Module 1: Fundamentals of Other skills needed in the design process:

Machine Design 1. Sketching , technical drawing, and

computer-aided design
New Machine
2. Properties of materials, materials
1. Conception
processing, and manufacturing processes
– to create a device that have a purpose
3. Application of chemistry such as
2. Study of arrangements
corrosion protection, plating, and painting
- of parts, location, length of links, the places
4. Static, dynamics, strength of
of bolts gears, spring, cams, and other
materials, kinematics, and mechanisms
elements of machines
5. Oral communication, listening,
technical writing, and teamwork skills
Machine design
6. Fluid mechanics, thermodynamics,
- is engineering and Mechanical Engineers
and heat transfer
can perform this.
7. Fluid power, the fundamentals of
electrical phenomena, and industrial controls
Machine Designers Responsibility
8. Experimental design and
(a) A good background in strength of
performance testing of materials and
materials.
mechanical systems
(b) A good acquaintance with the
9. Creativity, problem solving, and
properties of materials used in machines.
project management
(c) A familiarity with the major
10. Stress analysis
characteristics and economics of various
11. Specialized knowledge of the
manufacturing processes.
behavior of machine elements such as gears,
(d) Specialized knowledge in various
belt drives, chain drives, shafts, bearings,
circumstances, such as the
keys, splines, couplings, seals, springs,
properties of materials in
connections (bolted, riveted, welded,
corrosive atmosphere, at very low
adhesive), electric motors, linear motion
(cryogenic) temperature.
devices, clutches, and brakes.
(e) A preparation of deciding wisely:
i. when to use manufacture’s catalogs,
Classifications of Machine Design
buying stock or relatively available items,
1. Adaptive Design
and when custom design in necessary;
This classification is concerned with the
ii. when empirical design is justified;
adaptation of the existing designs and create
iii. when the design should be tested in
minor modifications or altercations as
service tests before manufacture starts: iv.
improvements in the existing design of the
when special measure should be taken
product. This type of design does not require
to control vibration and sound (and others).
special knowledge or skills and can be done
(f) Some aesthetic sense, “customer
by the designers with ordinary technical
appeal.”
training.
(g) A knowledge of economics and
2. Development Design
comparative costs.
This type requires considerable scientific
(h) Inventiveness and creative instincts.
training and design ability in order to modify
an existing design into a new idea by Factors need to be considered in Machine
integrating new materials or different way of Design.
manufacturing. a) The type of load and stresses caused by
3. New Design the load.
This type requires a lot of research, technical The load, on a machine component, may act
ability and creative thinking. Only those in several ways due to which the internal
designers who have personal qualities of a stresses are set up. The external loads can
sufficiently high order can take up the work cause internal stressed to the system. These
of a new design. stresses must be determined accurately since
these will be used in determining the
Types of Design based on Methods. component size. The system loading can be
a) Rational Design. attributed to: Energy transmission by a
-The type of design that depends upon machine member.
mathematical formulae of principle of ❑Dead weight.
mechanics. ❑Inertial forces.
b) Empirical design.
❑Thermal effects.
- The type of design that depends upon
❑Frictional forces.
empirical formulae based on the practice and
Loads can be classified either static (does not
experience.
change in magnitude and direction and
c) Industrial design.
normally increases gradually to a steady
The type of design that depends upon the
value) or dynamic (changes due to magnitude
production aspects to manufacture any
or direction)
machine component in the industry.
b) Motion of parts or kinematics of the
d) Optimum design.
machine.
The type that is the best design for the given
The operation of any system depends on the
objective function under the specified
simplest arrangement of the parts which will
constraints. It may be achieved by
give the motion required. The motion of the
minimizing the undesirable effects.
parts may be classified as:
e) System design.
The type of design for any complex ❑Rectilinear motion (either unidirectional

mechanical system like a motor car. and reciprocating motions)

