INDUS INSTITUTE OF

TECHNOLOGY & ENGINEERING

DEPARTMENT OF
MECHANICAL ENGINEERING
Name : Keval Patel

Subject Code : 131902

Subject Name : Machine Design and Industrial Drafting

B.E Mechanical Engineering , 3rd Semester

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
 1. Design consideration of Machine Parts

Contents:
1. Definition and understanding of various types of design
2. Morphology of design
3. Design procedure
4. Selection of materials, Properties and I.S. coding of
various materials,
5. Factors of safety
6. Stress Concentration and methods of relieving stresses
7. Types of stresses - tensile, compressive, shear, bending,
bearing, crushing, Eccentric axial stresses, principle
stress Residual stresses.

PREPARED BY: KEVAL PATEL 2

MECHANICAL ENGG. DEPT.
 Definition and Basic Understanding

• WHAT IS MACHINE?
• WHAT IS DESIGN?
• WHAT IS MACHINE DESIGN?

• If everything were known about the problem or

opportunity the task is no longer one of design. Design
therefore deals with the unknown and gives shape to this
unknown future and in this process creates a new vision
of the future that can be adopted through a rigorous
process of evaluation and testing.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
 Various Types of Design
• Adaptive design : This is based on existing design, for
example, standard products or systems adopted for a
new application. Conveyor belts, control system of
machines and mechanisms
• Developmental design : Here we start with an existing
design but finally a modified design is obtained. A new
model of a 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. Examples of this type of design may
include designing a small vehicle for transportation of
men and material on board a ship or in a desert. Some
research activity may be necessary.

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MECHANICAL ENGG. DEPT.
 Types of design based on methods

• Rational design : This is based on determining the

stresses and strains of components and thereby
deciding their dimensions.
• Empirical design : This is based on empirical formulae
which in turn is based on experience and experiments.
For example, when we tighten a nut on a bolt force
exerted is P=284d
• Industrial design : These are based on industrial
considerations and norms viz. market survey, external
look, production facilities, low cost, use of existing
standard products.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
 Morphology of Design

• The morphology of design refers to the study of the

chronological structure of design

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MECHANICAL ENGG. DEPT.
Basic Procedure of Machine Design
Market Survey

Define Specifications of Product

Study Alternative Mechanisms for

Product and select proper
Mechanism

Prepare General Layout of

Configuration

Design Individual Components

Prepare Assembly and Detail

Drawings and Modify Drawings after
Testing Prototype Model

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
 Selection of materials

 Selection of material depends on the following criterion.

• Properties of materials
• Cost of materials
• Availability of materials
• Application

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
PREPARED BY: KEVAL PATEL
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MECHANICAL ENGG. DEPT.
 Properties of materials

• Cast iron-
• It is an alloy of iron, carbon and silicon and it is hard and
brittle. Carbon content may be within 1.7% to 3% and
carbon may be present as free carbon or iron carbide
Fe3C.
• In general the types of cast iron are (a) grey cast iron
and (b) white cast iron (c) malleable cast iron (d)
spheroidal or nodular cast iron (e) austenitic cast iron (f)
abrasion resistant cast iron.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
 Advantages of Cast Iron
• Available in a wide range of mechanical/physical
properties, i.e. tensile strength from 20 KSI to over 200
KSI, hardness from 120 to about 300 Brinell in standard
grades and up to about 600 Brinell in special abrasion
resistant grades
• Good strength to weight ratio
• Typically lower cost than competing materials and
relatively low cost per unit of strength than other
materials
• Lower density and higher thermal conductivity than
steels at comparable tensile strength levels
• Excellent machinability, allowing for high speeds and
feeds and reduced (minimal) energy due to the presence
of free graphite
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MECHANICAL ENGG. DEPT.
• Excellent damping capacity, especially in Gray Irons
• Rapid transition from design to finished product
• Capability of producing highly complex geometries and
section sizes in a wide range of sizes, from ounces to
over 100 tons
• Possibility of casting intricate shapes as well as very thin
to very thick section sizes
• Capability of redesigning and combining two or more
components from other materials into a single casting,
thus reducing assembly cost and time
• Capability of casting with inserts of other materials
• Variety of casting processes for low, medium or high
production

