Under Graduate Course on

Machine Design-I
Design of Machine Elements
Dr. S. S. Roy
Assistant Professor Robotics & A.I Lab. (RAIL) Department of Mechanical Engineering

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Reference Books
1. 2. 3. V.B. Bhandari, Design of Machine Elements , <Third edition>, Tata McGraw Hill. J.E. Shigley, C.R. Mischke, Mechanical Engineering Design, Tata McGraw Hill. M.F. Spotts & T.E. Shoup, Design of Machine Elements, Pearson Education.

Machine Design Handbook

1. 2. Design Data, Compiled by Faculty of Mechanical Engineering, PSG College, Coimbatore CMTI Hand Book, Compiled by Scientists of Central Manufacturing technology Institute, Bangalore

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Design of Machine Element

Gear Drive C-frame Pressure vessel Clutch IC engine parts Brake

Coupling Spring Belt, Rope, chain Drive Cam Key Cotter & Knuckle Joint
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Bearing Connecting rod Power Screw Shaft & Axle Riveted Joint

Welded Joint

Bolted Joint

Introduction
Design is the process of problem solving Design is a decision making process Design is an iterative process Design is an innovative or creative process

Machine Design

In Mechanical Engineering
Objective of a Designer is to design & develop a product (devices, machinery, mechanical system) or process that is functional, safe, reliable, usable, manufacturable, competitive & marketable by using different engineering tools [ like Mathematics, CAD-CAE etc.]
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Mechanical Design
Energy Stem Mechanical Engineering Systems Structures & Motion Stem Energy Stem in Mechanical Engineering
Design of heat exchangers Design of IC engines Design of boilers Design of air compressors, gas turbine etc

They rely on the use of technical materials from thermodynamics, heat transfer, combustion etc.

Structures & Motion Stem in mechanical Engineering

Design of gear box Design of belt drive, chain drive system Design of suspension systems Design of machine structure etc They draw on technical materials from solid mechanics, kinematics, dynamics etc. Mechanical design applies to design in mechanical engineering systems where both stems can be involved Machine Design is a sub-set of mechanical design where the focus is on Structures & Motion stem only
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Mechanical Engineering Design/ Machine Design the use of scientific principles, technical information, skill & imagination in the description of configuration of a mechanical system/ machine to perform specific functions with maximum economy & efficiency Designer uses principles of basic engineering sciences has technical information of basic elements of machine like fasteners, gear, belt drive, bearing etc. - Relative advantages & disadvantages of basic elements & their suitability in different applications. uses skill & imagination to produce a configuration, which is a combination of basic elements. - Intellectual part of constructing a proper configuration is creative in nature

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Machine Design
Kinematic Link Kinematic Pair Kinematic Chain Machine Tool
One link fixed

transfers Motion transforms

Mechanism

Primary Objectives

Mechanism Machine Machine

transfers Energy transforms

All Machines are Mechanism but all Mechanisms are not Machine All Machine Tools are Machine but all Machines are not Machine Tool

Mechanism

assemblage of resistant bodies, connected by joints, to form a kinematic chain with one link fixed & having the purpose of transmitting & transforming motion.

Machine

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Combination of resisting bodies having definite motions & capable of performing useful work. - Combination of resistant bodies with successfully constrained relative motions which is used to transform, transmit & modify available energy to do some useful work
-

Machine Design
Design
Design Analysis
Inputs

Design Synthesis decision making process

Outputs determines the dimension

Mechanism
is given

process of creating new configuration/ mechanism Selecting optimum/best configuration from no. of existing mechanism Selecting materials from no. of alternative materials Determination of optimum shape & dimensions of the component on the basis of design analysis

Given Configuration, material & assume mode of failure

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Type of Design
Adaptive Design - This is based existing design. on - Starts with an existing design, but the final product may differ quite markedly from the original product. - A new model of a car Developmental Design New Design

- Existing standard product or systems with/ without minor modification, are adapted for a new application.

