Design of Machine Elements

Prof . S. H. Gawande
Department of Mechanical Engineering
M. E. Society's College of Engineering, Pune-1

1
 Structure and Examination Scheme

2
 Syllabus
▪ Unit – I Design process and design of Simple Machine
elements

▪ Unit – II Design of Shafts, Keys and Couplings

▪ Unit – III Design for Fluctuating Load

▪ Unit – IV Power Screws

▪ Unit –V Threaded joints andWelded joints

▪ Unit –VI Mechanical Springs

3
 What is Machine Design?

• The subject Machine Design is the creation of new and better

machines and improving the existing ones. Utilization of 4M
Optimally to complete new idea.
DDR
• 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. A new or
better machine is one which is more economical in the overall cost of
production and operation.

• The process of design is a iterative, long and time consuming one.

• In designing a machine component, it is necessary to have a good

knowledge of many subjects such as Mathematics, Engineering
Mechanics, Strength of Materials, Theory of Machines, Workshop
4
Processes and Engineering Drawing.
 Classifications of Machine Design

• Adaptive design
• Development design
• New design
1. Rational design
2. Empirical design
3. Industrial design
4. Optimum design
5. System design
6. Element design
7. Computer aided design
5
 General Considerations in Machine Design
The broad objective of designing a machine element is to ensure that it preserves
its operating capacity during the stipulated service life with minimum
manufacturing and operating costs. In order to achieve this objective, the
machine element should satisfy the following basic requirements:
1. Strength
Design Criterion
2. Rigidity
3. Wear Resistance
4. Minimum Dimensions andWeight
5. Manufacturability
6. Safety
7. Conformance to Standards
8. Reliability
9. Maintainability
6
10. Minimum: Life-cycle Cost
 The basic procedure of the design of machine elements

Recognition of Need

Definition of the Problem

Synthesis

Analysis & Optimization

Evaluation

Presentation

7
 The basic procedure of the design of machine elements

Recognition of Need

Definition of the Problem

Synthesis

Analysis & Optimization

Evaluation

Presentation

8
 Standards and Codes
Standardization is defined as 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 marking, packing and storing of the
product.

A standard is defined as a set of specifications for parts, materials or processes. The

objective of a standard is to reduce the variety and limit the number of items to a
reasonable level.
A code is defined as a set of specifications for the analysis, design, manufacture, testing
and erection of the product.The purpose of a code is to achieve a specified level of safety.

There are three types of standards used in design office.

1. Company standards They are used in a particular company or a group of
sister concerns.
2. National standards These are the IS (Bureau of Indian Standards), DIN
(German), AISI or SAE(USA) or BS (UK) standards.
3. International standards These are prepared by the International Standards
Organization (ISO).
9
 Preferred Numbers or Sizes (Renard Series)
• French balloonist and engineer Charles Renard first
introduced preferred numbers in the 19th century.

• In industrial design, preferred numbers (also

called preferred values or preferred series) are
standard guidelines for choosing exact product
dimensions within a given set of constraints.
• Preferred numbers therefore help to minimize the number of
different sizes that need to be manufactured or kept in stock.

• The system is based on the use of geometric progression to

develop a set of numbers.

• Preferred series are series of numbers obtained by GP and

rounded off.
• There are five basic series2, denoted as R5, R10, R20, R40
and R80 series, which increase in steps of 58%, 26%, 12%,
6%, and 3%, respectively. Each series has its own series factor.
10
The series factors are given in Table 1.1.
 Numerical on Preferred Numbers
Example 1. Find out the numbers of the R5 basic series from 1 to 10.
Sol:
• Step I Calculation of series factor: The series factor for the R5 series is given by

• Step II Calculation of numbers: The series R5 is established by taking the first number and
multiplying it by a series factor to get the second number. The second number is again
multiplied by a series factor to get the third number. This procedure is continued until
the complete series is built up.The numbers thus obtained are rounded.
First number = 1
Second number = 1 (1.5849) = 1.5849 = (1.6)
Third number = (1.5849)(1.5849) = (1.5849)2
= 2.51 = (2.5)
Fourth number = (1.5849)2(1.5849) = (1.5849)3
= 3.98 = (4)
Fifth number = (1.5849)3(1.5849) = (1.5849)4
= (6.3)
Sixth number = (1.5849)4(1.5849) = (1.5849)5
= (10)

