Welcome

2
All
In Online Class
Design of Machine
Elements

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 1
 Objectives of DOME
1. To understand procedure of machine design and develop an
ability to apply it for simple component design by using design
data hand book.
2. To understand the different theories of failure and develop an
ability to apply its knowledge for design of mechanical
component and determine the resisting areas against failure
3. To determine forces on transmission shaft and design of
transmission shaft
4. To determine the endurance strength and design of components
subjected to fluctuating loads
5. To determine the forces in welds and bolt joints and formulate
design solution for size of weld and size of bolt
6. To study standard procedure of bearing selection from
manufacturing catalogue
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 2
 Course Outcomes of DOME

After successfully completion of this course students will be able to:

1. Apply knowledge of the stress and strain of mechanical
components; and understand, identify and quantify factor of safety,
failure modes for simple mechanical components (Shaft and
Coupling) subjected to direct and bending and combined loading.
2. Develop logical and analytical ability to apply knowledge of various
theories of failures for design of joints, bolts, springs etc.
3. The selection of gear types, sizing, analysis and material selection of
spur and helical gear systems.
4. The selection of gear types, sizing, analysis and material selection of
bevel and worm gear systems.
5. Estimate endurance strength of ductile and brittle materials and
develop analytical ability to apply fatigue theories for ductile and
brittle material in static and dynamic loading.
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 3
 Unit 1
Introduction

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 4
 Introduction to Engineering Design:

Engineering design may be defined as the iterative decision

making activity to create a plan or plans by which the
available resources are converted into devices to perform the
desired functions and to meet human needs.

Engineering design has been defined in many ways but the

simplest ways to define engineering design as -
“An iterative decision making process to conceive and
implement optimum systems to solve society‟s problems and
needs.”

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 5
 Mechanical Engineering Design:
If the end product of the engineering design can be termed
as mechanical then this may be termed as Mechanical
Engineering Design.

Mechanical Engineering Design may be defined as:

“It is defined as iterative decision making process to describe a
machine or mechanical system to perform specific function with
maximum economy and efficiency by using scientific principles,
technical information, and imagination of the designer.”
A designer uses principles of basic engineering sciences, such as
Physics, Mathematics, Statics, Dynamics, Thermal Sciences,
Heat Transfer, Vibration etc.
For example: ÿ Newton‟s Laws of Motion; ÿ D‟ Alembert‟s Principle; ÿ Boyle‟s
and Charles Laws of Gases; ÿ Carnot Cycle; ÿ Bernoulli‟s Principle;
Dr. Prajitsen G Damle, SSBT's 6COET,
Jalgaon
 Design is…
 “The formulation of a plan for the satisfaction
of human need.”
 DOME deals with the design of m/cs,
mechanisms and their elements.
 It is the process of Prescribing the sizes,
shapes, material compositions, & arrangement
of mechanical elements.
 An innovative and iterative process.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 7
Machine :- It is a combination of rigid and resistant links having
definite motion and capable of performing some useful work.
Design :- It is to outline, plot or plan of action of work.
or
“It is the process of Prescribing the sizes, shapes, material
compositions, & arrangement of mechanical elements.”
or
“It is creation of new and better m/c or improving existing one to
perform desired function in better way.”

It is a iterative process in which we proceed through several steps,

evaluate the results and then return to an earlier phase of
procedure. Dr. Prajitsen G Damle, SSBT's COET, 8
Jalgaon
DOME is a creation of new and better m/c and
improving the existing one to performs the
desired function in better way with the help of
Scientific Principles, technical information and
imagination.

The basic procedure of DOME consists of a step by step

approach from given specifications of functional requirement
of a product to the complete description in the form of blue
prints of the final product.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 9
 Basic procedure of m/c design

Dr. Prajitsen G
Damle, SSBT's 10
COET, Jalgaon
 Basic procedure of m/c design

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 11
P G Damle
 Design Consideration
1. Strength
2. Stiffness
3. Wear
4. Corrosion
5. Safety
6. Reliability
7. Friction
8. Usability
9. Efficacy
10. Cost
14. Noise, 15. Styling, 16. Shape, 17. Size, 11. Processing
18. Control, 19. Thermal Properties, 20. Surface 12. Weight
21. Lubrication, 22. Marketability, 23. Maintenance 13. Life
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 12
 Requisites of Design Engineer
1. Sound and depth knowledge of design principles
and methods
2. Adequate knowledge of material properties.
3. Adequate knowledge of Manufacturing processes.
4. Adequate knowledge Cad tool ,FEA , etc.
5. Ability to read and prepare drawings.
6. Problem solving ability.
7. Ability to work in a team and lead the team.
8. Innovativeness and greater creativity.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 13
 Design Of M/C Element
Specify Function of element

