Course 26.

Machine Design 2 (Web Course)

Faculty Coordinator(s) :

1. Prof. R. Gopinath
Department of Mechanical Engineering
Indian Institute of Technology, Madras
Chennai- 600036

Email : mgopinath@iitm.ac.in,
gopinath@acer.iitm.ernet.in
Telephone : (91-44) Off : 2257 8507
Res : 2257 9507
2. Prof. M. M. Mayuram
Department of Mechanical Engineering
Indian Institute of Technology, Madras
Chennai- 600036

Email : mmme@iitm.ac.in
Telephone : (91-44) Off : 2257 8547
Res : 2257 9547

Detailed Syllabus :

Fatigue consideration in design 12
Variable load - basic concept; load or stress variations- different patterns Cyclic
stressing/straining - materials response and the origin of fatigue failure. Stress life relations;
S-N curve-fatigue strength and endurance limit Factors influencing fatigue and endurance
strength modification factors Effect of stress concentration and fatigue stress concentration
definition Effect of mean stress - Goodman and Soderberg's relations Design approach to
fatigue - design for infinite life and finite life Design of members under combined (steady and
variable) loading conditions

Design of gear tooth 14
Law of gearing - conjugate action and gear tooth profile-basics Analysis of forces on spur,
helical, bevel and worm gears - determination of bearing reaction forces Bending and contact
stress in gear tooth-dynamic loading and wear-Lewis and Buckingham equations for design.
Design of fixed ratio gear box-general design procedure

Design of sliding and journal bearings 6
Types of lubrication-hydro dynamic, hydro static and EHD lubrication. Petroffs equation and
the bearing haracteristic number-boundary and film lubrication Pressure distribution-
eccentricity and minimum film thickness Heat generation and thermal equilibrium

Design/analysis of Brakes clutches and fly wheels 8
Plate clutches design for uniform pressure and wear Shoe breakes short and long shoe
analysis automotive shoe breake design/analysis Ply wheel design basic concepts.


DETAILED LECTURE WISE COVERAGE
Module I - Fatigue consideration in design 12 Hours
Lecture 1 -Variable load- basic concept; Terminology associated with variable loading;
Patterns of load or stress variations
Lecture 2 -Cyclic stressing/straining-and materials response to cyclic loading
Lecture 3 -The mechanism of fatigue failure; origin and propagation of crack
Lecture 4- Stress life relations; S-N curve-fatigue strength and endurance limit
Lecture 5 -Factors influencing fatigue
Lecture 6 -Endurance strength modification factors
Lecture 7 -Effect of stress concentration and fatigue stress concentration definition and its
estimation from geometric stress concentration factor
Lecture 8 -Effect of mean stress- Goodman and Soderberg's relations
Lecture 9 -Design approach to fatigue- design for infinite life and finite life
Lecture 10 -Approach/Methods for design of members under combined (steady and variable)
loading conditions
Lecture 11- Worked out examples on fatigue design problems
Lecture 12- --do-
Module 2 -Design of gear tooth 14- Hours
Lecture 1 -Gears-types and application and gear terminology
Lecture 2 -Law of gearing-conjugate action and interference in gears
Lecture 3 -Gear tooth profiles, involute profile -basics, Influence of number of teeth and
pressure angle Lecture 4- Analysis of forces on spur, and helical gears
Lecture 5 -Bending and contact stress in gear tooth-
Lecture 6 -Lewise equation for design
Lecture 7 -Dynamic loading and wear-Buckingham equations for design.
Lecture 8 -Gear quality and selection aspects
Lecture 9-Force analysis on bevel and worm gears
Lecture 10- Design approach for bevel gears- equivalent tooth
Lecture 1 I -Design of fixed ratio gear box- general design procedure
Lecture 12 -Worked out example on design of a single stage reduction gear unit
Lecture 13- and 14- Determination of bearing reaction due to gear forces- Worked out
examples
Module 3 -Design of sliding and journal bearings 6 Hours
Lecture I -Types of lubrication- hydro dynamic, hydro static and EHD lubrication.
Lecture 2 -Petroff's equation and the bearing characteristic number
Lecture 3- Lubrication regimes- boundary and film lubrication
Lecture 4 -Hydro dynamic bearings- Pressure distribution-eccentricity and minimum
film thickness
Lecture 5 -Reynolds equation and use of bearing design charts
Lecture 6 -Heat generation and thermal equilibrium
Module 4 -Design/analysis of Brakes clutches and fly wheels 8 Hours
Lecture 1- Brakes and clutches -need and functioning -dynamic model
Lecture 2 -Plate clutches- design for uniform pressure and wear
Lecture 3- Shoe brakes- short and long shoe analysis
Lecture 4- Automotive shoe brake-design/analysis
Lecture 5 -Fly wheel basic concepts -design requirements
Lecture 6 -Moment diagram and energy estimations
Lecture 7- Worked out examples on brakes and clutches
Lecture 8 -Worked out examples on fly wheels