11
 Numerical on Preferred Numbers
Example 1. 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. (M-6)
Sol.
Step I Calculation of ratio factor
Let us denote the ratio factor as (ɸ). The derived series is based on geometric
progression.The power rating of five models will as follows,
First number = = 7.5
Second number =
Similarly, for next…

Hence,
The maximum power rating is 75 kW. Therefore,

Step II Power rating of models

12
 Numerical on Preferred Numbers
Example 1. 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. (M-6)
Sol.
Step I Calculation of ratio factor or Range ratio

Step II Power rating of models

13
 Numerical on Preferred Numbers
Example 2. In an manufacturing firm, it is required to standardize eleven shafts from 100 to
1000 mm diameter. Specify their diameters. (M-4)
Sol.
Step I Calculation of ratio factor or Range ratio

Step II Calculation Shaft diameters

14
 Factor of Safety
While designing a component, it is necessary to
provide sufficient reserve strength in case of an
accident. This is achieved by taking a suitable
factor of safety. Factor of safety is a measure
of the reliability of a particular design. This can
be referred to as a design factor.

• The allowable stress is the stress value, which is used in design to

determine the dimensions of the component.
• It is considered as a stress, which the designer expects will not be exceeded
under normal operating conditions.
• For ductile materials, the allowable stress is obtained by the following
relationship:

• For brittle materials, the relationship is,

15
 Selection of Factor of Safety
The selection of a proper factor of safety to be used in designing any
machine component depends upon a number of considerations, as,
• Material
• Mode of manufacture
• Type of stress
• General service conditions
• Shape of the parts or machine element
The magnitude of factor of safety depends upon the following factors:
• Effect of failure
• Type of load
• Degree of accuracy in force analysis
• Material component
• Reliability of component
• Cost of component
• Testing of machine element
16
• Service conditions
• Quality of manufacture
 Service Factor or Application Factor
• In design process the torque (load)
calculated from the power is an average
torque (or load),
• Whereas for a shorter duration, the
mechanical elements are subjected to high
momentary torque (or load)
• This high momentary torque (or load) is
accounted in design process by a factor Torque, Ta
known as Service Factor or Application
Factor or overload factor.

17
 Types of Loads
Modes of failure:
1. Failure by elastic deflection (σyt, σut insignificant, E,G significant)
2. Failure by general yielding
3. Failure by fracture

Sources
1. Energy transmitted Load 1. Dead or steady load
[Any external force
2. Weight of machine acting upon a 2. Live or variable load
machine part]
3. Frictional resistances 3. Suddenly applied or

4. Inertia of reciprocating parts shock loads.

4. Impact load.
5. Change of temperature, and
6. Imbalance of moving parts
18
 Stress–strain Relationship
When a mechanical component is subjected to an external static force, a
resisting force is set up within the component. The internal resisting force per
unit area of the component is called stress. The strain is deformation per unit
length.
σ = (F1or F2)/Area

19
 Numerical on Stress–strain Relationship
Example 2. Find the diameter of the link Example 3. A cast iron link, as shown in
stock of a coil chain of a crane required to Fig., is required to transmit a steady tensile
carry a maximum load of 50 kN, is shown in load of 45 kN. Find the tensile stress induced
Fig., if the permissible tensile stress in the in the link material at sections A-A and B-B.
link material is not to exceed 75 MPa.

Sol.. Given : P = 45 kN = 45 × 1000 N

Sol. Given : P = 50 kN = 50 × 1000 N ;
σt = 75 MPa = 75 N/mm2
Let d = Diameter of the link stock in mm.

