Dr.

Durmuş Ali BİRCAN

Introduction to
Introduction to Design of Machine Elements
ME 123 Principles of Mechanical Eng. (2+0)

Design of Machine
Elements

Assist. Prof.Dr. Durmuş Ali BİRCAN

 Dr. Durmuş Ali BİRCAN

Design is principally an original, cyclic and decision-making

process.
Design is to formulate a plan
to satisfy a particular need and
Introduction to Design of Machine Elements

to create something with a physical reality.

ME 123 Principles of Mechanical Eng. (2+0)

The number of factors need to be considered in design. For

example; design of a chair
(a) The purpose for which the chair is to be designed such as
whether it is to be used as an simple chair, an office chair or a dining
table chair.
(b) Whether the chair is to be designed for a grown up person or a
child.
(c) Material for the chair, its strength and cost need to be
determined.
(d) Finally, the aesthetics of the designed chair.
 Dr. Durmuş Ali BİRCAN

Decision making comes in every stage of design.

Consider two different cars. They may both be reasonable cars
and serve the same purpose but the designs are different.
Introduction to Design of Machine Elements

The designers consider different factors and come to certain

ME 123 Principles of Mechanical Eng. (2+0)

conclusions leading to an optimum design.

Market survey gives an indication of what people want.
Existing norms play an important role.
Once a critical decision is made, the rest of the design features
follow.
For example, once we decide the engine capacity, the shape and
size, then the subsequent course of the design would follow. A bad
decision leads to a bad design and a bad product.
 Dr. Durmuş Ali BİRCAN

The designed product must be

 Functional: fill a need or customer expectation
 Safe: not hazardous to users or public
Introduction to Design of Machine Elements

 Reliable: conditional probability that product will perform

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its intended function without failure to a certain age

 Competitive: contender in the market
 Usable: accommodates human size and strength
 Manufacturable: minimal number of parts and suitable for
production
 Marketable: product can be sold and serviced
The design process not only gives birth to a product but is also
responsible for its life and death.
 Dr. Durmuş Ali BİRCAN

Definition of machine:
A machine as a
combination of resisting bodies
Introduction to Design of Machine Elements

with successfully constrained relative motions

ME 123 Principles of Mechanical Eng. (2+0)

which is used to transform other forms of energy into

mechanical energy or transmit and modify available energy
to do some useful work.
The machines receive mechanical energy and modify it
so that a specific task is carried out, for example a hoist, a
bicycle.
 Dr. Durmuş Ali BİRCAN

Modification or transformation of energy requires a

number of machine elements, some small and some large.
Mechanical design process
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is a decision making process (often iterative)

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by using mathematics, scientific principles and technical

information along with innovations, ingenuity or imagination
to perform pre specified functions safely
with maximum economy and efficiency.
Design is…
 An innovative and iterative process
 A communication intensive activity
 Subject to constraints
 Dr. Durmuş Ali BİRCAN

In designing a machine component,

it is necessary to have a good knowledge of many subjects
such as;
Introduction to Design of Machine Elements

Mathematics,
ME 123 Principles of Mechanical Eng. (2+0)

Engineering Mechanics,
Strength of Materials,
Theory of Machines,
Manufacturing Processes and
Engineering Drawing.

A simple journal bearing involves fluid flow, heat

transfer, friction, energy transport, material selection,
thermo-mechanical treatments, statistical descriptions, and
so on.
 Dr. Durmuş Ali BİRCAN

Types of design
Adaptive design
This is based on existing design. For example, standard
products or systems adopted for a new application.
Introduction to Design of Machine Elements

This type of design needs no special knowledge or skill.

