Introduction to Machine Design

Recommended Books:
- Machine Design, An Integrated Approach, by Robert L Norton - Mechanical Engineering Design by Joseph Shigley - Design of Machine Elements by M.F. Spotts

Contents
What is machine design Prerequisites of the subject Design process Design stages Major areas in Machine Design CAD and CAE Basics of mechanics of materials Factor of safety Codes and Standards Basic Machine Elements

What is Machine Design?

Engineering design is a decision making process (often iterative) in which the basic sciences, mathematics, and engineering sciences are applied to convert resources optimally to meet a stated objective. Machine Design is the application of science and technology to devise new and improved products Product is any manufactured item including machine, structure, tool or instrument.

Prerequisites of the subject

Mathematics Mechanics Kinematics Materials Engineering Strength of materials Manufacturing process

Prerequisites of the subject

Mechanics: It is the branch of science concerned with the behavior of physical bodies when subjected to forces or displacements. Kinematics: It is the branch of classical mechanics that describes the motion of bodies without consideration of the causes of motion.

Prerequisites of the subject

Materials Engineering: It is a branch of science which deals with the study of properties and behavior of engineering materials. The basis of materials science involves relating the desired properties and relative performance of a material in a certain application to the structure of the atoms and phases in that material.

Prerequisites of the subject

Strength of materials: It deals with the behavior of materials under stresses and strains. Manufacturing Process: A design engineer must have a good understanding about the constraints and benefits of various manufacturing processes, which is very important for the realization of any design.

Applications of Machine Design

Applications of Machine Design

Applications of Machine Design

Applications of Machine Design

Applications of Machine Design

Di Pietro Compressed Air Engine

Design Process
1. Identification of need 2. Background Research 3. Goal Statement 4. Task Specifications 5. Synthesis 6. Analysis 7. Selection 8. Detailed Design 9. Prototyping and Testing 10. Mass Production

Design Process

Design Stages

Major areas in machine design

Initial design conception (CAD) Strength analysis (CAE) Material selection Manufacturability (CAM) Economy Safety Environmental effects Reliability

Computer Aided Design (CAD)

Computer-aided design (CAD) can be a defined as the way of creation, modification and optimization of a design by using computer system. By using a CAD software, we can generate
2D draft/drawing files 3D wireframe models 3D surface models 3D solid models.

Computer Aided Design (CAD)

The design-related tasks performed by CAD system are:
Geometric modeling. Engineering analysis. Design review and evaluation. Automated drafting. Parts classification and coding.

Computer Aided Design (CAD)

Computer Aided Engineering (CAE)

CAE (Computer-Aided Engineering) is the study of behavior of a product in different conditions with the help of computer. CAE software are used to analyze performance of products, without building prototypes. CAE software packages help designer to perform,
Stress/Structural Analysis Fluid flow Analysis Thermal Analysis etc.

Stress analysis of Connecting Rod

CFD Analysis of F-1 Racing car

CFD Animation

Thermal Analysis of Automobile Brake

Filling Analysis Injection Molding

CAD/CAM Methodology

Basics of mechanics of materials

Normal Stresses Shear Stresses Torsional Stresses Bending Stresses Fatigue Stresses Theories of Failure

Factor of Safety (F.O.S)

Factor of safety is defined as a ratio of absolute strength (structural capacity) to actual stress. This is a measure of the reliability of a particular design. =

A high safety factor well over the required design requirement sometimes implies "over-engineering" which can result in excessive weight and/or cost.

Factor of Safety (F.O.S)

Factor of Safety (F.O.S)

Factor of Safety (F.O.S)

Factor of Safety (F.O.S)

As the FOS in increased, the designed product become more reliable. But with the increase in the FOS, the weight and cost of material increases. Factor of safety for commercial aircrafts is in the range of 1.2 to 1.5. If FOS = 1, then the stress in the part becomes equal to the strength of the material, thus, failure occurs.

Choosing a Factor of Safety (F.O.S)

Choosing a Factor of Safety (F.O.S)

Brittle materials are designed against the ultimate strength, so failure means fracture. Whereas, Ductile materials are designed against the yield strength, and are expected to give some visible warning before fracture. F.O.S (Ductile) = MAX (F1, F2, F3) F.O.S (Brittle) = 2 x MAX (F1, F2, F3)

Codes and Standards

Code is a set of specifications for design, analysis and/or manufacturing of any thing. Standard is a set of specifications of parts, materials or processes intended to achieve uniformity, efficiency and specific quality. AGMA, AISI, ANSI, ASME, ISO, SAE, etc..

Basic machine elements

Shafts, keys and couplings Gears Bearings Joints Springs Brakes and clutches Threads and screws