MACHINE DESIGN-I

BTMC 502
3+1 Lectures
4 credits
Mr. A. J. Punewale
Assistant Professor,
Department of Mechanical Engineering,
Deogiri Institute of Engineering and Management Studies.
 Institute Vision & Mission
• Institute Vision:

Nation building by creating opportunities for rural and urban students through excellence in education and

research in the field of Engineering and Management.

• Institute Mission:
1. To develop the students for best academic and industrial practices by implementing innovative teaching
learning methodologies, promoting all round development by giving exposure to series of activities.

2. To prepare the students to face global challenges by equipping them with requisite technical expertise and
developing entrepreneurship skills among them.

3. To promote research attitude among faculty and students.

 Department Vision & Mission
• Department Vision:

Developing the department as a center of excellence to produce engineers with knowledge, skills and

character for all occupation.

• Department Mission:

1. To impart quality education to the students to develop technical skills and make them a competitive

mechanical engineer.

2. To educate, prepare, inspire and mentor students to excel professionally and personally to serve the

society.

3. To inculcate research attitude among faculty and students

 Welcome to Machine Design-I course
• Course Code: BTMC 502

• Course Category: Professional Core Courses (PCC) No. 9

• Teaching Scheme: 03 Hours Lectures + 01 Hour Tutorial

• No. of Credits: 04

• Total Units: 05

• No. of Lectures: 35

• Evaluation Scheme:

1. Continuous Assessment (CA): 20 Marks

(CA1: 10 Marks & CA2: 10 Marks)

2. Mid-Semester Examination (MSE): 20 Marks

3. End Semester Examination (ESE): 20 Marks

Pre-requisites

Engineering Mathematics

Engineering Drawing

Material Science & Metallurgy

Engineering Mechanics

Strength of Material (SOM)

Course Outcomes: COs
At the end of the course, students will be able to:
CO1: Understand design process, phases, & design
consideration, and apply various principles of design.

CO2: Anal yze different component behavior subjected to loads

and identify their failure criteria’s .

CO3: Appl y different theories of failures for designing various

machine components,such as, shaft, couplings, fasteners, etc.

CO4: Anal yze fluctuating loads and design the components for
finite and infinite life.
Course Contents:
Unit 1: Mechanical Engineering Design Process

Unit 2: Design of Machine Elements against Static Loading

Unit 3: Design against Fluctuating Loads

Unit 4: Design of Shafts Keys and Couplings

Unit 5: Design of Threaded Joints and Mechanical Springs

 INTRODUCTION
TO
DESIGN & MACHINE
DESIGN
Mr. A. J. Punewale
What is Design????
User and Environment
• Useful to the user.
• Sustainable solutions.

Form and Function

• Good looking shape/Form.
• Works well.

Creativity and Innovation

• Something new
• Innovative

Method and Process

• Solves Problem.
• Phase-by-Phase
What is Design????
• Design is about understanding needs, identifying Problems, that need to
be solved, and creating innovative appropriate solutions, considering
aspects of context, social concerns, sustainability and technology.

• It should make a difference to the problem.

What is Design????
• Design is to formulate a plan, to satisfy a particular need and to
create something with physical reality.

• Realization of a concept or idea into a configuration.

• Design is the creation of a plan or convention for the construction of an

object, system or measurable human interaction .
Who is Designer????
• A designer is a highly creative person, who enjoys solving problems.

• The reason why they enjoy being creative is that they are sensitive to
the needs of life and understand the extent of the issues in society and
environment.

• This sensitivity allows a designer to be logical (analytical) as well as

intuitive (creative) and to think of opportunities for creative design
solutions that enhance the lives of people and other living beings.
Professions for a Designer:
• Communication/Graphic Design, Product Design, Animation Design,
Vehicle Design, Architecture Design, Environmental Design,
Interface/Interaction Design, Textile/Fashion Design, Service Design,
and such.

• Systems Design, Software Design, Engineering Design, Digital Design,

Transportation Design, Structural Design, Equipment Design, Machine
Design, and such.
What is Design Thinking???
• Design Thinking is a method to solve problems using a process.

• It is one of the most effective ways to create something new.

• A process that helps you understand users, research relevant

information, identify and analyze the problem, explore creative ideas or
concepts, then prototype, build, test and get feedback - to find an
appropriate innovative solution to the problem.
What is Design Thinking???
• Design Thinking as a process converts a problem into a solution, and an
idea into something useful, whether it's a vehicle, a building, a graphic,
an equipment, a service or a system.
What is Design Thinking???
Let's summarize
What is Design Thinking???
Let's summarize
What is Machine???
• Machine is defined as a combination of resisting bodies with
successfully constrained relative motions which is used transform other
forms of energy into mechanical energy or transmit and modify available
energy to do some useful work.

• An apparatus using mechanical power and having several parts, each

with a definite function and together performing a particular task.

• Semi or fully automated device that magnifies human physical and/or

mental capabilities in performing one or more operations.
What is Machine Design???
• Machine is a combination of several machine elements
arranged to work together as a whole to accomplish specific
purpose.

