Machine Design - LESSON 1. INTRODUCTION TO MACHINE DESIGN

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2/16/2021 Machine Design: LESSON 1.

INTRODUCTION TO MACHINE DESIGN

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Machine Design
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MODULE 1. ► LESSON 1. INTRODUCTION TO MACHINE DESIGN

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LESSON 1. INTRODUCTION TO MACHINE DESIGN
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1.1 What is Design?
Current course
Machine Design The word ‘design’ can either be a noun or a verb. As a noun, ‘Design’ can be
Participants referred to an object’s aesthetic appearance as well as its function. For example, ‘a
General beautifully designed dress’ refers to its appeal to our visual perception, and ‘a nicely
MODULE 1. designed car engine that gives very good mileage and performance’ refers to the
LESSON 1. concept of function. As a verb, ‘Design’ is the act of formalizing an idea or concept
INTRODUCTION
TO MACHINE
into concrete information. It includes the processes of conception, invention,
DESIGN visualization, calculation, refinement and specification of details that determine the
LESSON 2. form of a product. Design may be defined as an iterative decision making process to
ENGINEERING formulate a plan by which resources are optimally converted into systems, processes
MATERIALS
or devices in order to solve a specific problem or to fulfill a specific need. It begins
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with a need, a problem, an idea or a concept and ends with concrete information, in
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the form of drawings, computer representation or in any other form, which helps in
MODULE 4.
manufacturing and utilization of a product.
MODULE 5.
MODULE 6.
MODULE 7.
MODULE 8.
1.2 Phases of Design Process
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MODULE 10.
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The design process begins with identification of a need and a decision to do something
about it. After a number of iterations, the process ends with the presentation of the
plans for satisfying the need. Depending on the nature of the design task, several
phases may be repeated before the design is finalized. Complete design process can be
explained with the help of Figure1.1, which shows the phases of design process and
iterations.
1.2.1 Identification of Need

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2/16/2021 Machine Design: LESSON 1. INTRODUCTION TO MACHINE DESIGN

Design process generally starts with the identification of need, a problem or with the
recognition of a potential market for a product, device or process. Recognition of the
need requires a lot of imagination and creativity, because the need is generally not
clear and evident and can be vague. It can be just a feeling of uneasiness or a sensing
that something is wrong. For example, there is a need to do something about the
design of a motor vehicle may be indicated by its low efficiency, lesser maximum
speed or high noise and vibration levels. Then the need statement may say that the
design of the motor vehicle needs an improvement.
1.2.2 Definition of Problem
Need statement is generally brief and doesn’t include the details. The definition of
problem is more specific and includes all the specifications for the object to be
designed, which include the input i.e. resources to be utilized, expected output, cost
limitations, quantity required, expected life and reliability, temperature limitations,
maximum range and expected variations in the variables, dimensional & weight
limitations, manufacturing limitations etc. Anything that limits the designer’s freedom
of choice is a constraint and all the constraints should be clearly defined in the
problem definition.
Background information on all the relevant aspects of the problem should also be
gathered. It includes the study to find out whether this, or a similar problem, has been
solved before. If a ready-made solution is available in the market, it can be used. Or
even if something new is to be done, the study of existing similar technologies,
products, relevant patent literature and technical publications can be very helpful.
1.2.3 Synthsis
Synthesis is the process of concept generation, the purpose of which is to develop as
many ideas as possible to offer potential solutions to the problem defined in previous
phase. Primary need is identified for initial focus and then all feasible design
alternatives are developed. Different proposed alternatives should not be compared
with each other, in this phase, and each alternative should be separately evaluated on
the basis of established criteria.
1.2.4 Analysis and Optimization
After synthesis, different proposed solutions are analyzed to assess their performance
and can be ranked. Alternatives having unsatisfactory performance can either be
revised and improved or discarded. It is always advisable to select two or three design
concepts and develop them instead of selecting presumably the best one only.
Concepts, with potential, are optimized to further increase their performance.
Optimization is the repetitive process of refining a set of criteria, which are often
conflicting, to achieve the best compromise. These competing design concepts can
finally be compared again so that the path leading to the most competitive product can
be chosen. For analysis and optimization, mathematical models are prepared to
simulate the real physical system.
Synthesis, analysis and optimization go hand in hand. Identification of any kind of
deficiency or inadequacy in the proposed solution, in the analysis and optimization
phase, may require synthesis of some new solution and process keeps on repeating
until an adequate and optimum solution is obtained.
1.2.5 Evaluation
In this phase, prototype model of the design is generally made and tested, which is the
final evaluation of the design to make sure that it satisfies the original requirements. In

