Design of Machine elements (3‐0‐0)

ME3L002
• Mechanical design is a complex process, requiring many skills.

• Extensive relationships need to be subdivided into a series of

simple tasks.

• The complexity of the process requires a sequence in which

ideas are introduced and iterated.
 Books:
1. Shigley’s Mechanical Engineering Design (In SI Units) – (TMH)
2. Machine Design (In SI Units) – Maleev & Hartmsn Edited by O P
Groover (CBS)
3. Machine Design – An Integrated Approach – Robert L. Norton
(Pearson Education)
4. Design of Machine Elements – M. F. Spotts (Pearson Education)

1. Design of Machine Elements (3rd Edition) – V B Bhandari (TMH)

2. A Textbook of Machine Design – Khurmi & Gupta (S. Chand)

1. Machine Design Data Book – V B Bhandari (TMH)

2. Machine Drawing – N D Bhatt (Charotar Publication)
3. Machine Design Data Book – K. Lingaiah (TMH)
The design engineer’s professional obligations include conducting activities in an
ethical manner. Reproduced here is the Engineers’ Creed from the National Society of
Professional Engineers (NSPE):

As a Professional Engineer I dedicate my professional knowledge and skill to the

advancement and betterment of human welfare.
I pledge:
To give the utmost of performance;

To participate in none but honest enterprise;

To live and work according to the laws of man and the highest standards of
professional conduct;

To place service before profit, the honour and standing of the profession before
personal advantage, and the public welfare above all other considerations.

In humility and with need for Divine Guidance, I make this pledge.
 INTRODUCTION
Creation of new and better machines/machine elements and improving the
existing one. (Practice + Experience)

• Efficient
• Economical
• Overall cost of production & operation
• Safe

Knowledge:
Mathematics, Engg. Mechanics, Mechanics of Solids, Theory of Machines,
Workshop Processes, Thermodynamics, Heat Transfer, Manufacturing
Processes, Workshop Technology, Materials Sciences, Engg. Drawing.
(AutoCAD, SolidWorks, UG, Pro-E, ANSYS, NASTRAN, ABAQUS, LS-
DYNA, CFD, COMSOL related softwares), CAD, CAM, CAE, Metrology
etc.

Classification:
1. Adaptive Design
2. Development design
3. New Design
General Considerations:
1. Load type
2. Stresses developed
3. Motion of parts
4. Material Selection
5. Parts size
6. Convenient & economical features
7. Use of standard parts
8. Safety features
9. Workshop facility
10. No. of machines to be manufactured
11. Cost of production
12. Plant facility for assembling
13. Marketability
14. Remanufacturing/resource recovery
Design Tools & Resources:
1. Conventional Drawing (Orthographic projections, Isometric
views etc.)
2. Computational Tools (CAD, CAE)
3. Acquiring Technical Information (Library, Government
sources, Professional societies, Commercial vendors,
Internet)

Standards & Codes: AGMA, ASTM, ASME, SAE, BSI, BIS,

IBR, AWS etc.

Economics: Micro and Macro economics

Economics

Dimensions & Tolerances: Limits, Fits, Tolerances, Allowances,

Clearances etc.
Home Task:

[Link]
[Link] processes
[Link] Engineering
[Link] of basic fundamental subjects
General Procedure:
1. Recognition of need
2. Synthesis (Mechanism)
3. Force Analysis
4. Material selection
5. Design of elements
6. Modification
7. Detailed drawing
8. Production
 Engineering Materials & Properties
Materials

Properties:
1. Strength
2. Stiffness
3. Elasticity
4. Plasticity
5. Ductility
6. Brittleness
7. Malleability
8. Toughness
9. Resilience
[Link]
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Manufacturing Processes
 RIVETED JOINTS

Classification of joints:
1. Permanent – cannot be disassembled without destroying
the connecting parts. Examples: soldered, brazed, welded
and riveted joints.
2. Temporary – disassembled without destroying the
connecting components. Examples: keys, cotters, pins,
flange couplings, nuts & bolts etc.

Riveted Joints:
Structural works, ship building,
bridges, tanks, boiler shells etc.
Where to use?
1. Where it is necessary to avoid the thermal after-effects.
2. Metals with poor weldability.
3. Joints made from heterogeneous materials.
4. Loading condition: Impact & Vibration
5. Thin plates are to assembled (Aircraft structures : Aluminum alloys)

Disadvantages:
1. Overall cost high as compared to welding
2. Heavy (Welding of steel)
3. No. of parts high
4. Holes: Stress concentration.
Methods of Riveting:
1. Cold riveting – structural joints (upto 12 mm)
2. Hot riveting – making leak proof joints. (large dia) eg. boiler

Materials: High tensile strength, Tough and Ductile

Steel (Low Carbon), brass, aluminium, copper etc.
When strength and fluid tight joint is the main
consideration – STEEL.
Manufactured according to standards:
1. IS: 1148-1982 (Reaffirmed 1992) – specification for hot
rolled rivet bars (upto 40 mm Dia) for structural purposes.
2. IS: 1148-1982 (Reaffirmed 1992) – specification for high
tensile steel rivet bars for structural purposes.
3. IS: 2100-1970 IS: 1148-1982 (Reaffirmed 1992) –
specification for steel rivets and stay bars for boilers.

