LY. Dip. Design of Machine Elements 1. @ (ii) 4.33 Introduction to Design 4.20.2 List of Machine Parts with Suggested Material Questions Recommend suitable materials for following components. Connecting rod. Machine tool spindle. (ii) Hydraulic cylinder. (iv) Heavy duty gear. Suggest suitable material for the following machine parts : a ii) Crank shaft. Helical spring. (ii) Bushes for knuckle pin. (iv) _Lathe bed. Table 1.3 Machine parts Suitable material 1L_ Crank shaft Alloy steel like 35Mn2Mo28 2. Helical spring Oil tempered carbon steel/ chromium vanadium alloy steel 3._ Bushes for knuckle pin Phosphor bronze, Grey C.L 4. Lathe bed Grey cast iron like FG150 5._ Spring for LC. engine valve Carbon steel 6._ Screw of screw jack Carbon steel, low alloy steel 7._ Nut of screw jack Phosphor bronze 8. Bearing bushes Bronze (Alloy steel) 9. Shaft Mild steel Cast iron 10. Body or casing of centrifugal pump 11. Balls for ball bearing Chrome steel 12. Hydraulic cylinder Plain carbon steel, steel casting or aluminium alloys, 13. Machine tool spindle High quality steel. 14. Heavy duty gear Ferrous metal. 15. Connecting rod Drop forged heat treated steel. 16. Turbine blade Chromium steel like 7Cr13 17. Clutch spring Plain carbon steel with magnese like 60C4 18. Locomotive carriage or Wagon wheels Fe 290 or FeE230, plain carbon steel 19. Closed coiled helical spring Low alloy steelLY. Dip. Design of Machine Elements 1.34 Inroducton ig, 1.21 DESIGNATION OF DIFFERENT MATERIALS Questions 1. State the following material specifications. (i) FeE230, (ii) FG200, (iii) 35C8, (iv) X20Cr18Ni2. R 2. Explain the following material specification. ()__FG3000, (ii) X20Cr 18Ni2. _R 1) Ferrous metals : Magnetite Fe,O3 Hematite Fe3O4 Limonite FeCOs Siderite Fe,03(H20 ) 2) Cast iron: a) Grey cast iron: FG200 Grey Cl. with tensile strength 200 MPa (N/mm’). [EERE FG300 Grey C.L with tensile strength 300 MPa (N/mm). Examples FG220, FG260, FG300, FG350, FG400. b) Malleable cast iron: wm400 White malleable cast iron with minimum tensile strength 350 N/mm?or 400 N/mm’. BM300 Black malleable C.. with 300 N/mm’ tensile strength. BM320 Black malleable C1. with 320 N/mm’ tensile strength. BM350 Black malleable C1. with 350 N/mm? tensile strength. pm450 Pearlitic malleable C.. with 450 N/mm* tensile strength. ©) Nodular or spheroidal C: $G450/10 __ | Spheroidal graphite cast iron with minimum tensile strength 450 N/mm? followed by 10% elongation. fw-09) Examples 'SG800/2, SG400/15, SG350/18. 3) Steels designated on the basis of mechanical properties : Fe290 Steel with minimum tensile strength of 290 N/mm”. FeE230 Steel with minimum yield strength of 230 N/mm”. Examples Fe310, Fe330, Fe360, Fe410, Fe490, FeS40, Fe620, £2690, FeE230, FeE250, FeE270, FeE310, Fe370, Feb400 ete Steel designated on the basis of chemical composition : 35C8 Steel with 0.35% carbon and 0.8% manganese 60c4 Examples 4 a) Steel with 0.6% carbon and 0.4% manganese. 30C8, 45C8, 50C4, 70C6, 75C6.,. Design of Machine Elements: E es a Introduction to Design 5) Free cutting steels : 10C8S10___| Steel with 0.1% carbon, 0.8% manganese and 0.1% sulphur Examples 14C14S14, 28C12S14, 40C10S18, 11C10S25, 40C15$12 «Instead of sulphur, Py ie. lead can be used. 6) Alloy steel : They are designated as ~ «Figure indicating 100 times average % of carbon. «Chemical symbol for alloying elements followed by figure for its average percentage content multiplied by a factor as given below. Element Multiplying Factor Cr, Co, Ni, Si, W, Mn 4 Al, Be, V, Pi, Cu, Ti, Zn and Mo 10 P,S and N 100 For example 40Cr4Mo2 Alloy steel having 0.4% carbon, 1% chromium and 0.2% molybdenum. 20Mn2 Alloy steel having 0.20% carbon and 0.5% manganese. 40Ni2Cr1Mo28 Alloy steel having 0.4% carbon, 0.5% nickel, 0.25% chromium and 2.8% molybdenum. 7) High alloy steel = They are designated as — Letter X. Figure indicating 100 times the percentage of carbon content. Chemical symbol for alloying elements followed by a figure for its average % content rounded off to nearest integer. 4) Chemical symbol to indicate specially ad Note: Ifit is not designated by X, then see chromium a) 2o8 ded element to provide desired properties. 9%. If it is written Cr13, Cr14 (ie. more than 9), then itis a type of high alloy steel (stainless steel or heat resisting stee). For example : 20Cr18Ni2 Alloy steel having carbon 0.20%, chromium 18%, and nickel 2%. ASCr16Ni2 ‘Alloy steel having average carbon 0.15%, chromium 16%, nickel 2%. 45Cr9Si4 Alloy steel having carbon 0. 45%, chromium 9% and silicon 4%. X20Cr18Ni2 High alloy steel having carbon 0.20%, chromium eae Nickel 2%.eee 1.25 ROLE AND ADVANTAGES OF STANDARDIZATION Question Explain the term ‘standardization’ with its advantages (any four). Standardization is defined as ‘the process of establishing standards so as to minimi varieties in the characteristics’. Standard is a set of specifications, defined by a certain body or an organization, to which various characteristics of a component, a system, or a Product should conform. The characteristics include materials, quality, dimensions, shapes, tolerances, surface finish, materials, method of testing, method of use, method of packing and storing etc.‘TY. Dip. Design of Machine Elements 1.37 ee The purpose of standardization is to establish the norms intended to achieve uniformity, specified quality, interchangeability, safety, and to put reasonable limit on the variety : «In india, BIS is responsible for evolving all types of technical standards. standards used in design are, 2 Standards for material, their mechanical properties and chemical composition. ensions of commonly used machine elements. 2. Standards for 3. Standards for fits, tolerances and surface finish of machine elements. 4. Standards for engineering drawing of components. Categories of Standards: Based on the defining body or organization, the standards can be divided into three categories: 1) Company Standards : These standards are defined or set by a company or a group of companies for their use. 2) National Standards : These standards are defined or set by a national apex body and are normally followed throughout the country. © The examples are standards prepared by : © Bureau of Indian Standards (BIS) co American Society of Mechanical Engineers (ASME) ‘American Gear Manufacturers Association (AGMA) © American Welding Society (AWS) co American National Standards Institute (ANSI). 3) International Standards: * These standards are defined and set by an international apex followed all over the world. «The examples are standards prepared by : © International Standards Organization (ISO) © International Bureau of Weights and Measures (IBWM). Benefits of Standardization : 1. Ithelps in manufacturing the components quit 2. It saves effort of design engineer to design an components are readily designed by experts. Ithelps in manufacturing the components on mass Pr Interchangeability of components is possible. It ensures certain minimum specified quality. Effective utilization of resources. Easy and quick replacement of the components is possible. It also contributes to ensure the safety. body and normally ickly and economically. \d manufacture new machines, as standard ‘duction. epNan aw1.27 PREFERRED NUMBERS SERIES Preferred numbers are an important tool, which minimize unnecessary variations in sizes They help the designer in avoiding selection of sizes, in an arbitary manner. The complete range is covered by minimum number of sizes, which is advantageous to both producer and consumer. With the acceptance of standardization, there is need to keep the standard sizes 9, dimensions of any component or product in discrete steps. The sizes should be spread over wide range, and at the same time, they should be space properly. For example, diameters are to be standardized between 10 mm and 25 mm, then sizes should be 10 mm, 12.5 mm, 16 mm, 20 mm and 25 mm. This led to use of geometric series known as preferred series. » Itincludes $5, $10, $20, $40 and S80 series. » Each series has a series factor. » The series factors are as shown in following table. Table 1.4 Series Multiplying Series Factor pa Vi0 = 158 S10 °F = 126 S20 PEG = 119 s40 "5 = 106 $80 5 = 103 For establishing a series, first a number is taken. By multiplying this number by a series factor, second number is obtained. By multiplying second number by a series factor, third number is obtained and procedure is continued.