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Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 1
Text Book
• All exams will be OPEN BOOK in this course (term final of ME 351 too)
• Without this book no one will be allowed to appear at any exam in this
course
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 2
Introductory Concepts
What is Machine Design?
Machine Design is a course in which the principles and practice of design of machine elements based on science and
engineering tools are carried out.
Hood
Seat
Mudguard
Seating
Base
Brake Suspension System
Base
Chain Wheel
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 4
Designing Rickshaw Components
Paddle
Chain
Power
Transmission Pulley
Base: Compressive Load
Rear Shaft: Torsion
Suspension System:
Leaf Spring
Bearing
Rear Pulley
Wooden Base
Leaf Spring bears bending load Rear Shaft Support Member Wheel Bearing
( not static but fluctuating)
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 5
Introductory Concepts
Basic Machine Elements: Column
Design Considerations: Key Points
• Bar • Gear Welding
Under any loading condition Stress should not cross
• Beam • Belt
the body Strength
• Shaft • Bearing Brake
No excessive Deformation
• Spring • Clutch
• Column • Brake
• Chain • Joints
Different Organizations:
Important Design Considerations: (page-08) They specify standards and code
Strength of M/C elements (page-32) • ASTM : American Society for Testing and Materials
Stiffness of M/C elements (page-32) • AISI : American Iron & Steel Institutes
Toughness of M/C elements • ISO : International Organization for Standardization
Reliability (page- 18) • BS : British Standard
Tolerance (page-19) • BDS : Bangladesh Standard
Wear, friction, lubrication
Noise and Vibration Engineering Materials are of 3 Kinds:
Corrosion • Metals (excellent conductors, take heavy load, offer ductility)
Thermal Effect • Polymers (easily molded, acts as adhesive and shock absorbers)
Cost, Aesthetics • Ceramics (excellent insulators, endures adverse environment)
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 6
Introductory Concepts
Stress- Strain Curve: (obtained from standard tensile test)
The standard tensile test is used to obtain a variety of material characteristics and strengths that are used in design.
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 7
Stress Strain Curve
• Point pl in Fig. is called the proportional limit. This is
the point at which the curve first begins to deviate
from a straight line. No permanent deformation will
be observable in the specimen if the load is removed
at this point. In the linear range, the uniaxial stress-
strain relation is given by Hooke’s law: σ = Eϵ
Where, E = Slope of linear part of Stress- Strain curve
= Young’s Modulus/ Modulus of Elasticity
E can be considered as stiffness of a material (Material
Property)
• Point el in Fig. is called the elastic limit. If the
specimen is loaded beyond this point, the
deformation is said to be plastic and the material will
take on a permanent deformation when the load is
removed. Between pl and el the diagram is not a
perfectly straight line, even though the specimen is
elastic.
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 8
Stress Strain Curve
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 9
Stress – Strength Concept
Stress:
Stress is a state property (physical variable) at a specific point within a body, which is a function of--
• Load
• Geometry
• Temperature
• Process or Handling
In an elementary course in mechanics of materials, stress related to load and geometry is emphasized with some discussion
of thermal stresses. However, stresses due to heat treatments, molding, assembly, etc. are also important and are
sometimes neglected.
Strength:
Strength is the magnitude of stress at which something of interest occurs, such as the proportional limit, 0.2 percent-offset
yielding, or fracture.
In many cases, such events represent the stress level at which loss of function occurs.
Strength is a property of a material or of a mechanical element. The strength of an element depends on--
• Choice of material
• Treatment
• Processing of material.
Strength is an inherent property of a part, a property built into the part because of the use of a particular
material and process.
Strength remains same weather the part is in an operating M/C or just lying on a workbench.
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 10
Various Strengths
• Strengths are known by tests, done according to standards whereas Stresses are known usually by theories.
Various Strengths:
t : tensile u : ultimate (strength)
Sut Suc Ssu c : compressive y : yield (strength) All are STATIC
Syt Syc Ssy s : shear (direct/torsional) STRENGTHS
Common Heat Treatment Processes for Steel: Tensile Strength of AISI 1040 Q&T* Steel at 650 oC = 634 Mpa
• Hardening
• Quenching Carbon Steel : (Principle Alloying Element is Carbon)
• Annealing
• Tempering Plain Carbon Steel : AISI 10XX
% of Carbon × 100
Example: AISI 1030 contains 0.3 % of Carbon.
Low Carbon Steels: 1005 - 1030
Strengths Medium Carbon Steels: 1035 – 1055
also depend High Carbon Steels: 1060-1095
on * Q&T : quenched and tempered.
