MCE 473-MACHINE DESIGN IV

INTRODUCTORY LECTURE NOTE

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1. Introduction
• Machine Design: 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

• Design is an innovative and highly iterative process

• Development of new and better machines

• using knowledge in many subjects:

• Mathematics, Engineering Mechanics, Strength of Materials, Theory of Machines, Workshop Processes and
Engineering Drawing.

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1.1 Classifications of Machine Design
1. Adaptive design
• adaptation of existing designs
• no special knowledge or skill
• ordinary technical training.
2. Development design
• modification of existing design into a new idea: adopting a new material or different method
of manufacture
• designer starts from the existing design, but the final product may differ quite markedly from
the original product.
• considerable scientific training and design ability

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Classifications of Machine Design Cont’d
• New design
• needs lot of research, technical ability and creative thinking
• Rational design: depends upon mathematical formulae of
principle of mechanics.
• Empirical design: depends upon empirical formulae based on the
practice and past experience
• Industrial design: depends upon the production aspects to
manufacture any machine component in the industry.
• Optimum design: best design for the given objective function
under the specified constraints and achieved by minimising the
undesirable effects
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Classifications of Machine Design Cont’d
• Element design: design of any element of the mechanical system
like piston, crankshaft, connecting rod, etc.
• Computer aided design: depends upon the use of computer
systems to assist in the creation, modification, analysis and
optimisation of a design.

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1.2General Considerations in Machine Design
• Type of load and stresses caused by it

• Motion of the parts or kinematics of the machine

• successful operation of any machine depends largely upon the simplest arrangement of the parts which
will give the motion required
• The motion of the parts may be:
(a) Rectilinear motion which includes unidirectional and reciprocating motions.
(b) Curvilinear motion which includes rotary, oscillatory and simple harmonic.
(c) Constant velocity.
(d) Constant or variable acceleration

Selection of materials
• thorough knowledge of the properties of the materials and their behaviour under working conditions.
• important characteristics of materials such as: strength, durability, flexibility, weight, resistance to heat
and corrosion, ability to cast, welded or hardened, machinability, electrical conductivity, etc.

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 General Considerations in Machine Design Cont’d
• Form and size of the parts
• based on judgement
• based on stresses induced in the designed cross-section and safety
• anticipate any suddenly applied or impact load which may cause failure

• Frictional resistance and lubrication

• friction of starting is higher than that of running friction
• careful attention must be given to the matter of lubrication for rubbing surfaces whether in rotating, sliding, or
rolling bearings

• Convenient and economical features

• starting, controlling and stopping levers should be located on the basis of convenient handling
• easy access for replacement of parts.
• production machines should have maximum capacity consistent with the production of quality items

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General Considerations in Machine Design Cont’d
• Use of standard parts
• standard or stock parts should be used as much as possible

• Safety of operation
• always provide safety devices for the safety of the operator.
• safety appliances should in no way interfere with operation of the machine

• Workshop facilities
• be familiar with the limitations of his employer’s workshop

• Cost of construction
• Aim to reduce the manufacturing cost to the barest minimum

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 1.3 General Procedure in Machine Design
• In designing a machine component, there is no rigid rule

• Recognition of need
• make a complete statement of the problem, indicating the need, aim or purpose for which the
machine is to be designed.

• Synthesis (Mechanisms)
• select the possible mechanism or group of mechanisms which will give the desired motion.

• Analysis of forces
• determine the forces acting on each member of the machine and the energy transmitted by each
member.

• Material selection
• select the material best suited for each member of the machine
• availability

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General Procedure in Machine Design Cont’d
• Design of elements (Size and Stresses)
• find the size of each member of the machine by considering the force acting on the member
• Consider the permissible stresses for the material to be used.
• Note that each member should not deflect or deform under operation
• Modification
• modify the size of the member to agree with the past experience and judgment
• modification may also be necessary to reduce overall cost.
• Detailed drawing
• draw the detailed drawing of each component
• include complete specification for the suggested manufacturing processes suggested.
• modify drawings after testing prototype
• Production
• manufacture component, as per the drawing, in the workshop

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Figure 1: Flow chart for the general procedure in machine design

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Basic Requirement of Design of Mechanical Elements

Strength
Minimum
Rigidity
Cycle Cost

Wear
Maintainability
Resistance
Mechanical
Elements
Reliability Minimum
Weight

Conformance to Manufacturability
Standards
Safety

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Ergonomic Considerations
• Ergonomics is defined as the relationship between man and machine
and the application of anatomical, physiological and psychological
principles to solve the problems arising from man-machine
relationship
• Design of driver’s seat
• Layout of instrument dials and display panels
• Design of hand levers and hand wheels
• Energy expenditure in hand and foot operations
• Lighting, noise and climatic conditions in machine environment

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 Ergonomic Considerations Cont’d

Man-Machine Close Loop System

Display instruments Control instruments

Quantitative measurement Easily accessible and logically positioned
State of affairs Conform to the anatomy of human parts
Predetermined settings Proper colour
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Aesthetic Considerations
• set of principles of beauty
• appearance should be attractive
• Should support performance

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Treated Topics in previous years
• Engineering materials and their relevant properties. Fabrication methods. Stress
calculations in design. Static and fatigue stresses. Stress concentration. Notch effect.
The use of theories of failure. Safety factor approach to design. Determination of the
sizes of machine parts

• Design of bolted joints. Types of joints and their application: brazing, bonding,
riveting and welding. Design of power screws. Design of springs. Application of springs
and spring materials. Design of hub-shift joints, shafting and shafts and axles. Fatigue,
strength, rigidity and critical speeds of shafts. Design of bearing. Application, selection,
installation and lubricating of bearings. Bearing materials

• Advanced treatment of gears and gearing: involutes gears, helical gears, bevel gears
and worm gears. Gear failure and lubrication. Design of hydrostatic torque transmission
systems. Performance and selection of hydrodynamic couplings and torque convertors.
Design of machine for production. Computer Aided Design (CAD), Product
development.
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