20
 Numerical on Stress–strain Relationship
Example 4 An offset link subjected to a force
of 25 kN is shown in Fig. It is made of grey cast
iron FG300 and the factor of safety is 3.
Determine the dimensions of the cross-section
of the link.
Fig. Offset Link
The cross-section is subjected to direct tensile
stress and bending stresses. The stresses are
maximum at the top fibre.At the top fibre.
21
Example 5 The frame of a hacksaw is
shown in Fig. The initial tension P in the
blade should be 300 N. The frame is made
of plain carbon steel 30C8 with a tensile
yield strength of 400 N/mm2 and the
factor of safety is 2.5. The cross-section of
the frame is rectangular with a ratio of
depth to width as 3, as shown in Fig.
Determine the dimensions of the cross-
section. Fig. (a) Frame of Hacksaw (b)
Section at XX.
Ans: t = 6.3 mm
 Numerical on Stress–strain Relationship

22
 Numerical on Stress–strain Relationship
Example 6 A C-frame subjected to a force of 15 kN is shown in Fig. 4.72.
It is made of grey cast iron FG 300 and the factor of safety is 2.5.
Determine the dimensions of the cross-section of the frame.

Sol. Given : P = 15 kN = 15 × 1000 N; σt = 300 Mpa, fs=2.5

Let t = thickness in mm.

We know, (1)

σt = P/A=

From Eq.(1)

23
 Numerical on Stress–strain Relationship

24
25
 Term-work Assessment

26
 Term-work Assessment

27
 List of Design Project

List of Projects :
• Knuckle joint
• Cotter joint
• Turn Buckle (RSK-Page No.463)
• Bell crank lever (RSK-Page No.576)
• Flange Coupling
• Flexible Bushed Pin Coupling
• Screw jack
• Sluice gate (RSK-Page No.649)

28
 Applications of Knuckle Joint
1. Tractor Trolley Joint
2. Link of a cycle chain,
3. Tie rod joint for roof truss,
4. Valve rod joint with eccentric rod,
5. Pump rod joint,
6. Tension link in bridge structure and lever and rod connections of various types.

Example : Design a knuckle joint to transmit 150 kN.

Step I : Selection of material (e.g.30C8, 40C8, 45C8) (Table2.2, Page No.31, VBB)
Step II : Selection of Factor of Safety
Step III :Calculation of Allowable or Design stresses
Step IV :Calculation of dimensions and checking for failures
Part V Dimensioned sketch of knuckle joint

29
 Design of Knuckle Joint

1. Single Eye
2. Double Eye
3. Knuckle Pin

30
 Free Body Diagram

In determining the strength of the joint for the various methods of failure, it is assumed
that
1. There is no stress concentration, and
2. The load is uniformly distributed over each part of the joint.
Due to these assumptions, the strengths are approximate, however they serve to indicate
a well proportioned joint.
31
 Methods of Failure of Knuckle Joint
1. Design of Single Eye DME-VBB-Page 94-99

32
2. Design of Knuckle Pin

Fig. Shear failure of pin

33
 3. Failure of knuckle pin in bending

4. Failure of knuckle pin in crushing

34
 3. Design of Double Eye or Forked End

35
36
 Design of Cotter Joint

37
 Design of Cotter Joint
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 and transmit torque.

Typical applications of cotter joint are as follows:

• Joint between the piston rod and the crosshead of a steam engine
• Joint between the slide spindle and the fork of the valve mechanism
• Joint between the piston rod and the tail or pump rod
Types of Cotter Joints

1. Socket and spigot cotter joint,

2. Sleeve and cotter joint,
3. Gib and cotter joint.
4. Foundation bolt

38
 Design of Cotter Joint

Example: Design a cotter joint to connect two steel rods of

equal diameter subjected to an axial tensile force of 50 kN.
39
 Notations used design of Cotter Joint

40
 Solution:
Given P = 50 KN

Part I Selection of material

Part II Selection of factor of safety

Part III Calculation of permissible stresses

41
 Design of Cotter Joint
1. Failure of the rods in tension (Spigot)

The rods may fail in tension due to the tensile load P.

We know that Area resisting tearing,

From this equation, diameter of the rods ( d ) may be determined.

2. Failure of spigot in tension across the weakest section (or slot)

Since the weakest section of the spigot is that

section which has a slot in it for the cotter, as
shown in Fig. , therefore,

Estimate and check with permissible

tensile stress .

43
3. Failure of the rod (Spigot)or cotter in crushing

4. Failure of spigot collar in crushing

Considering the failure of the spigot collar in crushing as

shown in Fig.
We know that area that resists crushing of the collar.

