UNIVERSITY OF SOUTHERN MINDANAO

ABE 412: Machine Design

for AB Production
ENGR. ROMEL B. NONOL JR.
SUBJECT INSTRUCTOR
Module 1
INTRODUCTION TO
MACHINE DESIGN for
AB Productions Systems
 What is Design?
▪ Design is to formulate a plan satisfy a particular need and to
create something with physical reality.

▪ Realization of a concept or idea into a configuration.

▪ Engineering design is the process of devising a system,
component, or process to meet desired needs, (ABET)
▪ Mechanical design means the design of components and
systems of a mechanical nature - machines, structures,
devices, and instruments. For the most part, mechanical
design utilizes the stress analysis methods and materials
engineering and energy concepts. (Ugural, 2015)

ABE 412: Machine Design for AB Production

 What is Machine?
▪ Machine is defined as a combination of resisting bodies with
successfully constrained relative motions which is used
transform other forms of energy into mechanical energy or
transmit and modify available energy to do some useful
work.
▪ An apparatus using mechanical power and having several
parts, each with a definite function and together performing
a particular task.
▪ A semi or fully automated device that magnifies human
physical and/or mental capabilities in performing one
or more operations.

ABE 412: Machine Design for AB Production

 What is Machine Design?

▪ Machine design is the art of planning or devising new or

improved machines to accomplish a specific purpose,
(Ugural, 2015)

▪ It is the process of obtaining dimensions and specifications

of a machine required for its desired function by utilizing
imagination, scientific principles and engineering
techniques. (www.magicmarks.com)

▪ Machine Design involves designing the elements and

arranging them optimally to obtain some useful work.

ABE 412: Machine Design for AB Production

Classification of Machine Design

Types of Design

Adaptive New
Design Design
Development
design

ABE 412: Machine Design for AB Production

 Types of Machine Design
Adaptive Design - The designer’s work is concerned with
adaptation of existing design. The designer only makes minor
alternation or modification in the existing designs of the
product.
Development Design - This type of design needs considerable
scientific training and design ability in order to modify the
existing design into a new idea by adopting a new material or
different method of manufacture. The designer starts from the
existing design, but final product may differ quite markedly
from the original product.
New Design - This type of design needs lots of research,
technical ability and creative thinking.
ABE 412: Machine Design for AB Production
Classification of Machine Design
(Based on Method)

Types of design
based on method

Rational Industrial
Design Empirical Design
Design

ABE 412: Machine Design for AB Production

 Types of Design based on method
Rational Design - Based on determining the stresses and strains
of components and thereby deciding their dimensions. This type
of design depends upon mathematical formulae of principal of
mechanics.
Empirical Design - This type of design depends upon empirical
formulae based on the practice and past experience.
Industrial Design - This type of design depends upon the production
aspects to manufacture any machine component in the industry.
Based on industrial considerations and norms viz. market survey,
external look, production facilities, low cost, use of existing standard
products

ABE 412: Machine Design for AB Production

General Procedure in Machine Design

By: Ugural (2015)

ABE 412: Machine Design for AB Production

 General Procedure in Machine Design

Identification of Need - The design process begins with a

recognition of a need, real or imagined, and a decision to do
something about it. For example, present equipment may
require improving durability, efficiency, weight, speed, or cost.

Definition of the Problem - This phase in design conceives the

mechanisms and arrangements that will perform the needed
function. For this, a broad knowledge of members is desirable,
because new equipment ordinarily consists of new members,
perhaps with changes in size and material.

ABE 412: Machine Design for AB Production

 General Procedure in Machine Design
Synthesis - Frequently termed the ideation and invention
phase, it is where the largest possible number of creative
solutions is originated. The philosophy, functionality, and
uniqueness of the product are determined during synthesis.

Analysis - Analysis has as its objective in satisfactory

performance as well as durability with minimum weight and
competitive cost. It is now necessary to draw the layouts,
providing details, and make the supporting calculations that will
ultimately result in a prototype design. The designer must
specify the dimensions, select the components and materials,
and consider the manufacturing, cost, reliability, serviceability,
and safety.

ABE 412: Machine Design for AB Production

 General Procedure in Machine Design

Testing and Evaluation - At this juncture, the working design is

first fabricated as a prototype. Product evaluation is the final
proof of a successful design and usually involves testing a
prototype in a laboratory or on a computer that provides the
analysis database.

Presentation - The designer must be able to understand the

need and describe a design graphically, verbally, and in
writing. This is the presentation of the plans for satisfying the
need. Drawings are utilized to produce blueprints to be passed
to the manufacturing process.

ABE 412: Machine Design for AB Production

 General Procedure in Machine Design

Testing and Evaluation - At this juncture, the working design is

first fabricated as a prototype. Product evaluation is the final
proof of a successful design and usually involves testing a
prototype in a laboratory or on a computer that provides the
analysis database.

Presentation - The designer must be able to understand the

need and describe a design graphically, verbally, and in
writing. This is the presentation of the plans for satisfying the
need. Drawings are utilized to produce blueprints to be passed
to the manufacturing process.

