Machine Design

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

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

Representation of a machine

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

Needs which are not well-identified

Road accidents are too many, nowadays. It is required to
reduce them.

Use of petroleum products are getting so increased that all

the oil wells are likely to be exhausted within a few years.
Do something to solve this problem.
The need itself is not well-defined
Difficult to formulate the real problem

Difficult to formulate a plan for its remedy

Designs. Classifications
Building Design
Highway Design
Ship Design
Process Design

Clothing Design
Machine design

......... to an endless number

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

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

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 characterised by continual change of theory and

practice
Knowledge of what has gone before, is important

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
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

Design Process

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

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

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

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

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

Final Design selection

Therell be several final designs satisfying the original
specifications (machines thatll 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

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

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
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 and provide problemsolving 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.