Temperature
(For Details of Numbering System, Page – 45)
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 11
Design Factor & Factor of Safety
Engineers must accommodate uncertainty. Material properties, load variability, fabrication fidelity, and validity of
mathematical models are among concerns to designers. To accommodate uncertainty-
𝐥𝐨𝐬𝐬 𝐨𝐟 𝐟𝐮𝐧𝐜𝐭𝐢𝐨𝐧 𝐩𝐚𝐫𝐚𝐦𝐞𝐭𝐞𝐫 𝐥𝐨𝐬𝐬 𝐨𝐟 𝐟𝐮𝐧𝐜𝐭𝐢𝐨𝐧 𝐒𝐭𝐫𝐞𝐧𝐠𝐭𝐡
Design Factor, nd = =
𝐦𝐚𝐱𝐢𝐦𝐮𝐦 𝐚𝐥𝐥𝐨𝐰𝐚𝐛𝐥𝐞 𝐩𝐚𝐫𝐚𝐦𝐞𝐭𝐞𝐫 𝐦𝐚𝐱𝐢𝐦𝐮𝐦 𝐚𝐥𝐥𝐨𝐰𝐚𝐛𝐥𝐞 𝐒𝐭𝐫𝐞𝐬𝐬
Where, parameters can be, loads, stresses, deflections etc. As stress may not vary proportionally with load, loads are not
usually used as loss of function parameter. Usually strength and stresses are used.
• All loss-of-function modes must be analyzed, and the mode leading to the smallest design factor governs.
• After the design is completed, the actual design factor may change as a result of changes such as rounding up to a
standard size or using off-the-shelf components with higher ratings instead of employing what is calculated by using the
design factor. The factor is then referred to as the factor of safety, n.
• The factor of safety has the same definition as the design factor, but it generally differs numerically.
16M
## A solid circular rod of diameter d undergoes a bending moment M = 100 Nm inducing a stress σ = πd3 . Using a material
of strength 170 MPa and a design factor of 2.5, determine the maximum diameter of the rod. Using TABLE A-17, select a
preferred fractional diameter and determine the factor of safety.
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 12
Types of Load
• Tensile Load ( Tension members, Bars)
• Compressive Load ( Most of the furniture, Columns*)
• Bending Load (Beams)
• Shear Load (Shear Members, Beams)
• Torsional Load (Shafts)
A member can be subjected to more than one of these
loadings.
*Columns can be subjected to Buckling too.
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 13
Properties
Properties involved in design can be-
• Geometric (length, width, diameter, moments of Inertia)
• Mechanical/ Material/ Physical (Modulus of Elasticity E, Modulus of Rigidity/Shear Modulus G, Strengths)
Modulus of Elasticity, E is not material Strength. It is just the slope of the linear part of Stress- Strain Curve.
E depends on composition of the material only.
Another property associated with deflection is Stiffness. Stiffness is a property of a part/component or a structure, which
involves material and geometric properties.
Extensional Stiffness = EA, Bending Stiffness = EI, Torsional/Twisting Stiffness = GJ
Where, I = 2nd Moment of Inertia, J = polar moment of Inertia
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 14
Designing Rickshaw Components, Revisited
Paddle
Chain
Power
Transmission Pulley
Base: Compressive Load
Rear Shaft: Torsion
Suspension System:
Leaf Spring
Bearing
Rear Pulley
Wooden Base
Leaf Spring bears bending load Rear Shaft Support Member Wheel Bearing
( not static but fluctuating)
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 15
Designing Rickshaw
Connecting
Rod
Suspension System: Welding
Leaf Spring
Brake
Rear Shaft
Bolts
Chain Bearing
Let us say,
We intend to design the suspension system of Rickshaw.
• Two curved members can be modeled as Leaf Springs.
• We asses how much load will act on each spring. Load calculation may require
Rigid Body Mechanics.
• The behave of Leaf Spring under that load is investigated from Mechanics of
Solids.
• We calculate how much stress will be developed from the physics of Leaf Spring.
• We select a suitable material with necessary strength and a design factor.
• Selection of material and design factor must be based on cost and availability.
• As material and design factor selected we calculate required size.
• Based on availability, we choose a suitable size from market.
• Factor of Safety is calculated.
• A model is made.
• Model is tested with design load or more than that.
• It is checked that whether the model can withstand that load or not.
• If yes, the design is okay for mass production.
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 17
Design Techniques
• The main difference between a mechanics problem and a design problem is,
In mechanics problems, geometric properties (l,w,d, inertia) is given, Loads, stresses etc. are to be determined.
In design problems, Strengths, stresses are given, geometric parameters are to be known choosing suitable material
properties.
• Sometimes the real physics of systems are not even really known. In those cases empirical formulae based on numerous
simulations and experiments are used. (Example: Welding Joints analysis, Fracture Mechanics, Fatigue Failure etc.)
• Sometimes empirical formulae are too much complex, it is better to develop a chart or graph to demonstrate the change
of parameters in certain intervals.
• Remember, there is nothing called an EXACT DESIGN. A design is always based on design factors or factors of safety.
• It is the designers decision how much design factor should be used. A house door definitely does not require as much
safety concern as an aircraft door does.
• Materials chosen should be effective. There is no point of designing normal water pipes with Titanium. Whereas in
NWPGCL, Khulna pipes are made with Titanium as the water is salty.
• Designs should be simple and reliable and as cost-effective. A rickshaw spring should not cost more than the
rickshaw itself or the monthly income of a rickshaw puller.
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 18
Topics Accommodated in Machine Design
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 19
Term Project
A term project has to be submitted in ME 352.
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 20
Marks Distribution
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 21
Md. Raihan Ali Khan, Dept. of ME, BUET L-3, T-2, Dept. of ME, BUET ME 352: Machine Design Sessional (July 2018) 22