DMM PPT 1

MEC 302 Design, materials and manufacturing
Semester: Monsoon 2021

Students: BTech (Mechanical) 2019 batch
Credits: 4 (about 40 classes)
Tuesday and Thursday 1100 – 1230 in Room 103, GICT
Course coordinator: Dr Shuja Ahmed

Course TA: Mr Ujjaval Modi
Why this course?
• Raw materials  Final products (Application of interest – Need – the driving force)
 Design and manufacturing of the materials
• High quality of product and Low cost of production is desired
• Product quality depends on design, material and manufacturing
• Various types of mechanical components and their design available
• Various types of engineering materials are available to choose from
• Various types of manufacturing/processing techniques to choose from
Sunday, September 5, 2021 2

Basics
• Various machine elements (mechanical components):-
Keys and Temporary Springs Screws and Power Brakes Bearings Levers
couplings joints screws
Shafts and its Permanent Belt drives Pressure vessels Clutches Gears Flywheel
components joints and cylinder
• Types of engineering materials:-

Ferrous (MS, SS, etc.) Plastics (thermoset, thermoplastic) Composites
Non-ferrous (Al, Mg, Cu, Ti, Ni, etc.) Ceramics and Diamond Glass
• Types of manufacturing (material processing) techniques:-

Shaping processes- Material removal processes- Joining processes- Regenerative manufacturing-
Solid- Forging, etc. Turning, drilling, grinding, Welding, Wire- FDM
Liquid- Casting, etc. EDM, Laser machining, Soldering, Brazing, Liquid- WAAM
Powder- Powder Abrasive jet machining, etc. Adhesive joining, Powder- SLS
metallurgy, etc.
Sunday, September 5, 2021 etc. Sheet- LOM 3
Basics
• Machine is a combination of various machine elements and is usually power driven
Overall it transmits force and motion and result in performing some useful work
• Machine design involves the process of material selection, shapes, sizes and
arrangements of mechanical elements so that the resulting machine performs the
desired task in an optimum way
• Power transmitting type machine elements:-
Gears, Shafts, Belts and pulleys, Clutches, Chains, etc.
• Holding type machine elements:-
Nuts, Bolts, Rivets, etc.
• Supporting type machine elements:-
Bearings, Axles, Bed, etc.
Basics
• Strength and stress
• Proportional limit Elastic Plastic

region region
• Elastic limit
• Yield point/strength
• Ultimate strength
• Fracture strength
Strength of component (Max load)
𝐂𝐚𝐩𝐚𝐜𝐢𝐭𝐲
FoS =
Actual load on component
• Factor of safety =
𝐃𝐞𝐦𝐚𝐧𝐝
Yield stress
• Factor of safety =
Design stress
0.2% offset in elongation
Ultimate stress
• Factor of safety = Fig. Engineering stress-strain curve for a ductile material
Design stress
Basics
• Engineers build machines and structures stronger than the design target
• Question: What is the stress capacity of the component material undergoing –

𝜎𝑥 = 100 𝑀𝑃𝑎 𝜎𝑦 = 50 𝑀𝑃𝑎 𝜏𝑥𝑦 = 50 𝑀𝑃𝑎
• Hint: Find the maximum principal stress in the body

• Answer: 130.9 MPa
• Maximum of applied stress is considered

(normal, shear, principal)
• Minimum of strength (a property) is considered
(yield, ultimate, endurance)
• Choose a material that has tensile (yield) strength greater or equal to 130.9 MPa
Types of design
• Adaptive design
• Using slider crank mechanism in reciprocating piston engine or pump
• Developmental design
• From simple wooden chairs to comfortable executive chairs
• New design
• Employing new design without any past references

Types of design
• Rational design
• Based on mechanics formulations and concepts
• Empirical design
• Based on experience and experiments
• Industrial design
• Based on demands of customers – look, weight, cost, quality – to sustain in
market

General procedure of machine design
• Need or Aim
• Synthesis or creating mathematical formulation
• Analysis of forces
• Material selection
• Design of elements
• Modification
• Detail drawing
• Production

End of lecture 1
Questions?

Material selection
• The choice of engineering metallic materials depends upon the properties,
availability, transportation cost and overall cost
• Ferrous metals – Cast iron, wrought iron, steel
• Non-ferrous metals – Aluminium and its alloys, Magnesium and its alloys,
Copper based alloys such as brass (Cu-Zn), bronze (Cu-Sn), Nickel, Titanium,
Silver, Bearing metals, etc.
Compared to wrought iron or steel,

cast iron is brittle, hard, and non-malleable.

