PUNJAB ENGINEERING COLLEGE

CHANDIGARH

ASSIGNMENT-1
DESIGN OF MACHINE ELEMENTS
PEN-208

Submitted to:
Dr. H.K. Banga

Submitted by:
Pranjal Tyagi
16109040
Question 1: Select suitable materials for the following parts stating the special property
which makes it most suitable for use in manufacturing:
1. Turbine blade
2. Bush bearing
3. Dies
4. Carburetor body
5. Keys (used for fastening)
6. Cams
7. Heavy duty machine tool beds
8. Ball bearing
9. Automobile cylinder block
10. Helical springs

Answer:
1. Turbine blades:
▪ The turbine is always located after combustion chamber. The blades are
exposed over to 2000ºC. Using a high melting point material is the way to solve
the problem.
▪ Predominantly turbine blades are made of Stainless Steel, Titanium, Nickel
alloys and ceramic material.
▪ The metals used for turbine blades are often grown as a single crystal.

2. Bush bearing:
▪ A bush bearing must have a very low coefficient of friction, high load bearing
capacity. So, we require a material with high hardness and good compressible
strength.
▪ Cast Iron is the best material for making bush bearings.
▪ Bronze: A good high load bearing material. This is very useful for split bushes as
it can be cast thus reducing machining time. Although, Bronze does require
regular lubrication.
▪ DEVA-Metal: Is a self-lubricating bearing material manufactured by advanced
powder metallurgy. It is fully compacted. It is provided with an evenly
distributed solid lubricant throughout its metallic matrix. It is suitable for dry
 running at slow sliding speeds and high loads as it has high resistance to
temperature and corrosion.

3. Dies:
▪ Pre-hardened steel: This material is commonly used because it can be machined
and is convenient because it can be used as is without heat treatment. It has
very high hardness and good resistance of impact load.
▪ Aluminum bronze: It is a copper-based alloy. It can withstand high press
pressures, has superior wear resistance, and high galling resistance. This is used
frequently in the dies for drawing or for forming hard to form materials such as
titanium.

4. Carburetor body:
▪ Zinc: The main reason for the choice is it is low cost, corrosion resistant, and
melts at low temperature. Because of the complex geometry it is normally made
by Hot chamber die casting.
▪ Cast iron and aluminum also have high flowability and low cost. So, they are also
used sometimes.

5. Keys (used for fastening):

▪ While transmitting torque, a rectangular key is subjected to both shear and
crushing or bearing stresses.
▪ Steel is the most commonly used material in fastener production. It’s popularity
stems from its high degree of formability coupled with tensile strength and
durability. Compared to other metal stock, steel is also relatively inexpensive to
fabricate.
▪ Carbon steel is the most common type of steel used in fastener production.

6. Cams:
▪ Cams provide timing related functions within an operational system, and
therefore are regularly manufactured to extremely precise specifications; even
a small flaw in design can lead to major implications for the mechanism
involved.
 ▪ Common materials include various steel alloys, such as high and low carbon
steel, nylon and polypropylene.
▪ These materials are used because of great formability and corrosion resistance.

7. Heavy duty machine tool beds:

▪ Vibration in machine tools causes poor part accuracy and surface finish. It is
therefore important that a large part of the machine is made of materials which
reduce the amplitude of the vibrations.
▪ Gray Cast Iron has extremely high damping capacity, and is therefore the
preferred material for machine tool beds, tables, columns, etc.
▪ G.C.I. has a high compressive strength and is highly resistant to deformation and
provides a rigid frame.It is highly resistant to rust. It is a perfect solution to avoid
the problem of corrosion.

8. Ball bearing:
▪ The bearing alloy must have low inherent friction, it must resist welding and
seizing, and it should have high thermal conductivity to remove frictional heat
from the bearing surface.
▪ Chrome Steel – SAE 52100: These bearings have a high resistance to cracking
and a hard surface, which helps them to resist wear and tear from rolling.
▪ Stainless steel is also used as it is more resistant to surface corrosion due to the
higher content of chromium (~18%) with the addition of nickel.

9. Automobile cylinder block:

▪ The cylinder block should have wear resistance, long lasting, maintenance, and
withstand the temperature & pressure created when combustion take place.
▪ Grey cast iron is used for this. It has excellent damping absorption, good wear
and thermal resistance, and it is easily machinable and has less cost due to its
availability.

10. Helical springs:

▪ Steel alloys are the most commonly used spring materials. The most popular
alloys include high-carbon, oil-tempered low-carbon, chrome silicon, chrome
vanadium, and stainless steel.
 ▪ Steel is used because it has great formability, high corrosion resistance, high
yield strength and low density.

Question 2: Select suitable materials for the following parts stating the special property
which makes it most suitable for use in manufacturing:
1. Diesel engine crankshaft
2. Automobile tyres
3. Roller bearings
4. High pressure steam pipes
5. Stay bar of boilers
6. Worm and worm gear
7. Dies
8. Tramway axle
9. Cam follower
10. Hydraulic brake piston

Answer:
1. Diesel engine crankshaft:
▪ Mainly forged steel is used for crank shaft because both rotational as well as
transverse forces acting on it so to prevent any wear and tear of material.
▪ Forged steel has excellent mechanical strength and high toughness.

2. Automobile tyres:
▪ Rubber is the main raw material used in manufacturing tires, and both natural
and synthetic rubber are used. The properties of natural rubber include
durability and abrasion resistance. Synthetic rubber has heat resisting
properties.
▪ Carbon black increases the strength of rubber.
▪ The white powder of silicon dioxide delivers better fuel efficiency and wet grip.
▪ Steel is used as a material of beads and steel belts in passenger tires.

