JIMMA UNIVERSITY, JIT

Faculty of Mechanical Engineering

Machinery Design,
(MEng 5303)
 CHAPTER 1

Introduction
 Introduction to machinery design
• What is Design
❖Creation of new and better machines and Improving existing ones So that it is
economical in the cost of production and operation.
❖Product design requires much research and development. Many concepts of an idea must be
studied, tried, refined, and then either used or discarded. Although the content of each
engineering problem is unique, the designers follow the similar process to solve the
problems.
 Cont.…
• What is machine?
• Machine is a device consisting of various elements arranged together, so as to perform the
prescribe task to satisfy human needs.
• Eg: A pump-set is a machine in which the input is electrical energy, the pump-set utilizes the electrical
energy to perform the prescribed task of lifting water to the desired location (output).

INPUT MACHINE OUTPUT

(Source of energy) (Arrangement of (Prescribed Task)
elements)

• What is machinery?
• Machines or machine parts considered as a group or working parts of a particular machine.
• What is mechanism?
• A mechanism is the members combination more than two or two connections with the members to
realize the regulation motion made up by way of the activity.
MACHINE/DEVICE/PRODUCT

Functional

Marketable Safe

Machine
/device/
Product
Manufacturable Reliable

Usable Competitive 5
 Cont..
• Machinery design is either to formulate an engineering plan for the satisfaction of
a specified need or to solve an engineering problem. It involves a range of
disciplines in materials, mechanics, heat, flow, control, electronics and production.
Machinery components
• The major part of a machine is the mechanical system.
• Mechanical system is decomposed into mechanisms, which can be further
decomposed into mechanical components. In this sense, the mechanical
components are the fundamental elements of machinery.
• Mechanical components can be classified as universal and special components.
Bolts, gear, and chains are the typical examples of the universal components,
which can be used extensively in different machines across various industrial
sectors.
Cont…
 Cont…
• Machine element is an individual component or a group of components of a machine
which performs a specific function. Its function may be of holding the components
together, to transmit power or to give supports.
• Depending upon these functions only, the machine elements are
• Following types.
1) Machine elements used for holding the components.
2) Machine elements used for transmitting the power.
3) Machine elements used for support of other components.
 Machine elements

Power Transmitting
Holding Elements Supporting Elements
Elements
 Cont…
• Machine elements used for holding the components :-
✓ These type of machine elements include nuts and bolts, Screw, cotters, keys, couplings, pins,
rivets.

• Machine elements used for support of other components:-

✓ Machine elements like bearings, axles, brackets, hangers Etc. Are used to give support to
rotating or stationary members.

• Machine elements used for transmitting the power :-

✓ Machine elements like gears, shafts, clutches and brakes, Pulleys, belts, chain, sprocket, are used to
transmit power from One place to another.
 The engineering design process: (core of engineering)
• Problem Identification: Get with Customer.
• Conceptual Design: Ideas, Sketches and Solution Lists.
• Refinement: Computer Modeling, Data Base Development.
• Testing: Analysis and Simulation of All Design Aspects.
• Prototyping: Visualizing and Improving the Design.
• Communication: Engineering Drawings, Specifications.
• Production: Final Design, Manufacturing, Distribution.

11
 What is the basic knowledge required for Machine Design?

• Mathematics•Mathematics
• Mechanics of Machines
• Engineering•Engineering • Mechanics of Materials
Mechanics Mechanics
• Fluid Mechanics & Thermodynamics
• Strength of Materials
•Strength of Materials

• Workshop Processes

• Engineering 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)
 Cont…
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.

Metal Non-metal

Ferrous Non-ferrous
 Cont…
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
 Cont…
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

16
 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, i.e. failure or deformation does not
occur
Modification Modify sizes to ease construction & reduce overall cost

Detailed drawing Production

 CHAPTER 2

Transmissions
 Introduction to transmission

• A transmission system uses a clutch, gear box, propeller shaft and a differential
gear to transmit power from engine to the road wheels
• The power may be transmitted to rear or front or all four wheels depending on the
drive used
• The clutch and gear box varies the ratio of torque output to torque input
• The propeller shaft transmits final torque to the rear axle from gear box
• A differential gear equally distributes the final torque between the road wheels.
❖Power transmission is the movement of energy from its place of generation to a
location where it is applied to performing useful work
 Functions of transmission system
• It disconnects engine from driving wheels when required
• The engine is connected to driving wheels when required
• It changes ratio of torque output to torque input, as desired
• It turns the drive through a right angle
 Why is a transmission necessary?

