manufacture and Testing.
Types:
1. Company Standards: Define by Company or group of companies
2. National Standards: Define by National Apex Body and followed throughout the country
Examples:
Bureau of Indian Standards (BIS),
American Society of Mechanical Engineers (ASME),
American Gear Manufacturers Association (AGMA),
American Welding Society (AWS),
American National Standards Institute (ANSI)
3. International Standards: Define by International Apex Body and followed all over the world.

Examples:

International Standards Organization (ISO),

International Bureau of Weights ad Measures (IBWM).

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Use of Standards in Design

Standards and Codes
The following Standards are used in Mechanical Engineering Design
A. Standards for Material, Their Chemical Compositions, Mechanical Properties
and Heat Treatments
Examples:
1. Indian Standard IS 210 Specifies 7 grades of Gray Cast Iron designated as FG 150, FG 200, FG 220, FG 260, FG 300,
FG 350 and FG 400.
The number Indicates Ultimate Tensile Strength in N/mm2

2. IS 1570 Specifies Chemical Compositions of various grades of alloy steel.

B. Standards for Shapes and Dimensions of Commonly used Machine Elements:

Bolts, Screws and nuts, Rivets, Belts and Chains, Ball and Roller Bearings, Wire Ropes, Keys and Splines etc.
Examples:
1. IS 2494 Specifies the dimensions and shape of V-belt

2. IS 5129 Specifies the Rotary shaft oil seal units

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 Use of Standards in Design
Standards and Codes
C. Standards for Fits, Tolerances and Surface Finish Components:
Examples:
1. IS 2709 Specifies the Selection of type of fit for different applications.

2. IS 919 Specifies the Tolerances or upper and lower limits for various size of holes and shafts

3. IS 10719 Explains the method for indicating surface texture on technical drawings.

4. IS 8000 explains the method of showing geometrical tolerances.

D. Codes for Testing of Products:

These Codes give procedure to test the product Such as Pressure vessel, Boiler, Crane and Wire rope, etc
where safety is an important consideration.
Examples:
1. IS 807 Used for testing of cranes and hoists.
2. IS 2825 explains the method of testing of pressure vessels.
E. Codes for Engineering Drawing of Components:
Examples:
1. SP 46 covers all standards related to engineering drawing.

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Use of Preferred Series

Preferred number is used to specify the size of product. The size of product includes
Power transmitting capacity, load carrying capacity, speed, dimensions etc.
Example: A company manufacturing 10 different electric motors to
fulfil the need of different customers in range of 1.0 to 10 kW.
R5 R10 R20 R40 R5 R10 R20 R40 R5 R10 R20 R40
1.0 1.0 1.0 1.0 2.50 2.50 2.50 2.50 6.30 6.30 6.30 6.30
1.06 2.65 6.70
Series Factor 1.12 1.12 2.80 2.80 7.10 7.10
1.18 3.00 7.50
1.25 1.25 1.25 3.15 3.15 3.15 8.00 8.00 8.00
1.32 3.35 8.50
1.40 1.40 3.55 3.55 9.00 9.00
1.50 3.75 9.50
1.60 1.60 1.60 1.60 4.00 4.00 4.00 4.00 10.00 10.00 10.00 10.00
1.70 4.25
1.80 1.80 4.50 4.50
1.90 4.75
2.0 2.0 2.0 5.00 5.00 5.00
2.12 5.30
2.24 5.60 5.60
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2.36 6.00

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 Use of Preferred Series
Numerical

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Use of Preferred Series

Numerical

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 Use of Preferred Series
Numerical

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ISO 9000

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 ISO 9000

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ISO 9000

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 ISO 9000

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ISO 9000

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 ISO 9000

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ISO 9000

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 Aesthetic Considerations in Design

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Aesthetic Considerations in Design

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 Ergonomic Considerations in Design

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Ergonomic Considerations in Design

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 Ergonomic Considerations in Design

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