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Machine Design Considerations and Procedure

The document discusses general considerations and procedures for machine design. Key considerations include the type of loads and stresses on components, selection of materials based on properties, and ensuring safety of operation. The general procedure involves recognizing the design need, selecting mechanisms to achieve desired motion, analyzing forces, selecting materials, sizing components based on stresses, modifying sizes based on experience, and producing detailed drawings for manufacturing.

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28 views

Machine Design Considerations and Procedure

The document discusses general considerations and procedures for machine design. Key considerations include the type of loads and stresses on components, selection of materials based on properties, and ensuring safety of operation. The general procedure involves recognizing the design need, selecting mechanisms to achieve desired motion, analyzing forces, selecting materials, sizing components based on stresses, modifying sizes based on experience, and producing detailed drawings for manufacturing.

Uploaded by

asasd
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Machine Design Considerations and Procedure

General Considerations in Machine Design

Following are the general considerations in designing a machine component :


1. Type of load and stresses caused by the load. The load, on a machine component,
may act in several ways due to which the internal stresses are set up.

2. Motion of the parts or kinematics of the machine. The 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.

3. Selection of materials. It is essential that a designer should have a thorough


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

4. Form and size of the parts. The form and size are based on judgement. The
smallest practicable cross-section may be used, but it may be checked that the stresses
induced in the designed cross-section are reasonably safe. In order to design any
machine part for form and size, it is necessary to know the forces which the part must
sustain. It is also important to anticipate any suddenly applied or impact load which
may cause failure.

5. Frictional resistance and lubrication. There is always a loss of power due to


frictional resistance and it should be noted that the friction of starting is higher than
that of running friction. It is, therefore, essential that a careful attention must be given
to the matter of lubrication of all surfaces which move in contact with others, whether
in rotating, sliding, or rolling bearings.

6. Convenient and economical features. In designing, the operating features of the


machine should be carefully studied. The starting, controlling and stopping levers
should be located on the basis of convenient handling. The adjustment for wear must
be provided employing the various take up devices and arranging them so that the
alignment of parts is preserved. If parts are to be changed for different products or
replaced on account of wear or breakage, easy access should be provided and the
necessity of removing other parts to accomplish this should be avoided if possible.
The economical operation of a machine which is to be used for production, or for the
processing of material should be studied, in order to learn whether it has the
maximum capacity consistent with the production of good work.

7. Use of standard parts. The use of standard parts is closely related to cost, because
the cost of standard or stock parts is only a fraction of the cost of similar parts made to
order. The standard or stock parts should be used whenever possible ; parts for which
patterns are already in existence such as gears, pulleys and bearings and parts which
may be selected from regular shop stock such as screws, nuts and pins. Bolts and
studs should be as few as possible to avoid the delay caused by changing
drills, reamers and taps and also to decrease the number of wrenches required.

8. Safety of operation. Some machines are dangerous to operate, especially those


which are speeded up to insure production at a maximum rate. Therefore, any moving
part of a machine which is within the zone of a worker is considered an accident
hazard and may be the cause of an injury. It is, therefore, necessary that a designer
should always provide safety devices for the safety of the operator. The safety
appliances should in no way interfere with operation of the machine.

9. Workshop facilities. A design engineer should be familiar with the limitations of


his employer’s workshop, in order to avoid the necessity of having work done in some
other workshop. It is sometimes necessary to plan and supervise the workshop
operations and to draft methods for casting, handling and machining special parts.

10. Number of machines to be manufactured. The number of articles or machines


to be manufactured affects the design in a number of ways. The engineering and shop
costs which are called fixed charges or overhead expenses are distributed over the
number of articles to be manufactured. If only a few articles are to be made, extra
expenses are not justified unless the machine is large or of some special design. An
order calling for small number of the product will not permit any undue expense in
the workshop processes, so that the designer should restrict his specification to
standard parts as much as possible.

11. Cost of construction. The cost of construction of an article is the most important
consideration involved in design. In some cases, it is quite possible that the high cost
of an article may immediately bar it from further considerations. If an article has been
invented and tests of hand made samples have shown that it has commercial value, it
is then possible to justify the expenditure of a considerable sum of money in the
design and development of automatic machines to produce the article, especially if it
can be sold in large numbers. The aim of design engineer under all conditions, should
be to reduce the manufacturing cost to the minimum.

12. Assembling. Every machine or structure must be assembled as a unit before it


can function. Large units must often be assembled in the shop, tested and then taken
to be transported to their place of service. The final location of any machine is
important and the design engineer must anticipate the exact location and the local
facilities for erection.

General Procedure in Machine Design


In designing a machine component, there is no rigid rule. The problem may be
attempted in several ways. However, the general procedure to solve a design problem
is as follows :

1. Recognition of need. First of all, make a complete statement of the problem,


indicating the need, aim or purpose for which the machine is to be designed.
2. Synthesis (Mechanisms). Select the possible mechanism or group of mechanisms
which will give the desired motion.

3. Analysis of forces. Find the forces acting on each member of the machine and the
energy transmitted by each member.

4. Material selection. Select the material best suited for each member of the machine.

5. Design of elements (Size and Stresses). Find the size of each member of the
machine by considering the force acting on the member and the permissible stresses
for the material used. It should be kept in mind that each member should not deflect
or deform than the permissible limit.

6. Modification. Modify the size of the member to agree with the past experience and
judgment to facilitate manufacture. The modification may also be necessary by
consideration of manufacturing to reduce overall cost.

7. Detailed drawing. Draw the detailed drawing of each component and the assembly
of the machine with complete specification for the manufacturing processes
suggested.

8. Production. The component, as per the drawing, is manufactured in the workshop.

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