National Institute of Technology, Jamshedpur

Department of Mechanical Engineering

Spring Semester 2016-17
Course Handout
Subject Code : ME603 (L-T-P: 3-1-0)
Course title : Mechanical System Design
Instructor In-Charge : Dr.K.Karthik Selva Kumar
Course Objectives
 To develop competency for system visualization and design.
 To enable student to design cylinders and pressure vessels and to use IS code.
 To enable student select materials and to design internal engine components.
 To introduce student to optimum design and use optimization methods to design mechanical components.
 To enable student to design machine tool gearbox.
 To enable student to design material handling systems.
 Ability to apply the statistical considerations in design and analyze the defects and failure modes in components.
Content:
Sr. Total %
Content
No. Hrs Weight
Design of Machine Tool Gearbox: age
Introduction to machine tool gearboxes, design and its applications, basic considerations in design of
1 drives, determination of variable speed range, graphical representation of speed and structure 7 20%
diagram, ray diagram, selection of optimum ray diagram, deviation diagram, difference between
numbers of teeth of successive gears in a change gear box.
Statistical considerations in design:
Frequency distribution-Histogram and frequency polygon, normal distribution - units of central
2 tendency and dispersion- standard deviation - population combinations - design for natural 7 15%
tolerances -design for assembly - statistical analysis of tolerances, mechanical reliability and factor
of safety.
Design of Belt conveyer system for material handling:
System concept, basic principles, objectives of material handling system, unit load and
containerization. Belt conveyors, Flat belt and troughed belt conveyors, capacity of conveyor, 8 20%
3 rubber covered and fabric ply belts, belt tensions, conveyor pulleys, belt idlers, tension take-up
systems, power requirement of horizontal belt conveyors for frictional resistance of idler and
pulleys.
Design of Cylinders and Pressure vessels:
Thin cylinders and spherical vessels, Wire wound cylinders. Thick cylinders: Principal stresses in
4 cylinder subjected to internal/external pressure, Lame’s equation, Clavarion’s and Bernie’s equations,
Autofrettage, Compounding of cylinders, Gasketted Joints, Thickness of cylindrical and spherical 8 25%
shells, Design of End closures, Area compensations for nozzles. Introduction to Design codes.
Optimum Design and DFMA:
Optimum Design: Objectives of optimum design, adequate and optimum design, Johnson‘s Method
of optimum design, primary design equations, subsidiary design equations and limit equations,
optimum design with normal specifications of simple machine elements- tension bar, transmission 8 20%
5 shaft and helical spring, Pressure vessel Introduction to redundant specifications ( Theoretical
treatment).
Design for manufacture, assembly and safety
General principles of design for manufacture and assembly (DFM and DMFA), principles of design
of castings and forgings, design for machining, design for safety.
Evaluation scheme
Evaluation Nature of
EC no. Duration Weightage Date time
Component component
1 Test I 60 min. 20% Closed book
2 Test II 60 min. 20% Closed book
3 End Semester exam 180 min. 40% Closed book
4 Assignments 10% Take home
5 Surprise Quizzes 5 min. 10% Closed book
Course Outcomes
 The student will understand the difference between component level design and system level design.
 Ability to design various mechanical systems like pressure vessels, machine tool gear boxes, material handling systems,
etc. for the specifications stated/formulated.
 Ability to learn optimum design principles and apply it to mechanical components.
 Ability to handle system level projects from concept to product.

Reference Books:
1. Shigley’s Mechanical Engineering Design, 8th Edition, McGraw Hill.
2. V B Bhandari, Design of Machine Elements, 3/e, McGraw Hill.
3. R C Juvinall, Fundamentals of Machine Component Design, 4/e, Wiley.
4. R L Norton, Machine Design An Introduction, Pearson.
5. E J Hearn, Mechanics of Materials, BH.

*Chamber Consultation Hrs: Thursday 12 Noon in the Chamber (Fluid Flow and Machinery Lab)
Notices: All notices regarding the course will be displayed only on the Department Of Mech. Engg. Notice Board.

K.Karthik Selva Kumar

Instructor in-Charge