- This is an entirely new one but based on existing scientific principles. - Needs lot of research, technical ability & creative thinking.

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Type of Design based on Methods

Rational Design Empirical Design - This is based on empirical formulae which in turn is based on experience and experiments. Industrial Design - These are based on industrial considerations and norms viz. market survey, external look, production facilities, low cost, use of existing standard products.

- This depends upon mathematical formulae of mechanics. - This is based on determining the stresses and strains of components and thereby deciding their dimensions.

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Manufacturer

Customer

General Procedure in Machine Design

Identification of Need Problem definition, Design specification Collecting relevant design information & feasibility study Design Conceptualization/ Preliminary design i.e. Mechanism synthesis Modeling & Simulation Engineering Analysis CAD/CAE Design Design Optimization Design Evaluation Detail Design of Components Design Communication & Documentation
Analysis Design Synthesis

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Basic Procedure of Design of Machine Element

Specify functions of element Determine forces acting on element Select suitable material for element Determine failure mode (s) of element Determine geometric dimensions of element based on above failure mode Check & modify dimensions for assembly & manufacture Check design at critical cross-sections
Prepare detail engineering drawing of element
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Basic Requirements of Machine Elements

Broad objective of designing a machine element is to ensure that it preserves its operating capacity during the stipulated service life with minimum manufacturing & operating costs. In order to achieve these objectives, the machine element should satisfy following basic requirements.

Strength Rigidity

- should have sufficient strength to avoid failure (fracture/ general yielding) due to force. - should not deflect or bend beyond permissible limit due to forces/moments. - Machine components like gear, cam should have sufficient wear resistance. Wear leads to the loss of accuracy, puts the part out of order. - Machine part should be sufficiently strong, rigid & wear resistant & at the same time, with minimum possible dimensions & weight.

Wear Resistance

Minimum Dimensions & Weight Manufacturability

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- ease of fabrication & assembly. - shape & material of the m/c part should be selected in such a way that it can be produced with minimum manufacturing cost
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Basic Requirements of Machine Elements

Safety Reliability
- shapes & dimensions of the machine parts should ensure safety to the user/operator. - is probability that a machine part will perform its intended functions under desired operating conditions over a specified period of time. - machine part should be reliable i.e. it should perform its function satisfactorily over its lifetime. - ease with which a machine part can be serviced or repaired. - machine part should be maintainable - machine part should confirm to the National or International standard.

Maintainability

Conformance to Standards

Minimum Life Cycle cost

- Total cost to be paid by the purchaser for purchasing the part and operating & maintaining it over its life span.
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Standards in Machine Design

Standardization
Standardization is defined as obligatory norms, to which various characteristics of a product should conform.
The characteristics include materials, dimensions and shape of the component, method of testing and method of marking, packing and storing of the product.

Standard

Standard is defined as a set of specifications for parts, materials or processes

Purpose of Standard to reduce the variety & limit the no. of items to a reasonable level

Code

Code is defined as a set of specifications for the analysis, design, manufacture, testing and erection of the product
Purpose of Code to achieve a specified level of safety

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Standards in Machine Design

Advantages of Standardization The reduction in types & dimensions of identical components, to a rational number, makes it possible to manufacture the standard component on mass scale in a centralized process. Standard parts are easy to replace when worn out due to interchangeability. The application of standard machine elements & especially the standard units reduce the time & effort needed to design a new machine. Standardization results in substantial saving in Designers effort The standards of specifications & testing procedures of machine elements improve their quality & reliability. In designing, the aim is to use as many standard components as possible for a given machine
Company Standards

Types of Standards

National Standards International Standards

I.S / B.I.S B.S A.I.S.I / S.A.E D.I.N

India UK USA German

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Standards in Machine Design

Indian Standards in Mechanical Engineering Design
SP 46 I.S. 210 I.S. 1570 I.S. 733 : 1983 I.S. 736 : 1986 I.S. 919 I.S. 2709 I.S. 8000 I.S. 4218 : 1996 Bureau of Indian Standards on Engineering Drawing Practice for Schools & Colleges Seven grades of grey cast iron Chemical composition of various grades of alloy steel Mechanical Properties of wrought Al. & Al alloy Bars, Rods for general purposes Mechanical Properties of wrought Al. & Al alloy Plates for general purposes Recommendations for Limits & Fits for Engineering Guide for selection of fits Geometrical tolerancing on technical drawings Designation & Dimension of screw threads, bolts & nuts

