05 January 2025 12:04

Lecture 1 & 2

Introduction
Machine design is defined as the use of scientific principles, technical information, and imagination in the
description of a machine or a mechanical system to perform specific functions with maximum
economy and efficiency.
Important features:
(i) A designer uses principles of basic and engineering sciences such as physics, mathematics, statics and dynamics,
thermodynamics and heat transfer, vibrations, and fluid mechanics.
Examples
(a) Newton’s laws of motion,
(b) D’ Alembert’s principle,
(c) Boyle’s and Charles’ laws of gases,
(d) Carnot cycle, and
(e) Bernoulli’s principle.

(ii) The designer has technical information on the basic elements of a machine.
Eg. : fastening devices, chains, belt and gear drives, bearings, oil seals and gaskets, springs, shafts, keys, couplings,
etc
A machine is a combination of these basic elements.

(iii) The designer uses his skill and imagination to produce a configuration, which is a combination of these basic
elements.

(iv) The outcome of the design process consists of the description of the machine. The description is in the form of
drawings of assembly and individual components.

(v) A design is created to satisfy the customer's recognized need. The need may be to perform a specific function
with maximum economy and efficiency.
BASIC PROCEDURE OF MACHINE DESIGN

Steps
1. Product Specifications
2. Selection of Mechanism
3. Layout of Configuration
4. Design of Individual Components
5. Preparation of Drawings

BASIC REQUIREMENTS OF MACHINE ELEMENTS

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 BASIC REQUIREMENTS OF MACHINE ELEMENTS

Each part of a machine, that has motion concerning some other part, is called a machine element.
Each machine element may consist of several parts, which are manufactured separately.
Eg.: A rolling contact bearing is a machine element and it consists of an inner race, outer race, cage, and rolling
elements like balls

Machine elements can be classified as:

a. General-purpose machine elements (used in large numbers)

Eg: shafts, couplings, clutches, bearings, springs, gears, and machine frames

b. Special-purpose machine elements (used only in certain types of applications)

Eg.: pistons, valves, or spindles

The broad objective of designing a machine element is to ensure that it preserves its operating capacity during the
stipulated service life with minimum manufacturing and operating costs.

The machine element should satisfy the following basic requirements:

1. Strength
2. Rigidity
3. Wear Resistance
4. Minimum Dimensions and Weight
5. Manufacturability
6. Safety
7. Conformance to Standard
8. Reliability
9. Maintainability
10. Minimum Life cycle cost

DESIGN OF MACHINE ELEMENTS

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 Steps:
1. Specification of Function
2. Determination of Forces
3. Selection of Material
4. Failure Criterion
5. Determination of Dimensions
6. Design Modifications
7. Working Drawing

DESIGN SYNTHESIS
Design synthesis is defined as the process of creating or selecting configurations, materials, shapes,
and dimensions for a product.

USE OF STANDARDS IN DESIGN

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.

The following standards are used in mechanical engineering design:

1. Standards for Materials, their Chemical Compositions, Mechanical Properties and Heat Treatment
Eg.:
• Indian standard IS 210 specifies seven grades of grey cast iron designated as FG 150, FG 200, FG 220, FG 260, FG 300, FG
350, and FG 400. The number indicates ultimate tensile strength in N/mm2.
• IS 1570 (Part 4) specifies the chemical composition of various grades of alloy steel. For example, alloy steel designated by
55Cr3 has 0.5–0.6% carbon, 0.10–0.35% silicon, 0.6–0.8% manganese, and 0.6–0.8% chromium.

2. Standards for Shapes and Dimensions of Commonly used Machine Elements

Eg.:
• The machine elements include bolts, screws and nuts, rivets, belts and chains, ball and roller bearings, wire ropes, keys
and splines, etc.
• IS 2494 (Part 1) specifies the dimensions and shape of the cross-section of endless V-belts for power transmission. The
dimensions of the trapezoidal cross-section of the belt, viz. width, height, and included angle are specified in this
standard.
• The dimensions of rotary shaft oil seal units are given in IS 5129 (Part 1). These dimensions include inner and outer
diameters and width of oil seal units.

3. Standards for Fits, Tolerances, and Surface Finish of Component

Eg.:
• Selection of the type of fit for different applications is illustrated in IS 2709 on ‘Guide for selection of fits’.
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• Selection of the type of fit for different applications is illustrated in IS 2709 on ‘Guide for selection of fits’.
• The tolerances or upper and lower limits for various sizes of holes and shafts are specified in IS 919 on
‘Recommendations for limits and fits for engineering’.
• IS 10719 explains a method for indicating surface texture on technical drawings.
• The method of showing geometrical tolerances is explained in IS 8000 on ‘Geometrical tolerancing on technical drawings’

4. Standards for testing of Products

Eg.:
• Standards, sometimes called ‘codes’, give procedures to test products such as pressure vessels, boilers, cranes, and wire
ropes, where the safety of the operator is an important consideration.
• IS 807 is a code of practice for the design, manufacture, erection, and testing of cranes and hoists.
• The method of testing pressure vessels is explained in IS 2825 on ‘Code for unfired pressure vessels’.

5. Standards for Engineering Drawing of Components

Eg.:
There is a special publication SP46 prepared by the Bureau of Indian Standards on ‘Engineering Drawing Practice for
Schools and Colleges’ which covers all standards related to engineering drawing.

Standard v/s code

A standard is defined as a set of specifications for parts, materials or processes.
The objective of a standard is to reduce the variety and limit the number of items to a reasonable level.

A code is defined as a set of specifications for the analysis, design, manufacture, testing and erection of the product. The
purpose of a code is to achieve a specified level of safety.

There are three types of standards used in design office.

(i) Company standards

They are used in a particular company or a group of sister concerns.

(ii) National standards

These are the IS (Bureau of Indian Standards), DIN (German), AISI or SAE (USA) or BS (UK) standards.

(iii) International standards

These are prepared by International Standard Organisation

SELECTION OF PREFERRED SIZES

The ‘size’ of the product is a general term, which includes different parameters like power transmitting capacity, load
carrying capacity, speed, dimensions of the component such as height, length and width, and volume or weight of the
product.
These parameters are expressed numerically, e.g., 5 kW, 10 kN or 1000 rpm.

Preferred numbers are used to specify the ‘sizes’ of the product.

The system is based on the use of geometric progression to develop a set of numbers.
There are five basic series, denoted as R5, R10, R20, R40 and R80 series, which increase in steps of
58%, 26%, 12%, 6%, and 3%, respectively.

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58%, 26%, 12%, 6%, and 3%, respectively.

Preferred Numbers

Basic series and Derived series

R5, R10, R20, R40 and R80 are called basic series.

Any series that is formed on the basis of these five basic series is called derived series.

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Find out the number of R5 basic series from 1 to 10

Find out the numbers of R20/4(100, …, 1000) derived series.

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A manufacturer is interested in starting a business with five different models of tractors ranging from
7.5 to 75 kW capacities. Specify power capacities of the models. There is an expansion plan to
further increase the number of models from five to nine to fulfil the requirement of farmers. Specify
the power capacities of the additional models.

It is required to standardize eleven shafts from 100 to 1000 mm diameter. Specify the series and its
diameters.

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It is required to standardize eleven shafts from 100 to 1000 mm diameter. Specify their diameters.

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