Books:

1. 2. 3. 4. 5. 6. 7.

Shigleys Mechanical Engineering Design (In SI Units) (TMH) Machine Design An Integrated Approach Robert L. Norton (Pearson Education) Design of Machine Elements M. F. Spotts (Pearson Education) Design of Machine Elements V B Bhandari (TMH) A Textbook of Machine Design Khurmi & Gupta (S. Chand) Machine Design DataBook K. Lingaiah (TMH) Machine Drawing N D Bhatt (Charotar Publication)

Design of Machine Elements + Machine Design Practice

INTRODUCTION
Creation of new and better machines/machine elements and improving the existing one. (Practice + Experience) Efficient Economical Overall cost of production & operation Knowledge:
Mathematics, Engg. Mechanics, Mechanics of Solids, Theory of Machines, Workshop Processes, Engg. Drawing. (AutoCAD, SolidWorks, UG, ProE, ANSYS, NASTRAN, ABAQUS, LS-DYNA, CFD related softwares), CAD, CAM, CAE, Metrology etc.

Classification:
1. Adaptive Design 2. Development design 3. New Design

General Considerations:
1. Load type 2. Stresses developed 3. Motion of parts 4. Material Selection 5. Parts size 6. Convenient & economical features 7. Use of standard parts 8. Safety features 9. Workshop facility 10. No. of machines to be manufactured 11. Cost of production 12. Plant facility for assembling 13. Marketability 14. Remanufacturing/resource recovery

Design Tools & Resources:

1. Conventional Drawing (Orthographic projections, Isometric views etc.) 2. Computational Tools (CAD, CAE) 3. Acquiring Technical Information (Library, Government sources, Professional societies, Commercial vendors, Internet)

Standards & Codes: AGMA, ASTM, ASME, BSI, BIS, IBR,

AWS etc.

Economics Dimensions & Tolerances: Limits, Fits, Tolerances,

Allowances, Clearances etc.

General Procedure:
1. Recognition of need 2. Synthesis (Mechanism) 3. Force Analysis 4. Material selection 5. Design of elements 6. Modification 7. Detailed drawing 8. Production

Engineering Materials & Properties

Mechanical Properties (Metals):
1. Strength 2. Stiffness 3. Elasticity 4. Plasticity 5. Ductility 6. Brittleness 7. Malleability 8. Toughness 9. Machinability 10.Resilience 11.Creep 12.Fatigue 13.Hardness

Materials Manufacturing Processes

RIVETED JOINTS
Classification of joints: 1. Permanent cannot be disassembled without destroying the connecting parts. Examples: soldered, brazed, welded and riveted joints. 2. Temporary disassembled without destroying the connecting components. Examples: keys, cotters, pins, flange couplings etc. Riveted Joints: Structural works, ship building, bridges, tanks, boiler shells etc.

Methods of Riveting: 1. Cold riveting structural joints (upto 12 mm) 2. Hot riveting making leak proof joints. (large dia) eg. boiler Materials: Tough and Ductile Steel (Low Carbon), brass, aluminium, copper etc. When strength and fluid tight joint is the main consideration STEEL. Manufactured according to standards: 1. IS: 1148-1982 (Reaffirmed 1992) specification for hot rolled rivet bars (upto 40 mm Dia) for structural purposes. 2. IS: 1148-1982 (Reaffirmed 1992) specification for high tensile steel rivet bars for structural purposes. 3. IS: 2100-1970 IS: 1148-1982 (Reaffirmed 1992) specification for steel rivets and stay bars for boilers. Manufacture: Cold heading or by hot forging.

Types of Rivet Heads:

IS: 2155 1982 (Reaffirmed 1996), general purpose, Dia < 12 mm.

Snap heads structural work & machine riveting. Counter sunk heads ship building since flush surface necessary. Conical head hand hammering. Pan heads max strength, but these are difficult to shape

Types of Riveted Joints:

1. Lap joint 2. Butt joint

Caulking and Fullering:

Failures of a Riveted Joint:

1. Tearing of the Plate at an edge:

m = 1.5 d

2. Tearing of the Plate across a row of rivets:

3. Shearing of the rivets

4. Crushing of the plate or rivets:

Strength of the Riveted Joint:

Efficiency of a Riveted Joint:

Lozenge Joint (Structural Use):

- Roof, bridge work, girders etc.

1. Diameter of rivet hole:

Unwins empirical relation

2. Number of rivets:

3. From the number of rivets, the number of rows and the number of rivets in each row is decided.

4. Thickness of butt strap:

5. Efficiency of the joint:

6. Pitch of the rivets = 3 d + 5

7. Marginal Pitch (m) = 1.5 d 8. Distance between the rows of rivets = 2.5 d to 3d

Eccentrically Loaded Riveted Joint:

Assumption: 1. Secondary shear load is proportional to the radial distance of the rivet under consideration from the c.g. of the rivet system. 2. Direction of the secondary shear load is perpendicular to the line joining the center of the rivet to the c.g. of the rivet system.

Design of Boiler:
Longitudinal joint - Butt joint Circumferential joint Lap joint with one ring overlapping the other alternately is used. I.B.R. Indian Boiler Regulations