ME 306

DESIGN OF MECHANICAL COMPONENTS

Course Coordinator:
DR. SHIVDAYAL PATEL
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
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 ME 306 (3L+1T) Credit :4
Design of Mechanical Components
• Introduction,
• Design of Cotter and Knuckle Joint,
• Design of Thick and Thin cylinders,
• Design of Shafts, Keys and Coupling,
• Design of Bolted and Welded Joints,
• Design of Springs, Selection of Bearings,
• Design and Selection of Gears and Belts,
• Design of Clutches and Brakes,
• Design for variable loading.
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 Text Books
1. Richard G. Budynas and Keith Nisbett, “Shigley’s Mechanical
Engineering Design,” 10th Edition, McGraw-Hill, 2014.
2. The Elements of Mechanical Design: James G. Skakoon
3. Fundamentals of Machine Component Design Robert C.
Juvinall and Kurt M, Marshek, Wiley; 5th edition.
4. Robert L. Norton, “Machine Design– An Integrated
Approach,” 5th Edition, Prentice Hall,2013.
5. Design of Machine Elements : V. B. Bhandari
6. Design Data Hand Book for Mechanical Engineering's : K.
Mahadevan and K. Balaveera Reddy
7. Design Data book of Engineers: PSG college of Technology
Coimbatore

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 DESIGN
 Design is essentially a decision-making process.
 If we have a problem, we need to design a solution.
 In other words, to design is to formulate a plan to satisfy a
particular need and to create something with a physical
reality.
• Consider for an example, design of a chair.
A number of factors need be considered first:
(a) The purpose for which the chair is to be designed such as
whether it is to be used as an easy chair, an office chair or to
accompany a dining table.
(b) Whether the chair is to be designed for a grown up person or a
child.
(c) Material for the chair, its strength and cost need to be
determined.
(d) Finally, the aesthetics of the designed chair.
• Almost everyone is involved in design, in one way or the other, in our
daily lives because problems
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 Basic concept of machine design
• Decision making comes in every stage of design.
• Consider two cars of different makes.
• They may both be reasonable cars and serve the same purpose but
the designs are different.
• The designers consider different factors and come to certain
conclusions leading to an optimum design.
• Market survey gives an indication of what people want.
• For example, once we decide the engine capacity, the shape and
size, then the subsequent course of the design would follow.
• A bad decision leads to a bad design and a bad product.
• Design may be for different products and with the present
specialization and knowledge bank, we have a long list of design
disciplines e.g. ship design, machine Design, building design,
process design, bridge design, clothing or fashion design and so on.

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 Machine Design
• Machine design is defined as the use of scientific principles, technical information and
imagination in the description of a machine or a mechanical system to perform specific
functions with maximum economy and efficiency.

This definition of machine design contains the following important features:

(i) A designer uses principles of basic and engineering sciences such as physics,
mathematics, statics and dynamics, thermodynamics and heat transfer, vibrations and
fluid mechanics. Some of the examples of these principles are
(a) Newton’s laws of motion, (b) D’ Alembert’s principle,
(c) Boyle’s and Charles’ laws of gases, (d) Carnot cycle, and
(e) Bernoulli’s principle.
(ii) The designer has technical information the basic elements of a machine. These
elements include fastening devices, chain, belt and gear drives, bearings, oil seals and
gaskets, springs, shafts, keys, couplings, and so on.
(iii) The designer uses his skill and imagination to produce a configuration, which is a
combination of these basic elements.

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 Machine Design
• We now define a machine as a combination of resisting
bodies with successfully constrained relative motions
which is used to transform other forms of energy into
mechanical energy or transmit and modify available
energy to do some useful work.
• If it converts heat into mechanical energy we then call
it a heat engine.

Fig.1 Conversion of heat to mechanical energy in a piston cylinder arrangement

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 This modification or transformation of energy requires a number of
machine elements, some small and some large.
 Machine design involves primarily designing these elements so that they
may transmit the forces safely and perform their task successfully.
 Consider the following simple mechanisms:
(a) Hand winch
(b) Small press operated by a power screw
In each one of these mechanisms some useful work is being obtained with
certain combinations of a number of machine parts.

