This document provides an introduction to machine design and its various considerations. It defines machine design as the process of engineering design that involves designing machine elements and arranging them optimally to obtain useful work. Some key points covered include:
- Classification of machine design types including adaptive, development, and new design.
- Factors to consider in machine design such as material selection, forces on elements, size, shape, weight, manufacturing method, reliability, and cost.
- The general procedure of machine design including need identification, mechanism synthesis, force analysis, material selection, element design, modification, and drawing production.
- Considerations for manufacturability such as reducing part counts, modular design, and designing for
This document discusses machine design and the basic procedures and requirements for designing machine elements. It defines machine design as using scientific principles, technical information, and imagination to describe machines that perform functions with maximum economy and efficiency. The basic requirements for machine elements are then listed, including strength, rigidity, wear resistance, manufacturability, safety, and more. The basic procedure for designing machine elements is then outlined in 6 steps: specification of function, determination of forces, selection of material, failure criterion, determination of dimensions, and preparation of working drawings. Materials that could be used like cast iron, plain carbon steel, and alloy steels are then described in more detail.
The document discusses different types of gears including spur gears, helical gears, herringbone gears, rack and pinion gears, bevel gears, and worm gears. It provides details on each type, such as how they transmit power at different angles, speeds, and ratios. Spur gears have parallel teeth and are used in devices like electric screwdrivers. Helical gears operate more smoothly than spur gears. Herringbone gears are a type of double helical gear. Rack and pinion gears convert rotational motion to linear motion. Bevel gears transmit power at intersecting shafts. Worm gears provide large gear reductions and can easily turn in one direction.
Unit 7-gear trains, Kinematics of machines of VTU Syllabus prepared by Hareesha N Gowda, Asst. Prof, Dayananda Sagar College of Engg, Blore. Please write to hareeshang@gmail.com for suggestions and criticisms.
This presentation gives the information about Screw thread measurements and Gear measurement of the subject: Mechanical measurement and Metrology (10ME32/42) of VTU Syllabus covering unit-4.
This document provides an introduction to machine elements and power transmission devices taught in the second semester of a mechanical engineering course. It discusses various machine elements like shafts, keys, couplings, bearings, clutches, and brakes. It also covers power transmission devices such as belt drives, chain drives, and gear drives. The document describes the function, types, materials, and design of these common mechanical components.
This document discusses various types of machine balancing. It begins by defining static and dynamic balancing. Static balancing deals with balancing forces when a machine is at rest, while dynamic balancing deals with balancing forces during motion. It then discusses balancing of single and multiple rotating masses, as well as reciprocating masses. Methods for analytically and graphically balancing multiple masses are provided. The document also covers balancing of engines with different cylinder configurations, including inline, V-shaped, radial, and locomotive engines. Partial balancing techniques are discussed for reducing unbalanced forces in locomotives.
- The document discusses different types of springs including helical compression springs, helical extension springs, helical torsion springs, and multileaf springs.
- It describes the functions and applications of springs which include absorbing shocks and vibrations, storing energy, and measuring forces.
- Key terms related to helical spring design are defined such as wire diameter, mean coil diameter, spring index, solid length, compressed length, free length, and pitch. Stress and deflection equations for helical spring design are also presented.
Capstan and turret lathes are production lathes used to manufacture large quantities of identical parts quickly. Unlike engine lathes, they do not have tail stocks and can hold multiple tools that operate simultaneously. Capstan lathes have hexagonal turrets mounted on slides that move longitudinally, while turret lathes have stationary hexagonal turrets mounted directly on the saddle. Both types of lathes are suited for machining bars and irregular workpieces, with turret lathes able to accommodate heavier work. Common tooling includes box, flanged, and slide tool holders that mount to the turrets.
This document discusses machine design and the basic procedures and requirements for designing machine elements. It defines machine design as using scientific principles, technical information, and imagination to describe machines that perform functions with maximum economy and efficiency. The basic requirements for machine elements are then listed, including strength, rigidity, wear resistance, manufacturability, safety, and more. The basic procedure for designing machine elements is then outlined in 6 steps: specification of function, determination of forces, selection of material, failure criterion, determination of dimensions, and preparation of working drawings. Materials that could be used like cast iron, plain carbon steel, and alloy steels are then described in more detail.
The document discusses different types of gears including spur gears, helical gears, herringbone gears, rack and pinion gears, bevel gears, and worm gears. It provides details on each type, such as how they transmit power at different angles, speeds, and ratios. Spur gears have parallel teeth and are used in devices like electric screwdrivers. Helical gears operate more smoothly than spur gears. Herringbone gears are a type of double helical gear. Rack and pinion gears convert rotational motion to linear motion. Bevel gears transmit power at intersecting shafts. Worm gears provide large gear reductions and can easily turn in one direction.
Unit 7-gear trains, Kinematics of machines of VTU Syllabus prepared by Hareesha N Gowda, Asst. Prof, Dayananda Sagar College of Engg, Blore. Please write to hareeshang@gmail.com for suggestions and criticisms.
This presentation gives the information about Screw thread measurements and Gear measurement of the subject: Mechanical measurement and Metrology (10ME32/42) of VTU Syllabus covering unit-4.
This document provides an introduction to machine elements and power transmission devices taught in the second semester of a mechanical engineering course. It discusses various machine elements like shafts, keys, couplings, bearings, clutches, and brakes. It also covers power transmission devices such as belt drives, chain drives, and gear drives. The document describes the function, types, materials, and design of these common mechanical components.
This document discusses various types of machine balancing. It begins by defining static and dynamic balancing. Static balancing deals with balancing forces when a machine is at rest, while dynamic balancing deals with balancing forces during motion. It then discusses balancing of single and multiple rotating masses, as well as reciprocating masses. Methods for analytically and graphically balancing multiple masses are provided. The document also covers balancing of engines with different cylinder configurations, including inline, V-shaped, radial, and locomotive engines. Partial balancing techniques are discussed for reducing unbalanced forces in locomotives.
- The document discusses different types of springs including helical compression springs, helical extension springs, helical torsion springs, and multileaf springs.
- It describes the functions and applications of springs which include absorbing shocks and vibrations, storing energy, and measuring forces.
- Key terms related to helical spring design are defined such as wire diameter, mean coil diameter, spring index, solid length, compressed length, free length, and pitch. Stress and deflection equations for helical spring design are also presented.
Capstan and turret lathes are production lathes used to manufacture large quantities of identical parts quickly. Unlike engine lathes, they do not have tail stocks and can hold multiple tools that operate simultaneously. Capstan lathes have hexagonal turrets mounted on slides that move longitudinally, while turret lathes have stationary hexagonal turrets mounted directly on the saddle. Both types of lathes are suited for machining bars and irregular workpieces, with turret lathes able to accommodate heavier work. Common tooling includes box, flanged, and slide tool holders that mount to the turrets.
This document discusses the calculation of bearing life and dynamic load ratings. It provides formulas and factors for calculating the radial and axial forces on bearings based on machine design and operating conditions. It also summarizes the Lundberg-Palmgren and SKF equations for calculating an equivalent dynamic bearing load and adjusted rating life of a bearing based on operating load and speed.
Helical gears have teeth formed in a helix around the gear. This allows two parallel shafts to be connected using helical gears instead of spur gears. The key characteristics of helical gears are:
- Teeth are formed in a helix rather than parallel to the axis, providing gradual engagement between gears.
- Recommended pressure angle is 15-25 degrees and helix angle is 20-45 degrees.
- The normal tooth load on helical gears has both tangential and axial components due to the helical teeth.
- Helical gears are designed to have more than one pair of teeth in contact at a time to smoothly transmit torque between parallel shafts.
