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INTRODUCTI

ON TO
DESIGN
UNIT 1

SYLLABUS CONTENTS

Definitions: normal, shear, biaxial and tri axial


stresses
Stress tensor, principal stresses.

Engineering materials and their mechanical


properties

Stress strain diagrams

Stress analysis

Design considerations: Codes and Standards

DEFINITION

Machine Design is defined as the use of


scientific principles, technical
information and imagination in the
description of a machine or a
mechanical system to perform specific
functions with maximum economy and
efficiency.

BASIC STEPS INVOLVED IN DESIGN


A designer uses principles of basic and engineering
sciences such as physics, mathematics, statics and
dynamics, thermodynamics, heat transfer, vibrations and
fluid mechanics.
A designer has technical information of the basic
elements of a machine such as gears, springs, shafts,
couplings, etc.
The designer uses his skill and imagination to produce a
configuration, which is a combination of these elements.
The final outcome of the design process consists of the
description of the machine in the form of drawings of
assembly and individual components.

A design is created to satisfy a recognized need of


customer.

MECHANICAL
ENGINEERING DESIGN
Production and processing of energy means of production,
tools of transportation and techniques of automation.
Disciplinary bases mechanics of solids and fluids, mass
and momentum transport, manufacturing process,
electrical and information theory.
Example
Journal bearing fluid flow, heat transfer, friction, energy
transport, material selection, thermo mechanical
treatments, statistical descriptions etc
A building heating, ventilation, air conditioning,
Internal combustion engine
Machine element design, machine component design,
system design, fluid power design.

DESIGN CONSIDERATIONS

BASIC PROCEDURE OF MACHINE


DESIGN

BASIC PROCEDURE OF
MACHINE DESIGN

PRODUCT SPECIFICATIONS
List of requirements of the product:
Output capacity of the machine
Service life
Cost and reliability
Dimensions and weight
External appearances, noiseless performance

Operating controls

SELECTION OF MECHANISMS
Rough sketches of different possible mechanisms for
the product
Eg: Press
Possible mechanisms:
1.Crank and connecting rod
2.Nut and screw
3.Hydraulic cylinder, piston and valves
An approximate estimation of the cost of each
alternative configuration is made and compared with
the cost of existing products.

10

Depending on the cost competitiveness, availability


of raw materials and manufacturing facility, the best
possible mechanism is selected for the product.

LAYOUT OF CONFIGURATION
Prepare a block diagram showing the
general layout of the selected
configuration.

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The designer specifies the joining


methods, such as riveting, bolting or
welding to connect the individual
components.

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DESIGN OF INDIVIDUAL COMPONENTS

PREPARATION OF DRAWINGS
Prepare drawings of the assembly and the
individual components
Material of the component, its dimensions,
tolerances, surface finish grades, and
machining symbols are specified
A prototype model is prepared for the
product and thoroughly tested before
finalizing the assembly drawings.

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The designer has to consult the


manufacturing engineer and find out the
suitable modification.

BASIC REQUIREMENTS
OF MACHINE ELEMENTS
Strength
Rigidity
Wear resistance
Minimum dimensions and weight
Manufacturability
Safety
Conformance to standard
Reliability
Maintainability
Minimum life cycle cost

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DESIGN OF MACHINE ELEMENTS

SPECIFICATION OF FUNCTION
Functions of some machine elements:
Bearing: To support the rotating shaft and
confine its motion
Key: To transmit the torque between the
shaft and the adjoining machine part like
gear, pulley or sprocket
Spring: To release stored energy
Fasteners: Screws, rivets, bolt-nut, etc. to
hold 2 or more machine parts together

Shafts: To transmit torque

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Frames (beams and pillars): To support


weight and hold machine components intact

DETERMINATION OF FORCES
External force due to energy, power or
torque transmitted by the machine part
Static force due to deadweight of the
machine part
Force due to frictional resistance
Inertia force due to change in velocity
Force due to variation in temperature
Forces due to manufacturing
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Forces due to stress concentration

SELECTION OF MATERIAL
Four basic factors considered in selecting the material:
Availability
Cost
Mechanical properties
Manufacturing considerations

FAILURE CRITERION

3 basic types:
Failure by Elastic Deflection
Failure by General Yielding
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Failure by Fracture

DETERMINATION OF DIMENSIONS
Dimensions are decided on the basis of failure criterion
In simple cases, dimensions are determined on the basis
of allowable stress or deflection
Various criteria such as yield strength, ultimate tensile
strength, torsional or lateral deflection and permissible
bearing pressure are used to find dimensions.

DESIGN MODIFICATIONS
Geometric dimensions of the machine element are
modified from assembly and manufacturing considerations

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Revised calculations for operating capacity, margin of


safety at critical cross sections and resultant stresses
taking
into
consideration
the
effect
of
stress
concentration.

PREPARATION OF DRAWINGS
Prepare drawings of the assembly and the
individual components
Material of the component, its dimensions,
tolerances, surface finish grades, and
machining symbols are specified
A prototype model is prepared for the
product and thoroughly tested before
finalising the assembly drawings.

20

The designer has to consult the


manufacturing engineer and find out the
suitable modification.

STRESSES
Defenition
Normal stress
Shear stress
Biaxial stress
Tri axial stress
Stress tensor
Principal stress

NORMAL STRESS
Stress is defined as the strength of a material per unit area or
unit strength. It is the force on a member divided by area,
which carries the force, formerly express in psi, now in N/mm 2
or MPa.

=P/A

where P is the applied normal load in Newton and A is the area in


mm2. The maximum stress in tension or compression occurs
over a section normal to the load.

Normal stress is either tensile stress or compressive stress.


Members subject to pure tension (or tensile force) is under
tensile stress, while compression members (members subject
to compressive force) are under compressive stress.

Compressive force will tend to shorten the


member. Tension force on the other hand will
tend to lengthen the member.

SHEAR STRESS
Shear stress
When forces are transmitted from one part of a
body to other, the stresses developed in a plane
parallel to the applied force are the shear
stresses and the average values of the shear
stresses are given by
in single shear
in double shear

BIAXIAL STRESS
A biaxial stress system has a stress state in two directions
and a shear stress typically

TRI AXIAL STRESS

ENGINEERING
MATERIALS AND THEIR
PROPERTIES

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