In-Sem: 30 Marks

Theory – 4hr/week
Practical – 2hr/week End-Sem: 70 Marks
TW: 50 Marks
• Unit I
– Design of Simple Machine Elements (10 Hrs)

• Unit II
– Design of Shafts, Keys and Couplings (8Hrs)

Prof A B Karpe
• Unit III
– Design for Fluctuating Load (8 Hrs.)

• Unit IV
– Power Screws (6 Hrs)
• Unit V
– Threaded joints and Welded joints (10 Hrs)

• Unit VI
– Mechanical Springs (6 Hrs)
 Machine Design
• Machine design is defined as the use of scientific
principles, technical information and imagination
in the description of a machine or a mechanical
system to perform specific functions with
maximum economy and efficiency.
Design cycle
General Design procedure
 Design considerations
• Strength:
• Rigidity/stiffness:
• Wear Resistance:
• Manufacturability:
• Safety:
• Conformance to Standards:
• Reliability:
• Maintainability:
• Assembly :
• Minimum: Life-cycle Cost
 Standards and codes
• Standardization is defined as obligatory norms, to which various
characteristics of a product should conform.
– materials,
– dimensions and shape of the component,
– method of testing
– method of marking,
– packing and storing of the product.

Types
1. Company standards
2. National standards- These are the IS (Bureau of Indian Standards),
DIN (German), AISI or SAE (USA) or BS (UK) standards.
3. International standards- International Standards Organization
(ISO).
 Use of preferred series
• Charles Renard first introduced preferred numbers in the 19th
century.
• The system is based on the use of geometric progression to
develop a set of numbers.

• R5, R10, R20, R40 and R80 series, which increase in steps of
58%, 26%, 12%, 6%, and 3%, respectively.
 Basic Series

Derived Series
Factor of safety
factor of safety depends upon
the following factors:
•Effect of Failure
•Type of load
•Degree of accuracy in force analysis
•Material of Component
•Cost of Component
•Testing of machine element
•Service Conditions
•Quality of manufacturing
 Service factor
• service factor (SF) Overload capacity built into a
component, device, engine, motor, etc., as a safety factor.
It is expressed usually a number greater than one: a SF of
1.15 means the item can take 15 percent more load than its
rated capacity without breakdown.
 Design of Knuckle joint
• Application-
– Joints between the tie
bars in roof trusses.
– Joints between the links
of a suspension bridge.
– Joints in valve mechanism
of a reciprocating engine.
– Fulcrum for the levers.
– Joints between the links
of a bicycle chain.
• Rod-
– Tensile Failure of Rods
• Eye
– Tensile Failure of Eye
– Shear Failure of Eye
– Crushing Failure of Eye
• Socket
– Tensile failure of Fork
– Shear failure of Fork
– Crushing failure of Fork
• Pin
– Shear failure of Pin
– Bending Failure of Pin
Tensile Failure of Rods
Tensile Failure of Eye
Shear Failure of Eye
 Crushing Failure of Eye
or
Crushing Failure of Pin in Eye
Tensile failure of Fork
Shear failure of Fork
 Crushing failure of Fork
or
Crushing Failure of Pin in Fork
Shear failure of Pin
Bending Failure of Pin
Design procedure for knuckle joint
 Design of cotter joint
• Application-
– Joint between the piston rod and
the crosshead of a steam engine
– Joint between the slide spindle
and the fork of the valve
mechanism
– Joint between the piston rod and
the tail or pump rod
– Foundation bolt
• Rod-
– Tensile Failure of Rods
• Spigot
– Tensile Failure of Spigot
– Shear Failure of Spigot End
– Crushing Failure of Spigot End
• Socket
– Tensile failure of Socket
– Shear failure of socket
– Crushing failure of socket
• Cotter
– Shear failure of cotter
– Bending Failure of cotter
Tensile Failure of Rods
Tensile Failure of Spigot
Shear Failure of Spigot End
Crushing Failure of Spigot End
Tensile failure of Socket
Shear failure of Socket
Crushing failure of socket
Shear failure of cotter
Bending failure of cotter
Design procedure for cotter joint
 Levers
• A lever is defined as a mechanical device in the form of a rigid bar pivoted about
the fulcrum to multiply or transfer the force.
 overhead valves of internal combustion engine,
bell crank levers in railway signal mechanisms and
levers of hand pumps

lever-loaded
safety valves
mounted on the
boilers

picking fork
 DESIGN OF LEVERS
• Force analysis