Shibendu S.

Roy
Dept. of Mechanical Engineering

www.geocities.com/ssroy99/homepage.html

31 July 2012

Machine Design

Reference Books
1.
2.

V.B. Bhandari, Design of Machine Elements , <second edition>, Tata McGraw Hill.
J.E. Shigley, C.R. Mischke, Mechanical Engineering Design, Tata McGraw Hill.

Machine Design Handbook

1. 2. Design Data, Compiled by Faculty of Mechanical Engineering, PSG College, Coimbatore CMTI Hand Book, Compiled by Scientists of Central Manufacturing technology Institute, Bangalore

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Machine Design

Topics to be Covered
Chapter Topics
- Review of Stress, Strain and Complex stresses in machine members - Basic procedure of machine design & machine element design - Manufacturing & other consideration in machine design - Modern Computational Tools for Machine Design - Role of CAD/CAE in Machine Design - Mechanical properties of Engineering materials - B.I.S system of designation of commonly used Engineering Materials - Selection of Materials
- Cotter Joint - Knuckle Joint

Introduction

Engineering Materials Rod Joints Plate Joints Design against Static Load Design against Dynamic Load Design of Shafts, Keys, Splines Statistical Considerations in Design
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- Threaded Joints - Welded Joints

- Elastic failure theories, Factor of safety, Service factor - General principles & procedures of design of machine elements - Stress Concentration factor, Fatigue failure, Endurance limit etc. - Reversed stresses- design for finite & infinite life, Impact stresses etc. - Design of Shaft under Torsion, Bending, Axial & Combined loads - Design of keys like square & flat, saddle, sunk, woodruff keys etc.

- Reliability, Probabilistic approach to Design etc.. Machine Design 3

Design of Machine Element

Gear Drive Pressure vessel Clutch IC engine parts Brake

C-frame

Coupling Spring Belt, Rope, chain Drive Cam

Bearing Connecting rod Power Screw Shaft & Axle Riveted Joint

Key Cotter & Knuckle Joint

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Welded Joint
Machine Design

Bolted Joint

Machine Design
Kinematic Link Kinematic Pair Kinematic Chain Machine Tool
One link fixed

transfers

Mechanism
transforms

Motion

Mechanism Machine

transfers Energy transforms

Machine

Machine tool is a contrivance having a combination of mechanisms/machines whereby a cutting tool is enabled to operate in a pre-conceived manner in order to produce a surface of desired shape, size or a degree of finish by removing metal from workpiece in the form of chips.
All Machines are Mechanism but all Mechanisms are not Machine All Machine Tools are Machine but all Machines are not Machine Tool

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Machine Design

Machine Design
Design
Design Analysis
Inputs

Design Synthesis
decision making process Outputs determines the dimension process of creating new configuration/ mechanism Selecting optimum/best configuration from no. of existing mechanism Selecting materials from no. of alternative materials Determination of optimum shape & dimensions of the component on the basis of design analysis

Mechanism
is given

Given Configuration, material & assume mode of failure

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Machine Design

Manufacture r

Custome r

General Procedure in Machine Design

Identification of Need Problem definition, Design specification Collecting relevant design information & feasibility study Design Conceptualization/ Preliminary design i.e. Mechanism synthesis Modeling & Simulation Engineering Analysis CAD/CAE Design Design Optimization Design Evaluation Detail Design of Components Design Communication & Documentation
Analysis Design Synthesis

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Machine Design

Basic Procedure of Design of Machine Element

Specify functions of element Determine forces acting on element Select suitable material for element Determine failure mode (s) of element Determine geometric dimensions of element based on above failure mode Check & modify dimensions for assembly & manufacture Check design at critical cross-sections
Prepare detail engineering drawing of element
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Basic Requirements of Machine Elements

Broad objective of designing a machine element is to ensure that it preserves its operating capacity during the stipulated service life with minimum manufacturing & operating costs
Strength

Rigidity
Wear Resistance Minimum Dimensions & Weight Manufacturability Safety Reliability Maintainability

Conformance to Standards
Minimum Life Cycle cost 31 July 2012 Machine Design 9

Standards in Machine Design

Standardization
Standardization is defined as obligatory norms, to which various characteristics of a product should conform.
The characteristics include materials, dimensions and shape of the component, method of testing and method of marking, packing and storing of the product.

Standard

Standard is defined as a set of specifications for parts, materials or processes

Purpose of Standard to reduce the variety & limit the no. of items to a reasonable level

Code

Code is defined as a set of specifications for the analysis, design, manufacture, testing and erection of the product
Purpose of Code to achieve a specified level of safety

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Standards in Machine Design

Advantages of Standardization The reduction in types & dimensions of identical components, to a rational number, makes it possible to manufacture the standard component on mass scale in a centralized process.
Standard parts are easy to replace when worn out due to interchangeability. The application of standard machine elements & especially the standard units reduce the time & effort needed to design a new machine.