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
Grey cast iron : Carbon here is mainly in the form of
graphite. Inexpensive,
• high compressive strength
• Graphite is an excellent solid lubricant and this makes it
easily machinable but brittle.
• Some examples of this type of cast iron are FG20, FG35
or FG35Si15.
White cast iron : In these cast irons carbon is present in
the form of iron carbide (Fe3C) which is hard and brittle.
• The presence of iron carbide increases hardness and
makes it difficult to machine. Consequently these cast
irons are abrasion resistant.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
Malleable cast iron :
• These are white cast irons rendered malleable by
annealing.
• These are tougher than grey cast iron and they can be
twisted or bent without fracture.
• They have excellent machining properties and are
inexpensive.
• Malleable cast iron are used for making parts where
forging is expensive such as hubs for wagon wheels,
brake supports.
• Depending on the method of processing they may be
designated as black heart BM32, BM30 or white heart
WM42, WM35 etc.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
Spheroidal or nodular graphite cast iron:
• In these cast irons graphite is present in the form of
spheres or nodules.
• They have high tensile strength and good elongation
properties.
• They are designated as, for example, SG50/7, SG80/2
etc where the first number gives the tensile strength in
Mpa and the second number indicates percentage
elongation.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
Austenitic cast iron :
• Depending on the form of graphite present these cast
iron can be classified broadly under two headings:
• Austenitic flake graphite iron designated, for example,
AFGNi16Cu7Cr2
• Austenitic spheroidal or nodular graphite iron designated,
for example,
• ASGNi20Cr2. These are alloy cast irons and they
contain small percentages of silicon, manganese,
sulphur, phosphorus etc. They may be produced by
adding alloying elements viz. nickel, chromium,
molybdenum, copper and manganese in sufficient
quantities. These elements give more strength and
improved properties.
• They are used for making automobile parts such as
cylinders, pistons, piston rings, brake drums etc.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
Abrasion resistant cast iron :
• These are alloy cast iron and the alloying elements
render abrasion resistance.
• A typical designation is ABR33 Ni4 Cr2 which indicates a
tensile strength in kg/mm2 with 4% nickel and 2%
chromium.

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MECHANICAL ENGG. DEPT.
Wrought iron :
• This is a very pure iron where the iron content is of the
order of 99.5%.
• It is produced by re-melting pig iron and some small
amount of silicon, sulphur, or phosphorus may be
present. It is tough, malleable and ductile and can easily
be forged or welded.
• It cannot however take sudden shock.
• Chains, crane hooks, railway couplings and such other
components may be made of this iron.

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MECHANICAL ENGG. DEPT.
Plain carbon steel:
• The properties of plain carbon steel depend mainly on
the carbon percentages and other alloying elements are
not usually present in more than 0.5 to 1% such as 0.5%
Si or 1% Mn etc.
• There is a large variety of plane carbon steel and they
are designated as C01, C14, C45, C70 and so on where
the number indicates the carbon percentage.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
Following categorization of these steels is sometimes made
for convenience:

• Dead mild steel- up to 0.15% C

• Low carbon steel or mild steel- 0.15 to 0.46% C
• Medium carbon steel- 0.45 to 0.8% C.
• High carbon steel- 0.8 to 1.5% C
• Detailed properties of these steels may be found in any
standard handbook but in general higher carbon
percentage indicates higher strength.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
Alloy steel :
• these are steels in which elements other than carbon are
added in sufficient quantities to impart desired
properties, such as wear resistance, corrosion
resistance, electric or magnetic properties.
• Chief alloying elements are
nickel for strength and toughness,
chromium for hardness and strength,
tungsten for hardness at elevated temperature,
vanadium for tensile strength,
manganese for high strength in hot rolled
silicon for high elastic limit,
cobalt for hardness and molybdenum for extra tensile
strength.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
• Some examples of alloy steels are 35Ni1Cr60,
30Ni4Cr1, 40Cr1Mo28, 37Mn2.
• Stainless steel is one such alloy steel that gives good
corrosion resistance.
• A typical designation of a stainless steel is
15Si2Mn2Cr18Ni8 where carbon percentage is 0.15.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
I.S. coding of various Materials

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
 Factors of Safety

• Older definition : FOS is totally empirical number used to

reduce the ultimate strength or the yield strength of a
material so as to obtain a value of design stress which
would prevent the failure of the machine part. It varies
with applicatio and depended on the experience of part
failure for which a clear explanation was not available.
Hence called
--------- Factor of Ignorance -------------
• New Definition : FOS is the amount by which the design
stress is kept below the limit stress.

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
 Factors of Safety

• Example
Ductile Material FOS = yield stress/design stress
Brittle Material FOS = ultimate stress/ design stress
Varying Load FOS = Endurance Limit/Design stress

Moreover for stress cycles other than completely reversed

stress the design will be base on Soderberg or Goodman
criterion

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
Stress Concentration

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
Methods of Relieving Stresses

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
 Types of stresses

• Compressive
• Tensile
• Shear

• Eccentric axial stresses

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.
 Types of stresses

• Bending
• Bearing
• Crushing
• Principle stress

PREPARED BY: KEVAL PATEL

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MECHANICAL ENGG. DEPT.