Professional Documents
Culture Documents
OF
MACHINE ELEMENTS
UNIT-1
PART-1
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MACHINE DESIGN:
Generally machine is a combination of various elements arranged to work
together to serve specific purpose. Machine design includes designing the elements and
arranging the elements optimally to serve the need.
TYPES OF DESIGN:
Adaptive Design
Development Design
New Design
ADAPTIVE DESIGN:
In most cases, the designers work is concerned with adaptation of existing
designs. This type of design needs no special knowledge or skill and can be attempted by
designers or ordinary technical training. The designer only makes minor alternation or
modification in the existing designs of the product
DEVELOPMENT DESIGN:
This type of design needs considerable scientific training and design ability
in order to modify the existing designs into a new idea by adapting a new material or
different method of manufacture.
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Recognition of need
Definition of Problem
Synthesis
Analysis of Optimization
Evaluation
Figure-1
Presentation
RECOGNITION OF NEED:
Consumption (or use) of the product usually decides the characteristics for the
need. To get the information concerning the market or consumer characteristic Research
of the past, Present and future consumption requirements is accomplished to get the
realistic estimates of the future demand. The final translation of need into statement of
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project goal or objective takes account of the constraints such as ability to solve, the
resources the time available and the risk factors.
DEFINITION OF THE PROBLEM:
Select the possible mechanism or group of mechanisms which will give the
desired motion.
ANALYSIS:
Find the size of each member of the machine by considering the forces/stresses
acting on the member of the machine and the energy transmitted by each member. Select
the material best suited for each member of the machine. The analysis may reveal that the
system is not an optimum one. If the design fails, the synthesis procedure must begin
again.
EVALUATION:
It is the final proof of a successful phase of the total design process and usually
involves the testing of a prototype in the laboratory. It is economical to manufacture and
to use.
PRESENTATION:
This is the final step of design process which refers to the proper communication
of design details like correct dimensions, machining process, tolerance details and other
working conditions to other engineers through written materials or orally for further
actions.
COMMUNICATION:
These are the written the oral and the graphical forms. Draw the detailed drawing of each
component and the assembly of the machine with complete specification for the manufacturing
drawings with tolerances.
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GENERAL CONSIDERATIONS
COMPONENT:
IN
DESIGNING
MACHINE
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2. Live or variable or dynamic load: Whose magnitude and direction change time
to time.
3. Suddenly or shock load: Initial velocity is zero.
Ex: Designing a lathe bed require cast iron which is more hard and high
compressive strength, for making dial gauge, glass may be employed.
4. Impact load: This is suddenly applied with some velocity.
Ex: blows of hammer, rough road reactions to the wheels and axles of motor cars.
In general the components to be designed or dynamic and impact load should be
stronger and bigger than that for steady load.
The load on a machine component may act in several ways due to which the internal
stresses are set up: Tensile, compressive, shear, Torsional, Bending, Combined stresses,
Thermal stresses.
Load
Static or dead or steady load,
Live or variable load,
Suddenly applied or shock load,
Impact load.
Stresses
Tensile, compressive, shear,
Torsion, Bending,
Combination of any stresses due to
Change in temp (Thermal stress)
2. Motion of the parts: Depending upon the given specification the suitable
prescribed motion of the part is to be evaluated. The motion of the parts are
(1) Rectilinear motion.(reciprocating)
(2) Curvilinear motion. (rotary)
(3) Constant speed.
(4) Constant or variable acceleration
3. Selection of materials: The selection of material for a part depends upon the
forces that are acting on that part and stresses developed on that part. The design
engineer should have a thorough or complete knowledge of the mechanical
behavior of materials under different loads.
4. Form and size of the parts: Based upon the stresses acting on the part, the size
and form shape (appearance) of a component is to be designed. In the process of
reducing the size of the machine or existing component the design engineer should
always check for the capability of that part to resist the stresses. The size is
inversely proportional to material strength if the load is kept constant.
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STANDARDIZATION IN DESIGN:
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and handling costs as well as the efforts to achieve uniformity, efficiency and a
specified quality.
PREFERRED NUMBERS:In engineering design many times the designer has to specify the size of the
product. The size of the product is a general term which includes different parameters
like power transmitting capacity, load carrying capacity, speed, dimensions of the
component such as height, length, width and weight of the product. These parameters are
expressed numerically e.g.: 5 KW, 10 KN, 1000 rpm. Often the product is manufacturing
in different sizes or models for instance, a company may be manufacturing different
models of electric motors ranging from 0.5 KW to 50 KW to cater to the need of different
customers. Preferred numbers are used to specify the sizes of the products in these
cases. Preferred numbers were first introduced by Charles Renard. These are nothing but
a series of numbers in a geometric progression (G.P) specially selected to be used for
standardization in preference to any other random numbers.
They are written as integral powers of 10. The first four are called basic series and
other are called derived series, (denoted as R5, R10, R20, R40 and R80 series) which
increase in steps of 58%, 26%, 12%, 6%, and 3% respectively. Each series has its own
series factor. The series factors are as follows:
R5 series 510 = 1.58
R10 series 1010 = 1.26
R20 series 2010 = 1.12
R40 series 4010 = 1.06
R80 series 8010 = 1.03
The resultant numbers are rounded as per international standards and shown in Design
Data Hand Book K. Mahadevan Page No: 402, Table 23.1, 23.2
Ex: Hydraulic cylinder capacities are in R5 series
Hoisting capacities (in tones) of cranes are in R10 series
Wire diameters of helical spring are in R40series
Hydraulic cylinder diameters are in R20 series
USES:Preferred numbers are an important tool, which minimize unnecessary variation in
sizes. They assist the designer in avoiding selection of sizes in an arbitrary manner. The
complete range is covered by minimum number of sizes which is advantageous to
producer and consumer. They are unlimited towards the lower as well as higher numbers.
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6. Toughness: It is the property o a material to resist fracture due to high impact loads
like hammer blows. The toughness of the material decreases when it is heated. This
property is desirable in parts subjected to shock and impact loads.
7. Malleability: It is a special case of ductility which permits materials to be rolled or
hammered into thin sheets due to compressive force. A malleable material should be
plastic but it is not essential to be so strong. The malleable materials commonly used in
engineering practice are lead, soft steel, Wrought iron, copper and aluminum.
8. Creep: When a part is subjected to a constant stress at high temp for a long period of
time, it will undergo a slow and permanent deformation called creep. This property is
considered in designing I.C engine, boilers and turbines.
9. Fatigue: When a material is subjected to repeated stresses it fails at stresses below the
yield point stresses. Such type of failure of a material is known as fatigue. The failure is
caused by means of progressive crack formations which are usually fine and microscopic
size. This property is considered in designing shafts, connecting rod, springs, gears etc.
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