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DESIGN OF MACHINE ELEMENTS:
Dr. Dinesh Kumar
Associate Professor
Dept. of Mech. Eng., MNIT Jaipur
Few major references are included here. Other references may be found in individual chapters.
1. Norton Robert L., “Machine Design: An Integrated Approach”,
Fourth Edition, Pearson Education Inc., New Jersey, 2011.
2. Shigley J. E. and Mischke C. R., Budynas R. G. and Nisbett K. J.,
“Mechanical Engineering Design“ McGraw Hill, 8th Edition, USA,
2008.
*It is impossible to write better than in the above mentioned references and paraphrasing any statements may lead to loss of technical
meanings /contents of the statements, and hence, many statements are quoted directly from these works.
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Schematic representation of the steps in ductile fracture (in pure tension)
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Types of failure in compression
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Show several revolutions
before breaking
Fatigue Strength and Endurance Limit Resilience and Toughness
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Impact Tests
Fracture toughness (Kc) Creep and Temperature Effects
• Fracture toughness is a property which describes the • All materials will, under the right environmental
ability of a material to resist fracture. conditions (particularly elevated temperatures), slowly
• An indication of the amount of stress required to creep (deform) under stress loadings well below the level
propagate a preexisting flaw. (yield point) deemed safe in the tensile test.
• Measured by subjecting a standardized, pre-cracked • E.g., Ferrous metals show creep at temperature around
test specimen to cyclical tensile loads until it breaks 30-60% of the its melting temperature; Low-melt-
• The effect of the crack on the local stress is measured temperature metals such as lead, and many polymers,
by a stress intensity factor K can exhibit significant creep at room temperature.
• When the stress intensity factor K reaches the • If your application involves either elevated or low
fracture toughness Kc, a sudden fracture occurs with no temperatures, you need to seek out relevant material-
warning. property data for your operating environment.
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Hardness
• The hardness of a material can be an indicator of its
resistance to wear.
• The strengths of some materials such as steels are
also closely correlated to their hardness.
• Measured on one of three scales: Brinell, Rockwell,
or Vickers.
• Hardness is indicated as 375 HB or 396 HV or 60
HRC.
• The Brinell hardness number provides a very
convenient way to quickly estimate the ultimate
tensile strength (Sut) of the material
Heat Treatments
• Quenching
• Tempering
• Annealing
• Normalizing
• Surface Hardening:
Carburizing, Nitriding,
Cyaniding, Flame hardening,
Induction hardening
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Forging
• An automation of the ancient art of
blacksmithing.
• The surface finish of a forging is as
rough as any hot-rolled part due to
oxidation and decarburization of
the heated metal.
• Virtually any wrought, ductile
metal can be forged.
• Forging has the advantage of
creating stronger parts than casting
or machining can.
• Forgings are used in highly stressed
parts, such as aircraft wing and
fuselage structures, engine
crankshafts and connecting rods,
and vehicle suspension links.
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Extrusion
General Properties of Metals
• Cast Iron: White, Grey, Malleable, and Ductile
Cast Iron.
• Cast and Alloy Cast Steels: Low carbon (< 0.2%),
medium carbon (0.2-0.5%), and high carbon (>
0.5%).
• Wrought Steels: Hot rolled and cold rolled steels
• Aluminum and its alloys
• Titanium
• Magnesium
• Copper alloys
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Steel Numbering System Steel Numbering System…
• ASTM and the SAE have developed a new Unified
Numbering System for all metal alloys.
• Uses the prefix UNS followed by a letter and a 5-digit
number.
• The letter defines the alloy category, F for cast iron, G
for carbon and low-alloy steels, K for special-purpose
steels, S for stainless steels, and T for tool steels. For
the G series, the numbers are the same as the
AISI/SAE designations in Table 2-5 with a trailing zero
added.
• For example, SAE 4340 becomes UNS G43400.
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General Properties of Nonmetals
• Polymers
• Ceramics
• Composites
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Materials Selection
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Summary Summary…
Problem 2.1
Problems:
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Problem 2.3: Which of the steel alloys shown in below
figure would you chose to obtain: Problem: 2.19
• Calculate the specific strength and specific
stiffness of the following materials and pick
one for use in an aircraft wing spar.
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