1 a. Introduction design of machine elementDr.R. SELVAM
The document discusses machine design and standardization. It defines machine design as designing machine elements and arranging them optimally to perform useful work. It categorizes machine design into adaptive, development, and new design. Standardization is defined as obligatory norms for product characteristics like materials and dimensions to reduce variety. Standards include company, national, and international standards for materials, shapes, fits, tolerances, surface finish, and testing. Benefits of standardization include inventory control, interchangeability, improved quality, and safety.
The document discusses jigs and fixtures, which are tools used to precisely locate and secure workpieces during manufacturing operations like machining. It defines jigs and fixtures, describes their key elements and principles of location and clamping. It also covers different types of locating and clamping devices as well as common types of jigs like drilling jigs. Jigs are used to guide cutting tools, while fixtures only position and hold the workpiece. Together, jigs and fixtures help improve accuracy, interchangeability and efficiency of mass production.
1. A shaft transmits power and rotational motion and has machine elements like gears and pulleys mounted on it.
2. Press fits, keys, dowel pins, and splines are used to attach machine elements to the shaft.
3. The shaft rotates on rolling contact or bush bearings and uses features like retaining rings to take up axial loads.
4. Couplings are used to transmit power between drive and driven shafts like between a motor and gearbox.
The document discusses static and dynamic balancing of rotating masses. Static balancing ensures the center of gravity remains stationary during rotation by balancing out centrifugal forces in any radial direction. Dynamic balancing prevents vibration during rotation by statically balancing and also balancing out moments and couples involved in accelerating moving parts. The types of balancing are defined as static, where forces due to gravity are balanced, and dynamic, where inertia forces are balanced in addition to static balance. Benefits include reduced vibration, noise, stresses, and increased quality, bearing life, and efficiency. Balancing is necessary to prevent problems from vibration like noise, abrasion, and shortened machine life.
The document is a presentation on bearings created by Akash Panchal. It discusses the definition of a bearing, provides a brief history, and examines various types of bearings like ball bearings, roller bearings, plain bearings, and their functions. It also looks at bearing selection, arrangement, lubrication, and life calculation. The presentation contains several diagrams and is intended to provide an overview of bearings.
Parson’s Turbine and condition for maximum efficiency of Parson’s reaction Tu...Jay Patel
The document discusses Parson's turbine and the condition for maximum efficiency of a Parson's reaction turbine. It explains that in a Parson's turbine, the blade section and mean diameter are the same for fixed and moving blades. It also derives equations showing that for maximum efficiency, the ratio of absolute velocity of steam at the moving blade outlet to inlet (β) must be equal to the blade angle (α). This results in symmetrical velocity triangles and maximum work output from the turbine.
The document discusses measurement and metrology of screw threads. It begins with definitions of screw thread terminology such as major diameter, minor diameter, pitch, angle, and forms of threads. It then describes methods for measuring the major diameter, minor diameter, effective diameter, and pitch of screw threads. The key measurement methods discussed are using micrometers, pitch gauges, and a tool maker's microscope. The goal is to understand principles and techniques for measuring characteristics of screw threads.
Rolling contact bearings and design procedureJashavant singh
this slide will give you idea about the rolling contact bearing , its types application areas and also you will learn how to design rolling contact bearing ,
comparison between the rolling contact and sliding contact bearing , advantage and disadvantages.
Hydrodynamic lubrication By Khairul BasharKhairul Bashar
The document discusses hydrodynamic lubrication, which occurs when there is a thick film of fluid between moving surfaces so that contact does not occur. For hydrodynamic lubrication to happen, there needs to be sufficient speed difference between the surfaces to form an "oil wedge" and build up pressure in the fluid film from their relative motion. Reynolds' equation describes the relationship between pressure buildup, sliding speed, viscosity, and geometry of the hydrodynamic film. The document presents diagrams showing the velocity and pressure distributions in an inclined pad bearing under hydrodynamic lubrication conditions.
ME6601 - DESIGN OF TRANSMISSION SYSTEM NOTES AND QUESTION BANK ASHOK KUMAR RAJENDRAN
This document contains the question bank for the subject ME6601 - Design of Transmission Systems for the sixth semester Mechanical Engineering students of RMK College of Engineering and Technology. It is prepared by R. Ashok Kumar and S. Arunkumar, faculty of the Mechanical Engineering department.
The question bank contains 190 questions divided into two parts: Part A containing conceptual questions and Part B containing design/numerical problems. The questions cover the five units of the subject - Design of Flexible Elements, Spur Gears and Parallel Axis Helical Gears, Bevel, Worm and Cross Helical Gears, Gear Boxes, and Cams, Clutches and Brakes. Most questions are related
Gear measurements:- MECHANICAL MEASUREMENTS AND METROLOGYJaimin Patel
This document provides information about gear measurement and metrology. It discusses various gear profiles like involute and cycloidal profiles. It also defines important gear terminology like pitch circle, pressure angle, addendum, etc. Several methods for measuring gear tooth thickness are described, including using a gear tooth Vernier caliper, constant chord method, base tangent method, and dimension over pins. The document also discusses gear inspection and a working method that uses two carriages and a dial gauge to measure variations when rotating meshed gears.
This document summarizes a presentation given by Nilrajsinh Vasandia on introduction to NC, CNC, and DNC machine tools. The presentation included definitions and components of NC, CNC, and DNC systems. It discussed the differences between NC, CNC, and DNC, covering topics like part program input/storage, program modification, the inclusion of feedback systems, and ability to import CAD files. Motion control systems and programming methods for NC and CNC machines were also outlined.
The toolmaker's microscope is an optical measuring device that can measure lengths, profiles, angles, and threads up to 1/100th of a millimeter. It works on the principle of projecting a shadow image of the workpiece through an optical system onto a screen with cross lines, allowing measurements to be taken. Key components include a base, measuring head with light source and lenses, and a glass table with scales for measuring movement in the X, Y, and rotational directions. It can be used to accurately measure various mechanical components and perform tasks like thread measurement and angle measurement of tools.
Slip gauges are precision rectangular blocks used as standards for linear measurement. They are made of materials like tungsten carbide, chrome-plated steel, and high-grade steel. Slip gauges come in sets designated by their range and accuracy, and are classified according to the precision of work for which they are suited. Proper care must be taken when cleaning, storing, handling, and using slip gauges to maintain their accuracy and prolong their working life.
This document discusses different types of bearings used in mechanical engineering. It describes bearings as machine components that support another element and allow relative motion while carrying a load. There are two main types - sliding contact bearings and rolling contact bearings. Rolling contact bearings, also called anti-friction bearings, use balls or rollers between elements and have lower coefficients of friction than sliding contact bearings. The document further details types of rolling contact bearings like ball bearings, roller bearings, and their construction and applications.
The document discusses the fundamentals of theory of machines and its subdivisions. It covers the following key points:
1. Theory of machines deals with the study of relative motion between machine parts and forces acting on them. It is subdivided into kinematics, dynamics, kinetics, and statics.
2. Kinematics studies relative motion, dynamics studies forces and their effects on moving parts, kinetics studies inertia forces, and statics studies forces on stationary parts.
3. Fundamental concepts like space, time, matter, body, mass, and force are defined. Newton's laws of motion are also summarized.
4. Methods for analyzing reciprocating engines like graphical and analytical methods are outlined. Forces
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise boosts blood flow, releases endorphins, and promotes changes in the brain which help regulate emotions and stress levels.
This document provides definitions and concepts related to machine elements design. It covers topics such as factor of safety, endurance limit, impact loads, design process phases, types of loads/stresses, factors affecting endurance strength, types of fractures, spring types and properties, joints, keys, couplings, screws, welds and failures. It contains questions and answers on these topics across 4 units - stresses and strains, shafts, fasteners and joints, and springs.
This document discusses the calculation of bearing life and dynamic load ratings. It provides formulas and factors for calculating the radial and axial forces on bearings based on machine design and operating conditions. It also summarizes the Lundberg-Palmgren and SKF equations for calculating an equivalent dynamic bearing load and adjusted rating life of a bearing based on operating load and speed.