ABE 412: Machine Design for AB Production

 Factors to be Considered in Machine Design
▪ What device or mechanism to ▪ The method of
be used (To decide the manufacturing the
relative arrangement of the components and their
constituent elements) assembly.
▪ Material ▪ How will it operate.
▪ Forces on the elements ▪ Reliability and safety
▪ Size aspects.

▪ Shape and space ▪ Inspectibilty

requirements ▪ Maintenance
▪ Weight of the product ▪ Cost and aesthetics of the
designed product.

ABE 412: Machine Design for AB Production

 Standardization
▪ Standardization is defined as obligatory (or compulsory) norms,
to which various characteristics of a product should comply (or
agree) with standard.
▪ The characteristics include materials, dimensions and shape of
the component, method of testing and method of marking,
packing and storing of the product.
▪ A standard is defined as a set of specifications for parts, materials
or processes. The objective of, a standard is to reduce the variety
and limit the number of items to a reasonable level.
▪ On the other hand, a code is defined as a set of specifications for
the analysis, design, manufacture, testing and erection of the
product. The purpose of a code is to achieve a specified level of
safety.
ABE 412: Machine Design for AB Production
 Standardization
There are three types of standards used in design:
▪ Company Standards: They are used in a particular company
or a group of companies.
▪ National standards:
Germany - DIN (Deutsches Institut für Normung),
USA - AISI (American Iron and Steel Institute) or SAE
(Society of Automotive Engineers),
UK - BS (British Standards)
PAES (Philippine Agricultural Engineering Standards)
▪ International standards: These are prepared by the
International Standards Organization (ISO).

ABE 412: Machine Design for AB Production

 Standards are used in machine design
▪ Standards for Materials, their chemical compositions,
Mechanical properties and Heat Treatment:
For example, 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.
▪ 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
For example, PAES 301 specifies dimensions and shape of the cross- section
of endless V-belts for power transmission. The dimensions of the trapezoidal
cross-section of the belt, viz. width, height and included angle are specified in
this standard.

ABE 412: Machine Design for AB Production

 Standards are used in machine design

▪ Standards for Fits, Tolerances and Surface Finish of

Component:
The tolerances or upper and lower limits for various sizes of
holes and shafts are specified in PAES 305
▪ 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, PAES 211 gives Corn Mill Methods of Tests.

ABE 412: Machine Design for AB Production

 Benefits of Standardization

▪ Reductions in types and dimensions of identical components

(inventory control).
▪ Reduction in manufacturing facilities.
▪ Easy to replace (Interchangeability). No need to design or
test the elements.
▪ Improves quality and reliability.
▪ Improves reputation of the company which manufactures
standard components.
▪ Sometimes it ensures the safety.
▪ It results in overall cost reduction.

ABE 412: Machine Design for AB Production

 Factor of Safety
Engineers employ a safety factor to ensure against the foregoing
unknown uncertainties involving strength and loading. This factor is
used to provide assurance that the load applied to a member does
not exceed the largest load it can carry. The factor of safety, n, is the
ratio of the maximum load that produces failure of the member to the
load allowed under service conditions:

Or,

The smallest value of n for any member is of the greatest concern,

because this predicts the most likely mode of failure.
ABE 412: Machine Design for AB Production
 Selection of Factor of Safety

The following numerical values of factor of safety are presented as

a guide. They are abstracted from a list by J.P. Vidosic. These
safety factors are based on the yield strength or endurance limit of
a ductile material. When they are used with a brittle material and
the ultimate strength, the factors must be approximately doubled:

ABE 412: Machine Design for AB Production

 Selection of Factor of Safety

Where higher factors of safety might appear desirable, a more-

thorough analysis of the problem should be undertaken before
deciding on their use. A concept closely related to safety factor is
termed reliability. It is the statistical measure of the probability that
a member will not fail in use. In the reliability method of design, the
goal is to achieve a reasonable likelihood of survival under the
loading conditions during the intended design life. For this purpose,
mean strength and load distributions are determined, and then,
these two are related to achieve an acceptable safety margin.

ABE 412: Machine Design for AB Production

 Preferred Numbers
▪ 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.
ABE 412: Machine Design for AB Production
 Preferred Numbers
▪ There are five basic series with step
ratios of:

▪ These ratios are approximately equal to 1.58, 1.26, 1.12,

1.06 and 1.03.
▪ The examples of preferred number series are: standard
shaft diameters, power rating of coupling, center
distances of standard gear boxes, etc.

ABE 412: Machine Design for AB Production

 Advantages Preferred Numbers

▪ The difference in two successive terms has a fixed

percentage.

▪ It provide small steps for small quantities and large steps

for large quantities.

▪ The product range is covered with minimum number of

sizes without restricting the choice of the customers.

