MODUL

E1:
INTRODUCTI
ONTOMACHI
NEDESI
GN

Abs
trac
tion:

1
.1Def
ini
ti
on:

Thes ubj
ec tMac hi
neDes i
gni st hecreationofnew andbet termac hinesandi mpr ovi
ng
theex i
st
ingones .Aneworbet termac hineisonewhi chismor eec onomi c
ali
nt heover al
l
costofpr oducti
onandoper ati
on.Thepr ocessofdes ignisal ongandt imec onsuming
one.Fr om t hestudyofex i
sti
ngi deas,anew i deahast obec onceived.Thei deai sthen
studiedk eepinginmi ndi t
sc ommer cial s
uccessandgi venshapeandf or
mi nt hef orm of
drawi ngs.Inthepr eparati
onoft hesedr awings,caremus tbet akenoft heavai l
abil
it
yof
resour c
esinmoney, inmenandi nmat er
ial
srequiredforthesuc c
es s
f ul c
omplet ionofthe
new i deai ntoanac tualreali
ty.Indes i
gni
ngamac hinecomponent ,itisnec essaryt o
haveagoodk nowledgeofmanys ubjectssuchasMat hemat i
cs,Engi neeri
ngMec hani
c s
,
StrengthofMat eri
als,TheoryofMac hines,WorkshopPr oces
sesandEngi neer
ingDr awing.

1
.2Cl
ass
if
icat
ionofMac
hineDes
ign

Themac
hinedes
ignmaybec
las
sif
iedasf
oll
ows:

1.
Adaptivedesi
gn.Inmos tcases,thedes i
gner
’
swor kisc onc
ernedwi thadaptat
ionof
exi
sti
ngdes i
gns
.Thistypeofdes i
gnneedsnos peci
alk nowledgeors ki
l
landc anbe
att
emptedbydes igner
sofor dinar
yt echni
caltr
aini
ng.Thedes igneronl
ymak esminor
al
ternat
ionormodi
f i
cat
ioni
nt heexist
ingdesi
gnsoftheproduct.

2.Developmentdes ign.Thi
stypeofdes ignneedsc onsi
derabl
es ci
ent
ifi
ctrai
ningand
desi
gnabi li
tyinordertomodifyt
heex i
st
ingdesi
gnsi nt
oanewi deabyadopt i
nganew
mat er
ialordif
fer
entmet hodofmanufact
ur e.
Int
hiscase,t
houghthedesignerst
artsfr
om
theex i
sti
ngdes i
gn,butt hefi
nalproductmaydi ff
erquitemar kedl
yfrom theor i
gi
nal
product.

3.New desi
gn.Thi
stypeofdesignneedsl
otofres
earch,t
echni
calabi
li
tyandcr
eat
ive
thi
nki
ng.Onl
ythosedesi
gner
swhohavepersonal
quali
ti
esofasuf
fic
ient
lyhi
ghor
derc
an
takeuptheworkofanewdes i
gn.

Thedesi
gns,dependi
ngupont hemet hodsused,maybec l
assi
fi
edasfoll
ows:( a)
Rat
ional
desi
gn.Thi
stypeofdes
igndependsuponmathemat
ic
alfor
mulaeofpri
nci
pl
eof
mechani
cs.

(b)Empir
ic
aldes
ign.Thi
stypeofdes
igndependsuponempi
ri
calf
ormul
aebas
edont
he
pract
ic
eandpastexperi
ence.

(
c)I
ndus
tri
aldes
ign.Thi
stypeofdes
ign dependsupon t
hepr
oduc
ti
on as
pec
tst
o
manuf
act
ureanymac
hinec
omponenti
nthei
ndus
try.

(
d)Opti
mum design.Iti
sthebestdesi
gnforthegivenobjec
ti
vef unc
ti
onundert
he
s
peci
fi
edcons
trai
nts.
Itmaybeachi
evedbymini
mis
ingtheundesi
rabl
eeff
ect
s.

(
e)Sys
temdes
ign.
Iti
sthedes
ignofanyc
ompl
exmec
hani
cal
sys
teml
i
keamot
orc
ar.

(
f)El
ementdesi
gn.Iti
sthedesi
gnofanyel
ementoft
hemec
hani
cals
yst
em l
i
kepi
st
on,
c
ranks
haft
,connec
ti
ngrod,et
c.

(
g)Comput
erai deddesi
gn.Thi
stypeofdesigndependsupontheus eofcomput
er
s
yst
emstoass
istinthec
reat
ion,
modif
ic
ati
on,
analys
isandopt
imi
zat
ionofades
ign.

