Machine design -1

Module 1
Learning Objectives

1.Basic concept of design in general

2.Concept of Machine Design & its types
3.Factors to be considered in Machine Design
 Design
Design – the design may lead to an entirely new machine
or an improvement on an existing machine.

Design is essentially a decision- making process about the

need to design a solution.
In other words, to design is to formulate a plan to satisfy a
particular need and to create something with a physical
reality.

Machine design involves primarily designing these

elements so that they may transmit the forces safely and
perform their task successfully
Example : Design of a Chair.

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 Factors need be considered first
A number of factors need be considered first
– (a) The purpose for which the chair is to be
designed such as whether it is to be used as
an easy chair,
an office chair or
to accompany a dining table.
– (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 chair.
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 Basic Concept of Machine design

Design is essentially a decision- making

Optimum design
Market survey
Engine capacity
Shape & size
 Introduction

Machine – A machine may be defined as a combination of

stationary and moving parts constructed for the useful
purpose of generating, transforming, or utilizing mechanical
energy.

A machine is a device, consisting of various elements

arranged together, so as to perform the prescribed task to
satisfy the human need.

e.g. pump set -> electrical -> Mechanical -> Hydraulic, it raises
water from low level to high level.

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 Machine
A machine may be defined as a combination of stationary and moving parts
constructed for the useful purpose of generating, transforming, or utilizing
mechanical energy,

Machines can be classified as

1 Machines for generating mechanical energy.

(also known as prime movers)
These machines convert some form of energy into
mechanical work. e.g. steam engines, steam turbines,
gas turbines , I.C. Engine, Water turbines etc.

2 Machines for transforming mechanical Energy.

(also known as converting machines )
e.g. electric generators.
Air pump
Hydraulic pump.

3 Machine for utilizing mechanical energy.

e.g. lathe machine.
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Machine Elements Transforming Energy
Machine Element
A machine element or part is a separate part of machine, either
integral or consisting of several small pieces which are rigidly joined
together by riveting, welding etc.

When many individual joined machine parts are grouped together

and work together. These are known as machine units.

The machine elements may be classified in two groups.

1. General purpose elements.

e.g. nuts and bolts, keys, axles, shafts, coupling, bearing.

2. Special purpose elements :

e.g. Pistons, connecting rods, cam shafts, push rods, turbine
blades. 10
General purpose elements can be sub
divided as
1 Fasteners – The machine elements which connect or join
the parts of a machine

Two types of joints.

Permanent Joint e.g. riveted joints, welded joints.
Temporary joint e.g. nut and bolt joints, cotter joints.

2 Elements of Rotary motion drive.

e.g. belt, rope, chain, gears, worm drives, shafts, axles,
coupling, bearing etc.

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Machine Element
 Machine design
Machine design – The machine design is the
creation of the right combination of
correctly Proportioned moving and stationary components so
constructed and joined as to enable the liberation,
transformation and utilization of energy.
Or
Machine design – It is the process of selection of the
materials, shapes, sizes, and arrangements of mechanical
elements so that a resultant machine will perform the
prescribed task.

Machine design is an iterative process i.e. head to tail

fashion and vise versa.

The aim of the iteration process is to optimize the design.

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 Introduction to Machine design

Selection of
Arrangements

What is Selection
Selection
of sizes
machine design of shapes
?

Selection
of
materials 14
Machine design requires the knowledge of
1 Mathematics. Also subjects such as
1 Electrical Theory.
2 kinematics.
2 Thermodynamics.
3 Statics. 3 Hydraulics.

4 Dynamics. Electrical motors.

b) generators.
5 Mechanics of materials.
c) I.C Engines.
6 Engineering materials d) Steam engines and turbines.

7 Mechanical technology. e) Gas turbines.

f) water turbine.
8 Engineering drawing. 15
e) water pump.
Types of Design
Classifications of Machine Design

Adaptive design.

In most cases, the designer’s work is concerned

with adaptation of existing designs.

This type of design needs no special

knowledge or skill and can be
attempted by designers of ordinary
technical training.

The designer only makes minor alternation

or modification in the existing designs
of the product.

e.g. fruit crushing machine. 17

2. Development design.

This type of design needs considerable scientific

training and design ability in order to modify the
existing designs into a new idea by adopting a
new material or different method of manufacture.

In this case, though the designer starts from the existing

design, but the final product may differ quite markedly from
the original product.

E.g. : A new model of a car.

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3. New design.

This type of design needs lot of

Research,
Technical ability and
Creative thinking.

Only those designers who have personal qualities of a

sufficiently high order can take up the work of a new design.

It is an entirely new one but based on existing scientific

principles.

Ex: Patented Product

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Types of Design Based on Methods
The designs, depending upon the method.

(a)Rational design.

This type of design depends upon mathematical formulae,

principle of mechanics.

This is based on determining the stresses and strains of

components and thereby deciding their dimensions.

(b)Empirical design.
This type of design depends upon empirical formulae based on the
practice and past experience.

Experience shows that the tightening force may be given by P = 284d

where, ”d” is the bolt diameter in mm and ”P” is the applied force
in kg. 21
Empirical design
(c) Industrial design.
This type of design depends upon the production aspects to
manufacture any machine component in the industry.

