Machine Design I(NME-501)

UNIT 1

Dr. Suvandan Saraswat

1
 Design of Machine Elements

• An “applications” course
• Separates “Designer” from “Design Engineer”
• Uses a wide range of your background courses:

• Statics & Dynamics • Technical Drawing

• Strength of Materials • Intro to Design
• Materials and Processes • Machines & Mechanisms
• Manufacturing Processes
 Design of Machine Elements
The determination of appropriate
geometry and materials for the
individual components of a mechanical
design
Requires:
• Attention to details
• Engineering analysis
 Mechanical Design

The process of selecting mechanical components

and putting them together to accomplish a desired
function.
Integration

Requires:
• Imagination
• Component familiarity
 Introduction
• Engg. Design: it may be defined as the iterative
decision making activity to create the plans by
which resources are converted preferably
optimally into systems, processes, or devices to
perform desired function to meet human meets.

• M/C Design: The creation of New and better

machines or equipment or improving the
existing ones.
 Engineering Design
• Identify a Need

• Conceptual Design

Design of
• Preliminary Design Machine
Elements
• Final Design

• Manufacture

• Sales & Delivery

 Types of design

Based on Idea Based on methods

• Adaptive design • Rational design

• Developmental • Empirical design

design
• Industrial design
• New design
 General Considerations
•Cost
•Output/ Efficiency
•Device/Mechanism to be used
•Material
•Size, shape and space requirements.
•Weight
•Method of manufacturing
•Operation
•Reliability and safety aspects
•Inspectibility
•Maintenance, cost and aesthetics
•No. of items required
 Design Procedure
Function of element Working Drawing of Element

Forces on element
Check Design at Critical Section

Failure mode of element Manufacture

Dimensions Modification for Assembly

 Standards in design
• Standard for Material
• Standard for Shapes and dimension
• Standard for Fits Tolerances and Surface
finish
• Standard for testing of products
• Standards for Drawings
 Types of Standards
• Company (SKF for bearing)

• National (BIS for India, DIN for Germany, SAE for USA)

• International (ISO)
 Advantage for Standards
• Easy to replace
• Reduction in types and dimension of identical
component
• Reduction in manufacturing facility
• Reduction in time and efforts for design
• Improvement in quality and reliability
Designation of steel
 Steels contd…
Low Alloy High Alloy
low carbon Med carbon high carbon
<0.25 wt% C 0.25-0.6 wt% C 0.6-1.4 wt% C

heat austenitic
Name plain HSLA plain plain tool
treatable stainless
Cr,V Cr, Ni Cr, V,
Additions none none none Cr, Ni, Mo
Ni, Mo Mo Mo, W
Example 1010 4310 1040 43 40 1095 4190 304
Hardenability 0 + + ++ ++ +++ 0
TS - 0 + ++ + ++ 0
EL + + 0 - - -- ++
Uses auto bridges crank pistons wear drills high T
struc. towers shafts gears applic. saws applic.
sheet press. bolts wear dies turbines
vessels hammers applic. furnaces
blades V. corros.
resistant
increasing strength, cost, decreasing ductility
Based on data provided in Tables 11.1(b), 11.2(b), 11.3, and 11.4, Callister 7e.
 Contd..
• Steels designated on the basis of mechanical
properties, and

• Steels designated on the basis of chemical"

composition.
 Steels Designated on the Basis of Mechanical Properties

• Symbol Fe or FeE depending on whether the steel has been specified on the

basis of maximum tensile strength or yield stress.

• Figure indicating the miximum tensile strength or yield stress in N/mm2• If no

minimum tensile or yield strength is guaranteed, the figure shall be 00.

• Chemical symbols for elements the presence of which characterize the steel,

• Symbol indicating special characteristics covering method of deoxidation, steel

quality, degree of purity, weldability guarantee, resistance to brittle fracture,

surface condition, formability, surface finish, heat treatment, elevated

temperature and low temperature properties.

• Symbol indicating applications

 Contd..
• Method of deoxidation - Depending on whether
the steel is killed, semi-killed or rimming variety,
the following symbols shall be used to indicate
the steel making practice:
i) R for rimming steel, and
ii) K for killed steel.

NOTE - If no symbol is used, it mean that the steel

of semi-killed type
• Steel quality - The following symbols shall be
used to indicate
steel quality:
QI-Non-ageing quality,
Q2-Freedom from flakes,
Q3 - Grain size controlled,
Q4 - Inclusion controlled, and
Q5- Internal homogeneity guaranteed.
Degree of purity - The sulphur and phosphorus levels (ladle analysis)
shall be expressed as follows:

