Design of Machine Elements

Introduction
Lecture 2

Prof. Sujatha Srinivasan

404, Machine Design Section
311, TTK Center for Rehabilitation Research and Device Development
(R2D2)
Department of Mechanical Engineering
IIT Madras
Email: sujsree@iitm.ac.in

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Basic Procedure of Machine Design (Product)

Current Subject
DOME

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 Need for Swimming Pool Lift

• Physically challenged

• Swimming (Exercise)

• Swimming pool

• Stairs for entry/exit

• Swimming pool lift

Figure: Ms. P Madhavi Lata and other physically challenged at pool

Courtesy: Swostik Sourav Dash (DD 2013)
 Kinematic Configurations
Kinematic 1 Kinematic 2 Kinematic 3

Kinematic Configuration

M M
Inspired by

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 Methodology

• Understanding existing products

• Market survey
• Patent study
• Design Requirements
• Safety and ergonomics guidelines
• Customer survey
• Kinematic design of mechanism
• Detailed design
• Solid modeling
• Force analysis
• Stress analysis
• Design for manufacture and assembly
• Prototyping
• Testing
Design of the device
 Operation

Step-1 Step-2

Step-3 Step-4
 Basic Requirements Of Machine Elements
➢ Objective: 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:

(i) Strength: A machine part should have sufficient strength to avoid failure either due to
fracture or due to general yielding.

(ii) Rigidity: A machine component should be rigid, that is, it should not deflect or bend
too much due to forces or moments that act on it.

(iii) Wear Resistance: Surface hardening can increase the wear resistance of the
machine components, such as gears and cams.

(iv) Minimum Dimensions and Weight: with minimum possible dimensions and weight
(minimum material cost)
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(v) Manufacturability: The shape and material of the machine part should be selected in such
a way that it can be produced with minimum labour cost, ease of fabrication.

(vi) Safety: should ensure safety to the operator of the machine.

(vii) Conformance to Standards: A machine part should conform to the national or international
standard covering its profile, dimensions, grade and material.

(viii) Reliability: A machine part should be reliable, that is, it should perform its function
satisfactorily over its lifetime.

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 Basic Procedure for Design of a Machine Element

In order to ensure the basic

requirements of machine elements
……………
▪ calculations are carried out to find
out the dimensions of the machine
elements.
▪ These calculations form an integral
part of the design of machine
elements.

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• This course builds on Strength of Materials;
Materials and Design
• You will refer to a lot of data: standards, charts
and empirical formulae etc.

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 The following standards are used in Mech. Engg. design:
(i) Standards for Materials, their Chemical Compositions, Mechanical Properties and Heat
Treatment :
▪ Indian standard IS 210 specifies seven grades of grey cast iron designated as FG 150, FG
200, FG 220, FG 260, FG 300, FG 350 and FG 400.
▪ The number indicates ultimate tensile strength in N/mm2
(ii) Standards for Shapes and Dimensions of Commonly used Machine Elements :
▪ The machine elements include bolts, screws and nuts, rivets, belts and chains, ball and
roller bearings, wire ropes, keys and splines, etc.
▪ IS 2494 (Part 1) specifies dimensions and shape of the cross section of endless V-belts for
power transmission.
(iii) Standards for Fits, Tolerances and Surface Finish of Component

(iv) Standards for Testing of Products:

▪ These standards, sometimes called ‘codes’, give procedures to test the products such as
pressure vessel, boiler, crane and wire rope, where safety of the operator is an important
consideration.
▪ For example, IS 807 is a code of practice for design, manufacture, erection and testing of
cranes and hoists.
(v) Standards for Engineering Drawing of Components
▪ For example, there is a special publication SP46 prepared by Bureau of Indian
Standards on ‘Engineering Drawing Practice for Schools and Colleges’, which covers all
standards related to engineering drawing.

Standardization offers the following advantages:

(a) Manufacture of a standard component on mass production basis reduces cost.

the reduction in types and dimensions of identical components to a rational
number makes this possible.
▪ For example, a specialised factory like Associated Bearing Company (SKF)
manufactures ball and roller bearings, which are required by all engineering
industries.

(b) Reduces the manufacturing facilities required by the individual organisation

▪ This is due to the availability of standard components like bearings, seals,
knobs, wheels, roller chains, belts, hydraulic cylinders and valves.

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(c) Reduction in maintenance cost of machines.
▪ Standard parts are easy to replace when worn out due to interchangeability.
▪ Availability of standard spare parts is always assured.
▪ The work of servicing and maintenance can be carried out even at an ordinary service
station.

