Machine element design

Introduction
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Design means to create a plan or sketch of something that is going
to be made later, especially a plan that details what the finished
thing will do and look like.
Classifications of Machine Design : The machine design may be classified as follows:

1.Adaptive design. In most cases, the designer’s work is concerned with

adaptation of existing designs. This type of design needs no special knowledge or skill and
can be attempted by designers of ordinary technical training. The designer only makes minor
alternation or modification in the existing designs of the product.

2.Development design. This type of design needs considerable scientific

training and design ability in order to modify the existing designs into a new idea by
adopting a new material or different method of manufacture. In this case, though the designer
starts from the existing design, but the final product may differ quite markedly from
the original product.
3. New design. This type of design needs lot of research, technical ability and creative
thinking. Only those designers who have personal qualities of a sufficiently high order can
take up the work of a new design.
 Analyze Problem
Design means to create a plan or sketch of something that is going
to be made later, especially a plan that details what the finished
thing will do and look like.
Classifications of Machine Design : The machine design may be classified as follows:

3. New design. This type of design needs lot of research, technical ability and creative
thinking. Only those designers who have personal qualities of a sufficiently high order can
take up the work of a new design.

The designs, depending upon the methods used, may be classified as follows:
(a) Rational design. This type of design depends upon mathematical formulae of principle of
mechanics.
(b) Empirical design. This type of design depends upon empirical formulae based on the
practice and past experience.
(c) Industrial design. This type of design depends upon the production aspects to
manufacture any machine component in the industry.
 Analyze Problem
Design means to create a plan or sketch of something that is going
to be made later, especially a plan that details what the finished
thing will do and look like.
Classifications of Machine Design : The machine design may be classified as follows:

3. New design. This type of design needs lot of research, technical ability and creative
thinking. Only those designers who have personal qualities of a sufficiently high order can
take up the work of a new design.

The designs, depending upon the methods used, may be classified as follows:
(d) Optimum design. It is the best design for the given objective function under the specified
constraints. It may be achieved by minimizing the undesirable
effects.

(e) System design. It is the design of any complex mechanical system like a motor car.
(f) Element design. It is the design of any element of the mechanical system like piston,
crankshaft, connecting rod, etc.
(g) Computer aided design. This type of design depends upon the use of computer systems to
assist in the creation, modification, analysis and optimization of a design.
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THE ELEMENT OF MACHINE Definition of key terms

Element is an elementary part of machine that is produced without any assembling

operations.
Machine is a technical device in which mechanical motions are performed in order to
replace or facilitate human’s physical and mental work.

Machine is a device consisting of various elements arranged together, so as to

perform the prescribe task to satisfy human needs.

E.g.: A pump-set is a machine in which the input is electrical energy, the pump-set utilizes
the electrical energy to perform the prescribed task of lifting water to the desired
location (output).
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THE ELEMENT OF MACHINE Definition of key terms

Elements are divided into:

 Simple (screws, nuts, keys, ball, etc.)
 Elaborate in shape (crankshaft, gearbox, toothed wheel, etc.)

Subassembly is a combination of assembly units and elements which perform the

identical functions (bearings, clutches, speed reducers).
Serviceability is ability of an element or machine to perform its function according
to specifications.
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Machine element design
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General application of Machine element

1. Machine elements used for holding the components: - These type of machine
elements include nuts and bolts, screw, cotters, keys, couplings, pins, revettes.
2. Machine elements used for transmitting the power: - Machine elements like gears,
shafts, clutches and brakes, pulleys, belts, chain, sprocket, are used to transmit
power from one place to another.
3. Machine elements used for support of other components: - Machine elements like
bearings, axles, brackets, hangers etc. are used to give support to rotating or
stationary members.
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General application of Machine element

TRANSMISSIONS SYSTEM

Transmission is a mechanism intended to transmit power from the prime mover (an
engine or a motor) to the driven machine.
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General application of Machine element

CLASSIFICATION OF TRANSMISSIONS

Transmission by friction: a power transmission system utilizing a set of friction gears so

arranged that varying their positions relative to one another gives a wide range of speed
ratios.

