# Machine Design

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# Code(Credit) : DIME0210(2-1-0)

## Course Objectives

• Understanding the design procedure for a product with the factors governing it.
• Understanding the design of various mechanical elements.
• Understanding the different failures of design elements.
• Understanding the application of computer based techniques for design, simulation and analysis of various elements.

## Learning Outcomes

Students will be able to:

• Demonstrate the machine design procedure.
• Use the design data hand book for solving numericals.
• Describe the design and failure of welded joints, riveted joints, shafts, keys, flat belts, springs and clutch.
• Design and analyze the nut and bolt, rivets, shaft, flat belt, springs and clutch using ANSYS software

## Course Syllabus

MODULE I

Introduction: Introduction to Machine Design and Classify it.State the types of loads. Define working stress, yield stress, ultimate stress & factor of safety. State mechanical properties of the material. State the factors governing the design of machine elements. Describe the design procedure.

Design of fastening elements: Design of Screw thread (Nut and Bolt). State types of welded joints. State advantages of welded joints over other joints. Determine the strength of welded joints for eccentric loads. State types of riveted joints. Describe the failure of riveted joints. Determine the strength & efficiency of riveted joints. Design riveted joints for pressure vessels. Solving simple numerical on the above topics.

Practice and Demonstration:

• Demonstration of shaper machine and CNC machine and their working mechanism.
• Demonstration using rubber, plastic pen, springs used in pens and bulb.
• Design and analysis of nut and bolt using ANSYS software.
• Design and analysis of riveted joint using ANSYS software.

MODULE II

Design of shafts and Keys: State function of shafts. State materials for shafts. Design solid & hollow shafts to transmit a given power at given rpm based on a) Strength: (i) Shear stress, (ii) Combined bending & tension; b) Rigidity: (i) Angle of twist, (ii) Deflection, (iii) Modulus of rigidity. State function of keys, types of keys & material of keys. Describe the failure of the sunk key, the effect of the keyway. Design rectangular sunk key considering its failure against shear & crushing. Design rectangular sunk key by using empirical relation for a given diameter of the shaft. Solving simple numerical on the above topics.

Practice and Demonstration:

• Design and analysis of shaft using ANSYS software.

MODULE III

Design of belt drivers and pulleys: State types of belt drives & pulleys. State formula for the length of the open and crossed belt, the ratio of driving and driven side tension, centrifugal tension, the relation between centrifugal tension and tension on the tight side for maximum power transmission. Determine belt thickness and width for given permissible stress for open and crossed belt considering centrifugal tension. Design a cast iron (C.I) pulley using empirical formula only. Solving simple numerical on belt and pulley.

Design a closed coil helical spring and leaf spring: Materials used for helical spring.  Terms used in compression spring. Stress in helical spring of a circular wire. End connection for helical tension spring. Deflection of helical spring of circular wire. Eccentric loading of spring. The surge in spring. Design of leaf spring. Construction of leaf spring. Nipping. Length of leaf spring. Solving simple numerical on the above topics.

Design of friction clutch: Clutch and its types. Friction clutches. Design of single plate and multiple plate clutch. Solving simple numerical on Clutch.

Practice and Demonstration:

• Design and analysis of helical spring using ANSYS software.
• Design and analysis of leaf spring using ANSYS software.
• Design and analysis of leaf spring using ANSYS software.

Learning Resources:

• A textbook of Machine Design by R.S. Khurmi & J.K. Gupta

## Session 1

LECTURE:

Introduction to Machine Design and Classify it.

DEMO:
Demonstration of Shaper machine and CNC machine and their working mechanism

STUDY MATERIALS:
Video: Description of machine design and its classification

## Session 2

LECTURE:

State the types of loads. Define working stress, yield stress, ultimate stress & factor of safety.

DEMO:
Demonstration using rubber, plastic pen and bulb.

STUDY MATERIALS:
Video:Different types of load considered in machine design

Working stress, yield stress, ultimate stress and Factor of Safety

VIdeo: Stress-Strain Diagram

## Session 3

LECTURE:

State mechanical properties of the material.

DEMO:
Demonstration using rubber, plastic pen, springs used in pens and bulb.

STUDY MATERIALS:
Video: Mechanical properties of materials

## Session 4

LECTURE:

State the factors governing the design of machine elements. Describe the design procedure.

STUDY MATERIALS:

## Session 5

LECTURE:

Design of Screw thread (Nut and Bolt) and Solving simple numerical problems.

Use Of design data handbook.

## Session 6

PRACTICE:

Design and analysis of Nut and Bolt using ANSYS Workbench

STUDY MATERIALS:

Video: Design and analysis of Nut and Bolt using ANSYS Workbench

## Session 7

LECTURE:

State types of welded joints. State advantages of welded joints over other joints. Determine the strength of welded joints for eccentric loads.

