PRESENTATION ON

“DESIGN OF MACHINE
ELEMENTS”

BY
MADHU CHANDRA.J
 CONTENT
• Introduction to Machine Design
• Design procedure
• Standardization
• Metal work and shop processes
• Metal Fits and Tolerances
• Terms and definitions
• Fits and types of fits
• Basis of limit system
• Surface roughness
• Stress-Strain diagrams
• Stress and types of stress
• Strain and types of strain
• Stress concentration factor
 OUTCOME OF PRESENTATION
After the presentation we come to know the following topics related
to Design of machine elements:

• Basic definition and types of machine design

• Procedure followed to design a machine or structure.
• Standards to be considered before designing.
• Which are the processes the designer should be convenient with.
• Terms we use in limit system in designing.
• Brief knowledge about surface roughness
• Fundamentals of mechanics which involves
 Stress-strain curves for different material.
 Stress and its types
 Strain and its types
 What is Stress concentration factor? How to reduce it?
 MACHINE DESIGN
It involves:
• Creation of new and better machine or
• Improving Existing one
So that it is economical in the cost of production and operation.

Design activities include:

 Creativity,
 Decision-making,
 Modeling.
CLASSIFICATION OF MACHINE
DESIGN
ADOPTIVE DESIGN

MACHINE DESIGN DEVELOPMENT

DESIGN

NEW DESIGN

INDUSTRIAL
DESIGN

RATIONAL DESIGN

EMPIRICAL
DESIGN
DESIGN PROCEDURE
Identifying the need

Selecting the Mechanisms

Analysis of Forces

Selection of Materials

Design of Elements

Modification

Detailed Drawings

Production

Quality Checking
 STANDARDIZATION
It provides:
• Better product quality , reliability, and longer life service.
• Mass production of components at low cost.
• Easy availability of parts for replacement and maintenance.
• Less time and effort required to manufacture.
• Reduction in variations in size and grades of an article.
Some of the standard specification of material are:
• SAE (Society of Automotive Engineers)
• ISO (International Organization for Standardization)
• AISI (American Iron and Steel Institute)
• ASTM (American Society for Testing and Materials)
• ASME (American Society of Mechanical Engineers)
 METAL WORK AND SHOP
PROCESSES
The design engineer must be conversant with the metal work
& shop processes.
 Some of the metal work & shop processes are:
oSoldering & Brazing
oCasting
oForging
oRolling
oCold drawing
oExtrusion
oGalvanizing
oPlating
oHeat treatment
oSintering
owelding
 MEATL FITS AND TOLERANCE
Below Fig. explains the terminologies used in defining tolerance and
limit.

• The zero line, shown in the figure, is the basic size or the nominal
size.
 TERMS USED IN LIMIT SYSTEM
• Allowance: It is the difference of dimension between two
mating parts.
• Deviation: It is the algebraic difference between a size(actual,
normal) and the corresponding basic size.
• Upper deviation: It is the difference of dimension between the
maximum possible size of the component and its nominal size.
• Lower deviation: Similarly, it is the difference of dimension
between the minimum possible size of the component and its
nominal size.
• Limits: Limits are the extreme permissible dimension of any
part. There are two extreme permissible size for a dimension
i.e. Upper limit and Lower limit.
TOLERANCE:
• Tolerance is the difference between between upper limit and
lower limit.
• Tolerance is of two types, bilateral and unilateral.

• When tolerance is present on both sides of nominal size, it is

termed as bilateral.
• Unilateral has tolerance only on one side.
 FITS:
• The degree of tightness or looseness between the two coupling
parts is known as a fit of the parts.
• The nature of fit is characterized by the presence and size of
clearance and interference.

 TYPES OF FITS
• Clearance fit
• Interference fit
• Transient fit
TYPES OF FITS
 BASIS OF LIMIT SYSTEM

HOLE BASIS: In this system the size of the hole kept constant and different
fits are obtained by varying the size of the shaft.

SHAFT BASIS: : In this system the size of the shaft kept constant and
different fits are obtained by varying the size of the hole.
 SURFACE ROUGHNESS

• Surface roughness is a component of surface texture.