Helical gears have teeth formed in a helix around the gear. This allows two parallel shafts to be connected using helical gears instead of spur gears. The key characteristics of helical gears are:
- Teeth are formed in a helix rather than parallel to the axis, providing gradual engagement between gears.
- Recommended pressure angle is 15-25 degrees and helix angle is 20-45 degrees.
- The normal tooth load on helical gears has both tangential and axial components due to the helical teeth.
- Helical gears are designed to have more than one pair of teeth in contact at a time to smoothly transmit torque between parallel shafts.
1 a. Introduction design of machine elementDr.R. SELVAM
The document discusses machine design and standardization. It defines machine design as designing machine elements and arranging them optimally to perform useful work. It categorizes machine design into adaptive, development, and new design. Standardization is defined as obligatory norms for product characteristics like materials and dimensions to reduce variety. Standards include company, national, and international standards for materials, shapes, fits, tolerances, surface finish, and testing. Benefits of standardization include inventory control, interchangeability, improved quality, and safety.
The document discusses jigs and fixtures, which are tools used to precisely locate and secure workpieces during manufacturing operations like machining. It defines jigs and fixtures, describes their key elements and principles of location and clamping. It also covers different types of locating and clamping devices as well as common types of jigs like drilling jigs. Jigs are used to guide cutting tools, while fixtures only position and hold the workpiece. Together, jigs and fixtures help improve accuracy, interchangeability and efficiency of mass production.
1. A shaft transmits power and rotational motion and has machine elements like gears and pulleys mounted on it.
2. Press fits, keys, dowel pins, and splines are used to attach machine elements to the shaft.
3. The shaft rotates on rolling contact or bush bearings and uses features like retaining rings to take up axial loads.
4. Couplings are used to transmit power between drive and driven shafts like between a motor and gearbox.
The document discusses static and dynamic balancing of rotating masses. Static balancing ensures the center of gravity remains stationary during rotation by balancing out centrifugal forces in any radial direction. Dynamic balancing prevents vibration during rotation by statically balancing and also balancing out moments and couples involved in accelerating moving parts. The types of balancing are defined as static, where forces due to gravity are balanced, and dynamic, where inertia forces are balanced in addition to static balance. Benefits include reduced vibration, noise, stresses, and increased quality, bearing life, and efficiency. Balancing is necessary to prevent problems from vibration like noise, abrasion, and shortened machine life.
The document is a presentation on bearings created by Akash Panchal. It discusses the definition of a bearing, provides a brief history, and examines various types of bearings like ball bearings, roller bearings, plain bearings, and their functions. It also looks at bearing selection, arrangement, lubrication, and life calculation. The presentation contains several diagrams and is intended to provide an overview of bearings.
Parson’s Turbine and condition for maximum efficiency of Parson’s reaction Tu...Jay Patel
The document discusses Parson's turbine and the condition for maximum efficiency of a Parson's reaction turbine. It explains that in a Parson's turbine, the blade section and mean diameter are the same for fixed and moving blades. It also derives equations showing that for maximum efficiency, the ratio of absolute velocity of steam at the moving blade outlet to inlet (β) must be equal to the blade angle (α). This results in symmetrical velocity triangles and maximum work output from the turbine.
The document discusses measurement and metrology of screw threads. It begins with definitions of screw thread terminology such as major diameter, minor diameter, pitch, angle, and forms of threads. It then describes methods for measuring the major diameter, minor diameter, effective diameter, and pitch of screw threads. The key measurement methods discussed are using micrometers, pitch gauges, and a tool maker's microscope. The goal is to understand principles and techniques for measuring characteristics of screw threads.
Rolling contact bearings and design procedureJashavant singh
this slide will give you idea about the rolling contact bearing , its types application areas and also you will learn how to design rolling contact bearing ,
comparison between the rolling contact and sliding contact bearing , advantage and disadvantages.
Hydrodynamic lubrication By Khairul BasharKhairul Bashar
The document discusses hydrodynamic lubrication, which occurs when there is a thick film of fluid between moving surfaces so that contact does not occur. For hydrodynamic lubrication to happen, there needs to be sufficient speed difference between the surfaces to form an "oil wedge" and build up pressure in the fluid film from their relative motion. Reynolds' equation describes the relationship between pressure buildup, sliding speed, viscosity, and geometry of the hydrodynamic film. The document presents diagrams showing the velocity and pressure distributions in an inclined pad bearing under hydrodynamic lubrication conditions.
ME6601 - DESIGN OF TRANSMISSION SYSTEM NOTES AND QUESTION BANK ASHOK KUMAR RAJENDRAN
This document contains the question bank for the subject ME6601 - Design of Transmission Systems for the sixth semester Mechanical Engineering students of RMK College of Engineering and Technology. It is prepared by R. Ashok Kumar and S. Arunkumar, faculty of the Mechanical Engineering department.
The question bank contains 190 questions divided into two parts: Part A containing conceptual questions and Part B containing design/numerical problems. The questions cover the five units of the subject - Design of Flexible Elements, Spur Gears and Parallel Axis Helical Gears, Bevel, Worm and Cross Helical Gears, Gear Boxes, and Cams, Clutches and Brakes. Most questions are related
Gear measurements:- MECHANICAL MEASUREMENTS AND METROLOGYJaimin Patel
This document provides information about gear measurement and metrology. It discusses various gear profiles like involute and cycloidal profiles. It also defines important gear terminology like pitch circle, pressure angle, addendum, etc. Several methods for measuring gear tooth thickness are described, including using a gear tooth Vernier caliper, constant chord method, base tangent method, and dimension over pins. The document also discusses gear inspection and a working method that uses two carriages and a dial gauge to measure variations when rotating meshed gears.
This document summarizes a presentation given by Nilrajsinh Vasandia on introduction to NC, CNC, and DNC machine tools. The presentation included definitions and components of NC, CNC, and DNC systems. It discussed the differences between NC, CNC, and DNC, covering topics like part program input/storage, program modification, the inclusion of feedback systems, and ability to import CAD files. Motion control systems and programming methods for NC and CNC machines were also outlined.
The toolmaker's microscope is an optical measuring device that can measure lengths, profiles, angles, and threads up to 1/100th of a millimeter. It works on the principle of projecting a shadow image of the workpiece through an optical system onto a screen with cross lines, allowing measurements to be taken. Key components include a base, measuring head with light source and lenses, and a glass table with scales for measuring movement in the X, Y, and rotational directions. It can be used to accurately measure various mechanical components and perform tasks like thread measurement and angle measurement of tools.
Slip gauges are precision rectangular blocks used as standards for linear measurement. They are made of materials like tungsten carbide, chrome-plated steel, and high-grade steel. Slip gauges come in sets designated by their range and accuracy, and are classified according to the precision of work for which they are suited. Proper care must be taken when cleaning, storing, handling, and using slip gauges to maintain their accuracy and prolong their working life.
This document discusses different types of bearings used in mechanical engineering. It describes bearings as machine components that support another element and allow relative motion while carrying a load. There are two main types - sliding contact bearings and rolling contact bearings. Rolling contact bearings, also called anti-friction bearings, use balls or rollers between elements and have lower coefficients of friction than sliding contact bearings. The document further details types of rolling contact bearings like ball bearings, roller bearings, and their construction and applications.
The document discusses the fundamentals of theory of machines and its subdivisions. It covers the following key points:
1. Theory of machines deals with the study of relative motion between machine parts and forces acting on them. It is subdivided into kinematics, dynamics, kinetics, and statics.
2. Kinematics studies relative motion, dynamics studies forces and their effects on moving parts, kinetics studies inertia forces, and statics studies forces on stationary parts.
3. Fundamental concepts like space, time, matter, body, mass, and force are defined. Newton's laws of motion are also summarized.
