SCHOOL OF MECHANICAL AND BUILDING SCIENCES

MEE 302 Design of Machine Elements

UNIT I
Design Process
By
Dr. T. CHRISTO MICHAEL
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Objectives
Basic concept of design methodology for machine elements
To solve the real time problem with appropriate design
methodology
To understand and importance of the various standards and
methods of standardization
To apply the concept of parametric design and validation by
strength analysis
Outcomes
Student will be able to
Analyze and select machine elements/components
Know the applications of the various elements, materials
used to make them, and methods used
Integrate various machine elements and components into the
design of a machine or mechanical system through a design
project
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Contents
Unit I
Introduction to Design Process
Unit II
Fatigue strength and design of springs
Unit III
Design of Shafts and Joints
Unit IV
Design of Couplings
Unit V
Design of Engine Components
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Text Books
1. Joseph Edward Shigley and Charles, R. Mischke, (2008)
Mechanical Engineering Design, McGraw Hill
International Editions. Eighth Edition.
2. Bhandari.V.B. (2010) Design of Machine elements,
Tata Mc Graw Hill Book Co, Third Edition.
3. R.S.Khurmi, J.K.Gupta. (2008) Machine Design,
Eurasia Publishing House (Pvt.) Ltd. Revised Edition.

References
1. Design Data book PSG College of Technology,
Coimbatore., 2006
2. Juvinal, R.C., (2002) Fundamentals of Machine
component Design, John Wiley.
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What is Design?
Design is essentially a decision making process. If we have a
problem, we need to design a solution. In other words, to
design is to formulate a plan to satisfy a particular need and to
create something with a physical reality.
For example, Design of a chair
The purpose for which the chair is to be designed such as
whether it is to be used as an easy chair, an office chair or to
accompany a dining table
Whether the chair is to be designed for a grown up person or a
child
Material for the chair, its strength and cost need to be
determined
Finally, the aesthetics of the designed chair
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Machine, Machine Design and Machine Elements

Machine
A machine is a combination of several machine elements
arranged to work together as a whole to accomplish
specific purposes
Machine Design
Machine design involves designing the elements and
arranging them optimally to obtain some useful work.
Machine Elements
Components of a machine that transmit the forces safely
and perform their task successfully.
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Types of Design
Adaptive Design:- This is based on existing design, for
example, standard products or systems adopted for a new
application.
Example:- Conveyor belts, control system of machines and
mechanisms are some of the examples where existing
design systems are adapted for a particular use.
Developmental Design:- Here we start with an existing
design but finally a modified design is obtained. A new
model car is a typical example of a developmental design.
New Design:- This type of design is an entirely new one but
based on existing scientific principles. No scientific
invention is involved but requires creative thinking to solve
a problem.
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Factors to be Considered in Machine Design

There are many factors to be considered while attacking a
design problem.
What device or mechanism to be used
Material
Loads or forces on the elements
Size, shape and space requirements. The final weight of the
product is also a major concern.
The method of manufacturing the components and their
assembly.
How will it operate?
Reliability and safety aspects
Inspectability
Maintenance, cost and aesthetics of the designed project
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Design Process
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Design Process
Identification of Need
It is highly creative act
The need is often not evident at all
Recognition of need is usually triggered by a particular adverse
circumstance
Definition of Problem
It is not a statement
It is more specific and must include all specifications for the
object to be designed
Specifications are the input and output quantities
The specifications define the cost, the number to be
manufactured, the expected life, the range, the operating
temperature, and the reliability
The restrictions on a designers freedom affect the specification
of the product
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Design Process
The restrictions are,
Manufacturing process selection
Labour skills available and the competitive situation
Non availability of materials
Synthesis
The synthesis of a scheme connecting possible system
elements is sometimes called the invention of the concept
or concept design. Various schemes must be proposed,
investigated and quantified
In this stage, the designer can try for a number of possible
solutions. It deals with a complete defining of all the
details of the possible solutions; including material
processing methods and dimensions
This may be done by computation
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Design Process
Analysis and optimization:
Analysis must be performed to assess whether the
system performance is satisfactory or better, and, if
satisfactory, just how well it will perform
Mathematical models are developed to simulate the real
physical system
Optimum solution is the best of all possible solutions
Evaluation:
Evaluation is the final proof of a successful design and
usually involves the testing of a prototype in the laboratory
Here, we wish to discover if the design really satisfies the
need
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Design Process
Presentation
Communicating the design to others is the final and vital
step
Many great designs, inventions and creative works have
been lost simply because the originators were unable to
explain their accomplishments to others
It is a selling job and the designer is benefitted
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Selection of Materials Based on Mechanical

Properties
The best material is one which will serve the desired
objective at minimum cost.
1. Availability
2. Cost:-Cost of material and Cost of processing the
material into finished goods
3. Mechanical Properties
4. Manufacturing consideration
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Mechanical Property and its measurement

Property Measured Quantity
Strength (static load) Ultimate tensile strength or tensile yield strength
Strength (fluctuating Endurance strength Ex: connecting rod.
load)
Rigidity Modulus of Elasticity
Ductility Percentage elongation
Hardness Brinell or Rockwell hardness number
Toughness Charpy or Izod impact value
Frictional properties Co-efficient of friction
Example:
Bearing- low co-efficient of friction is preferable.
Clutch & Brake High co-efficient of friction is
preferable.
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Stress Equations
Direct

= =

Bending

= =

Torsion

= =

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Impact Loading
Maximum Deformation and Maximum Stress due to a
Falling Weight on a Prismatic Bar

If height is large compared to static elongation

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Suddenly Applied Load

When h is zero

Impact Factor