Machine Elements in

Design
 Presentation Outline
 Overview
 Subject Content
 References
 Introduction and Basic Design Considerations

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3
 Overview

Subject : Machine Elements in Design

Subject Code : ME 3123
Credit Rating : 03 GPA
Time Allocated : 50 hrs.
Lectures: 40 hrs.
CAS : 10 hrs.

Evaluation : End Examination: 70%

CAS : 30%
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 Learning Outcomes
 LO1: Define key terms in design and explain
the design process
 LO2: Select materials in design machine
components
 LO3: Analyse stresses in mechanical
components under different loading conditions
 LO4: Design different types of machine
elements
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 Subject Content
 Introduction and Basic design considerations
 Materials and their properties
 Design Methodology
 Stresses in machine elements
 Modes of failure
 Assembly of machine elements
 Mechanical power transmission elements
 Design of other machine elements
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 References

 Design of Machine Elements by V B

Bhandari, Tata McGraw-Hill Education,
ISBN: 9780070681798

 A Text Book of Machine Design (SI Units)

by R S Khurmi & J K Gupta, Eurasia
Publishing House (Pvt.) Ltd., ISBN:
8121925371, 9788121925372
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 Introduction and Basic Design
Considerations

• Machine design is defined as the use of scientific

principles, technical information and imagination in
the description of a machine or a mechanical
system to perform specific functions with maximum
economy and efficiency

• Machine design is the creation of new and better

machines and also improving the existing ones
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 Introduction contd..
• A designer may utilize fundamentals of basic
engineering sciences including, Engineering
mechanics, Theory of machines, Mechanics of
materials, Thermodynamics, Fluid mechanics,
Workshop Technology, etc.

• Technical information related to the basic elements

of machines including, power transmission devices,
fastening devices, supporting devices etc. are also
made use of
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 Introduction contd..
• Imagination and innovation to produce appropriate
configurations, with combination of different
machine elements.
• Generate specifications for the individual machine
elements and to the entire assembly according to
the configuration.
• Generate production and assembly drawings for
the machine as per manufacturing processes
needed and assembly of machine elements to be
carried out.
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 Basic Requirements of Machine
Elements

• The broad objective is to ensure that the

machine element preserves its operating
capacity during the stipulated service life with
minimum operating costs.

• In order to achieve this objective, the

machine element should satisfy several basic
requirements.
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 Basic Requirements of Machine
Elements contd..

• Strength: A machine component should not fail

under the influence of the forces that act upon it
during its operation. It should have sufficient
strength to avoid failure either due to fracture or
due to yielding.

• Rigidity: A machine component should be rigid

against forces and moments that act upon it. In this
case maximum permissible deflection and
permissible angle of twist are the criteria for design.
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 Basic Requirements of Machine
Elements contd..

• Wear Resistance: Wear and tear is the main cause

that makes the machine element out of order or
reduces its useful life. Wear also leads to the loss
of accuracy of machine tools. It may be due to
abrasive wear, corrosive wear and pitting.

• Manufacturability: This is the ease of fabrication

and assembly of the machine element with
minimum manufacturing cost.
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 Basic Requirements of Machine
Elements contd..

• Safety: The designer should consider worst

possible scenario of operation during the design of
the machine element and should ensure that it fails
safe.

• Conformance to standards: A machine element

should conform to the National or International
standards with respect to its profile, dimensions,
quality etc.
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 Basic Requirements of Machine
Elements contd..
• Reliability: Reliability is the probability that a machine
element will perform its intended functions under
desired operating conditions over a specified period
of time.

• Maintainability: A machine element should be

maintainable (serviced or repaired) with ease.

• Minimum Life Cycle Cost: Life cycle cost of the

machine element is the total cost to be incurred for
purchasing, operating and maintaining it over its life
span. 15
 Basic Design Procedure of Machine
Elements

• The basic design procedure consists of a

step-by-step approach starting from
functional requirement of the machine
element to the working drawings of the final
product.

• The steps of the process are interrelated and

interdependent, each reflecting and affecting
all the other steps.
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 Basic Design Procedure of Machine
Elements contd..
• Step 1: Specify functions of machine element
 The design process begins with the specification of
the intended functions of the machine element.
 For example,
1. A Gear wheel to transfer the required torque (Nm)
and power (kW) at the correct speed (rpm).
2. A Shaft to transfer the required torque and power in
a machine.
3. A Bearing to support the rotating shaft and confine
its motion. 17
 Basic Design Procedure of Machine
Elements contd..
• Step 2: Determination of forces
 A free body diagram of forces is constructed to
determine the forces acting on different parts of the
machine element.