4. Methods for analyzing reciprocating engines like graphical and analytical methods are outlined. Forces
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise boosts blood flow, releases endorphins, and promotes changes in the brain which help regulate emotions and stress levels.
This document provides definitions and concepts related to machine elements design. It covers topics such as factor of safety, endurance limit, impact loads, design process phases, types of loads/stresses, factors affecting endurance strength, types of fractures, spring types and properties, joints, keys, couplings, screws, welds and failures. It contains questions and answers on these topics across 4 units - stresses and strains, shafts, fasteners and joints, and springs.
Solutions for machine design by KHURMI and GUPTAAzlan
This document appears to be notes from a machine design textbook created by Eng. Younis Fakher of Thi-Qar University's College of Engineering. It contains solutions to problems from chapters 4-6 of a machine design textbook by Khurmi and Gupta for 4th year mechanical engineering students from the 2010-2011 academic year. The notes are broken down by chapter and contain problem solutions.
This document appears to be from Ashoka Institution in Malkapur, Hyderabad regarding the design of a machine. It includes sections on machine members or elements, basic university-level questions, and answers to those questions in Part I.
The document discusses the process of machine design, which involves recognizing needs, specifying product requirements, selecting mechanisms and materials, developing a general configuration layout, designing individual elements, testing and modifying prototypes, and creating detailed drawings for production. Some key steps include considering various design options, balancing costs and performance, and using flexible approaches to solve problems that arise during the design process.
This document discusses stress-strain diagrams and mechanical properties of materials. It includes 8 figures showing stress-strain diagrams for different material types (ductile, elastic, plastic, brittle) as well as diagrams for resilience, toughness, and creep. The document defines key points on stress-strain diagrams like proportional limit, elastic limit, yield limit, ultimate point, and fracture point. It also describes material properties including elasticity, plasticity, stiffness, ductility, brittleness, malleability, resilience, toughness, and creep. The document serves to explain stress-strain behavior and mechanical characteristics.
Solutions Manual for machine design by khurmi and GuptaAdnan Aslam
This document contains solutions to problems from machine design textbooks by Khurmi and Gupta provided by Eng. Younis Fakher for 4th year mechanical engineering students at Thi-Qar University College of Engineering in 2010-2011. The solutions cover problems from chapters 4 through 6.
The document discusses stress concentration and fatigue failure in machine elements. It defines stress concentration as irregular stress distribution caused by abrupt changes in cross-section shape. Stress concentration factors are introduced to quantify the maximum stress compared to nominal stress. The document also discusses endurance limit and fatigue strength testing methods. Factors that affect fatigue strength like material properties, surface finish, size and temperature are summarized. Methods to evaluate and reduce stress concentration in designs are provided.
The document discusses different types of machine elements used for joining parts, including fasteners, screws, bolts, nuts, keys, and cotter joints. It describes various thread types like V-threads, square threads, and ACME threads. It also explains different forms of bolts, nuts, keys, and cotter joints; when each type would be used; and how they function to join parts together both permanently and temporarily.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms.
The document discusses the key elements of design including line, figure and ground, scale and proportion, texture and pattern, rhythm and repetition, direction, weight, balance, and the rule of thirds. These elements are the fundamental building blocks that designers use to create unified compositions and deliver effective visual messages to audiences. When used successfully together, these elements create design harmony.
Mechanical engineering involves understanding core concepts in mechanics, kinematics, thermodynamics, materials science, and structural analysis. Mechanical engineers design and analyze machines, manufacturing plants, engines, transport systems, medical devices, and more. Examples of mechanical engineering include bicycles, CD players, video game consoles, snowmobiles, microelectromechanical systems, robotics, composite materials, biomechanics, aerospace engineering, and careers in automotive, manufacturing, utilities, HVAC, and space research industries.
A heat exchanger transfers heat from one medium to another without allowing the two media to mix. Heat naturally flows from higher to lower temperatures, so a heat exchanger brings two fluids of different temperatures into close contact while preventing mixing. Common applications include heating, cooling, and industrial processes. Key factors that impact heat transfer include material properties, surface area, flow rates, and temperature differences of the fluids. Heat exchangers are classified based on flow patterns, such as parallel, counter, and cross flow designs. The rate of heat transfer depends on the overall heat transfer coefficient, surface area, and log mean temperature difference between the fluids.
Machine Elements - company presentationKaran Asrani
A leading manufacturer of Machine Tool Accessories under the brand name 'STRIBECK'. Some of the products manufactured include Revolving Centres, Keyless Drill Chucks (capacity : 1/4" and 1/2"), Pipe Centres (upto 500mm dia), Dead Centres (Plain, Carbide Tipped and HSS), Collets and Collet Adaptors, Reduction sleeves, Extension Sockets, Stub Arbours and Long Milling Arbours and CNC Toolings.
We also re-condition old HMT, BFW and other imported milling, drilling, lathe and grinding machines and the replacement spares for the following machines are available with us:
HMT MILLING - FN2 - FN3 - M2 - EM3 - EM4 - FH3 - FV3 - E2
CYLINDRICAL GRINDING - G13 - K130 - G17
LATHE - LB 17/20/25 - H22 - H26 - NH 22 - NH 26 - LTM 20 - LBS 17, VIKRAM LATHE
RADIAL DRILL - RM 61/62/63/65 - COLUMN DRILL TYPE
BFW MILLING NO. 1 - NO 1.5 - NO 2. - NO. 3.0 - NO. 3.5
KIRLOSKAR LATHE – TURN MASTER SERIES, ENTERPRISE SERIES (1330, 2215, 1550, 1675, 1810), SHIMOGA LATHE, BOMBAY LATHE
HORIZONTAL BORING - HMT AZ9 - AZ11
ARGO & M1TR MILLING
We also manufacture machinery spares and accessories based on a customers drawing / specifications / sample.
This document discusses cutting tool materials and their properties. It covers various tool materials including carbon steels, high-speed steel, cemented carbides, ceramics, and diamond. Cemented carbides are the most commonly used and contain tungsten carbide and a cobalt binder. The document provides details on selecting cutting tool materials based on the application, and guidelines for cutting tool design including tool angles and operating conditions.
This document provides an overview of screw thread metrology. It begins with an introduction to screw thread classification and the key elements that define screw threads, such as major diameter, minor diameter, pitch, etc. It then discusses various types of pitch errors that can occur in screw threads and how they are measured. The document outlines different methods for measuring elements of screw threads, including using indicating thread gages or individual measurement processes like bench micrometers or optical projection. It provides details on measuring major diameter, minor diameter, pitch errors, and flank angles. In summary, the document covers the principles and techniques for inspecting and measuring the various geometric parameters that define screw threads.
Design and fabrication of motorized screw jackshashin vyas
This document describes the design of a motorized screw jack. It begins with an introduction to screw jacks and their history. Traditionally, screw jacks required high manual labor to lift vehicles. The objectives of this project were to design a device that can lift vehicles smoothly without impact using a motor as the power source. The proposed system is a remote-controlled cylinder jack that uses a DC motor powered by a battery. Design calculations are provided for the bevel gears, battery, screw dimensions and strength. The motorized screw jack is able to lift vehicles easily without manual effort. Advantages include easy lifting and maintenance, while disadvantages include higher costs and need for a power source. In conclusion, the motorized screw jack meets the
The document discusses the history and development of artificial intelligence over the past 70 years. It outlines some of the key milestones in AI research from the early work in the 1950s to modern advances in machine learning using neural networks. While progress has been made, fully general human-level artificial intelligence remains an ongoing challenge that researchers are still working to achieve.
This document discusses the key components and functions of computers. It describes the three types of computers based on size and storage capacity, as well as the four main parts of a computer: input, output, memory, and the central processing unit (CPU). The CPU is made up of the control unit and arithmetic logic unit. Memory is divided into random access memory (RAM) and read only memory (ROM). The document also defines common computer terms like bits, bytes, and memory sizes and provides an overview of how computer chips are made.