Various forces
• Types of constant load or dead load (static condition / gradual loading):-
• Types of live load or variable load (dynamic condition):-
Sudden or shock load, Impact load, Fatigue, Bearing or crushing load

Various loads and resulting stresses
• Direct load (Axial bars)
𝑃 𝑃
Normal Stress 𝜎 = and shear stress 𝜏 =
𝐴𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝐴𝑠ℎ𝑒𝑎𝑟
• Bending load (Beams)

𝑀 𝑆𝐴𝑦
Bending stress 𝜎𝑏 = 𝑦 and shear stress 𝜏 =
𝐼 𝐼𝑏
• Twisting load (Shafts subjected to torsion)

𝑇
Shear stress 𝜏 = 𝑅
𝐽
• Bearing crushing load

𝑃
Crushing stress 𝜎𝑐 =
𝐴𝑝𝑟𝑜𝑗𝑒𝑐𝑡𝑒𝑑
• Thermal load (rods fixed at two ends and temp raised)

Thermal stress 𝜎𝑡ℎ𝑒𝑟𝑚𝑎𝑙 = 𝛼 ∆𝑇 𝐸
Important properties of material
• Ductility
• Brittleness
• Malleability
• Hardness
Resistance of material against scratch or indentation
• Resilience (strain energy up to elastic limit)
Ability to withstand elastic deformation without deforming plastically
• Toughness (strain energy up to fracture)
Ability to absorb energy and withstand shock up to fracture
• Fatigue
Under cyclic loading, materials fails at a stress lower than yield strength
• Creep or cold flow
Under constant loading, there is permanent deformation over time
Factor of safety
• For ductile materials-
𝜎𝑦𝑖𝑒𝑙𝑑
FoS =
𝜎𝑤𝑜𝑟𝑘𝑖𝑛𝑔
• For brittle materials-

𝜎𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒
FoS =
𝜎𝑤𝑜𝑟𝑘𝑖𝑛𝑔
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑜𝑎𝑑 𝑜𝑟 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑠𝑡𝑟𝑒𝑠𝑠 𝑡ℎ𝑒 𝑝𝑎𝑟𝑡 𝑐𝑎𝑛 𝑠𝑢𝑠𝑡𝑎𝑖𝑛 𝑜𝑟 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑣𝑎𝑙𝑢𝑒
• FoS =
𝐴𝑐𝑡𝑢𝑎𝑙 𝑙𝑜𝑎𝑑 𝑜𝑟 𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑟 𝐷𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑔𝑡ℎ
• For a constant or dead load, FoS = Less (at least 1); Even lesser in cheap products!
• For variable or dynamic load, FoS = More (2 or more)

Revise
Question: A large uniform plate containing a hole of diameter 5 cm is subjected to
uniform uniaxial tension of 95 MPa . What is the maximum stress in the plate?
10 cm
95 MPa
Answer: 190 MPa

Revise
Question: Two shafts A and B are made of the same material. The diameter of shaft B
is twice that of shaft A. The ratio of power which can be transmitted by shaft A to that
of shaft B is how much?
HINT:
Answer: 1/8
Revise
Question: The state of stress at a point is given by –
𝜎𝑥 = −6 𝑀𝑃𝑎 𝜎𝑦 = 4 𝑀𝑃𝑎 and 𝜏𝑥𝑦 = −8 𝑀𝑃𝑎
The maximum tensile stress at the point is how much?
Answer: 8.43 MPa

Revise
Question: A motor driving a solid circular steel shaft transmits 40 kW power at 500
rpm. If the diameter of the shaft is 400 mm, then the maximum shear stress in the
shaft will be how much? Answer in MPa.
Answer: 0.06 MPa

Revise
Question: A solid circular shaft needs to be designed to transmit a torque of 50 N-m. If
the allowable shear stress of the material is 140 MPa the minimum allowable design
diameter is how much?
Answer: 12.2 mm

Revise
Question: The shear strength of a sheet metal is 300 MPa. The blanking force required
to produce a blank of 100 mm diameter from a 1.5 mm thick sheet is how much?
General note: The cutting force in punching and blanking mainly depends upon
the shear strength of the material.
Answer: 141.3 kN
End of lecture 2
Questions?

Revise
Theories of column
𝜋2 𝐸𝐼
Euler’s critical buckling load =
𝐿2𝑒

Combined loads
• In industrial applications, the structure or machine elements are subjected to a
combination of following three types of general loadings –
Axial, Bending and Torsion

Combined axial and bending loads
M M
P P
Maximum tensile stress and its location
Maximum compressive stress and its location

Combined axial and twisting loads
T
Ød
P P
Maximum normal stress?