A friction drive or friction engine is a type of transmission that utilizes two wheels in the transmission
to transfer power from the engine to the driving wheels. The system is inherently a continuously
variable transmission; by adjusting the positions of the two disks, the output ratio changes
continuously.
 General application of Machine element
CLASSIFICATION OF TRANSMISSIONS
For example, in a manual transmission system for a vehicle, engagement refers to the
connection of gears when the driver selects a specific gear using the gear shifter. This
engagement allows power to be transmitted from the engine to the wheels, determining the
speed and direction of the vehicle.
 General application of Machine element
CLASSIFICATION OF TRANSMISSIONS
The efficiency and effectiveness of a transmission system with direct contact depend on
the design, materials, and lubrication used to minimize wear and ensure smooth operation.
It contrasts with systems that use indirect methods like fluid couplings or
electromechanical systems where there is no direct physical contact between transmission
components.
 General application of Machine element
CLASSIFICATION OF TRANSMISSIONS
Transmission by flexible connection typically refers to a method of transferring power or
motion between two components using flexible elements. Unlike rigid connections,
flexible connections allow for some degree of movement, misalignment, or vibration
isolation. There are various types of flexible connections, each suitable for different
applications. Some common examples include:

Fastenings These type of machine elements include nuts and bolts, screw, cotters, keys,
couplings, pins, revettes are used for holding the components.
 Machine Element Design
Classification of Engineering Materials
The engineering materials are mainly classified as:

 Metals and their alloys, such as iron, steel, copper, aluminum, etc.
 Non-metals, such as glass, rubber, plastic, etc.
 Metals and nonmetals are two broad categories of elements on the periodic table, and
they exhibit distinct characteristics. Here are some key differences between metals and
nonmetals:
 Physical Properties:

 Metals: Typically have a shiny, lustrous appearance. They are good conductors of heat
and electricity. Metals are usually solid at room temperature (with the exception of
mercury) and are malleable (can be hammered into thin sheets) and ductile (can be
drawn into wires).
 Nonmetals: Often have a dull appearance. They are generally poor conductors of heat
and electricity. Nonmetals can exist in various states at room temperature (solid, liquid,
or gas) and are often brittle.
 State at Room Temperature:
 Metals: Most metals are solids at room temperature. Mercury is an exception, being a
metal that is liquid at room temperature.
 Nonmetals: Nonmetals can exist in various states at room temperature. For example,
oxygen and nitrogen are gases, bromine is a liquid, and sulfur is a solid.
 Machine Element Design
Classification of Engineering Materials
The engineering materials are mainly classified as:

 Malleability and Ductility:

 Metals: Metals are malleable (can be hammered or rolled into sheets) and ductile (can
be drawn into wires). These properties arise from the ability of metal atoms to slide past
each other.
 Nonmetals: Nonmetals are generally not malleable or ductile. They tend to be brittle
and can break or shatter when subjected to stress.
 Electrical Conductivity:
 Metals: Metals are good conductors of electricity due to the presence of free electrons
that can move easily through the metal lattice.
 Nonmetals: Nonmetals are generally poor conductors of electricity. They may become
conductive under certain conditions, but this conductivity is usually much lower than
that of metals.
 Chemical Properties:
 Metals: Tend to lose electrons and form positively charged ions (cations) in chemical
reactions. They often react with acids to produce hydrogen gas.
 Nonmetals: Tend to gain electrons and form negatively charged ions (anions) in
chemical reactions. They may react with metals to form ionic compounds or with other
nonmetals to form covalent compounds.
 Machine Element Design
Classification of Engineering Materials
 Density:

 Metals: Generally have high densities.

 Nonmetals: Generally have lower densities compared to metals.

