Arba Minch University

Arba Minch Institute of Technology /AMiT/

Faculty of Mechanical Engineering [FME]`

Course Code -MEng2151

Course Name -Machine Element I

Degree Program -B.Sc. in Mechanical Engineering

By- kibrom M. March 1/2020

 Chapter One
• Basics
–Introduction
•Machines
•Design
•Mechanical Engineering Design
•Phases and Interactions of the Design Process
–Engineering Materials
–Allowable Stresses and Factor of Safety
04/03/2020 2
 1.1. Introduction
1.1.1. WHAT IS A MACHINE?

 A machine is an apparatus consisting of inter related elements or

devices that modify force or motion.
An apparatus consisting of interrelated units (machine elements)
 A device that modifies force and motion
A machine receives energy in some available form and uses it to
do some particular kind of work
A petrol engine is a machine, which may use the heat energy
derived from the combustion of the fuel to propel a vehicle along
the road
04/03/2020 3
• A lathe is a machine which receives mechanical energy from the
line shaft through the belt or gears and uses that energy to remove
metal from a bar or other piece of work
• LINK OR ELEMENT : Each part of a machine which has motion

relative to some other part

• STRUCTURES : Made up of series of members of regular shape that

have a particular function for load carrying

• SYNTHESIS : Concerned with the problem of selecting the size
of the mechanism to perform a given function
• STRESS : Internal reacting force per unit area due to the effects
of external applied forces
04/03/2020 4
1.1.2. DESIGN

• Formulate a plan for the satisfaction of a human need

• The need for the problem has to be identified
• Design problem have no unique answer
• An innovative and iterative process
• A communication intensive activity

04/03/2020 5
Types of design

1. Adaptive Design- based on existing design, for example,

standard products or systems adopted for a new application
2. Developmental design-start with an existing design but
finally a modified design is obtained
3. New design-This type of design is an entirely new one but
based on existing scientific principles
• A design must be:
Functional - fill a need or customer expectation
Safe- not hazardous to users or bystander

Reliable- conditional probability that product will perform

its intended function without failure to a certain age.
Competitive- competitor in the market

Usable- accommodates human size and strength

Manufacturable- minimal number of parts and suitable for

production
Marketable- product can be sold and serviced
04/03/2020 7
Design Process Actions

 Conceive alternative solutions

 Analyze, test, simulate, or predict performance of
alternatives
 Choose the “best” solution
 Implement design

04/03/2020 8
 A good answer today may well turn out to be a poor
answer tomorrow, if there is a growth of knowledge during
the period
 A design is always subject to certain problem-solving
constraints
 A design problem is not a hypothetical (theoretical)
problem
 Design has a genuine purpose the creation of an end result
by taking explicit action, or the creation of something
having physical reality
04/03/2020 9
 1.1.3. ENGINEERING DESIGN
• The process in which scientific principles and the tools of
engineering mathematics, computers, graphics and English
are used to produce a plan which, when carried out, will
satisfy a human need
• Design of things and systems of mechanical nature,
machines, products, structures, devices, and instruments
• For the most part, mechanical design utilizes mathematics, the
materials sciences, and the engineering mechanics sciences

04/03/2020 10
 The ultimate goal in machine design is to

size and shape the parts

choose appropriate material and
choose manufacturing process
So that resulting machine can be expected to perform its
intended function without failure

04/03/2020 11
• An engineer should be able to calculate and predict the mode
and conditions of failure for each element and then design it
to prevent that failure
• This requires stress and deflection analysis for each part
• Stresses are functions of applied and inertial loads
• An analysis of the forces, moments, torques and dynamics of
system must be done before stresses and deflections can be
completely calculated

04/03/2020 12
1.2.Phases & Interactions of the Design Process
• Machine design is applied through a specific process
including determining what the machine needs to do,
benchmarking and defining goals and requirements,
brainstorming, evaluating and selecting from the different
options, creating an in-depth design, creating and testing a
prototype, and finally manufacturing the machine.

04/03/2020 13
 Cont…
• What is the design process? How does it begin? Does the
engineer simply sit down at a desk with a blank sheet of
paper and write down some ideas? What happens next?
What factors influence or control the decisions that have to
be made? Finally, how does the design process end?

