21RTC301A - Design of Machine Elements

Lecture- 1

Introduction-1
Course Leader:

Praveen Kittali
[email protected]

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Lecture Objectives
At the end of this lecture, students will be able to:
• Define a machine, types of machine design

• Explain the general machine design considerations and design procedure

• Describe the significance of mechanical properties of engineering materials

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What is a “Machine”?
• Definition:

A machine is an assemblage of rigid bodies that transmits and/or transforms forces,

motion and energy in a predetermined manner, to do work.

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Introduction to Engineering Design

• Modern industry requires Mechanical Engineers who are capable of designing machinery to
perform tasks by receiving an explanation or statement of the task which the machine is to
perform

• The science and art of dealing with materials and forces to achieve economic design, assuring
most advantageous combination of Accuracy, Safety, Durability, Speed, Simplicity, Efficiency.

• The profession in which a knowledge of the mathematical and physical sciences gained by study,
experience and practice is applied with judgment to develop materials economically for the
progressive well being of mankind.

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Design
• To design is to innovate and to create.

• To design is either to formulate a plan for the satisfaction of a specified need or to solve a
problem.

• The process of designing is to suggest or outline ways to put together man-made things, or to
suggest modifications in man-made things to satisfy optimally (under given constraints) some
specified human needs.

• Finding the right physical components of a physical structure to give optimal solution for a
particular set of solutions.

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Difference between Design and
Engineering design
• Difference between Design and Engineering design is the level of sophistication required in the
manipulation and application of technological factors and the extent to which a well developed
understanding of the underlying physical phenomena is necessary.

• When the technology involved is complex then the design is termed as Engineering Design and if
the routine technology can be used to accomplish the goal, it is termed as Design.

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Classification of Machine Design
• Adaptive design:
 In this case, work is concerned with the adaptation of existing designs.

 Design needs no special knowledge or skill and ordinary technically trained designers can
attempt.
 Designer only makes minor alteration or modification in the existing designs of product

• Development design:
 Designer needs considerable scientific training and design ability in order to modify the existing
design into a new idea by adapting a new material of new manufacturing method.

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 Though the designer starts with existing design, but the final product may differ quite markedly
from the original product
• New design:
 This type needs lot of research, technical ability and creative thinking. Only those designers who
have personal qualities of a sufficiently high order can take up a new design

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General Steps in Machine Design
Voice of customer and identification of
need

Technical Specifications of the product

Dynamics
Study alternative mechanisms for the and
product and select proper mechanism Mechanism
Design
Identify individual components and
Prepare general layout of configuration

Design individual components ,

assemble and produce final machine
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General Considerations in a Machine Design
• Type of stresses caused by the load.

• Motion of the parts or Kinematics of the machine: Motions may be Rectilinear ( such as
reciprocating motions), Curvilinear( rotary, oscillatory and simple harmonic), Constant velocity,
constant or variable acceleration.

• Selection of materials: The designer should have thorough knowledge about the properties of the
materials and their behavior under the working/loading conditions. Some of the properties
include strength, weight, durability, resistance to heat and corrosion etc.

• Form & Size of the parts: In order to design any machine part for form and size, it is necessary to
know the forces which the part must sustain . It is important anticipate any suddenly applied or
impact load which may cause failure.
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General Considerations in a Machine Design
• Frictional resistance and lubrication: There is always a loss of power due to frictional resistance and it
is, therefore, essential that a careful attention must be given to the matter of lubrication at all contact
surfaces.

• Use of Standard parts: The standard or stock parts should be used whenever possible; parts for which
patterns are already in existence such as gears, pulleys and bearings and parts which may be selected
from regular shop stock as screws, nuts and pins. The use of standard parts is closely related to cost,
because the cost of standard or stock parts is only a fraction of the cost of similar parts made to order.

• Safety of operation: Any high speed moving part which is regarded as dangerous to operate is
considered as accident hazard and hence designer should always provide safety devices for the safety
of the operator.