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 Types of design
There may be several types of design such as
• Adaptive design
This is based on existing design, for example, standard products or systems
adopted for a new application. Conveyor belts, control system of machines
and mechanisms or haulage systems are some of the examples where
existing design systems are adapted for a particular use.
• Developmental design
Here we start with an existing design but finally a modified design is
obtained.
A new model of a car is a typical example of a developmental design.
• New design
This type of design is an entirely new one but based on existing scientific
principles. No scientific invention is involved but requires creative thinking
to solve a problem.
Examples of this type of design may include designing a small vehicle for
transportation of men and material on board a ship or in a desert.
Some research activity may be
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 Types of design based on methods

• Rational design:
This is based on determining the stresses and strains of components and
thereby deciding their dimensions.
• Empirical design:
This is based on empirical formulae which in turn is based on experience and
experiments.
• For example, when we tighten a nut on a bolt the force exerted or
the stresses induced cannot be determined exactly but experience shows
that the tightening force may be given by P=284d where, d is the bolt
diameter in mm and P is the applied force in kg.
There is no mathematical backing of this equation but it is based on
observations and experience.
• Industrial design:
These are based on industrial considerations and norms viz. market survey,
external look, production facilities, low cost, use of existing standard products.

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 Factors to be considered in machine design
• Some of these factors are as follows:
a) What device or mechanism to be used? This would decide
the relative arrangement of the constituent elements.
b) Material
c) Forces on the elements
d) Size, shape and space requirements.
e) The final weight of the product is also a major concern.
f) The method of manufacturing the components and their
assembly.
g) How will it operate?
h) Reliability and safety aspects
i) Maintenance, cost and aesthetics of the designed product.

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• Material-
• This is a very important aspect of any design. A wrong choice of material may
lead to failure, over or undersized product or expensive items. The choice of
materials is thus dependent on suitable properties of the material for each
component, their suitability of fabrication or manufacture and the cost.
• Load-
• The external loads cause internal stresses in the elements and these stresses
must be determined accurately since these will be used in determining the
component size. Loading may be due to:
i) Energy transmission by a machine member.
ii) Dead weight.
iii) Inertial forces.
iv) Thermal effects.
v) Frictional forces.
In other ways loads may be classified as:
i) Static load- Does not change in magnitude and direction and normally
increases gradually to a steady value.
ii) Dynamic load-
a) changes in magnitude- for e.g. traffic of varying weight passing a bridge.
b) changes in direction- for e.g. load on piston rod of a double acting cylinder.

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 Loading

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 Engineering Materials

Instructional Objectives
• Properties and applications of common engineering materials.
• Types and uses of ferrous metals such as cast iron, wrought iron
and steel.
• Types and uses of some common non-ferrous metals.
• Types and uses of some non-metals.
• Important mechanical properties of materials.
Choice of materials for a machine element depends very much on its properties, cost,
availability and such other factors.
Common engineering materials are normally classified as metals and nonmetals.
Metals may conveniently be divided into ferrous and non-ferrous metals.
Important ferrous metals for the present purpose are:
(i) Cast iron
(ii) Wrought iron
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 Non-ferrous metals used in engineering design are:
(a) Light metal group such as aluminium and its alloys, magnesium and
manganese alloys.
(b) Copper based alloys such as brass (Cu-Zn), bronze (Cu-Sn).
(c) White metal group such as nickel, silver, white bearing metals eg. SnSb7Cu3,
Sn60Sb11Pb, zinc etc.
Ferrous materials:
Cast iron- It is an alloy of iron, carbon and silicon and it is hard and brittle.
Carbon content may be within 1.7% to 3% and carbon may be present as free
carbon or iron carbide Fe3C.
In general the types of cast iron are
• Grey cast iron: High compressive strength, Graphite is an excellent solid lubricant
(a) White cast iron: hard and brittle,
(b) Malleable cast iron:
(c) Spheroidal or nodular cast iron:
(d) Austenitic cast iron:
(e) Abrasion resistant cast iron:

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 Wrought iron
• Wrought iron- This is a very pure iron where the
iron content is of the order of 99.5%.
• It is produced by re-melting pig iron and some
small amount of silicon, sulphur, or phosphorus
may be present.
• It is tough, malleable and ductile and can easily be
forged or welded.
• Chains, crane hooks, railway couplings and such
other components may be made of this iron.

