Lecture 1 - Design of Machine Elements (ME314)

Instructor - Dr. B.S. Reddy

Mechanical Engineering, IIT Guwahati

25 July 2019

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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 1 / 12
 Course Outline - 3-0-0-6

Basics
Principles of Mechanical Design, Factor of Safety, strength, rigidity,
fracture, wear and material considerations, Limits and Fits

Failure Prevention
Design for failure resulting from Static loading
Design for Fatigue failure

Design of Mechanical Elements

Design of riveted,bolted and welded joints
Rigid and flexible couplings
Belt and chain drives
Power screws
Shafts, Clutches, Brakes, Axles, Springs . . . . . . . . . . . . . . . . . . . .
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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 2 / 12
 Textbooks and References
Texts
Design Data Book of Engineers, Compiled by Faculty of Mech Engg,
PSG College of Technology, Publisher Kalaikathir Achchagam,
Coimbataore, 2009
M.F Spotts, T.E Shoup, L.E. Hornberger, S.R Jayram, and C. V.
Venkatesh, Design of Machine Elements, Person Education, 2006

References
J. E. Shigley, Mechanical Engineering Design, McGraw Hill, 1989
A. H. Burr and J. B. Cheatham, Mechanical Analysis and Design, 2nd
Ed., Prentice Hall, 1997
V B Bhandari, Design of Machine Elements, 2nd Ed., Tata Mcgraw
Hill, 2007.
R. C Juvinall and K. M Marshek, Fundamentals of Machine
Component Design, 3rd Ed., Wiley Student Edition, 2007
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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 3 / 12
 Grading Policy

1 Assignments - 10%
2 Quiz 1 and 2 - 10% each
3 Mid-Sem - 30%
4 End-Sem - 40%

There will be at least two quizzes, dates for which will be

announced one week beforehand

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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 4 / 12
 You must first write the appropriate formula in terms of variables.
Then write the formula with all appropriate values of various variables.
You cannot choose any name of the variables. For example σa−eq as
σa−max for just σ for σnom or for σmax etc., then it is wrong
understanding of variable itself and marks will be deducted. If you
select τ symbol for normal stress σ, then also marks will be deducted.
Please try to solve each question on a fresh page.
First, you must write two formulas associated with Gerber, Goodaman
and Soderberg criteria and then substitute appropriate values. Do not
try to solve problem using simple straight-line properties. In such case
I have deduct marks. You must use standard equations given to you.
You cannot leave the calculation as a = 1.7045 x 2.4958. You must
calculate and give final answer of the variable “a”. Marks will be
deducted those who do not give the answer.
You must write clearly the answer to a question. Put Ans. If not
done, marks will be deducted.
Do not leave a variable value as a fraction, for example as p =
345.56/23.48. Solve the fraction-using calculator and provide the
answer. Any variable found as above will not get marks.
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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 5 / 12

 Design Philosophy

Objectives of lecture
Basic Concept of Design (in general)

Design Process

Concept of Machine Design and their types

Design Tools and Resources

Professional Responsibilities of Designers

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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 6 / 12
 Basic Concept of Design
Design is a decision making process ⇒ formulate a plan to satisfy a
particular need and to create something with a physical reality

Design is a strategic approach to achieve a unique expectation within the

constraints imposed by real world

Design - with little/no information (sometimes contradictory). Decisions

are made tentatively, with adjustment as more becomes known.

Designer - knowledge of technology and first principles.

Design of a chair
The purpose for which the chair is to be designed
Whether the chair is to be designed for a grown up person or a child
Material for the chair, its strength and cost need to be determined
Finally, the aesthetics of the designed chair . . . . . . . . . . . . . . . . . . . .
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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 7 / 12
 Design Process

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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 8 / 12
 Identification of need
Why you want the design?
Intuitive, based on the sense that something is missing/not right?

Definition of Problem
Specifications - input and output quantities (together with
characteristics and limitations)
Cost, the number to be manufactured, the expected life, the range,
the operating temperature, and the reliability
Specified characteristics can include the speeds, feeds, temperature
limitations, maximum range, expected variations in the variables,
dimensional and weight limitations, etc.
Implied specifications - certain facilities not available. Eg. - A plant
might not own cold-working machinery. Knowing this, the designer
might select other metal-processing methods that can be performed
in the plant. The labor skills available and the competitive situation
also constitute implied constraints . . . . . . . . . . . . . . . . . . . .
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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 9 / 12
 Power Transmission
Many industrial applications deal with power sources - run most efficiently
at a narrow range of rotational speed. Application requires power to be
delivered at a slower speed than supplied by the motor - a speed reducer.
Speed reducer should transmit the power from motor to application with
least energy loss, while reducing the speed and increasing the torque

Design Requirements Design Specifications

Power to be delivered - 20 hp Power efficiency: 95%
Input speed 1750 rev/min, Steady state input speed: 1750
Output speed: 85 rev/min rev/min, Maximum input speed:
2400 rev/min, Steady-state
Targeted for uniformly loaded
output speed: 82–88 rev/min
applications, such as conveyor
belts, blowers, and generators Manufacturing cost per unit: ,
Rs. 300 Production: 10,000
Continuous operation, 6-year
units per year Operating
life, with 8 hours/day, 5
temperature range: −100 to
days/wk
1200 F
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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 10 / 12
 Synthesis - Concept Design
Various schemes are proposed and their performance is investigated
and quantified.
Schemes not working are discarded and schemes that are working are
compared to find best scheme to optimize.

Analysis and Optimization

Requires mathematical model - simulate the real physical system. (Eg. use
CAD drawings)

Evaluation - Final proof of concept

Requires testing of a prototype
Is it reliable, economical, easy to replace and maintain?

Presentation - Sell the product

Solution is good and better than existing products
Write good technical reports and present drawings at seminars, etc.
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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 11 / 12
 Machine Design

Machine - Combination of resisting bodies with successfully constrained

relative motions that transforms available energy to do useful work

Modification of energy requires a number of machine elements

Machine Design ⇒ Designing machine elements so that they transmit

forces safely and perform task successfully.

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Instructor - Dr. B.S. Reddy (IIT Guwahati) Lecture 1 25 July 2019 12 / 12