ME- 214 (2+1)

Machine Design & CAD-I

Lect. # 1
INTRODUCTION TO
MACHINE DESIGN & CAD-I

Engr. Dr. Nazeer Ahmad Anjum

Mechanical Engineering Program
University of Engineering & Technology
Taxila

Machine Design 2
What is the importance of Machine Design for
Engineers?

What is Machine Design?

Creation of new and better machines AND

Improving existing ones

So that it is economical in the cost of production

and operation.
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 Some Background Philosophy 3

• Engineering may be describe as a judicious

blend of science and art in which Natural
resources, including energy sources, are
transformed into useful Products,
structures, or machines that benefit
humankind. Science may be define As any
organized body of knowledge.

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Some Background Philosophy 4

Art may be thought of as a skill or set of skills
acquired through a combination of study,
observation, practice, and experience, or by
intuitive capability or creative insight.
Creating new devices or improving existing
devices in an attempt to provide the “best”, or
“optimum” design with constraints of time,
money, and safety, as dictated by the
application and the market place.

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 Concept and Definitions of Mechanical5
Design
• Mechanical design may be defined as an
iterative decision-making process that has as
its objective the creation and optimization of
a new or improved mechanical engineering
system or device for the fulfillment of a
human need or desire, with due regard for
conservation of resources and environment
impact.

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Design 6

• Design – to formulate a plan for the satisfaction of a

specified need or to solve a problem
• Innovative and highly iterative process
• Decision making process

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 Design Product 7

• Functional
• Safe
• Reliable
• Competitive
• Usable
• Manufacturable
• Marketable

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How a design is born 8

Market
survey
Aesthetic
marketability
Ease of
Requirement handling
Availability of Safety
Creation FUNDS
Economical
Model Available
(Rough idea) material Recyclability
Manufacturing
resources
Material/s
Analysis Force/stress Sizes
used
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 Mechanical Engineering Design 9
• Mechanical engineering design involves all the
disciplines of mechanical engineering
• Example: Fluid Flow, Heat Transfer, Friction
(Tribology), Energy, Transport, Material Selection,
Thermo Mechanical Treatments, Statistical
Descriptions…
• Phases- Machine design, machine-element design,
machine-component design, systems design, and fluid-
power design

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What is Machine Design? 10

• Core of mechanical – Stress Concentrations

engineering
– Stress and strain
– Designing for safety
– Static failure theories
– Fatigue failure theories
– Machine elements
– Mechanical material
properties
– Fracture Mechanics
– Optimization
– Composite Materials
– Manufacturing Processes
– Computer Aided Machine
Design and Analysis
– Measuring Stress and Strain

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 What is the basic knowledge required for
11
Machine Design?
••Mathematics
Mathematics
• Mechanics of Machines
••Engineering
EngineeringMechanics
Mechanics • Mechanics of Materials
• Fluid Mechanics & Thermodynamics
••Strength
Strengthof
ofMaterials
Materials

••Workshop
WorkshopProcesses
Processes

••Engineering
EngineeringDrawing
Drawing

• Computing

• Finite Element Analysis, Computational Fluid Dynamics etc

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Design Considerations 12
• Functionality • Friction
• Strength/Stress • Weight
• Distortion/deflection/stiffness • Life
• Wear • Noise
• Corrosion • Styling
• Safety • Shape
• Reliability
• Size
• Manufacturability
• Control
• Utility
• Thermal properties
• Cost
• Surface
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 Important considerations in Machine Design
13
1. Type of LOAD and STRESSes caused by the load

• Dead loads • Stress and strain

(Tensile, compressive, shear)
• Live loads

Steady loads • Thermal stresses

Variable loads
• Torsional stresses
• Shock loads (suddenly)
• Bending stress

• Impact loads (applied

with some velocity)
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Loads 14
• Mechanical  forces, moments…
• Thermal
• Chemical changing in place/ time
• …
static cyclic dynamic

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 Effect of Varying Load 15
Fatique limits
σv σr

 min cycle assymetry m

r v cycle mean stress
 max ratio  max ratio 4/25/2017

Loads & Stresses 16

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 Important considerations in Machine Design
17
2. KINEMATICS of the machine (Motion of the
parts)
Find the simplest arrangement that would give
the most efficient motion that is required.

3. Selection of MATERIALs

Knowledge of the properties of the materials

and their behaviour under working
conditions is required.

Strength, hardness, durability, flexibility, weight,

resistance to heat and corrosion, electrical
conductivity, machinability, etc.
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Materials 18
• Metals • density
– ferrous/ non~ • conductivity
• cast iron
• …
• steel
– carbon/ alloy
• elasticity
• plastics • plasticity
• ductility
• ceramics
• brittleness
• composite
• toughness (impact)
• creep
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 Important considerations in Machine Design
19
3. Selection of MATERIALs
Metal Non-metal

Ferrous Non-ferrous

Physical properties: Density, Melting point,

Elec/thermal properties
Mechanical properties:
• STRENGTH – resist externally applied loads without breaking or yielding
• STIFFNESS – resist deformation under stress
• ELASTICITY – regain original shape once the force is removed
• PLASTICITY – property which retains deformation (required for forging etc)
• DUCTILITY – ability to be drawn into a wire by a tensile force
• BRITTLENESS – sudden breaking with minimum distortion
• TOUGHNESS – resist fracture due to high impact load
• CREEP – deformation under stress and high temperature
• FATIGUE – ability to withstand cyclic stresses
• HARDNESS – resistance to wear, scratching, deformation, machinability etc
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Important considerations in Machine Design

20
4. Form and size of the parts

Use I-beam or Angle-iron?

The size will be determined by the
forces/torques applied (stresses on the
object) and the material used such that
failure (fracture or deformation) would not
occur

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 General procedure in Machine Design…
21
Need or aim Recognize and specify the problem
Select the mechanism that would
Synthesis give the desired motion and form
the basic model with a sketch etc
Analysis of the FORCES

Material selection
Determine the stresses and thereby
Design of elements the sizes of components s.t. failure or
deformation does not occur

Modification Modify sizes to ease construction & reduce

overall cost
Detailed
drawing Production
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22

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 Designer Responsibilities 23

• Understand the problem

• Identify the known
• Identify the unknown and formulate
• State all assumptions and decisions
• Analyze the problem
• Evaluate solution
• Present solution

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Machine Design: Research Areas 24

• Finite Element Analysis

• Design Optimization
• Biomechanics
• Nanotechnology
• Fracture Mechanics
• Mechanical Material Properties
• Composite Materials
• Designing for Manufacturing
• Welding

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 Keystone objectives 25
The keystone objectives of all mechanical design activity are:
1. Selection of the best possible material and
2. Determination of the best possible geometry for each part.
3. Audits
4. Fits and tolerances
During the first iteration, engineering designers concentrate on
meeting functional performance specifications by selecting
potential materials and geometric arrangements that will
provide strength and life adequate for the loads,
environment, and potential failure modes governing the
application. A reasonable design safety factor is chosen at
this stage to account for uncertainties.

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Keystone objectives 26
Preliminary considerations of manufacturing methods
are also included in the first iteration.
The second iteration usually establishes all nominal
dimensions and detailed material specifications to
safely satisfy performance, strength, and life
requirements.
The third iteration audits the second-iteration design
from the perspectives of fabrication, assembly,
inspection, maintenance, and cost.
The fourth iteration includes careful establishment of
fits and tolerances, modifications resulting from the
third-iteration audits, and a final check on the safety
factor to assure that strength and life are suitable for
the application.
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 Stages of Design 27

Mechanical design activity in an

industrial setting embodies a
continuum effort from initial concept
to development and field service.

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Stages of Design 28

1. Preliminary design,
2. Intermediate design,
3. Detail design, and
4. Development and field service.

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 Stages of Design 29

Preliminary design, or conceptual design, is primarily

concerned with synthesis, evaluation, and comparison
of proposed machines or system concepts. A “black-
box” approach is often used, in which reasonable
experience based performance characteristics are
assigned to components or elements of the machine or
system.

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Stages of Design 30

Overall system analyses, including force analyses,

deflection analysis, thermodynamic analysis, fluid
mechanic analysis, heat transfer analysis, electro-
mechanic analysis, or control system analysis may be
required at the preliminary design stage.

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 Stages of Design 31

The result of the preliminary design stage is the

proposal of a likely-successful concept to be
designed in depth to meet specified criteria of
performance, life ,weight, cost, safety, or
others.

