What is design ?
In general, the definition of design is a plan or design that is carried out
before the manufacture of an object, system, component, or structure.
Another opinion says that the meaning of design is the process of planning or
designing an object which aims to make the object created has a function, has
aesthetic value, and is useful for humans.
Etymologically, the term design comes from English, which is "design" which
means a design, plan, or design. The design process will take into account
various aspects, such as; aesthetics, function, and various other aspects obtained
from human research and thinking.
What is machine ?
Machine is defined as a combination of resisting bodies with succesfully
constrained relative motions which is used transform other form of energy into
mechanical energy of transmit and modify available energy to do some useful
work.
What is machine design ?
Machine design is the process of engineering design. A machine is made
up of mechanism that work together to satisy the requirements of what the
machine need to accomplish.
Types of machine design
Machine design can be classified into following types:
Adaptive design
The designer’s work is concerned with adaption of existing design. The
designer only makes minor alternation or modification in the existing
designs of the product.
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.
New design
This type of design needs lots of research, technical ability and creative
thinking.
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.
Empirical design
This type of design depends upon empirical formulae based on the
practice and past experience.
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
What device or mechanism to be used ?
To decide the relative arrangement of the constituent elements :
Material
Forces on the elements
Size
Shape and space requirements
Weight of the product
The method of manufacturing the components and their assembly
How will it operate
Reliability and safety aspects
Inspectibilty
Maintenance
Cost and aesthetics of the designed product
Basic procedure of machine design:
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:
Strength : a machine part should not fail under the effect of the
forces that act upon it. It should have sufficient strength to avoid
failure either due to fracture or due to general yielding.
Rigidity : a machine component should be rigid, i.e. it should not
deflect or bend too much due to forces or moments that act upon it.
A transmission shaft is many times, designed on the basis of lateral
and torsional rigidities. In these cases, maximum permissible
deflection and permissible angle of twist are the criterion for
design.
Wear resistance : wear is the main reason that puts the machine
part out of order. It reduces the useful life of the components. Wear
also leads to the loss of accuracy of machine tools. There are
different types of wear such as abrasive wear, corrosive wear and
pitting. Surface hardening can increase the wear resistance of the
machine components, such as gear and cams.
Minimum dimension and weight : A machine part should be
sufficiently strong, rigid and wear resistant and at the same time,
with minimum possible dimensions and weight. This will result in
minimum material cost.
Manufacturability : manufacturability is the ease of fabrication
and assembly. The shape and material of the machine part should
be selected in such a way that it can be produced with minimum
labour cost.
Safety : the shapes and dimensions of the machine parts should
ensure safety to the operator of the machine. The designer should
assume the worst possible conditions and apply ‘fail-safe’ or
‘redundancy’ principle in such cases.
Conformance to standards : A machine part should conform to
the national standard, covering its profile, dimensions, grade and
material.
Reliability : Reliability is probability that a machine part will
perform its intended functions under desired operating conditions
over a specified period of time. A machine part should be reliable,
i.e. it should perform its function satisfactorily over its lifetime.
Maintainability : A machine part should be maintainable.
Maintainability is the ease with which a machine part can be
serviced or repaired.
Minimum life cycle cost : Life cycle cost of the machine part is
the total cost to be paid by the purchaser for purchasing the part
and operating and maintaining it over its life span.