ME 123 Principles of Mechanical Eng. (2+0)

The designer only makes minor modifications in the existing

designs. Ex: Conveyor belts, control system of machines and
mechanisms.
Developmental design
Start with an existing design but, finally a modified design is
obtained. Ex: A new model of a car is a typical example.
 Dr. Durmuş Ali BİRCAN

New /Original / innovative design

This type of design is an entirely new one but based on
existing scientific principles.
No scientific invention is involved but requires lot of
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research, technical ability and creative thinking to solve a

ME 123 Principles of Mechanical Eng. (2+0)

problem.
Ex:Designing a small vehicle for transportation of men
and material on board a ship or in a desert.
Tesla’s Cybertruck
 Dr. Durmuş Ali BİRCAN

Types of design based on methods

a)Rational design

This is based on determining the stresses and strains of

Introduction to Design of Machine Elements

components and thereby deciding their dimensions. Design depends

ME 123 Principles of Mechanical Eng. (2+0)

upon mathematical formulae of principle of mechanics.

b)Empirical design

This is based on empirical formula which is based on

experience and experiments.

For example, when we tighten a nut on a bolt, the force

exerted or the stresses induced cannot be determined exactly but,
experience shows that the tightening force may be given by
P=2,84d where, d is the bolt diameter in mm and P is the applied
force in kg.
 Dr. Durmuş Ali BİRCAN

c) Industrial design: These are based on industrial

considerations and norms, market survey, external look,
production facilities, low cost, use of existing standard
products.
Introduction to Design of Machine Elements

(d) Optimum design: It is the best design for the given objective
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function under the specified constraints. It may be achieved by

minimising the undesirable effects.
(e) System design: It is the design of any complex mechanical
system like a car engine.
(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.
 Dr. Durmuş Ali BİRCAN

Factors to be considered in machine design:

(a)What device or mechanism to be used?
(b)Selection of materials
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(c)Loading
(d)Size, shape, space requirements and weight
ME 123 Principles of Mechanical Eng. (2+0)

(e)Manufacture
(f)How will it operate
(g)Reliability and safety
(h)Maintenance, cost and aesthetics
(i) Safety of operation
(j) Workshop facilities
(k)Number of machines to be manufactured
(l) Cost of construction (production)
(m)Assembly
 Dr. Durmuş Ali BİRCAN

(a) What device or mechanism to be used?

 Decide the relative arrangement of the constituent elements.
Introduction to Design of Machine Elements

 This is best judged by understanding the problem thoroughly.

ME 123 Principles of Mechanical Eng. (2+0)

 Sometimes a particular function can be achieved by using

different mechanisms and the designer has to decide which
one is most effective under the working conditions.

Belt/Chain/Cam
 Dr. Durmuş Ali BİRCAN

b). Selection of materials. It is essential that a designer should

have a knowledge of the properties of the materials and their
behaviour under working conditions.
Some of the important characteristics of materials are:
Introduction to Design of Machine Elements

durability,
ME 123 Principles of Mechanical Eng. (2+0)

strength,
flexibility,
weight,
resistance to heat,
resistance to corrosion,
ability to cast,
ability to welded or hardened,
machinability,
electrical conductivity, etc.
 Dr. Durmuş Ali BİRCAN

A wrong selection of material may lead to failure, over or

undersized product or expensive items.
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The choice of materials is depend on suitable properties of

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the material for each component, their suitability of fabrication

or manufacture and the cost.

c)Load

The external loads cause internal stresses in the elements

and these stresses must be determined accurately since these
will be used in determining the component size.
 Dr. Durmuş Ali BİRCAN

Loading may be due to:

i) Energy transmission by a machine member,
ii) Dead weight,
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iii) Inertial forces,

ME 123 Principles of Mechanical Eng. (2+0)

iv) Thermal effects,

v) Frictional forces.
In other ways loads may be classified as:

i) Static load: Does not change in

magnitude and direction and normally
increases gradually to a steady value.
 Dr. Durmuş Ali BİRCAN

ii) Dynamic load-

a) changes in magnitude- Ex:
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traffic of varying weight passing

a bridge.
ME 123 Principles of Mechanical Eng. (2+0)

b) changes in direction- Ex: load

on piston rod of a double acting
cylinder.
c) Vibration and shock loading
 Dr. Durmuş Ali BİRCAN

d)Size, shape, space requirements and weight

Preliminary analysis would give an approximate size but if a
standard element is to be chosen, the next larger size must be
taken.
Introduction to Design of Machine Elements
ME 123 Principles of Mechanical Eng. (2+0)

