Machine Design I

by
Dr. Prakash Shinde

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 Unit 1
Fundamentals of Machine
Design

 Mechanism and Machine

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 Mechanical Engineering Design or
Machine Design
• Formulation of a plan for the satisfaction
of human needs.
• Art of planning new or improved machines
to accomplish specific purpose
• 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.
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 Designer

Economy Efficiency

A decision making process

Problem Solution
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 Types of Design
1) Adaptive Design : Based on existing design.
Standard product or system is adopted for a
new application. Eg: Conveyor belts, Pulleys,
Nuts & bolts, Gears, Zip, etc.

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2) Development Design : We start with existing
design but finally we get a improved, modified
design. Eg: New model of a car, Clutch pencil
from wooden pencil

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• 3) New Design : entirely new design based on
scientific principles. Eg: New model of a car

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 Design based on Methods
1) Rational Design : based on determining
stresses and strains of component and thereby
deciding their dimensions.
2) Empirical Design : based on empirical
relationships given by experts and experienced
designers
Dia of boss = 2x shaft dia.
Pretension on bolt = 4280x shaft dia., N
3) Industrial Design : based on Industrial
requirements
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System Design Cycle (Phase of Design)

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Design of Individual Components

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 Standards in Design
• A Standard is a set of obliquity norms
(specifications) defined by a certain
organization, to which various characteristics
of component a system or a product should
confirm. Characteristics include dimensions,
shapes, tolerances, surface finish, materials,
method of testing, use of packing & storing
etc.
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• The Purpose of standardization is to achieve
uniformity, specified quality, interchangeability,
safety and to put a reasonable limit on the
variety.
• Aim of the designer should be to use as many
standard parts as possible in a machine or a
system.

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 Different Standards used in
Mechanical Engineering applications
1) Standards for sizes and shapes of component
like Nuts & bolts, bearings, keys, belts,
chains, gears, etc.
2) Standards for products like electric motors,
engines, gear boxes, etc.
3) Standards for fits, tolerances & surface finish
of component.
4) Standards for conventional representation of
component on drawing. 17
 Types of Standards
1) Company Standards : Set by a company or group
of companies for their use.
2) National Standards : Set by a national apex body
& are followed all over the nation.
i. Indian Standards Institute (I.S.I)
ii. Bureau of Indian Standards (B.I.S.)
iii. American Society of Mechanical Engineers
(A.S.M.E.)
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 iv. American Gear Manufacturers Association
(A.G.M.A.)
v. American Welding Society (A.W.S.)
vi. American National Standards Institute
(A.N.S.I.)
vii. Society of Automotive Engineers (S.A.E.)
3) International Standards : Set by international
apex body & are normally followed all over
the world.
i. International Standards Organization (I.S.O.)
ii. International Bureau of Weights &
Measures (I.B.W.M.) 19
 Advantages of Standardization
1) Interchangeability of components is possible.
2) Reduces inventory of the required
components.
3) Ensures certain minimum specified quality.
4) Easy & quick replacement of component is
possible.
5) Ensures safety.
6) Reduces overall cost of the product.
7) Mass production is achieved.
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 Preferred Series
• In Engineering design, many times the
designer has to specify the size of the product.
Often a product is manufactured in different
sizes. The sizes should be spread over the wide
range at the same time these should be spaced
properly. This led to the use of geometric
series known as series of preferred numbers or
preferred series.
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• Preferred series are series of numbers obtained
by geometric progression and rounded off.
There are five basic series designated as R5,
R10, R20, R40 and R80.
• These series was first introduced by a French
engineer Renard, and therefore is also called as
Renard Series.
• The sizes are obtained by multiplying the next
number by its series factor and then rounding
off that number to its nearest integer value.
• So on the further numbers/ sizes are obtained. 22
Series Factor of Preferred Series

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Preferred Numbers

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Basic series of Preferred Numbers
• R5 : 1.00, 1.60, 2.50, 4.00, 6.30, 10.00
• R10 : 1.00, 1.25, 1.60, 2.00, 2.50, 3.15, 4.00,
5.00, 6.30, 8.00, 10.00
• R20 : 1.00, 1.12, 1.25, 1.40, 1.60, 1.80, 2.00
• R40 : 1.00, 1.06, 1.12, 1.18, 1.25, 1.32, 1.40…

• If the product is to be manufactured in

limited quantity with minimum no. of sizes,
R5 series to be used. If quantity increase
then accordingly R10, R20, R40 or R80
series may be used. 25
 Advantages of Preferred Series
1) The difference in two successive terms
has a fixed percentage.
2) Provides small steps for small quantities
and large steps for large quantities.
3) The product range is covered with
minimum number of sizes without
restricting the choice of customer.
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1) A electric motors manufacture firm
“Crompton Greaves” wants to launch
electric motors ranging from 0.5 kW to
50 kW. Find the power capacity for these
motors using R5 and R10 series

2) A lifting tackle wants to introduce nine

different models of capacities ranging
from about 15 kN to 100 kN. Establish
the capacities using R10 series 27
Material Selection

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Material Selection

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 Factors for Material Selection
1) Availability : should be readily available in
market in large quantities
2) Cost : Material cost should be low than
processing cost
3) Mechanical Properties : Depending upon
functional requirement & service conditions
different mech. Properties are considered
4) Manufacturing Considerations : sometimes an
expensive material is more economical than
low priced one, which is difficult to machine.
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Techniques of Material Selection

1) Weighted Point Method

2) Ashby Chart Method

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