Unit – I Design process and design of Simple Machine elements (08 hrs)

3.Design 5.Use of
1.Machine 2.Design 4.Standard 6.Factor of 7.Service
Part 1 Design Process
considerati
ons
s and codes
preferred
series
safety factor
Part 1.Design
of Cotter
2.Knuckle
joint
2 joint
 Machine Design
Machine design is defined as the use of scientific principles,
technical information and imagination in the description of a
machine or a mechanical system to perform specific
functions with maximum economy and efficiency.

The designer uses A design is

his skill and created to
A designer uses The designer has imagination to satisfy a
principles of technical produce a recognized
Drawing of
Features of MD: basic and information of the configuration, need of
Machine
engineering basic elements of a which is a customer with
sciences machine. combination of maximum
these basic economy and
elements. efficiency.
 BASIC PROCEDURE OF MACHINE DESIGN

1
• Survey of Market

2
• Specify specifications of Product

3
• Search and study Alternative Mechanism and select proper mechanism

4
• Prepare general layout of configuration and select joining methods between components

5
• Design each component

• Prepare drawing s of assembly and detail and modify design after testing prototype
6 models
 Types of
loads and
stresses Kinematics
Assembling
of Machine

Cost of
Selection of
constructio
Materials
n

Number of
machines Design Forms and
to be Considerati size of
manufactur ons Parts
ed

Frictional
Resistance
Workshop
and
facilities
Lubricatio
n

Safety of Economical
operation Use of Features
standard
parts
 Standards and codes
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.

A standard is defined as a set of specifications for parts, materials or processes.(reduces the variety
and limit the number of items)

A code is defined as a set of specifications for the analysis, design, manufacture, testing and
erection of the product(The purpose of a code is to achieve a specified level of safety.)
Company standards?
National standards?
International standards?

• Advantages of standardization??????????????????????
 …………Standards and codes
(i) Standards for Materials IS 210:Grey CI: The number indicates ultimate tensile strength in
FG 150, FG 200, FG 220, FG 260, FG N/mm2.
300, FG350 and FG 400

ii) Standards for Shapes and IS 2494 specifies dimensions and shape of the cross section of
Dimensions (Part 1) endless V-belts for power transmission.

(iii) Standards for Fits, IS 2709:Guide for selection of fits IS 10719:method for indicating surface texture on
Tolerances and Surface Finish IS 919:‘Recommendations technical
of Component for limits and fits for engineering’ Drawings
IS 8000:Geometrical tolerance on technical drawings

(iv)Standards for Testing of IS 807 is a code of practice for design, IS 2825:‘Code for unfired pressure
Products(codes) manufacture, erection and testing of vessels’.
cranes and hoists.

(v) Standards for Engineering BIS(SP46):Engineering Drawing

Drawing of Components Practice for Schools and Colleges
 SELECTION OF PREFERRED SIZES
The ‘size’ of the product is a general term.
Eg.
1.transmitting capacity, load carrying capacity, speed
2.height, length and width, and volume
3.weight of the product.
Charles Reynard in the 19th century

Courtesy:Design of
Machine Elements By
V.B.Bhandary online
Edition
Basic Series

Courtesy:Design of
Machine Elements By
V.B.Bhandary online
Edition
 Derived Series
Derived series is designated by the symbol of the basic series followed by the
number 2, 3, 4 or p and separated by ‘/’ sign.
Eg:Series R 10/3 (1, … ,1000) indicates a derived series comprising of every
third term of the R10 series and having the lower limit as 1 and higher limit as
1000.
Find out the numbers of the R5 basic series from 1 to 10.
Solution:
5
10  1.5849
First number  1
second number  1 x 1.5849  1.5849
Third number  1 x 1.5849 x 1.5849  1.5849 2  2.51
Fourth number  1 x 1.5849 x 1.5849 x 1.5849  1.5849 3  3.98
and so on.........................
 A manufacturer is interested in starting a business with five different
models of tractors ranging from 7.5 to 75 kW capacities. Specify power
capacities of the models. There is an expansion plan to further increase
the number of models from five to nine to fulfill the requirement of
farmers. Specify the power capacities of the additional models.