Shapes of standard elements are known but for non-

standard element, shapes and space requirements must depend on
available space in a particular machine assembly.
A scale layout drawing (Draft) is often useful to arrive at an
initial shape and size.
Weight is important depending on application.
For example, an aircraft must always be made light. This
means that the material chosen must have the required strength
yet it must be light. Similar arguments apply to choice of material
for ships.
 Dr. Durmuş Ali BİRCAN

The use of standard parts is closely related to cost, because

the cost of standard or stock parts is only a fraction of the cost
of similar parts made to order.
Introduction to Design of Machine Elements

The standard or stock parts should be used whenever

ME 123 Principles of Mechanical Eng. (2+0)

possible; parts for which patterns are already in existence such as

gears, pulleys and bearings and parts which may be selected from
regular shop stock such as screws, nuts and pins.
Bolts and studs should be as few as possible to avoid the
delay caused by changing drills, reamers and taps and also to
decrease the number of wrenches required.
 Dr. Durmuş Ali BİRCAN

e)Manufacture

Designed elements may be manufactured with ease, within the

available facilities and at low cost.
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f)How will it operate

ME 123 Principles of Mechanical Eng. (2+0)

In the final stage of the design, a designer must ensure that the
machine may be operated with ease.

In many power operated machines it is simply a matter of

pressing a knob or switch to start the machine.

However in many other cases, a sequence of operations is to be

specified. This sequence must not be complicated and the
operations should not require excessive force.

Consider the starting, accelerating and stopping a car.

 Dr. Durmuş Ali BİRCAN

g) Reliability and safety

A designed machine should work effectively and reliably.
Introduction to Design of Machine Elements

The probability that an element or a machine will not fail in use

is called reliability.
ME 123 Principles of Mechanical Eng. (2+0)

Reliability lies between 0 ≤ R< 1.

Possible overloading, wear of elements, excessive heat
generation and other such detrimental factors must be avoided.
There is no single answer for this but, an overall safe design
approach and care at every stage of design would result in a
reliable machine.
Industrial regulations ensure that the manufacturer is liable
for any damage or harm arising out of a defective product.
 Dr. Durmuş Ali BİRCAN

i) Maintenance, cost and aesthetics

Good maintenance ensures good running condition of machinery.
Often a regular maintenance schedule is maintained and a thorough
check up of moving and loaded parts is carried out to avoid
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catastrophic failures.
ME 123 Principles of Mechanical Eng. (2+0)

Low friction and wear is maintained by proper lubrication. This is a

major aspect of design since wherever there are moving parts, friction
and wear are inevitable.
High friction leads to increased loss of energy. Wear of machine
parts leads to loss of material and premature failure.
Cost and aesthetics are essential considerations for product
design.
Cost is essentially related to the choice of materials which in turn
depends on the stresses developed in a given condition.
Although in many cases aesthetic considerations are not essential
aspects of machine design, ergonomic aspects must be taken into
considerations.
 Dr. Durmuş Ali BİRCAN

j. Safety of operation
Some machines are dangerous to operate, especially those
which are speeded up to insure production at a maximum rate.
Therefore, any moving part of a machine which is within
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the zone of a worker is considered an accident hazard and may be

ME 123 Principles of Mechanical Eng. (2+0)

the cause of an injury. It is, therefore, necessary that a designer

should always provide safety devices for the safety of the
operator.
k. Workshop facilities
A design engineer should be familiar with the limitations of
his employer’s workshop, in order to void the necessity of having
work done in some other workshop.
It is sometimes necessary to plan and supervise the
workshop operations and to draft methods for casting, handling
and machining special parts.
 Dr. Durmuş Ali BİRCAN

k. Number of machines to be manufactured

The number of machines to be manufactured affects the

design in a number of ways. The engineering and shop costs which
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are called fixed charges or overhead expenses are distributed

ME 123 Principles of Mechanical Eng. (2+0)

over the number of machines to be manufactured.

If only a few machines are to be made, extra expenses are

not justified unless the machine is large or of some special design.

