INTRODUCTION TO MACHINE DESIGN

Various products, systems and services that enrich our standard of living are largely the result of the design activities of those in
engineering.

A new machine is born because there is a real or imagined need for it.

Almost everyone is involve with design in one way or another, even in our daily living,

In engineering, the word “DESIGN” conveys different meanings to different persons. It may be defined as “to formulate plan for
the satisfaction of a human need.

Classification of Design

1. Scientific Design

2. Empirical Design

3. Combination of both
 Designer’s Capabilities

The designer of a machine is a versatile person, not a specialist because he must have knowledge of science “to know” and
knowledge of engineering “to produce”.

A competent designer in order to successfully attain a sound design should have the following capabilities:

1. Adequate engineering and scientific knowledge in various aspects.

2. Should have access to various handbooks and books related to his field.

3. Should have the ability to communicate verbally, symbolically and graphically.

The technical information necessary to design a machine varies with the type and field of application and no one designer can
become expert in all types of design.

Design experience and knowledge of existing designs are essential to a thorough understanding of machine design, but previous
designs should not be considered in any way that would hinder the designer’s creative ability.

Human element is receiving more and more attention in the design room. There has been considerable study leading to the
simplification of the operating controls and to a reduction of a physical effort necessary to operate the machine.
 Stages in the Design Process

The engineering design begins with the awareness of human need or want.

1. Identification of Problems

2. Concepts or Ideas

3. Compromise Solution

4. Models or Prototypes

5. Production of Working Drawing

Attributes of a Good Designer

1. A good background in Strength of Materials.

2. Acquaintance with properties of materials.

3. Familiarity with characteristics and economics of manufacturing processes.

4. When to use catalogues, available items or when custom design is necessary; when empirical design is needed; or
measures taken for sound and vibration.

5. An aesthetic sense (customer appeal) if is to sell.

6. Economics and comparative cost (Engineers must save money in designing)

7. Inventiveness and creativeness.

ENGINEERING MATERIALS

It is the study of properties, behaviour, composition and effects of materials when it is combined of different elements that is
found in metals, ceramics, polymers and composites.
Ferrous Materials are those materials containing iron as principal constituent.

Steel is an example of ferrous materials where:

a. It is the most extensively used material for machine components.

b. It contains carbon up to 2.0%

c. It is generally produced by crucible furnace or electric furnace.

d. It is tough and malleable.

e. It can be forged.

f. It has more tensile strength.

CLASSIFICATION OF STEELS

A. Plain Carbon Steel

 It is also known as Mild Steel.

 It is the most common form of steel because its price is relative tow

 It provides material properties that are acceptable for mar applications

.

B. Alloy Steel

 It is the combination of iron and carbon and other alloying elements.

 It is rust proof.

 It is harder and tougher.

 It can be hardened uniformly

 It is hard for machining.

 It is nonmagnetic.
Carbon Percentage Present in Steel

a. Low Carbon Steel contains 0.05—0.15% carbon.

b. Mild Steel contains 0.16—0.29% carbon.

c. Medium Carbon Steel contains 0.30—0.59% carbon

d. High Carbon Steel contains 0.6—0.99% carbon.

e. Ultra-High Carbon Steel contains 1.0—2.0% carbon content.

Impurities Present in Steel

a. Sulfur………….......0.02 to 0.05%

b. Phosphorous. .0.02 to 0.05%

c. Silicon……………0.05 to 0.20%

d. Manganese..……...0.30 to 1.50%
Carbon Effect in the Properties of Steel

a. When carbon content is higher, the melting point is lower.

b. When carbon percentage is lower, it is easy for forging.

c. When carbon percentage is higher, the degree of hardness is more.

d. When carbon percentage is lower, it is easy for forge welding.

AISI and SAE Designation of Steels

The first digit indicates the Class of Steel

1: used to indicate carbon steels

2: for Nickel steels

3: for Chrome-Nickel steels

4: for Molybdenum steels

5: for Chromium steels

6: for Chrome-Vanadium steels

7: for Tungsten steels

8: for the National emergency steels

9: for Silicon-Manganese steels

The second digit indicates the approximate percentage of the principal alloying element present in the steel.

The remaining two (sometimes three) digits represent a number 100 times the approximate percentage of carbon present in the
steel. In the AISI system, a one-or two-letter prefix (usually one letter) is added to the above four or five digits to indicate the
method of producing the steel.

A: for basic open hearth alloy steels

B: for acid Bessemer carbon steels

C: for basic open hearth carbon steels

D: for acid open hearth carbon steels

E: for electric steels

NE: for the national emergency steel

THE AISI DESIGNATION SYSTEM

The AISI uses a four-digit designation system for carbon and alloy steel as shown in the illustration below. The first two digits
indicate the specific alloy group that identifies the primary alloying elements other than carbon in the steel. The last two digits
indicate the amount of carbon in the steel.
For Example :

•SAE 1018 indicates non-modified carbon steel containing 0.18% of carbon.

•SAE 5130 indicates a chromium steel alloy, containing 1% of chromium and 0.30% of carbon.

