Under Graduate Course on

Machine Design-I
Design of Machine Elements
Shibendu Shekhar Roy
Robotics & A.I Lab. (RAIL) Department of Mechanical Engineering

4 February 2009

Machine Design

Reference Books
1. 2. 3. V.B. Bhandari, Design of Machine Elements , <second 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

4 February 2009

Machine Design

Topics to be Covered
Chapter
Introduction

Topics
- Review of Stress, Strain and Complex stresses in machine members - Basic procedure of machine design & machine element design - Manufacturing & other consideration in machine design - Modern Computational Tools for Machine Design - Role of CAD/CAE in Machine Design - Mechanical properties of Engineering materials - B.I.S system of designation of commonly used Engineering Materials - Selection of Materials
- Design of Cotter Joint - Design of Knuckle Joint

Engineering Materials

Rod Joints Plate Joints

4 February 2009

- Design of Threaded Joints - Design of Welded Joints

Machine Design

Topics to be Covered
Chapter
Design against Static Load

Topics
- Elastic failure theories, Factor of safety, Service

factor - General principles & procedures of design of machine elements

- Stress Concentration factor, Fatigue failure,

Design against Dynamic Load Design of Shafts, Keys, Splines

Endurance limit etc.

- Reversed stresses- design for finite & infinite life,

Impact stresses etc.

- Design of Shaft under Torsion, Bending, Axial &

Combined loads - Design of keys like square & flat, saddle, sunk, woodruff keys etc.

4 February 2009

Machine Design

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
4 February 2009

Bearing Connecting rod Power Screw Shaft & Axle Riveted Joint

Welded Joint
Machine Design

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.]
4 February 2009 Machine Design 6

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
4 February 2009 Machine Design 7

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

4 February 2009

Machine Design

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

transfers

Mechanism
transforms

Motion

Primary Objectives

Mechanism Machine Machine

transfers Energy transforms

Machine tool is a contrivance having a combination of mechanisms/machines whereby a cutting tool is enabled to operate in a pre-conceived manner in order to produce a surface of desired shape, size or a degree of finish by removing metal from workpiece in the form of chips.
All Machines are Mechanism but all Mechanisms are not Machine All Machine Tools are Machine but all Machines are not Machine Tool

4 February 2009

Machine Design

Basics of Mechanism
Kinematic Link Kinematic Pair Kinematic Chain
One link fixed

transfers

Mechanism
transforms

Motion

Mechanism Machine

Kinematic Link

- Each part of a mechanism which has motion relative to some other part

Kinematic Pair

- is a joint of two links having relative motion between them

Machine Design 10

4 February 2009

Basics of Mechanism
According to Nature of Contact
Lower Pair Higher Pair

Types of Kinematic Pairs According to Nature of Relative Motion

Sliding/ Prismatic Pair

Turning/ Revolute Pair

Screw Pair

Cylindrical Pair

Spherical Pair
4 February 2009 Machine Design 11

Basics of Mechanism
Kinematic Link
transfers

Kinematic Pair Kinematic Chain

One link fixed

Machine Mechanism Machine

transforms

Energy

Kinematic Chain

- A combination of kinematic pairs joined in such a way the relative motion of any point on a link w.r.t the any other point on other link follows a definite law.
Closed Chain

Open Chain

Mechanism

- A kinematic chain in which one link fixed & used for transmitting & transforming motion.
Machine Design 12

4 February 2009

Mechanism

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

Machine

- Combination of resistant bodies having definite motions & capable of performing useful work.

4 February 2009

Machine Design

13

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

4 February 2009

Machine Design

14

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

4 February 2009

Machine Design

15

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
4 February 2009 Machine Design 16

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

4 February 2009

- 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
Machine Design 17

Basic Requirements of Machine Elements

Safety
- 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.

Reliability

Maintainability - ease with which a machine part can be serviced or repaired.

- machine part should be maintainable

Conformance to Standards

- machine part should confirm to the National or International standard.

Minimum Life Cycle cost

- Total cost to be paid by the purchaser for purchasing the part and operating & maintaining it over its life span.
Machine Design 18

4 February 2009

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

4 February 2009

Machine Design

19

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

4 February 2009

Machine Design

20

10

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

4 February 2009

Machine Design

21

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

4 February 2009

Machine Design

22

11

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
4 February 2009 Machine Design 23

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.

4 February 2009

Machine Design

24

12

Manufacturing Considerations in Machine Element Design

4 February 2009

Machine Design

25

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.

4 February 2009

Machine Design

26

13

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.