Standardization results in substantial saving in Designers effort

The standards of specifications & testing procedures of machine elements improve their quality & reliability. In designing, the aim is to use as many standard components as possible for a given machine
Company Standards

Types of Standards

National Standards

I.S / B.I.S B.S A.I.S.I / S.A.E D.I.N

India UK USA German

International Standards
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Standards in Machine Design

Indian Standards in Mechanical Engineering Design
SP 46 I.S. 210 I.S. 1570 : I.S. 733 : 1983 I.S. 736 : 1986 I.S. 919 I.S. 2709 I.S. 8000 I.S. 4218 : 1996 Bureau of Indian Standards on Engineering Drawing Practice for Schools & Colleges Seven grades of grey cast iron Chemical composition of various grades of alloy steel Mechanical Properties of wrought Al. & Al alloy Bars, Rods for general purposes Mechanical Properties of wrought Al. & Al alloy Plates for general purposes Recommendations for Limits & Fits for Engineering Guide for selection of fits Geometrical tolerancing on technical drawings Designation & Dimension of screw threads, bolts & nuts

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Preferred Numbers
When a machine is to be made in several sizes with different powers or capacities, it is necessary to decide what capacities will cover a certain range efficiently with minimum number of sizes. For example, a company want to manufacture seven different models of electric motors ranging from 0.25 HP to 5 HP to cater to the need of different customers. Preferred numbers are used to specify the sizes of the product in these cases. French Engineer Charles Renard first introduced Preferred Numbers in the 19th century.

The system is based on the use of geometric progression to develop a set of numbers.
Basic series R 5 series R 10 series R 20 series R 40 series R 80 series Common Ratio 101/5 101/10 101/20 101/40 101/80 1.58 1.26 1.12 1.06 1.03 % increase in steps 58% 26% 12% 6% 3% Preferred Numbers [in between 1 to 10]
1.0, 1.6, 2.5, 4.0, 6.3, 10.0 1.0, 1.25, 1.6, 2.0, 2.5, 3.15, 4.0, 5.0, 6.3, 8.0,10.0 1.0,1.12,1.25,1.4,1.6,1.8,2.0,2.24,2.5,2.8,3.15,3.55,4.0,4.5,5.0,5.6,6.3,7.1,8.0,9.0,10.0 1.0,1.06,1.12,1.18,1.25,1.32,1.4,1.5,1.6, , 10.0 1.0,1.03, 1.06,1.09, 1.12,1.16, 1.18, 1.21,1.25,1.29,1.32,1.36,1.4,..1.6, , 10.0

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Aesthetic Considerations in Machine Design

When there are a number of products in the market, having the same qualities of efficiency, durability and cost, the customer will naturally attracted towards the most appealing product. The external appearance is an important feature, which not only gives grace and luster to the product but also dominates the sale in market.

Automobiles

Household Appliances

Audio Visual Equipments

Industrial Design

The job of an Industrial Designer is to create new forms & shapes, which are aesthetically pleasing.

The external appearance of the products is a cumulative effects of number of factors : Form
Step Stream Taper Shear Sculpture

Colour

Surface finish & Tolerances

Materials

Manufacturing Methods

Relationship between Functional requirement & Appearance of the Product

In many cases, functional requirements result in shapes, which are aesthetically pleasing. The evolution of the streamlined shape of the boeing is the result of studies in aerodynamics for effortless speed. Chromium plating on the household appliances is for corrosion resistance rather than for pleasing appearance
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Ergonomic Considerations in Machine Design

Ergonomics is defined as the relationship between Man & Machine and the application of anatomical, physiological and psychological principles to solve the problems arising from Man-Machine relationship.

Topics of Ergonomic studies in machine design

Anatomical factors in design of drivers seat.

Layout of instrument dials & display panels for accurate perception by the operators
Design of hand levers & hand wheels.

Ergonomists have carried out experiments to determine the best dimensions of drivers seat, the most convenient hand or foot pressure or dimensions of levers and hand wheels.