An order calling for small number of the product will not

permit any undue expense in the workshop processes, so that the
designer should restrict his specification to standard parts as
much as possible.
 Dr. Durmuş Ali BİRCAN

k. Cost of construction (Production)

The cost of construction of an machine is the most
important consideration involved in design. In some cases, it is
quite possible that the high cost of an machine may immediately
Introduction to Design of Machine Elements

bar it from further considerations.

ME 123 Principles of Mechanical Eng. (2+0)

The aim of design engineer under all conditions, should be to

reduce the manufacturing cost to the minimum.
m. Assembling
Every machine or structure must be assembled as a unit before
it can function.
Large units must often be assembled in the shop, tested and
then taken to be transported to their place of service.
The final location of any machine is important and the design
engineer must anticipate the exact location and the local facilities
for installation.
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Introduction to Design of Machine Elements

Phases and steps in Engineering Design Process

Dr. Durmuş Ali BİRCAN
 ME 123 Principles of Mechanical Eng. (2+0)
Introduction to Design of Machine Elements
Position of Design in Product Lifecycle
Dr. Durmuş Ali BİRCAN
 Dr. Durmuş Ali BİRCAN

The Four C’s of design:

 Creativity: requires creation of something that has not
existed before or not existed in the designer’s mind before.
Introduction to Design of Machine Elements

 Complexity: requires decisions on many variables and

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parameters.
 Compromise: requires balancing multiple and sometimes
conflicting requirements.
 Choice: requires making choices between many possible
solutions at all levels, from basic concepts to smallest detail
of shape.
 Dr. Durmuş Ali BİRCAN

General Procedure in Machine Design

In designing machine components, there is no rigid rule. The
problem may be solved in several ways.
Introduction to Design of Machine Elements
ME 123 Principles of Mechanical Eng. (2+0)
 Dr. Durmuş Ali BİRCAN

The process begins with an identification of a need and a

decision to do something about it.
Introduction to Design of Machine Elements

After many iterations (repetitive and revisions), the process

ME 123 Principles of Mechanical Eng. (2+0)

ends with the presentation of the plans for satisfying the need.

Depending on the nature of the design task, several design

phases may be repeated throughout the life of the product,
from setting up to termination.
 Dr. Durmuş Ali BİRCAN

1.Recognition of need. First of all, make a complete statement of the

problem, indicating the need, aim or purpose for which the machine is to be
designed.
 In some cases the designer may have to invent a product. An example
Introduction to Design of Machine Elements

might be a game for blind persons.

ME 123 Principles of Mechanical Eng. (2+0)

 At other times the designer may change an existing design. (If the
handle of a pot becomes too hot to touch, it must be redesigned.)
 Designers also improve existing products. They make the product work
even better. Could the chair in the waiting room of a bus or train station
be altered so that waiting seems shorter?
For example, the need to do something about a food-packaging machine
may be indicated by:
the noise level,
variation in package weight, and
variations in the quality of the packaging or wrap.
 Dr. Durmuş Ali BİRCAN

2. Synthesis (Mechanisms). Select the possible mechanism or

group of mechanisms which will give the desired motion.
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3. Analysis of forces. Find the forces acting on each member of

ME 123 Principles of Mechanical Eng. (2+0)

the machine and the energy transmitted by each member.

4. Material selection. Select the material best suited for each

member of the machine.

5. Design of elements (Size and Stresses). Find the size of each

member of the machine by considering the force acting on the
member and the permissible stresses for the material used.

It should be kept in mind that each member should not

deflect or deform than the permissible limit.
 Dr. Durmuş Ali BİRCAN

6. Modification. Modify the size of the member to agree with

the past experience and judgement to facilitate manufacture.
The modification may also be necessary by consideration of
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manufacturing to reduce overall cost.