The metals may be further classified as:

(a) Ferrous metals, and (b) Non-ferrous metals.

The primary distinction between ferrous metals and nonferrous metals lies in the presence of
iron. Here are the key differences between ferrous metals and nonferrous metals:

Composition:

Ferrous Metals: Contain iron as a significant component. Common examples include iron,
steel, and cast iron. Stainless steel, which contains iron but also includes chromium and
nickel, is also considered ferrous.
Nonferrous Metals: Do not contain iron as a major component. Examples include aluminum,
copper, lead, zinc, and precious metals such as gold and silver.
 Machine Element Design

Calculation of loads applied on machine part.

 Machine Element Design

Calculation of loads applied on machine part.

Hooke's Law is a fundamental principle in physics and materials science that describes
the behavior of elastic materials, particularly in the context of stretching or
compressing. The law is named after the 17th-century English scientist Robert Hooke,
who first formulated it.
 Machine Element Design

Calculation of loads applied on machine part.

Hooke's Law is a fundamental principle in physics and materials science that describes
the behavior of elastic materials, particularly in the context of stretching or
compressing. The law is named after the 17th-century English scientist Robert Hooke,
who first formulated it. Hooke's Law can be stated mathematically as:

F=−k⋅ΔL

Hooke's Law is commonly applied to the behavior of springs and elastic materials, but it
also serves as a starting point for understanding the mechanical properties of materials in
general. It is important to note that Hooke's Law has limitations and may not accurately
describe the behavior of materials under extreme conditions or beyond their elastic limits.
 Machine Element Design

Application of machine parts

DESIGN OF POWER SCREW

Power screw is a mechanical device used to convert rotary motion into linear motion in order
to transmit power. Power screws are used to obtain high mechanical advantage. Unlike
the threaded fasteners which are used to clamp the machine members, power screws
are used to transmit power.

A power screw is a mechanical device that converts rotary motion into linear motion and vice
versa. It consists of a threaded shaft (screw) and a mating nut, and its design allows for the
efficient transmission of power and motion. Power screws are commonly used in various
engineering applications, such as in machinery, automotive systems, and manufacturing
equipment.

Common applications of power screws are:

 Screw jacks: to move large loads with minimum effort.
 Lead screw of lathe: for axial movement of tool and its precise positioning.
 Tensile testing machine: to exert large force.
 Vice: to clamp the work piece
Power screw comprises of two main components: screw and nut, and can operate in
following three ways
 Machine Element Design

Application of machine parts

DESIGN OF POWER SCREW
Power screw comprises of two main components: screw and nut, and can operate in
following three ways:

 Screw rotates in bearings and nut moves axially

 Screw rotates and also moves axially while nut is kept fixed
 Nut rotates and screw moves in axial direction

Summary : Power screws have large load carrying capacity, are compact, provide large
mechanical advantage, provide very accurate and precise linear motion, have smooth and
noiseless operation, are reliable and have lesser cost. Disadvantages are that power
screws have poor efficiency and high rate of wear.
 Machine Element Design
Application of machine parts
Types of Screw Threads used for Power Screws
Square thread: is adapted for the transmission of power in either direction. This thread
results in maximum efficiency and minimum radial or bursting pressure on the nut. The
square threads are employed in screw jacks, presses and clamping devices.

Trapezoidal thread: is a modification of square thread. The slight slope given to its
sides lowers the efficiency slightly than square thread and it also introduce some
bursting pressure on the nut, but increases its area in shear. It is used where a split nut is
required and where provision is made to take up wear as in the lead screw of a lathe.

Buttress thread: is used when large forces act along the screw axis in one direction
only. This thread combines the higher efficiency of square thread and the ease of
cutting and the adaptability to a split nut of acme thread. It is stronger than other threads
because of greater thickness at the base of the thread. The buttress thread has limited use for
power transmission. It is employed as the thread for light jack screws and vices.

