Machine Design.pdf

Free mechanical engineering course material (still from ECE Kharagpur), consists of 40 lessons about engineering materials, machine design, machine elements and strength of materials.

Stay close with this ebook if you want to learn about springs, brakes, dampers, thread, design and manufacturing, bolts and fasteners …, quite complete ebook in mechanical engineering subject, however this is not a Machinery handbook.


  • Lesson 1 Design philosophy, objectives: Basic concept of design in general., Concept of machine design and their types., Factors to be considered in machine design, contents [ Basic concept of machine design ~ Types of design based on methods ~ Factors to be considered in machine design ]
  • Lesson 2 Engineering Materials, objectives: Properties and applications of common engineering materials., Types and uses of ferrous metals such as cast iron, wrought iron and steel., Types and uses of some common non-ferrous metals., Types and uses of some non-metals., Important mechanical properties of materials., contents [ Ferrous materials ~ Non-ferrous metals ~ Non-metals ~ Mechanical properties of common engineering materials ]
  • Lesson 3 Brief overview of design and manufacturing, objectives: Concept of limits and fits, Preferred numbers, Various manufacturing processes, contents [ Design and Manufacturing ~ Fit System ~ Common manufacturing processes ]
  • Module 2 Stresses in machine elements
    • Lesson 1 Simple stresses, objectives: Simple stresses in machine elements; tensile, compressive, bearing and shear stresses, Flexture formula and their limitations, Torsion formula and its limitations., Design of members subjected to combined bending, torsion and axial loading., Buckling of beams., contents [ Bending of beams ~ Torsion of circular members ~ Buckling ~ Stress at a point—its implication in design ]
    • Lesson 2 Compound stresses in machine parts, objectives: Elements of force system at a beam section., Superposition of axial and bending stresses., Transformation of plane stresses; principal stresses, Combining normal and shear stresses, contents [ Strain superposition due to combined effect of axial force P and bending moment M. ~ Superposition of stresses due to axial force and bending moment ~ Superposition of stresses due to axial force, bending moment and torsion ~ Transformation of plane stresses ]
    • Lesson 3 Strain analysis, objectives: Normal and shear strains., 3-D strain matrix., Constitutive equation; generalized Hooke’s law, Relation between elastic, shear and bulk moduli ( E, G, K)., Stress- strain relation considering thermal effects., contents [ Normal strains ~ Shear strain ~ Constitutive equation ~ Relations between E, G and K ~ Elementary thermoelasticity ]
  • Module 3 Design for Strength
    • Lesson 1 Design for static loading, objectives: Types of loading on machine elements and allowable stresses., Concept of yielding and fracture., Different theories of failure., Construction of yield surfaces for failure theories., Optimize a design comparing different failure theories, contents [ Allowable Stresses: Factor of Safety ~ Theories of failure ~ Yield criteria ~ Superposition of yield surface ]
    • Lesson 2 Stress Concentration, objectives: Stress concentration and the factors responsible., Determination of stress concentration factor; experimental and theoretical methods., Fatigue strength reduction factor and notch sensitivity factor., contents [ Methods of reducing stress concentration. ~ Theoretical basis of stress concentration ]
    • Lesson 3 Design for dynamic loading, objectives: Mean and variable stresses and endurance limit., S-N plots for metals and non-metals and relation between endurance limit and ultimate tensile strength., Low cycle and high cycle fatigue with finite and infinite lives., Endurance limit modifying factors and methods of finding these factors., contents [ Stress cycle ~ Endurance limit ~ Stress concentration ~ Surface characteristics ]