Symbol Maximum Content in Percent

Phosphorus Sulphur
P25 0.025 0.025
P35 0.035 0.035
P50 0.050 0·050
P70 0·070 0·070
No symbol will mean 0'055 0·055
 Steels Designated on the Basis of Chemical
Composition
Unalloyed steels (IS: 7598-1974*) - The code
designation shall consist of the following in the order given:
a) Figure indicating 100 times the average percentage of
carbon content,
b) Letter C and
c) Figure indicating 10 times the average percentage of
manganese content.
The figure after multiplying shall be rounded off to the
nearest integer according to the rules given in IS : 2-1960
 Cont..
Unalloyed tool steels- The designation shall consist of:
Figure indicating 100 times the average percentage of
carbon;
• Symbol ' T' for tool steel; and
• Figure indicating 10 times the average percent
manganese Content.
• 75T5 Unalloyed tool steel with average 0.75 percent
carbon and 0.5 percent manganese
• 80T11 Unalloyed tool steel with average carbon
content of 0.80 percent and I-I percent manganese
 Cont..
Unalloyed free cutting steels - The designation shall consist
Figure indicating 100 times the average percentage of carbon;
• Letter' c';
• Figure indicating 10 times the average percentage of manganese;
• Symbol'S', 'Se', 'Te' or ' Pb ' depending on the element present which
makes the steel free cutting followed by the figure indicating 100
times the percentage content of the element.
• In the case of the phosphorized steels the symbol P shall be included;
and Symbol indicating special characteristics covering the method of
deoxidation, surface condition and heat treatment
• 35C10S14K Free cutting steel with average 0-35 percent carbon, I0
percent manganese and 0·14 percent sulphur, killed quality.
• 20CI2Pb15T Free cutting steel with average 0·15 percent lead, 0-20
percent carbon and 1.2 percent manganese, hardened and tempered.
 Alloy steels (IS: 7598·1974·):

Low and medium alloy steels (total alloying elements not exceeding10
percent) - The designation of steels shall consist of:
1) Figure indicating 100 times the average percentage carbon,
2) Chemical symbols for alloying elements each followed by the figure
for its average percentage content multiplied by a factor as given
below:

Note1- The figure after multiplying shall be rounded off to integer.

Note2- Symbol (Mn' for manganese shall be included in case manganese
content is equal to or greater than one percent,
Note3-The chemical symbols and their figures shall be listed in the designation in the order of
decreasing content.
• 3) Symbol indicating special characteristics covering
degree of purity, hardenability, weldability guarantee,
elevated temperaure properties, surface condition,
surface finish and heat treatment
• Examples:
25Cr4Mo2G Steel with guaranteed hardenability and
having average 0.25 percent carbon, 1 percent
chromium and 0'25 percent molybdenum
40Ni8Cr8V2 Hot rolled Heel with average 0'40 percent
carbon, 2 percent chromium, 2perrent nickel and 0'2
percent vanadium
High alloy steels (total alloying elements more
than 10 percent)
The designation shall consist of:
I) Letter 'X'.
2) Figure indicating 100 times the percentage
carbon content.
3) Chemical symbol for alloying elements each
followed by the figure for its average percentage
content rounded off to the nearest integer
4) Chemical symbol to indicate specially added element to
attain the desired properties.
5) Symbol indicating specific characteristics covering
hardenability, weldability guarantee, elevated
temperature properties, surface condition, surface finish
and heat treatment
Examples:
XIOCrl8Ni9S3 Steel in pickled condition with average
Carbon 0.10 percent, chromium 18 percent and nickel 9
percent.
XI5Cr25Nil2 Steel with 0.15 percent carbon, 25 percent
chromium and 12 percent nickel
 Alloy tool steels -
The steel designation shall be as for low,
medium and high alloy steels as given under
(a) and (b) above except that the. symbol 'T'
will be included in the beginning of the
designation of low alloy and medIum alloy tool
steels and XT instead of 'X' in the case of high
alloy tool steels
• Examples:
XT75W18Cr4V1 High alloy tool steel with average
carbon 0.75 percent, tungsten 18 percent,
chromium 4percent and vanadium 1percent
XT98W6Mo5Cr4V1 High alloy steel with average
carbon 0.98 percent, tungsten 6 percent,
molybdenum 5 percent, chromium 4 percent and
vanadium 1percent
 Free cutting alloy steels
• The steel designation shall be as for low, medium and
high alloy steels except that depending on the
percentage of S, Se, Te and Zr present the designation
shall also consist of the chemical symbol of the element
present followed by the figure indicating 100 times its
content.
Examples:
• X15Cr25Ni15S40 Alloy free cutting steel with carbon
0.15 percent, chromium 25 percent, nickel 15 percent
and sulphur 0'40 percent
• XI2Cr18Ni3S25 Alloy free cutting steel with 18 percent
chromium, nickel 3percent and sulphur 0'25 percent.
 Selection of material
• Availability: delivery time, transportation cost
etc.
• Cost: initial , processing, maintenance,
transportation

• Mechanical Properties: strength, rigidity,

ductility, hardness, toughness etc..
• Manufacturing Consideration: production,
Noise, safety, reliability, accuracy, aesthetics etc.
 Numerical
• It is required to select a material by weighted
point method, there are four candidate materials
viz. low alloy steel, plain carbon steel, stainless
steel and chromium steel, which have passed
through screening test. For a particular
application, the designer has given 5 point
weightage age to ultimate tensile strength, 3
points weightage for hardenebility and 2 points
weightage for cost/economy. The data for
candidate material is given in table. Find the
suitable material.
Material Ultimate tensile BHN COST per unit
strength n/mm2
Low alloy steel 850 60 30
Plain carbon steel 850 80 50
Stainless steel 1200 30 100
Chromium steel 950 100 80
Loading
Factor of safety
 Design for static loading
Simple Stresses
Contd..
Contd..
Contd..
Theories of Failure