Determine Forces Acting on Element

Select Suitable material for Element

Determine failure mode of element

Determine Geometric Dimensions of element

Modify Dimension for assembly and manufacturing

Check design at critical cross section

Dr. Prajitsen G Damle, SSBT's COET,

P G Damle
Prepare working drawing of element
Jalgaon 14
STRENGTH
The strength of a material is the capacity of material to withstand destruction under the
action of external loads. OR It is the property of a material which opposes the
deformation or breakdown of material in presence of external forces or load.
It determines the ability of a material to withstand stress without failure. The maximum
stress that any material will withstand before destruction is called ultimate strength.
Materials which we finalize for engineering products, must have suitable mechanical
strength to be capable to work under different mechanical forces or loads.
ELASTICITY
The property of material by virtue of which deformation caused by applied load
disappears upon removal of load. OR It is the property of certain materials of
returning back to their original position, after removing the external force, is
known as elasticity. It is only possible, if the deformation, caused by the external force, is
within a certain limit. Such a limit is called elastic limit.
PLASTICITY
The plasticity of a material is its ability to undergo some degree of permanent
deformation without rupture (crack) or failure. Plastic deformation will take only
after the elastic limit is exceeded. It increases with increase in temperature. This property
of the material is necessary for forgings, in stamping images on coins and in ornamental
work. Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 15
STIFFNESS / RIGIDITY
It is the resistance of a material to elastic deformation or deflection is called
stiffness or rigidity. A material which suffers slight deformation under load has a
high degree of stiffness or rigidity. E.g. Steel beam is more stiffer or more rigid than
aluminium beam.
DUCTILITY
Ductility is a property of a solid material which indicates that how easily a
material gets deformed under tensile stress. It is often categorized by the ability
of material to get stretched into a wire by pulling or drawing. With rise in
temperature, the ductility of material increases.
E.g., Mild steel is a ductile material. The percent elongation and the reduction in area
in tension is often used as emperical measures of ductility.
MALLEABILITY
It is a special case of ductility which permits materials to be rolled or hammered
into thin sheets, making wire by hot or cold working.. 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.

Ductility is tensile quality,Dr.

while malleability is compressive quality.
Prajitsen G Damle, SSBT's COET,
Jalgaon 16
HARDNESS
Hardness is a fundamental property which is closely related to strength. Hardness is
usually defined in terms of the ability of a material to resist to scratching,
cutting, identation, or penetration. Methods used for determining hardness: Brinel,
Rockwell.

There are various measure of hardness – Scratch Hardness, Indentation Hardness

and Rebound Hardness.
Scratch Hardness
Scratch Hardness is the ability of materials to the oppose the scratches to outer
surface layer due to external force.
Indentation Hardness
It is the ability of materials to oppose the dent due to punch of external hard and
sharp objects.
Rebound Hardness
Rebound hardness is also called as dynamic hardness. It is determined by the height
of “bounce” of a diamond tipped hammer dropped from a fixed height on the
material.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 17
TOUGHNESS
It is the ability of a material to absorb the energy and gets plastically deformed
without fracturing. Its numerical value is determined by the amount of energy per
unit volume. Its unit is Joule/ m3. Value of toughness of a material can be
determined by stress-strain characteristics of a material. For good toughness,
materials should have good strength as well as ductility.
For example: brittle materials, having good strength but limited ductility are not tough enough.
Conversely, materials having good ductility but low strength are also not tough enough. Therefore, to
be tough, a material should be capable to withstand both high stress and strain.

RESILIENCE
It is the capacity / ability of a material to absorb energy when it is deformed
elastically by applying stress and release the energy when stress is removed. The
maximum energy which can be stored in a body upto elastic limit is called the proof
resilience, and the proof resilience per unit volume without permanent deformation
is called modulus of resilience. The quantity gives capacity of the material to bear
shocks and vibrations.
It can be determined by integrating the stress-strain cure from zero to elastic limit. Its
unit is joule/m3.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 18
BRITTLENESS
It is the property of breaking without much permanent distortion OR Brittleness of
a material indicates that how easily it gets fractured when it is subjected to a force or
load. Non-Ductile material is considered to be brittle material. E.g, Glass, Cast iron,
etc.
CREEP
Creep is the property of a material which indicates the tendency of material to
move slowly and progressive deformation of a material with time at constant stress.
Depending on temperature, stresses even below the elastic limit can cause some
permanent deformation. It results due to long time exposure to large external
mechanical stress with in limit of yielding
FATIGUE
This phenomenon leads to fracture under repeated or fluctuating loading / stress of
material. When a material is subjected to cyclic loading, and loading greater than
certain threshold value but much below the strength of material (ultimate tensile
strength limit or yield stress limit), microscopic cracks begin to form at grain
boundaries and interfaces. Fatigue fractures are progressive beginning as minute
cracks and grow under the action of fluctuating stress. This crack propagates
suddenly and the structure gets fractured Many components of high speed aero and
turbine engines are of this type.
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 19
STRESS