    • Lesson 4 Low and high cycle fatigue, objectives: Design of components subjected to low cycle fatigue; concept and necessary formulations., Design of components subjected to high cycle fatigue loading with finite life, concept and necessary formulations., Fatigue strength formulations; Gerber, Goodman and Soderberg equations., contents [ Low cycle fatigue ~ High cycle fatigue with finite life ~ Fatigue strength formulations ]
  • Module 4 Fasteners
    • Lesson 1 Types of fasteners: Pins and keys, objectives: Fasteners and their types: permanent and detachable fasteners., Different types of pin joints., Different types of keys and their applications., contents [ Pin Joints ~ Keys ]
    • Lesson 2 Cotter and knuckle joint, objectives: A typical cotter joint, its components and working principle., Detailed design procedure of a cotter joint., A typical knuckle joint, its components and working principle., Detailed design procedure of a knuckle joint., contents [ Design of a cotter joint ~ Knuckle Joint ]
    • Lesson 3 Threaded Fasteners, objectives: Different types of bolts, screws and studs., Some details of tapping and set screws., Thread forms in details., contents [ Bolts, screws and studs are the most common types of threaded fasteners. They are used in both permanent or removable joints. ~ Thread forms ]
    • Lesson 4 Design of bolted joints, objectives: Different types of stresses developed in screw fasteners due to initial tightening and external load., Combined effect of initial tightening and external load on a bolted joint., Leak proof joints and condition for joint separation., contents [ Stresses in screw fastenings ~ Leak proof joint ~ Joint separation ]
  • Module 5 Couplings
    • Lesson 1 Introduction, types and uses, objectives: The function of couplings in machinery., Different types of couplings: rigid and flexible couplings., Types of rigid couplings such as sleeve, clamp, ring compression type and flange couplings., Types of misalignments and couplings suitable to connect misaligned shafts., contents [ Types and uses of shaft couplings ]
    • Lesson 2 Design procedures for rigid and flexible rubber-bushed couplings, objectives: Detailed design procedure of a typical rigid flange coupling., Detailed design procedure of a typical flexible rubber-bush coupling., contents [ Rigid Flange Coupling ~ Flexible rubber - bushed couplings ]
  • Module 6 Power Screws
    • Lesson 1 Power Screw drives and their efficiency, objectives: Power screw mechanism., The thread forms used in power screws., Torque required to raise and lower a load in a power screw, Efficiency of a power screw and condition for self locking., contents [ Efficiency of a power screw ]
    • Lesson 2 Design of power screws, objectives: Stresses in power screw., Design procedure of a power screw., contents [ Stresses in power screws ~ Design procedure of a Screw Jack ]
  • Module 7 Design of Springs
    • Lesson 1 Introduction to Design of Helical Springs, objectives: Uses of springs, Nomenclature of a typical helical spring, Stresses in a helical spring, Deflection of a helical spring, contents [ Commonly used spring materials ~ Spring manufacturing processes ~ Helical spring ~ Stresses in the helical spring wire: ~ Stresses in helical spring with curvature effect ~ Deflection of helical spring ~ How to compute the deflection of a helical spring ? ]
    • Lesson 2 Design of Helical Springs for Variable Load, objectives: Nature of varying load on springs, Modification of Soderberg diagram, Estimation of material properties for helical spring, Types of helical springs, Design considerations for buckling and surge., contents [ Design of helical spring for variable load ~ Soderberg failure criterion ~ Estimation of material strength ~ Compression springs & Extension springs ~ Buckling of compression spring ~ Spring surge (critical frequency) ]
    • Lesson 3 Design of Leaf Springs, objectives: Working of leaf spring, Types of leaf springs, Design theme of leaf springs, Laminated spring and its modifications, contents [ Design theme of a leaf spring ~ Laminated Springs ~ Laminated semi-elliptic spring ~ Materials for leaf spring ~ Standard sizes of leaf spring ~ Stresses due to support hinges ]
  • Module 8 Design of Shaft
    • Lesson 1 Shaft and its design based on strength, objectives: Definition of shaft, Standard shaft sizes, Standard shaft materials, Design of shaft based on strength, contents [ Standard sizes of Shafts ~ Material for Shafts ~ Design considerations for shaft ~ Design based on Strength ~ ASME design Code ]
    • Lesson 2 Design of shaft for variable load and based on stiffness, objectives: Design method for variable load, Equivalent stress on shaft, Design based on stiffness and torsional rigidity, Critical speed of shaft, contents [ Design of Shaft for variable load ~ Design based on Stiffness ~ Lateral stiffness ~ Torsional rigidity ~ A note on critical speed of rotating shaft ]
  • Module 9 Thin and thick cylinders
    • Lesson 1 Thin Cylinders, objectives: Stresses developed in thin cylinders., Formulations for circumferential and longitudinal stresses in thin cylinders., Basic design principles., Joint design; Welded or Riveted., contents [ Stresses in thin cylinders ~ Design Principles ]
    • Lesson 2 Thick cylinders- Stresses due to internal and external pressures., objectives: Stresses in thick cylinders., Lame’s equation for radial and circumferential stresses., Distribution of radial and circumferential stresses for different boundary conditions., Methods of increasing elastic strength of thick cylinders by prestressing., contents [ Stresses in thick cylinders ~ Methods of increasing the elastic strength of a thick cylinder by pre-stressing ]
    • Lesson 3 Design principles for thick cylinders, objectives: Failure theories applied to thick walled pressure vessels., Variation of wall thickness with internal pressure based on different failure theories., Failure criterion of prestressed thick cylinders., Comparison of wall thickness variation with internal pressure for solid wall, single jacket and laminated thick walled cylinders., Failure criterion for thick walled cylinders with autofrettage., contents [ Application of theories of failure for thick walled pressure vessels. ]
  • Module 10 Design of Permanent Joints
    • Lesson 1 Riveted Joints : Types and Uses, objectives: Basic types of riveted joints., Different important design parameters of a riveted, Uses of riveted joints., contents [ ~ Rivets as permanent joints ~ Rivets and Riveting: ~ Types of riveted joints and joint efficiency: ~ Lap Joint ~ Butt Join ~ Important terms used in riveted joints: ]
    • Lesson 2 Design of Riveted Joints, objectives: Basic failure mechanisms of riveted joints., Concepts of design of a riveted joint., contents [ Design of rivet joints ]
    • Lesson 3 Welded Joints: Types and Uses, objectives: Different types of welded joints., Factors that affect strength of a welded joint., Symbols and specifications of welded joints., contents [ Welded joints and their advantages ~ Basic types of welded processes: ~ Strength of welded joints: ~ Types of welded joints ~ Welding symbol ]
    • Lesson 4 Design of Welded Joints, objectives: Possible failure mechanisms in welded joints., How to design various kinds of welding joints., contents [ Design of a butt joint: ~ Design of transverse fillet joint ~ Design of parallel fillet joint: ~ Design of circular fillet weld subjected to torsion: ~ Design stresses of welds: ]
    • Lesson 5 Design of Adhesive Joints, objectives: Different types of adhesives, Stress distribution in adhesive joints, Design procedure of adhesive joints, contents [ Adhesive joints and their advantages ~ Types of Adhesive Joints ~ Stresses within adhesive ~ Adhesive materials ]
  • Module 11 Design of Joints with Special Loading
    • Lesson 1 Design of Eccentrically Loaded Bolted/Riveted Joints, objectives: Meaning of eccentricity in loading., Procedure for designing a screw/bolted joint in eccentric loading., Procedure for designing riveted joint under eccentric loading., contents [ Eccentrically loaded screwed joint: ~ Eccentrically loaded riveted joint: ]
    • Lesson 2 Design of Eccentrically Loaded Welded Joints, objectives: Ways in which eccentric loads appear in a welded joint., General procedure of designing a welded joint for eccentric loading., How to avoid eccentric loading in simple cases.., contents [ Eccentrically loaded transverse fillet joint: ~ Eccentrically loaded parallel fillet joint: ~ Asymmetric Welded Section: ]
