DESIGN PRINCIPLES OF

MACHINE ELEMENT
DESIGN FACTORS
 DESIGN FACTORS
• Design factors are the characteristics which influence the design of the element or perhaps, the entire system. Normally, a
number of such characteristics have to be considered in any design problem. In a given design problem, the design engineer
should identify the various design considerations and incorporate them in the design process in their order of importance.For
example, in the design of a spring, two most significant design considerations are strength and stiffness.
• Introduction of Machine design:
• The term design can be defined as the formulation of a plan for the satisfaction of human need.
• Design means to create something new or arrange existing things in a new order to satisfy a recognized need of society.
• Mechanical engineering design means the design of the parts, products and systems of mechanical nature. It deals with all the
disciplined of mechanical engineering, such as machine design, thermal engineering, fluid power engineering, refrigeration and air
conditioning etc.
• Machine design deals with the design of machines, mechanisms and their elements. The design of machines or mechanisms
ultimately comes to the design of their individual elements.
• Machine design is the process of selection of the materials, shapes, sizes and arrangements of mechanical elements so that the
resultant machine will perform the prescribed task.
• Design of machine element can be defined as the selection of material and the values for independent geometrical parameters so
that the element satisfies its functional requirements and undesirable effects and kept within the permissible limits.
• The concept of machine design may be illustrated in the figure below.
Concept of Machine Design
For example, the process of design of a belt drive
consists of:
 Selection of arrangement of mechanical elements
like pulleys, belt, shaft, keys bearings etc.
 Selection of shapes of these elements.
 Selection of materials of these mechanical elements.
 Selection of sizes of these mechanical elements.
• Most of the problems in mechanical engineering
design or specifically in machine design, do not have
a unique right answer. There are nearly endless
number of workable designs, none of which could be
called an incorrect answer. But of the correct
answers, some are obviously better than others.
Design Procedure
The general procedure that is followed in machine design is given in
the above figure. It consists of following steps:
1. Definition of Problem:
• Define the design problem giving all input parameters, output
parameters and constraints.
2. Synthesis:
• Once the problem is defined, the next step is synthesis. Synthesis
is the process of selecting or creating the mechanism for the
machine and the shapes of the mechanical elements so as to get
the desired output with the given input.
3. Analysis of Forces:
• Draw the free body diagram of each element of the machines.
Find out the forces (including moments and torque) acting on
each element by force analysis.
4. Selection of Material:
• Select the suitable material for each element. Four basic factors
that are to be considered while selecting the materials are:
availability, cost, mechanical properties, and manufacturing
considerations.
5. Determination of Mode of Failure:
• Before finding out the dimensions of the elements, it is necessary
to know the type of failure by which the element will fail when
put into the use.
Design Procedure cont..
9. Preparation of Drawings:
• 6. Selection of Factor of Safety: • Prepare working drawing of each element or
• Based on the application, select the factor of component with minimum two views showing
safety. Knowing factor of safety and material following details:
strength, determine the permissible or design • a. Dimensions
stress. • b. Dimensional Tolerances
• 7. Determination of Dimensions: • c. Surface Finish
• Find the dimensions of each element of the • d. Geometrical Tolerances
machine by considering the forces acting on the
• e. Special production requirement like heat treatment
element and the permissible stress.
• Prepare assembly drawing giving part number, overall
• 8. Modification of Dimensions: dimensions and part list
• Modify the dimensions of the elements on the • The component drawing is supplied to the shop floor
higher side, if required, based on the following for manufacturing purpose, while assembly drawing is
considerations: supplied to the assembly shop.
• Selection of standard parts available in the market. 10. Preparation of Design Report
• Convenience of assembly • Prepare design report containing details about step 1
• Convenience of Manufacturing. to step 8.
DESIGN CONSIDERATIONS
• Design considerations are the characteristics which • 7. Ergonomics
influence the design of the element or perhaps, the entire • 8. Aesthetics
system. Normally, a number of such characteristics have to
be considered in any design problem. • 9. Manufacturing
• In a given design problem, the design engineer should • 10. Conformance to Standards
identify the various design considerations and incorporate • 11. Assembly
them in the design process in their order of importance. • 12. Friction and Wear
• For example, in the design of a spring, two most significant • 13. Life
design considerations are strength and stiffness.
• 14. Vibrations
• Some of the common design considerations are as follows:
• 15. Thermal considerations
•
• 16. Lubrication
1. Strength
• 17. Maintenance
• 2. Rigidity
• 18. Flexibility
• 3. Reliability
• 19. Size and Shape
• 4. Safety
• 20. Stiffness
• 5. Cost
• 21. Corrosion
• 6. Weight
• 22. Noise
• A machine is not a genie, it does not work by magic, it does not
possess a will, and nothing comes out which has not been put in.
Discuss in relation to design factors
 Safety and reliability in machine element design
• Over a period of time, the level of safety achieved will connect directly with the stature of the initial design of
facilities, hardware, equipment, tooling operations layout, work environment, and work methods, and their
redesign as continuous improvement is sought. The design stage offers the greatest chance and most cost-
effective time to anticipate, analyze, eliminate, or control hazards.
• As a designer you can directly control safety. Designers must take account of the General Principles of Prevention
when preparing designs. The Principles of Prevention are a hierarchy or risk elimination and reduction.
The General Principles of Prevention are set out in descending order of preference as follows:
 Avoid risks.
 Evaluate unavoidable risks.
 Combat risks at source.
 Adapt work to the individual, especially the design of places of work
 Adapt the place of work to technical progress.
 Replace dangerous articles, substances, or systems of work by non-dangerous or less dangerous articles,
substances, or systems
 Use collective protective measures over individual measures
 Develop an adequate prevention policy
 Give appropriate training and instruction to employees.
 Reliability - The ability of an item to perform a required function under stated conditions for a stated period of
time. It is usually denoted as probability or as a success.
 The best approaches to the prevention of product liability are good engineering in analysis and design, quality
control, and comprehensive testing procedures.