Machine Design

What is the importance of Machine Design for

engineers?
What is Machine Design?
Creation of new and better machines AND
Improving existing ones
So that it is economical in the cost of production and operation.
Machine Design
Requirement
Model
(Rough idea)
Creation
How a design is born
marketability
Availability of
FUNDS
Available
material
Manufacturing
resources
Analysis
Market
survey
Aesthetic
Ease of
handling
Safety
Economical
Recyclability
Force/stress
Material/s
used
Sizes
What is the basic knowledge required for Machine
Design?
Mathematics
Engineering Mechanics
Strength of Materials





Mathematics
Engineering Mechanics
Strength of Materials
Workshop Processes
Engineering Drawing
Mathematics
Engineering Mechanics
Strength of Materials
Workshop Processes
Engineering Drawing
Computing
Finite Element Analysis, Computational Fluid Dynamics etc
Mechanics of Machines
Mechanics of Materials
Fluid Mechanics & Thermodynamics
Important considerations in Machine Design
1. Type of LOAD and STRESSes caused by the load
Steady loads
Dead loads
Live loads
Variable loads
Shock loads (suddenly)
Impact loads (applied
with some velocity)
Stress and strain
(Tensile, compressive, shear)
Thermal stresses
Torsional stresses
Bending stress
Important considerations in Machine Design..
2. KINEMATICS of the machine (Motion of the parts)
Find the simplest arrangement that would give the most
efficient motion that is required.
3. Selection of MATERIALs
Knowledge of the properties of the materials and their
behaviour under working conditions is required.
Strength, hardness, durability, flexibility, weight, resistance
to heat and corrosion, electrical conductivity, machinability,
etc.
Important considerations in Machine Design..
3. Selection of MATERIALs
Physical properties: Density, Melting point, Elec/thermal properties
Mechanical properties:
STRENGTH resist externally applied loads without breaking
or yielding
STIFFNESS resist deformation under stress
ELASTICITY regain original shape once the force is removed
PLASTICITY property which retains deformation (required for
forging etc)
DUCTILITY ability to be drawn into a wire by a tensile force
BRITTLENESS sudden breaking with minimum distortion
TOUGHNESS resist fracture due to high impact load
CREEP deformation under stress and high temperature
FATIGUE ability to withstand cyclic stresses
HARDNESS resistance to wear, scratching, deformation,
machinability etc
Metal
Non-metal
Ferrous Non-ferrous
Important considerations in Machine Design..
4. Form and size of the parts
Use I-beam or Angle-iron?

The size will be determined by the forces/torques
applied (stresses on the object) and the material used
such that failure (fracture or deformation) would not
occur
General procedure in Machine Design..
Detailed drawing
Need or aim
Synthesis
Analysis of the FORCES
Material selection
Design of elements
Modification
Recognize and specify the problem
Select the mechanism that would give the desired
motion and form the basic model with a sketch etc
Determine the stresses and thereby the
sizes of components s.t. failure or
deformation does not occur
Modify sizes to ease construction & reduce overall cost
Production
WITH PROPER MACHINE DESIGN
KNOWLEDGE
Syllabus and method of evaluation
MACHINE DESIGN II

Subject code : ME603
Number of Lecture Hrs per week : 03+01 Hrs.
Question to be set : 3 from unit I & II and 2 from
unit III.
Question to be answered : 2 from unit I & II and 1 from
unit III.
UNIT I
Spur Gears: Review of involute characteristics, standard systems of gear
tooth, force analysis, gear tooth failures , loads on gear teeth- dynamic
loads, beam strengths, Lewis equation, Lewis form factor, effective load
on gear teeth, dynamic load, wear strength, Buckinghams equation,
gear design for maximum power transmitting capacity.
Helical gears: Terminology, virtual number of teeth, tooth proportions,
force analysis, beam strength, effective load, wear strength.
Bevel Gears: Terminology, force analysis, beam strength, effective load,
wear strength.
Worm Gears: Terminology, proportions of worm and worm gears, force
analysis, strength rating and wear rating of worm gears, thermal
considerations. (14 L + 4T)


UNIT II

Springs: Types, materials, end connections fort helical springs, stresses
and deflection of helical springs of circular wire, design of springs
subjected to static and fluctuating load, springs in series and parallel,
helical torsion springs, leaf springs, ripping of leaf springs, length of
leaves.
Pressure Vessels: Classification- thin cylinders and thick pressure
vessels subjected to internal pressure, thick cylinder shells- Lamis
equation, Clavarionos equation and Birnis equation, compound
cylindrical shells, cylinder heads and cover plates.
Design of connecting rod and crank shaft
(14 L + 4T)
UNIT III
Rolling contact bearings: Types, Stribecks equation, static and
dynamic carrying capacity, equivalent bearing load, load- life
relationship, selection of radial bearings, reliability of a bearing,
lubrication of ball and roller bearings.
Journal Bearing: Hydrodynamic lubrication and Reynolds equation,
wedge film and squeeze film journal bearing, bearing characteristic
number and bearing module for journal bearing, co-efficient of friction,
critical pressure, Sommerfield Number, Heat generated in journal
bearing, Design procedure.
(10 L + 3T)





Textbooks:
1. K.Mahadevan and K.Balaveera reddy- Design Data Handbook (SI
Units), KREC, Surathkal
2. R.S. Khurmi & J.K. Gupta- Machine Design, S Chand Publications
3. V B Bhandari- Design of machine elements, TMH

Reference books:
1. J.Shigley- Mechanical Engineering Design, McGraw Hill
2. Siegel, Maleev & Hartman- Mechanical Design, International
Textbook Co.
3. Sadhu Singh- Machine Design, Khanna Publishers.
4. Ghosh- Practical Machine Design, S. Bhattacharya Co.
5. Spotts- Design Of Machine Elements, Prentice Hall (India)


Requirement:
Design Data Handbook
Scientific Calculator

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