• Machine Design involves designing the elements and arranging them

optimally to obtain some useful work.

• Machine design is the process of engineering design.

Classification of Machine Design

Types of design

Adaptive New
Design Development Design
design
Types of Machine Design
1) Adaptive Design:- The designer’s work is concerned with adaptation
of existing design. The designer only makes minor alternation or
modification in the existing designs of the product.

2) Development Design:- This type of design needs considerable

scientific training and design ability in order to modify the existing
design into a new idea by adopting a new material or different
method of manufacture. The designer starts from the existing design,
but final product may differ quite markedly from the original product.

3) New Design:- This type of design needs lots of research, technical

ability and creative thinking.
Classification of Machine Design

Types of design
based on
method

Rational Industrial
Design Empirical Design
Design
Types of Design based on method
1. Rational Design:-
Based on determining the stresses and strains of components and
thereby deciding their dimensions. This type of design depends upon
mathematical formulae of principal of mechanics.

2. Empirical Design:-
This type of design depends upon empirical formulae based on the
practice and past experience .
Types of Design based on method
3. Industrial Design:-
• This type of design depends upon the production aspects to
manufacture any machine component in the industry.
• Based on industrial considerations and norms viz. market survey,
external look, production facilities, low cost, use of existing
standard products
 Factors to be considered in
Machine Design
1. What device or mechanism to be used???
2. To decide the relative arrangement of the constituent elements.
• Material
• Forces on the elements
• Size
• Shape and space requirements
• Weight of the product
 Factors to be considered in
Machine Design
3. The method of manufacturing the components and their assembly.
4. How will it operate.
5. Reliability and safety aspects.
6. Inspectiabilty
7. Maintenance
8. Cost and aesthetics of the designed product.
General procedure in Machine
Design
Need or Aim Synthesis (Mechanisms) Analysis of forces

Design of Elements Material Selection

Modification Detailed Drawing

Production
 Standardization
• Standardization is defined as obligatory (or compulsory) norms,
to which various characteristics of a product should comply (or
agree) with standard.
• The characteristics include materials, dimensions and shape of
the component, method of testing and method of marking,
packing and storing of the product.
• 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.
 Standardization
• On the other hand, 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 :-
➢ Company Standards: They are used in a particular company or
a group of sister concerns.
 Standardization
➢ National standards:
– India - BIS (Bureau of Indian Standards),
– Germany - DIN (Deutsches Institut für Normung),
– USA - AISI (American Iron and Steel Institute) or SAE (Society of Automotive
Engineers),
– UK - BS (British Standards)

➢ International standards: These are prepared by the International

Standards Organization (ISO).
Standards are used in mechanical
engineering design
Standards for Materials, their chemical compositions, Mechanical
properties and Heat Treatment:
For example, 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.

Standards for Shapes and dimensions of commonly used Machine Elements:

The machine elements include bolts, screws and nuts, rivets, belts and chains, ball
and roller bearings, wire ropes, keys and splines, etc
For example, IS 2494 (Part 1) specifies 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
Standards are used in mechanical
engineering design
Standards for Fits, Tolerances and Surface Finish of Component:
For example, 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 method for indicating surface texture on technical drawings.
Standards for Tes ting of Products:

These standards, sometimes called 'codes', give procedures to test the products
such as pressure vessel, boiler, crane and wire rope, where safety of the
operator is an important consideration.

For example, IS 807 is a code of practice for design, manufacture, erection and
testing of cranes and hoists.
 Benefits of Standardization
• Reductions in types and dimensions of identical components (inventory
control).
• Reduction in manufacturing facilities.
• Easy to replace (Interchangeability).
• No need to design or test the elements.
• Improves quality and reliability.
• Improves reputation of the company which manufactures standard
components.
• Sometimes it ensures the safety.
• It results in overall cost reduction.
 Preferred Numbers
• With the acceptance of standardization, there is a need to keep the standard sizes or
dimensions of any component or product in discrete steps.
• The sizes should be spread over the wide range, at the same time these should be
spaced properly.
• For example, if shaft diameters are to be standardized between 10 mm and 25 mm,
then sizes should be like : 10 mm, 12.5 mm, 16 mm, 20 mm, 25 mm and not like : 10
mm, 11 mm, 13 mm, 18 mm, 25 mm.
• This led to the use of geometric series known as series of preferred numbers or
preferred series.
.
• Preferred series are series of numbers obtained by geometric progression and
rounded off
Preferred Numbers
• There are five basic series with step ratios of:

5
10 , 10
10 , 20
10 , 40
10 & 80
10

• These ratios are approximately equal to 1.58, 1.26, 1.12, 1.06 and 1.03.

• The five basic series of preferred numbers (known as preferred series)

are designated as: R5, R10, R20, R40, and R80.

• The examples of preferred number series are: standard shaft diameters,

power rating of coupling, center distances of standard gear boxes, etc.
Advantages Preferred Numbers
• The difference in two successive terms has a fixed percentage.

• It provides small steps for small quantities and large steps

for large quantities.

• The product range is covered with minimum number of

sizes without restricting the choice of the customers.
Advantages Preferred Numbers
• The difference in two successive terms has a fixed percentage.

