The design engineer’s professional obligations include conducting activities in an

ethical manner. Reproduced here is the Engineers’ Creed from the National Society of
Professional Engineers (NSPE):

As a Professional Engineer I dedicate my professional knowledge and skill to the

advancement and betterment of human welfare.
I pledge:
To give the utmost of performance;
To participate in none but honest enterprise;
To live and work according to the laws of man and the highest standards of
professional conduct;
To place service before profit, the honour and standing of the profession before
personal advantage, and the public welfare above all other considerations.
In humility and with need for Divine Guidance, I make this pledge.
Design of Machine elements (3‐0‐0)
Mechanical design is a complex process, requiring many skills.
Extensive relationships need to be subdivided into a series of
simple tasks. The complexity of the process requires a sequence in
which ideas are introduced and iterated.
 Books:
1. Shigley’s Mechanical Engineering Design (In SI Units) – (TMH)
2. Machine Design (In SI Units) – Maleev & Hartmsn Edited by O P
Groover (CBS)
3. Machine Design – An Integrated Approach – Robert L. Norton
(Pearson Education)
4. Design of Machine Elements – M. F. Spotts (Pearson Education)

1. Design of Machine Elements (3rd Edition) – V B Bhandari (TMH)

2. A Textbook of Machine Design – Khurmi & Gupta (S. Chand)

1. Machine Design Data Book – V B Bhandari (TMH)

2. Machine Drawing – N D Bhatt (Charotar Publication)
3. Machine Design Data Book – K. Lingaiah (TMH)
 INTRODUCTION
Creation of new and better machines/machine elements and improving the
existing one. (Practice + Experience)

• Efficient
• Economical
• Overall cost of production & operation
• Safe

Knowledge:
Mathematics, Engg. Mechanics, Mechanics of Solids, Theory of Machines,
Workshop Processes, Thermodynamics, Heat Transfer, Manufacturing
Processes, Workshop Technology, Materials Sciences, Engg. Drawing.
(AutoCAD, SolidWorks, UG, Pro-E, ANSYS, NASTRAN, ABAQUS, LS-
DYNA, CFD, COMSOL related softwares), CAD, CAM, CAE, Metrology
etc.

Classification:
1. Adaptive Design
2. Development design
3. New Design
General Considerations:
1. Load type
2. Stresses developed
3. Motion of parts
4. Material Selection
5. Parts size
6. Convenient & economical features
7. Use of standard parts
8. Safety features
9. Workshop facility
10. No. of machines to be manufactured
11. Cost of production
12. Plant facility for assembling
13. Marketability
14. Remanufacturing/resource recovery
Design Tools & Resources:
1. Conventional Drawing (Orthographic projections, Isometric
views etc.)
2. Computational Tools (CAD, CAE)
3. Acquiring Technical Information (Library, Government
sources, Professional societies, Commercial vendors,
Internet)

Standards & Codes: AGMA, ASTM, ASME, SAE, BSI, BIS,

IBR, AWS etc.

Economics: Micro and Macro economics

Economics

Dimensions & Tolerances: Limits, Fits, Tolerances, Allowances,

Clearances etc.
Home Task:

1.Metrology
2.Manufacturing processes
3.Materials Engineering
4.Revision of basic fundamental subjects
General Procedure:
1. Recognition of need
2. Synthesis (Mechanism)
3. Force Analysis
4. Material selection
5. Design of elements
6. Modification
7. Detailed drawing
8. Production
 Engineering Materials & Properties
Materials

Properties:
1. Strength
2. Stiffness
3. Elasticity
4. Plasticity
5. Ductility
6. Brittleness
7. Malleability
8. Toughness
9. Resilience
10.Creep
11.Fatigue
12.Hardness

Manufacturing Processes
 RIVETED JOINTS

Classification of joints:
1. Permanent – cannot be disassembled without destroying
the connecting parts. Examples: soldered, brazed, welded
and riveted joints.
2. Temporary – disassembled without destroying the
connecting components. Examples: keys, cotters, pins,
flange couplings, nuts & bolts etc.

Riveted Joints:
Structural works, ship building,
bridges, tanks, boiler shells etc.
Where to use?
1. Where it is necessary to avoid the thermal after-effects.
2. Metals with poor weldability.
3. Joints made from heterogeneous materials.
4. Loading condition: Impact & Vibration
5. Thin plates are to assembled (Aircraft structures : Aluminum alloys)

Disadvantages:
1. Overall cost high as compared to welding
2. Heavy (Welding of steel)
3. No. of parts high
4. Holes: Stress concentration.
Methods of Riveting:
1. Cold riveting – structural joints (upto 12 mm)
2. Hot riveting – making leak proof joints. (large dia) eg. boiler

Materials: High tensile strength, Tough and Ductile

Steel (Low Carbon), brass, aluminium, copper etc.
When strength and fluid tight joint is the main
consideration – STEEL.
Manufactured according to standards:
1. IS: 1148-1982 (Reaffirmed 1992) – specification for hot
rolled rivet bars (upto 40 mm Dia) for structural purposes.
2. IS: 1148-1982 (Reaffirmed 1992) – specification for high
tensile steel rivet bars for structural purposes.
3. IS: 2100-1970 IS: 1148-1982 (Reaffirmed 1992) –
specification for steel rivets and stay bars for boilers.

Manufacture: Cold heading or by hot forging.

Types of Rivet Heads:
IS: 2155 – 1982 (Reaffirmed 1996), general purpose, Dia < 12 mm.

Snap heads – structural work & machine riveting. Counter sunk heads – ship
building since flush surface necessary. Conical head – hand hammering. Pan
heads – max strength, but these are difficult to shape
Types of Riveted Joints:
1. Lap joint 2. Butt joint

1. Pitch (p)
2. Back pitch (pb)
3. Diagonal pitch (pd)
4. Margin (m)
Caulking and Fullering:
Failures of a Riveted Joint:
Lozenge Joint/Diamond Joint (Economical & for Structural Use):
- Roof, bridge work, girders, cranes etc.

This type of joint results in economical construction because a plate of smaller width is
required for this joint.
1. Diameter of rivet hole:
2. Number of rivets:
3. From the number of rivets, the number of rows and the number of rivets in
each row is decided.

4. Thickness of butt strap:

5. Efficiency of the joint:

In order to calculate the

efficiency of the joint, we
will proceed from the
outer row of the rivets to
the inner row and identify
the weakest section of the
joint first.
5. Efficiency of the joint:
6. Pitch of the rivets = 3 d + 5

7. Marginal Pitch (m) = 1.5 d

8. Distance between the rows of rivets = 2.5 d to 3d

Eccentrically Loaded Riveted Joint:
Line of action of the load does not pass through the centroid of the rivet system
and thus rivets are not equally loaded.
Assumption:
1. Secondary shear load is proportional to the radial
distance of the rivet under consideration from the
c.g. of the rivet system.
2. Direction of the secondary shear load is
perpendicular to the line joining the center of the
rivet to the c.g. of the rivet system.
 Determine the resultant shear load on each rivet.

Choose the highest

 The standard diameter of the rivet hole and rivet diameter (d) may be
specified according to

 When the thickness of the plate is given, then the diameter of the rivet hole
may be checked against crushing.
Design of Boiler:
Longitudinal joint - Butt joint (plate bent to form ring: double strap triple riveted butt
joint)
Circumferential joint – Lap joint with one ring overlapping the other alternately is
used.

I.B.R. –
Indian Boiler Regulations
Thank you