C.U.SHAH COLLEGE OF ENGG. & TECH.

DEPARTMENT OF MECHANICAL ENGINEERING

Name :A.B.Solanki Subject Code : 131902 Subject Name : Machine Design and Industrial Drafting B.E Mechanical Engineering , 3rd Semester

1. Design consideration of Machine Parts

Contents: 1. Definition and understanding of various types of design 2. Morphology of design 3. Design procedure 4. Selection of materials, Properties and I.S. coding of various materials, 5. Factors of safety 6. Stress Concentration and methods of relieving stresses 7. Types of stresses - tensile, compressive, shear, bending, bearing, crushing, Eccentric axial stresses, principle stress Residual stresses.

Definition and Basic Understanding

WHAT IS MACHINE? WHAT IS DESIGN? WHAT IS MACHINE DESIGN?

If everything were known about the problem or opportunity the task is no longer one of design. Design therefore deals with the unknown and gives shape to this unknown future and in this process creates a new vision of the future that can be adopted through a rigorous process of evaluation and testing.
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Various Types of Design

Adaptive design : This is based on existing design, for example, standard products or systems adopted for a new application. Conveyor belts, control system of machines and mechanisms Developmental design : Here we start with an existing design but finally a modified design is obtained. A new model of a car is a typical example of a developmental design . New design : This type of design is an entirely new one but based on existing scientific principles. No scientific invention is involved but requires creative thinking to solve a problem. Examples of this type of design may include designing a small vehicle for transportation of men and material on board a ship or in a desert. Some research activity may be necessary.
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Types of design based on methods

Rational design : This is based on determining the stresses and strains of components and thereby deciding their dimensions. Empirical design : This is based on empirical formulae which in turn is based on experience and experiments. For example, when we tighten a nut on a bolt force exerted is P=284d Industrial design : These are based on industrial considerations and norms viz. market survey, external look, production facilities, low cost, use of existing standard products.
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Morphology of Design
The morphology of design refers to the study of the chronological structure of design

Basic Procedure of Machine Design

Market Survey Define Specifications of Product Study Alternative Mechanisms for Product and select proper Mechanism

Prepare General Layout of Configuration

Design Individual Components Prepare Assembly and Detail Drawings and Modify Drawings after Testing Prototype Model
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Selection of materials
Selection of material depends on the following criterion. Properties of materials Cost of materials Availability of materials Application
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Engineering Materials

Metals

Non-Metals

Ferrous

Non Ferrous

Timber

Cast Iron

Aluminium Alloys

Rubber

Wrought Iron

Copper Alloys

Plastic

Steel

Y-Alloys

Leather

Other Alloys

Properties of materials
Cast iron It is an alloy of iron, carbon and silicon and it is hard and brittle. Carbon content may be within 1.7% to 3% and carbon may be present as free carbon or iron carbide Fe3C. In general the types of cast iron are (a) grey cast iron and (b) white cast iron (c) malleable cast iron (d) spheroidal or nodular cast iron (e) austenitic cast iron (f) abrasion resistant cast iron.
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Advantages of Cast Iron

Available in a wide range of mechanical/physical properties, i.e. tensile strength from 20 KSI to over 200 KSI, hardness from 120 to about 300 Brinell in standard grades and up to about 600 Brinell in special abrasion resistant grades Good strength to weight ratio Typically lower cost than competing materials and relatively low cost per unit of strength than other materials Lower density and higher thermal conductivity than steels at comparable tensile strength levels Excellent machinability, allowing for high speeds and feeds and reduced (minimal) energy due to the presence of free graphite
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 Excellent damping capacity, especially in Gray Irons Rapid transition from design to finished product Capability of producing highly complex geometries and section sizes in a wide range of sizes, from ounces to over 100 tons Possibility of casting intricate shapes as well as very thin to very thick section sizes Capability of redesigning and combining two or more components from other materials into a single casting, thus reducing assembly cost and time Capability of casting with inserts of other materials Variety of casting processes for low, medium or high production
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Grey cast iron : Carbon here is mainly in the form of graphite. Inexpensive, high compressive strength Graphite is an excellent solid lubricant and this makes it easily machinable but brittle. Some examples of this type of cast iron are FG20, FG35 or FG35Si15. White cast iron : In these cast irons carbon is present in the form of iron carbide (Fe3C) which is hard and brittle. The presence of iron carbide increases hardness and makes it difficult to machine. Consequently these cast irons are abrasion resistant.