Combined bending and twisting loads
Ød
Maximum normal stress?

Mohr’s circle
Use Mohr’s circle to calculate the Principal Stresses, maximum shear stress, angles to
principal planes and plane of maximum shear stress, normal stress on plane with maximum
shear stress, and draw the results (square stress element). Draw to scale on graph paper and
clearly indicate the scale.

Mohr’s circle

End of lecture 3
Questions?

Revise
Question: The cutting force in punching and blanking operations mainly depends on -
(a) The modulus of elasticity of the material

(b) The shear strength of the material
𝐵𝑢𝑙𝑘 𝑠𝑡𝑟𝑒𝑠𝑠 𝑃 −𝑃𝑉
(c) The bulk modulus of the material (𝐵 = = −∆𝑉 = )
𝐵𝑢𝑙𝑘 𝑠𝑡𝑟𝑎𝑖𝑛 ∆𝑉
𝑉
(d) The yield strength of the material
Answer: (b)
Punching force = Shear stress x Shear area

Revise
Question: The stepped bar which is shown in the figure is subjected to a tensile load
of 152 kN. Find the diameter of the middle portion if the stress at that position has
not to exceed 140 MPa.
152 kN 152 kN
Ø 50 mm Ød Ø 50 mm
Answer: d ≥ 37.18 mm

Revise
Question: What is Factor of safety?
Answer: It is a margin over the theoretical design to allow for any uncertainties in the
design process or the application process.

Factor of safety
FoS in application
Factor of safety Applications
1.25 – 1.5 Material properties are known in detail
Operating conditions are know in detail
Loading and resulting stresses are known to a high degree of accuracy
Low weight is significantly important
2-3 For less tried and tested materials
For brittle materials under average environment, load and stress
conditions
3-4 For untried materials under average environment, load and stress
conditions
For better known materials under uncertain environment and stress
conditions
Combined loading
Eccentric loading
e e
P P P P
P Pe
P
Pe
P P
P P

Combined loading
2
1 3
𝜎1 = ?
P
Pe
𝜎2 = ?
A
𝜎3 = ?

Revise
Question: A rectangular strut is 150 mm by 120 mm. It carries a load of 180 kN at an
eccentricity ‘e’ of 10 mm in the plane bisecting the thickness as shown in the figure.
e
Find the maximum and minimum intensity of stress in the section?
P
Answer: Minimum intensity of stress is 6 MPa and P

maximum stress intensity is 14 MPa
Revise
Question: A solid shaft can resist a bending moment of 3 kN-m and a twisting moment
of 4 kN-m together. The maximum torque that can be applied is …?
Hint: Combined bending and twisting
Answer: 5 kN-m

Revise
Question: A piston rod of diameter 20 mm and length 700 mm in a hydraulic cylinder
is subjected to a compressive force of 10 kN due to the internal pressure. The end
conditions of the rod may be assumed as guided at the piston end and hinged at the
other end. The Young’s modulus is 200 GPa. The factor of safety for the piston rod is
how much?
𝐿
Hint: One end is fixed and one end pinned, effective length of column is
2
𝜋𝑑 4
Moment of inertia 𝐼 =
64
Answer: 6.32
Revise
Question: Calculate the diameter of a solid steel shaft so as to transmit 20 kW at 200
rpm. The ultimate shear stress for the steel can be taken as 360 MPa and a factor of
safety of 8.
Answer: ~ 48 mm
End of lecture 4
Questions?

Revise
Question: Under the given loading condition, what is the axial stress value at the
corner point P?
P
F
L
L-b
2b
𝐹(3𝐿−2𝑏)
Answer: 2b
4𝑏3

Theories of failure
Factors of failure and corresponding theories
1. Failure due to stress

a) Due to maximum principal stress, 𝜎1 𝑜𝑟 𝜎2 - Rankine’s theory
b) Due to maximum shear stress, 𝜏𝑚𝑎𝑥 - Guest and Tresca’s theory
2. Failure due to strain

a) Due to maximum principal strain, 𝜀1 - ST. Venant’s theory
3. Failure due to energy

a) Due to maximum strain energy, 𝑆𝐸𝑡𝑜𝑡𝑎𝑙 - Beltrami Haigh’s theory
b) Due to maximum shear strain energy OR Distortion energy, 𝑆𝐸𝑑𝑖𝑠𝑡𝑜𝑟𝑡𝑖𝑜𝑛 -
von-Mises and Henky’s theory
Maximum principal stress theory (Rankine’s theory)
Under a state of complex stress, failure starts when the value of maximum principal
stress is equal to that of the yield strength/ultimate strength of the material as found
in a simple tensile test.
So for design criterion,