04/03/2020 14
 1.2.1. Steps to Design

04/03/2020 15
 1.2.2. Design Considerations
1. Strength 14. Noise
2. Stiffness 15. Styling
3. Wear 16. Shape
4. Corrosion 17. Size
5. Safety 18. Control
6. Reliability 19. Thermal Properties
7. Friction 20. Surface
8. Usability 21. Lubrication
9. usefulness 22. Marketability
10. Cost 23. Maintenance
11. Processing 24. Volume
12. Weight 25. responsibility
04/03/2020
13. Life 26. improvement 16
 1.2.3. Codes and Standards
• Code - a set of specifications for the analysis, design,
manufacture, and construction of something
• Standard - a set of specifications for parts, materials, or

processes intended to achieve uniformity, efficiency, and a

specified quality

04/03/2020 17
 1.2.4. Organizations
• Aluminum Association (AA) • American Bearing Manufacturers
• American Gear Manufacturers Association (ABMA)
Association (AGMA) • British Standards Institute (BSI)
• American Institute of Steel • Industrial Fasteners Institute (IFI)
Construction (AISC) • Institution of Mechanical Engineers (I.
Mech. E.)
• American Iron and Steel Institute
(AISI) • International Bureau of Weights and
Measures (BIPM)
• American National Standards • International Standards Organization
Institute (ANSI) (ISO)
• American Society for Metals (ASM) • National Institute for Standards and
• American Society of Mechanical Technology (NIST)
Engineers (ASME) • Society of Automotive Engineers (SAE)
• American Society of Agricultural and
• American Society of Testing Biological Engineers (ASABE)
Materials (ASTM)
• American Welding Society (AWS)
04/03/2020 18
 1.2.5. Economics
• Cost plays an important role in design decision process
–No matter how great the idea may be, if it’s not profitable
it may never be seen
• The use of standard sizes and large manufacturing tolerances
reduce costs
• Evaluating design alternatives with regard to cost
–Breakeven Points
–Cost Estimates
04/03/2020 19
 Product Liability
• “Strict liability” concept prevails in the U.S.
–Manufacturers are liable for any damage or harm that
results from a defect.

04/03/2020 20
 1.3. Engineering materials

04/03/2020 21
Mechanical properties of common engineering materials

 The important properties from design point of view are:

Elasticity- is the property of a material to regain its original
shape after deformation when the external forces are removed.
Plasticity- the permanent deformation of material when the
stress level exceeds the yield point.
Hardness- Property of the material that enables it to resist
permanent deformation, penetration, indentation etc.
Ductility- the property of the material that enables it to be
drawn out or elongated to an appreciable extent before rupture
occurs
Malleability- It is a special case of ductility where it can be
rolled into thin sheets but it is not necessary to be so strong.
Brittleness- This is opposite to ductility.
Resilience- the property of the material that enables it to resist
shock and impact by storing energy
Toughness- the property which enables a material to be
twisted, bent or stretched under impact load or high stress
before rupture
Creep- When a member is subjected to a constant load over a
long period of time it undergoes a slow permanent deformation.
04/03/2020 23
 Allowable Stresses and Factor of Safety

Determination of stresses in structural or machine components would

be meaningless unless they are compared with the material strength. If
the induced stress is less than or equal to the limiting material strength
then the designed component may be considered to be safe and an
indication about the size of the component is obtained.
Ultimate stress - is the ratio of the ultimate load to the
original cross-sectional area.
.

 Allowable stress - is the working stress/critical stress which

is always less than the limiting material strength.

For design purpose an allowable stress is used in place of the
critical stress to take into account the uncertainties including
the following:
Uncertainty in loading.
Inhomogeneity of materials.
Various material behaviors. e.g. corrosion, plastic flow,
creep.
Residual stresses due to different manufacturing process.
Fluctuating load (fatigue loading)
Safety and reliability
For ductile materials, the yield strength and for brittle
materials the ultimate strength are taken as the critical stress.
An allowable stress is set considerably lower than the ultimate
strength. The ratio of ultimate to allowable load or stress is
known as factor of safety i.e.

Ultimate stress
F.S= ≥1
Allowable stress

The ratio must always be greater than unity. It is easier to refer

to the ratio of stresses since this applies to material properties
 Measures of Strength

• S – Strength
• Ss – Shear Strength
• Sy – Yield Strength
• Su – Ultimate Strength
• S - Mean Strength

04/03/2020 27
 Measures of Stress
• t – Shear Stress
• s – Normal Stress
• s1 – Principal Stress
• sy – Stress in y-direction
• sr – Radial Stress
• st – Tangential Stress

04/03/2020 28
 Allowable Stress
(AISC)
• Tension: 0.45 Sy ≤ sall ≤ 0.60 Sy
• Shear: tall = 0.40 Sy
• Bending: 0.60 Sy ≤ sall ≤ 0.75 Sy
• Bearing: sall = 0.90 Sy

04/03/2020 29