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General Considerations in a Machine Design
• Work shop facilities: A designer should be familiar with his employer’s workshop limitations so as
to avoid the necessity of having work done in some other workshop. And designer should always
plan and supervise the work shop operations and to draft methods for casting, handling and
machining special parts.

• Cost of construction: The aim design engineer under all conditions should be to reduce the
manufacturing cost to the minimum.

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Design Process
• The process begins with an identification of a
need and a decision to do something about it.
• After many iterations, the process ends with
the presentation of the plans for satisfying
the need.
• Depending on the nature of the design task,
several design phases may be repeated
throughout the life of the product, from
inception to termination.

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Identification of Need
• Identification of need generally starts the design process. Recognition of the need and phrasing
the need often constitute a highly creative act, because the need may be only a vague discontent,
a feeling of uneasiness, or a sensing that something is not right.

• The need is often not evident at all; recognition is usually triggered by a particular adverse
circumstance or a set of random circumstances that arises almost simultaneously.
• For example, the need to do something about a food-packaging machine may be indicated by the
noise level, by a variation in package weight, and by slight but perceptible variations in the quality
of the packaging or wrap.

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Definition of problem
• The definition of problem is more specific and must include all the specifications for the object
that is to be designed.

• The specifications are the input and output quantities, the characteristics and dimensions of the
space the object must occupy, and all the limitations on these quantities.

• We can regard the object to be designed as something in a black box. In this case we must specify
the inputs and outputs of the box, together with their characteristics and limitations.
• The specifications define the cost, the number to be manufactured, the expected life, the range,
the operating temperature, and the reliability.
• Specified characteristics can include the speeds, feeds, temperature limitations, maximum range,
expected variations in the variables, dimensional and weight limitations, etc.
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Synthesis
• The synthesis of a scheme connecting possible system elements is sometimes called the invention
of the concept or concept design.

• This is the first and most important step in the synthesis task.

• Various schemes must be proposed, investigated, and quantified in terms of established metrics.

• It has to be noted, and emphasized, that design is an iterative process in which we proceed
through several steps, evaluate the results, and then return to an earlier phase of the procedure.

• Thus, we may synthesize several components of a system, analyze and optimize them, and return
to synthesis to see what effect this has on the remaining parts of the system.

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Synthesis

• For example, the design of a system to transmit power requires attention to the design and
selection of individual components (e.g., gears, bearings, shaft).

• However, as is often the case in design, these components are not independent.

• In order to design the shaft for stress and deflection, it is necessary to know the applied forces.

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Functions and Design requirements
• Ultimate objective of mechanical design is to produce a useful device that is safe, efficient,
economical and practical to manufacture.

• It is important to define the functions of device/ component clearly and completely in the
beginning.

• These statements of functions tell what the device is supposed to do.

• After the functions are defined, a set of design requirements is prepared.

• Design requirements must be detailed and specific, giving quantitative data wherever possible.

• Careful preparation of function statements and design requirements will ensure that the design

effort is focused on the desired results.

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Machine design criteria
While working on the procedure the designer must be care full to consider every important factor
which should rightfully influence his design. In general, the most important points are
1.Proper functioning of the finished machine
2.Cost
3.Lubrication
4.Strength and rigidity of parts
5.Ease of manufacture and assembly
6.Wear of parts
7.Ease of service and replacement of parts
8.Proportion of parts
9.Appearance that is attractive and appropriate to the
application
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Procedure of Machine Design
• Before starting work on the design of any machine, get thoroughly familiar with what the machine is
intended to accomplish and what special requirements or limitations must be considered.

• Make free hand sketches of various ways the machine might be constructed and make any preliminary
calculations which might be required to substantiate your ideas or to establish approximate sizes.

• Make a layout drawing of the feasible construction of the machine bringing out the details of the
construction.

• Analyze the layout of forces, stresses etc. and make whatever calculations are necessary to be certain
that the parts will perform satisfactorily.