Every material is elastic in nature. That is why, whenever some external

forces acts on a body, it undergoes some deformation. As the body
undergoes deformation, its molecules set up some resistance to
deformation. This resistance per unit area to deformation, is
known as stress. OR
When a material is subjected to an external force, a resisting force
is set up within the component. The internal resistance force per
unit area acting on a material is called the stress. The units of
stress is newtons per square meter (N/m2 or Pascals (Pa)
There are three types of
Stress
1. Tensile stress ,
2. Compressive stress,
3. Shear stress
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 20
Strain (ε)
The displacement per unit length (dimensionless) is known
as strain.
Tensile strain (εt) - The elongation per unit length as shown
in the figure is known as tensile strain.
εt = ΔL/ Lo
It is engineering strain or conventional strain.
Here we divide the elongation to original length not actual
length (Lo + ΔL)
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 21
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 22
•A material is said to be elastic, when it undergoes a deformation
on the application of load and it regain its original shape on the
removal of load.
•It has been found that for a every material has a limiting value of
load up to and within which, the deformation entirely disappears
on the removal of load.
•The value of intensity of stress corresponding to this
limiting value of laod is called elastic limit of the material.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 23
The modulus of elasticity (Young's modulus) E is a material
property, that describes its stiffness and is therefore one of the
most important properties of solid materials. From the Hook's law
the modulus of elasticity is defined as the ratio of the stress to the
strain : Stress is not directly measurable.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 24
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 25
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 26
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 27
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 28
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 29
 (µ or 1/m)
Poisson's ratio measures the deformation in the material in a direction
perpendicular to the direction of the applied force. It has been
experimentally found that, if a body is stressed within its elastic
limit, the ration of lateral strain to the linear strain is constant.
Poisson's ratio is dimensionless and ranges between 0.1 and 0.45. Low Poisson's
ratio, such as 0.1–0.25, means materials fracture easier whereas high Poisson's
ratio, such as 0.35–0.45, indicates the materials are harder to fracture. Please note
that Poisson's ratio changes from layer to layer.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 30
 Deformation of a Body Due to Force
Consider a body subjected to a tensile stress.
Let P = Load or force acting on the body
l = Length of the body,
A = Cross-sectional area of the body
σ = Stress induced in the body
E = Modulus of elasticity for the material of the body
ε = Strain, and
δl (Δ ) = Deformation of the body.

We know that the stress From these three equations, we get

As per Young’s
Modulus

Dr. Prajitsen G Damle, SSBT's COET, Jalgaon 31

Relationship between stress and strain of Two-Dimensional Stress System

Consider a two-dimensional figure ABCD, subjected

to two mutually perpendicular stresses σ1 and σ2.
Let σ1 = Normal stress in x-direction
σ2 = Normal stress in y-direction
Consider the strain produced by σ1.
The stress σ1 will produce strain in the direction of x and also
in the direction of y. The strain in the direction of x will be
longitudinal strain and will be equal to . whereas the strain in the
direction of y will be lateral strain and will be equal to [as per
poisson’s ratio Lateral strain = µ x Longitudinal strain]
Now consider the strain produced by σ2
The stress σ2 will produce strain in the direction of y and also in
the direction of x. The strain in the direction of y will be
longitudinal strain and will be equal to . whereas the strain in
the direction of x will be lateral strain and will be equal to
Total strain in the direction of x due to
stresses σ1 and σ2 is

Similarly total strain in the direction of y due to

stresses σ1 Dr.
and σ2G Damle,
Prajitsen is SSBT's COET, Jalgaon 32
Relationship between stress and strain of Three-Dimensional Stress System
Consider a three-dimensional body subjected to three
orthogonal normal stresses σ1, σ2, σ3 acting in the directions
of x, Y and z respectively.
strains produced by each stress separately
Strain produced by σ1.
The stress σ1 will produce strain in the direction of x and also
in the direction of y & z. The strain in the direction of x will be
longitudinal strain . whereas the strain in the direction of y & z
will be lateral strain [as per poisson’s ratio Lateral strain
= µ x Longitudinal strain]
Similarly strain produced by σ2.
The stress σ2 will produce strain in the direction of y and also in
the direction of x & z. The strain in the direction of y will be
longitudinal strain . whereas the strain in the direction of x &
z will be lateral strain .