𝜎1,2 ≤ 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠
𝜎1,2 ≤
𝐹𝑜𝑆
This theory works satisfactorily for brittle materials, which do not fail by yielding but
undergo brittle fracture

Maximum shear stress theory (Guest and Tresca’s theory)
Under a state of complex stress, failure starts when the value of maximum shearing
stress at any point reaches its failure value for the material as found in a simple tensile
test of the material.

𝜏𝑚𝑎𝑥 ≤ 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠
𝜏𝑚𝑎𝑥 ≤
2×𝐹𝑜𝑆
This theory is not applicable to materials subjected to hydrostatic state of stress,

where the shear stress is almost zero, which means failure does not occur, which is
not possible. This theory is justified for ductile materials.

Maximum principal strain theory (ST. Venant’s theory)
Under a state of complex stress, failure starts when the value of maximum principal
strain reaches the strain at which yielding occurs in the material as found in a simple
tensile test of the material.

𝜀1,2 ≤ 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑎𝑖𝑛
𝜀1,2 ≤
𝐸×𝐹𝑜𝑆
This theory overestimates the elastic strength of ductile materials.

NOTE: If the area bounded by the theory of failure curves in a quadrant increases, then failure stresses will
increase due to this dimension of the component decreases which decrease the safety of the component.
So the area of the curve should be within proper limit.
Maximum strain energy theory (Beltrami Haigh’s theory)
Under a state of complex stress, failure starts when the value of total strain energy on
the body reaches the strain energy at elastic limit as found in a simple tensile test of
the material.

𝑆𝐸𝑡𝑜𝑡𝑎𝑙 ≤ 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑎𝑖𝑛 𝑒𝑛𝑒𝑟𝑔𝑦
2
𝑆𝐸𝑡𝑜𝑡𝑎𝑙 ≤
2𝐸×𝐹𝑜𝑆
This theory does not suit the brittle materials for which the elastic limit stress in
tension and compression are quite different.

Maximum shear strain or distortion energy theory (von-Mises-Henky’s theory)
Under a state of complex stress, failure starts when the value of strain energy of
distortion per unit volume absorbed at a point reaches the strain energy of distortion
absorbed per unit volume at any point in a bar stressed to the elastic limit under the
state of uniaxial stress as occurs in a simple tension or compression test of the
material.

𝑆𝐸𝑑𝑖𝑠𝑡𝑜𝑟𝑡𝑖𝑜𝑛 ≤ 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑎𝑖𝑛 𝑒𝑛𝑒𝑟𝑔𝑦
𝑆𝐸𝑑𝑖𝑠𝑡𝑜𝑟𝑡𝑖𝑜𝑛 ≤ 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑆𝐸 𝑜𝑓 𝑑𝑖𝑠𝑡𝑜𝑟𝑡𝑖𝑜𝑛
2
2×𝜎𝑦𝑖𝑒𝑙𝑑
𝑆𝐸𝑑𝑖𝑠𝑡𝑜𝑟𝑡𝑖𝑜𝑛 ≤
2𝐸×𝐹𝑜𝑆
This theory is highly recommended theory and is economical.

Summary
𝜎𝑦
Rankine’s 𝜎1 = Max principal stress theory
𝐹𝑜𝑆
𝜎𝑦
𝜏𝑚𝑎𝑥 =
Guest and Tresca’s 2 × 𝐹𝑜𝑆 Max shear stress theory
𝜎𝑦
𝜎1 − 𝜗𝜎2 =
ST. Venant’s 𝐹𝑜𝑆 Max principal strain theory
𝜎𝑦
Beltrami Haigh’s 𝜎12 + 𝜎22 − 2𝜗𝜎1 𝜎2 = Maximum strain energy theo.
𝐹𝑜𝑆
𝜎𝑦 Max distortion energy theo. /

Von-Mises and Henky’s 𝜎12 + 𝜎22 − 𝜎1 𝜎2 =
𝐹𝑜𝑆 Max shear strain energy theo.
Revise
Question: The principal stresses at a point inside a solid object are 𝜎1 = 100 𝑀𝑃𝑎,
𝜎2 = 100 𝑀𝑃𝑎 and 𝜎3 = 0 𝑀𝑃𝑎. The yield strength of the material is 200 𝑀𝑃𝑎. The
factor of safety calculated using Tresca’s maximum shear stress theory is 𝑛 𝑇 and the
factor of safety calculated using von-Mises distortion energy theory is 𝑛𝑉 . Then find
the relation between 𝑛 𝑇 and 𝑛𝑉 .
Answer: 𝑛 𝑇 = 𝑛𝑉

End of lecture 5
Questions?

