ME3004D
Design of Machine Elements
Text Book:
Mechanical Engineering Design –
Joseph Edward Shigley
(McGraw Hill Book Company)
Dr. P.K. Rajendrakumar
Professor
Department of Mechanical Engineering
National Institute of Technology, Calicut
Other References
J.E. Shigley and C.R. Mischke, Mechanical Engineering Design, Tata
McGraw Hill, Sixth Edn., 2003
R.C. Juvinall and K.M. Marshek, Fundamentals of Machine Component
design, John Wiley & Sons
R.L. Norton, Machine Design, Pearson Education
M.J. Siegel, V.L. Maleev and J.B. Hartman, Mechanical Design of
Machines, International Textbook Company
V.L. Doughtie and A.V. Vallance, Design of Machine elements,
McGraw Hill
B.R. Narayana Iyengar and K. Lingaigh, Machine Design Data
Handbook, Vol. I & II
P.S.G. Tech., Machine Design Data Hand Book
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Definitions
Engineering is the art and science by which the properties
of matter and the sources of power in nature are made
useful in structures, machines and fabricated parts
A machine is a combination of resistant parts so arranged
as to cause the forces of nature to produce definite work
with constrained motion
To design is to formulate a plan for the satisfaction of a
human need
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Representation of a machine
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Some well-defined needs
A machine has to be made which produces square and
hexagonal holes, on plates with a maximum thickness of
20mm, with a reasonably good finish and accuracy
This gear shaft is troublesome; within two weeks there
has been six failures. Do something with the system so
that frequent failures are avoided
The final goal is known
A plan has to be formulated to achieve this
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Needs which are not well-identified
Road accidents are too many, nowadays. It is required to
avoid them.
Use of petroleum products are getting so increased that all
the oil wells are likely to be exhausted within a few years.
Devise a way to solve this problem.
The need itself is not well-defined
Difficult to formulate the real problem
Difficult to formulate a feasible plan to solve it
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Designs…. Classifications
Building Design
Highway Design
Ship Design
Process Design
Clothing Design
Machine design
......... to an endless number
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Everyone does design exercises in one
way or other
Examples:
Problem of organising an arts festival in the Institute
Plan the events, time and structure of the festival such that
every student feels that he/she enjoyed the events well and
the deserving participants have won the titles
Design of a family vacation
Plan the vacation such that every family member should feel
that he or she had a good time
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Design as a Process
Design has an authentic purpose
The creation of an end result by taking definite action or the
creation of something having physical reality
Engineering Design is the process in which scientific
principles and the tools of engineering (Mathematics,
Computers, Graphics, English) are used to produce a plan
which, when carried out, will satisfy a human need
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Machine Design
The art and technique of planning the construction of new or
improved machines
A new machine may be:
entirely new in concept performing new types of work (as, an
invention)
performing more efficiently and economically, work that can be
done by existing machines
Incorporating some new inventions and some improvements of
existing machines
Design is characterized by continual change of theory and
practice
Knowledge of what has gone before, is important
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The essence of machine design is the knowledge of :
Kinematics
Load
Stress and deformation
analysis
Behavior of materials
Material fabrication
Evolution of design –
A creative blend of theory and experience
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on materials and fabricating processes
Nature of Design Process
Not a rigid or fixed series of steps which can be
prescribed
Approach varies with individual requirements
Industrial practices in a given field
Size of the project
Company practices
Individual training
Still, a logical sequence of steps, common to all
design projects, does exist
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Design Process 13
Need
A design is always generated by a need
Need is either to satisfy a new requirement or to improve
the method of performing an existing task
Need is motivated economically, politically, socially or a
combination of these factors
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Defining the Problem
The nature and scope of the requirements are translated to
physical terms
The machine is defined in terms of
its inputs and outputs
shape, weight and size requirements
environmental conditions
noise level
……….and other limiting conditions
Specifications should be as accurate as possible
Requirements that go beyond what is necessary to satisfy the
need, increase costs and create unnecessary design problems
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Feasibility
Very often, economic or technological requirements may
be too rigid to permit feasible design
Technological feasibility mainly depends on
Materials technology
Space limitations
Prime importance is generally given to the economic
feasibility
Cost of production
Cost of operation
Cost of maintenance 16
Preliminary Design Alternatives
This is the System Design Phase
Considers the best possible methods and kinematic paths
by which the machine input may be converted to machine
output in accordance with the specifications
It is possible to have different systems which are kinematically
equivalent
Uses theoretical links having idealized properties
Rigid links (do not change shape)
Pins do not wear and have no diameter
Hydraulic links that are incompressible
Pneumatic links which obey perfect gas laws
Friction losses and the generated heat are not considered
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Final design alternatives
Mechanical Design Phase
Considers
Materials properties
Deformation characteristics
Load analysis (internal & external)
Stress analysis
Wear analysis
Size of the members and inertia effects
In the absence of insufficient information, assumptions are
made, which should be on the safe side in any case
Feasibility is also studied on the basis of the above
considerations
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Final Design selection
There’ll be several final designs satisfying the original
specifications (machines that’ll do the job for the minimum
prescribed time)
Selection of one of them is an Engineering Management
Problem
Cost
Aesthetics
Salability
Manufacturing facilities available
Compatibility with existing equipment
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Preliminary and final plans and drawings
Drawings are the most economical and simplest means of
communicating ideas and information
Indicate interferences
Visualize shapes
Aid in designing lubricating systems
Show the problems of assembly and disassembly
Point out possible maintenance difficulties
Sometimes prototypes also are to be constructed before
production
Even a minor error can be costly when large number of units are to
be produced
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Manufacturing
Design and manufacturing go hand in hand
Design for manufacturability (DFM) is a well-established
and needed tool for design engineers
A brilliant concept that cannot be manufactured cannot be a design
Decisions made early in the design process can reduce the
manufacturing costs considerably
Design for assembly (DFA) is another consideration
Individual components should be easily fabricated, assembled and
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constructed
Computers in Design
Computers are useful in virtually integrating all phases of the
design process
Computer Aided Design (CAD) allows the design engineer to
visualize geometries without making costly models, iterations or
prototypes
Designs can be optimized and modified directly and easily at any time
Information stored by the computer can be accessed and retrieved from
anywhere within the organization
Expert systems are rule-based computer programs that solve
specialized problems on an expert level
Provide problem-solving skills to the design engineer
Eg: An expert system could analyze a part drafted on a computer system for
ease of manufacturing. If an excessively tight tolerance is found, the expert
system warns of manufacturing difficulties and suggests easing the tolerance.
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