Lecture 1

• Introduction to course Design of Machine

Elements
• Importance and application of course in
Mechanical Industry.
• Course Syllabus discussion
• Discussion on Course outcomes
• Activity – Quiz using MS Team 68 students
have submitted out of 78.
 Lecture 2
Concept of Machine Design

By
Prof. S. R. Patil
R.I.T.
 Word Design

• Interior Design

• Fashion Design

• Building Design

• Ship Design

• Mechanical Design

Ex. I. C. Engine
 Concept of Machine Design
• It is a creative, iterative process directed towards
fulfillment of human needs by using scientific
knowledge.
• Human needs should be well defined.
Ex. Gear shaft giving trouble, There have been 8
failures in the last 6 days.
• In contrast to scientific or mathematical problems,
design problems have no unique answer.
• Today’s good answer may turnout to be a poor answer
tomorrow.
 Lecture 3
• General Design Process
• Significance of stress-strain curves
• Use of stress strain curves in design
• Factor of Safety
• Activity – Quiz on MS Team on factor of safety
69 students have submitted out of 78.
 Market survey

Product Specification
`
Selection of Mechanism

Layout of Configuration
And
Selection of Joining Methods

Design of Individual Components

Assembly Preparation
And
Detailed Drawings
 Stress-strain curve for ductile & brittle
material

• Significance of stress-strain curves

• Use of stress strain curves in design

• Strength is the property of material.

Allowable stress/Design stress = Yield stress/Ultimate stress

Allowable stress/Design stress ˂ Yield stress/Ultimate stress

 Factor of Safety
F. S. = Failure Stress/Allowable Stress
F. S. = Failure load/Working Load

For Ductile Material

σ (Allowable Stress) = Syt / F.S.

For Brittle Material

σ (Allowable Stress) = Sut / F.S.
 Magnitude of F.S. Depends on
• Effect of Failure
• Type of Load
• Degree of Accuracy in force Analysis
• Material of Component
• Reliability of Component
• Cost of Component
• Testing of Machine Element
• Service Conditions
• Quality of Manufacture
 Lecture 4
Types of loads
• Static load – Force which gradually applied to a
mechanical component and which does not change its
magnitude or direction with respect to time.
• Uniformly varying load – Magnitude is varying along
the length.
• Uniformly distributed load – Not varying
• Fluctuating load – Load acting on shaft subjected to
bending.
• Impact load – Ex. Mechanical hammer, Gun
• Shock load – Ex. I C Engine piston.
 Basic Requirements of Machine Elements

•Strength – sufficient strength

•Rigidity – Should not deflect or bend
•Wear Resistance – Reduces useful life of component
•Min. Dimension & Weight
•Manufacturability Ease of fabrication & assembly
•Safety
•Conformance to Std.
• Reliability – component should perform its function over its lifetime
•Maintainability
•Min. Life Cycle Cost
 Lecture 5
Design of Machine Element
Specify Functions of Element

Specify Forces acting on Element

Select Material For Element

Determine Failure Mode of

Element

Determine Geometric
Dimensions of Element

Modify Dimensions for Assembly & Mfg.

and
Check Design for critical Cross- Sections

Prepare Working Drawing of Element

 Selection of Material
• Availability
• Cost
• Mechanical Properties
• Manufacturing Considerations
 Lecture 6
Mechanical Properties

The important mechanical properties of materials

from the considerations of design are

• Strength • Rigidity
• Resilience • Shock resistance
• wear resistance • Creep
• corrosion resistance • frictional properties
• Hardness • Toughness
 Contd…..
• Strength – is defined as the ability of the
material to resist, without rupture, to external
forces causing various types of stresses.
Strength is expressed as a tensile strength, a
compressive strength or a shear strength.
• Stiffness or rigidity - is defined as the ability of
the material to resist deformation under the
action of external load.
The modulus of elasticity is measure of stiffness.
 Contd….
• Resilience - is defined as the ability of the
material to absorb energy when deformed
elastically and release this energy when unloaded.
Resilience is measured by quantity called modulus
of resilience, which is strain energy per unit
volume.
It is represented by an area under stress-strain
curve from origin to the elastic limit point.
The property is essential for spring material.
 Contd….
• Toughness - is defined as the ability of the
material to absorb the energy before fracture
has taken place.
This property is essential for components
which are subjected to impact loads.
All structural steels are tough means are able
to bend, twist or stretch before fails.
• Modulus of toughness – is total area under
stress-strain curve.
 Difference