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 STEEL

• Steel- This is by far the most important engineering

material and there is an enormous variety of steel
to meet the wide variety of engineering
requirements.
• Steel is basically an alloy of iron and carbon in
which the carbon content can be less than 1.7%
and carbon is present in the form of iron carbide to
impart hardness and strength.
• Two main categories of steel are
(a) Plain carbon steel
(b) Alloy steel

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 Plain carbon steel
• The properties of plain carbon steel depend mainly on the carbon
percentages and other alloying elements are not usually present in more
than 0.5 to 1% such as 0.5% Si or 1% Mn etc.
• Dead mild steel- up to 0.15% C
• Low carbon steel or mild steel- 0.15 to 0.46% C
• Medium carbon steel- 0.45 to 0.8% C.
• High carbon steel- 0.8 to 1.5% C
• Detailed properties of these steels may be found in any standard handbook
but in general higher carbon percentage indicates higher strength.
Alloy steel- these are steels in which elements other than carbon are added in sufficient
quantities to impart desired properties, such as wear resistance, corrosion resistance,
electric or magnetic properties. Chief alloying elements added are usually nickel for
strength and toughness, chromium for hardness and strength, tungsten for hardness at
elevated temperature, vanadium for tensile strength, manganese for high strength in
hot rolled and heat treated condition, silicon for high elastic limit, cobalt for
hardness and molybdenum for extra tensile strength.

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 Alloy steel
• Alloy steel- these are steels in which elements other than
carbon are added in sufficient quantities to impart desired
properties, such as wear resistance, corrosion resistance,
electric or magnetic properties.
Chief alloying elements added are usually
Nickel for strength and toughness,
Chromium for hardness and strength,
Tungsten for hardness at elevated temperature,
Vanadium for tensile strength,
Manganese for high strength in hot rolled and heat treated
condition,
Silicon for high elastic limit,
Cobalt for hardness and
Molybdenum for extra tensile strength.

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 Probabilistic Design
/Reliability based Design

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 Reliability Method of Design
• Reliability method of design – A method of
design that relates the distribution of stresses
with the distribution of strengths to achieve an
acceptable success rate.
• Reliability, R – The statistical measure of the
probability that a mechanical element will not
fail in use

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 Stress and Strength
• Strength
– An inherent property of a material or of a
mechanical element
– Depends on treatment and processing
– May or may not be uniform throughout the part
– Examples: Ultimate strength, yield strength
• Stress
– A state property at a specific point within a body
– Primarily a function of load and geometry
– Sometimes also a function of temperature and
processing
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 Uncertainty
• Common sources of uncertainty in stress or
strength

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 Uncertainty
• Stochastic method
– Based on statistical nature of the design
parameters
– Focus on the probability of survival of the design’s
function (reliability)
– Often limited by availability of statistical data

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 Gaussian (Normal) Distribution
• The probability density function (PDF) of the
Gaussian distribution
ˆ
is expressed in terms of
its mean, mx, and its standard deviation
x

large ˆ x
small ˆ x

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plots of the
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 Design Factor Method
 Often used when statistical data is not available
 Since stress may not vary linearly with load, it is more common
to express the design factor in terms of strength and stress.

• All loss-of-function modes must be analyzed, and the

mode with the smallest design factor governs.
• Stress and strength terms must be of the same type and
units.
• Stress and strength must apply to the same critical
location in the part.
• The factor of safety is the realized design factor of the
final design, including rounding up to standard size or
available components.
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