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 Basic Design Procedure of Machine
Elements contd..
• Step 2: Determination of forces contd.. - The
external and internal forces that act on machine
elements include:
 Torsional forces due to power transmitted by the
machine element.
 Static forces due to self weight of machine
elements
 Forces due to frictional resistance
 Inertia forces due to change in linear or angular
velocity
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 Basic Design Procedure of Machine
Elements contd..
• Step 2: Determination of forces contd..
 Centrifugal forces due to change in direction of
velocity
 Forces due to thermal gradients or stresses
 Forces setup during manufacture of the machine
element, resulting in residual stresses.
 Forces exerted by stress concentration due to
abrupt change in cross section or surface
roughness.
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 Basic Design Procedure of Machine
Elements contd..

• Step 3: Failure Criteria

 The machine element is said to have failed when it
is unable to perform its functions as specified.

 The basic types of failure are:

1. Failure by elastic deflection
2. Failure by general yielding
3. Failure by fracture
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 Basic Design Procedure of Machine
Elements contd..

• Step 4: Selection of materials

 Basic factors to be considered in this regard
1. Availability
2. Cost
3. Mechanical Properties
4. Manufacturing Considerations

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 Basic Design Procedure of Machine
Elements contd..

• Step 5: Determination of specifications

 Specification of the machine element depends
upon:
1. Operating conditions
2. Specification of the adjoining machine element

 Geometrical dimensions of the machine element

are determined on the basis of failure criteria.
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 Basic Design Procedure of Machine
Elements contd..

• Step 5: Determination of specifications contd.

 Determination of geometrical dimensions is an
important step in design of machine elements.
 This is done as per following different criteria:
1. Yield Strength
2. Ultimate Tensile Strength
3. Torsional Strength
4. Allowable Lateral Deflection
5. Endurance Limit 24
 Basic Design Procedure of Machine
Elements contd..
• Step 6: Design Modifications
 Geometrical dimensions of the machine element are
modified based on the assembly and manufacturing
considerations.
 Revised calculations are carried out for operating
capacity, margin of safety at critical cross sections
and resultant stresses, taking into consideration the
effect of stress concentration.
 The process is continued until the desired values and
corresponding geometrical dimensions are obtained.
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 Basic Design Procedure of Machine
Elements contd..

• Step 7: Generate Working Drawings

 Last step in the design of a machine element is to
prepare a set of working drawings indicating the
dimensions, tolerances, surface texture, special
manufacturing requirements etc.
 The working drawings must be clear, concise and
complete.
 It must have adequate number of views and cross-
sections to show all details.
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 Design Analysis
 In design analysis, the designer assumes, a
particular mechanism, a particular material and
mode of failure for the component.

 With this information, designer determines the

dimensions of the product.

 There may exist several workable designs of the

same machine element.
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 Design Synthesis
 Design synthesis is defined as the process of
creating or selecting configurations, materials,
shapes and dimensions for a product for optimizing
its performance.
 It is a decision making process with the main
objective of optimization.
 The designer selects the optimum design /
configuration from a number of alternative working
designs.
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 Design Synthesis contd..
 Material for the machine element is decided from a
number of alternative materials.
 Optimum shape and dimensions of the machine
element are determined on the basis of
mathematical analysis.
 In design synthesis, the designer has to establish
the objective to be optimized.
 The objective can be minimum cost, minimum
weight or volume or maximum life time.
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 Design Synthesis contd..
 Then the mathematical formulation of the set
objectives and requirements is done.
 Optimization is carried out through mathematical
analysis.
 Finally the results are interpreted in terms of
geometrical dimensions, materials, shape and
other related parameters.
 Generation of the optimum design is ensured
through design synthesis.
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Ergonomic Considerations in Design

 Ergonomics is defined as the relationship between

man and machine and the application of
anatomical, physiological, and psychological
principles to solve the problems arising from man-
machine relationship.

 The aim of ergonomics is to reduce the operational

difficulties present in man-machine systems and
thereby, reduce the resulting physical and mental
stresses.
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 Concurrent Engineering
 Conventional design process is sequential, where
the main activities are executed in a sequence.

 At present, there is a fundamental shift in the way

the design process is implemented.

 The sequential design process is being replaced

by simultaneous or concurrent engineering, where
various activities are carried out in parallel, instead
of in series.
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 Concurrent Engineering contd..

 The trend is to bring the design and manufacturing

activities together as a single engineering
discipline.
 Concurrent Engineering is defined as the design
process that brings both design and manufacturing
engineers together during the early phase of the
design process.
 In this process a team of specialists examines the
design from different perspectives.
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Concurrent Engineering contd..
Customer
Requirements

Sales &
Manufacturability
Servicing

Design
Engineering
Reliability,
Cost Maintainability
and Safety

Ergonomics and
Aesthetics
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 Concurrent Engineering contd..

 They consider various aspects of the product such

as feasibility, manufacturability, reliability,
performance, maintainability, safety and cost.
 Aforementioned aspects are simultaneously
considered early in the design stage.
 This results in less modifications of the design at a
later stage and reduces the time interval from
conceptual stage to marketing stage.
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