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Preferred Numbers
When a machine is to be made in several sizes with different powers or capacities, it is necessary to decide what capacities will cover a certain range efficiently with minimum number of sizes. For example, a company want to manufacture six different models of electric motors ranging from 1.0 HP to 105 HP to cater to the need of different customers. Preferred numbers are used to specify the sizes of the product in these cases.

French Engineer Charles Renard first introduced Preferred Numbers in the 19th century. The system is based on the use of geometric progression to develop a set of numbers.
Basic series R 5 series R 10 series R 20 series R 40 series R 80 series Common Ratio 101/5 101/10 101/20 101/40 101/80 1.58 1.26 1.12 1.06 1.03 % increase in steps 58% 26% 12% 6% 3% Preferred Numbers [in between 1 to 10]
1.0, 1.6, 2.5, 4.0, 6.3, 10.0 1.0, 1.25, 1.6, 2.0, 2.5, 3.15, 4.0, 5.0, 6.3, 8.0,10.0 1.0,1.12,1.25,1.4,1.6,1.8,2.0,2.24,2.5,2.8,3.15,3.55,4.0,4.5,5.0,5.6,6.3,7.1,8.0,9.0,10.0 1.0,1.06,1.12,1.18,1.25,1.32,1.4,1.5,1.6, , 10.0 1.0,1.03, 1.06,1.09, 1.12,1.16, 1.18, 1.21,1.25,1.29,1.32,1.36,1.4,..1.6, , 10.0

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Aesthetic Considerations in Machine Design

When there are a number of products in the market, having the same qualities of efficiency, durability and cost, the customer will naturally attracted towards the most appealing product. The external appearance is an important feature, which not only gives grace and luster to the product but also dominates the sale in market.

Automobiles

Household Appliances

Audio Visual Equipments

Industrial Design

The job of an Industrial Designer is to create new forms & shapes, which are aesthetically pleasing.

The external appearance of the products is a cumulative effects of number of factors : Form
Step Stream Taper Shear Sculpture

Colour

Surface finish & Tolerances

Materials

Manufacturing Methods

Relationship between Functional requirement & Appearance of the Product

In many cases, functional requirements result in shapes, which are aesthetically pleasing. The evolution of the streamlined shape of the boeing is the result of studies in aerodynamics for effortless speed. Chromium plating on the household appliances is for corrosion resistance rather than for pleasing appearance
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Ergonomic Considerations in Machine Design

Ergonomics is defined as the relationship between Man & Machine and the application of anatomical, physiological and psychological principles to solve the problems arising from Man-Machine relationship.

Topics of Ergonomic studies in Machine Design

Anatomical factors in design of drivers seat. Layout of instrument dials & display panels for accurate perception by the operators Design of hand levers & hand wheels. Ergonomists have carried out experiments to determine the best dimensions of drivers seat, the most convenient hand or foot pressure or dimensions of levers and hand wheels.

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Manufacturing Considerations in Machine Design

Design Considerations of Castings
General Principles :

Round all external corners All sections in a casting should be designed of uniform thickness, as far as possible. If variation is unavoidable, it should be done gradually Avoid very thin section : Minimum thickness for CI component in sand casting is about 6 mm. The cast components should be designed in such a way that it will require a simpler pattern & its moulding is easier. In designing a casting, the various allowances must be provided in making a pattern. The casting should be designed as simple as possible, but with a good appearance.

