Design of Machine Element

ME - 6205

Sujeet Kumar Mishra

Assistant Professor
Department of Mechanical Engineering
Birla Institute of Technology
(A Deemed University)
Mesra, Ranchi – 835 215 India

E-mail: sujeetmishra@bitmesra.ac.in
Machine design is defined as the use
of scientific principles, technical
information & imagination in the
description of a machine or a
mechanical system to perform
specific functions with maximum
economy & efficiency
Design Process
Basic requirements of Machine Elements

Strength
Rigidity
Wear Resistance
Minimum Dimensions & Weight
Manufacturability
Safety
Conformance to standards
Reliability
Maintainability
Minimum Life-cycle Cost
Basic procedure of Design of Machine Element
 Use of Standard in Design

Standardization is the obligatory norms, to which various characteristics of a

product should conform. The characteristics include materials, dimensions and
shape of the component, method of testing and method of marketing, packing
and storing of the product.

Following standards are used in Mechanical Engineering Design

i) Standards for materials, their chemical compositions, Mechanical properties &

heat treatment
ii) Standards for shapes and dimensions of commonly used machine elements
iii) Standards for fits, tolerances and surface finish of component
iv) Standards for testing of products
v) Standards for engineering drawing of components
Ergonomic considerations in Design
The word ergonomics is coined from two Greek words
‘ergon’ means ‘work’ and ‘nomos’ means ‘natural laws’
Ergonomics means the natural laws of work
Ergonomics is defined as the relationship between man and machine and the application of
anatomical, physiological & pshychological principles to solve the problems arising from man-
machine relationship.

Man-Machine closed loop system

Preferred Numbers
The system is based on the use geometric progression to develop a set of numbers
There are five basic series denoted as R5, R10, R20, R40, and R80 series which increases
in steps of 56%, 26%, 12%, 6% and 3% respectively
Each series has its own series factor as shown below
Q (1) Find out the number of the R5 basic series from 1 to 10

Q (2) Find out the numbers of R20/4 (100, ……………………..1000) derived series

Q (3) A manufacturer is interested in starting a business with five different models of tractors
ranging from 7.5 to 75 kW capacities. Specify power capacities of the models. There is an
expansion plan to further increase the number of models from five to nine to fulfill the
requirement of farmers. Specify the power capacities of the additional models.
Selection of Material
• Selection of proper material for the machine components is one of the most
important steps in process of machine design
• The best material is one which will serve the desired purpose at minimum costs

Factors Considered while selecting the material:

i) Availability: Material should be readily available in market in large enough
quantities to meet the requirement
ii) Cost:
iii) Mechanical properties:
iv) Manufacturing Considerations:
• In some applications machinability of material is an important consideration in
selection
• Where the product is of complex shape, castability or ability of the molten metal
to flow into intricate passages is the criterion of material selection
• In fabricated assemblies of plates & rods, weldability becomes the governing
factor
Engineering Materials

Stress-Strain diagram of ductile materials

Mechanical Properties of Materials
a) Strength: Ability of the material to resist, without rupture, external forces causing
various types of stresses
b) Elasticity: Ability to regain its original shape & size after deformation, when the
external forces are removed
c) Plasticity: Ability to retain the deformation produced under the load on a permanent
basis
d) Stiffness or Rigidity: Ability to resist deformation under the action of an external
load
e) Resilience: Ability to absorb energy when deformed elastically & to release this
energy when unloaded
f) Toughness: Ability to absorb energy before fracture takes place
g) Malleability: Ability to deform to a greater extent before the sign of crack, when it is
subjected to compressive force
h) Ductility: Ability to deform to a greater extent before the sign of crack, when
subjected to tensile force
i) Brittleness: Property of the material which shows negligible plastic deformation
fracture takes place
j) Hardness: Resistance to penetration or permanent deformation
 Cast Iron
Cast iron is an alloy of iron & carbon, containing more than 2% of carbon
Typical composition of ordinary cast iron is:
Carbon = 3-4%
Silicon = 1-3%
Manganese = 0.5-1%
Sulphur = up to 0.1%
Phosphorous = up to 0.1%
Iron = Remainder
The mechanical properties of cast iron components are inferior to the parts, which
are machined from rolled steels
Advantages:

Available in large quantities, higher compressive strength, components can be given

any complex shape without involving costly machining operations, excellent ability to
damp vibrations, more resistance to wear even under the conditions of boundary
lubrication, mechanical properties of parts do not change between room temperature
and 350 degree centigrade
 Designation of STEELS
Steels are designated by a group of letters or numbers indicating any one of the
following three properties
•Tensile strength
•Carbon content
•Composition of alloying elements

Example:
Fe 360 indicates a steel with a minimum tensile strength of 360 N/mm2
FeE 250 indicates a steel with a minimum yield strength of 250 N/mm2

55C4 indicates a plain carbon steel with 0.55% carbon and 0.4% manganese
40C8 indicates a steel with 0.35-0.45% carbon and 0.7-0.9% manganese

25C12S14 indicates a free cutting steel with 0.25% carbon, 1.2% manganese and 0.14%
sulphur
20C12Pb15 indicates a free cutting steel with an average of 0.20% carbon, 1.2%
manganese, and 0.15% lead
 Plain Carbon Steels
Depending upon the percentage of carbon, plain carbon steels are classified as:
i) Low carbon steel – Less than 0.3% carbon, popularly known as mild steel, its soft
& ductile, easily machined & welded, however due to low carbon content
unresponsive to heat treatment
ii) Medium carbon steel – carbon content in the range of 0.3% to 0.5%, popularly
known as machinery steel, easily hardened by heat treatment , stronger &
tougher than low carbon steel, well machined, respond readily to heat treatment
iii) High carbon steel – more than 0.5% carbon, popularly known as hard steels or
tool steels, respond readily to heat treatment, when heat treated attain high
strength combined with hardness, less ductile than low carbon steels & medium
carbon steels, difficult to weld, excessive hardness accompanied by excessive
brittleness
In applications like automobile bodies & hoods, the ability of the material to deform to
a greater extent or ‘ductility’ is the most important consideration so a plain carbon
is preferred
In applications like gears, machine tool spindles & transmission shaft, strength
toughness & response to heat treatment are important considerations, medium &
high carbon steels are preferred
Spring wires are subjected to severe stress & strength is the most important
consideration so high carbon steel is selected for helical & leaf springs
 Alloy Steels
• Carbon steel to which one or more alloying elements are added to obtain certain
beneficial effects
• The commonly added elements include silicon, manganese, nickel, chromium,
molybdenum and tungsten
• The term ‘alloy steels’ usually refers to ‘low’ alloy steels containing from 1-4% of
alloying elements
• Alloy steels have higher strength, hardness & toughness, higher hardenability,
retain their strength & hardness at elevated temperatures, higher resistance to
corrosion and oxidation
Silicon increases strength & hardness without lowering the ductility. Silicon is added
in spring steel to increase its toughness
Manganese increases hardness and toughness and also increases the depth of
hardening
Nickel increases strength, hardness and toughness without sacrificing ductility
Chromium increases hardness & wear resistance, steel containing more than 4%
chromium have excellent corrosion resistance
Molybdenum increases hardness & wear resistance, resists softening of steel during
tempering and heating
Tungsten & molybdenum have similar effects. Tungsten is expensive. 2-3% tungsten
is required to replace 1% of molybdenum

Application of Alloy steels

55Si7 Leaf and coil springs

37C15 Axle, shaft and crankshaft
35Mn6Mo3 Bolt, stud, axle lever and general engineering components
16Mn5Cr4 Gears and shafts
40Cr4 Coil, laminated and volute springs
40Cr4Mo2 Shaft, axle high tensile bolt, stud and propeller shaft
40Cr13Mo10V2 Components subjected to high tensile stresses
30Ni5Cr2 Heavy duty gears
40Ni6Cr4Mo2 General machine parts, nuts and bolts, gears, axles, shafts and
connecting rod
Ceramics
Plastics
Fibre Reinforced Plastics
Natural & Synthetic Rubbers
Tolerances
• Due to the inaccuracy of manufacturing methods, it is not possible to machine a
component to a given dimension
• The components are so manufactured that their dimensions lie between two limits –
maximum and minimum
• The basic dimension is called the normal or basic size while the difference between
the two limits is called permissible tolerance
• Tolerance is the permissible variation in the dimensions of the component
• The two limits are the upper and lower deviations
• There are two systems of specification for tolerances namely unilateral & bilateral

• In unilateral systems, one tolerance is zero while the other takes care of all
permissible variations in basic size

Example:

• In case of bilateral tolerances, the variations are given in both directions from
normal size