1
.3Gener
alCons
ider
ati
onsi
nMac
hineDes
ign

Fol
l
owi
ngar
ethegener
alc
ons
ider
ati
onsi
ndes
igni
ngamac
hinec
omponent
:

1.
Typeofloadandst
res
sesc
ausedbytheload.Theload,
onamac hi
nec
omponent
,may
acti
nseveral
waysduetowhi
chthei
nter
nalstr
essesaresetup.

2.
Motionoft hepartsorki
nemati
csofthemac hine.Thes
ucc
ess
fuloper
ati
onofany
machi
nedependsl ar
gel
yuponthesi
mplestar
rangementoft
hepar
tswhichwil
lgi
vet
he
moti
onrequi
red.Themoti
onofthepar
tsmaybe:

(
a)Rec
ti
li
nearmot
ionwhi
chi
ncl
udesuni
di
rec
ti
onal
andr
eci
proc
ati
ngmot
ions
.

(
b)Cur
vil
i
nearmot
ionwhi
chi
ncl
udesr
otar
y,os
cil
l
ator
yands
impl
ehar
moni
c.

(
c)Cons
tantvel
oci
ty.

(
d)Cons
tantorvar
iabl
eac
cel
erat
ion.

3.Sel
ecti
onofmat er
ial
s.I
tisessent
ial
thatadesignershouldhaveat horoughknowl edge
ofthepropert
iesoft hemat eri
al
sandt hei
rbehavi
ourunderwor kingcondit
ions.Someof
theimportantc haracter
is
ti
c sofmat eri
alsar
e:s t
rength,durabil
i
ty,fl
exi
bil
it
y,wei ght,
resi
st
ancet oheatandc orrosi
on,abil
it
yt ocast,weldedorhar dened,mac hinabi
li
ty,
elec
tri
calc
onduc ti
vit
y,etc.

4.Form ands i
zeoftheparts.Thef or
m ands izearebas edonj udgement.Thes mall
est
pract
icablecr
oss-s
ecti
onmaybeus ed,butitmaybec heckedthatthest
ressesinducedin
thedes i
gnedc r
oss-
sect
ionarereasonablys af
e.Inordert odesi
gnanymac hinepartfor
form ands i
ze,i
tisnecess
arytok now thef or
ceswhi cht hepartmustsustain.I
tisalso
i
mpor tanttoanti
ci
pateanysuddenlyappliedorimpac tloadwhichmayc ausef ai
lur
e.

5.Fri
cti
onalresi
stanceandl ubri
cati
on.Thereisal
waysal ossofpowerduetofri
ct
ional
resi
st
anceandi ts houldbenot edt hatthefri
ct
ionofs tarti
ngishi
gherthanthatof
runni
ngf r
icti
on.Itis,ther
efor
e,essenti
althatac ar
efulattenti
onmustbegiventothe
mat t
erofl ubri
cati
onofal lsurf
aceswhic hmovei nc ontactwit
hothers
,whetherin
rotat
ing,
sli
ding,orroll
i
ngbearings.
6.Conveni entand ec onomi calfeatur es.In desi
gning,theoper at
ing featuresoft he
mac hines houldbec areful
lystudied.Thes tar
ti
ng,control
l
ingands t
oppingl ever
ss hould
bel ocatedont hebas i
sofc onveni enthandl i
ng.Theadj ustmentf orwearmus tbe
provided empl oying the varioust ak eup devicesand ar ranging them s ot hatt he
ali
gnmentofpar t
sispr eser
ved.I fpar tsar etobec hangedf ordiff
erentpr oduc t
sor
repl
ac edonac countofwearorbr eak age,easyac cessshouldbepr ovidedandt he
neces si
tyofr emovingot herpar t
st oac compli
shthisshouldbeavoi dedi fpos s
ible.The
economi caloper ati
onofamac hinewhi c
hi stobeus edforpr oduction,orf ort he
processingofmat eri
alshouldbes t
udi ed,inordertolearnwhet herithast hemax imum
capac i
tycons i
stentwiththepr oducti
onofgoodwor k.