Solution: Pmin=7.5kW, Pmax=75kW

A)Staring plan: Number of Motors(number of steps)=5(5 different models)
Pmax 75
1.First motor rating= P1 =Pmin *Ø 0=7.5kW Range ratio    10
Pmin 7.5
2.Second motor Rating=P2 =Pmin * Ø 1
3.Third motor Rating=P3 =Pmin * Ø 2
4.Fourth motor Rating=P4 =Pmin * Ø 3
5.Fifth motor Rating=P5=Pmin * Ø 4
Ratio factor Ø=?
For Ø,
Pmax=Pmin* Ø4 , 75=7.5 * Ø4 ,Ø4 =(75/7.5)=10,Ø=(10)^(1/4),Ø=1.7783
Put Ø in
1.First motor rating= P1 =Pmin *Ø 0=7.5kW
2.Second motor Rating=P2 =Pmin * Ø 1 =7.5 * 1.7783= 13.34kW(13kW)
3.Third motor Rating=P3 =Pmin * Ø 2 = 7.5 * 1.77832 = 23.72kW(24kW)
4.Fourth motor Rating=P4 =Pmin * Ø 3 = 7.5 * 1.77833 = 42.18kW(42kW)
5.Fifth motor Rating=P5=Pmin * Ø 4 = 7.5 * 1.77834 = 75.0kW(75kW)
B)Expansion plan: Number of motors are 9
1.First motor rating= P1 =Pmin *Ø 0
Now Ø : P  P x Ø 8
2.Second motor rating= P2 =Pmin *Ø 1 max
1
min
1
3.Third motor rating= P3=Pmin *Ø 2  Pmax  8  75  8
Ø        1.3335
4.Fourth motor rating= P4 =Pmin *Ø 3  Pmin   7.5 
5.Fifth motor rating= P5=Pmin *Ø 4
6.Sixth motor rating= P6=Pmin *Ø 5
7.Seventh motor rating= P7=Pmin *Ø 6
8.Eighth motor rating= P8=Pmin *Ø 7
9.Ninth motor rating= P9=Pmin *Ø8
1.First motor rating= P1 =Pmin *Ø 0=7.5 *1.33350 =7.5kW
2.Second motor rating= P2 =Pmin *Ø 1=7.5 *1.33351 =10kW
3.Third motor rating= P3=Pmin *Ø 2=7.5 *1.33352 = 13.34=13.34kW
4.Fourth motor rating= P4 =Pmin *Ø 3=7.5 *1.33353 =17.78 = (18) kW
5.Fifth motor rating= P5=Pmin *Ø 4=7.5 *1.33354 = 23.72 = (24) kW
6.Sixth motor rating= P6=Pmin *Ø 5=7.5 *1.33355 = 31.62 = (32) kW
7.Seventh motor rating= P7=Pmin *Ø 6=7.5 *1.33356 = 42.17 = (42) kW
8.Eighth motor rating= P8=Pmin *Ø 7=7.5 *1.33357 = 56.24 = (56) kW
9.Ninth motor rating= P9=Pmin *Ø 8=7.5 *1.33358 = 74.99 = (75) kW
Find out the numbers of R20/4(100,…, 1000) derived series.
Solution: Step III Calculation of numbers

First number = 100

Step I Calculation of series factor
Second number = 100(1.5848) = 158.48 = (160)

The series factor for the R20 series is given by: Third number = 100(1.5848)(1.5848) = 100(1.5848)2
= 251.16 = (250)
20
10  1.122 Fourth number = 100(1.5848)2(1.5848) = 100(1.5848)3 =
398.04 = (400)
Step II Calculation of ratio factor
Fifth number = 100(1.5848)3(1.5848) = 100(1.5848)4 =
630.81= (630)
Since every fourth term of the R20
series is selected, the ratio factor (Ø) is Sixth number = 100(1.5848)4(1.5848) = 100(1.5848)5 = 999.71
given by, Ø= (1.122)4 = 1.5848 = (1000)
 FACTOR OF SAFETY
• While designing a component, it is
necessary to provide sufficient reserve
• For ductile materials, the allowable stress σ
strength in case of an accident. This is is obtained by the following relationship:
achieved by taking a suitable factor of
safety (fs).
• The factor of safety is defined as
• For brittle materials, the relationship is,

• where Syt and Sut are the yield strength and

• The allowable stress is the stress value, the ultimate tensile strength of the material
which is used in design to determine the respectively.
dimensions of the component.
Magnitude of FoS depends upon: The selection of magnitude of the
factor of safety:
Effect of Failure
For cast iron components, ultimate tensile strength is
Type of Load considered to be the failure criterion.(usually 3 to 5)

