CHAPTER 1 - INTRODUCTION

Machine Design is the creation of new and better machines and improving the existing ones.

Classifications of Machine Design

1. Adaptive design. - The designer only makes minor alternation or modification in the
existing designs of the product.
2. Development design. - Designer starts from the existing design, but the final product
may differ quite markedly from the original product.
3. New design. - This type of design needs lot of research, technical ability and creative
thinking.

General Procedure in Machine Design

1. Recognition of need:

First of all, make a complete statement of the problem, indicating the need, aim or purpose for
which the machine is to be designed.
2. Synthesis (Mechanisms):

Select the possible mechanism or group of mechanisms which will give the desired motion.

3. Analysis of forces:

Find the forces acting on each member of the machine and the energy transmitted by each
member.

4. Material selection:

Select the material best suited for each member of the machine.

5. Design of elements (Size and Stresses):

Find the size of each member of the machine by considering the force acting on the

member and the permissible stresses for the material used.

6. Modification:

Modify the size of the member to agree with the past experience and judgment to facilitate
manufacture.

7. Detailed drawing:

Draw the detailed drawing of each component and the assembly of the machine with complete
specification for the manufacturing processes suggested.

8. Production:

The component, as per the drawing, is manufactured in the workshop.

Classification of Engineering Materials

The engineering materials are mainly classified as :

1. Metals and their alloys, such as iron, steel, copper, aluminium, etc.

2. Non-metals, such as glass, rubber, plastic, etc.

The metals may be further classified as :

(a) Ferrous metals, and (b) Non-ferrous metals.

The ferrous metals are those which have the iron as their main constituent, such as cast iron,

wrought iron and steel.

The non-ferrous metals are those which have a metal other than iron as their main constituent,

such as copper, aluminium, brass, tin, zinc, etc.

Load

It is defined as any external force acting upon a machine part.

1. Dead or steady load - A load is said to be a dead or steady load, when it does not change in

magnitude or direction.

2. Live or variable load - A load is said to be a live or variable load, when it changes
continually.

3. Suddenly applied or shock loads - A load is said to be a suddenly applied or shock load,
when it is suddenly applied or removed.

4. Impact load - A load is said to be an impact load, when it is applied with some initial
velocity.

Stress

Internal force per unit area at any section of the body is known as unit stress or simply a stress.

Stress, = P/A

where P = Force or load acting on a body, and

A = Cross-sectional area of the body.

In S.I. units, the stress is usually expressed in Pascal (Pa) such that 1 Pa = 1 N/m2.

1 MPa = 1 106 N/m2 = 1 N/mm2

1 GPa = 1 109 N/m2 = 1 kN/mm2

Strain

Deformation per unit length is known as unit strain or simply a strain. Mathematically,

Strain, e = l / l or l = e.l

where l = Change in length of the body, and

l = Original length of the body.

Young's Modulus or Modulus of Elasticity

Hooke's law states that when a material is loaded within elastic limit, the stress is directly

proportional to strain.

E= /e

where E is a constant of proportionality known as Young's modulus or modulus of elasticity

Stress-strain Diagram

A- Proportional limit
B- Elastic limit
C- Upper yield point
D- Lower yield point
E- Ultimate stress point
F- Breaking stress point

Working Stress

When designing machine parts, it is desirable to keep the stress lower than the maximum or
ultimate stress at which failure of the material takes place. This stress is known as the working
stress or design stress. It is also known as safe or allowable stress.

Factor of Safety

It is defined, in general, as the ratio of the maximum stress to the working stress.
 CHAPTER 2 - STRESS CALCULATION

Design for static load

Problems for practice:

1. A reciprocating steam engine connecting rod is subjected to a maximum load of 65 kN. Find
the diameter of the connecting rod at its thinnest part, if the permissible tensile stress is
35 N/mm2. [Ans. 50 mm]
2. The maximum tension in the lower link of a Porter governor is 580 N and the maximum stress
in the link is 30 N/mm2. If the link is of circular cross-section, determine its diameter.
[Ans. 5 mm]
3. A wrought iron rod is under a compressive load of 350 kN. If the permissible stress for the
material is 52.5 N/mm2, calculate the diameter of the rod. [Ans. 95 mm]
4. A load of 5 kN is to be raised by means of a steel wire. Find the minimum diameter required,
if the stress in the wire is not to exceed 100 N/mm2. [Ans. 8 mm]
5. A square tie bar 20 mm 20 mm in section carries a load. It is attached to a bracket by means
of 6 bolts. Calculate the diameter of the bolt if the maximum stress in the tie bar is 150 N/mm2
and in the bolts is 75 N/mm2. [Ans. 13 mm]
6. Find the minimum size of a hole that can be punched in a 20 mm thick mild steel plate having
an ultimate shear strength of 300 N/mm2. The maximum permissible compressive stress in the
punch material is 1200 N/mm2. [Ans. 20 mm]
7. A bar of 2 m length, 20 mm breadth and 15 mm thickness is subjected to a tensile load of 30
kN. Find the final volume of the bar, if the Poissons ratio is 0.25 and Young's modulus is 200
GN/m2. [Ans. 600 150 mm3]
8. A bar of 12 mm diameter gets stretched by 3 mm under a steady load of 8 kN. What stress
would be produced in the bar by a weight of 800 N, which falls through 80 mm before
commencing the stretching of the rod, which is initially unstressed? Take E = 200 kN/mm2.
[Ans. 170.6 N/mm2]
9. A steel shaft 50 mm diameter and 500 mm long is subjected to a twisting moment of
1100 N-m, the total angle of twist being 0.6. Find the maximum shearing stress developed in the
shaft and modulus of rigidity. [Ans. 44.8 MPa; 85.6 kN/m2]
10. A shaft is transmitting 100 kW at 180 r.p.m. If the allowable stress in the material is 60 MPa,
find the suitable diameter for the shaft. The shaft is not to twist more than 1 in a length of
3 metres. Take C = 80 GPa. [Ans. 105 mm]
11. Design a suitable diameter for a circular shaft required to transmit 90 kW at 180 r.p.m. The
shear stress in the shaft is not to exceed 70 MPa and the maximum torque exceeds the mean by
40%. Also find the angle of twist in a length of 2 metres. Take C = 90 GPa.
[Ans. 80 mm; 2.116]