• Resilience is the ability of material to absorb

energy within elastic range.
• Toughness is the ability of the material to
absorb energy within elastic and plastic
range.
 Properties
• Hardness – is defined as the resistance of the
material to penetration or indentation.
• It is usually indicates resistance to abrasion,
scratching, cutting or shaping.
• Hardness is an important property in
selection of material for parts which rub on
one another such as pinion and gear, cam and
follower, rail and wheel and parts of ball
bearing.
 Ductility & Brittleness
• Ductile materials deform to greater extent
before fracture in tension test.
• Brittle materials show negligible plastic
deformation prior to fracture.
• Ductile material – steel, copper, and aluminum
• Brittle material – cast iron
• D.M. - Failure by gradual yielding
• B.M. – Failure by sudden fracture
 Contd….
• Depending up on the service condition and the
functional requirement, different mechanical
properties are considered and a suitable material is
selected.
Ex. – 1) connecting rod of IC engine – should be
capable to withstand fluctuating stresses, hence
endurance strength is criterion of design.
 Examples

• Piston ring – should have resistance to wear, so

surface hardness is design criterion.

• Bearing materials – low coefficient of friction.

• Resilience should be considered when a material is

subjected to shock loading.

 Contd…….

• Ductility is required in order to relieve stress

concentrations in the part.
• Weight may be important in case of foundations
and flywheels.
• Electrical and thermal properties are important
in expansion and contraction conditions.
Manufacturing Considerations

• Machinability is important consideration

• Sometimes an expensive material is more

economical than a low priced one which is
difficult to machine.
• For the product of complex shape casting
properties are important.
 Lecture 7
Sources of Design Data
• Handbooks
• Textbooks
• National & International Std. (Its more Use in Design)
• Manufacturer’s Catalogues
• Design Journals
 I.S. Coding for Various Engineering
Materials
• Designation of steels –
Steels are designated by group of letters or
numbers indicating any of the three
following properties,
Tensile strength
Carbon content
composition of alloying elements
 Contd….
• Steels on the basis of their tensile strength
are designated by two way
• I) symbol Fe followed by the tensile strength
in N/mm2
• FeE followed by yield strength.
• Ex. Fe360 – Min. tensile strength 360 N/mm2
FeE 250 – Min. yield strength 250 N/mm2
 Designation of Plain Carbon Steel
It consists of following three quantities
• A figure indicating 100 times avg. percentage of
carbon
• A letter C
• A figure indicating 10 times avg. percentage of
manganese.

