Institution of Engineers,

Dhaka - 1000
May 24, 2015

MECHANICAL DESIGN
PART - 01
Dr. Mohammad Motalab
Assistant Professor
Department of Mechanical Engineering
Bangladesh University of Engineering and Technology
BUET, Dhaka - 1000

BUET

Department of Mechanical Engineering

MACHINE DESIGN
Introduction to Mechanical Engineering Design
Mechanical Engineering Design refers to the decision
making processes which are used by the mechanical
engineers in order to formulate plans for the physical
realization of machines, devices, and systems.
The systematic and creative application of scientific and
mathematical principles to practical ends such as the
design, manufacture, and operation of efficient and
economical structures, machines, processes, and
systems is called Design.
The purpose of this course to understand these decision
making processes and for applying them to practical
situations.

BUET

Department of Mechanical Engineering

MACHINE DESIGN
Introduction to Mechanical Engineering Design (Contd.)
The design is to formulate a plan for the satisfaction of
human need.
An example illustrating need for design
Failure of a microprocessor component due to the
thermal cycling operation. Example of using underfill
material in microprocessor in order to minimize solder
strains.
Invention of GPS during world war-II.

BUET
Department of Mechanical Engineering

MACHINE DESIGN
Introduction to Mechanical Engineering Design (Contd.)
Mechanical Design means the design of things and
systems of a mechanical nature machines, products,
structures, devices, and instruments.
Mechanical Engineering Design includes all disciplines of
mechanical engineering, such as the thermal and fluid
sciences, too.
The first studies in mechanical engineering design are in
mechanical design, which is the contents of the courses
Machine Design-I and Machine Design-II.

BUET
Department of Mechanical Engineering

MACHINE DESIGN
Introduction to Mechanical Engineering Design (Contd.)
Design Consideration
The characteristics that influence the design of the
machine or the entire system are referred as the design
consideration. Some typical design considerations are
strength, reliability, mechanical and thermal properties, life
of the parts, weight, size and shape, etc.
Standards Used
A standard is a set of specification of parts, materials, or
processes intended to achieve uniformity, efficiency, and
specified quality.

BUET
Department of Mechanical Engineering

MACHINE DESIGN
Introduction to Mechanical Engineering Design (Contd.)
Better control of inventory of tooling.
ASME, ASTM, AISC, AISI, BSI, etc.
Strength
Strength is a property of a material or mechanical
element. It depends upon the choice, the treatment of the
material (forging, rolling, cold forming etc.), and the
processing of the material. Example: Different strength of
solder material for different aging, testing temperatures.
Strength is usually denoted as the S. Su is ultimate
strength and Sy is yield strength. Example of a stressstrain curve of solder material.

BUET
Department of Mechanical Engineering

MACHINE DESIGN
Introduction to Mechanical Engineering Design (Contd.)
Stress
Normal stress is denoted as
and shear stress is denoted
as .
Stress components:
x ,
1 etc.
Allowable Stress refers to the reduced value of strength
that is used in design to determine the geometrical
dimensions of parts in mechanical systems. The strength
reduction is based on the specified standards. For
example, according to AISC, for a member in tension,
0.45

  0.60

BUET
Department of Mechanical Engineering

MACHINE DESIGN
Introduction to Mechanical Engineering Design (Contd.)
The dimensions of Stress components are selected such
as:



Factor of Safety
A design factor of safety nd, or n, sometimes called simply
design factor, is defined by the relation:
Material internal flaw, size effect (example of standard
deviation), load effect, computed stress, environmental
concern (corrosive agent), for complicated part stress
cant be accurately determined, accidental load, danger to
life or property, price class etc.

BUET
Department of Mechanical Engineering

MACHINE DESIGN
Introduction to Mechanical Engineering Design (Contd.)


 


     !" 

#  "  $

 

%
%

Factor of safety for brittle material

 

&'"((   

)*"  +" 




Factor of safety for ductile material

,"  
 
)*"  +" 



Margin of safety,
.   / 1

BUET
Department of Mechanical Engineering

MACHINE DESIGN
Factor of Safety for Different Load
Kind of Load

Ductile Material Cast Iron

(Steel)

Timber

Leather

Based
on Su

Based
on Sy

Based on ultimate strength

Dead Load

3-4

1.5-2

5-6

Repeated Load,
one direction,
gradual (mild
shock)

7-8

10

Repeated,
Reverse, Gradual
(mild shock)

10-12

15

12

Shock

10-15

5-7

15-20

20

15

BUET
Department of Mechanical Engineering

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MACHINE DESIGN
Stress Analysis
Pure Tension/ Simple Tension
Characteristics of Simple Tension
Bar is straight and made of homogeneous material
Line of action of the force coincides with the center (axis)
of the bar.
The section is taken much away from any discontinuity or
abrupt change in the geometry.
The bar that fulfills these conditions is said to be in simple
tension/

BUET
Department of Mechanical Engineering

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MACHINE DESIGN
Stress Analysis
Engineering Stress/ Nominal Stress
%

The value
 may only be the average stress at a

#
section. This is called Engineering Stress.

BUET
Department of Mechanical Engineering

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MACHINE DESIGN
Stress Analysis
Pure Shear/ Simple Shear


%
#

 012
3

Normal Strain and Shear Strain

BUET
Department of Mechanical Engineering

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MACHINE DESIGN
Stress Analysis
Isotropic Stress
The stress across any imaginary internal surface turns out
to be equal in magnitude and always directed
perpendicularly to the surface.