(a) Square thread (b) Trapezoidal tread (c) Buttress tread

 Machine Element Design
Application of machine parts
Types of Screw Threads used for Power Screws

Multiple Threads: The power screws with multiple threads such as double, triple etc. are
employed when it is desired to secure a large lead with fine threads or high efficiency. Such
type of threads are usually found in high speed actuators.
 Machine Element Design
Application of machine parts
 Torque Required to Raise Load by Square Threaded Screws
The torque required to raise a load by means of square threaded screw may be determined
by considering a screw jack as shown in Fig.(a). The load to be raised or lowered is placed
on the head of the square threaded rod which is rotated by the application of an effort at the
end of lever for lifting or lowering the load.
 Machine Element Design
Application of machine parts
 Torque Required to Raise Load by Square Threaded Screws
A little consideration will show that if one complete turn of a screw thread be imagined to be
unwound, from the body of the screw and developed, it will form an inclined plane as shown
in Fig. (a).

From the geometry of the Fig. (a), we find that

 Machine Element Design
 Torque Required to Raise Load by Square Threaded Screws
 Machine Element Design
 Torque Required to Raise Load by Square Threaded Screws

When the axial load is taken up by a thrust collar as shown in below, so that the load
does not rotate with the screw, then the torque required to overcome friction at the
collar,

Collar Commonly found in power transmission applications, shaft collars are ring-shaped
plastic or metal devices that clamp around a shaft. The purpose of the collar is usually to
hold motor components, gear assemblies, sprockets, bearings, and other parts in place and
sometimes facilitate their proper movement.
 Machine Element Design
 Torque Required to Raise Load by Square Threaded Screws

Where: :outside and inside radius of collar

If an effort P1 is applied at the end of a lever of arm length l, then the total torque required
to overcome friction must be equal to the torque applied at the end of lever, i.e.
 Machine Element Design
 Torque Required to Raise Load by Square Threaded Screws
 Machine Element Design
 Torque Required to lower Load by Square Threaded Screws
A little consideration will show that when the load is being lowered, the force of friction
(F = µ.RN) will act upwards. All the forces acting on the body are shown
Resolving the forces along the plane,
 Machine Element Design
 Torque Required to lower Load by Square Threaded Screws

Torque required to overcome friction between the screw and nut,

 Efficiency of Square Threaded Screws

The efficiency of square threaded screws may be defined as the ratio between the ideal effort
(i.e. the effort required to move the load, neglecting friction) to the actual effort (i.e. the effort
required to move the load taking friction into account).

The effort applied at the circumference of the screw to lift the

load is

Note that If there would have been no friction between the screw and the nut, then φ will be
equal to zero.
 Machine Element Design
 Torque Required to raise Load by Square Threaded Screws

This shows that the efficiency of a screw jack, is independent of the load raised.
In the above expression for efficiency, only the screw friction is considered. However, if
the screw friction and collar friction is taken into account, then
 Machine Element Design
 Torque Required to raise Load by Square Threaded Screws

Note that : The efficiency may also be defined as the ratio of mechanical advantage to the
velocity ratio.
We know that mechanical advantage,
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 Torque Required to raise Load by Square Threaded Screws

Maximum Efficiency of a Square Threaded Screw

Multiplying the numerator and denominator by 2, we have,

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 Over Hauling and Self Locking Screws

The effort required at the circumference of the screw to lower the load is

In the above expression, if φ < α, then torque required to lower the load will be negative. In
other words, the load will start moving downward without the application of any torque.
Such a condition is known as over hauling of screws. If however, φ > α, the torque required
to lower the load will be positive, indicating that an effort is applied to lower the load. Such
a screw is known as self locking screw. In other words, a screw will be self locking if the
friction angle is greater than helix angle or coefficient of friction is greater than tangent of
helix angle i.e. µ or tan φ > tan α.
 Machine Element Design
 Efficiency of Self Locking Screws
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