MEE-3001

Design of Machine Elements

Dr. Benedict Thomas

School of Mechanical Engineering
 Module-I
Introduction to Design Process
 Course Objectives
1. Develop an ability to apply knowledge of mechanics and materials
2. Develop an ability to design a system / component to meet desired needs within
realistic constraints using suitable design methodology.
3. Utilize various standards and methods of standardization.
4. Apply the concept of design and validation by strength analysis.
Expected Course Outcomes
Upon successful completion of the course the students will be able to
1. Analyse machine components using theories of failure
2. Design machine parts against fatigue failures of components subjected to
variable and cyclic loads
3. Design springs for withstanding static and fatigue loads
4. Design welded, riveted and bolted joints
5. Design keys, cotter and knuckle joints
6. Design shafts and different types of couplings using computers
7. Design engine components like piston, connecting rod, crankshaft and flywheel
 Course Contents
Module I
Introduction to Design Process
Module II
Fatigue strength
Module III
Design of Mechanical Springs
Module IV
Design of Riveted, Welded and Bolted Joints
Module V
Design of Keys, cotters and knuckle joints
Module VI
Design of Shafts and Couplings
Module VII
Design of Engine Components
Module VII
Contemporary Discussion
 Text Books
1. Joseph Edward Shigley and Charles, R. Mischke, “Mechanical Engineering
Design”, McGraw –Hill International Editions. Eighth Edition.

2. Bhandari.V.B. (2010) “Design of Machine elements”, Tata Mc Graw Hill Book

Co, Third Edition.

3. R.S.Khurmi, J.K.Gupta. (2008) “Machine Design”, Eurasia Publishing House

(Pvt.) Ltd. Revised Edition.

References
1. Design Data book– PSG College of Technology, Coimbatore., 2006

2. Juvinal, R.C., (2002) “Fundamentals of Machine component Design”, John

Wiley.
 MACHINE DESIGN
What is the importance of Machine Design for engineers?

What is Machine Design?

 Design is either to formulate a plan for the satisfaction of a specified need

(specifically human need) or to solve a problem (to obtain optimum solution).
 Design is an innovative and highly iterative process
 It is also a decision-making process
 If the design results of physically real, then the product must be functional, safe,
reliable, competitive, usable, manufacturable, and marketable

Creation of new and better machines AND

Improving existing ones

So that it is economical in the cost of production and operation.

 How a design is born

Market
survey

Aesthetic
marketability
Ease of
Requirement handling

Safety
Availability of
Creation FUNDS
Economical
Model Available
(Rough idea) material Recyclability

Manufacturing
resources
Material/s
Analysis Force/stress Sizes
used
What is the basic knowledge required for Machine Design?

••Mathematics
Mathematics
• Mechanics of Machines
••Engineering
EngineeringMechanics
Mechanics
• Mechanics of Materials
••Strength
Strengthof
ofMaterials
Materials • Fluid Mechanics & Thermodynamics

••Workshop
WorkshopProcesses
Processes

••Engineering
EngineeringDrawing
Drawing

• Computing

• Finite Element Analysis, Computational Fluid Dynamics etc

 Important considerations in Machine Design
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)
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.
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
 Types of Materials
Ductile and Brittle Material
Engineering Materials

Materials

Metals Plastics

Ferrous Non-ferrous Thermoplastics Thermosets Elastomers

Steel Aluminum Acrylic Phenolic Rubber

Stainless steel Copper Nylon Polymide Polyurethane
Die & tool steel Zinc ABS Epoxies Silicone
Cast iron Titanium Polyethylene Polyester
Tungsten Polycarbonate
PVC
Engineering Materials

Materials

Ceramics
Metals Plastics Glass Composites

Carbides Reinforced
plastics
Nitrides
Metal-Matrix
Graphite
Ceramic-Matrix
Diamond
Laminates
Glasses
Glass ceramics
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
General Considerations in Design

 Functionality  Weight
 Strength/Stress  Life
 Distortion/deflection/stiffness  Noise
 Wear  Styling
 Corrosion  Shape
 Safety  Size
 Reliability  Control
 Manufacturability  Thermal properties
 Utility  Surface
 Cost
 Friction
 What is Machine Design
• Machine Design is defined as the use of scientific principles,
technical information and imagination in the description of a
machine or mechanical system to perform specific functions with
maximum economy and efficiency.
 Types of Design
Adaptive Design: This is based on existing design, for example, standard
products or systems adopted for a new application.
Example: The commonly used standard-model car is manufactured in
different models to obtain high speed, style and various sizes. Similarly the
different models of watches, clocks, televisions etc. In this adaptive design the
initial product and final product are basically similar in their structures.
Developmental Design:- Here we start with an existing design but finally a
modified design is obtained. A new model 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.
 Factors to be Considered in Machine Design