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7. Detailed drawing. Draw the detailed drawing of each

component and the assembly of the machine with complete
specification for the manufacturing processes suggested.
8. Production. The component, as per the drawing, is
manufactured in the workshop.
 Dr. Durmuş Ali BİRCAN

Usually, quite a number of such characteristics must be considered

and ordered in priority in a given design situation. Many of the important
ones are as follows (not necessarily in order of importance):

1. Functionality
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2. Strength/Stress 15. Styling

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3. Distortion/Deflection/Stiffness 16. Shape

4. Wear 17. Size
5. Corrosion 18. Control
6. Safety 19. Thermal properties
7. Reliability 20. Surface
8. Manufacturability 21. Lubrication
9. Utility (Usefulness, 22. Marketability
Effectiveness & Convenience) 23. Maintenance
10. Cost 24. Volume
11. Friction (Energy) 25. Liability
12. Weight 26. Remanufacturing/Resource
13. Life recovery
14. Noise
 Dr. Durmuş Ali BİRCAN

Designing action steps

Understand the problem clearly
Introduction to Design of Machine Elements

Identify what are known

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Identify what are unknown and formulate solution

strategy
State all assumptions and decisions
Analyze the problem with the solution strategy
Evaluate your solution (Is it sound good for real
life?)
Present your solution
 Dr. Durmuş Ali BİRCAN

Understand the problem

Problem definition is probably the most significant step
in the engineering design process. Carefully, collect all
Introduction to Design of Machine Elements

information from all involved persons.

ME 123 Principles of Mechanical Eng. (2+0)

After that: read, understand, and refine the problem

statement.

Identify the known

From the refined problem statement, describe
concisely what information is known and relevant.
Identify the unknown and formulate the solution strategy
State what must be determined, in what order, so as to
arrive at a solution to the problem
 Dr. Durmuş Ali BİRCAN

For example for the pallet-moving device include aspects

for consideration such as:

What sizes of pallet are to be moved?

Introduction to Design of Machine Elements

What is the maximum mass on the pallet?

ME 123 Principles of Mechanical Eng. (2+0)

What is the maximum size of the load on the pallet?

What range of materials are to be moved and are they
packaged?

What maximum height must the pallet be lifted?

 Dr. Durmuş Ali BİRCAN

Is a particular energy source/fuel to be used?

What area must the pallet-moving device operate on?
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What range is required for the pallet-moving device?

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What lifetime is required?

Are there manufacturing constraints to be considered?
What is the target sales price?
How many units can the market sustain?
Is the device to be automatic or manned?
What legal constraints need to be considered?
 Dr. Durmuş Ali BİRCAN

Sketch the component or system under investigation,

identifying known and unknown parameters.
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Create a flowchart of the steps necessary to reach the

ME 123 Principles of Mechanical Eng. (2+0)

final solution.
The steps may require the use of free-body diagrams;
material properties from tables; equations etc. from
first principles, textbooks, or handbooks relating the
known and unknown parameters; experimentally or
numerically based charts; specific computational tools
 Dr. Durmuş Ali BİRCAN

State all assumptions and decisions

Real design problems generally do not have unique,
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ideal, closed-form solutions.

ME 123 Principles of Mechanical Eng. (2+0)

Selections, such as choice of materials, and heat

treatments, require decisions.

Analyses require assumptions related to the

modelling of the real components or system.

All assumptions and decisions should be identified

and recorded.
 Dr. Durmuş Ali BİRCAN

Analyze the problem

Using your solution strategy in conjunction with
your decisions and assumptions, execute the analysis
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of the problem.

 Reference the sources of all equations, tables,

charts, software results, etc. Check the reliability
of your results.

Check the order of magnitude, dimensionality,

trends, signs, etc.
 Dr. Durmuş Ali BİRCAN

Evaluate your solution

Evaluate each step in the solution, nothing how

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changes in strategy, decisions, assumptions, and

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execution might change the results, in positive or

negative ways.

If possible, incorporate the positive changes in

your final solution.
 Dr. Durmuş Ali BİRCAN

Present your solution

Here, is where your communication skills are important.

At this point, you are selling yourself and your technical
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abilities. If you cannot capable of explaining what you have

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done, some or all of your work may be misunderstood and

unaccepted.

Know your audience.

All design processes are interactive and
iterative. Thus, it may be necessary to repeat some
or all of the above steps more than once if less than
satisfactory results are obtained.