1 b. Machine design - Prefered numbers, asthetic and ergonomic designDr.R. SELVAM
The document discusses preferred number series which are standardized sizes used for machine elements. There are five basic preferred number series with step ratios between 1.03 to 1.58. These series provide minimum number of sizes to cover a product range without restricting customer choice. Aesthetic considerations for product design include appropriate form, color, material, and surface finish. Forms include step, taper, shear, streamline and sculpture. Color selection should follow conventions. Ergonomic design aims to decrease physical and mental stress on the user by considering anthropometry, physiology and psychology of human interaction with machines.
This document provides a syllabus for a Machine Design course. The syllabus covers the design of simple machine elements, shafts, keys, couplings, elements under fluctuating loads, power screws, threaded joints, welded joints, and mechanical springs. The course aims to teach students how to identify failure modes, design various machine elements to withstand stresses, and design elements subjected to different loading conditions. The syllabus is divided into 6 units that will cover these various machine design topics. Required textbooks are also listed.
The document describes Aditya Thombare's 6-month internship at Kirloskar Brothers Ltd. It discusses the company's products and departments. Aditya worked on three projects - a pattern management system to organize the storage of patterns, an angular drilling machine stand to allow drilling at different angles, and reverse engineering an impeller. The pattern management system took 3 months and involved sorting, cataloging, and reorganizing the storage of 4000 patterns and core boxes.
The document discusses the contents of Unit 1 of the subject ME 8593-DESIGN OF MACHINE ELEMENTS. It includes an introduction to the design process and factors influencing machine design. It also discusses selection of materials based on mechanical properties, preferred numbers, fits and tolerances. Additionally, it covers direct, bending and torsional stress equations, impact and shock loading, calculation of principle stresses for various load combinations, eccentric loading, curved beams, crane hook and 'C' frame. The document also mentions factor of safety, theories of failure, design based on strength and stiffness, stress concentration and design for variable loading.
The document provides an introduction to machine design, outlining key requirements for machine elements such as strength, rigidity, and wear resistance. It discusses the mechanical engineering design process and various topics that will be covered in the machine design course, including design of elements against static and fluctuating loads, shaft keys and couplings, threaded joints, and mechanical springs. Standardization, aesthetics, and other considerations in machine design are also introduced.
This document discusses various topics related to machine design including the design process, requirements of machine elements, procedures for designing elements, design synthesis, concurrent engineering, aesthetic considerations, ergonomics considerations, standards and standardization, manufacturing considerations, design of castings, forgings, machined parts, fits and tolerances, and factors of safety. It provides information on each topic with definitions and explanations of key concepts and principles for machine design.
Design and Development of Dynamo Testing MachineIRJET Journal
The document describes the design and development of a dynamo testing machine. It aims to increase productivity and reduce manual labor required for testing tools. The key components of the machine include a base plate, upper plate, supporting plate, channel plate, channel, rod, bush, nut and gripper. Finite element analysis is performed using ANSYS to analyze stresses on components under expected loads. The machine is expected to reduce manpower needs, improve productivity by allowing more tools to be tested, and improve quality and safety.
The document discusses key aspects of manufacturing including specifications, standardization, tolerance, limits and fits, and quality. Specifications define requirements for manufacturing products. Standardization is the process of agreeing on technical standards. Tolerance defines acceptable variation in dimensions. Limits and fits specify how parts fit together during assembly. Quality assurance ensures products meet specifications through quality control techniques.
This document discusses limits, fits, tolerances and surface roughness. It defines standardization and interchangeability, explaining their benefits. It describes limit systems and the terminology used, including types of fits. Clearance, interference and transition fits are defined. Surface roughness is discussed, including how it is measured and expressed. Preferred number series for dimensions are also covered.
The document provides an overview of the fundamentals of machine design course, including the objectives, syllabus, and key concepts covered. The main points are:
1. The course aims to introduce students to machine design fundamentals, material selection, and solving basic design problems. Key topics include modeling robot links and joints, computer graphics, and designing end-effectors.
2. The syllabus covers topics such as engineering design processes, material selection factors, standards and codes, stress analysis, failure theories, and static and dynamic load considerations.
3. Key concepts taught are stress-strain analysis, factors of safety, strength and efficiency principles, and manufacturing and ergonomic considerations in the design process.
The document discusses process planning, which involves selecting and sequencing manufacturing processes and operations to transform raw materials into finished components. It covers manual and computer-aided process planning methods. The key steps in manual process planning are interpreting drawings, selecting processes and operations, choosing tools and equipment, and documenting the plan. Computer-aided process planning can retrieve existing plans or generate new optimized plans. Important considerations in process planning include equipment selection, tooling selection, and interpreting engineering drawings and specifications.
This document provides an introduction to machine design. It defines machine design as using scientific principles, technical information, and imagination to describe a machine to perform specific functions with maximum economy and efficiency. The document then outlines the basic principles of mechanical design, including the design process and considerations for static and fatigue loads. It also discusses standards and material selection in machine design.
MFG 240 - Manufacturing DesignFinal ProjectScope of Project.docxARIV4
MFG 240 - Manufacturing Design
Final Project
Scope of Project
You must develop a manufacturing plan to machine the part to the final dimensions. The company is a small company of about 30 workers currently.
Product Design
You will design 1 tensile test bar using the following diagram
Develop a part print WITH tolerancing for this part
Material Cost
The raw material will be a material you specify. It will come as 1 diameter bar stock at a length you specify
Labor Cost
The labor cost for your plant is $15 per hour for all employees, except maintenance personnel, which cost $22 per hour.
Volume
Your manufacturing facility must provide 200,000 of the tensile test specimens
The equipment will be a stand alone cell or line. No other parts will flow though this area at this time.
Operational Plan
The facility is scheduled to operate 250 days per year and run two 8 ½ hour shifts per day. The workers must be given 30 minutes for lunch and two 15-minute breaks. The product life cycle is expected to be 5 years or more.
Reports
Reports must be written using a word processor and spreadsheet when appropriate. All drawings must be completed using CAD.
1) Title Page
2) Table of Contents
3) Executive Summary
4) A written report detailing the manufacturing plan. The individual manufacturing deliverables must support all information presented in the manufacturing plan summary.
i) Part prints (components plus assembly)
ii) Initial investment required and projected cost per part
iii) Conclusions, Recommendations
5) Manufacturing Plan Deliverables including all supporting data
Manufacturing Plan Deliverables
TAKT Time Calculations - TAKT is a German word for pace. TAKT time is the rate at which your customer requires the product. TAKT time defines the manufacturing line speed and the cycle time for the manufacturing operations. TAKT time is computed as:
Available work time per day / Daily required demand (parts/day)
Design Cycle Time Calculations – Design cycle time is the cycle time at which you design your manufacturing operations after considering contractual breaks, setup time, planned maintenance, estimated downtime, reject rates, etc. All of the items above reduce your actual work time available per day and reduce the required cycle time. Each team must also consider the reject produced by the system and increase the required production to offset the loss. The team must report the manufacturing cells planned operational availability. Operational availability is the Planned operating time /Available work time.
Process Plan Block Diagram – After reviewing the product prints, develop a process plan block diagram that represents the product flow through the various machines and processes. Include equipment, material handling, material flow, quality checks, repair loops, etc..
Equipment Sequence of Operations and Balance Chart – Develop a detailed step-by-step sequence of operations for each process or piece of equipme ...
This document discusses product design and process selection. It begins by defining product design as determining the characteristics of a company's products, such as appearance, materials and performance standards. Reasons for redesign include market changes, costs and regulations. The main objectives of design are customer satisfaction and functional requirements. The product design process involves idea generation, screening, preliminary and final design. Issues in design addressed include concurrent engineering, standardization, mass customization, and environmentally friendly design. The document then defines process as activities that transform inputs into more valuable outputs. Process selection considers type of process, integration, flexibility and resources. Process types range from intermittent to continuous production.
