Introduction to Machine

Design
330:148 (g)
Objectives
Machine Design Field of activities in Machine Design

Course Details
Nageswara Rao Posinasetti

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What is machine design? What is Good Design?

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.
Activity done by engineers (includes
technologists) to create devices,
structures, processes to fill a need
Problem solving
Optimization
Cost containment/ reduction
System analysis

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 Background for Machine
Definition of Engineering
Design
.that profession in which knowledge of Technical drawing
the mathematical and natural sciences Kinematics
gained by study, experience and practice Mechanics
is applied with judgement to develop ways
to utilise, economically, the materials and Materials engineering
forces of nature for the benefit of the Strength of materials
mankind. (ABET) Manufacturing processes

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Philosophy of Machine
Check list for Designers
Design
Requires fundamentals of knowledge Does it satisfy the need?
No memorisation of formulae or tables of Will it be competitive?
data Is it economical to produce?
Build upon old ideas Can it be readily maintained?
Be innovative and search for ideas Will it sell and make a profit?

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Major areas in Machine Major areas in Machine

Design Design
Initial design conception Economy
Strength analysis Safety
Material selection Environmental effects
Appearance Reliability and life
Manufacturability Legal consideration

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 Design process elements Recognition of need

Decide on a number alternatives Stages Definition of problem

in the
Evaluate each alternative and discard the design Synthesis
unsatisfactory ones process
Choose the optimum one from the Analysis and optimisation
alternatives Iteration
Implement the design Evaluation
Iteration
Presentation

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Design considerations Design considerations

Strength/stress Deflection/stiffness Styling Shape
Wear Corrosion Size Control
Safety Reliability Thermal properties Surface
Friction Usability Lubrication Marketability
Utility Cost Maintainability Volume
Processing Weight Liability Recycling
Life Noise

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Material Properties Design problem

Yield strength Select a round bar to be constructed from an AISI 1020
Su cold-
cold-drawn steel to support the 300-
300-pound ball. Assume
Ultimate strength Sy a safety factor of 2, and determine the deflection for the
size selected
Modulus of Elasticity Proportional limit
Stress, S Yield stress = 61,000 psi
Ductility S
E=e

Thermal expansion

Strain, e

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 Information in Machine
Design problem
Design
Cantilever beam Catalogues
Max bending moment = 300 36
= 10,800 in-
Catalogue services - CDROM
in-lb
Stress in the beam, S = M/Z Internet
S = 10,800 32 / (
( d3) Yellow pages
Allowable stress = 61,000 / 2 = 30,500 psi
Equating the above two, and solving
Trade publications
d = 1.533 in = 1.625 in (preferred size) Trade shows
Deflection = -FL3 / (3EI) = 0.455 in Product registers

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Codes and standards Standard Institutions

Standard is a set of specifications for Professional National Standards
parts, materials or processes intended to societies ANSI
achieve uniformity, efficiency and a AGMA DIN
specified quality. AISI JIS
Code is a set of specifications for the AFBMA BIS
analysis, design, manufacture and ASM ISO
construction of some thing. ASME
ASTM
AWS
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Economics Break even chart

Standard sizes
Break even chart
Large tolerances
80
Breakeven points
Average cost per

60
Cost estimates
piece

Open die forging

40
Closed die forging
20

0
1 10 100 1000
Production Quantity

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 Safety and product liability
Manufacturer of an article is liable for any
damage or harm that results because of a
defect.
Good Engineering
Analysis
Design
Quality control

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Computational tools
Module 1-3a
Properties of Rectangular Cross Sections

b/2

MathCad h x
C
h/2
MATLAB
b
TK Solver b=
h=
2.000
1.000
in
in
width
height

Area = 2.000 in

Excel or Lotus 1- A = bh
1-2-3 4
Ix = 0.166667 in b h3
Ix=
CAD and FEA 12
4
Iy = 0.666667 in h b3
Iy=
12
kx = 0.288675 in
Ix
kx =
A
Courtesy: M.F.Spotts Design
ky = 0.333333 in Iy of Machine Elements
ky =
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Module 1-3a Problem using Finite Element Analysis (FEA)

Properties of Rectangular Cross Sections

b/2 Start with 2 in dia; Max stress = 13,751 lower than

the allowable 30,500 psi
h x
C
h/2

b
b= 3.000 in width
h= 2.000 in height

Area = 6.000 in
A = bh
4
Ix = 2 in b h3
Ix=
12
4
Iy = 4.5 in h b3
Iy=
12
kx = 0.57735 in
Ix
kx =
A
Courtesy: M.F.Spotts Design
ky = 0.75 in Iy of Machine Elements
ky=
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 Problem using FEA (contd..) Problem using FEA (contd..)
Next try 1.5 in dia; Max stress = 32,599 higher Next try 1.625 in dia; Max stress = 25,635 lower
than the allowable 30,500 psi than the allowable 30,500 psi - Acceptable