Ex. 55C4 – 0.55 % carbon & 0.4 % manganese

A steel with 0.35 – 0.45 Carbon & 0.7 – 0.9 % manganese is
designated as 40C8.
Important Applications of Plain Carbon
Steel
• 7C4 – automobile bodies & hoods where
ability to deform i.e. ductility is important
consideration.
• 10C4 – case hardened components such as
cam & cam shaft, worm & gudgeon pin.
• 40C8 – transmission shaft, crank shaft,
spindle, connecting rod, stud & bolt
• 65C8 – Spring subjected to excessive stresses
 Lecture 8
Designation of Alloy Steels
• Chemical symbols of significant alloying
elements are arranged in descending order of
a percentage content.
• The avg. percentage of each alloying element
is indicated by the no. following its chemical
symbol.
• When the alloying element is less than 1 % it
is written up to two decimal places
underlined by a bar.
 Contd……
• Ex. – Carbon = 0.12 to 0.18 %
• Silicon = 0.10 to 0.35 %
• Manganese = 0.40 to 0.60 %
• Chromium = 0.50 to 0.80 %
Here average ‘c’ % is 0.15
Silicon & Manganese are not much important
The significant element is chromium and its average
percentage is 0.65 which is less than one percent .
• Therefore designation is 15 Cr 65
 Contd……..
• Carbon = 0.15 to 0.25 %
• Silicon = 0.10 to 0.50 %
• Manganese = 0.30 to 0.50 %
• Chromium = 16 to 20 %
• Nickel = 1.5 to 2.5 %
• The major alloying elements are chromium
and nickel
• 20 Cr 18 Ni 2
•P.C.S. - low or medium stresses, more cheaper.
•The tensile strength of plain carbon steels cannot be
increased beyond 700 N/mm2 without substantial loss in
ductility and impact resistance.
•Low corrosion resistance, poor impact resistance at low
temperatures.
Advantages-
•Alloy steels have higher strength, hardness and
toughness.
•It retains their strength & hardness at elevated
temperatures.
•Have higher resistance to corrosion and oxidation.
Effects of Major Alloying Materials
• Silicon – increases strength & hardness
without lowering ductility. Increases
toughness in spring steel.
• Manganese – increases strength &
hardness. Cheap alloying element.
• Nickel – increases strength, hardness &
toughness without lowering ductility.
Increases impact resistance at low
temperatures.
 Contd….

• Chromium – hardness &wear resistance. More

than 4 % Cr have excellent corrosion resistance.
It retains their strength & hardness at elevated
temperatures.
• Molybdenum - hardness &wear resistance. It
resist softening of steel during tempering and
heating.
• Tungsten – same effect as like molybdenum but
expensive alloying element.
 Guidelines for Selection
Components Material Reason
Spring wire 55Si7 Strength, Toughness
Screws, bolts & 40Ni14 Highly stressed so high
axles strength & toughness
Gears 40Cr4 Requires soft core & hard
surface
Surface hardness & wear
resistance, response to
heat treatment
Cams, camshaft & 16Ni3Cr2, Hardness, toughness,
transmission shaft 30Ni16Cr5 strength & ductility
 Lecture 9
Designation of Cast Irons
For gray cast iron – FG 200
FG is for Gray Cast Iron and Ultimate tensile strength is 200 N/mm2

Adv:

Available in large quantity

Complex shape

Compressive strength is 3 to 4 times more than that of steel

Excellent ability to damp vibrations – machine tool guides or frames

Wear resistance, Low notch sensitivity.

Drawbacks:

Poor tensile strength

Section sensitive

Brittle material – sudden fracture

 Types of CI
• Grey CI – Graphite flakes
Cyl. Block, brake drum, clutch plate, cylinder, cylinder head,
gears, housing of gear box, flywheel, machine frame, bed.
• Malleable CI- Iron carbide
First cast as white CI then after heat treatment becomes
malleable CI
Blackheart: BMtensile strength
(BM350 – Brake shoe, pedal, lever, axle)
Pearlitic: PMtensile strength
(PM 600 – Pipe fittings)
Whiteheart: WMtensile strength (WM400)
• Ductile CI – Nodular CI (nodular C in ductile
matrix)
SG200/2
200 – Tensile strength
2 – Elongation
Appl: Crankshaft, Heavy duty gears, Doorhinges
 Designation of Aluminum Alloys

• Aluminum alloys are designed by digital system.