• Provide torque multiplication at low speeds

• Reduce engine RPM at highway speeds
• Allow the engine to operate within its most efficient RPM range
• Allows the engine to be disengaged from the rear wheels while the vehicle is not moving
(torque converter & clutch)
 Clutch
• A clutch is a mechanical Device which transmits motion from one shaft to the
other which are along a straight line or same axis of rotation.
• A clutch is a machine member used to connect the driving shaft to a driven shaft,
so that the driven shaft may be started or stopped when ever needed, without
stopping the driving shaft.
• It is so designed that the two members may be engaged or disengaged whenever
required either by a hand operated device or automatically by the action of some
power driven devices.
Parts of a clutch
 Types of clutches

jaw clutch
positive contact
clutch
toothed clutch

mechanical
disc clutch

pneumatic friction clutches

cone clutch
Clutches
hydraulic centrifugal
clutch

electromagnetic
 Cont…
• The major types of friction clutches are:

1. Disc clutch (single plate) or multiple plates

- Operates by a principle of engaging and disengaging a single or multiple rotating friction discs.
 Cont….
• A cone clutch, consists of inner and outer conical surfaces.
• The outer cone is keyed to the driving shaft, while the inner cone is free to slide
axially on the driven
 Requirements of a clutch
1. Torque transmission.---The clutch must be able to transmit maximum torque of the engine
2. Gradual engagement----the clutch should engage gradually to avoid sudden jerks
3. Heat dissipation---the clutch should be able to dissipate large quantity of heat which is generated during
the clutch operation due to friction
4. Dynamic balancing---the clutch should be dynamically balanced. This is particularly required incase of
high speed engine clutches.
5. Vibration damping ---the clutch should have suitable mechanism to damp vibrations and to eliminate
noise produced during power transmitted.
6. Size---the clutch should be as small as possible so that it occupies minimum space
7. Inertia -- clutch rotating parts should have minimum inertia
8. Clutch free pedal play – to reduce effective clamping load on carbon thrust bearing
9. Ease of operation – as clutch transmits higher torque , its disengagement should not tiresome the driver
10. Lightness
Factors should be considered while designing friction clutches:
• Selection of a proper type of clutch that is suitable for the given application
• Selection of suitable friction material at the contacting surfaces
• Designing the clutch for sufficient torque capacity
• Engagement and disengagement should be without shock or jerk
• Provision for holding the contacting surfaces together by the clutch itself and
without any external assistance
• Low weight for rotating parts to reduce inertia forces, particularly in high-speed
applications
• Provision for taking or compensating wear of rubbing surfaces
• Provision for carrying away the heat generated at the rubbing surfaces
 Mechanical drives
• A mechanical drive is defined as a mechanism, which is intended to transmit mechanical power
over a certain distance, usually involving a change in speed and torque.
• Belt, chain and gear drives are often called ‘mechanical’ drives.
• In general, the mechanical drive is required between the prime mover, such as electric motor and
the part of the operating machine. A mechanical drive is used on account of the following
reasons:

➢The torque and speed of the machine are always different than that of electric motor or engine
➢In certain machines, variable speeds are required for the operation, whereas the prime mover
runs at constant speed
➢Standard electric motors are designed for uniform rotary motion
 Cont…
• Mechanical drives are classified into two groups according to their principle of operation. The
two broad groups are as follows:
I. mechanical drives that transmit power by means of friction, ex., Belt drive and rope
drive
II. mechanical drives that transmit power by means of engagement, ex., Chain drives and
gear drives
 Gear drives
• A gear is a wheel with teeth on its outer edge. The teeth of one gear mesh (or engage) with the
teeth of another.
• The teeth of one gear mesh with or engage the teeth of another gear - transmitting rotary motion.

• Gears are used to change the torque, speed, and direction of rotation .
 Driver and driven

• The driver (or input) gear would be the gear that is

moved by a crank handle or motor.
• The driver’s teeth engage the teeth of the driven (or
output) gear, causing it to rotate.

Direction of rotation
• Two meshed gears always rotate
in opposite directions.

Driven gear
Driver gear
 Gear ratio
• A gear ratio is the ratio used to determine the angular speed and torque of a geared system.

Number of driven teeth : number of driver teeth

Also written as:
Driven teeth
Driver teeth

• If a set of gears has a driver and driven gear of the same size. The gear ratio would be 1:1.
• This causes a change in the direction of the motion with no change to speed or torque.
 Cont…

Find the Gear ratio for the following gear set. Fill in the following blanks:
If the driving gear turns 1 time, the driven gear will turn _______ times.

Driving gear has

30 teeth

Driven gear has

10 teeth
 Gearing up: need for speed
• To increase the speed the driver should be
larger than the driven gear.
• Example: the driver gear has 60 teeth and the
driven gear is 30 teeth.
• Gear ratio = 30/60 = ½ or 1:2
• This means that for every 1 turn of the driver
gear, the driven will rotate 2 times.
 Gearing up: need for speed

• With this 1:2 ratio, the speed of the driven gear is 2 times
greater than the input.
Why gear up?
• Using the top gear on your bike, you can make the back
wheel spin faster than you can pedal.
• A fan’s blades can whir at a greater speed than the electric
motor that drives it.
 Gearing down: pulling torque
• To increase the torque the driver should be smaller than
the driven.
• The force translated from the driver gear to the driven
gear is the same.
• However, the driven gear has a longer lever arm, therefore
the torque is larger for the driven gear.
• Example: the driven torque is multiplied by the gear ratio
which is 3/1 . therefore, the torque of the driven gear is 3
times greater than the torque of the driver gear.