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Stages of Design 32
2. Intermediate design
embraces the spectrum of in-depth engineering design of
individual components and subsystems for the already
preselected machine or system. Intermediate design is vitally
concerned with the internal workings of the black boxes, and
must make them work as well or better than assumed in the
preliminary design proposal. Material selection, geometry
determination, and component arrangement are important
elements of the intermediate design effort, and appropriate
consideration must be given to fabrication, assembly,
inspection, maintenance, safety, and cost factors, as well.

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 Stages of Design 33

•The result of the intermediate design stage is

establishment of all critical specifications
relating to function, manufacturing, inspection,
maintenance, and safety.

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Stages of Design 34

3. Detail design
is concerned mainly with configuration, arrangement,
form, dimensional compatibility and completeness,
fits and tolerances, standardization, meeting
specifications, joints, attachment and retention
details, fabrication methods, assimilability,
producibility, inspectability, maintainability, safety,
and establishing bills of material and purchased
parts.

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 Stages of Design 35

• The result of the detail design stage is a

complete set of drawings and specifications,
including detail drawings of all parts, or an
electronic CAD file, approved by engineering
design, production, marketing, and any other
interacting departments, ready for
production of a prototype machine or system.

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Stages of Design 36

4. Development and field service

activities follow in sequence after the production of a
prototype machine or system. Development of the
prototype from a first model to an approved
production article may involve many iterations to
achieve a product suitable for marketing.

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 Stages of Design 37

Field service information, especially warranty

service data on failure rates, maintenance
problems, safety problem, or other user-
experience performance data, should be
channeled back to the product design team for
future use in product improve-ment and
enhancement of life cycle performance.

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Fail Safe and Safe Life Design Concepts

38
Catastrophic failures of machines or system that
result in loss of life, destruction of property, or
serious environmental degradation are simply
unacceptable to the human community, and, in
particular, unacceptable to the designers of such
failed machines or systems.
A designer can never provide a design of 100 percent
reliability, that is, she or he can never provide a
design absolutely guaranteed not to fail. There is
always a finite probability of failure.

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 Fail Safe and Safe Life Design Concepts
39
The Fail Safe Design technique provides unnecessary
load paths in the structure so that if failure of a primary
structural member occurs, a secondary member is
capable of carrying the load on an emergency basis until
failure of the primary structure is detected and repair can
be made.
The safe life Design technique is to carefully select a
large enough safety factor and establish inspection
intervals to assure that the stress levels, the potential
flaw sizes, and the governing failure strength levels of
the material combine to give such a slow crack growth
rate that the growing crack will be detected before
reaching a critical size for failure.
Both fail safe life design depend upon inspectability,
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Failure Criteria 40
• Any change in the size, shape, or
material properties of a machine or
machine part that renders it incapable of
performing its intended function must
be regarded as a mechanical failure.

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 Modes of Mechanical Failure 41
1. Force- and/or temperature-induced elastic deformation
2. Yielding
3. Brinnelling
4. Ductile rupture
5. Brittle fracture
6. Fatigue:
a. High cycle fatigue
b. Low-cycle fatigue
c. Thermal fatigue
d. Surface fatigue
e. Impact fatigue
f. Corrosion fatigue
g. Fretting fatigue

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Modes of Mechanical Failure 42

7 Corrosion:
a. Direct chemical attack
b. Galvanic corrosion
c. Pitting corrosion
d. Intergranular corrosion
e. Selective leaching
f. Erosion corrosion
g. Cavitation corrosion
h. Hydrogen damage
i. Biological corrosion
j. Stress corrosion
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 Modes of Mechanical Failure 43
8 Wear:
a. Adhesive wear
b. Abrasive wear
c. Corrosive wear
d. Surface fatigue wear
e. Deformation wear
f. Impact wear
g. Fretting wear
9 Impact:
a. Impact fracture
b. Impact deformation
c. Impact wear 4/25/2017

Modes of Mechanical Failure 44

d. Impact fretting
e. Impact fatigue
10. Fretting:
a. Fretting fatigue
b. Fretting wear
c. Fretting corrosion
11. Creep
12. Thermal relaxation
13. Stress rupture
14. Thermal shock
15. Galling and seizure
16. spalling

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 Modes of Mechanical Failure 45
17. Radiation damage
18. Buckling
19. Creep bucking
20. Stress corrosion
21. Corrosion wear
22. Corrosion fatigue
23. Combined creep and fatigue

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Machine Elements 46

46
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