• Revise the layout drawing as necessary for the finished design.

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Materials Science and Engineering

• Materials science deals with basic knowledge about the internal structure, properties and
processing of materials.

• Materials engineering deals with the application of knowledge gained by materials science to
convert materials to products.
Materials Science and
Materials Science Engineering Materials Engineering

Basic Knowledge Resultant Applied

of Knowledge Knowledge
Materials of Structure and of Materials
Properties

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Processing, Structure and Properties

• Required Performance determines material properties

• Properties depend on structure

• Processing can change structure

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Types of Engineering Materials

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Types of Engineering Materials

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Case Study – Material Selection

• Problem: Select suitable material for bicycle frame and fork

Carbon fiber
Steel and Aluminum Ti and Mg
Wood Reinforced
alloys alloys alloys
plastic

Low cost but Light and Very light and Light, moderately Slightly better
Heavy. Less strong. But strong. No Strong. Corrosion Than Al
Corrosion Cannot be corrosion. Resistance. alloys. But much
resistance shaped Very expensive expensive expensive

Cost important? Select steel

Properties important? Select CFRP

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Some of the metallic and nonmetallic
materials used in a typical automobile

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Mechanical Properties
• Stiffness - Elastic Modulus or Young’s Modulus (MPa)

• Strength - Yield, Ultimate, Fracture, Proof, Offset Yield. Measured as stress (MPa)

• Ductility - Measure of ability to deform plastically without fracture - Elongation,

Area Reduction, Fracture Strain - (no units or mm/mm)

• Toughness, Resilience - Measure of ability to absorb energy (J/m3).

• Hardness - Resistance to indentation/abrasion (Various scales, e.g.; Rockwell,

Brinell, Vickers.)

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Mechanical Behaviour of Materials
• Mechanical behaviour of materials is the study of deformation and fracture of
materials.

• Materials tests are used to evaluate the behaviour of a material, such as its
resistance to failure in terms of the yield strength or fracture toughness.

• The materials strength is compared with the stresses expected for a component in
service to assure that the design is adequate.

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Summary
• The following concepts which are important from the point of machine
component design and material selection during design process are discussed
along with the meanings of Design, Machine design, Mechanical engineering
Design.
– Functions and Design requirements
– Machine design criteria & general design procedure
– Mechanical Properties
– Mechanical behaviour of materials
– Uniaxial tension testing
– Concepts of strength and failure resistance
– Different types of failures

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Course Details
• Programme: B. Tech. (Mechanical Engineering)
• Department: Mechanical & Manufacturing Engineering
• Head of the Department: Dr. N. C. Mahendra Babu (
[email protected])
• Faculty: Engineering & Technology
• Dean: Dr. Dilip Kumar Mahanty ([email protected])

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Course Details

This course is aimed at preparing the students to carry out design of common
machine elements used in robots. Students will acquire the knowledge on stress
analysis of different components subjected to different types of loadings to
predict state of stress under static condition. Students will be taught to design
machine components based on predicted stress state andappropriate failure
theories. Students will be able to analyse and design machine components like
shafts, power screws, couplings and mechanical joints like fastener joints, gears,
bearings and chains.
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Course Intended Learning Outcomes (ILO)
After undergoing this course, students will be able to:
• Describe basic concepts and principles of machine component design
• Identify the loading conditions on a machine element and predict state of stress
at critical locations
• Calculate design stress based on appropriate failure theory and select suitable
material
• Design machine elements like shafts, keys and couplings, power screws, gears,
chains
• Perform iterative design calculations to achieve induced stress values well within
design stress values for various machine elements
The course is being delivered to meet the highlighted objective of the programme to achieve the
programme aim.
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Course Content
Unit 1 - Introduction, Load Analysis, Stress, Strain and Deflection
Introduction:
General considerations, factors affecting machine design, procedure of machine design;
Material properties and selection
Load Analysis:
Types of loads - static-axial, bending, torsion, dynamic, Impact Loading and cyclic loadings
Stress, Strain and Deflection:
Stress analysis, Simple stress, combined stresses, Principal stress, Maximum shear stress,
uniaxial, biaxial and triaxial states of stress; Examples involving different types of
machinery components
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Course Content
Unit 2 - Stress concentrations and Static Failure Theories
Stress concentrations:
Stress concentration under static loading, determination of stress concentration factors,
designing to avoid stress concentrations; Examples involving different types of machinery
components
Static Failure Theories:
Need of failure theories, Maximum shear stress theory, Distortion energy theory,
Maximum principal stress theory, Mohr's theory, design of simple machine elements using
failure theories