• It is quantified by the deviations in the direction of the normal
vector of a real surface from its ideal form.
• If these deviations are large, the surface is rough; if they are
small, the surface is smooth.
• The descriptors shown below are used when
pictorially representing surface roughness.
SYMBOL EXPLANATORY DIAGRAM EXAMPLE

Shaped surface

Shaped surface (turned on

a lathe; seen from the
side), cylindrically ground
surface.

Honing finished surface

Lapped surface, super-

finished surface.

Faced surface
 Stress-Strain Diagram
Stress-Strain Curve for Ductile material (Mild Steel)

Portion OA: Proportional limit

Portion AB: Elastic limit.
Point B: Upper yield point
Point C: Lower yield point
Portion CD: Ultimate tensile stress point
Portion DE: Breaking stress
Stress-Strain for Brittle material

• Brittle materials, which includes cast iron, glass, and stone, are
characterized by the fact that rupture occurs without any noticeable
prior change in the rate of elongation.
• Brittle materials such as concrete or carbon fiber do not have a yield
point, and do not strain-harden. Therefore, the ultimate strength and
breaking strength are the same.
 STRESS
• When a body is subjected to external forces, equal and opposite internal
forces are developed at the various sections of that body. This resisting force
is known as stress.
• Stress is calculated by dividing force acting on body and cross sectional area.
• Mathematically it is given as:
F
σ
A
F : load applied in newton
A : cross sectional area in mm2
σ : stress in N/mm2
There are six major types of stress that cause failures.
 Compression
 Tension
 Shear
 Bending
 Torsion
 Fatigue
 TYPES OF STRESS
• Compression stress is the result of axially-loaded forces pointing towards
the center of an object.
• Tension stress is caused when axially-loaded forces are pulling away from
an object's center, and perpendicular to the object's surface.
• Shear stress is caused when the forces applied to an object are parallel to
the object's cross-section.
• Bending stress is seen in longitudinally-loaded objects. The forces cause
the object to bend, usually in a downward direction.
• Torsional stress is the shear stress produced in the shaft due to the twisting.
This twisting in the shaft is caused by the couple acting on it.
 STRAIN
• When a body experiences a system of force, some deformation (elastic or plastic)
takes place. This deformation per unit length of the body is known as the unit
strain or simply strain.
• Mathematically,

e Lo e
ε
Lo
L
e : elongation (mm)
Lo : Original length of a material (mm)

Elongation:

e  L  Lo

L : Loaded length of a material (mm)

 TYPES OF STRAIN
 According to the direction of loading:
 Lateral Strain: The ratio of change in length to its original length in
the perpendicular direction of the loading .
 Longitudinal Strain: The ratio of change in length to its original
length in the direction of loading.
 According to the loading:
Compressive strain: Strain measure under compressive loading.
It tends to increase the cross section area and decrease the length of
the body.
Tensile Strain: Strain measure under tensile loading.
It tends to decrease the cross section and increase the length of the
body.
Shear Strain: The change in tangential angle in the direction of the
loading is called shear strain.
Volumetric strain: The ratio of change in volume to original volume
under normal loading condition.
 Stress Concentration Factor (Kt)
•It is a dimensionless factor that is used to quantify how the stress is
concentrated in a material.
•It is defined as the ratio of the highest stress in the element to the
reference stress.

Stress concentration factors may also be obtained using any one

of the following experimental techniques:
 Strain gage method
 Photo elasticity method
 Brittle coating technique
 Grid method
 METHODS OF REDUCING STRESS
CONCENTRATION

• Provide a fillet radius so that the cross-section may change

gradually.
• Sometimes an elliptical fillet is also used.
• If a notch is unavoidable it is better to provide a number of small
notches rather than a long one.
• If a projection is unavoidable from design considerations it is
preferable to provide a narrow notch than a wide notch.
• Stress relieving groove are sometimes provided.
Force flow around a sharp corner Force flow around a corner with fillet:

Force flow around a large notch Force flow around a no. of small notches

Force flow around a narrow projection:

Force flow around a wide projection

Force flow around a sudden change

in diameter in a shaft Force flow around a stress relieving groove.