Example AISI/SAE No. 1020

the first digit indicates that this is plain carbon steel.

the second digit indicates there are no alloying elements
the last two digits indicates that the steel contains approximately 0.20 percent carbon

Example AISI/SAE No. 4340

the first two digits indicates a Nickel-Chromium-Molybdenum alloy steel

the last two digits indicates carbon content roughly 0.4 percent
PRECIOUS METALS

1. Gold is soft and ductile, and it has good corrosion resistance at any temperature. It is the most malleable metal with
enormous commercial value. Used in trade jewelry, reflectors, coinage, good leaf for decorative purposes, dental work,
electroplating, and contacts and terminals.

2. Silver-is a ductile metal and it has the highest electrical and thermal conductivity of any metal. The typical applications
for silver include tableware, jewelry, coinage, electroplating, photographic film, electrical contacts, solders, bearing linings,
and food and chemical equipment.

3. Platinum is a soft, ductile, grayish-white metal that has good corrosion resistance even at elevated temperature: -
Platinum alloys are used as electrical contacts, for spark-plug electrodes, as catalyst for automobile pollution-control
devices, in filaments, in nozzles, in dies for extruding glass fibers, thermocouples, in the electrochemical industry, as
jewelry, and in dental work.
HEAT TREATMENT OF METALS

1. Annealing consists of heating the metal to a temperature slightly above the critical temperature and then cooling slowly,
usually in the furnace, to produce an even grain structure, reduce the hardness, and increase the ductility, usually at a reduction
of strength.

2. Normalizing is a form of annealing (cooling in air) used to remove the effects of any previous heat treatment and to
produce a uniform grain structure before other heat treatments are applied to develop particular properties of metal.

3. Quenching is a rapid cooling from above the critical temperature by immersion in cold water or other cooling medium.

4. Tempering or drawing consists of reheating the quenched metal below critical temperature to restore some of the
ductility and reduce the brittleness.

5. Case hardening or carburizing is a process of hardening the outer portion of the metal by prolonged heating free from
contact with air while the metal is packed in carbon in the form of bone char, leather, or charcoal.
6. Cyaniding is casehardening with powdered potassium cyanide or potassium ferrocyanide mixed- with potassium
bichromate (dichromate) substituted for the carbon.

7. Nitriding is a surface hardening accomplished by heating certain steel alloys immersed in ammonia fumes.

8. Surface Hardening is any heat-treatment method used to alter properties within the surface or localized area of a
metal.

9. Spheroidizing forms when carbon steel is heated to approximately 700 'C for over 30 hours. The purpose is to soften
higher carbon steels and allow more formability. This is the softest and most ductile form of steel.
PROPERTIES OF METALS

1. Malleability is the property of metal on account of which it can be extended in all directions by hammering or rolling.

Example; Lead, Tin

Order of Malleability
1. Copper
2. Aluminum
3. Tin
4. Lead
5. Iron
6. Zinc

2. Machinability is the property of metal due to which a metal can easily be cut by cutting tools to obtain a desired finished
on its surface.

Example: Mild Steel, Brass

3. Hardness is the property of metal which makes a metal capable of resisting surface penetration by other metals.

Example: High carbon steel, high speed steel

The Mohs Scale Hardness

1. Talc

2. Gypsum

3. Calcite

4. Fluorite

5. Apatite

6. Feldspar

7. Quartz

8. Topaz

9. Ruby
4. Toughness is the property of metal due to which a metal is able to withstand bending or torsion without fracture.

Example: Wrought iron, Mild steel

5. Ductility is the property of metal due to which a metal can be drawn into the form of wires without; rupture, at the
same time retaining enough strength.

Order of Ductility

1. Copper

2. Iron

3. Aluminum

4. Zinc

5. Tin

6. Lead
6. Fusibility is the property of metal due to which a metal becomes fluid when it is heated.

7. Stiffness is the property of metal -due to which a metal is capable of resisting deflection due to an externally applied load.

Nonferrous Materials are those materials, which do not contain iron as principal constituent.

Non-metallic Materials are of great importance in engineering applications.

Thermosetting Plastics are soft and pliable during one stage of chemical transition only.

Thermoplastics include those materials that become soft and pliable when heated to moderate temperature.
CLASSIFICATION OF MATERIALS

1. Ductile Material demonstrates large amounts of plastic deformation.

2. Brittle Material is a material's unwillingness to be drawn, stretched, or formed. It tends to break or crack if subjected to
these forces. It shows little or no plastic deformation before fracture.
TERMINOLOGY

 Elasticity is the ability of a material to return to its original shape and size after being stretched, compressed, twisted or
bent.

 Elastic Limit is the greatest stress a material can undergo and still return to its original dimensions.

 Plasticity is the ability of a material to remain deformed after the load which is causing the deformation has been
removed.

 Proportional Limit is the greatest stress which a material -is capable of sustaining without deviation from
proportionality of stress and strain (Hooke's Law) or the point on the stress-strain curve at which stress ceases to be
proportional to strain.

 Yield Point is the first point at which permanent deformation of a stressed specimen begins to take place. This is a point
on the stress-strain curve at which the increase in strain is no longer proportional to the increase in stress.

 Yield Strength is the stress at the yield point. It often defined as the stress needed to produce a specified amount of
plastic deformation (usually, a 0.2 percent change in length).

 Ultimate Strength is the term used to describe the maximum unit stress that a material can withstand when subjected to
an applied load in a compression, tension or shear test.

 Rupture Strength is the strength of the material at rupture. This is also known as the breaking strength.