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Malleable cast iron : These are white cast irons rendered malleable by annealing. These are tougher than grey cast iron and they can be twisted or bent without fracture. They have excellent machining properties and are inexpensive. Malleable cast iron are used for making parts where forging is expensive such as hubs for wagon wheels, brake supports.
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Spheroidal or nodular graphite cast iron: In these cast irons graphite is present in the form of spheres or nodules. They have high tensile strength and good elongation properties. They are designated as, for example, SG50/7, SG80/2 etc where the first number gives the tensile strength in Mpa and the second number indicates percentage elongation.
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Austenitic cast iron : Depending on the form of graphite present these cast iron can be classified broadly under two headings: Austenitic flake graphite iron designated, for example, AFGNi16Cu7Cr2 Austenitic spheroidal or nodular graphite iron designated, for example, ASGNi20Cr2. These are alloy cast irons and they contain small percentages of silicon, manganese, sulphur, phosphorus etc. They may be produced by adding alloying elements viz. nickel, chromium, molybdenum, copper and manganese in sufficient quantities. These elements give more strength and improved properties. They are used for making automobile parts such as cylinders, pistons, piston rings, brake drums etc.
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Abrasion resistant cast iron : These are alloy cast iron and the alloying elements render abrasion resistance. A typical designation is ABR33 Ni4 Cr2 which indicates a tensile strength in kg/mm2 with 4% nickel and 2% chromium.

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Wrought iron : This is a very pure iron where the iron content is of the order of 99.5%. It is produced by re-melting pig iron and some small amount of silicon, sulphur, or phosphorus may be present. It is tough, malleable and ductile and can easily be forged or welded. It cannot however take sudden shock. Chains, crane hooks, railway couplings and such other components may be made of this iron.
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Plain carbon steel: The properties of plain carbon steel depend mainly on the carbon percentages and other alloying elements are not usually present in more than 0.5 to 1% such as 0.5% Si or 1% Mn etc. There is a large variety of plane carbon steel and they are designated as C01, C14, C45, C70 and so on where the number indicates the carbon percentage.
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Following categorization of these steels is sometimes made for convenience: Dead mild steel- up to 0.15% C Low carbon steel or mild steel- 0.15 to 0.46% C Medium carbon steel- 0.45 to 0.8% C. High carbon steel- 0.8 to 1.5% C Detailed properties of these steels may be found in any standard handbook but in general higher carbon percentage indicates higher strength.
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Alloy steel : these are steels in which elements other than carbon are added in sufficient quantities to impart desired properties, such as wear resistance, corrosion resistance, electric or magnetic properties. Chief alloying elements are nickel for strength and toughness, chromium for hardness and strength, tungsten for hardness at elevated temperature, vanadium for tensile strength, manganese for high strength in hot rolled silicon for high elastic limit, cobalt for hardness and molybdenum for extra tensile strength.
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 Some examples of alloy steels are 35Ni1Cr60, 30Ni4Cr1, 40Cr1Mo28, 37Mn2. Stainless steel is one such alloy steel that gives good corrosion resistance. A typical designation of a stainless steel is 15Si2Mn2Cr18Ni8 where carbon percentage is 0.15.
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I.S. coding of various Materials

AISI(American Iron and Steel Ind.) Steel-SAE1020-0.2% C And 13% t.

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Factors of Safety
Older definition : FOS is totally empirical number used to reduce the ultimate strength or the yield strength of a material so as to obtain a value of design stress which would prevent the failure of the machine part. It varies with applicatio and depended on the experience of part failure for which a clear explanation was not available. Hence called --------- Factor of Ignorance ---------

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Factors of Safety
Example Ductile Material FOS = yield stress/design stress Brittle Material FOS = ultimate stress/ design stress Varying Load FOS = Endurance Limit/Design stress Moreover for stress cycles other than completely reversed stress the design will be base on 25 Soderberg or Goodman criterion

Stress Concentration

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 In developing a machine it is impossible to avoid changes in cross-section, holes,notches, shoulders etc.

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We see from the stress-distribution that the stress at the point away from the hole is practically uniform and the maximum stress will be induced at the edge of the hole.

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Stress Concentration

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Methods of Relieving Stresses

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we see that stress lines tend to bunch up and cut very close to the sharp reentrant corner. In order to improve the situation, fillets may be provided, as shown in Fig. (b) and (c) to give more equally spaced flow lines. It may be noted that it is not practicable to use large radius fillets as in case of ball and roller bearing mountings.

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Types of stresses
Compressive Tensile Shear

Eccentric axial stresses

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Types of stresses
Bending Bearing Crushing Principle stress

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