University of Gonder

Institute of Technology (IoT)

Department of Mechanical Engineering
Machine Elements-I MEng 3152
CHAPTER # 1

INTRODUCTION: Introduction in Mechanical Design

(Machine Element; Engineering Materials; Allowable Stresses;
Safety Factor;) By: Andebet T.
Machine Design
 The term design can be defined as the formulation of a plan for the
satisfaction of human need.

 Design means to create something new or arrange existing things in a

new order to satisfy a recognized need of society.

 Mechanical Engineering Design essentially means the design of the

parts, products and systems of mechanical nature.

 It deals with all the disciplines of mechanical engineering, such as,

machine design, thermal engineering, fluid power engineering,
refrigeration and air conditioning, etc.
Machine Design

 The subject Machine Design 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.
Machine Design

 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
1.1 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.

 Machine Design is defined as to fix dimension for machine

components.

 Design of machine element can be defined as the selection of material

and the values for independent geometrical parameters so that the
element satisfies its functional requirements and undesirable effects
and kept within the permissible limits
Various Steps in Design Process
 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.

 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.

 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.
 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.
 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 8. Use of standard parts
2. by the load 9. Safety of operation
3. Motion of the parts or kinematics of 10. Workshop facilities
the machine 11. Number of machines to
4. Selection of materials be manufactured
5. Form and size of the parts 12. Cost of construction
6. Frictional resistance and lubrication
7. Convenient and economical features
 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.
 1.2 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, Aluminum
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:
 Color Electrical 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
 Material Selection Based on
Mechanical Properties
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

 1.3 Types of Loads
Load:
Any external force acting upon a machine member(element)
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
 (iii) 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

 Eccentric Loading
 An external load, whose line of action is parallel but does
not coin side 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.
 1.4 Types of stresses (Direct stress , Bending stress,
torsional stress and shar stress ) and strains

Tensile Stress:

 Compressive Stress

Shear Stress:

 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.
 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.
Cont…
T/J = τ/R = Gθ/l

θ= angle of twist, radian

T=Torque = twisting moment = turning moment, N-mm

J= Polar movement of Inertia, mm4

τ= Torsional shear stress , N/mm2

G= Modulus of rigidity (or) shear modulus, N/mm2

l= Length of the shaft, mm

Cont…
Torsional rigidity:

T/J =Gθ/l

θ= T×l/G×J

The quantity G×J is called torsional rigidity

Power transmitted by shaft (p):

P = 2πNT/60 ---- Watts (or) N.m/s

T= torque-----N-m

N=speed------rpm
Cont…
Polar modulus zp:

T/J = τ/R

T = τ× J/R

J/R is called the polar modulus (zp)

T= τ. zp

For solid shaft of diameter (d)

J=πd4/32

R = d/2

Zp = J/R = πd3/16

T = τ× (πd3 /16) ---- N-mm



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

1.4 Allowable stress, Factor of Safety and Lateral Strain
Allowable/Working Stress:

 It is the safe stress taken within the elastic range of the material. For brittle
materials, it is taken equal to the ultimate strength divided by suitable factor
of safety. However, for materials possessing well defined yield point, it is
equal to yield stress divided by a factor of safety. It is the stress which
accounts all sorts of uncertainties.

 It is also called allowable stress, permissible stress, actual stress

and safe stress.
 1.4 Allowable stress, 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.

It is defined as the ratio of ultimate stress to working stress for brittle materials
or yield stress working stress for ductile materials

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

Original Lateral Dimension
 Hooke’s Law

1.5 Stress Strain Diagram
Ultimate Strength

Yield Point
Breaking Limit
STRESS/LOAD

Elastic Limit
Proportional 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.

 Stress Strain Diagram
• 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 plastic
mode.
 Stress Strain Diagram
• 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.
Cont…
 Percentage reduction in area:

% reduction in area = (A-A1)/A ×100

A – Original area of cross-section.m2

A1 – Cross- sectional area after fracture at the neck,m2

Percentage elongation:

% elongation in length= (l1-l/l × 100

l1 – Length of specimen after fracture, mm

l – original length, mm
 Examples #1
A cast iron link, as shown in Fig., is required to transmit a steady
tensile load of 45 KN. Find the tensile stress induced in the link
material at sections A-A and B-B.

#2. The piston rod of a steam engine is 50 mm in diameter and

600 mm long. The diameter of the piston is 400 mm and the
maximum steam pressure is 0.9 N/mm2. Find the compression of
the piston rod if the Young's modulus for the material of the
piston rod is 210 kN/mm2
 Examples #3
Acicular steel column is loaded at shown in fig. find the stresses
produced in the column.

#4. A steel column, square cross section

of 80 mm side carries a load of 150 KN @ an

eccentricity of 10 mm in a plane bisecting

the thickness. Find the maximum and

minimum intensities of stress in the section.

Examples #3
 Fig. shown a link, which has a rectangular cross section.

A pull of 25 KN acts @ an eccentricity equal to (1/4) th of the

link depth. Find the stresses induced in the link cross section
link depth=120 mm
Examples #4
 A crane hook has a section, which for the purpose of
analysis is considered trapezoidal as shown in fig. it is made
of plain carbon steel with an yield strength of 380 MPa in
tension. Determine the load capacity of the hook, for a factor
of safety of 3.
 Problem #5
A mild steel bracket as shown in fig., is subjected to a pull of
6000 N acting at 45º to its horizontal axis. The bracket has a
rectangular section whose depth is twice the thickness. Find
the cross- sectional dimensions of the bracket, if the
permissible stress in the material of the bracket is limited to
60 MPa.
 Problem #6
A mild steel bracket as shown in fig., is subjected to a pull of 6000
N acting at 45º to its horizontal axis. The bracket has a
rectangular section whose depth is twice the thickness. Find the
cross- sectional dimensions of the bracket, if the permissible
stress in the material of the bracket is limited to 60 MPa.
 Problem #7
A wall bracket of rectangular cross-section as shown in fig. It is
subjected to a pull of 6 kN acting at 30º to the horizontal. If
the maximum stress induced in the bracket material is not to
exceed 25 N/mm2 in both tension and compression. Design the
cross-section of the bracket.
 Problem #8
 The crane hook carries a load of 20 kN as shown in fig. The
section at X-X is rectangular whose horizontal side is 100
mmm. Find the stresses in the inner and outer fibers at the
given section.
 Problem #10
 The frame of a punch press is shown in fig. Find the stresses at
the inner and outer surface at section X-X of the frame,

if W= 5000N. (NOV/DEC 2013)

Problem #5
3. A C- clamp is subjected to a maximum load of W, as
shown in fig. If the maximum tensile stress in the clamp is
limited to 140 Mpa, find the value of load W. (M/J 2012)
Problem #6
1. A punch press, used for stamping sheet metal, has a punching
capacity 50 kN. The section of the frame is as shown in fig.
Find the resultant stress at the inner and outer fibre of the
section.
THANK YOU