• The upper limit in this case is the basic size plus non-zero positive tolerance and
the lower limit is the basic size plus non-zero negative tolerance

Example:
Fits
• When two parts are to be assembled, the relationship resulting from the difference
between their sizes before assembly is called a fit
• Depending upon the limits of the shaft & hole, fits are broadly classified into three
groups – clearance fit, transition fit and interference fit
• Clearance fit always provide a positive clearance between the hole and the shaft
over the entire range of tolerances
• Interference fit always provides a positive interference over the whole range of
tolerances
• Transition fit provides either a clearance or interference depending upon the actual
values of the individual tolerances of the mating components

Types of Fits: (a) Clearance fit (b) Transition fit (c) Interference fit
Design against Static loads
A static load is a force which is gradually applied to a mechanical component and
which does not change its magnitude or direction with respect to time
A mechanical components may fail, i.e., may be unable to perform its function
satisfactorily, as a result of any one of the following three modes of failure:
i) Failure by elastic deflection
ii) Failure by general yielding &
iii) Failure by fracture
In applications like transmission shaft supporting gears , the maximum force
acting on the shaft, without affecting its performance, is limited by the permissible
elastic deflection. Elastic deflection results in unstable conditions, such as
buckling of columns or vibrations
A mechanical components made of ductile material loses its engineering
usefulness due to a large amount of plastic deformation after the yield point is
reached. Considerable portion of the component is subjected to plastic
deformation called general yielding
Components made of brittle material cease to function satisfactorily because of
the sudden fracture without any plastic deformation. The failure in this case is
sudden & total
Design of Cotter Joint
• A cotter joint is used to connect two co-axial rods, which are subjected to either axial
tensile force or axial compressive force
• It is also used to connect a rod on one side with some machine part like a crosshead
or base plate on the other side
• It is not used for connecting shafts that rotate & transmit torque

Typical applications of cotter joint:

i) Joint between the piston rod & the crosshead of a steam engine
ii) Joint between the slide spindle & fork of the valve mechanism
iii) Joint between the piston rod & the tail or pump rod
iv) Foundation bolt
 Notations used:

P = tensile force acting on rods (N)

d = diameter of each rod (mm)
d1 = outside diameter of socket (mm)
d2 = diameter of spigot or inside diameter of socket (mm)
d3 = diameter of spigot-collar (mm)
d4 = diameter of socket-collar (mm)
a = distance from end of slot to the end of spigot on rod-B (mm)
b = mean width of cotter (mm)
c = axial distance from slot to end of socket collar (mm)
t = thickness of cotter (mm)
t1 = thickness of spigot-collar (mm)
l = length of cotter (mm)
 Design procedure for Cotter joint
i) Calculate the diameter of each rod by
d= 4P/πσt
ii) Calculate the thickness of the cotter by the empirical relation
t = 0.31d
iii) Calculate the diameter d2 of spigot on the basis of tensile stress
P = [π/4(d22 - d2 t]σt
iv) Calculate the outside diameter d1 of the socket on the basis of tensile stress in
the socket
P = [π/4(d12 – d22) – (d1 – d2)t] σt
v) The diameter of the spigot collar d3 & diameter of the socket collar d4 are
calculated by the following empirical relationship
d3 = 1.5d
d4 = 2.4d
vi) The dimensions ‘a’ and ‘c’ are calculated by the following empirical relationship
a = c = 0.75d
vii) Calculate the width ‘b’ of the cotter by shear consideration and bending
consideration and select the width, whichever is maximum between these two values


b = P/2 t or
Knuckle Joint
Knuckle Joint is used to connect two rods whose axes either coincide or intersect
and lie in one plane
Knuckle joint is used to transmit axial tensile force
The construction of this joint permits limited angular movement between rods, about
the axis of the pin
Knuckle joint is unsuitable to connect two rotating shafts which transmit torque

Typical application of Knuckle joint

i) Joints between the tie bars in roof trusses
ii) Joints between the links of a suspension bridge
iii) Joints in valve mechanism of a reciprocating engine
iv) Fulcrum for the levers
v) Joints between the links of a bicycle chain
Threaded Joints
Threaded joint is defined as a separable joint of two or more machine parts that are
held together by means of a threaded fastening such as a bolt and a nut
It is used to hold two or more machine parts together. These parts can be dismantled
if required without any damage to machine parts or fastening, therefore detachable
joints