Ubaidillah, ST.,M.

Sc
ubaid.ubaidillah@gmail.com

 Machine design is the creation of new and better machines

and improving the existing one especially in terms of

economical and overall cost product and operation.
In designing a machine component, it is necessary to have
a good knowledge of many subject such as Mathematics,
Engineering Mechanics, Strength of Material, Workshop
Process and Technical Drawing

PRODUCT POINT OF
VIEW

Adaptive Design

Concern with
adaptation of existing
design

Development Design

Need scientific training

and design ability to
modify existing design
into a new idea

New Design

Needs lot of researches,

creative thinking and
technical ability

METHOD POINT
OF VIEW

Rational Design

Mathematical formulae of principle mechanics

Empirical Design

Empirical formulae based on the practice and past experience

Industrial Design

The production aspect to manufacture any machine component in

industry

Optimum design

The best design for the given objective function under specific
constrain

System Design

Complex mechanical system

Element Design

Design of any machine elements

Computer Aided
Design

The use of computer system to assist in creation, modification,

analysis and design optimisation

Type of load and stresses caused by the load

Motion of the parts or kinematics of the machine
Selection of materials
Form and size of the parts
Frictional resistance and lubrication
Convenient and economical feature
Use of standard part
Safety operation
Workshop facilities
Number of machines to be manufactured
Cost of construction
Assembling

 Bricks and glass do not deform and break easily.

Rubber bands deform a lot but return to their original

shape
A paper clip easily deforms but does not easily return
to its original shape
The thicker something is, the more force we have to
exert to get it to break

 The knowledge of materials and their properties is of great

significance for design engineer.

The machine elements should be made of such a material
which has properties suitable for the conditions of
operation
A design engineer must be familiar the effects which the
material processes and heat treatment have on the
properties of the materials

Ferrous material
(Iron, steel)
Metals and their
alloys
ENGINEERING
MATERIALS
Non-metals

Non-ferrous
material (copper,
aluminum, and
etc.)
Glass, rubber,
plastic and etc

Availability of the materials

Selection Factors

Sustainability of the materials for the

working condition

The cost of the materials

 Strength. The ability of a material to resist the externally applied

force without yielding

Stiffness. The ability of material to resist deformation under
stress. The modulus of elasticity is the measure of stiffness
Elasticity. The property of material to regain its original shape
after deformation when the external forces are removed
Plasticity. Property of material which retains the deformation
produces under load permanently.
Ductility. The property of material enabling it to be drawn into
wire with the application of a tensile force. It must be both
strong and plastic. It is measured by the terms percentage
elongation and percentage reduction area in a tensile test

 Brittleness. Opposite to ductility, breaking of a material

with little permanent distortion

Malleability. A special case of ductility which permits
materials to be rolled or hammered into thin sheets
Toughness. The property of material to resist fracture due
to high shock or impact loads like hammer blows.
Machinability. Property of material which refers to a
relative case with which a material can be cut.
Resilience. The property of material to absorb energy and
to resist shock and impact loads

 Creep. When a part is subjected to a constant stress at high

temperature for a long period of time, it will undergo a

slow and permanent deformation
Fatigue. When a material is subjected to repeated stresses,
it fails at stresses below the yield point stresses
Hardness. It is a very important property of the metals and
has a wide variety of meanings such as resistance to wear,
scratching, deformation and machinability.

Engineering Materials

Materials

Ferrous metals: carbon-, alloy-, stainless-, tool-and-die steels

Non-ferrous metals: aluminum, magnesium, copper, nickel,
titanium, superalloys, refractory metals,
beryllium, zirconium, low-melting alloys,
gold, silver, platinum,
Plastics: thermoplastics (acrylic, nylon, polyethylene, ABS,)
thermosets (epoxies, Polymides, Phenolics, )
elastomers (rubbers, silicones, polyurethanes, )
Ceramics, Glasses, Graphite, Diamond, Cubic Boron Nitride
Composites: reinforced plastics, metal-, ceramic matrix composites
Nanomaterials, shape-memory alloys, superconductors,

Properties of materials

Mechanical properties of materials

Strength, Toughness, Hardness, Ductility,
Elasticity, Fatigue and Creep

Physical properties
Density, Specific heat, Melting and boiling point,
Thermal expansion and conductivity,
Electrical and magnetic properties

Chemical properties
Oxidation, Corrosion, Flammability, Toxicity,

 Chemical composition

Mechanical properties Strength, hardness (under

various conditions: temperature, humidity, pressure)

Physical properties density, optical, electrical,
magnetic
Environmental green, recycling

 Ferrous Metals
Cast irons
Steels
Super alloys
Iron-based
Nickel-based
Cobalt-based

Non-ferrous metals
Aluminum and its alloys
Copper and its alloys
Magnesium and its alloys
Nickel and its alloys
Titanium and its alloys
Zinc and its alloys
Lead & Tin
Refractory metals
Precious metals

 Ferrous alloys are useful metals in terms

of mechanical, physical and chemical
properties.
Alloys contain iron as their base metal.
Carbon steels are least expensive of all
metals while stainless steels is costly.