(d) Reduction of the time and effort needed to design a new machine:
▪ This is due to the application of standard machine elements and especially the standard
units(e.g. couplings, bearings, pumps, pressure reducing valves and electric motors).
▪ It is no longer necessary to design, manufacture and test these elements and units, and
all that the designer has to do is to select them from the manufacturer’s catalogues.
▪ Standardization results in substantial saving in the designer’s effort.

(e) The standards of specifications and testing procedures of machine elements

improve their quality and reliability.
▪ Standard components like SKF bearings, Dunlop belts or Diamond chains have a long-
standing reputation for their reliability in engineering industries.
▪ Use of standard components improves the quality and reliability of the machine to be
designed

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 Follow the conventions

➢ It pays to standardize on the arrangement and operation of controls

because it enhances user knowledge.
➢ For example, the placement of the brake, clutch, and accelerator
pedals in an automobile is arbitrary, but once standardized they
become part of the user knowledge base and should not be changed.

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 Design goals
➢ Machine components are subjected to complicated
loadings
➢ Loadings cause stress, critical stresses cause components
to fail
➢ Main idea - Prevent failure during service
➢ In this course we are mainly concerned with
▪ Determination of geometry – Primary
▪ Choice of material – Primary
▪ Economy - Secondary
▪ Aesthetics - Secondary
▪ Ergonomics - Secondary
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Beams

Flexural rigidity = E I h

b
Where E = Young's Modulus

I = Moment of inertia of the section

= bh3/12

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Design of beams
➢ When a beam is loaded,
the upper surface is under
compression and lower in
tension.

➢ Along the imaginary

centre line, neutral axis :
no stress

Designers aim to produce beams that are

strong enough to do the required job, but
at a minimum cost and weight.
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 Types of members and their uses
▪ Different members within a
structure have to resist
different kinds of forces
▪ It is important to choose
the most suitable for the job.
▪ In addition to resist forces,
cost, weight, and appearance
are also important factors in
the choice of a member

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 5. Mechanical Properties of Materials
➢ Materials are characterized by their properties. They may be hard, ductile or soft or light etc.
➢ The mechanical properties of materials are the properties that describe the behaviour of
the material under the action of external forces.
➢ They usually relate to elastic and plastic behaviour of the material.
➢ Mechanical properties are of significant importance in the selection of material for structural
machine components.

• Strength ---- Ultimate strength or yield strength

• Strength (fluctuating loads) --- endurance strength
• Rigidity -- modulus of elasticity
• Ductility -- % elongation
• Hardness -- BHN, VHN, RC Hardness number
• Toughness -- Charpy or Izod impact value
• Frictional property -- Coefficient of friction
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 Selection Of Material
▪ The best material is one which will serve the desired purpose
at minimum cost.

➢ The factors which should be considered while selecting the

material for a machine component are as follows:

(i) Availability : The material should be readily available in the

market, in large enough quantities to meet the requirement. Cast
iron and aluminium alloys are always available in abundance.

(ii) Cost: When cost limit is exceeded, the designer has to

consider other alternative materials. Cost includes the cost of
material and the cost of processing the material into finished goods.

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(iii) Mechanical Properties: Depending upon the service conditions and the
functional requirement, different mechanical properties are considered and a
suitable material is selected.
Example: In case of bearing materials, a low coefficient of friction
is desirable while clutch or brake lining requires a high
coefficient of friction.

(iv) Manufacturing Considerations: In some applications, material

machinability is an important consideration in selection. Sometimes, an
expensive material is more economical than a low priced one, which is
difficult to machine.
Example: Free cutting steels have excellent machinability, which
is an important factor in their selection for high strength
bolts, axles and shafts.

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Mechanical Design Aspects

Simultaneous or Concurrent Engineering

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Design Considerations for Castings

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Design for Assembly

Modification needed for Tool clearance

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 Tolerances
➢ It is impossible to manufacture a part or a component to an exact size say 20mm.
➢ Since variation from drawing is inevitable, acceptable degree of variation must be
applied.
➢ Large variation may affect the functionality, small variations may effect the
economy of the part .

Unilateral & Bilateral Tolerances Hole (Bearing) Shaft (Journal)

Dimensions

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▪ When two parts are to be assembled, the relationship resulting from the difference
between their sizes before assembly is called a fit.
▪ Fundamental deviation and magnitude of tolerance of various grades are given in
the standards:
50 H8/g7 or 50 H8-g7

Example: The valve seat fitted inside the housing of a Valve Seat
pump is shown in Figure. Find: (i) maximum & minimum
diameters of housing and valve seat (ii) the magnitude
of the maximum and minimum interferences between
the seat and housing.

Basic size Hole Shaft Pump

housing

(i)

(ii)
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