Machine Design-I
Course Outline
Introduction to Machine design
Introduction to temporary joints, including pins, bolts and nuts etc.
Flexible Mechanical Elements including Belts, ropes and Chains
Sample and Numerical problems on flexible elements
Basic criteria of Design of Machine Parts
Design of Keys, Cotters
Design and Types of Couplings
Design of Brakes and clutches, Flywheel
Course outline
Sample Problems on brakes and clutches
Design of welded, riveted and bolted joints
Design of translation screws
Design codes and standards
Tolerances, standards of fits & Tolerances.
Determination of permissible and actual stresses, factor of safety
Text books and Recommended Books
Title
Author(s)
Mechanical Engineering Design
Shigley, McGraw Hill
Machine Design, An integrated
Approach
R L Norton, McGraw Hill
Design of Machine Elements
M. F. Spotts, Prentice Hall
Fundamentals of Machine Component
Design
R.C. Juvinall & K.M Marshek, John Wiley
Introduction
Meaning of Design
Mechanical Engineering Design
Design Phases
Design Considerations
Design Tools and Resources
The Design Engineers Professional Responsibilities
Codes & Standards
Economics
Stress and Strength
Uncertainty
Meaning of Design
To design is to formulate a plan or strategy for satisfaction of specified
need or solve a problem
Design is a highly innovative and iterative process
Design is also a decision making process
Sometimes, when information is limited, decisions are made tentatively,
with the provision to adjust when more information is available
A designer will have to effectively communicate and work with people
from different fields and specialisations
Meaning of Design
Engineering tools (such as mathematics, statistics, computers, graphics,
languages) are combined to produce a plan that , when carried out,
produces a product that is functional, safe, reliable, competitive, usable,
manufacturable, and marketable, regardless of who builds or uses it
Mechanical Engineering Design
Mechanical engineers are associated with the production and processing
of energy and with providing means of production, the tools of
transportation, and the techniques of automation
The skills and knowledge base are extensive
Among the disciplinary bases are mechanics of solids and fluids, mass
and momentum transport, manufacturing processes, and electrical and
information theory/technology
Mechanical engineering design involves all the disciplines of mechanical
engineering
Example: A simple journal bearing involves fluid flow, heat transfer,
friction, energy transport, material selection, thermo-mechanical
elements, statistical descriptions and so on
Design Phases
The complete design process, from start
to finish, is often as outlined in the figure
on the right
Identification of need generally starts
the design process
The definition of problem is more
specific and must include all the
specifications for the object that is to be
designed
Design Phases
The synthesis of a scheme connecting possible system elements is
sometimes called the invention of concept or concept design
Synthesis and analysis and optimisation are intimately and
iteratively related. Emphasize that design is an iterative process in
which we proceed though several steps, evaluate the results, and then
return to an earlier phase of the procedure
Evaluation is a significant phase of the total design process.
Evaluation is the final proof of a successful design and usually involves
testing the prototype in a lab
Communicating the design to others is the final, vital presentation
step in the design process
Design Considerations
1.
Functionality
2.
Strength / Stress
3.
Distortion / Deflection / Stiffness
4.
Wear
5.
Corrosion
6.
Safety
7.
Reliability
8.
Manufacturability
9.
Utility
10. Cost
11. Friction
12. Weight
13. Life
14. Noise
15. Styling
16. Shape
17. size
18. Control
19. Thermal properties
20. Surface
21. Lubrification
22. Marketability
23. Maintenance
24. Volume
25. Liability
26. Remanufacturing/ Resource recovery
Design Tools and Resources
Computational Tools
CAD
CAE
CFD
FEA
Acquiring Technical Information
Libraries
Government Sources
Professional Societies
Commercial Vendors
Internet
The Design Engineers Professional Responsibilities
In general, the design engineer is required to satisfy the needs of
customers (management, clients, consumers, etc.)
It is expected to do so in a competent, responsible, ethical and
professional manner
To start on the road to success, you need to cultivate your professional
work ethic and process skills before graduation, so that when you begin
your formal engineering career, you will be prepared to meet the
challenges
Development of communication skills
Codes and Standards
A code is a set of specifications for the analysis, design,
manufacture and construction of something
A standard is a set of specifications for parts, materials, or
processes intended to achieve uniformity, efficiency and a
specified
quality
Aluminium
Association
(AA)
American Gear Manufacturers Association (AGMA)
American Institute of Steel Construction (AISC)
American Iron and Steel Institute (AISI)
American National Standards Institute (ANSI)
ASM International (formerly American Society for Metals)
American Society of Mechanical Engineers (ASME)
American Society for Testing and Materials (ASTM)
American Welding Society (AWS)
American Bearing Manufacturers Association (ABMA)
British Standards Institute (BSI)
Industrial Fasteners Institute (IFI)
Institute of Mechanical Engineers (I.Mech.E)
International Bureau of Weights and Measures (BIPM)
International Standards Organisation (ISO)
National Institute for Standards and Technology (NIST)
Society of Automotive Engineers (SAE)
Economics
The consideration of cost plays an immensely
important role in the design decision process
We could easily spend as much time in studying the
cost factor as in the study of the entire subject of
design
The use of standard or stock sizes is the first principle
of cost reduction
Among the effects of design specifications on costs,
tolerances are perhaps the most significant.
Tolerances, manufacturing processes and surface
finish are interrelated and influence the producibility
of the end product in many ways.
Economics
Close tolerances may necessitate additional steps in
processing and inspection or even render a part
completely impractical to produce economically
At times, it happens that when two or more design
approaches are compared for cost, the choice
between the two depends on a set of conditions such
as the quantity of production, the speed of the
assembly lines, or some other condition
There then occurs a point corresponding to equal cost,
called the breakeven point
Economics
There are many ways of obtaining relative cost
figures so that two or more designs can be roughly
compared
Comparing the monetary cost per unit weight
Compare the number of parts
Other cost estimators such as area, volume,
horsepower, torque, capacity, speed and various
other performance ratios
Stress and Strength
The survival of many products depends on how the
designer adjusts the maximum stress in a component
to be less than the components strength at specific
locations of interest
The designer must allow the maximum stress to be
less than the strength by a sufficient margin so that
despite the uncertainties, failure is rare
Strengths are the magnitudes of stresses at which
something of interest occurs, such as the proportional
limit, 0.2 percent-offset yielding, or fracture
Strength is a property of a material or of a
mechanical element
Stress and Strength
The strength of an element depends on the
choice, the treatment and the processing of the
material
Remember that strength is an inherent
property of a part, a property built into the part
because of the use of a particular material and
process
Various metalworking and heat-treating
processes, such as forging, cold forming, cause
variations in strength from point to point
throughout a part
