Mechanical System

Design
Semester VII - Mechanical Engineering
(Pune University)

R. B. Patil
M.E. (Mech) (Design Engg.)
Head,
Department of Mechanical Engineering,
Army Institute of Technology,
Pune.

Mechanical System Design

R. B. Patil
(Semester VII Mechanical Engineering, Pune University)
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ISBN 978-81-8407-858-9

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Price Rs. 500/-

Scope of the Book

UNIT - 1

Design of Cylinders and Pressure Vessels :

Thick and thin cylinders - Thin cylindrical and spherical vessels - Lame's equation - Clavarinos
and Birnies equations - Design of hydraulic and pneumatic cylinders - Autofrettage and
compound cylinders - Gasketed joints in cylindrical vessels - Modes of failures in pressure vessels
- Unfired pressure vessels - Classification of pressure vessels as per I. S. 2825 - Categories and
types of welded joints - Weld joint efficiency - Corrosion, erosion and protection vessels - Stresses
induced in pressure vessels - Materials of construction - Thickness of cylindrical and spherical
shells - Design of end closures as per code - Nozzles and Openings in pressure vessels Reinforcement of openings in shell and end closures - Area compensation method - Types of
vessel supports.

(Refer Chapter 2)

UNIT - 2

Optimum Design :

Objectives of optimum design - Johnson's Method of Optimum Design (MOD) - Adequate and
optimum design - Primary, subsidiary and limit equations - Optimum design with normal and
redundant specifications of simple machine elements like : tension bar, transmission shaft, helical
spring.

(Refer Chapter 3)

UNIT 3

Design of Flywheel :

Design of flywheel - Fundamental equation of motion - Torque analysis - Disk and rimmed
flywheels - Stresses in flywheel rim and spokes - Design of disc and rimmed flywheels for various
applications - Standard dimensions of flywheels.

(Refer Chapter 1)

UNIT - 4

Statistical Consideration in Design :

Frequency distribution - Histogram and frequency polygon - Normal distribution - Units of

measurement of central tendency and dispersion - Standard variable - Population combinations -

Design and natural tolerances - