UNIT 1: DESIGN PHILOSOPHY

INTRODUCTION:
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.

BASIC PROCEDURE OF MACHINE DESIGN:

The basic procedure of machine design consists of a step-by-step approach ----- from given
specifications about the functional requirements of a product, to the complete description in
the form of drawings of the final product.
Market
f config
Survey

Define

Specifications
Product

of

Study Alternative Mechanisms for Product & select proper

mechanism

Prepare general layout of configuration& select joining

methods

Design individual
components

Prepare Assembly & detail drawings & modify drawings after testing
prototype

BASIC REQUIREMENTS OF MACHINE ELEMENTS:

The broad objective of designing a machine element is to ensure that it preserves its
operating capacity during the stipulated service life with minimum manufacturing and
operating costs. In order to achieve this objective, the machine element should satisfy
following basic requirements:

Strength

Rigidity

Wear resistance

Minimum dimensions and weight

Manufacturability

Safety

Conformance to standards

Reliability

Maintainability

Minimum life cycle cost

DESIGN OF MACHINE ELEMENTS:

The design of machine elements is the most important step in the complete procedure of
machine design. In order to ensure the basic requirements of machine elements,
calculations are carried out to find out the dimensions of the machine elements. These
calculations form an integral part of the designing of machine elements.
Specify functions of element

Determine forces acting on

element

Select suitable material for

element

Determine failure mode of element

Determine geometric dimensions of

element

Modify dimensions for assembly &

manufacture

Prepare working model/drawing of

element
Fig.:- Basic procedure of design of machine element

FEASIBILTY STUDY:
Once the problems need has been established and the specifications have been prepared,
accepted and submitted, the feasibility study is done. The purpose of this study is to check
the possibility of success or failure of the proposed project both from technical and
economic standpoint. In this study, various questions are to be answered:1. Is any natural law being defied?
2. Are some of the specifications beyond what is technically available at present?
3. Is there any dependence on scarce materials?
4. Will the cost of the end product be too high?
The person doing the feasibility study will be the engineers with strong design background,
knowledge of engineering sciences, a good knowledge of material usage, knowledge of
production methods and requirements of the sales department. In fact, it is likely that the
men responsible for the feasibility study will be same engineers who will ultimately have
the design responsibility for the overall project.
Quite often, as a result of feasibility study, some changes are to be made in the
specifications and requirements in order to provide a greater likelihood of project success.

DESIGN SYNTHESIS:

The design synthesis is defined as the process of creating or selecting configurations,

materials, shapes and dimensions for a product. It is a decision making process with the
main objective of optimization.

In design analysis, the designer assumes a particular mechanism, a particular

material etc and with the help of this information, he determines the dimension of
the product.

In design synthesis, the designer has to fix the objective. The objective can be cost,
minimum weight or volume, maximum reliability or maximum life. The second step
is mathematical formulation of these objectives and requirements. The final step is
mathematical analysis for optimization and interpretation of the results.

USE OF STANDARDS IN DESIGN:

Standardization is defined as obligatory norms, to which various characteristics of a
product should conform. 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.

A code is defined as a set of specifications for the analysis, design, manufacture,

testing and erection of the product. The purpose of code is to achieve a specified
level of safety.

There are three types of standards----------------1. Company standards used in a particular company or a group of sister concerns.
2. National standards eg.- B.I.S, D.I.N ( Germany)
3. International standards eg. I.S.O
Standardization offers following advantages:1. The reduction in types and dimensions of identical components, makes it possible
to manufacture the standard component on mass scale in a centralized process.
2. Availability of standard components have considerably reduced the manufacturing
facilities required by an individual organisation.
3. Standard parts are easy to replace when worn out due to interchangeability.
4. The application of standard machine element reduces the time and effort needed to
design a new machine.
5. The standards of specifications and testing procedures of machine elements
improve their quality and reliability.

SELECTION OF PREFERRED SIZES:

The size of the product is a general term, which includes different

parameters like power transmitting capacity, load carrying capacity, speed and
dimensions of the component such as height, length and width of the product.
Preferred numbers are used to specify the sizes of the product.
There are two terms namely:1. Basic series ( R5, R10, R20, R40, R80)
2. Derived series

AESTHETIC CONSIDERATIONS IN DESIGN:

Each product has a definite purpose. It has to perform specific functions to the satisfaction
of customer. The contact between the product and the people arises due to the sheer
necessity of the functional requirement.
The external appearance is an important feature, which not gives grace and lustre to the
product but also dominates the sale in market. This is particularly true for consumer
durables like automobiles, household appliances and audio visual equipment.
The growing realization of the need of aesthetic considerations in product design has given
rise to a separate discipline, known as industrial design. The job of an industrial designer
is to create new forms and shapes, which are aesthetically pleasing.
The outward appearance of the product has undergone many changes over the years.
There are five basic forms:1. Step form eg. multi-storeyed buildings
2. Stream/streamline eg. automobile
3. Taper eg. tapered blocks
4. Shear eg. free standing engineering products
5. Sculpture eg. ellipsoids, paraboloids
Selection of proper colour is an important consideration in product aesthetics. The choice
of colour should be compatible with the conventional ideas of the operator.

Colour

Meaning

Red

Danger Hazard Hot

Orange

Possible danger

Yellow

Caution

Green

Safety

Blue

Caution Cold

Grey

Dull

The external appearance of the product is a cumulative effect of a number of factors such
as rigidity and resilience, tolerances and surface finish, motion of individual components,
materials, manufacturing methods and noise.

ERGONOMIC CONSIDERATIONS IN DESIGN:

Ergonomics is defined as the relationship between man and machine and the application
of anatomical, physiological and psychological principles to solve the problems arising
from man machine relationship.
Ergonomics

ergon + nomos

work

Information reception

natural laws

Information display

MAN

MACHINE

Corrective action

Machine controls

Fig.:- Man machine closed loop system

From design considerations, the topics of ergonomic studies are as follows:

Anatomical factors in design of drivers seat

Layout of instrument dials and display panels for accurate perception by the
operators

Design of hand levers and hand wheels

Energy expenditure in hand and foot operations; and

Lighting, noise and climatic conditions in machine environment.