Design equations are not available or are complex.

These are based on industrial considerations and norms viz.

market survey,

external look,

production facilities,

low cost,

use of existing standard products.

e.g. design of gear box casing, machine tool body, knife cover.
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(d) Optimum design. It is the best design for the given
objective function under the specified constraints.
It may be achieved by minimizing the undesirable effects.

(e) System design. It is the design of any complex

mechanical system like a motor car.

(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.
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Engineering Design

It can be defined as the iterative decision making activity

to create the plans by which resources are converted
preferably optimally into systems, processes or devices
to perform the desired functions and to meet human
needs.

The objective is not teach a new Engg. course, but to help the
students learn how to use purposely and effectively what is known
to him/her.

Machine design or Mechanical design is one of the branch of

Engg. Design

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General Procedure/ Steps/ phases/ stages in Machine Design

Definition of problem

Determination of
Synthesis (Mechanisms). dimensions

Analysis of forces. modification of

dimensions

Material selection
Preparation of drawing.

Determination of mode
of failure Preparation of design
report , Production.
Selection of factory of
safety

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Definition of problem

Define the design problem giving all

input parameters,
output parameters, and
Constraints.

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 given input.

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Analysis of Forces
Draw the force body diagram
of each element of the machine.
Find out the forces (including moments and torque) acting
on each element by force analysis

Selection of Material
Select the suitable material for each element.
Four basic factors that are to be considered:-
availability,
cost,
mechanical properties, and
manufacturing considerations. 30
Determination of Mode of Failure

Before finding out the dimensions of the element, it is

necessary to know the type of failure by which the element
will fail when put into the use.
e.g. buckling failure.

Selection of Factor of Safety

Based on the application, select the factor of safety.

Knowing factor of safety and material strength,

determine the permissible or design stresses.
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Determination of Dimensions
Find the dimensions of each element of the machine by
considering the forces acting on the element and the
permissible stresses.

Modification of Dimensions
Modify the dimensions of the elements on the higher side,
if required, based on the following considerations.

Selection of standard parts available in the market;

Convenience of assembly; and
Convenience of manufacturing. 32
 MACHINE DESIGN- I

Modules 1

Design considerations for casting and forging

Casting
The castings are obtained by re-melting of ingots in a cupola or some other
foundry furnace and then pouring this molten metal into metal or sand
molds.

The various important casting processes are as follows:

1. Sand mould casting.

2. Permanent mould casting.
3. Slush casting.
4. Die casting.
5. Centrifugal casting.

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However, a few rules for designing castings are given below to serve
as a guide:
1. The sharp corners and frequent use of fillets should be avoided in order
to avoid concentration of stresses.

2. All sections in a casting should be designed of uniform thickness, as

far as possible. If, however, variation is unavoidable, it should be done
gradually.

3. An abrupt change of an extremely thick section into a very thin

section should always be avoided.

4. The casting should be designed as simple as possible, but with a good

appearance.

5. Large flat surfaces on the casting should be avoided because it is

difficult to obtain true surfaces on large castings.

6. In designing a casting, the various allowances must be provided in

making a pattern.
7. The ability to withstand contraction stresses of some members of the
casting may be improved by providing the curved shapes e.g., the arms
of pulleys and wheels.

8. The stiffening members such as webs and ribs used on a casting

should be minimum possible in number, as they may give rise to various
defects like hot tears and shrinkage, etc.

9. The casting should be designed in such a way that it will require a

simpler pattern and its moulding is easier.

10. In order to design cores for casting, due consideration should be given
to provide them adequate support in the mould.

11. The deep and narrow pockets in the casting should invariably be
avoided to reduce cleaning costs.

12. The use of metal inserts in the casting should be kept minimum.
13. The markings such as names or numbers, etc., should never be
provided on vertical surfaces because they provide a hindrance in the
withdrawal of pattern.

14. A tolerance of ± 1.6 mm on small castings (below 300 mm)

should be provided. In case more dimensional accuracy is desired, a
tolerance of ± 0.8 mm may be provided.
Forging
It is the process of heating a metal to a desired temperature in order to
acquire sufficient plasticity, followed by operations like hammering,
bending and pressing, etc. to give it a desired shape.

The various forging processes are.

1. Smith forging or hand forging

2. Power forging,

3. Machine forging or upset forging, and

4. Drop forging or stamping

1. Smith forging or hand forging 2. Machine forging or upset forging, and

3. Drop forging or stamping

Forging Design
In designing a forging, the following points should always be considered.

1. The forged components should ultimately be able to achieve a radial

flow of grains or fibres.

2. The forgings which are likely to carry flash, such as drop and press
forgings, should preferably have the parting line in such a way that
the same will divide them in two equal halves.

3. The parting line of a forging should lie, as far as possible, in one

plane.

4. Sufficient draft on surfaces should be provided to facilitate easy

removal of forgings from dies.

5. The sharp corners should always be avoided in order to prevent

concentration of stress and to facilitate ease in forging.
6. The pockets and recesses in forgings should be minimum in
order to avoid increased die wear.

7. The ribs should not be high and thin.

8. Too thin sections should be avoided to facilitate easy flow of

metal.
Thank you