7.Useofs tandardparts
.Theuseofs t
andardpar t
siscl
osel
yrel
at edtocost,
becausethe
costofstandardors t
ockpart
sisonl
yaf ract
ionofthecostofsi
milarpart
smadet oorder.
Thes t
andar dorstockpart
sshouldbeus edwheneverpos s
ibl
e;par tsf
orwhichpatter
ns
arealreadyi nexi
stencesuchasgear s,pul
leysandbear i
ngsandpar tswhichmaybe
sel
ectedfromr egul
arshopstocksuchass cr
ews,nutsandpins.
Bol t
sands t
udsshoul
dbe
asfew aspos s
ibl
et oavoi
dthedelayc ausedbyc hangi
ngdr i
l
ls,reamersandtapsand
als
ot odecreasethenumberofwr enchesrequir
ed.

8.Saf et
yofoperation. Somemac hinesaredangeroustooperat e,espec
ial
l
ythosewhich
ares peededupt oins urepr oducti
onatamax i
mum r at
e.Therefore,anymovingpartofa
mac hinewhichiswi thint hez oneofawor k
erisconsi
deredanac ci
denthazardandmay
bet hec aus
eofani nj ury.Itis
,ther
ef or
e,neces
sar
yt hatadesigners houl
dalwaysprovi
de
safetydev i
cesfort hes afetyoft heoperator
.Thes afetyappliancesshoul
dinnoway
i
nterferewithoperationoft hemac hine.

9.Works
hopf aci
l
it
ies
.Ades i
gnengineershouldbefamil
iarwitht helimi
tat
ionsofhi s
empl
oyer’
swor k
shop,inordertoavoi
dt henecess
it
yofhavingwor kdoneinsomeot her
work
shop.I
tissometimesnec es
sar
yt oplanandsuper
vis
et hewor k
s hopoper
ationsand
todr
aftmethodsforcast
ing,handl
i
ngandmac hi
ni
ngspeci
al par
ts.

10.Numberofmac hi nestobemanuf ac t
ured.Thenumberofar ti
cl
esormac hi
nest obe
manuf ac
tur
edaf fec tsthedes i
gninanumberofways .Theengineeri
ngands hopc osts
whicharecall
edf i
x edc hargesoroverheadex pens
esar edist
ri
butedovert henumberof
arti
cl
estobemanuf actur
ed.Ifonl
yaf ewar t
icl
esaret obemade, ext
raexpens esarenot
j
ustif
iedunl
essthemac hi
nei slar
georofs omes pecialdesign.Anorderc all
i
ngf orsmall
numberofthepr oduc twil
lnotpermitanyundueex pens eintheworkshoppr ocesses,
so
thatthedesi
gners houl dr
estri
cthi
sspecif
icat
iontostandar dpartsasmuc haspos si
ble.

11
.Cos tofconst
ructi
on.Thec ostofc onstruct
ionofanar ti
clei
st hemos timpor t
ant
consi
derati
oni
nvolvedindesi
gn. I
nsomec ases,iti
squitepossi
blet
hatt hehighcos tofan
art
icl
emayi mmediatel
ybaritfrom fur
therconsiderati
ons.I
fanarti
cl
ehasbeeni nvented
andt est
sofhandmades ampleshaves hownt hatithasc ommercialvalue,i
ti sthen
possi
bletojust
if
yt heexpendi
tureofac ons i
derablesum ofmoneyi nt hedesignand
devel
opmentofaut omati
cmac hi
nestopr oducet hearti
cl
e,espec
ial
lyifitcanbes ol
din
l
argenumbers.
Theaim ofdes
ignengi
neerunderal
lcondi
ti
ons
,shoul
dbet
oreduc
ethe
manufac
tur
ingcos
ttothemini
mum.

1
2.Assembli
ng.Everymac hi
neors t
ructur
emus tbeas s
embl edasauni tbefor
eitcan
f
unct
ion.Largeunitsmustoft
enbeas sembledi ntheshop,testedandthentakentobe
t
rans
portedt othei
rpl
aceofs ervi
ce.Thefinallocati
onofanymac hi
neisimport
antand
t
hedes i
gnengineermustanti
cipat
et heexactlocati
onandt helocalf
aci
l
it
iesf
orerec
ti
on.

Note: Whent her

earenumberofc omponentsint
hemarkethavi
ngthesamequali
ti
esof
eff
ic
iency,durabi
l
it
yandc ost,thenthecustomerwil
lnat
ural
lyat
trac
ttowardsthemost
appeali
ngpr oduct
.Theaes theti
cander gonomicsareveryimport
antfeatur
eswhich
gi
vesgr aceandlust
ret
opr oductanddomi natest
hemarket
.
1
.5SI
Uni
ts(
I
nter
nat
ional
Sys
temofUni
ts
)