Detail proposal of project including activities such as Deliverables, Scope, Resources, Proposed Approach, Scheduling in Microsoft Project, Costs, Potential Problems, Critical Path Analysis, Linear Responsibility Chart, Evaluation Methods and Budget.
1. The document discusses various aspects of designing products for manufacturing including design for manufacturing (DFM) and design for assembly (DFA). It outlines three methods to implement DFM: organizing cross-functional teams, using design rules, and applying CAD tools.
2. Major objectives of DFM include reducing component costs, assembly costs, and production support costs. Methods to reduce costs include standardizing parts, choosing appropriate production scales, and integrating parts.
3. Prototyping principles outlined in the document are that analytical prototypes are more flexible than physical ones, physical prototypes are needed to detect unanticipated issues, and prototypes can reduce risks and expedite the development process.
- Vedhanayagam is seeking a challenging position as a Design Engineer where he can utilize his 4.6 years of experience in product design and development.
- He has expertise in sheet metal design, modeling, materials selection, and manufacturing processes for automotive and heavy machinery industries.
- He holds a Bachelor's degree in Aeronautical Engineering and has experience working as a Design Engineer for companies that manufacture concrete mixing machinery and automotive components.
Randall Vinton has over 30 years of experience in design, manufacturing, tool/model making, and automated systems. He has worked at SCS-AIM and IBM where he designed products, fixtures, tooling, and cable interconnect systems. He is proficient in CADAM, CATIA, SolidWorks, and CNC machines.
Standardization(work study & measurement)Nisarg Shah
Standardization involves developing and applying common standards for products, components, or procedures. This provides benefits such as improved communication, facilitation of trade by removing technical barriers, and technology transfer. Process standardization formalizes work rules and procedures to make activities transparent and uniform. Product standardization sets uniform characteristics for goods or services to allow competition while providing consistency for consumers. Both provide benefits like reduced costs, increased quality and cycle time improvements, while standardization also improves management and organizational flexibility.
Similar to Introduction of design of machine element (20)
This is an overview of my career in Aircraft Design and Structures, which I am still trying to post on LinkedIn. Includes my BAE Systems Structural Test roles/ my BAE Systems key design roles and my current work on academic projects.
Sachpazis_Consolidation Settlement Calculation Program-The Python Code and th...Dr.Costas Sachpazis
Consolidation Settlement Calculation Program-The Python Code
By Professor Dr. Costas Sachpazis, Civil Engineer & Geologist
This program calculates the consolidation settlement for a foundation based on soil layer properties and foundation data. It allows users to input multiple soil layers and foundation characteristics to determine the total settlement.
This is an overview of my current metallic design and engineering knowledge base built up over my professional career and two MSc degrees : - MSc in Advanced Manufacturing Technology University of Portsmouth graduated 1st May 1998, and MSc in Aircraft Engineering Cranfield University graduated 8th June 2007.
Covid Management System Project Report.pdfKamal Acharya
CoVID-19 sprang up in Wuhan China in November 2019 and was declared a pandemic by the in January 2020 World Health Organization (WHO). Like the Spanish flu of 1918 that claimed millions of lives, the COVID-19 has caused the demise of thousands with China, Italy, Spain, USA and India having the highest statistics on infection and mortality rates. Regardless of existing sophisticated technologies and medical science, the spread has continued to surge high. With this COVID-19 Management System, organizations can respond virtually to the COVID-19 pandemic and protect, educate and care for citizens in the community in a quick and effective manner. This comprehensive solution not only helps in containing the virus but also proactively empowers both citizens and care providers to minimize the spread of the virus through targeted strategies and education.
2. • Design is to formulate a plan satisfy a particular need and to
create something with physical reality.
• Realization of a concept or idea into a configuration.
• Design is the creation of a plan or convention for the
construction of an object, system or measurable human
interaction .
What is design????
3. • Machine is defined as a combination of resisting bodies with successfully
constrained relative motions which is used transform other forms of energy
into mechanical energy or transmit and modify available energy to do some
useful work.
• An apparatus using mechanical power and having several parts, each with a
definite function and together performing a particular task.
• Semi or fully automated device that magnifies human physical and/or
mental capabilities in performing one or more operations.
What is Machine???
4. • Machine is a combination of several machine elements
arranged to work together as a whole to accomplish specific
purpose.
• Machine Design involves designing the elements and arranging
them optimally to obtain some useful work.
• Machine design is the process of engineering design.
A machine is made up of mechanisms that work together to
satisfy the requirements of what the machine needs to
accomplish.
What is Machine Design???
6. 1) Adaptive Design:- The designer’s work is concerned with adaptation
of existing design. The designer only makes minor alternation or
modification in the existing designs of the product.
2) Development Design:- This type of design needs considerable
scientific training and design ability in order to modify the existing
design into a new idea by adopting a new material or different
method of manufacture. The designer starts from the existing design,
but final product may differ quite markedly from the original product.
3) New Design:- This type of design needs lots of research, technical
ability and creative thinking.
Types of Machine Design
7. Classification of Machine Design
Types of design
based on
method
Rational
Design Empirical
Design
Industrial
Design
8. 1) Rational Design:- Based on determining the stresses and strains
of components and thereby deciding their dimensions. This type
of design depends upon mathematical formulae of principal of
mechanics.
2) Empirical Design:- This type of design depends upon empirical
formulae based on the practice and past experience .
Types of Design based on method
9. 1) Industrial Design:- This type of design depends upon the
production aspects to manufacture any machine component
in the industry. Based on industrial considerations and norms viz.
market survey, external look, production facilities, low cost, use
of existing standard products
Types of Design based on method
10. What device or mechanism to be used???
To decide the relative arrangement of the constituent
elements.
Material
Forces on the elements
Size
Shape and space requirements
Weight of the product
Factors to be considered in
Machine Design
11. The method of manufacturing the components and their
assembly.
How will it operate.
Reliability and safety aspects.
Inspectibilty
Maintenance
Cost and aesthetics of the designed product.
Factors to be considered in
Machine Design
12. General procedure in Machine
Design
Need or Aim Synthesis (Mechanisms) Analysis of forces
Material SelectionDesign of Elements
Modification Detailed Drawing
Production
13. • Standardization is defined as obligatory (or compulsory) norms,
to which various characteristics of a product should comply (or
agree) with standard.
• 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. The objective of, a standard is to reduce
the variety and limit the number of items to a reasonable level.
Standardization
14. • On the other hand, 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.
• There are three types of standards used in design :-
Company Standards: They are used in a particular company or
a group of sister concerns.
Standardization
15. National standards:
– India - BIS (Bureau of Indian Standards),
– Germany - DIN (Deutsches Institut für Normung),
– USA - AISI (American Iron and Steel Institute) or SAE (Society of Automotive
Engineers),
– UK - BS (British Standards)
International standards: These are prepared by the International
Standards Organization (ISO).
Standardization
16. Standards for Materials, their chemical compositions, Mechanical
properties and Heat Treatment:
For example, Indian standard IS 210 specifies seven grades of grey cast iron
designated as FG 150, FG 200, FG 220, FG 260, FG 300, FG 350 and FG 400. The
number indicates ultimate tensile strength in N/mm2.
Standards for Shapes and dimensions of commonly used Machine Elements:
The machine elements include bolts, screws and nuts, rivets, belts and chains, ball
and roller bearings, wire ropes, keys and splines, etc
For example, IS 2494 (Part 1) specifies dimensions and shape of the cross- section of
endless V-belts for power transmission.
The dimensions of the trapezoidal cross-section of the belt, viz. width, height and
included angle are specified in this standard
Standards are used in mechanical
engineering design
17. Standards for Fits, Tolerances and Surface Finish of Component:
For example, selection of the type of fit for different applications is illustrated in IS
2709 on 'Guide for selection of fits'.
