Mechanical System

Design
Semester VII - Mechanical Engineering
(Pune University)

R. B. Patil
M.E. (Mech) (Design Engg.)
Head,
Department of Mechanical Engineering,
Army nstitute of !echnology,
Pune.
Mechanical System Design
". #. Patil
($emester % & Mechanical Engineering, Pune University)

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First Printed in India : 2uly 3445

Second Edition : 6ctoer 3447
Third Revised Edition : 2uly 3448
Fourth Revised Edition : August 3449
Reprint : August 34:4

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Scope of the Book…

UNIT - 1

• Design of Cylinders and Pressure essels !

Thick and thin cylinders - Thin cylindrical and spherical vessels - Lame's equation - Clavarino’s
and Birnie’s equations - Design of hydraulic and pneumatic cylinders - Autofrettage and
compound cylinders - asketed !oints in cylindrical vessels - "odes of failures in pressure vessels
- #nfired pressure vessels - Classification of pressure vessels as per $% &% () - Categories and
types of *elded !oints - +eld !oint efficiency - Corrosion, erosion and protection vessels - &tresses
induced in pressure vessels - "aterials of construction - Thickness of cylindrical and spherical
shells - Design of end closures as per code - o..les and /penings in pressure vessels -
0einforcement of openings in shell and end closures - Area compensation method - Types of 
vessel supports% "#efer Chapter $%

UNIT - $

• &pti'u' Design !

/1!ectives of optimum design - 2ohnson's "ethod of /ptimum Design 3"/D4 - Adequate and
optimum design - 5rimary, su1sidiary and limit equations - /ptimum design *ith normal and
redundant specifications of simple machine elements like 6 tension 1ar, transmission shaft, helical
spring% "#efer Chapter (%

UNIT ) (

• Design of *ly+heel !

Design of fly*heel - 7undamental equation of motion - Torque analysis - Disk and rimmed
fly*heels - &tresses in fly*heel rim and spokes - Design of disc and rimmed fly*heels for various
applications - &tandard dimensions of fly*heels% "#efer Chapter 1%

UNIT - ,

• Statistical Consideration in Design !

7requency distri1ution - 8istogram and frequency polygon - ormal distri1ution - #nits of 
measurement of central tendency and dispersion - &tandard varia1le - 5opulation com1inations -
Design and natural tolerances - Design of assem1ly - &tatistical analysis of tolerances -
"echanical relia1ility and factor of safety% "#efer Chapter ,%

• Design for anufacture !

eneral principles of design for manufacture and assem1ly 3D7" and D7A4 - 5rinciples of design
of castings and forgings - Design for machining - Design for po*der metallurgy - Design for 
*elding% "#efer Chapter .%

UNIT - /

• Design of 0ear Boes for achine Tool 2pplications !

Basic considerations in design of drives - Determination of varia1le speed range - raphical

representation of speed and structure diagram - Deviation diagram - 0ay diagram - &election of 
optimum ray diagram - Difference 1et*een num1er of teeth of successive gears in a change gear 
1o9 - Analysis of t*elve speed gear 1o9 : Compound ra y diagram% "#efer Chapter /%

• 2esthetic and 3rgono'ic Considerations in Design of Products !

Basic types of product forms - Designing for appearance - &hape, features, materials, finishes,
proportions, symmetry, contrast etc% - "organ's colour code - ;rgonomic considerations - 0elation
1et*een man, machine and environmental factors - Design of displays and controls - 5ractical
e9amples of products or equipments using ergonomic and aesthetic design principles%
"#efer Chapter 4%

UNIT - 5

• Design of aterial 6andling Syste's !

&ystem concept - Basic principles, /1!ectives of material handling system - #nit load and
containeri.ation%

Belt conveyors 6

7lat 1elt and troughed 1elt conveyors - Capacity of conveyor - 0u11er covered and fa1ric ply 1elts
- Belt tensions - Conveyor pulleys - Belt idlers - Tension take-up systems - 5o*er requirement of 
hori.ontal 1elt conveyors for frictional resistance of idlers and pulleys% "#efer Chapter 5%


 Preface

It gives a great pleasure to present this book on

‘Mechanical System Design’. This book has been
written for the third course in ‘Machine Design’
especially for the !nal year students of mechanical
engineering. This is the third book of the series on
‘Machine Design’ which comprehensively covers the
design of di"erent mechanical systems and various
aspects of system design used in engineering
applications. The main ob#ective of this book is to
bridge the gap between the reference books written
by the renowned international authors and the
re$uirements of undergraduate students.
 The book has been presented in a simple language
without compromising the $uality of te%t. The
concepts have been developed from the
fundamentals. The main emphasis has been given on
e%plaining the concepts rather than merely providing
the information. &very concept is illustrated with the
help of number of solved e%amples which are
arranged in the order of increasing degree of di'culty.
 The list of formulae has been given at the end of each
chapter for the ready reference. This book is an
outcome of the years of classroom interaction with the
students.
I would like to e%press my thanks to Shri. Sachin Shah
and Shri (radeep )unawat of ‘Tech*Ma% (ublications’
for their e"orts in publishing this book. My thanks are
due to all those people who have directly or indirectly
contributed to this book.
)ast but not least my special thanks go to all my
students whose continuous feedback while teaching
this sub#ect is the source of inspiration behind this
book.
+ feedback in the form of suggestions and comments
from the readers for further improvement of the book
will be highly appreciated.

1st October 2007 - R.B. Patil

To My

Daughter
Neha
&
- 2uthor