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Course Content
Unit 3 - Design of shafts, keys and coupling
Design of shafts, keys and coupling:
Types of shafts, shaft design on strength and torsional rigidity basis, ASME Code, design of hollow
shafts; types of keys, design of flat and square key, design of splines; types of couplings, design
procedure for couplings, design of rigid flange coupling and flexible coupling
Unit 4 - Design of Power Screws and Threaded Fasteners
Types of screws, Terminology of power screws, self-locking screw, torque requirement-lifting load
and lowering load, design of screw and nut, threaded joints, types of screw fastening, terminology
of screw threads, ISO Metric screw threads, torque requirement of bolt tightening, design of
turnbuckle, elastic analysis of bolted joints
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Course Content
Unit 5 - Design of Gear
Classification of gears; Nomenclature; Law of gearing, Conjugate action, Gear profiles,
Pressure angle, Standard gear tooth, Backlash, Interference and undercutting; Simple and
compound gear trains; Force analysis, Gear tooth failure, Material selection, Gear blank
design, Strength of gear tooth, Permissible stress, Module estimation with beam and wear
strength; Design of spur gear; Internal gear, helical gear, Herringbone gear, bevel and worm
gears

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Course Content
Unit 6 - Design of Rolling Contact Bearings and Design of Chain Drives
Overview of types and classification of bearings, static and dynamic load bearing capacity,
Stribeck's equation, equivalent bearing load, load-life relationship, load factor, equivalent
bearing load, selection of bearings from manufacturer's catalogue, mounting of bearing
Advantages of Chain drives over other drives, geometrical relationships in roller chains,
polygonal effects, power rating based on failure criteria’s, design of chain drives

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References
a. Essential Reading
1. Class Notes
2. V. B. Bhandari, 2007, Design of Machine Elements, Tata McGraw-Hill
3. K. Lingaiah, 2002, Machine design Data Hand Book, Volume I and II,
Suma Publications
4. Joseph Shigley, Charles Mischke, and Richard Budynas, 2003, Mechanical
Engineering Design, McGraw-Hill Professional
b. Recommended Reading
1. Robert C. Juvinall, Kurt M. Marshek, 2000, Fundamentals of Machine
Component Design, John Wiley and Sons
2. Joseph Shigley, Charles Mischke, Thomas H. Brown, 2004, Standard Handbook of
Machine Design, McGraw-Hill Professional
3. Robert L. Norton, 2005, Machine Design: An Integrated Approach, Prentice Hall
4. Boris M. Klebanov, David Barlam, Frederic E. Nystrom, 2007, Machine Elements:
Life and Design, CRC Press
5. Allen S. Hall, Alfred R. Holowenko, Herman G. Laughlin, 2000, Schaum's Outline of
Theory and Problems of Machine Design, McGraw-Hill Professional
6. Robert L. Mott, 1992, Machine Elements in Mechanical Design, Merrill 38
 References

c. Magazines and Journals

1. Journal of Advanced Mechanical Design, Systems, and Manufacturing
2. Journal of Machine Design

d. Other Electronic Resources

1. http://www.machinedesignonline.com
2. http://www.asminternational.org
3. https://nptel.ac.in/

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