The tolerances or upper and lower limits for various sizes of holes and shafts are
specified in IS 919 on 'Recommendations for limits and fits for engineering'.
IS 10719 explains method for indicating surface texture on technical drawings.
Standards for Tes ting of Products:
These standards, sometimes called 'codes', give procedures to test the products
such as pressure vessel, boiler, crane and wire rope, where safety of the
operator is an important consideration.
For example, IS 807 is a code of practice for design, manufacture, erection and
testing of cranes and hoists.
Standards are used in mechanical
engineering design
18. Reductions in types and dimensions of identical components (inventory
control).
Reduction in manufacturing facilities.
Easy to replace (Interchangeability).
No need to design or test the elements.
Improves quality and reliability.
Improves reputation of the company which manufactures standard
components.
Sometimes it ensures the safety.
It results in overall cost reduction.
Benefits of Standardization
19. With the acceptance of standardization, there is a need to keep the
standard sizes or dimensions of any component or product in discrete steps.
The sizes should be spread over the wide range, at the same time these
should be spaced properly.
For example, if shaft diameters are to be standardized between 10 mm and
25 mm, then sizes should be like : 10 mm, 12.5 mm, 16 mm, 20 mm, 25 mm and
not like : 10 mm, 11 mm, 13 mm, 18 mm, 25 mm.
This led to the use of geometric series known as series of preferred numbers
or preferred series.
Preferred series are series of numbers obtained by geometric progression
and rounded off.
Preferred Numbers
20. • There are five basic series with step ratios of:
5
10 ,
10
10 ,
20
10 ,
40
10 &
80
10
• These ratios are approximately equal to 1.58, 1.26, 1.12, 1.06 and 1.03.
• The five basic series of preferred numbers (known as preferred series)
are designated as: R5, R10, R20, R40, and R80.
• The examples of preferred number series are: standard shaft diameters,
power rating of coupling, center distances of standard gear boxes, etc.
Preferred Numbers
21. • The difference in two successive terms has a fixed percentage.
• It provides small steps for small quantities and large steps
for large quantities.
• The product range is covered with minimum number of
sizes without restricting the choice of the customers.
Advantages Preferred Numbers
22. • The difference in two successive terms has a fixed percentage.
• It provides small steps for small quantities and large steps
for large quantities.
• The product range is covered with minimum number of
sizes without restricting the choice of the customers.
Advantages Preferred Numbers
24. • In a present days of buyer's market, with a number of products available in
the market are having most of the parameters identical, the appearance of
product is often a major factor in attracting the customer.
• This is particularly true for consumer durables like: automobiles, domestic refrigerators,
television sets, etc.
• Aesthetics is defined as a set of principles of appreciation of beauty. It deals
with the appearance of the product.
• Appearance is an outward expression of quality of the product and is the first
communication of the product with the user.
• For any product, there exists a relationship between the functional requirement and
the appearance of a product.
Aesthetic Considerations
25. • The aesthetic quality contributes to the performance of the product, though
the extent of contribution varies from the product to product.
• The following guidelines may be used in aesthetic design (design for
appearance):
• The appearance should contribute to the performance of the product.
For example, the aerodynamic shape of the car will have a lesser air
resistance, resulting in the lesser fuel consumption.
• The appearance should reflect the function of the product.
For example, the aerodynamic shape of the car indicates the speed.
• The appearance should reflect the quality of the product.
For example, the robust and heavy appearance of the hydraulic press reflects its
strength and rigidity
Aesthetic Considerations
26. • The appearance should not be at too much of extra cost unless it is a prime
requirement.
• The appearance should be suitable to the environment in which the product is
used.
• The growing importance of the aesthetic considerations in product design has
given rise to a separate disciple known as industrial design.
• The job of an industrial designer is to create new shapes and forms for the
product which are aesthetically appealing
– Form (Shape)
There are five basic forms of the products, namely, step, taper, shear, streamline and sculpture
Aesthetic Considerations
27. Step form:
The step form is a stepped structure having vertical accent
It is similar to the shape of a multistorey building.
Taper form
The taper form consists of tapered blocks or tapered cylinders.
Shear form
The shear form has a square outlook.
Streamline form
The streamline form has a streamlined shape having a smooth flow as seen in automobile and
aeroplane structures
Sculpture form
Aesthetic Considerations
28. Aesthetic Considerations
The sculpture and stream forms are suitable for mobile products like vehicles, while step
and shear forms are suitable for stationary products
29. • Colour
Colour is one of the major contributors to the aesthetic appeal of the product.
Many colours are linked with different moods and conditions.
The selection of the colour should be compatible with the conventions.
Morgan has suggested the colour code given in the following Table.
Aesthetic Considerations
Colour Meaning
Red Danger, Hazard, Hot
Orange Possible Danger
Yellow Caution
Green Safety
Blue Caution-Cold
Grey Dull
30. • Material and Surface Finish
The material and surface finish of the product contribute significantly to
the appearance.
The material like, stainless steel gives better appearance than the cast irons,
plain carbon steels or low alloy steels.
The brass or bronze give richness to the appearance of the product.
The products with better surface finish are always aesthetically pleasing.
The surface coating processes like: spray painting, anodizing, electroplating,
etc. greatly enhances the aesthetic appeal of the product.
Aesthetic Considerations
31. • Ergonomics is defined as the scientific study of the man-machine-working
environment relationship and the application of anatomical, physiological
and psychological principles to solve the problems arising from this
relationship
• The word ergonomic is formed from two Greek word: ergo means work and
nomic mean natural laws.
• The final objective of the ergonomics is to make the machine fit for user rather
than to make the user adapt himself or herself to the machine.
• It aims at decreasing the physical and mental stresses to the user.
• Psychology - Experimental psychologists who study people at work to provide
data on such things as: Human sensory capacities, psychomotor
performance, Human decision making, Human error rates, Selection tests and
procedures, Learning and training.
Ergonomic Considerations
32. • Anthropometry - An applied branch of anthropology concerned with the
measurement of the physical features of people. Measures how tall we are,
how far we can reach, how wide our hips are, how our joints flex, and how
our bodies move.
• Applied Physiology - Concerns the vital processes such as cardiac function,
respiration, oxygen consumption, and electromyography activity, and the
responses of these vital processes to work, stress, and environmental
influences.
Ergonomic Considerations
34. Ergonomic Considerations
• This man-machine closed loop system in influenced by the working environmental
factors such as: lighting, noise, temperature, humidity, air circulation, etc.
• Ergonomic Considerations in Design of Displays
• Ergonomic Considerations in Design of Controls
• Working Environment.
• Lighting
• Noise
• Temperature
• Humidity and air circulation
35. Design for Manufacturing and Assembly
(DFMA)
• Design for manufacturing and assembly are simple guidelines
formulated to get the below benefits
• It simplifies the design
• It simplifies the production processes and decreases the product cost
• It improves product quality and reliability (because if the production
process is simplified, then there is less opportunity for errors).
• It decreases the assembly cost.
• It decreases the assembly time.
• It reduces time required to bring a new product into market.
36. Design for Manufacturing and Assembly
(DFMA)
• Design for Assembly or DFA Guidelines (Assembly Considerations in Design)
– Reduce the Part Counts
– Design engineers should try for product design that uses the minimum number
of parts
– Fewer parts result in lower costs
– It also makes assembly simpler and fewer chances of defects.
37. Design for Manufacturing and Assembly
(DFMA)
• Design for Assembly or DFA Guidelines (Assembly Considerations in Design)
– Use modular designs:
– Modularize multiple parts into single sub-assemblies
– Modular design reduces the number of parts being assembled at any
one time and also simplifies final assembly
– Field service becomes simple, fast and cheap because dismantling is
faster and requires fewer tools.
