Machine design- I

Assignment 01: Case study of components (include

selection of materials for various components showing
their IS codes, composition and properties)

1
SELECTION OF MATERIAL
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 desired
purpose at minimum cost. It is not always easy to select such a material and the process may
involve the trial and error method. The factors which should be considered while selecting
the material for a machine component are as follows:

• Availability of material
• Cost of material- Cost of material and cost of processing the material
• Material properties
• Manufacturing considerations

2
Select and review of engineering material for following components

Component 01: Spur gear

Component 02: Keys for fastening
Component 03: Cotter joint rods
Component 04: Screw jack frame
Component 05: Spring

3
Component 1: Spur gear
Selection of material:
The desirable properties of gear material are as follows:
• The gear material should have sufficient strength to resist failure due to breakage of the
tooth.
• The gear material should have sufficient surface endurance strength to avoid failure due to
destructive pitting.
• For high-speed power transmission, the sliding velocities are very high and the material
should have low coefficient of friction to avoid failure due to scoring.
• For gears strength, toughness and response to heat treatment are important considerations.
The surface of gears are heavily stressed , while the stresses in the core are of comparatively
small magnitude. These components require soft core and hard surface. This is achieved by
case hardening.

4
Component 1: Spur gear (Continued…)
Suitable material:
Gears are made of cast iron, steel and bronze.
Large size gears are made of grey cast iron of Grades FG 200, FG 260 or FG 350.
Medium duty applications are 40C8, 45C8, 50C4, 55C8 and 60C4
For heavy duty applications, alloy steels 4OCr1, 30Ni4Cr1 and 4ONi3Cr65Mo55 are used.

Composition and properties:

FG200: A grey cast iron with ultimate tensile strength 200 N/𝑚𝑚𝑚𝑚2
40C8 : Plain carbon steel with 0.4% carbon and 0.8% manganese.
4OCr1: An alloy steel having average 0.4% carbon, 0.25% chromium and negligible amount of
silicon and manganese
30Ni4Cr1: An alloy steel having average 0.3% carbon, 1% nickel, 0.25% chromium and
negligible amount of silicon and manganese
4ONi3Cr65Mo55: An alloy steel having average 0.4% carbon, 0.75% nickel, 0.65% chromium
and 0.55% molybdenum
5
Component 2: Keys for fastening

Selection of material:
Keys should withstand shear and compressive stresses resulting from transmission
of torque. According to B.I.S, steel of tensile strength not less than 600 N/𝑚𝑚𝑚𝑚2
shall be used as the material for the key

Suitable material:
Keys are made of steel 45C8, 50C8 or 55C8

Composition and properties:

45C8: Plain carbon steel with 0.45% carbon and 0.8% manganese.

6
Component 3: Cotter joint rods
Selection of material:
The rods are subjected to tensile force and strength is the criterion for the selection of the rod
material.

Suitable material:
On the basis of strength, the material of the rods is selected as plain carbon steel of Grade
30C8, 40C8 or 45C8

Composition and properties:

30C8 : Plain carbon steel with 0.3% carbon and 0.8% manganese.

7
Component 4: Screw jack frame
Selection of material:
The frame of the screw jack has complex shape. It is subjected to compressive stress.

Suitable material:
Cast iron is suitable for the frame. Cast iron is cheap and it can be given any complex shape
without involving costly machining operations. Cast iron has higher compressive strength
compared with steel. Therefore, it is technically and economically advantageous to use cast iron
for the frame.
FG 200, FG220 or FG260

Composition and properties:

FG200: A grey cast iron with ultimate tensile strength 200 N/𝑚𝑚𝑚𝑚2

8
Component 5: Spring
Selection of material:
Spring wires are subjected to severe stress and strength is the most important consideration in
selection of their material.

Suitable material:
The most extensively used spring material is high-carbon steel having maximum tensile
strength.
65C6, 55Si7 etc.

Composition and properties:

65C6 : Plain carbon steel with 0.65% carbon and 0.6% manganese.
55Si7: An alloy steel having average 0.55% carbon and 1.6- 2% silicon