44
5. Failure of the spigot collar in shearing

Considering the failure of the spigot collar in shearing

as shown in Fig. We know that area that resists
shearing of the collar.

6. Failure of rod end in shear

Since the rod end is in double shear, therefore the area
resisting shear of the rod end

45
 7. Failure of cotter in shear
Considering the failure of cotter in shear as shown in Fig.
Since the cotter is in double shear, therefore shearing area of
the cotter

8. Failure of cotter in bending

46
9. Failure of the socket in tension across the slot
We know that the resisting area of the socket
across the slot, as shown in Fig.

Estimate and compare with permissible stress.

47
 10. Failure of socket end in shearing
Since the socket end is in double shear,
therefore area that resists shearing of
socket collar

11. Failure of the socket collar in crushing

We know that area that resists crushing of
socket collar

48
 Design and draw a cotter joint to support a load varying from 30 kN
in compression to 30 kN in tension. The material used is carbon steel for
which the following allowable stresses may be used. The load is applied
statically. Tensile stress = compressive stress = 50 MPa ; shear stress = 35
MPa and crushing stress= 90 MPa.

49
 Design of Levers

50
 Design of Levers
A lever is a mechanical device in the form of Load arm Effort arm
a rigid bar pivoted about the fulcrum to
multiply or transfer the force.

• The ratio of load to effort, i.e., (F/P) is called the

‘mechanical advantage’ of the lever.

• The ratio of the effort arm to the load arm, i.e.,

(l1/l2) is called the ‘leverage’.
• So, Mechanical advantage is equal to the leverage.

51
• Lever design is easy compared to design of other machine elements.
• The length of the lever is decided on the basis of leverage required to exert a given
load F by means of an effort P.
• The cross-section of the lever is designed on the basis of bending stresses.
• The design of a lever consists of the following steps:
Step 1: Force Analysis
Step 2: Design of Lever Arm
Step 3: Design of fulcrum pin
Step 1: Force Analysis
In any application, the load or the force F to be
exerted by the lever is given.
The effort required to produce this force is calculated by
taking moments about the fulcrum.Therefore,

In these cases, the forces are assumed to be parallel. Sometimes, the forces F and P act along lines that
are inclined to one another. In such cases, l1 is the perpendicular distance from the
fulcrum to the line of action of the force P. Similarly, l2 is the perpendicular distance
52 from the fulcrum to the line of action of the force F.
 In such cases, l1 is the perpendicular distance from
the fulcrum to the line of action of the force P.
Similarly, l2 is the perpendicular distance from the
fulcrum to the line of action of the force F.

1. The magnitude of the reaction R is equal to the resultant of the load F and the effort P.
It is determined by the parallelogram law of forces.
2. The line of action of the reaction R passes through the intersection of P and F, i.e., the
point O in Fig. and also through the fulcrum.
Bell-crank lever Fig. illustrates a bell-crank lever with the arms that are
inclined at angle ɵ with one another. The load F and the effort
P act at right angles to their respective arms. The reaction R
at the fulcrum is given by,

When the arms of the bell-crank lever are at right angles to one another,

53
 Step 2: Design of Lever Arm • Find the dimensions of the cross-section of the
lever.
• The cross-section of the lever is subjected to
bending moment.
• In case of a two-arm lever, as shown in Fig.,the
bending moment is zero at the point of
application of P or F and maximum at the boss of
the lever.
• The cross-section at which the bending moment
is maximum can be determined by constructing
a bending-moment diagram.
• The bending moment is maximum at section XX
and it is given by,

• Fig. shows the variation of bending moment. It varies from a maximum value Mb at the section XX to zero at
the point of application of P.
54 • Therefore, the cross-section of the arm is usually tapered from the boss of the fulcrum to the end.
 Step 3: Design of fulcrum pin
• The fulcrum pin is subjected to reaction R as shown in Fig.
• The forces acting on the boss of lever and the pin are equal and
opposite.
• The dimensions of the pin, viz., diameter d1 and length l1 in
lever boss are determined by bearing consideration and then
checked for shear consideration.
• There is relative motion between the pin and the boss of lever
and bearing pressure becomes the design criterion.
• The projected area of the pin is (d1 x l1).Therefore,