Revise
Question: The principal stresses at a point in a critical section of a machine
component are 𝜎1 = 60 𝑀𝑃𝑎, 𝜎2 = 5 𝑀𝑃𝑎 and 𝜎3 = −40 𝑀𝑃𝑎. For the material of
the component, the tensile yield strength is given as 𝜎𝑦 = 200 𝑀𝑃𝑎. According to the
maximum shear stress theory, calculate the factor of safety.
Answer: 2
Revise
Question: A machine element is subjected to the following biaxial state of stress: 𝜎𝑥 =
80 𝑀𝑃𝑎, 𝜎𝑦 = 20 𝑀𝑃𝑎 and 𝜏𝑥𝑦 = 40 𝑀𝑃𝑎. If the shear strength of the material is
100 𝑀𝑃𝑎, then the factor of safety as per Tresca’s maximum shear stress theory
would be how much?
Answer: 2
Revise
Question: A shaft is subjected to a pure torsional moment. The maximum shear stress
developed in the shaft is 100 MPa. The yield and ultimate strengths of the shaft
material in tension are 300 MPa and 450 MPa, respectively. How much is the factor of
safety using maximum distortion energy (von-Mises) theory?
Answer: 1.732
Revise
Question: The uniaxial yield stress of a material is 300 MPa. According to von-Mises
yield criteria, what will be the shear yield stress of this material?
Answer: 173.1 MPa

Revise

Revise

Revise

Revise

Revise

End of lecture 6
Questions?

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MEC 302 Design, materials and manufacturing

Semester: Monsoon 2021

Credits: 4 (about 40 classes)

Tuesday and Thursday 1100 – 1230 in Room 103, GICT

Course coordinator: Dr Shuja Ahmed

• High quality of product and Low cost of production is desired

• Product quality depends on design, material and manufacturing

• Various types of mechanical components and their design available

• Various types of engineering materials are available to choose from

• Various types of manufacturing/processing techniques to choose from

Sunday, September 5, 2021 2

• Types of engineering materials:-

• Types of manufacturing (material processing) techniques:-

• Proportional limit Elastic Plastic

• Question: What is the stress capacity of the component material undergoing –

• Hint: Find the maximum principal stress in the body

• Maximum of applied stress is considered

Sunday, September 5, 2021 7

Sunday, September 5, 2021 8

Sunday, September 5, 2021 9

Sunday, September 5, 2021 10

Compared to wrought iron or steel,

Sunday, September 5, 2021 11

• Types of live load or variable load (dynamic condition):-

Sudden or shock load, Impact load, Fatigue, Bearing or crushing load

Sunday, September 5, 2021 12

• Bending load (Beams)

• Twisting load (Shafts subjected to torsion)

• Bearing crushing load

• Thermal load (rods fixed at two ends and temp raised)

• For brittle materials-

• For variable or dynamic load, FoS = More (2 or more)

Answer: 190 MPa

Sunday, September 5, 2021 16

𝜎𝑥 = −6 𝑀𝑃𝑎 𝜎𝑦 = 4 𝑀𝑃𝑎 and 𝜏𝑥𝑦 = −8 𝑀𝑃𝑎

The maximum tensile stress at the point is how much?

Answer: 8.43 MPa

Answer: 0.06 MPa

Sunday, September 5, 2021 19

Sunday, September 5, 2021 20

Sunday, September 5, 2021 22

Sunday, September 5, 2021 23

Axial, Bending and Torsion

Sunday, September 5, 2021 24

Maximum tensile stress and its location

Maximum compressive stress and its location

Sunday, September 5, 2021 25

Maximum normal stress?

Sunday, September 5, 2021 26

Maximum normal stress?

Sunday, September 5, 2021 27

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Sunday, September 5, 2021 29

Sunday, September 5, 2021 30

(a) The modulus of elasticity of the material

Punching force = Shear stress x Shear area

Sunday, September 5, 2021 32

Sunday, September 5, 2021 33

Sunday, September 5, 2021 35

Sunday, September 5, 2021 36

Answer: Minimum intensity of stress is 6 MPa and P

Hint: Combined bending and twisting

Sunday, September 5, 2021 38