And Strain produced by σ3.

The stress σ3 will produce strain in the direction of z and also in
the direction of x & y. The strain in the direction of z will be
longitudinal strain . whereas the strain in the direction of y &
z will be lateral strain
Dr. Prajitsen G Damle, SSBT's COET, Jalgaon 33
 Total strain in the direction of x due to stresses σ1, σ2, σ3 is

Similarly total strains in the direction of y due to stresses σ1, σ2, σ3 is

Similarly total strains in the direction of z due to stresses σ1, σ2, σ3 is

Above three equations give the stress and strain relationship for
the three orthogonal normal stress system.

Dr. Prajitsen G Damle, SSBT's COET, Jalgaon 34

Source of Design Data:- Designer needs variety
of information such as competitive products,
available materials and their properties, size and
the load capacities of standard components like
belt drive, bearings etc.
 Design Data Book, Manufacturing Catalogues,
Design Journals etc.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 35
 Codes and Standards
 Codes- A set of specifications for the analysis,
design, manufacture and construction of
something.

 Standards- A set of specifications for parts,

materials, manufacturing processes proposed to
achieve uniformity, efficiency, and a specified
quality.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 36
 USE OF STANDARDS IN DESIGN

Standardization is defined as mandatory norms, to which various

characteristics of a product should conform. The characteristics include
materials, dimensions and shape of the component, method of testing and
method of marking, packing and storing of the product. The following
standards are used in mechanical engineering design:
(i) Standards for Materials, their Chemical Compositions, Mechanical
Properties and Heat Treatment.
(ii) Standards for Shapes and Dimensions of Commonly used Machine
Elements.
(iii) Standards for Fits, Tolerances and Surface Finish of Component.
(iv) Standards for Testing of Products .
(v) Standards for Engineering Drawing of Components.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 37
 Preferred Series
• The „size‟ of the product is a general term, which includes different
parameters like power transmitting capacity, load carrying capacity,
speed, dimensions of the component such as height, length and width,
and volume or weight of the product.
• In engineering design, the designer has to specify the size of the product.
• These parameters are expressed numerically, e.g., 5 kW, 10 kN or 1000
rpm. Often, the product is manufactured in different sizes or models; Ex.
a company may be manufacturing seven different models of electric
motors ranging from 0.5 to 50 kW to cater to the need of different
customers. Preferred numbers are used to specify the „sizes‟ of the
product in these cases.
French balloonist and engineer Charles Renard first introduced preferred
numbers in the 19th century. The system is based on the use of
geometric progression to develop a set of numbers.
There are five basic series, denoted as R5, R10, R20, R40 and R80
series, which increase in steps of 58%, 26%, 12%, 6%, and 3%,
respectively. Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 38
 Preferred Series
With the acceptance of standardization, there is a need to keep the standard sizes
or dimensions of any component or product in discrete steps. The sizes should be
spread over the wide range, at the same time these should be spaced properly.
For example, if shaft diameters are to be standardized between 10 mm and 25 mm,
then sizes should be like : 10 mm, 12.5 mm, 16 mm., 20 mm, 25 mm and not like :
10 mm, 11 mm. 13 mm. 18 mm. 25 mm. This led to the use of geometric series
known as series of preferred numbers or preferred series.
Preferred series are series of numbers obtained by geometric progression and
rounded off .
There are five basic series with a step ratios of :

The five basic series of preferred numbers (known as preferred series)

arc designated as : R5. R1O. R20. R40, and R80. These series were first
introduced by the French engineer Renard.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 39
P G Damle
 Preferred
Numbers of Basic
Series

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 40
 Organizations
 Aluminum Association (AA)  American Bearing Manufacturers
 American Gear Manufacturers Association (ABMA)
Association (AGMA)  British Standards Institute (BSI)
 American Institute of Steel  Industrial Fasteners Institute (IFI)
Construction (AISC)  Institution of Mechanical
 American Iron and Steel Institute Engineers (I. Mech. E.)
(AISI)  International Bureau of Weights
 American National Standards and Measures (BIPM)
Institute (ANSI)  International Standards
 American Society for Metals (ASM) Organization (ISO)
 American Society of Mechanical  National Institute for Standards
Engineers (ASME) and Technology (NIST)
 American Society of Testing  Society of Automotive Engineers
Materials (ASTM) (SAE)
 American Welding Society (AWS)  American Society of Agricultural
and Biological Engineers (ASABE)
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 41
 Aesthetic in Product Design.

 Ergonomics in Design.

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon 42
Stress Concentration

Dr. Prajitsen G Damle, SSBT's COET,

Jalgaon
43
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon
44
Dr. Prajitsen G Damle, SSBT's COET,
Jalgaon 45