• The numbers given to alloying elements in this

system are
Al – 1 Cu – 2 Mn – 3 Si – 4 Mg – 5
Magnesium silicate – 6 Zn – 7 Other element – 8

• Cast Al alloys are designated by four digit system

while wrought Al alloys by five digit system.
 Contd……..
• First digit – identifies major alloying
element
• Second digit – Avg. percentage of major
alloying element halved. (round off figure)
• Third, fourth & fifth digit – Identifies the
minor alloying elements in order of their
decreasing percentage.
 Example
• Al alloy – 9.8 % Cu, 1.0 % Fe, 0.25% Mg

First digit – Identification of Cu – 2

Second digit – Avg. %ge = 9.8/2 = 4.9 or 5 – 5
Third digit – Identification of Iron – 8
Fourth digit - Identification of Mg – 5

Complete designation is - 2585

 Design advantages
• Low specific gravity – Relative density for Al –
2.7 and for steel – 7.9 (1/3rd of steel) results in
light weight.
• Corrosion resistance – Thin but very dense
film of oxide.
• Ease of fabrication – Cubic crystal structure.
• High thermal conductivity
 Important Applications

• Alloy 4450 – engine cylinder block, castings

for valve body, large fan blade.
• Alloy 2280 – connecting rod & flywheel
housing
• Alloy 2285 – piston & cylinder head

• Alloy 4652 – piston of IC engine.

 Applications of Wrought Al

• Alloy 24534 – stressed components of

aircraft

• Alloy 54300 – welded structures and tank

• Alloy 74530 – welded pressure vessel

 Weight Point Method
Systematic Method for Selecting Material
1) Prepare a list of desirable properties of
material for the application.
2) Assigned values to desirable properties.
3) Divide properties in two groups go – no go
parameters.
4) Select material according to weighting factor.
1 to 5 - 1 for poorest and 5 for the best.
 Theories Of Elastic Failure

• Machine components are subjected to complex

loads
Ex. Power screw subjected to torsional load and axial load,
Transmission shaft or propeller shaft subjected to torsional
load, bending load and side thrust……….like wise complex
loads.
Failure of such components by
Elastic failure or
General yielding and fracture
 Lecture 10
Case Study on Selection of Material

• Road wheel tyre

• Car headlight cover

• Car chasis
 Theories Of Elastic Failure

• Theories of elastic failure provide a relationship between the

strength of machine component subjected to complex state of
stresses with the mechanical properties obtained in simple
tension test. (like yield strength, ultimate strength & percentage
elongation).

• The Principal theories of elastic failure are

- Maximum Principal stress theory (Rankine’s Theory)

- Maximum shear stress theory (Coulomb Tresca and

Guest’s Theory)

- Distortion energy theory (Huber Von Mises Theory)

 Theories Of Elastic Failure

• Maximum Normal Stress Theory

This theory postulates that failure will occur in
a machine part if the maximum normal stress in
the part exceeds the normal strength of the
material as determined from uniaxial testing.
• As the three principal stresses at a point in the
part σ1, σ 2 & σ3 may be comprised of both
tensile and compressive stresses, when this
theory is applied, we need to check for failures
both from tension and compression.
• The largest positive value among σ1, σ 2 & σ3is the
maximum tensile stress and the smallest negative
value is the maximum compressive stress.
• For Ductile Material-The maximum tensile stress
should be less than or equal to Syt/fs and The
magnitude of the maximum compressive stress
should less than Syc/fs

• For Brittle Material-The maximum tensile stress

should be less than or equal to Sut/fsand The
magnitude of the maximum compressive stress
should less than Suc/fs
• Maximum shear stress theory
This theory postulates that failure will occur in a
machine part if the magnitude of the maximum shear
stress (τmax) in the part exceeds the shear strength
(τsy)of the material determined from uniaxial testing.
(Mohr’s circle – Uni axial stress means σ = σ1 and σ2=
0)
τ max= σ1/2
Maximum shear stress during tension would be when
yielding begins, therefore, σ1 = Syt
τ max= Syt/2
Ssy= 0.5 Syt
Yield stress in shear is half of yield stress in tension.
 Distortion Energy theory
• The theory states that the failure of the
mechanical component subjected to bi axial or
tri axial stresses occurs, when the strain
energy of distortion per unit volume at any
point in the component, becomes equal to the
strain energy of distortion per unit volume in a
standard specimen of tension test when
yielding starts.
Thank you