Carbon steels
Classified as low, medium and high:
1. Low-carbon steel or mild steel, <
0.3%C, bolts, nuts and sheet plates.
2. Medium-carbon steel, 0.3% ~ 0.6%C,
machinery, automotive and agricultural
equipment.
3. High-carbon steel, > 0.60% C, springs,
cutlery, cable.

Alloy steels
Steels containing significant amounts of
alloying elements.
Structural-grade alloy steels used for
construction industries due to high strength.
Other alloy steels are used for its strength,
hardness, resistance to creep and fatigue, and
toughness.
It may heat treated to obtain the desired
properties.

High-strength low-alloy steels

Improved strength-to-weight ratio.
Used in automobile bodies to reduce
weight and in agricultural equipment.
Some examples are:
1. Dual-phase steels
2. Micro alloyed steels
3. Nano-alloyed steels

 Characterized by their corrosion resistance,

high strength and ductility, and high
chromium content.
Stainless as a film of chromium oxide protects
the metal from corrosion.


1.
2.
3.
4.
5.

Five types of stainless steels:

Austenitic steels
Ferritic steels
Martensitic steels
Precipitation-hardening (PH) steels
Duplex-structure steels

TABLE 5.1
Product
Aircraft forgings,
tubing, fittings
Automobile bodies
Axles
Ball bearings and races
Bolts
Camshafts
Chains (transmission)
Coil springs
Connecting rods
Crankshafts (forged)

Steel

Product

Steel

4140, 8740

Differential gears
Gears (car and truck)
Landing gear
Lock washers
Nuts
Railroad rails and wheels
Springs (coil)
Springs (leaf)
Tubing
Wire
Wire (music)

4023
4027,
4140,
1060
3130
1080
1095,
1085,
1040
1045,
1085

1010
1040, 4140
52100
1035, 4042, 4815
1020, 1040
3135, 3140
4063
1040, 3141, 4340
1045, 1145, 3135, 3140

4032
4340, 8740

4063, 6150
4063, 9260, 6150
1055

TABLE 5.2 Typical Mechanical Properties of Selected Carbon and Alloy Steels in the Hot-Rolled,
Normalized, and Annealed Condition
AISI

Condition

1020

As-rolled
Normalized
Annealed
As-rolled
Normalized
Annealed
Normalized
Annealed
Normalized
Annealed
Normalized
Annealed

1080
3140
4340
8620

Ultimate
tensile
strength
(MPa)
448
441
393
1010
965
615
891
689
1279
744
632
536

Yield
Strength
(MPa)

Elongation in
50 mm (%)

Reduction of
area (%)

Hardness
(HB)

346
330
294
586
524
375
599
422
861
472
385
357

36
35
36
12
11
24
19
24
12
22
26
31

59
67
66
17
20
45
57
50
36
49
59
62

143
131
111
293
293
174
262
197
363
217
183
149

TABLE 5.3
Yield Strength
psi x 10
35
40
45
50
60
70
80
100
120
140

Chemical
Composition

Deoxidation
Practice

MPa
240
275
310
350
415
485
550
690
830
970

S = structural alloy

F = killed plus sulfide inclusion control

X = low alloy
K = killed
W = weathering
O = nonkilled
D = dual phase

TABLE 5.4 Room-Temperature Mechanical Properties and Typical Applications of Selected Annealed
Stainless Steels
Ultimate
tensile
Yield
Elongation
AISI
strength
strength
in 50 mm
(UNS)
(MPa)
(MPa)
(%)
Characteristics and typical applications
303
550620
240260
5350
Screw machine products, shafts, valves, bolts,
(S30300)
bushings, and nuts; aircraft fittings; bolts; nuts;
rivets; screws; studs.
304
(S30400)

565620

240290

6055

Chemical and food processing equipment,

brewing equipment, cryogenic vessels, gutters,
downspouts, and flashings.

316
(S31600)

550590

210290

6055

High corrosion resistance and high creep strength.

Chemical and pulp handling equipment,
photographic equipment, brandy vats, fertilizer
parts, ketchup cooking kettles, and yeast tubs.

410
(S41000)

480520

240310

3525

416
(S41600)

480520

275

3020

Machine parts, pump shafts, bolts, bushings, coal

chutes, cutlery, tackle, hardware, jet engine parts,
mining machinery, rifle barrels, screws, and
valves.
Aircraft fittings, bolts, nuts, fire extinguisher
inserts, rivets, and screws.

 Designed for high strength, impact

toughness, and wear resistance at a range
of temperatures.