• For the fulcrum pin, the ratio of length to diameter (l1/d1) is usually taken
from 1 to 2.
• The outside diameter of the boss in the lever is taken as twice of the diameter
of the pin, i.e., (2d1).
• A phosphor bronze bush, usually 3 mm thick, is fitted inside the boss to reduce
the friction.
• The permissible bearing pressure for a phosphor bronze bush is 5 to 10 MPa.
•55 A lubricant is provided between the pin and the bush to reduce the friction.
 It can be observed that expressions for bearing pressure and
compressive or crushing stress are same. the bearing pressure
is given by,

Example : A lever-loaded safety valve is mounted on the boiler to blow off at a

pressure of 1.5 MPa gauge. The effective diameter of the opening of the valve is 50
mm. The distance between the fulcrum and the dead weights on the lever is
1000mm. The distance between the fulcrum and the pin connecting the valve spindle
to the lever is 100 mm. The lever and the pin are made of plain carbon steel 30C8
(Syt = 400 N/mm2) and the factor of safety is 5. The permissible bearing pressure at
the pins in the lever is 25 N/mm2. The lever has a rectangular cross-section and the
56 ratio of width to thickness is 3:1. Design a suitable lever for the safety valve.
 The pin at the point of application of the force F is subjected
to maximum force and as such, it is to be designed from
bearing consideration. Suppose, d1 and l1 are the diameter
and the length of the pin at F and assume,
The forces acting on the lever are shown in
Fig. (a). Considering equilibrium of vertical
57forces,
The pin is subjected to double shear stress, which is
given by,

• The force on the fulcrum pin (R) is comparatively

less than the force acting on the spindle pin (F).
• Therefore, the dimensions d1 and l1 of the pin at
the fulcrum will be slightly less.
• However, we will assume both pins of the same
diameter and length to facilitate
interchangeability of parts and variety reduction.

The bending moment diagram for the lever is

shown in Fig. The bending moment is maximum
at the valve spindle axis. It is given by,
58
Example 2. A right angled bell-crank lever is to be designed
to raise a load of 5 kN at the short arm end. The lengths of
short and long arms are 100 and 450 mm respectively. The
lever and the pins are made of steel 30C8 (Syt = 400
N/mm2) and the factor of safety is 5. The permissible bearing
pressure on the pin is 10 N/mm2. The lever has a rectangular
cross-section and the ratio of width to thickness is 3:1. The
length to diameter ratio of the fulcrum pinis 1.25:1.
Calculate (i) The diameter and the length of the fulcrum pin
(ii) The shear stress in the pin (ii) The dimensions of the boss
of the lever at the fulcrum (iii) The dimensions of the cross-
section of the lever. Assume that the arm of the bending
moment on the lever extends up to the axis of the fulcrum.

59
60
 Eccentric Loading
Eccentric Loading - Direct and Bending Stresses Combined
• An external load, whose line of action is parallel but does not coincide with the
centroidal axis of the machine component, is known as an eccentric load.
• The distance between the centroidal axis of the machine component and the eccentric
load is called eccentricity and is generally denoted by e.

61
 Design of Turn Buckle
Project.3-Design a turnbuckle for
connecting the tie rods in the roof truss
sujected to the maximum pull of 50 kN.

62
 Design Bell crank lever

63
 Power Screws
• Design of a C-Clamp [VBB-201,203,, RSK-Page No.652]

64
 Power Screws
Design of screw jack, [VBB-Page No.206, RSK-Page No.658]

65
65
Design of helical compression and tension springs
Different Numericals on Design of helical compression and tension springs

66
 References
1. Bhandari V.B., Design of Machine Elements, Tata McGraw
Hill Publication Co. Ltd.
2. Khurmi R.S. & Gupta P. K., Machine Design, S. Chand &
Sons Publishers, New Dehli, Ed.6, 2013.
3. Design Data - P.S.G. College of Technology, Coimbatore.
4. Bhandari, V. B. Machine Design data book, Tata McGraw Hill
Publication Co. Ltd.
5. Mahadevan K. , Reddy B. K., Design Data Handbook for
Mechanical Engineers, CBS Publishers.

67
 THE BEGINNING………..

68