3. Roller bearings:
▪ Most common used material is Chrome steel. It has high mechanical strength,
high resistance of wear and tear, high toughness and low thermal expansion.
4. High pressure steam pipes:
▪ Pipes for steam systems are commonly manufactured from carbon steel ASTM
A106.
▪ For high temperature superheated steam mains, additional alloying elements,
such as chromium and molybdenum, are included to improve tensile strength
and creep resistance at high temperatures.

5. Stay bar of boilers:

▪ Stay bolts, or stays for short, are an integral part of a boiler, to keep distortions
to a minimum when subjected to heat and pressure.
▪ Most small loco boilers are made of copper and for these boilers the best stay
material is also copper. This is to avoid wasting away in the water space due to
electrolysis.

6. Worm and worm gear:

▪ Steel is used for high strength worm gears (worm wheel) and steel may be plain
carbon steel or alloy steel. The steel gears are usually heat treated to combine
properly the toughness and tooth hardness.
▪ The phosphor bronze is widely used for worm drive to reduce wear of the worms
which will be excessive with cast iron or steel.

7. Dies:
▪ Pre-hardened steel: This material is commonly used because it can be machined
and is convenient because it can be used as is without heat treatment. It has
very high hardness and good resistance of impact load.
▪ Aluminum bronze: It is a copper-based alloy. It can withstand high press
pressures, has superior wear resistance, and high galling resistance. This is used
frequently in the dies for drawing or for forming hard to form materials such as
titanium.

8. Tramway axle:
▪ Steel is mostly used in tramway axles.
 ▪ Steel has high mechanical strength, high yield strength, high toughness and high
resistance to wear and tear.

9. Cam follower:
▪ It is used in I.C. engines to operate the valve mechanism. Most common material
used in it is stainless steel.
▪ Stainless steel is used because it has high tensile yield strength, great
formability, low density and corrosion resistance.

10. Hydraulic brake piston:

▪ The material should have enough strength to withstand all the loads acting on
it in dynamic conditions
▪ Grey Cast Iron is used which has enough strength to sustain under variable
loading condition.

Question 3: What are the common materials used in Mechanical Engineering Design?
How can the properties of steel be improved?

Answer: The most common materials used in Mechanical Engineering Design are:
• Cast Iron
• Alloy steel
• Plastic
• Aluminum alloy

METALS NON-METALS

➢ Ferrous (contains iron)- Alloy ➢ Polymers- PVC, Polythene, Resins,

steels, Cast Irons, Carbon steels Bakelite
➢ Non-Ferrous (contains no iron)- ➢ Ceramics- Abrasives, Glass, Cement,
Aluminum, Copper, Lead, Silver, Tin, Concrete etc.
Zinc
There are three general ways to change the properties of steel:
1. Chemical Composition- Add Carbon (C), Mangenese (Mn), and other Alloying
elements such as Nickel (Ni), Chromium (Cr), Molybdenum (Mo). Adding C and Mn
is cheaper and others is expensive, others are only added when steel for special
purposes are to be manufactured.

2. Mechanical Working- Hot Working (Forging, Hammering, Rolling) or Cold Working

(Cold rolling, Warm Forging or cold swaging)

3. Heat Treatment- It is done to change the properties of steel to suit our

requirements. It involves the following:
▪ Normalizing: Steel is heated from 30° to 50° C above its upper critical temperature
and held at this temperature for about 1 hour and then allowed to cool down in air.
▪ Annealing: Steel is heated from 30° to 50° C above its upper critical temperature
and held at this temperature for 5 minutes to enable the internal changes take
place. It is cooled slowly in furnace.
▪ Spheroidizing: Cementite structure produced in granular form in this process.
▪ Hardening by Quenching: In this process, steel is quickly cooled by dipping it in
water or other liquid like oil or brine. This process is used to harden the steel.
▪ Tempering: It involves reheating the hardened steel to some temperature below
lower critical temperature followed by desired rate of cooling.
Question 4: Why are metals in their pure form unsuitable for industrial use? Explain
with industrial examples.
Answer: Most pure metals are either too soft, brittle or chemically reactive for
practical use.
For making a component of a machine, it should have many desirable qualities like
strength, hardness, ductility, malleability, corrosive resistance etc. But the pure metals
do not have all these qualities in general and hence to get the required qualities, pure
metals are mixed with each other and the resulting alloy metals are mostly used for
making machine components instead of using pure metals.
The aim of making alloys is generally to make them less brittle, harder, resistant to
corrosion, or have a more desirable color and luster.
For example: The addition of silicon to iron will produce cast irons, while the addition
of chromium, nickel and molybdenum to carbon steels (more than 10%) results in
stainless steels. So, the properties of iron are modified to suit the requirement of
industrial application.
Question 5: What is meant by working stress and how is it calculated from the ultimate
stress or yield stress of a material? What will be the factor of safety in each case for
different types of loading?
Answer:
▪ The working stress is stress value which is used in design to determine
dimensions of the component. It is considered as a stress which the designers
expect will not be exceeded while operating under normal conditions. Safe
working stress is known as the maximum allowable stress that a material or
object will be subjected to when in service.
▪ Yield stress is the stress at the instant when the strain in the body increase
without any further increase in load. Yielding starts in the body after this point.
After this point, permanent deformation occurs
▪ Ultimate stress is the maximum stress a body can behold before it breaks or
weakens.
▪ Factor of Safety- while designing the component, it is necessary to provide
sufficient reserve strength in case of an accident.

o F.O.S= Max. Stress/ Working Stress

o In ductile material, F.O.S.= Yield Pt. Stress/Working stress
o In brittle material, F.O.S.= Ultimate stress/Working stress
o Safe working stress is always less than the Elastic limit for a given
material.