There are many factors to be considered while solving a design

problem.
• What device or mechanism to be used
• Material
• Loads or forces on the elements
• Size, shape and space requirements. The final weight of the
product is also a major concern.
• The method of manufacturing the components and their
assembly.
• How will it operate?
• Reliability and safety aspects
• Inspectability
• Maintenance, cost and aesthetics of the designed project
 General procedure in Machine Design

Need or aim Recognize and specify the problem

Synthesis Select the mechanism that would give the desired motion and
form the basic model with a sketch etc

Analysis of the FORCES

Material selection

Determine the stresses and thereby the sizes of

Design of elements
components so that failure or deformation does not
occur

Modification Modify sizes to ease construction & reduce overall cost

Detailed drawing Production

Phases in Design
 Design Process
Identification of Need
• It is highly creative act
• The need is often not evident at all
• Recognition of need is usually triggered by a particular adverse
circumstance
Definition of Problem
• It is not a statement
• It is more specific and must include all specifications for the object to
be designed
• Specifications are the input and output quantities
• The specifications define the cost, the number to be manufactured, the
expected life, the range, the operating temperature, and the reliability
 Design Process Cont.….
The restrictions on a designer’s freedom affect the specification of the
product. The restrictions are,
Manufacturing process selection
Labour skills available and the competitive situation
Non availability of materials
Synthesis
• The synthesis of a scheme connecting possible system elements is
sometimes called the invention of the concept or concept design.
Various schemes must be proposed, investigated and quantified
• In this stage, the designer can try for a number of possible solutions.
It deals with a complete defining of all the details of the possible
solutions; including material processing methods and dimensions
• This may be done by computation
 Design Process Cont.….
Analysis and optimization:
• Analysis must be performed to assess whether the system performance
is satisfactory or better, and, if satisfactory, just how well it will perform
• Mathematical models are developed to simulate the real physical system
• Optimum solution is the best of all possible solutions
Evaluation:
• Evaluation is the final proof of a successful design and usually involves
the testing of a prototype in the laboratory
• Here, we wish to discover if the design really satisfies the need
Presentation
• Communicating the design to others is the final and vital step
• Many great designs, inventions and creative works have been lost
simply because the originators were unable to explain their
accomplishments to others
• It is a selling job and the designer is benefitted
 Classification of Design
According to the methods used, the design may be classified as follows:
 Empirical design: This type of design depends upon empirical formulae
based on the existing practice and past experience.
 Rational design: This type of design depends upon mathematical
formulae of principle of mechanic.
 Industrial design: This type of design depends upon the production
aspects to manufacture any machine component in the industry.
 Optimum design: It is the best design for the given objective function
under the specified constraints. It may be achieved by minimizing the
undesirable effects.
 Element design: It is the design of any element of the mechanical
system like a piston, crank shaft, connecting rod etc..
 System design: It is the design of any complex mechanical system like a
motor car.
 Computer aided design: This type of design depends upon the use of
computer systems to assist in the creation, modification, analysis and
optimization of a design.
GENERAL CONSIDERATIONS IN DESIGNING A MACHINE
COMPONENT
1. Type of load and stresses caused by the load:
The load or force is an external agent which, when applied on a
machine part produce or tends to produce/destroy motion. Generally
the machine members are subjected to various external forces due to
1. Self weight of the machine.
2. Inertia due to reciprocating parts.
3. Power transmission.
4. Change of nature like temp and other
5. Frictional forces.
The load is classified with respect to its nature of application as
1. Steady or static or dead load: Whose magnitude and direction
will not change with respect to time.
2. Live or variable or dynamic load: Whose magnitude and
direction change time to time.
3. Suddenly or shock load: Initial velocity is zero.
4. Impact load: This is suddenly applied with some velocity.
2. Motion of the parts: Depending upon the given specification the
suitable prescribed motion of the part is to be evaluated. The motion of
the parts are
 Rectilinear motion.(reciprocating)
 Curvilinear motion. (rotary)
 Constant speed.
 Constant or variable acceleration
3. Selection of materials: The selection of material for a part depends
upon the forces that are acting on that part and stresses developed on
that part. The design engineer should have a thorough or complete
knowledge of the mechanical behavior of materials under different
loads.
4. Form and size of the parts: Based upon the stresses acting on the
part, the size and form shape (appearance) of a component is to be
designed. In the process of reducing the size of the machine or existing
component the design engineer should always check for the capability
of that part to resist the stresses. The size is inversely proportional to
material strength if the load is kept constant.
5. Lubrication: There is always a lot of heat is dissipated between movable
parts (rotating, sliding or rolling bearings),a design engineer should always
provide a better means of lubrication between the parts.

