INTRODUCTION OF

DESIGN OF
MACHINE ELEMENT
What is design????
• Design is to formulate a plan satisfy a particular need and
to create something with physical reality.

• Realization of a concept or idea into a configuration.

• Design is the creation of a plan or convention for the construction

of an object, system or measurable human interaction .
What is Machine???
• Machine is defined as a combination of resisting bodies with successfully constrained relative
motions which is used transform other forms of energy into mechanical energy or transmit
and modify available energy to do some useful work.

• An apparatus using mechanical power and having several parts, each with a definite function
and together performing a particular task.

• Semi or fully automated device that magnifies human physical and/or mental
capabilities in performing one or more operations.
What is Machine Design???
• Machine is a combination of several machine elements arranged to work
together as a whole to accomplish specific purpose.
• Machine Design involves designing the elements and arranging them
optimally to obtain some useful work.
• Machine design is the process of engineering design. A machine is made up
of mechanisms that work together to satisfy the requirements of what the
machine needs to accomplish.
Classification of Machine Design

Types of design

Adaptive New
Design Development Design
design
Types of Machine Design
1) Adaptive Design:- The designer’s work is concerned with adaptation of existing
design. The designer only makes minor alternation or modification in the existing
designs of the product.

2) Development Design:- This type of design needs considerable scientific training and
design ability in order to modify the existing design into a new idea by adopting a
new material or different method of manufacture. The designer starts from the
existing design, but final product may differ quite markedly from the original
product.

3) New Design:- This type of design needs lots of research,

technical
ability and creative thinking.
Classification of Machine Design

Types of design
based on method

Rational Industrial
Design Empirical Design
Design
Types of Design based on method
1) Rational Design:- Based on determining the stresses and strains of
components and thereby deciding their dimensions. This type of design
depends upon mathematical formulae of principal of mechanics.

2) Empirical Design:- This type of design depends upon empirical formulae

based on the practice and past experience .
 Types of Design based on method

 1) Industrial Design:- This type of design depends upon the

production aspects to manufacture any machine component in
the industry. Based on industrial considerations and norms viz.
market survey, external look, production facilities, low cost, use
of existing standard products
 Factors to be considered in
Machine Design
 What device or mechanism to be used???

To decide the relative arrangement of the constituent elements.

 Material
 Forces on the elements
 Size
 Shape and space requirements
 Weight of the product
 Factors to be considered in
Machine Design
 The method of manufacturing the components and their assembly.
 How will it operate.
 Reliability and safety aspects.
 Inspectibilty
 Maintenance
 Cost and aesthetics of the designed product.
General procedure in Machine
Design
Need or Aim Synthesis (Mechanisms) Analysis of forces

Design of Elements Material Selection

Modification Detailed Drawing

Production
Standardization
• Standardization is defined as obligatory (or compulsory) norms, to which
various characteristics of a product should comply (or agree) with standard.
• The characteristics include materials, dimensions and shape of the
component, method of testing and method of marking, packing and storing
of the product.
• A standard is defined as a set of specifications for parts, materials or
processes. The objective of, a standard is to reduce the variety and limit the
number of items to a reasonable level.
Standardization
• On the other hand, a code is defined as a set of specifications for the analysis,
design, manufacture, testing and erection of the product. The purpose of a
code is to achieve a specified level of
safety.
• There are three types of standards used in design :-
 Company Standards: They are used in a particular company or a group
of sister concerns.
Standardization
 National standards:
– India - BIS (Bureau of Indian Standards),
– Germany - DIN (Deutsches Institut für Normung),
– USA - AISI (American Iron and Steel Institute) or SAE (Society of Automotive
Engineers),
– UK - BS (British Standards)

 International standards: These are prepared by the International Standards

Organization (ISO).
Standards are used in mechanical
engineering design
 Standards for Materials, their chemical compositions, Mechanical properties
and Heat Treatment:
For example, Indian standard IS 210 specifies seven grades of grey
cast iron
designated as FG 150, FG 200, FG 220, FG 260, FG 300, FG 350 and FG 400. The
number indicates ultimate tensile strength in N/mm2.
 Standards for Shapes and dimensions of commonly used Machine Elements:
The machine elements include bolts, screws and nuts, rivets, belts and chains, ball
and roller bearings, wire ropes, keys and splines, etc

For example, IS 2494 (Part 1) specifies dimensions and shape of the cross- section of endless V-belts
for power transmission.
The dimensions of the trapezoidal cross-section of the belt, viz. width, height and
included angle are specified in this standard
Standards are used in mechanical
engineering design
 Standards for Fits, Tolerances and Surface Finish of Component:
For example, selection of the type of fit for different applications is illustrated in IS 2709 on
'Guide for selection of fits'.
The tolerances or upper and lower limits for various sizes of holes and shafts are
specified in IS 919 on 'Recommendations for limits and fits for engineering'.

IS 10719 explains method for indicating surface texture on technical drawings.

 Standards for Testing of Products:
These standards, sometimes called 'codes', give procedures to test the products
such as pressure vessel, boiler, crane and wire rope, where safety of the operator is an
important consideration.
For example, IS 807 is a code of practice for design, manufacture, erection and testing of
cranes and hoists.
Benefits of Standardization
 Reductions in types and dimensions of identical components (inventory control).
 Reduction in manufacturing facilities.
 Easy to replace (Interchangeability).
No need to design or test the elements.
 Improves quality and reliability.
 Improves reputation of the company which manufactures standard
components.
 Sometimes it ensures the safety.
 It results in overall cost reduction.
Preferred Numbers
 With the acceptance of standardization, there is a need to keep the standard sizes or
dimensions of any component or product in discrete steps.
 The sizes should be spread over the wide range, at the same time these
should be spaced properly.

 For example, if shaft diameters are to be standardized between 10 mm and 25 mm, then sizes
should be like : 10 mm, 12.5 mm, 16 mm, 20 mm, 25 mm and not like : 10 mm, 11 mm, 13
mm, 18 mm, 25 mm.
 This led to the use of geometric series known as series of preferred numbers
or preferred series.

 Preferred series are series of numbers obtained by geometric

progression and rounded off.
Preferred Numbers
• There are five basic series with step ratios of:

5 80
10 , 1 0 10 , 2 0 10 , 4 0 10 & 10

• These ratios are approximately equal to 1.58, 1.26, 1.12, 1.06 and 1.03.

• The five basic series of preferred numbers (known as preferred

series) are designated as: R5, R10, R20, R40, and R80.

• The examples of preferred number series are: standard shaft

diameters, power rating of coupling, center distances of standard gear boxes, etc.
Advantages Preferred Numbers
• The difference in two successive terms has a fixed percentage.

• It provides small steps for small quantities and large steps

for large quantities.

• The product range is covered with minimum number

of sizes without restricting the choice of the
customers.
Advantages Preferred Numbers
• The difference in two successive terms has a fixed percentage.

• It provides small steps for small quantities and large steps

for large quantities.

• The product range is covered with minimum number

of sizes without restricting the choice of the
customers.
Aesthetic Considerations
• In a present days of buyer's market, with a number of products available in the
market are having most of the parameters identical, the appearance of product is often a
major factor in attracting the customer.
• This is particularly true for consumer durables like: automobiles, domestic refrigerators,
television sets, etc.

• Aesthetics is defined as a set of principles of appreciation of beauty. It deals with the

appearance of the product.
• Appearance is an outward expression of quality of the product and is the first
communication of the product with the user.

• For any product, there exists a relationship between the functional requirement and the appearance of
a product.
 Aesthetic Considerations
• The aesthetic quality contributes to the performance of the product, though the extent of
contribution varies from the product to product.

• The following guidelines may be used in aesthetic design (design for

appearance):

• The appearance should contribute to the performance of the product.

For example, the aerodynamic shape of the car will have a lesser air
resistance, resulting in the lesser fuel consumption.

• The appearance should reflect the function of the product.

For example, the aerodynamic shape of the car indicates the speed.

• The appearance should reflect the quality of the product.

For example, the robust and heavy appearance of the hydraulic press reflects its strength and
rigidity
 Aesthetic Considerations
• The appearance should not be at too much of extra cost unless it is a prime requirement.

• The appearance should be suitable to the environment in which the product is used.

• The growing importance of the aesthetic considerations in product design has given rise to a
separate disciple known as industrial design.
• The job of an industrial designer is to create new shapes and forms for the
product which are aesthetically appealing

– Form (Shape)
There are five basic forms of the products, namely, step, taper, shear, streamline and sculpture
 Aesthetic Considerations
 Step form:

The step form is a stepped structure having vertical accent It is similar

to the shape of a multistorey building.

 Taper form

The taper form consists of tapered blocks or tapered cylinders.

 Shear form

The shear form has a square outlook.

 Streamline form

The streamline form has a streamlined shape having a smooth flow as seen in
automobile and
aeroplane structures

 Sculpture form
Aesthetic Considerations

The sculpture and stream forms are suitable for mobile products like vehicles, while step
and shear forms are suitable for stationary products
Aesthetic Considerations
• Colour
 Colour is one of the major contributors to the aesthetic appeal of the product.
 Many colours are linked with different moods and conditions.
 The selection of the colour should be compatible with the conventions.
 Morgan has suggested the colour code given in the following Table.
Colour Meaning
Red Danger, Hazard, Hot
Orange Possible Danger
Yellow Caution
Green Safety
Blue Caution-Cold
Grey Dull
Aesthetic Considerations
• Material and Surface Finish
 The material and surface finish of the product contribute
significantly to the appearance.

 The material like, stainless steel gives better appearance than the cast irons, plain carbon
steels or low alloy steels.

 The brass or bronze give richness to the appearance of the product.

 The products with better surface finish are always aesthetically pleasing.

 The surface coating processes like: spray painting, anodizing,

electroplating,
etc. greatly enhances the aesthetic appeal of the product.
 Ergonomic Considerations
• Ergonomics is defined as the scientific study of the man-machine-working environment
relationship and the application of anatomical, physiological and psychological
principles to solve the problems arising from this relationship
• The word ergonomic is formed from two Greek word: ergo means work and
nomic mean natural laws.

• The final objective of the ergonomics is to make the machine fit for user rather than to make
the user adapt himself or herself to the machine.
• It aims at decreasing the physical and mental stresses to the user.

• Psychology - Experimental psychologists who study people at work to provide data on such
things as: Human sensory capacities, psychomotor performance, Human decision making,
Human error rates, Selection tests and procedures, Learning and training.
 Ergonomic Considerations
• Anthropometry - An applied branch of anthropology concerned with the measurement of
the physical features of people. Measures how tall we are, how far we can reach, how
wide our hips are, how our joints flex, and how our bodies move.

• Applied Physiology - Concerns the vital processes such as cardiac function, respiration,
oxygen consumption, and electromyography activity, and the responses of these vital
processes to work, stress, and environmental influences.
Ergonomic Considerations

Man-Machine Closed Loop System

Ergonomic Considerations
• This man-machine closed loop system in influenced by the working environmental factors such
as: lighting, noise, temperature, humidity, air circulation, etc.

• Ergonomic Considerations in Design of Displays

• Ergonomic Considerations in Design of Controls

• Working Environment.

• Lighting

• Noise

• Temperature

• Humidity and air circulation