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Lecture # 1

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19 views

Lecture # 1

Uploaded by

Muhammad Taimoor
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Machine Design and CAD-1 (Lecture # 01)

What is a Machine?
Anything that utilizes the energy in any available form to do some useful work.

What is Design?
Design is either to formulate a plan for the satisfaction of a specified need or to solve a specific
problem.

Mechanical engineering design means the design of the parts, products and systems of mechanical
nature.

Machine design deals with the design of machines, mechanisms and their elements. The design of
machines or mechanisms ultimately comes to the design of their individual elements.

DESIGN PROCEDURE
It consists of following steps:

1. Definition of Problem:
Define the design problem giving all input parameters, output parameters and constraints.

2. Synthesis:
Once the problem is defined, the next step is synthesis. Synthesis is the process of selecting or creating
the mechanism for the machine and the shapes of the mechanical elements to get the desired output
with the given input.

3. Analysis of Forces:
Draw the free body diagram of each element of the machines. Find out the forces (including moments
and torque) acting on each element by force analysis.

4. Selection of Material:
Select the suitable material for each element. Four basic factors that are to be considered while
selecting the materials are: availability, cost, mechanical properties, and manufacturing
considerations.

5. Determination of Mode of Failure:


Before finding out the dimensions of the elements, it is necessary to know the type of failure by which
the element will fail when put into the use.
6. Selection of Factor of Safety:
Based on the application, select the factor of safety. Knowing factor of safety and material strength,
determine the permissible or design stress.

7. Determination of Dimensions:
Find the dimensions of each element of the machine by considering the forces acting on the element
and the permissible stress.

8. Modification of Dimensions:
Modify the dimensions of the elements on the higher side, if required, based on the following
considerations:

▪ Selection of standard parts available in the market.


▪ Convenience of assembly
▪ Convenience of Manufacturing.

9. Preparation of Drawings:
Prepare working drawing of each element or component with minimum two views showing following
details:

a. Dimensions
b. Dimensional Tolerances
c. Surface Finish
d. Geometrical Tolerances
e. Special production requirement like heat treatment

Prepare assembly drawing giving part number, overall dimensions and part list. The component
drawing is supplied to the shop floor for manufacturing purpose, while assembly drawing is supplied
to the assembly shop.

10. Preparation of Design Report


Prepare design report containing details about step 1 to step 8.

DESIGN CONSIDERATIONS:
Design considerations are the characteristics which influence the design of the element or perhaps,
the entire system. Normally, several such characteristics must be considered in any design problem.
In a given design problem, the design engineer should identify the various design considerations and
incorporate them in the design process in their order of importance.
For example, in the design of a spring, two most significant design considerations are strength and
stiffness.
Some of the common design considerations are as follows:
1. Strength
A machine element should have enough strength to avoid failure either due to yielding or due to
fracture under the loads.
2. Rigidity
A machine element should have enough rigidity so that its linear as well as angular deflections, under
the loading are within permissible limits.
3. Reliability
The reliability is defined as the probability that a component, system or device will perform without
failure for a specific period of time under the specified operating conditions. A machine element
should have reasonably good reliability so that it can perform its function satisfactorily over its life
span.
4. Safety
A machine element should be designed such that it ensures safety of users and machine.
5. Cost
The life cycle cost of the machine element consists of production cost, operating cost, maintenance
cost and disposal cost. A machine element should have a minimum possible life cycle cost.
6. Weight
A machine element should have a minimum possible weight.
7. Manufacturing
In a design of machine element, the selection of manufacturing processes must be given a due
importance. The manufacturing processes should be selected such that the machine element can be
produces with minimum manufacturing cost and as far as possible, with existing manufacturing
facilities.
8. Conformance to Standards
A design of machine element should conform to the national and/or international standards and codes.
9. Assembly
A machine element or a product should be designed such that it facilitates to minimize the assembly
cost and time.
10. Friction and Wear
Friction and wear are major contributing factors for reducing the life of machine elements and
increasing the power loss. The friction can be reduced by improving the surface finish, adequately
lubricating the surfaces and replacing the sliding motion by rolling motion. The wear can be reduced
by increasing the surface hardness.
11. Life
A machine element should be designed for an adequate life.
12. Vibrations
A machine element should be designed so as to keep the vibrations at minimum level.
13. Thermal considerations
A machine element should be able to withstand the temperature to which it may be subjected. In
addition, it should dissipate the heat generated, if any.
14. Lubrication
In the design of machine elements, due considerations must be given for the lubrication of the
elements, if there is relative sliding or rolling motion between the elements.
15. Maintenance
A machine element should be such that it can be easily repaired or serviced.
16. Flexibility
A machine element should be flexible so that the modifications can be carried out with minimum
efforts.
17. Size and Shape
As far as possible, standard sizes and shaped should be adopted for machine elements
18. Stiffness
Whenever stiffness is a functional requirement like in springs, the machine element should be
designed with a precise value of required stiffness.
19. Corrosion
A machine element should be corrosion resistant. This can be achieved by a proper selection of
material and adopting the surface coating.
20. Noise
The machine element should be designed such that the noise during operation is at minimum.

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