6. Operational features: The designer should always consider the operational

features of the machine. For example the start button, controlling levers, stop
button should be designed based upon the convenient handling of the operator.

7. Use of standard parts: using the existing standard parts like bolts, nuts,
washers, Gears and pulleys etc Reduces the cost of a machine and also it
simplifies the manufacturing process. The designer should always go for
selection of available parts of standard sizes; however, if the design requires a
new part, then designer has to suggest a new manufacturing process.

8. Safety of operation: Some machines are dangerous to operate at maximum

speed. It is necessary that a designer should always provide safety devices for
the safety of the operator. The safety appliances should in no way interference
with operation of the machine Ex: Electrical main-Switch.
9. Work shop facilities: The designer has to always design the part based
upon his employer’s work shop facilities available to him. Sometimes it is
necessary to plan and supervise the work shop operations and to draft methods
for casting, handling and machining special parts.

10. Number of components to be manufactured: Based upon the number of

parts to be manufactured, the designer has flexibility in designing the part. If
the number of components to be manufactured are less, the designer should
always look at using the standard shapes and sizes of parts available to him.
However if the number of components to be manufactured are more, he can go
for a new product (design) of the part.

11. Cost of construction: The designer has to always try to minimize the cost
of construction of a machine. Use of standard parts and using the
manufacturing process available to him can reduce the cost of construction.

12. Assembling: Based upon the local conditions at errection of the machine,
the designer should design the different components of a machine.
 Standards and Codes
 A standard is a set of specifications for parts, materials, or
processes intended to achieve uniformity, efficiency, and a
specified quality.
 One of the important purposes of a standard is to place a limit on
the number of items in the specifications so as to provide a
reasonable inventory of tooling, sizes, shapes, and varieties.
 A code is a set of specifications for the analysis, design,
manufacture, and construction of something.
 The purpose of a code is to achieve a specified degree of safety,
efficiency, and performance or quality. It is important to observe
that safety codes do not imply absolute safety.
 In fact, absolute safety is impossible to obtain. Sometimes the
unexpected event really does happen.
 SELECTION OF MATERIALS
Selection of a proper material for the machine component is one of the most
important steps in the process of machine design. The best material is one
which will serve the designed objective at minimum cost .
Selection of material based on trial and error method. Following factors are
influencing the selection of materials
(1) Availability
(2) Cost
(3) Mechanical properties
(4) Manufacturing considerations.
Availability: The material should be readily available in the market

Cost: there is a limiting cost for all the product. If it is exceeded the
designer has to consider other alternative materials.
In cost analysis there are two factors, namely cost of material and the cost of
processing the material into finished goods.
Mechanical properties: These properties govern the selection of materials.
Depending upon the service conditions and the functional requirement, different
mechanical properties are considered and a suitable material is selected.
Example:
 connecting rod of I .C-Withstand fluctuating stresses due to combination of
fuel- Endurance strength criterion of design.
 Piston rings resist wear- Surface hardness criterion of design.
 Bearing material – have low coefficient of friction.
 Clutch or brake lining -has high coefficient of friction.

Manufacturing considerations:
 The manufacturing processes such as casting, rolling, forging, extrusion,
welding and machining govern the selection of the material.
 Machine ability of material is an important consideration in selection.
Sometimes, an expensive material is more economical than a low priced one.
Which is difficult to machine. Where the product is of a complex shape,
casting properties are important.
 Past experience is a good guide for the selection of material.
Various Properties of materials are classified as follows:
1. Physical properties: density, porosity, structure, Fusibility,
Shape and size.
2. Mechanical properties: Strength, stiffness, elasticity, plasticity,
ductility, brittleness, creep, fatigue, hardness etc…
3. Magnetic properties: thermal permeability and hysterics.
4. Thermal properties: thermal conductivity, specific heat, latent
heat and thermal stresses.
5. Electrical properties: dielectric strength, conductivity and
resistively.
6. Chemical properties: chemical composition, corrosion
resistance, acidity and alkalinity.
 Mechanical properties of materials
The mechanical properties of the metals are those which are
associated with the ability of the material to resist mechanical forces
and load. Which undergo any changes in shape and structure during
the application of force on these elements.

1. Strength: It is the ability of a material to resist the externally

applied forces without breaking or yielding.
Static load: Ultimate tensile Strength or tensile yield strength.
Fluctuating load: Endurance strength.