For components made of ductile materials like steel and

Degree of Accuracy in Force Analysis which are subjected to external static forces, yield strength
is considered to be the criterion of failure.(1.5 to 2)
Material of Component
For components made of ductile materials and those
Reliability of Component subjected to external fluctuating forces, endurance limit is
considered to be the criterion of failure. (1.3 to 1.5)

Cost of Component Cams and followers, gears, rolling contact bearings or rail and
wheel is based on the calculation of contact stresses by the
Hertz’ theory. Failure of such components is usually in the form
Testing of Machine Element of small pits on the surface of the component. Pitting is surface
fatigue failure, which occurs when contact stress exceeds the
surface endurance limit.(1.8 to 2.5)
Service Conditions
piston rods, power screws or studs, are designed on the
Quality of Manufacture basis of buckling consideration.( 3 to 6)
 Service factor
The service factor is the ratio of the gearbox/motor rated horsepower (or torque)
to the application’s required horsepower (or torque).
In practical applications, the torque developed by the source of power varies
during the work cycle.
Similarly, the torque required by the driven machine also varies. The two sides
are balanced by means of a flywheel.

In gear design, the maximum force (due to maximum torque) is the criterion.
This is accounted by means of a service factor.
 Design of Cotter Joint
• A cotter joint is used to connect two co-axial rods, which are
subjected to either axial tensile force or axial compressive
force.
• Typical applications for joint Between
1.The piston rod and the crosshead of a steam engine
2. The slide spindle and the fork of the valve mechanism
3. the piston rod and the tail or pump rod
4. Foundation bolt
 Design of Cotter Joint

Cotter:Wedge shaped
1:24 or 32 taper

Courtesy:Design of Machine Elements By

V.B.Bhandary online Edition

Animation of the failure of Cotter joint on

https://www.youtube.com/watch?v=H0RwP6PB58Q

LMS videos\U1\cotter_joint_failure.mp4
Dimensions of Cotter Joint

P = tensile force acting on rods (N)

d = diameter of each rod (mm)
d1 = outside diameter of socket (mm)
d2 = diameter of spigot or inside
diameter of socket (mm)
d3 = diameter of spigot-collar (mm)
d4 = diameter of socket-collar (mm)
a = distance from end of slot to the end
of spigot on rod- (mm)
Courtesy:Design of b = mean width of cotter (mm)
Machine Elements By c = axial distance from slot to end of
V.B.Bhandary online socket collar (mm)
Edition t = thickness of cotter (mm)
t1 = thickness of spigot-collar (mm)
l = length of cotter (mm)
Free Body Diagram of Cotter Joiint

Courtesy:Design of
Machine Elements By
V.B.Bhandary online
Edition
Mode of Failure of component Area /Diagram of failure Stress Equation
(i) Tensile Failure of Rods
Each rod of diameter d is
subjected to a tensile force P.
The tensile stress in the rod is
given by
(ii) Tensile Failure of Spigot:
Figure shows the weakest
cross-section at XX of the spigot
end, which is subjected to
tensile stress.

t = 0.31d
Mode of Failure of component Area /Diagram of failure Stress Equation
(iii) Tensile Failure of Socket:
shows the weakest section at YY of
the socket end, which is subjected to
tensile stress. The area of this The tensile stress at section YY is
section is given by given by

(iv) Shear Failure of Cotter The

cotter is subjected
to double shear as illustrated in Fig.
The area of each of the two planes
that resist shearing failure is (bt).
Therefore, shear stress in the cotter is
given by,
Mode of Failure of component Area /Diagram of failure Stress Equation
(v) Shear Failure of Spigot End τ is permissible shear stress for
the spigot.
The spigot end is subjected to double
shear as shown in Fig. The area of
each of the two planes that resist shear
failure is (ad2). Therefore, shear stress
in the spigot end is given by

(vi) Shear Failure of Socket c can be determined by

End
The socket end is also subjected to double
shear as shown in Fig.
The area of each of the two planes that
resist shear failure is given by,
Mode of Failure of component Area /Diagram of failure Stress Equation
(vii) Crushing Failure of Spigot End As shown
in Fig. the force P causes compressive stress
on a narrow rectangular area of thickness t
and width d2 perpendicular to the plane of
the paper.
The compressive stress is given by,