• It provides small steps for small quantities and large steps

for large quantities.

• The product range is covered with minimum number of

sizes without restricting the choice of the customers.
 R5 R10 R20 R40
1.00 1.00 1.00 1.00
1.06
1.12 1.12
1.18
1.25 1.25 1.25
1.32
1.40 1.40
1.50
1.60 1.60 1.60 1.60
1.70
1.80 1.80
1.90
2.00 2.00 2.00
2.12
2.24 2.24
2.36
2.50 2.50 2.50 2.50
2.65
2.80 2.80
3.00
3.15 3.15 3.15
3.35
3.55 3.55
3.75
4.00 4.00 4.00 4.00
4.25
4.50 4.50
4.75
5.00 5.00 5.00
5.30
5.60 5.60
6.00
6.30 6.30 6.30 6.30
6.70
7.10 7.10
7.50
8.00 8.00 8.00
8.50
9.00 9.00
9.50
 Aesthetic Considerations
• In a present days of buyer's market, with a number of products available in the
market are having most of the parameters identical, the appearance of
product is often a major factor in attracting the customer.
• This is particularly true for consumer durables like: automobiles, domestic
refrigerators, television sets, etc.
• Aesthetics is defined as a set of principles of appreciation of beauty. It deals
with the appearance of the product.
• Appearance is an outward expression of quality of the product and is the first
communication of the product with the user.
• For any product, there exists a relationship between the functional requirement
and the appearance of a product.
Aesthetic Considerations
• The aesthetic quality contributes to the performance of the product, though
the extent of contribution varies from the product to product.

• The following guidelines may be used in aesthetic design (design for

appearance):

• The appearance should contribute to the performance of the product.

For example, the aerodynamic shape of the car will have a lesser air
resistance, resulting in the lesser fuel consumption.

• The appearance should reflect the function of the product.

For example, the aerodynamic shape of the car indicates the speed.

• The appearance should reflect the quality of the product.

For example, the robust and heavy appearance of the hydraulic press reflects its
strength and rigidity
 Aesthetic Considerations
• The appearance should not be at too much of extra cost unless it is a prime
requirement.

• The appearance should be suitable to the environment in which the product is

used.

• The growing importance of the aesthetic considerations in product design has

given rise to a separate disciple known as industrial design.

• The job of an industrial designer is to create new shapes and forms for the
product which are aesthetically appealing

– Form (Shape)
There are five basic forms of the products, namely, step, taper, shear, streamline and sculpture
 Aesthetic Considerations
Step form:

The step form is a stepped structure having vertical accent

It is similar to the shape of a multistorey building.

Taper form

The taper form consists of tapered blocks or tapered cylinders.

Shear form

The shear form has a square outlook.

Streamline form

The streamline form has a streamlined shape having a smooth flow as seen in automobile and
aeroplane structures

Sculpture form
Aesthetic Considerations
• Colour
Colour is one of the major contributors to the aesthetic appeal of the product.
Many colours are linked with different moods and conditions.
The selection of the colour should be compatible with the conventions.
Morgan has suggested the colour code given in the following Table.

Colour Meaning
Red Danger, Hazard, Hot
Orange Possible Danger
Yellow Caution
Green Safety
Blue Caution-Cold
Grey Dull
Aesthetic Considerations
• Material and Surface Finish
The material and surface finish of the product contribute significantly to
the appearance.

The material like, stainless steel gives better appearance than the cast irons,
plain carbon steels or low alloy steels.

The brass or bronze give richness to the appearance of the product.

The products with better surface finish are always aesthetically pleasing.

The surface coating processes like: spray painting, anodizing, electroplating,

etc. greatly enhances the aesthetic appeal of the product.
 Ergonomic Considerations
• Ergonomics is defined as the scientific study of the man-machine-working
environment relationship and the application of anatomical, physiological
and psychological principles to solve the problems arising from this
relationship

• The word ergonomic is formed from two Greek word: ergo means work and
nomic mean natural laws.

• The final objective of the ergonomics is to make the machine fit for user rather
than to make the user adapt himself or herself to the machine.

• It aims at decreasing the physical and mental stresses to the user.

• Psychology - Experimental psychologists who study people at work to provide

data on such things as: Human sensory capacities, psychomotor
performance, Human decision making, Human error rates, Selection tests and
procedures, Learning and training.
Ergonomic Considerations
• Anthropometry - An applied branch of anthropology concerned with the
measurement of the physical features of people. Measures how tall we are,
how far we can reach, how wide our hips are, how our joints flex, and how
our bodies move.

• Applied Physiology - Concerns the vital processes such as cardiac function,

respiration, oxygen consumption, and electromyography activity, and the
responses of these vital processes to work, stress, and environmental
influences.
Ergonomic Considerations
• This man-machine closed loop system in influenced by the working environmental
factors such as: lighting, noise, temperature, humidity, air circulation, etc.

• Ergonomic Considerations in Design of Displays

• Ergonomic Considerations in Design of Controls

• Working Environment.

• Lighting

• Noise

• Temperature

• Humidity and air circulation