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Design Considerations of Machined Components

Machining is basically secondary & finishing manufacturing process.
Dimensional Accuracy
Geometric / Form Accuracy

Dimensional Tolerance Geometric Tolerance Surface roughness

Surface finish

General Principles :

Avoid sharp corners Avoid too many shoulders & undercuts Avoid hard materials.

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Sequential Engineering Approach Vs. Concurrent Engineering Approach

Sequential Design Process
Prototype Development Stage

Customer

Marketing Department

Design Office
Production Department

Sales & Service Department

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Sequential Engineering Approach

Vs. Concurrent Engineering Approach

Concurrent Engineering is defined as the design process/approach that brings together a wide spectrum of expert/specialist from several functional areas (like R & D, Engineering, Manufacturing, Quality control, Marketing, sales & service etc.) during the early phases of the design process in new product development.

Concurrent Engineering

The team reviews the design from different aspects design for Manufacturing & Assembly (DFx) quality assurance & standardization aesthetics & ergonomics maintenance reliability & safety process, facility, capacity planning tool design functional / performance testing cost
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Sequential Engineering Approach Vs. Concurrent Engineering Approach

Concurrent Engineering
Any possible bottleneck/mistake is thoroughly studied & rectified. This results in small nos. of modification in the design at a later stage & reduce time interval from conceptual stage to marketing stage.
Customers requirement

Simultaneous Engineering Cross Functional Team Approach Parallel Engineering

Cost, Sales & servicing

Manufacturability Assembly & Testability

Design Engineering : Concurrent Engineering

Approach

Ergonomics & Appearance 1/18/2012

Reliability, Maintainability & safety 25

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Motivation
Most Economic

Requirements

Most Productive Improved Quality

Successful entry of a product into the market can best occur if it can complete the above cycle in the shortest possible time & at the lowest cost while maintaining very high product quality & reliability

CAD CAE CAM VP & VR

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Computer Aided Design Computer Aided Engineering Computer Aided Manufacturing Virtual Prototyping & Virtual Reality
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Scope of CAD-CAM-CAE
Design & Analysis Theories
(FEM, CFD)

Geometric Modeling

Automation
(Robot, FMS, CAPP)

CAD-CAM-CAE
Manufacturing Process
(RP&T, CNC)

Computer Graphics

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CAD-CAM-CAE Software
CAD/CAM/CAE software CATIA ( CATIA PLM Express ) NX ( Siemens PLM ) PRO-ENGINEER SOLID WORKS SOLID EDGE INVENTOR Mechanical DESKTOP MasterCAM SolidCAM SmartCAM 3-D modeling & Manufacturing Simulation 3-D modeling, Analysis & Simulation etc. Purpose

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CAD-CAE Software
CAE software ADAMS SimDESIGNER Motion with CATIA Working Model ANSYS NASTRAN ABAQUS LS-DYNA DEFORM PAMCRASH FLUENT Altair Hyper Mesh Purpose
Multi-body dynamic analysis & simulation Multi-body dynamic analysis & simulation Multi-body dynamic analysis & simulation Finite Element Analysis Finite Element Analysis Finite Element Analysis Finite Element Analysis, Crash simulation Finite Element Analysis, Crash simulation Finite Element Analysis, Crash simulation Computational Fluid Dynamics Meshing for Finite Element Analysis

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Computational Tools
Software MATLAB Mathematica MathCAD Maple TK Solver Excel
Design calculation

Purpose
Design calculation, dynamic analysis & simulation, design optimization, control

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Assignment # 1
1. Explain with example, the different steps involved in machine design process & in design of machine elements? What are the basic requirements of machine elements? 2. Distinguish between design synthesis and design analysis. 3. What is Standardization & what are the advantages of standardization? Give examples of Indian standards for commonly used engineering materials. 4. What are preferred numbers? How many basic series are used? What is R10 series? Develop R 10 series from 2 to 20. 5. What is an industrial design? What is the relationship between functional requirement and external appearance of the product. 6. Define ergonomics. What is the scope of ergonomics in machine design? 7. Distinguish between sequential design and concurrent engineering.

Last date of submission : 08th February, 2012

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