(viii) Crushing Failure of Socket End As

shown in
Fig. the force P causes compressive stress
on a narrow rectangular area of thickness t.
The other dimension of rectangle,
perpendicular to the plane of paper is (d4 –
d2). Therefore, compressive stress in the
socket end is given by,
Mode of Failure of component Area /Diagram of failure Stress Equation
(ix) Bending Failure of Cotter When the
cotter
is tight in the socket and spigot, it is
subjected to shear stresses. When it
becomes loose, bending occurs. The
forces acting on the cotter are shown in
Fig. (a). The force P between the cotter
and spigot end is assumed as uniformly
distributed over the length d2. The force
between the socket end and cotter is
assumed to be varying linearly from zero
to maximum with triangular distribution.
The cotter is treated as beam as shown in
Fig.(b). For triangular distribution,
Cotter Treated as Beam (a) Actual
Distribution of Forces (b) Simplified
Diagram of Forces
Empirical relations for Cotter Joint
 Design procedure of cotter joint
(i) Calculate the diameter of (vi) The dimensions a and c are (vii) Calculate the width b of the cotter by
calculated by the following shear consideration using Eq. and
each rod by Eq. bending consideration using Eq. and
empirical relationship, select the width, whichever is maximum
a = c = 0.75 d between these two values.

(v) The diameter of the spigot collar

d3 and the diameter of the socket
collar d4 are calculated by the
(ii) Calculate the thickness of following empirical relationships, (viii) Check the crushing and shear
the cotter by the empirical d3 = 1.5 d ,d4 = 2.4 d stresses in the spigot end by
relationship given in Eq.
t = 0.31 d

(iv) Calculate the outside diameter (ix) Check the crushing and shear
d1 of the socket on the basis of stresses in the socket end
(iii) Calculate the diameter tensile stress in the socket
d2 of the spigot on the basis
of tensile stress.
 Numerical of cotter joint
It is required to design a cotter joint to connect two steel rods of equal diameter. Each
rod is subjected to an axial tensile force of 50 kN. Design the joint and specify its
main dimensions. The material of the two rods and the cotter is selected as plain
carbon steel of Grade 30C8 (Syt = 400 N/mm2). The factor of safety for the rods,
spigot end and socket end is assumed as 6, while for the cotter, it is taken as 4.
Solution:
Step I:
Given:
T=tensile force=50KN,
Syt = 400 N/mm2 ………………..for all socket, spigot, rods and cotter,
fsr=factor of safety for rods=6
fsc=factor of safety for cotter=4
Step II: Calculation of permissible stresses
• The permissible stresses for rods, spigot end and socket end are as follows:

Permissible stresses for the cotter are as follows:

Step III Calculation of dimensions:

Courtesy:Design of
1. Diameter of rods: Machine Elements By
V.B.Bhandary online
Edition
2. Thickness of cotter 7.Width of cotter
t = 0.31 d = 0.31(32) = 9.92 or 10 mm
3.Diameter (d2) of spigot
=50mm

8. Check for crushing and shear stresses in

d2 = 37.91 or 40 mm
4.Outer diameter (d1) of socket

and
9.Check for crushing and shear stresses in socket end
d1 = 52.04 or 55 mm
5.Diameters of spigot collar (d3) and socket collar (d4)
d3 = 1.5d = 1.5(32) = 48 mm
d4 = 2.4d = 2.4(32) = 76.8 or 80 mm
6.Dimensions a and c The stresses induced in the spigot and the socket ends
a = c = 0.75d = 0.75(32) = 24 mm are within limits.
10. Thickness of spigot collar
t1 = 0.45d = 0.45(32) = 14.4 or 15 mm
The taper for the cotter is 1 in 32.

Step IV. Dimensioned sketch of cotter joint

Courtesy:Design of
Machine Elements By
V.B.Bhandary online
Edition
Two rods are connected by means of a cotter joint. Step I :
The inside diameter of the socket and outside Permissible stresses for cotter
diameter of the socket collar are 50 and 100 mm
respectively. The rods are subjected to a tensile
force of 50 kN. The cotter is made of steel 30C8
(Syt = 400 N/mm2) and the factor of safety is 4.
The width of the cotter is five times of thickness.
Calculate:
(i) width and thickness of the cotter on the basis Step II
of shear failure; and Width and thickness on the basis of shear failure,
(ii) width and thickness of the cotter on the basis
of bending failure.
Solution:
t = 10 mm and b = 5t = 50 mm
Given:
Step III
Syt = 400 N/mm2, fs = 4
Width and thickness on the basis of bending failure
P = 50 × 103N, d4 = 100 mm, d2 = 50 mm d4 = 100 mm d2 = 50 mm
t = 10.77 or 12 mm and b = 5t = 60 mm