BUET
Department of Mechanical Engineering

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MACHINE DESIGN
Stress Analysis
Stress-Strain Diagram
Proportional limit, yield stress, ultimate strength.

Modulus of elasticity.

BUET
Department of Mechanical Engineering

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MACHINE DESIGN
Three Dimensional Stress State at a Point

1st subscript in a stress notation

Identifies the axis

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Department of Mechanical Engineering

2nd subscript identifies the

Direction of the stress component
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MACHINE DESIGN
Three Dimensional Stress State at a Point

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Department of Mechanical Engineering

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MACHINE DESIGN
Stress-Strain Relation

BUET
Department of Mechanical Engineering

567896: ;8<:8=7>?
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MACHINE DESIGN
Stress-Strain Relation

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Department of Mechanical Engineering

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MACHINE DESIGN
Stress-Strain Relation

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Department of Mechanical Engineering

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Design of Knuckle joint

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Department of Mechanical Engineering

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Design of Knuckle joint

Two or more rods subjected to
tensile and compressive forces are
fastened together

Their axes are not in

alignments but meet in a point

The joint allows a

small angular moment
of one rod relative to
another

It can be easily
connected and
disconnected

Applications: Elevator chains, valve rods, etc

BUET
Department of Mechanical Engineering

D ; E
C 

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Department of Mechanical Engineering

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C  B / ;1 G

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Department of Mechanical Engineering

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C  B / ;1 @

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Department of Mechanical Engineering

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C  2 B / ;1 @ 

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Department of Mechanical Engineering

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C

I 2
2
J

C  ;1 G

C  2 ;1 @

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Department of Mechanical Engineering

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Fatigue Failure

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Department of Mechanical Engineering

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Endurance Strength

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Department of Mechanical Engineering

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Endurance Strength
Aluminum Alloy

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Department of Mechanical Engineering

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Endurance Strength

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Department of Mechanical Engineering

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Endurance Strength
Surface Effects

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Department of Mechanical Engineering

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Endurance Strength
Size Effects

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Department of Mechanical Engineering

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Endurance Strength
Load Effects

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Department of Mechanical Engineering

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Endurance Strength
Temperature Effects

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Department of Mechanical Engineering

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Endurance Strength
Reliability Effects

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Department of Mechanical Engineering

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Endurance Strength
Stress Concentration Effects

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Department of Mechanical Engineering

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Fluctuating Load

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Department of Mechanical Engineering

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Design for Fatigue Loading

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Department of Mechanical Engineering

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Design for Fatigue Loading

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Department of Mechanical Engineering

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Design of Shaft

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Department of Mechanical Engineering

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Design of Shaft

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Department of Mechanical Engineering

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Design of Shaft

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Department of Mechanical Engineering

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Design of Shaft

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Department of Mechanical Engineering

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Design of Shaft

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Department of Mechanical Engineering

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Design of Shaft

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Department of Mechanical Engineering

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Design of Shaft
Torque Calculation

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Department of Mechanical Engineering

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Design of Shaft

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Department of Mechanical Engineering

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Design of Shaft

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Department of Mechanical Engineering

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Design of Shaft (Combined Load)

Bending Stress

Torsional Stress

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Department of Mechanical Engineering

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Design of Shaft (Combined Load)

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Department of Mechanical Engineering

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Design of Shaft (Combined Load)

ASME Design Formula for Fully Reversed Bending
and Steady Torsion

For Bending, Axial, and Torsional Load: DE-ASME

BUET
Department of Mechanical Engineering

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Design of Shaft
Torsional Rigidity

Lateral Rigidity

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Department of Mechanical Engineering

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Design of Shaft

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Department of Mechanical Engineering

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Limits and Fits

Related Terms

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Department of Mechanical Engineering

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Department of Mechanical Engineering

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Department of Mechanical Engineering

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Department of Mechanical Engineering

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Stress Concentration

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Department of Mechanical Engineering

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Stress Concentration
Reducing the Stress Concentration Factor

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Department of Mechanical Engineering

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Stress Concentration
Determining Stress Concentration Factor

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Department of Mechanical Engineering

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Stress Intensity Factor

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Department of Mechanical Engineering

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Stress Intensity Factor

Determining Stress Intensity Factor

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Department of Mechanical Engineering

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Stress Intensity Factor

Fracture Toughness

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Department of Mechanical Engineering

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Compression Members - Column

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Department of Mechanical Engineering

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Critical Load of Column

Euler
formula

Parabolic
Expression

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Department of Mechanical Engineering

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Critical Load of Column

Euler
formula

Parabolic
Expression

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Department of Mechanical Engineering

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Critical Load of Column

Effects of End Conditions

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Department of Mechanical Engineering

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Critical Load of Column

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Department of Mechanical Engineering

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Eccentric Column
Secant Formula for Eccentric Column

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Department of Mechanical Engineering

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Eccentric Column

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Department of Mechanical Engineering

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