f) Element design. ❑Curvilinear motion (rotary, oscillatory,

The type of design for any element of the or simple harmonic)
mechanical system like piston, crankshaft, ❑Motion with constant velocity
connecting rod, etc. ❑Motion with constant or variable
g) Computer aided design. acceleration.
The type of design that depends upon the use c) Selection of materials.
of computer systems to assist in the creation, The designer should be knowledgeable of the
modification, analysis and optimization of a properties of the materials and their
design. characteristics under working conditions.
Some of the important characteristics of
materials that are needed to be considered The safety and reliability of the machine
are: strength, durability, flexibility, weight, should be served with high quality
resistance to heat and corrosion, ability to maintenance to ensure the optimum running
cast, welded or hardened, machinability, condition. Regular scheduled maintenance
electrical conductivity, etc. should be done to moving and loaded parts to
d) Shape, size, and space requirements avoid catastrophic failures. The designer
The shape and size of the machine parts are should give careful attention to the matter of
based on judgment. To design any machine lubrication of all surfaces that interacts with
part for form and size, the forces which the other parts whether in rotating, sliding, or
part must sustain must be known. It is also rolling bearings.
necessary to anticipate any suddenly applied The cost of the manufacturing and additional
or impact load that may cause failure of parts. cost due to aesthetic should also be
For non-standard element, the shapes and considered in the design. Although in many
space requirements depend in the available cases, aesthetic is not an essential aspect of
space in a particular machine assembly that it machine design.
will be used.
e) Manufacture. Functions, Design Requirements, and
The designer should ensure that the designed Evaluation Criteria
elements can be manufactured with ease and In the design process, it is established that the
can be produces within the available facilities needs and expectations of the customers are
at low cost. identified
f) Operational parameters. before starting the design of mechanical
The designer should ensure that machines can device. It is done by formulating clear and
be operated with ease. The sequence of complete statements of functions, design
operation should be simplified and must not requirements, and evaluation criteria.
be complicated or would require an excessive Functions.
force. -Functions would tell what the device is
g) Reliability and safety capable of and in general, it uses
Reliability is defined as the probability of the nonquantitative statements that employ
element or a machine not to fail when action phrases including to support a load, to
exposed to operation. To ensure a high lift a crate, to transmit power, or to hold two
reliability, attention to detail should be done structural members together.
in every stages of the design process. Design requirements.
Safety should also be of paramount The design requirements are detailed and
importance in designing. Machines must be usually quantitative statements of expected
designed to address and serve the needs of performance levels, environmental
mankind and not to harm them. In some conditions in which the device must. operate,
cases, the designer must include in the design limitations on space or weight, or available
of the machine the necessary safety devices materials and components that may be used.
for the safety of the operator. Evaluation criteria
h) Maintenance, cost, and aesthetics The evaluation criteria are statements of
desirable qualitative characteristics of a
design that assists the designer in deciding
which alternative design is optimum or the
design that maximizes the benefits while
minimizing the disadvantages.
Achieving a high overall performance should
also be a high priority. Certain design
concepts may have desirable features not
present on others:
• Safety (the relative inherent safety
over and above stated requirements)
• Performance (the degree to which the
design concept exceeds requirements)
• Ease of manufacture
• Ease of service or replacement of
components
• Ease of operation
• Low initial cost
• Low operating and maintenance costs
• Small size and low weight
• Low noise and vibration; smooth
operation
• Use of readily available materials and Figure shows a sample design calculation
purchased components of a beam that subjected to concentrated
• Prudent use of both uniquely loading. 2050 pounds (lb). The design
designed parts and commercially available assumes that a rectangular shape is to be
components
used for the cross section of the beam.
• Appearance that is attractive and
Other practical shapes could have been
appropriate to the application
used. The objective is to compute the
required dimensions of the cross section,
considering both stress and deflection. A
Design Calculations
material for the beam is also chosen
The design calculation is an integral part of
the mechanical design process to ensure the
reliability and accuracy of the outcomes. Factor of Safety for Wire Ropes (SI Units)

Therefore, it is important to conduct the The factor of safety for wire ropes based on

calculations neatly, completely, and in an the ultimate strength are given in the

orderly fashion. following table. These values are used to

There will be cases wherein the designer will calculate the design load by taking a factor of

have to explain to others the approached used safety 2 to 2.5 times the factor of safety given

in the design, which data used, and which in the table below.

assumptions and judgments are made.

More on factor of safety and design stress
In general way, the greater the uncertainties
the greater the design factor, and the lower
the design stress should be. Uncertainties and
other factors that affect the magnitude of the
design stress are as follows.
(a) Material
(b) Size effect
(c) Loading
(d) Computed Stress Environment
(e) Inspection
(f) The Chance of an Accidental Load
(g) The Danger to Life or Property
(h) The Price Class in Which the Machine
Is to Sell