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2/16/2021 Machine Design: LESSON 1. INTRODUCTION TO MACHINE DESIGN

addition to this, design is evaluated for its reliability, competitiveness, economic


viability, maintenance requirements, profitability and so on.
1.2.6 Presentation
Final phase of the design process is to communicate the design to others. This
presentation can be in the form of drawings, computer models on in any other form
that would help in manufacturing and utilization of the product.
1.3 Machine Design
Machine is a combination of linkages having definite motion and capable of
performing useful work. Machine Design is creation of plans for the machine to
perform the desired functions. Machine design can be defined as creation of right
combination of correctly proportioned moving and stationary components so
constructed and joined as to enable the liberation, transformation and utilization of
energy. Scientific principles, technical knowledge and imagination are used to develop
a machine or mechanical system to perform specific functions with maximum
economy and efficiency. It includes the creation of new better machines or improving
the existing ones. Machine Design requires the knowledge of basic and engineering
sciences such as Physics, Mathematics, Engineering Mechanics, Strength of Materials,
Theory of Machines, Thermodynamics and Heat Transfer, Vibrations, Fluid
Mechanics, Metallurgy, Manufacturing Processes and Engineering Drawing.
In machine design, the designer’s task is to determine the motion, forces and energy
transfer involved so as to determine the sizes, shapes and materials for each element of
the machine. When any component of machine ceases to perform its intended function,
machine element or machine is said to have failed. Generally the machine elements are
designed on the basis of strength and rigidity so that they are able to withstand the
applied load with permissible deformation or stress. In addition to strength and
stiffness, other factors that are considered in design of machine element are weight,
cost, wear, safety, reliability etc. Design work may involve concentrating on one
component at a time, but it is very important to simultaneously consider its relation
with the other components and the product as a whole.
In machine design, as in any other kind of design, no standard procedure or rigid rules
can be specified for the designer, but the following steps are generally followed:
1. Problem to be solved or desired purpose of the machine is completely and clearly
stated.
2. Possible mechanisms that will provide the desired motion or set of motions are
selected.
3. Forces acting on and energy transmitted by each element of the machine are
determined.
4. Best suitable material is selected for each of the machine element.
5. Allowable values of stress and deflection are determined for each machine
element, depending upon its material and functional requirements.
6. Size and shape of each machine element is determined so that it can withstand the
applied loads without failure.
7. Dimensions of the machine elements are modified considering manufacturing
aspects.
8. Assembly and detailed drawings of the machine are made with complete
specification of materials and manufacturing methods.
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2/16/2021 Machine Design: LESSON 1. INTRODUCTION TO MACHINE DESIGN

1.4 Design Considerations


As discussed in the previous article, strength and stiffness are very important factors
that are considered in machine design but there are a number of other considerations
that the designer has to keep in mind while designing any product. Some of the
important factors considered in design are listed below:
1. Functionality
2. Strength
3. Stiffness
4. Wear
5. Corrosion
6. Thermal Properties
7. Surface Finish
8. Lubrication
9. Friction
10. Weight
11. Noise
12. Shape
13. Size
14. Safety
15. Reliability
16. Manufacturability
17. Utility
18. Maintenance
19. Liability
20. Cost
21. Life
22. Styling
23. Control
24. Volume
25. Marketability
26. Remanufacturing

References
1. Design of Machine Elements by VB Bhandari
2. Mechanical Engineering Design by J.E. Shigley
3. Analysis and Design of Machine Elements by V.K. Jadon
4. Machine Design by R.S. Khurmi
5. Mechanical Design by Peter Childs
6. Engineering Design by G.E. Dieter
7. Machine Design by PC Sharma & DK Aggarwal

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