•
38. Design for Manufacturing and Assembly
(DFMA)
• Design for Assembly or DFA Guidelines (Assembly Considerations in Design)
• Assemble in the open
• Design to allow assembly in open spaces, not confined spaces
• Assembly operation should be carried out in clear view. This is
important in manual assembly
•
39. Design for Manufacturing and Assembly
(DFMA)
• Design for Assembly or DFA Guidelines (Assembly Considerations in Design)
• Design parts for simple assembly:
• Design parts with orienting features to make alignment easier
•
40. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Why casting????
• Complex parts which are difficult to machine, are made by the casting
process
• Almost any metal can be melted and cast. Most of the sand cast parts
are made of cast iron, aluminum alloys and brass
• The size of the sand casting can be as small as 10 g and as large as 200
x 103 kg
• Sand castings have irregular and grainy surfaces and machining is
required if the part is moving with respect to some other part or
structure
41. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Why casting????
• Cast components are stable, rigid and strong compared with
machined or forged parts.
• Typical examples of cast components are machine tool beds
and structures, cylinder blocks of internal combustion engines,
pumps and gear box housings.
42. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Basic considerations of casting
• Always keep the stressed areas of the parts in compression
• Round all external corners
• Wherever possible, the section thickness throughout should be held
as uniform as compatible with overall design considerations
• Avoid concentration of metal at the junctions
• Avoid very thin sections
• The wall adjacent to the drilled hole should have a thickness
equivalent to the thickness of the main body
43. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Basic considerations of casting
• Oval-shaped holes are preferred with larger dimensions along the
direction of forces
• To facilitate easy removal, the pattern must have some draft
• Outside bosses should be omitted to facilitate a straight pattern
draft
44. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Always keep the stressed areas of the parts in compression
• Cast iron has more compressive strength than its tensile strength
• The castings should be placed in such a way that they are
subjected to compressive rather than tensile stresses.
•
(a) Incorrect (Part in tension) (b) Correct (Part in compression)
45. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Always keep the stressed areas of the parts in compression
• When tensile stresses are unavoidable, a clamping device such as
a tie rod or a bearing cap should be considered.
• The clamping device relieves the cast iron components from tensile
stresses
46. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Round all external corners
• It increases the endurance limit of the component and reduces the
formation of brittle chilled edges
• When the metal in the corner cools faster than the metal adjacent
to the corner, brittle chilled edges are formed
• Appropriate fillet radius reduces the stress concentration
47. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Wherever possible, the section thickness throughout should be held as
uniform as compatible with overall design considerations
• Abrupt changes in the cross-section result in high stress concentration
• If the thickness is to be varied at all, the change should be gradual
48. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Avoid concentration of metal at the junctions
• At the junction, there is a concentration of metal.
• Even after the metal on the surface solidifies, the central portion still
remains in the molten stage, with the result that a shrinkage cavity or
blowhole may appear at the center
• There are two ways to avoid the concentration of metal.
• One is to provide a cored opening in webs and ribs
• Alternatively, one can stagger the ribs and webs
49. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Avoid concentration of metal at the junctions
Cored Holes Staggered ribs
50. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Avoid very thin sections
• It depends upon the process of casting such as sand casting ,
permanent mold casting or die casting
– The wall adjacent to the drilled hole should have a thickness equivalent to the
thickness of the main body
• The inserted stud will not restore the strength of the original thickness.
•
51. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Oval-shaped holes are preferred with larger dimensions along the
direction of forces
52. Design for Manufacturing and Assembly
(DFMA)
• Design of components for casting
• Outside bosses should be omitted to facilitate a straight pattern draft
53. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Forging
• Why forging????
• A properly designed forging is not only sound with regard to strength but it also
helps reduce the forging forces, improves die life and simplifies die design
• Forged components are usually made of steels and non-ferrous metals.
• They can be as small as a gudgeon pin and as large as a crankshaft.
• Forged components are used under the following circumstances:
• Moving components requiring light weight to reduce inertia forces, e.g.
connecting rod of I. C. engines, Components subjected to excessive stresses, e.g.
aircraft structures, Small components that must be supported by other structures
or parts, e.g. hand tools and handles, Components requiring pressure tightness
where the part must be free from internal cracks, e.g. valve bodies, Components
whose failure would cause injury and expensive damage are forged for safety.
54. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Forging
• Why forging????
• A properly designed forging is not only sound with regard to strength but it also
helps reduce the forging forces, improves die life and simplifies die design
• Forged components are usually made of steels and non-ferrous metals.
• They can be as small as a gudgeon pin and as large as a crankshaft.
• Forged components are used under the following circumstances:
• Moving components requiring light weight to reduce inertia forces, e.g.
connecting rod of I. C. engines, Components subjected to excessive stresses, e.g.
aircraft structures, Small components that must be supported by other structures
or parts, e.g. hand tools and handles, Components requiring pressure tightness
where the part must be free from internal cracks, e.g. valve bodies, Components
whose failure would cause injury and expensive damage are forged for safety.
55. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Forging
While designing a forging, advantage should be taken of the direction of fibre lines
• There are no fibre lines in the cast component and the grains are scattered.
• In case of a component prepared by machining methods, such as turning
or milling, the original fibre lines of rolled stock are broken.
• It is only in case of forged parts that the fibre lines are arranged in a favorable
way to withstand stresses due to external load.
• While designing a forging, the profile is selected in such a way that fibre lines
are parallel to tensile forces and perpendicular to shear forces
56. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Forging
While designing a forging, advantage should be taken of the direction of fibre lines
57. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Forging
The forged component should be provided with an adequate draft
• The draft angle is provided for an easy removal of the part from the die
impressions
58. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Forging
• The parting line should be in one plane as far as possible and it should divide the
forging into two equal parts.
• When the parting line is broken, it results in unbalanced forging forces, which tends to displace
the two die halves.
59. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Welding
• Why welding?????
• Welding is the most important method of joining the parts into a complex
assembly
• Select the Material with High Weldability
• In general, low carbon steel is more easily welded than high carbon steel.
• Higher carbon content tends to harden the welded joint, as a result of which the weld
is susceptible to cracks.
60. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Welding
• Use Minimum Number of Welds
• Only the adjoining area of the joint is heated up, which has no freedom
to expand or contract.
• Uneven expansion and contraction in this adjoining area and parent metal
results in distortion.
• Since distortion always occurs in welding, the design should involve a
minimum number of welds and avoid over welding.
• It will not only reduce the distortion but also the cost
61. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Welding
• Use Standard Components
• The designer should specify standard sizes for plates, bars and rolled sections.
• Non-standard sections involve flame cutting of plates and additional welding.
• As far as possible, the designer should select plates of equal thickness for a
butt joint.
62. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Welding
• Select Proper Location for the Weld
• The welded joint should be located in an area where stresses and deflection are not critical.
• Also, it should be located at such a place that the welder and welding machine has
unobstructed access to that location.
• Prescribe Correct Sequence of Welding
• The designer should consider the sequence in which the parts should be
welded together for minimum distortion.
• This is particularly important for a complex job involving a number of welds.
• An incorrect sequence of welding causes distortion and sometimes cracks in
the weld metal due to stress concentration at some point in fabrication
63. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Welding
• Reduce edge preparation
• It is necessary to prepare bevel edges for the components prior to
welding operation.
• This preparatory work can be totally eliminated by making a slight change in
the arrangement of components.
(a) Incorrect (b) Correct
64. Design for Manufacturing and Assembly
(DFMA)
• Design of components for Machining
• Why machining???
• Machined components are widely used in all industrial products.
• They are usually made from ferrous and non-ferrous metals.
• They are as small as a gear in a wristwatch and as large as huge turbine
housing.
• Metal-cutting operations: Turning, Milling, drilling, shaping, boring, reaming
etc.
• Surface finishing operations: Grinding, buffing etc.