2. Elasticity: It is the property of a material to regain its original

shape after deformation when the external forces are removed. This
property is designable for materials used in tools and machines. It
may be noted that steel is more elastic than rubber .
3. Plasticity: It is the property of a material which retain the deformation
produced under load permanently. This property of the material is necessary
for forging, in stamping images on coins and in or nonmetal work.

4. Ductility: It is the property of a material enabling it to be drawn into wire

with the application of a tensile force. A ductility is usually measured by the
terms percentage elongation and percentage reduction in area. The ductile
material commonly used in engineering practice are mild steel, copper,
aluminum, nickel, zinc, tin and lead.

5. Brittleness: It is the property of a material opposite to ductility it is the

property of breaking of a material with little permanent distortion. Brittle
materials when subjected to tensile loads snap off without giving any sensible
elongation. Cast iron is a brittle material.

6. Toughness: It is the property of a material to resist fracture due to high

impact loads like hammer blows. The toughness of the material decreases
when it is heated. This property is desirable in parts subjected to shock and
impact loads.
7. Stiffness or Rigidity: It is defined the ability of a material to resist deformation under
action of external load. The modulus of elasticity is the measure of stiffness.

8. Resilience: It is the property of a material to absorb energy and to resist shock and
impact loads. It is measured by the amount of energy absorbed per unit volume within
elastic limit. This property is essential for spring materials.

9. Hardness: It is a very important property of the metals and embraces many different
properties such as resistance to wear, scratching, deformation and machinability etc. It
also means the ability of a metal to cut another metal. The hardness is usually expressed
in numbers which are dependent on the method of making the test.
The hardness of a metal may be determined by the following tests:
(a) Brinell hardness test
(b) Rockwell hardness test
(c) Vickers hardness (also called Diamond Pyramid) test

10. Machinability: It is the property of a material which refers to a relative case with
which a material can be cut. The machinability of a material can be measured in a
number of ways such as comparing the tool life for cutting different materials or thrust
required to remove the material at some given rate or the energy required to remove a
unit volume of the material. It may be noted that brass can be easily machined than steel.
11. Malleability: It is a special case of ductility which permits materials to
be rolled or hammered into thin sheets due to compressive force. A
malleable material should be plastic but it is not essential to be so strong.
The malleable materials commonly used in engineering practice are lead,
soft steel, Wrought iron, copper and aluminum.

12. Creep: When a part is subjected to a constant stress at high temp for a
long period of time, it will undergo a slow and permanent deformation
called creep. This property is considered in designing I.C engine, boilers and
turbines.
Time dependent strain is called creep.

13. Fatigue: When a material is subjected to repeated stresses it fails at

stresses below the yield point stresses. Such type of failure of a material is
known as fatigue. The failure is caused by means of progressive crack
formations which are usually fine and microscopic size. This property is
considered in designing shafts, connecting rod, springs, gears etc.
 Manufacturing considerations in Machine
design
The knowledge of manufacturing processes is of great importance for a design
engineer. The following are the various manufacturing processes used in
Mechanical Engineering.

1. Primary shaping processes. The processes used for the preliminary shaping
of the machine component are known as primary shaping processes. The
common operations used for this process are casting, forging, extruding,
rolling, drawing, bending, shearing, spinning, powder metal forming,
squeezing, etc.

2. Machining processes. The processes used for giving final shape to the
machine component, according to planned dimensions are known as
machining processes. The common operations used for this process are
turning, planning, shaping, drilling, boring, reaming, sawing, broaching,
milling, grinding, hobbing, etc.
3. Surface finishing processes. The processes used to provide a good
surface finish for the machine component are known as surface
finishing processes. The common operations used for this process
are polishing, buffing, honing, lapping, abrasive belt grinding,
barrel tumbling, electroplating, super finishing, sheradizing, etc.

4. Joining processes. The processes used for joining machine

components are known as joining processes. The common
operations used for this process are welding, riveting, soldering,
brazing, screw fastening, pressing, sintering, etc.

5. Processes effecting change in properties. These processes are

used to impart certain specific properties to the machine
components so as to make them suitable for particular operations or
uses. Such processes are heat treatment, hot-working, cold-working
and shot peening.
Other considerations in Machine design
1. Workshop facilities.
2. Number of machines to be manufactured
3. Cost of construction
4. Assembling

Optimum manufacturing method is selected by considering the

following factors:
1. Material of the component
2. Cost of manufacture
3. Geometric shape of the component
4. Surface finish and tolerance required, and
5. Volume of production
 Task:
To design a new product based on
the design process