Industrial Drafting and

Machine Element Design

Dr. Dhaval B. Shah
Mechanical Engineering Department,
Institute of Technology,
Nirma University
Course Learning Outcomes (CLOs):

After successful completion of the course, student will be able to

1. Relate properties of materials, principal stresses and theories of
failure
2. Construct the 3D features like extrude, revolve, sweep,
blend(loft), swept blend, and other advanced features
3. Build assembly and prepare drawing of mechanical components
using solid modelling software
4. Evaluate the design of mechanical components like shaft,
coupling, key, lever, spring, power screw and columns.
 What is Design?
• Design is essentially an innovative, iterative and decision making process.
• If we have a problem, we need to design a solution.
• Design is to formulate a plan to satisfy a particular need and to create something
with a physical reality.
• Products should be
• Functional
• Safe
• Reliable
• Competitive
• Usable
• Manufacturable
• Marketable
 Types of design

Adaptive design Development design

New design
 Adaptive design

• This based on existing design, for example standard

products or systems adopted for a new application.

• Conveyer belts, control system of a machines are some of

the examples where existing design systems are adapted
for a particular use.
 Developmental design

• Here we start with an existing design but finally a

modified design is obtained.

• A new model of a car is a typical example of a

developmental design.
 New design
• This type of design is an entirely new one but based on
existing scientific principles.
• No scientific invention is involved but requires creative
thinking to solve a problem.
• Example of this type of design may include designing a small
vehicle for transportation of man and material in a desert.
• Some research activity may be necessary.
 Types of design
based on methods

Rational design Empirical design

Industrial design
 Rational design
• This is based on determining the stresses and strains of components
and there by deciding their dimensions.

Industrial design
• These are based on industrial consideration and norms viz. market
survey, external look, production facilities, low cost, use of existing
standard products.

Empirical design
• This is based on empirical formulae which in turn is based on experience
and experiments.
• There is no mathematical backing of this equation but it is based on
observations and experience.
 Design disciplines
Ship design Clothing/fashion design

Process design Bridge design

Building design Air-craft design

Machine design
 Definition of Machine
• Machine is defined as a combination of a resisting bodies with successfully
constrained relative motions which is used to transform other forms of energy into
mechanical energy or transmit and modify available energy to do some useful work.

Machine can receive mechanical energy and modify it so that a specific

task is carried out.
• A Machine is:
(1) an apparatus consisting of interrelated units, or
(2) a device that modifies force or motion

• A Structure has no moving parts.

 Machine Design
• Process of applying scientific principles and techniques to create
machinery that works reliably and safely.

• Application of science and technology to devise new or improved

products.

• Product is any manufactured item including machine, structure, tool

and instruments.

• People who design are called design engineers.

• Example : bicycle, lathe machine

 Basic concept of machine design
Decision making at every stage of design

• Consideration of various factor

• To draw certain conclusion leading to an
optimum design
• Market survey to read people’s mind
• Study of existing solutions

A bad decision leads to a bad design and a bad product

 What is Good Design?
• Activity done by engineers to create devices, structures, processes to fill a
need of problem solving, optimization, cost reduction, system analysis.
 Background of Machine Design
• Technical Drawing
• Kinematics
• Mechanics
• Material Science Engineering
• Strength of Materials
• Manufacturing Processes

Philosophy of Machine Design

• Requires fundamentals of knowledge
• No memorization of formulae or tables of data
• Build upon old ideas
• Be innovative and search for ideas
 Design Process
1. Identification of need
2. Background research
3. Goal statement
4. Task Specification
5. Synthesis • Design involves constrained creation
6. Analysis • Constraints:
• Technology limits
7. Selection • Human and environment concerns
8. Detailed Design • Durability and reliability
9. Prototype and Testing • Cost
• Market requirements, etc.
10. Production
1. Identification of need
Steel roofs – dangerous, hot.
Concrete roofs – unaffordable.
Alternate roofing is sought.
 2. Background research

Existing materials for roof

Cost for various possible

Alternate Possible Materials
available options

Life of available options

1. Clay Tile 6. Terracotta Tiles

2. Concrete Tile 7. Bamboo & Thatch Roofing
3. Metal Roofing 8. Asbestos Cement Sheets
4. Asphalt Shingles 9. Fibre Cement Roofing
5. RCC Slabs 10. Bituminous Roofing
 3. Goal Statement
To develop a durable, affordable, comfortable and sustainable
roofing system for low income groups.
4. Task Specification – which bound the
problem and limit its scope
4. Task Specification – which bound the
problem and limit its scope
4. Task Specification – which bound the
problem and limit its scope
5. Synthesis- Idea generation
5. Detailed synthesis for generated concepts
• Ultimate goal of detailed synthesis is to size and shape of the
element so that elements perform expected function without
failure