Gear ratio = 75/25 = 3/1

 Gearing down: pulling torque

Why gear down?

• Need to pull a tree stump out of the ground? You’ll need a
machine with lots of pulling torque. Tractors are geared for
tasks like this.
 Speed and torque
• Torque and speed are inversely proportional.

• 1A. This gearing increases the speed

but decreases the torque.

• 2A. This gearing increases the torque,

but decreases the speed.
 Types of gears
• Several types of gears are in common use. Four principal types of gears are:
• Spur gears
• Helical gears
• Bevel gears
• Worm gears
How does the transmission produce torque multiplication and/or RPM reduction?
Transmissions use gears
• Spur
• Helical
• Planetary
• Bevel gear
 Spur gears
• A spur gear is one of the most fundamental types of gears.
• Its teeth are straight and parallel to the axis of the shaft that carries the gear. The
teeth have the involute form.
Advantages
• Low cost
• Ease of manufacture
• Availability

Disadvantages
• Only works with mating gear
• Axis of each gear must be parallel
 Cont…

• Teeth are cut straight, parallel to the shaft.

• Only one tooth is in full contact at any given moment.

• Spur gear teeth minimize the possibility of popping out of gear.

• For this reason, spur gears are often used in the reverse gear train.

• A disadvantage of spur gears is noise.

• At higher turning speeds, their clicking noise becomes a constant whine.
 Helical gears
• Teeth are at an angle to the gear axis (usually 10° to 45°) – called helix angle
Advantages
• Smooth and quiet due to gradual tooth engagements (spur gears whine at high speed due
to impact). Helical gears good up to speeds in excess of 25.4 m/s
• More tooth engagement allows for greater power transmission for given gear size.
Disadvantage
• More expensive
• Resulting axial thrust component
 Cont….

• Teeth are cut at an angle. (Helical to the axis of rotation)

• Two or more teeth may be in mesh at the same time providing more evenly
distributed load.
• They are useful in applications requiring high torque to transfer loads.
• They perform more quietly than spur gears because they mesh with mating gears
with a wiping action.
• The main disadvantage of helical gears is the longitudinal thrust they create during
operation.
 Bevel gears
• Bevel gears are useful when the direction of a shaft's rotation needs to be changed
• Gear axis at 90°, based on rolling cones
• Advantages
• Right angle drives

• Disadvantages
• Get axial loading which complicates bearings and housings
Nomenclature of spur gears
 Idler gears

• An idler gear may be used to transfer torque without changing

the direction of rotation.
• Idler gears are also used to provide reverse gearing.
• If two idler gears are used, the driven gear will rotate in the
opposite direction of the drive gear.
• Idler gears can also transfer power in place of a chain drive or
belt drive.
• Idler gears do not affect the relative speeds of either the drive
or driven gears.
 Gear trains
• Gear Trains: Sometimes, two or more gears are made to mesh with each other
to transmit power from one shaft to another. Such a combination is called gear
Driver
train or train of toothed wheels. Compound
Gear
• It reduces speed and increases torque

➢ Types of Gear Trains:

1. Simple gear train,
2. Compound gear train,
3. Reverted gear train, and
4. Planetary gear Train or Epicyclic gear train.
Driven
➢ Direction or sense of roation :
• Clockwise direction = +ve
• Anticlockwise direction = - ve
 Gear ratio of gear trains
• In gear trains the ratio will change from set to set. Multiplying the gear ratio for each set of
gears will give you the net gear ratio for the train.
• In a gear train with each gear on a separate axle the idler gears can be ignored. Therefore the
net gear ratio can still be found by:
Driven teeth
Driver teeth
Example:

• The driving gear has 30 teeth, the idler gear has 90 teeth and
the driven gear has 15 teeth.
• The ratio for A:B is 3/1; the ratio for B:C is 1/6. Net
gear ratio = 3/1 x 1/6 = 1/2.
• Ignoring the idler gears results in the same gear ratio.
A:C = 15/30 = 1/2
 Cont…
• In a gear train in which some gears share the same axle the gear ratio must be found by
multiplying each individual gear ratio.
Example
• Find the ratios for each set of gears.
• A:B is 40/120 = 1/3
• C:D is 20/80 = 1/4
• The net gear ratio = 1/3 x 1/4 = 1/12.
 You are the designer!!

When you design Gear box:-

• The teeth must not break;
• They must have a sufficiently long life to meet the needs of the customer
who uses the reducer.