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ME314 Lecture 3 01 08 2023

This document discusses considerations for machine element design related to manufacturing processes and material selection. It covers: 1) How increased carbon content in steel affects properties like ductility, strength, weldability and forgability, and which applications suit different carbon percentages. 2) Manufacturing considerations for processes like casting, deformation, cutting, and welding that influence material and design choices. 3) Standards for materials, dimensions, fits, tolerances, and engineering drawings. 4) Design for manufacture and assembly concepts like tolerances, fits, and clearance vs interference fits.

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Ankit Gurwan
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45 views

ME314 Lecture 3 01 08 2023

This document discusses considerations for machine element design related to manufacturing processes and material selection. It covers: 1) How increased carbon content in steel affects properties like ductility, strength, weldability and forgability, and which applications suit different carbon percentages. 2) Manufacturing considerations for processes like casting, deformation, cutting, and welding that influence material and design choices. 3) Standards for materials, dimensions, fits, tolerances, and engineering drawings. 4) Design for manufacture and assembly concepts like tolerances, fits, and clearance vs interference fits.

Uploaded by

Ankit Gurwan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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ME 314 Design of Machine Elements

Lecture 3: 01.08.2023

Debabrata Chakraborty
Department of Mechanical Engineering
Indian Institute of Technology Guwahati

1
Objective of this Lecture – Manufacturing Consideration

In the last lecture, we discussed—


o Importance of Material Selection
o Important Mechanical Properties of Materials
o Significance of Mechanical Properties
o Dependency of Material Selection and Manufacturing

2
Choice of Carbon Steel – Influence of Carbon Content
o Increased Carbon % – Reduced ductility – Applications requiring high
ductility need to choose low carbon steel eg. Automobile bodies, hoods etc

o Increased Carbon % – Increased strength – Applications requiring high


strength need to choose high carbon steel or medium carbon steel eg, gear,
spring wire etc.

o Increased Carbon % – Reduced weldability – Applications requiring


welding assembly need to choose low /medium carbon steel

o Increased Carbon % – Reduced forgability – Applications requiring forged


components like connecting rod, crank shaft etc need low/medium carbon
steel
3
Similar criteria do exist for other materials also. That is manufacturing process will dictate the
material composition.
Manufacturing Considerations
o Select a material which fits to the manufacturing process

o Cost of manufacturing needs to be minimized

o In general, Design – 5% of the cost, but design decides 70% of the


manufacturing cost and only 30% of the cost could be controlled.

o Design and Manufacturing need to be considered in a coordinated way.

o It is not only the cost and availability of materials but also the cost of
manufacturing process which needs to be considered during design.

4
Manufacturing Considerations
o Casting Processes – Design considerations

o Deformation Processes – Design considerations

o Cutting or material removal processes – Design considerations

o Welding assembly – Design considerations

5
Standards in Design – ISO, IS, DIN, BS…

o Standards in materials and composition – eg. 55C4

o Standards in shape and dimensions eg. M20

o Standards in Fits and Tolerances

o Standards in Testing – ASTM, DIN, BS,

o Standards in Engineering Drawing

6
DESIGN FOR MANUFACTURE AND ASSEMBLY

o Inaccuracy of manufacturing methods – not possible to machine a


component to a given dimension.

o The components are so manufactured— dimensions lie between two


limits—maximum and minimum (the upper and lower deviations).

o The basic dimension is called the normal or basic size

o Difference between the two limits is called permissible tolerance.

7
DESIGN FOR MANUFACTURE AND ASSEMBLY

o Tolerance
–Unilateral

– Bilateral

o FITs – When two parts are to be assembled, the relationship resulting from
the difference between their sizes before assembly is called a FIT.

o Clearance Fit

o Interference Fit

o Transition Fit
8
SELECTION OF PREFERRED SIZES

o In engineering design, many a times, the designer has to specify the size of
the product.

o The ‘size’ of the product includes different parameters like power


transmitting capacity, load carrying capacity, speed, dimensions of the
component, volume or weight of the product.e.g., 5 kW, 10 kN or 1000
rpm.

o Often, the product is manufactured in different sizes

o A company may be manufacturing seven different models of electric


motors ranging from 0.5 to 50 kW to cater to the need of different
customers.
1
0
o Preferred numbers are used to specify the ‘sizes’ of the product in
SELECTION OF PREFERRED SIZES

• In the initial stages— product is manufactured in a


limited quantity— R5 series.
• As the scale of production is increased— R5 to
R10 series, introducing new sizes of intermediate
values
AESTHETIC CONSIDERATIONS IN DESIGN

o When there are a number of products in the market having the same
qualities of efficiency, durability and cost, the customer is attracted
towards the most appealing product

o External appearance is an important feature, dominates sale in the market,


particularly true for consumer durables like automobiles, household
appliances and audio-visual equipment.

ERGONOMIC CONSIDERATIONS IN DESIGN

1
2
Uncertainties in Design—Factor of Safety

Uncertainties in
o Composition of Materials and hence material properties

o Variation in properties – non uniformities

o Effect of processing on properties

o Effect of near by assemblies like welding

o Intensity and distribution of load

o Stress concentration

o FoS = Significant Strength / Corresponding Stress 1


3
Uncertainties in Design—Factor of Safety
o FoS = 1.25 to 1.5 for exceptionally reliable materials used under controllable
conditions and subjected to loads and stresses that can be determined with
certainty—used almost invariably where low weight is a particularly important
consideration.
o FoS = 1.5 to 2 for well-known materials, under reasonably constant environmental
conditions, subjected to loads and stresses that can be determined readily.
o FoS = 2 to 2.5 for average materials operated in ordinary environments and
subjected to loads and stresses that can be determined.
o FoS = 2.5 to 3 for less tried materials or for brittle materials under average
conditions of environment, load, and stress.
o FoS = 3 to 4 for untried materials used under average conditions of environment,
load, and stress.
o FoS = 3 to 4 should also be used with better known materials that are to be used in
uncertain environments or subjected to uncertain stresses.
o Repeated loads: The factors established in items 1 to 6 are acceptable but must be
applied to the endurance limit rather than to the yield strength of the material.
1
4
Concurrent Engineering

1
5

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