4 February 2009

Machine Design

27

Sequential Engineering Approach Vs. Concurrent Engineering Approach

Sequential Design Process
Prototype Development Stage

Customer

Marketing Department

Design Office
Production Department

Sales & Service Department

4 February 2009

Machine Design

28

14

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. 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

Concurrent Engineering

4 February 2009

Machine Design

29

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

4 February 2009

Ergonomics & Appearance Machine Design

Reliability, Maintainability & safety 30

15

4 February 2009

Machine Design

31

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

4 February 2009

Computer Aided Design Computer Aided Engineering Computer Aided Manufacturing Virtual Prototyping & Virtual Reality
Machine Design 32

16

 is the use of Information technology/ computer based tools for supporting Engineers in tasks such as Design, Analysis, Simulation, Optimization, Manufacturing, Planning etc. is to design, develop and optimize the product or process. CAE areas: Stress analysis, Vibration analysis using FEM Thermal & fluid flow analysis using CFD Kinematic & Dynamic Analysis & Simulation Analysis tools for manufacturing process simulation Optimization of the product or process is the use of wide range of computer based tools that assist Engineers & other Design Professionals in their design activities. is to design, develop and optimize the product. is the use of wide range of computer based tools that assist Production Engineers & Tool and Die maker, CNC machinists, in the manufacture or prototyping of products.
4 February 2009 Machine Design 33

Scope of CAD/CAE

Geometric Modeling Concept

CAD/CAE

Computer Graphics Algorithm

Design & Analysis Theories/ Tools

(FEA, CFD)

4 February 2009

Machine Design

34

17

Scope of CAD/CAM

Geometric Modeling & Computer Graphics

Automation
CAM/CAM (Robot, FMS, CAPP)

Manufacturing Process
(RP&T, CNC)

4 February 2009

Machine Design

35

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

4 February 2009

Machine Design

36

18

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

VP : Virtual Prototyping
VP is about Presentation, Testing, & Analysis of 3-D CAD models prior to creating any physical prototype Visualization Models : greater communication, productivity & efficiency through realistic graphical modelling based on full colour, natural texture & appearance, dynamic viewing of models from any userspecified angle & orientation. Fit & Interference checking of mechanical assemblies Testing & Verification of functions & performance : Structural & Physical phenomena analysis [FEM, CFD], Motion analysis. Manufacturing Evaluation Assembly analysis Human factor analysis
4 February 2009 Machine Design 37

VP : Virtual Prototyping Digital Prototyping

VP is about Presentation, Testing, & Analysis of 3-D CAD models prior to creating any physical prototype Visualization Models : greater communication, productivity & efficiency through realistic graphical modelling based on full colour, natural texture & appearance, dynamic viewing of models from any userspecified angle & orientation. Fit & Interference checking of mechanical assemblies Testing & Verification of functions & performance : Structural & Physical phenomena analysis [FEM, CFD], Motion analysis. Manufacturing Evaluation Assembly analysis Human factor analysis

4 February 2009

Machine Design

38

19

4 February 2009

Machine Design

39

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

4 February 2009

Machine Design

40

20

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

4 February 2009

Machine Design

41

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

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

4 February 2009

Machine Design

42

21

CAD-CAE Tools
Design Phase
Design

Required Modules of CAD-CAE Tools

Geometric modeling, Graphics aids, visualization Geometric modeling, Graphics aids, visualization, Simulation module Geometric modeling, Analysis module, visualization Geometric modeling, Optimization module Geometric modeling, Customized programs & Package Geometric modeling, Drafting module

Related Software (s) (available at ME, NITD)

CATIA Part design, Assembly, Generative Shape, Surface Design, CATIA DMU Kinematics, SimDesigner Motion, ADAMS CATIA SimDesigner Structural, NASTRAN, ANSYS CATIA DMU Optimizer, MATLAB Optimization tool box CATIA DMU Navigator, Fitting, Space analysis, Tolerancing review CATIA -Drafting, AutoCAD, MATLAB, MS-EXCEL

conceptualization
Modeling & Simulation Design Analysis Design Optimization Design Evaluation Design communication & documentation

4 February 2009

Machine Design

43

CAD-CAE Tools
Performed computation on high end computer

CAD

3-D CAD model

Pre-Processor

Solver
CAE

Post-Processor

Define the model & environment factors to be applied

Display results in graphical form using visualization tools

4 February 2009

Machine Design

44

22

Engineering Analysis : CAD-CAE Tools

Experimental methods

Analysis
Analytical methods: Simulation

Both are performed to assess product performance

CAE areas: Stress analysis, Vibration analysis using FEM Thermal & fluid flow analysis using CFD Kinematics & Dynamic Analysis & Functional Simulation Manufacturing process simulation Optimization of the product or process

4 February 2009

Machine Design

45

Thank You

4 February 2009

Machine Design

46

23

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. 8. Explain the functional area of a basic CAD-CAE system & their applications & benefits in machine design process with examples.

Last date of submission : 02nd February, 2009

4 February 2009 Machine Design 47

24