Manufacture: Cold heading or by hot forging.

Types of Rivet Heads:
IS: 2155 – 1982 (Reaffirmed 1996), general purpose, Dia < 12 mm.

Snap heads – structural work & machine riveting. Counter sunk heads – ship
building since flush surface necessary. Conical head – hand hammering. Pan
heads – max strength, but these are difficult to shape
Types of Riveted Joints:
1. Lap joint 2. Butt joint

1. Pitch (p)
2. Back pitch (pb)
3. Diagonal pitch (pd)
4. Margin (m)
Caulking and Fullering:
Failures of a Riveted Joint:
Lozenge Joint/Diamond Joint (Economical & for Structural Use):
- Roof, bridge work, girders, cranes etc.

This type of joint results in economical construction because a plate of smaller width is
required for this joint.
1. Diameter of rivet hole:
2. Number of rivets:
3. From the number of rivets, the number of rows and the number of rivets in
each row is decided.

4. Thickness of butt strap:

5. Efficiency of the joint:

In order to calculate the

efficiency of the joint, we
will proceed from the
outer row of the rivets to
the inner row and identify
the weakest section of the
joint first.
5. Efficiency of the joint:
6. Pitch of the rivets = 3 d + 5

7. Marginal Pitch (m) = 1.5 d

8. Distance between the rows of rivets = 2.5 d to 3d

Eccentrically Loaded Riveted Joint:
Line of action of the load does not pass through the centroid of the rivet system
and thus rivets are not equally loaded.
Assumption:
1. Secondary shear load is proportional to the radial
distance of the rivet under consideration from the
c.g. of the rivet system.
2. Direction of the secondary shear load is
perpendicular to the line joining the center of the
rivet to the c.g. of the rivet system.
 Determine the resultant shear load on each rivet.

Choose the highest

 The standard diameter of the rivet hole and rivet diameter may be specified
according to

 When the thickness of the plate is given, then the diameter of the rivet hole
may be checked against crushing.
Design of Boiler (Self Study):
Longitudinal joint - Butt joint (plate bent to form ring: double strap triple riveted butt
joint)
Circumferential joint – Lap joint with one ring overlapping the other alternately is
used.

I.B.R. –
Indian Boiler Regulations
Example 1. A double riveted double cover butt joint in plates 20 mm thick is made with
25 mm diameter rivets (Assume: Assembled condition, this represents the diameter of
the rivet hole) at 100 mm pitch. The permissible stresses are :
t = 120 MPa;  = 100 MPa; c = 150 MPa
Find the efficiency of joint, taking the strength of the rivet in double shear as twice than
that of single shear.

Solution:

Tearing resistance of the plate per pitch length

Pt = (p – d ) t × σt = (100 – 25) 20 × 120 = 180 000 N

Shearing resistance of the rivets per pitch length

Since the joint is double riveted butt joint, therefore the strength of two rivets in double
shear is taken. We know that shearing resistance of the rivets,
Ps = n × 2 × × d2 × τ = 2 × 2 × (25)2 × 100 = 196 375 N

Crushing resistance of the rivets per pitch length

Pc = n × d × t × σc = 2 × 25 × 20 × 150 = 150 000 N

Strength of the joint

Least of Pt, Ps and Pc = 150 000 N
Efficiency of the joint
We know that the strength of the unriveted or solid plate,
P = p × t × σt = 100 × 20 × 120 = 240 000 N

Efficiency of the joint

Least of Pt , Ps and Pc /P = 150 000/240 000
= 0.625 or 62.5%
Example 2. Two lengths of mild steel tie rod having width 200 mm and thickness 12.5 mm
are to be connected by means of a butt joint with double cover plates. Design the joint if the
permissible stresses are 80 MPa in tension, 65 MPa in shear and 160 MPa in crushing.
Make a sketch of the joint.
 Parameters Value
1. Thickness of plate (t): 12.5 mm
2. No of rivets (n): 5
3. Strength of the joint: 178.5 kN
4. Efficiency (h): 89.25 %
5. Pitch of rivets (p): 70 mm
6. Marginal pitch: 35 mm
7. Distance between the rows of the rivets: 55 mm
 Parameters Value
1. Thickness of plate (t): 12.5 mm
2. No of rivets (n): 5
3. Strength of the joint: 178.5 kN
4. Efficiency (h): 89.25 %
5. Pitch of rivets (p): 70 mm
6. Marginal pitch: 35 mm
7. Distance between the rows of the rivets: 55 mm

All dimension are in mm

Thank you