ABE 412: Machine Design for AB Production

 Aesthetic Considerations
In a present day market with a number of products available are
having most of the parameters identical, the appearance of product is
often a major factor in attracting the customer.
▪ This is particularly true for consumer durables like: automobiles,
domestic refrigerators, television sets, etc.
▪ Aesthetics is defined as a set of principles of appreciation of
beauty. It deals with the appearance of the product.
▪ Appearance is an outward expression of quality of the
product and is the first communication of the product with the
user.
▪ For any product, there exists a relationship between the functional
requirement and the appearance of a product.

ABE 412: Machine Design for AB Production

 Aesthetic Considerations
The aesthetic quality contributes to the performance of the
product, though the extent of contribution varies from the
product to product. The following guidelines may be used in
aesthetic design (design for appearance):
▪ The appearance should contribute to the performance of the
product.
For example, the aerodynamic shape of the car will have lesser air
resistance, resulting in the lesser fuel consumption.

▪ The appearance should reflect the function of the product.

For example, the rugged shape of the tractor indicates its heavy use.

ABE 412: Machine Design for AB Production

 Aesthetic Considerations
▪ The appearance should reflect the quality of the product.
For example, the robust and heavy appearance of the hydraulic press
reflects its strength and rigidity

▪ The appearance should not be at too much of extra cost

unless it is a prime requirement.
▪ The appearance should be suitable to the environment in
which the product is used.
▪ The growing importance of the aesthetic considerations in
product design has given rise to a separate disciple known
as industrial design.
▪ The job of an industrial designer is to create new shapes and
forms for the product which are aesthetically appealing
ABE 412: Machine Design for AB Production
 Aesthetic Considerations
Form (Shape) - There are five basic forms of the products,
namely, step, taper, shear, streamline and sculpture:

Step form: The step form is a stepped structure having vertical accent
It is similar to the shape of a multistory building.
Taper form: The taper form consists of tapered blocks or tapered
cylinders.
Shear form: The shear form has a square outlook.
Streamline form: The streamline form has a streamlined shape having
a smooth flow as seen in automobile and aeroplane structures
Sculpture form: The sculpture form consists of ellipsoids, paraboloids
and hyperboloids.

ABE 412: Machine Design for AB Production

 Aesthetic Considerations

The sculpture and stream forms are suitable for mobile products
like vehicles, while step and shear forms are suitable for stationary
products.

ABE 412: Machine Design for AB Production

 Aesthetic Considerations
Color
❑ Color is one of the major contributors to the aesthetic appeal of the
product.
❑ Many colours are linked with different moods and conditions.
❑ The selection of the colour should be compatible with the conventions.
❑ Morgan has suggested the colour code given in the following Table.

Colour Meaning
Red Danger, Hazard, Hot
Orange Possible Danger
Yellow Caution
Green Safety
Blue Caution-Cold
Grey Dull
ABE 412: Machine Design for AB Production
 Aesthetic Considerations
Material and Surface Finish
▪ The material and surface finish of the product contribute
significantly to the appearance.
▪ The material like, stainless steel gives better appearance than
the cast irons, plain carbon steels or low alloy steels.

▪ The brass or bronze give richness to the appearance of the

product.

▪ The products with better surface finish are always aesthetically

pleasing.

▪ The surface coating processes like: spray painting, anodizing,

electroplating, etc. greatly enhances the aesthetic appeal of the
product.
ABE 412: Machine Design for AB Production
 Ergonomic Considerations
▪ Ergonomics is defined as the scientific study of the man-machine-
working environment relationship and the application of anatomical,
physiological and psychological principles to solve the problems arising
from this relationship
▪ The word ergonomic is formed from two Greek word: ergo means work and
nomic mean natural laws.
▪ The final objective of the ergonomics is to make the machine fit for user
rather than to make the user adapt himself or herself to the machine.
▪ It aims at decreasing the physical and mental stresses to the user.
▪ Psychology - Experimental psychologists who study people at work to
provide data on such things as: Human sensory capacities, psychomotor
performance, Human decision making, Human error rates, Selection tests
and procedures, Learning and training.

ABE 412: Machine Design for AB Production

 Ergonomic Considerations

Anthropometry - An applied branch of anthropology concerned

with the measurement of the physical features of people.
Measures how tall we are, how far we can reach, how wide
our hips are, how our joints flex, and how our bodies move.

Applied Physiology - Concerns the vital processes such as

cardiac function, respiration, oxygen consumption, and
electromyography activity, and the responses of these vital
processes to work, stress, and environmental influences.

ABE 412: Machine Design for AB Production

Ergonomic Considerations

Man-Machine Closed Loop System

ABE 412: Machine Design for AB Production

 Ergonomic Considerations
▪ This man-machine closed loop system in influenced by the
working environmental factors such as: lighting, noise,
temperature, humidity, air circulation, etc.
▪ Ergonomic Considerations in Design of Displays
▪ Ergonomic Considerations in Design of Controls
▪ Working Environment.
• Lighting
• Noise

• Temperature
• Humidity and air circulation

ABE 412: Machine Design for AB Production

God bless you!