TABLE 5.5
Type
High speed
Hot work
Cold work
Shock resisting
Mold steels
Special purpose
Water hardening

AISI
M (molybdenum base)
T (tungsten base)
H1 to H19 (chromium base)
H20 to H39 (tungsten base)
H40 to H59 (molybdenum base)
D (high carbon, high chromium)
A (medium alloy, air hardening)
O (oil hardening)
S
P1 to P19 (low carbon)
P20 to P39 (others)
L (low alloy)
F (carbon-tungsten)
W

TABLE 5.6 Processing and Service Characteristics of Common Tool and Die Steels
Resistance to
decarburization
Medium
High
Low
Medium
Medium
Medium

Resistance to
cracking
Medium
High
Medium
Highest
Highest
Highest

Approximate
hardness
(HRC)
6065
6065
6065
3855
5762
3556

Machinability
Medium
Medium
Medium
Medium to high
Medium
Medium

Toughness
Low
Low
Low
Very high
Medium
High

Resistance to
softening
Very high
Very high
Highest
High
High
High

D2

Medium

Highest

5461

Low

Low

High

D3
H21

Medium
Medium

High
High

5461
3654

Low
Medium

Low
High

High
High

H26
P20

Medium
High

High
High

4358
2837

Medium
Medium to high

Medium
High

Very high
Low

P21
W1, W2

High
Highest

Highest
Medium

3040
5064

Medium
Highest

Medium
High

Medium
Low

AISI
designation
M2
T1
T5
H11, 12, 13
A2
A9

Source: Adapted from Tool Steels, American Iron and Steel Institute, 1978.

Resistance to
wear
Very high
Very high
Very high
Medium
High
Medium to
high
High to very
high
Very high
Medium to
high
High
Low to
medium
Medium
Low to
medium


1.
2.
3.
4.
5.

Factors for selecting are:

High strength to weight ratio
Resistance to corrosion
High thermal and electrical conductivity
Ease of Machinability
Non-magnetic

 Magnesium (Mg) is the lightest metal.

Alloys are used in structural and nonstructural applications.
Typical uses of magnesium alloys are aircraft
and missile components.
Also has good vibration-damping
characteristics.

 Copper alloys have electrical and

mechanical properties, corrosion
resistance, thermal conductivity and wear
resistance.
Applications are electronic components,
springs and heat exchangers.
Brass is an alloy of copper and zinc.
Bronze is an alloy of copper and tin.

 Nickel (Ni) has strength, toughness, and

corrosion resistance to metals.
Used in stainless steels and nickel-base
alloys.
Alloys are used for high temperature
applications, such as jet-engine components
and rockets.

 Superalloys are high-temperature alloys

use in jet engines, gas turbines and
reciprocating engines.

 Titanium (Ti) is expensive, has high strengthto-weight ratio and corrosion resistance.
Used as components for aircrafts, jet-engines,
racing-cars and marine crafts.

 Refractory metals have a high melting point

and retain their strength at elevated
temperatures.

Applications are electronics, nuclear power

and chemical industries.
Molybdenum, columbium, tungsten, and
tantalum are referred to as refractory metal.

1. Beryllium
2. Zirconium
3. Low-melting-point metals:
- Lead
- Zinc
- Tin
4. Precious metals:
- Gold
- Silver
- Platinum

1. Shape-memory alloys (i.e. eyeglass frame,

helical spring)
2. Amorphous alloys (Metallic Glass)
3. Nanomaterials
4. Metal foams

 Ceramics
Traditional ceramics
New ceramics
Glass

 Traditional ceramics
clays: kaolinite
silica: quartz, sandstone
alumina
silicon carbide

New ceramics
oxide ceramics : alumina
carbides : silicon carbide, titanium carbide, etc.

nitrides : silicon nitride, boron nitiride, etc.

 Glass products
window glass
containers
light bulb glass
laboratory glass

glass fibers
optical glass

Glass ceramics - polycrystalline structure

 Thermoplastics
Thermosets

Elastomers

 Thermoplastics - reversible in phase by heating and

cooling. Solid phase at room temperature and liquid

phase at elevated temperature.
Thermosets - irreversible in phase by heating and
cooling. Change to liquid phase when heated, then
follow with an irreversible exothermic chemical
reaction. Remain in solid phase subsequently.
Elastomers - Rubbers

 Acetals
Acrylics - PMMA
Acrylonitrile-Butadiene-Styrene - ABS
Cellulosics
Fluoropolymers - PTFE , Teflon
Polyamides (PA) - Nylons, Kevlar

Polysters - PET
Polyethylene (PE) - HDPE, LDPE
Polypropylene (PP)
Polystyrene (PS)

Polyvinyl chloride (PVC)

 Amino resins

Epoxies
Phenolics
Polyesters

Polyurethanes
Silicones

 Natural rubber
Synthetic rubbers

butadiene rubber
butyl rubber
chloroprene rubber
ethylene-propylene rubber
isoprene rubber
nitrile rubber
polyurethanes
silicones
styrene-butadiene rubber
thermoplastic elastomers

 Metal Matrix Composites

Ceramic Matrix Composites

Polymer Matrix Composites

 Metal Matrix Composites (MMC)

Mixture of ceramics and metals reinforced by strong, highstiffness fibers

Ceramic Matrix Composites (CMC)

Ceramics such as aluminum oxide and silicon carbide

embedded with fibers for improved properties, especially
high temperature applications.
Polymer Matrix Composites (PMC)

Thermosets or thermoplastics mixed with fiber

reinforcement or powder.

1D fibre

Woven fabric

Random fibre