    • Lesson 3 Design of Joints with Variable Loading, objectives: Design of a bolted joint with fluctuating loading, Design of welded joints with variable loading, contents [ Variable loading in mechanical joints: ~ Bolted joints with variable loading: ~ Welded joints with variable loading: ]
  • Module 12 Design of brakes
    • Lesson 1 Design of shoe brakes, objectives: Different types of shoe brakes and their operating principles, Design procedure of different shoe brakes, contents [ Types of brakes ~ Shoe or block brake ~ Single Shoe brake ~ Double shoe brake ~ External expanding shoe brake ~ Internal expanding shoe brake ]
    • Lesson 2 Design of Band and Disc Brakes, objectives: Different types of band brakes, Design of band brakes, Design of disc brakes, Properties of friction materials, contents [ Band brakes: ~ Band and block brakes: ~ Disc brake: ~ Friction materials and their properties. ]
  • Module 13 Belt drives
    • Lesson 1 Introduction to Belt drives, objectives: Uses and advantages of belt drives, Types of belt drives and their nomenclature, Relationship between belt tensions, Some commonly used design parameters, contents [ Flexible Machine Elements ~ Typical belt drives ~ Nomenclature of Open Belt Drive ~ Belt tensions ~ Derivation of relationship between belt tensions ~ Elastic Creep and Initial Tension ~ Velocity ratio of belt drive ~ Power transmission of belt drive ]
    • Lesson 2 Design of Flat Belt drives, objectives: Features of flat belt drives, Flat belt materials, Flat belt stresses and its specifications, Types of design factors, A sample design procedure., contents [ Belt Material ~ Typical Belt drive specifications ~ Modification of Belt stress ~ Design considerations for flat belt drives ]
    • Lesson 3 Design of V- Belt drives, objectives: Features of V-belt drives, Nomenclature of V-belt, types of V-belt section, Selection procedure of V-belt, contents [ V - Belt Drives ~ Nomenclature of V-belt ~ Standard V-belt sections ~ Designation of V belt ~ V- belt Equation ~ V-belt power rating ~ V belt design factors ~ Selection of V- belt ]
  • Module 14 Brief overview of bearings
    • Lesson 1 Fluid Film bearings, objectives: Types of bearings, Comparison of bearing friction characteristics, Basics of hydrodynamic theory of lubrication, Design methods for journal bearings, contents [ Brief overview of bearings ~ Comparison of bearing frictions ~ Journal Bearing ~ The Reynolds' equation (simplified form) ~ Design parameters of journal bearing ~ Methods for journal bearing design ~ Materials for bearing ]
    • Lesson 2 Rolling contact bearings, objectives: About rolling contact bearings, Ball bearing and roller bearing, Basics definitions of design parameters of rolling contact bearings, Selection method for rolling contact bearings, contents [ Rolling contact bearing ~ Ball bearing ~ Rolling contact bearing selection ~ The selection procedure ]



    29 Responses to “Machine Design.pdf”

    1. shuaib muhammed on June 27th, 2008 9:51 pm

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    2. saurabh on June 29th, 2008 2:20 am

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    5. Mustafa on August 3rd, 2008 9:50 am

      So helpful!!! thanks alot..

    6. Parag Godbole on August 16th, 2008 2:11 pm

      I’m not able to get access to this book as I get a message as reproduced below. Please Help.

      You don’t have permission to access /courses/Webcourse-contents/IIT Kharagpur/Machine design1/pdf/ on this server.

    7. admin on August 16th, 2008 4:37 pm

      @Parag Godbole: Links just fixed, enjoy download

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    9. Last on September 15th, 2008 5:42 pm

      Module 13 There is NO LINK FOR LESSON 1

    10. admin on September 15th, 2008 8:15 pm

      @Last: you have great eyes on that! Nobody realize it but you!
      Link for module 13 lesson 1 was added, thanks for the feedback!

    11. pradip on September 20th, 2008 5:52 pm

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