STUDY MATERIALS:

Video: Types of welding joint

## Session 8

LECTURE:

Solving of numerical problems on Welded joint based upon eccentric loads.

STUDY MATERIALS:
Problem on Eccentrically loaded welded joints

Problem on Eccentrically Loaded Welded Joints

## Session 9

LECTURE:

State types of riveted joints. Describe the failure of riveted joints. Determine the strength & efficiency of riveted joints.

STUDY MATERIALS:
Video: Introduction to riveted joints

Video: Modes of failure and strength of riveted joints

Video:Hot riveting

Video: Hydraulic riveting

## Session 10

LECTURE:

Design riveted joints for pressure vessels. Solving numerical problems on the riveted joint and pressure vessels.

STUDY MATERIALS:

Video: Numericals Design of Double Riveted Butt Joint

Video: Design of Boiler & Pressure Vessel Joints Using Rivets

## Session 11

PRACTICE:
Design and analysis of riveted joint using ANSYS Workbench

STUDY MATERIALS:
Video: Riveted joint structural analysis using ANSYS

## Session 12

LECTURE:

State function of shafts. State materials for shafts. Design solid & hollow shafts to transmit a given power at given rpm based on a) Strength: (i) Shear stress, (ii) Combined bending & tension

## Session 13

LECTURE:

Solving numerical on the design of solid & hollow shafts to transmit a given power at given rpm based on a) Strength: (i) Shear stress, (ii) Combined bending & tension

PRACTICE:

Analysis of shaft using ANSYS Workbench.

STUDY MATERIALS:

Video:Problem on design of shaft based upon twisting and bending

## Session 14

LECTURE:

Design solid & hollow shafts to transmit a given power at given rpm based on

Rigidity: (i) Angle of twist, (ii) Deflection, (iii) Modulus of rigidity

Solving Numerical of shafts based upon Rigidity.

## Session 15

LECTURE:

State function of keys, types of keys & material of keys. Describe the failure of the sunk key, the effect of the keyway.

STUDY MATERIALS:

Video: Explanation of Different Type of Keys

Video: Design of Sunk key

## Session 16

LECTURE:

Numericals on the design of rectangular and square sunk key considering its failure against shear & crushing.

Design rectangular sunk key by using empirical relation for a given diameter of the shaft.

## Session 17

LECTURE:

State types of belt drives & pulleys. State formula for length of open and crossed belt, ratio of driving and driven side tension, centrifugal tension, relation between centrifugal tension and tension on tight side for maximum power transmission.

STUDY MATERIALS:

Video: Belts and Belt-Drives

Video: Velocity Ratio Of Belt Drive

## Session 18

LECTURE:

Determine belt thickness and width for given permissible stress for open and crossed belt considering centrifugal tension.

Solving numerical problems.

STUDY MATERIALS:

Video: Problems on belt drive

## Session 19

PRACTICE:

Design and analysis of belt drive using Solidworks and ANSYS

STUDY MATERIALS:

Video:Design a V belt and pulley assembly with motion analysis in solidworks.

Video: CONVEYOR BELT SIMULATION IN ANSYS

## Session 20

LECTURE:

Design a cast iron (C.I) pulley using empirical formula only.

Solving numerical problems on cast iron pulley

## Session 21

LECTURE:

Materials used for helical spring. Terms used in compression spring. Stress in helical spring of a circular wire. End connection for helical tension spring. Deflection of helical spring of circular wire.

STUDY MATERIALS:
Design of helical springs

Spring design

## Session 22

LECTURE:

Numerical problems on helical springs.

STUDY MATERIALS:
Spring design and problems

## Session 23

PRACTICE:

Design and analysis of helical spring using ANSYS Workbench.

STUDY MATERIALS:

Video: Ansys Workbench Spring Design

Video: Ansys Workbench Spring Structural Analsys

## Session 24

LECTURE:

Design of leaf spring. Construction of leaf spring. Nipping. Length of leaf spring.

STUDY MATERIALS:

Leaf spring

## Session 25

LECTURE:

solving numerical problems on Leaf spring.

PRACTICE:

Design and analysis of leaf spring using ANSYS Workbench

STUDY MATERIALS:

Video: Ansys LEAF SPRING analysis Part 1

Video: Ansys LEAF SPRING analysis Part 2

## Session 26

LECTURE:

Clutch and its types. Friction clutches. Design of Single plate and multiple plate clutch.

STUDY MATERIALS:

Video: Working of clutch

## Session 27

LECTURE:

Solving numerical problems on clutch.

PRACTICE:

Structural analysis of clutch using ANSYS Worbench

STUDY MATERIALS: