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Module 1.1

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18 views16 pages

Module 1.1

Uploaded by

Ziyad Kpr
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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AUT306: AUTOMOTIVE COMPONENTS

DESIGN

MODULE 1.1
Machine Design:

• Machine design is defined as the use of


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

• Machine Design is also defined as the creation of


new design or improving the exist one
Design of Machine Elements
– Specify Functions of Elements
– Determine Forces Acting on Element
– Select suitable Material for Element
– Determine failure mode of element
– Determine geometric dimensions of
element
– Modify dimensions for assembly and
manufacture and check design at critical
cross section
– Prepare working drawing of element
Basic Requirement of Machine
Element
– Strength
– Rigidity
– Wear resistance
– Minimum Dimensions and
Weight
– Manufacturability
– Safety
– Conformance to
Standards
– Reliability
– Maintainability
– Minimum Life Cycle Cost
Material Selection
• Selection of proper material for the machine
components is one of the most important steps
in process of machine design
• The best material is one which will serve the
desired purpose at minimum costs
Factors Considered while selecting the
material:
i) Availability: Material should be readily
available in market in large enough quantities
to meet the requirement
Material Selection
ii) Cost:
iii)Mechanical properties:
Manufacturing Considerations:

In some applications machinability of material


is an important consideration in selection
Where the product is of complex shape,
castability or ability of the molten metal to flow
into intricate passages is the criterion of
material selection
In fabricated assemblies of plates & rods,
weldability becomes the governing factor
Properties of Material
Strength: Ability of the material to resist,
without rupture, external forces causing
various types ofstresses
Elasticity: Ability to regain its original shape &
size after deformation, when the external forces
are removed
Plasticity: Ability to retain the deformation
produced under the load on a permanent basis
Stiffness or Rigidity: Ability to resist
deformation under the action of an external
load
Properties of Material
Toughness: Ability to absorb energy before
fracture takes place
Malleability: Ability to deform to a greater
extent before the sign of crack, when it is
subjected to compressive force
Ductility: Ability to deform to a greater extent
before the sign of crack, when subjected to
tensile force
Brittleness: Property of the material which
shows negligible plastic deformation fracture
takes place
Hardness: Resistance to penetration or
permanent deformation
Engineering Material
Cast Iron
Cast iron is an alloy of iron & carbon,
containing more than 2 % of carbon
- Typical composition of ordinary cast iron is:
Carbon = 3-4%
Silicon = 1-3%
Manganese = 0.5-1%
Sulphur = up to 0.1%
Phosphorous = up to 0.1%
Iron = Remainder
Engineering Material
Cast Iron

Advantages:
Available in large quantities,
higher compressive strength,
components can be given any complex shape
without involving costly machining operations,
excellent ability to damp vibrations,
more resistance to wear even under the conditions
of boundary lubrication,
mechanical properties of parts do not change
between room temperature and 350 degree
centigrade
Engineering Material
Plain Carbon Steel
Depending upon the percentage of carbon, plain
carbon steels are classified as:
i) Lowcarbon steel – Less than 0.3% carbon,
popularly known as mild steel, its soft & ductile,
easily machined & welded, however due to low
carbon content unresponsive to heat treatment
ii)Medium carbon steel – carbon content in the
range of 0.3% to 0.5%, popularly known as
machinery steel, easily hardened by heat
treatment , stronger & tougher than low carbon
steel, well machined, respond readily to heat
treatment
Engineering Material
Plain Carbon Steel
iii) High carbon steel – more than 0.5% carbon,
popularly known as hard steels or tool steels,
respond readily to heat treatment, when heat
treated attain high strength combined with
hardness, less ductile than low carbon steels &
medium carbon steels, difficult to weld,
excessive hardness accompanied by excessive
brittleness
In applications like automobile bodies & hoods,
the ability of the material to deform to a greater
extent or ‘ductility’ is the most important
consideration so a plain carbon is preferred
Engineering Material
Plain Carbon Steel

In applications like gears, machine tool


spindles & transmission shaft, strength
toughness & response to heat treatment are
important considerations, medium & high
carbon steels are preferred
Spring wires are subjected to severe stress &
strength is the most important consideration so
high carbon steel is selected for helical & leaf
springs
Engineering Material
Alloy Steel
• Carbon steel to which one or more alloying
elements are added to obtain certain beneficial
effects
• The commonly added elements include silicon,
manganese, nickel, chromium, molybdenum and
tungsten
• The term ‘alloy steels’ usually refers to ‘low’ alloy
steels containing from 1-4% of alloying elements
• Alloy steels have higher strength, hardness &
toughness, higher hardenability, retain their
strength & hardness at elevated temperatures,
higher resistance to corrosion and oxidation
Engineering Material
Alloy Steel
- Silicon increases strength & hardness without lowering
the ductility. Silicon is added in spring steel to
increase its toughness
- Manganese increases hardness and toughness and
also increases the depth of hardening
- Nickel increases strength, hardness and
toughness without sacrificing ductility
- Chromium increases hardness & wear resistance,
steel containing more than 4 % chromium have
excellent corrosion resistance
- Molybdenum increases hardness & wear resistance,
resists softening of steel during tempering and
heating
Factor of safety
Is used to provide a design margin over the
theoretical design

capacity to allow for uncertainty in the design


process.

In the calculations,
Material strengths,
Manufacturing process

Strength of the component (Max load)


FoS =
Load on the component (Actual load)

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