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Problem using FEA (contd..) Why Calculating Moments is

For 1.625 in dia; Max displacement = 0.47 in
Compare this to analytical solution of 0.455 in, a
Important?
3% error http://www.sv.vt.edu/classes/ESM2204/ES
M2204_kriz_NoteBook/moments/moments
.html

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http://www.sv.vt.edu/classes/ESM2204/ESM2204_kriz_NoteBook/moments/moments.html http://www.sv.vt.edu/classes/ESM2204/ESM2204_kriz_NoteBook/moments/moments.html

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http://www.sv.vt.edu/classes/ESM2204/ESM2204_kriz_NoteBook/moments/moments.html http://www.sv.vt.edu/classes/ESM2204/ESM2204_kriz_NoteBook/moments/moments.html

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http://www.sv.vt.edu/classes/ESM2204/ESM2204_kriz_NoteBook/moments/moments.html http://www.sv.vt.edu/classes/ESM2204/ESM2204_kriz_NoteBook/moments/moments.html

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http://www.sv.vt.edu/classes/ESM2204/ESM2204_kriz_NoteBook/moments/moments.html

August 15, 2007

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http://www.sv.vt.edu/classes/ESM2204/ESM2204_kriz_NoteBook/moments/moments.html

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http://www.sv.vt.edu/classes/ESM2204/ESM2204_kriz_NoteBook/moments/moments.html http://www.sv.vt.edu/classes/ESM2204/ESM2204_kriz_NoteBook/moments/moments.html

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Objectives of the course Text Book

Develop understanding of the design
principles involved in the design of various Wentzell,
Wentzell, T. H.
machine elements. - Machine
The machine elements that would be Design, Delmar
covered are gears, bearings, shafts, etc. Learning, 2004,
We will develop methods of applying ISBN
140180517-
140180517-5.
principles learned in previous courses on
mechanics and strength of materials

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Reference Books Reference Books

A. Esposito and J.R.Thrower - Machine Design, J.E. Shigley,
Shigley, C.R. Mischke,
Mischke, and R G
2nd Edition, Delmar Publishers, Albany, 1991, Budynas - Mechanical Engineering Design,
480 pages, ISBN 0- 0-8273-
8273-4081-
4081-8. (No more in 7th Edition, McGraw Hill, New York, 2004,
print)
ISBN 0-
0-07-
07-292193-
292193-5.
R.L. Mott Machine Elements in Mechanical
Bernard J. Hamrock,
Hamrock, Bo O. Jacobson, and
Design, 4th Edition, Prentice Hall, New Jersey,
2004, ISBN 0-13-
Steven R. Schmid,
Schmid, Fundamentals
Fundamentals of
13-0618853.
0618853.
Machine Elements,
lements, McGraw Hill Publishing,
Ansel C. Ugural,
Ugural, Mechanical Design: An ISBN: 0-
0-07-
07-297682-
297682-9, 2005 / Hardcover /
Integrated Approach, McGraw Hill, New York, 980 pages
2004, ISBN 0-0-07-
07-2921854.
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 Evaluation procedure Examinations
Examinations during the semester are not
Examinations (3) 35% comprehensive.
Home work (10) 40% Final examination is comprehensive.
Questions may be in the form of problems, short
Design project 15% answers, fill in the blank and/or True/False.
Class participation 10% During the tests you can make use of the textbook
and class work for referring the equations or any data required for
solving the problems.
You may also bring one sheet on which the
necessary equations are written. (see p. 497
502)
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Examinations Design Project

The coverage of the examinations will be
announced in the class prior to the tests and
generally include the lectures, text, homework,
etc.
There will be no chance to makeup for the
missed examinations, unless arrangements
have been made before the examination that is
considered reasonable by the professor.
The aim of this is to combine the various
principles being studied in the course for a
final product design.
You are expected to go through the design
procedures that are being studied and
apply them to a particular product.
Submission: December 8th

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Research Paper
Design Project - Report
(Graduate students only)
Functions of the project They are expected to do a detailed study
of a topic relevant to the course content,
Design requirements subject to the approval of the instructor.
Selection criteria used The topic and a brief written description
Design alternatives examined for the various are to be submitted to the instructor by
components September, 15th.
Detailed design of the individual components The type written, 8 to 12 page APA format
in the system such as housing, gears, shafts, paper is to be submitted by December 8th
bearings, seals, etc.
Final assembly of the designed power
transmission
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 Grading Summary
Design is an exciting and fulfilling activity
Percentage Grade Percentage Grade for an engineer.
range range Design requires basic knowledge in a
95 100 A 90 94 A- number of disciplines.
87 89 B+ 84 86 B Design engineer should be a person with
80 83 B- 77 79 C+ sound judgement and wide experience.
74 76 C 70 73 C-
67 69 D+ 64 66 D
60 63 D- < 60 F
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