1. Force/Moment/Torque analysis

2. Stress and deflection analysis

3. Predict mode & conditions of failure.

4. Selection of appropriate material.

 6. Analysis
• To ensure the reliable performance, the concepts are evaluated for
mechanical strength view point
 7. Selection
• The concepts satisfying all the functional requirement, material cost
and ease of fabrication is to be selected by comparison
• Critical task and involves authorities decision making
 8. Detailed Design/Drawing
• Generation of
production ready
drawings
• Implementation of
required machining
tolerances, precision,
joining and finishing
methods, QC Methods
e.g. Real time
radiography, Real time
Ultrasonic Testing
• decision of purchase of
brought out items
considering available
manufacturing facilities
9. Prototype and Testing

10. Production
 Concurrent Engineering
• Conventional design process is sequential
• Sequential design process (over the wall design)

Marketing
Design office
department

Sales and service Production

department department
 Concurrent Engineering
Customer manufacturing
requirements

Sales and Design

reliability
service engineering

Ergonomics
Cost and aesthetics
 Design of a chair
Factors need to be considered

• The purpose for which the chair is to be designed such as weather it is to

be used as an easy chair, an office chair or to accompany a dining table.
• Whether the chair is to be designed for a grown up person orchild.
• Material for chair.
• Strength and cost need to be determined.
• The aesthetic and ergonomics of the designed chair.
• Almost every one is involved in design, in one way or other, in our daily
lives because problems are posed and they need to be solved.
 Factors to be considered in machine design
There are many factors to be considered while attacking a design problem. In
many cases these are common sense approach to solving a problem. Some of
these factors are as follows:
• What device or mechanism to be used? This would decide the relative arrangement
of the constituent elements.
• Material
• Forces on the elements.
• Size, shape and space requirements. The final weight of the product is also a major
concern.
• The method of manufacturing the components and their assembly.
• How will it operate?
• Reliability and safety aspects.
• Inspectibility
• Maintenance, cost and aesthetics of the designed product.
 Aesthetic consideration in design
• Each product has a definite purpose
• Customer is attracted towards the most appealing product
• Industrial Design Centre (IDC)
• There are five basic forms
➢ Step, stream, taper, shear (square outlook), sculpture (ellipsoid,
paraboloids, hyperboloids)
• Functional requirement and appearance of the product
➢ Aerodynamic structure for effortless speed
➢ Chromium plating on household appliance
• Selection of proper colour
➢ Red (danger-hazard-hot), orange (possible danger), yellow (caution),
green (safety)
 Ergonomic consideration in design
• Relationship between man and machine
• Ergon (work)
• Nomos (natural laws)
• Natural laws of work
• From design consideration
➢ Anatomical factors in design of driver’s seat
➢ Layout of instruments dial and display panels
➢ Design of hand levers and hand wheels
➢ Energy expenditure in hand and foot operation
➢ Lighting, noise and climate conditions in machine environment
 Ergonomic consideration in design
• The ergonomic consideration in design of control are as follows:

➢ The control should be easily accessible and logically positioned.

The control operation should involve minimum motions and
avoid awkward movements.

➢ The shape of the control component, which comes in contact

with hands, should be in conformity with anatomy of human
hands.

➢ Proper colour produces beneficial psychological effects.

 Factors in selection of factor of safety

• Degree of uncertainty about loading

 Factors in selection of factor of safety
• Degree of uncertainty about material strength
• Uncertainties in relating applied loads to material strength via stress
analysis

Isotropic material –simple Composite material-difficult

Functionally graded material –complex

Complexity in material, geometry and loading

 Factors in selection of factor of safety

• Consequence of failure – human safety and economics

• Cost of providing a large safety factor

Key point in selection of design is “BALANCE”

Factor of Safety (FOS)
Factor of Safety (FOS)
 Recommended values – factor of safety
• SF = 1.25 to 1.5 – exceptionally reliable materials used under controllable
condition and subjected to loads and stresses that can be determined with
certainty
• SF = 1.5 to 2 – well known material, under reasonably constant environmental
conditions, subjected to loads and stresses that can be determined readily
• SF = 2 to 2.5 – average material operated in ordinary environments and
subjected to loads and stresses that can be determined
• SF = 3.5 to 3 – less tried materials or for brittle material under average
conditions of environment, load and stress
• SF = 3 to 4 – untried material used under average conditions of environment,
load and stress OR better known material that are used in uncertain
environment or subjected to uncertain stresses
• Repeated load – Endurance limit
• Impact Load – additional impact factor
• Brittle material – with ultimate strength, at least double factor of safety to be used than
ductile