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Concurrent Engineering: Simultaneous Design Process

Sequential Design Process
Marketing Department

Concurrent Engineering
Concurrent Engineering is defined as the design process that brings both design & manufacturing engineers together during the early phases of the design process.
Customers requirement

Design Office
Production Department

Sales & Service Department

Manufacturability & Testability Cost, Sales & servicing

Design Engineering

: Concurrent Engineering
Concept

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Ergonomics & Appearance Machine Design

Reliability, Maintainability & safety 16

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Motivation
Most Economic

Requirements

Most Productive Improved Quality

Successful entry of a product into the market can best occur if it can complete the above cycle in the shortest possible time & at the lowest cost while maintaining very high product quality & reliability

CAD CAE CAM

Computer Aided Design Computer Aided Engineering Computer Aided Manufacturing

VP & VR
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Virtual Prototyping & Virtual Reality

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 is the use of Information technology/ computer based tools for supporting Engineers in tasks such as Design, Analysis, Simulation, Optimization, Manufacturing, Planning etc.
is to design, develop and optimize the product or process. CAE areas: Stress analysis, Vibration analysis using FEM Thermal & fluid flow analysis using CFD Kinematic & Dynamic Analysis & Simulation Analysis tools for manufacturing process simulation Optimization of the product or process is the use of wide range of computer based tools that assist Engineers & other Design Professionals in their design activities. is to design, develop and optimize the product. is the use of wide range of computer based tools that assist Production Engineers & Tool and Die maker, CNC machinists, in the manufacture or prototyping of products.
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Motivation
Most Economic

Requirements

Most Productive Improved Quality

Successful entry of a product into the market can best occur if it can complete the above cycle in the shortest possible time & at the lowest cost while maintaining very high product quality & reliability

VP : Virtual Prototyping
VP is about Presentation, Testing, & Analysis of 3-D CAD models prior to creating any physical prototype Visualization Models : greater communication, productivity & efficiency through realistic graphical modelling based on full colour, natural texture & appearance, dynamic viewing of models from any userspecified angle & orientation. Fit & Interference checking of mechanical assemblies

Testing & Verification of functions & performance : Structural & Physical phenomena analysis [FEM, CFD], Motion analysis.
Manufacturing Evaluation Assembly analysis

Human factor analysis

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CAD-CAM-CAE Software
CAD/CAM/CAE software Purpose 3-D modeling, analysis & simulation etc.

CATIA
NX (UniGraphics + IDEAS) PRO-ENGINEER SOLID WORKS SOLID EDGE INVENTOR Mechanical DESKTOP MasterCAM SolidCAM SmartCAM 3-D modeling & manufacturing simulation

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CAD-CAE Software
CAE software ADAMS SimDESIGNER with CATIA Visual NASTRAN Working Model ANSYS NASTRAN ABAQUS LS-DYNA DEFORM PAMCRASH FLUENT Purpose
Multi-body dynamic analysis & simulation Multi-body dynamic analysis & simulation Multi-body dynamic analysis & simulation Multi-body dynamic analysis & simulation Finite Element Analysis Finite Element Analysis Finite Element Analysis Finite Element Analysis, Crash simulation Finite Element Analysis, Crash simulation Finite Element Analysis, Crash simulation Computational Fluid Dynamics

Altair Hyper Mesh

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Meshing for Finite Element Analysis

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Computational Tools
Software
MATLAB

Purpose
Design calculation, dynamic analysis & simulation, design optimization, control Design calculation

Mathematica
MathCAD Maple TK Solver Excel

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CAD-CAE Tools
Design Phase
Design

Required CAD-CAE Tools

Related Software (s)

CATIA, NX, SolidWorks, Solid Edge, Pro-E, Inventor CATIA, ADAMS. CATIA, NASTRAN, ANSYS CATIA, MATLAB CATIA CATIA, AutoCAD

Geometric modeling, Graphics aids, conceptualization visualization Modeling & Simulation Design Analysis Design Optimization Design Evaluation Design communication & documentation Geometric modeling, Graphics aids, visualization, Simulation Package Geometric modeling, Analysis Package, visualization Geometric modeling, Optimization module Geometric modeling, Customized programs & Package Geometric modeling, Drafting package

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CAD-CAE Tools
Performed computation on high end computer

CAD

3-D CAD model

Pre-Processor

Solver
CAE

Post-Processor

Define the model & environment factors to be applied

Display results in graphical form using visualization tools

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Assignment # 1
1. Explain with example, the different steps involved in machine design process & in design of machine elements? What are the basic requirements of machine elements? 2. Distinguish between design synthesis and design analysis. 3. What is Standardization & what are the advantages of standardization? Give examples of Indian standards for commonly used engineering materials. 4. What are preferred numbers? How many basic series are used? What is R10 series? Develop R 10 series from 2 to 20. 5. What is an industrial design? What is the relationship between functional requirement and external appearance of the product. 6. Define ergonomics. What is the scope of ergonomics in machine design? 7. Distinguish between sequential design and concurrent engineering. 8. Explain the functional area of a basic CAD-CAE system & their applications & benefits in machine design process with examples. 9. Class Test Problem # 1. 10. Class Test Problem # 2. Last date of submission : 08th February, 2008
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Thank You

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Machine Design

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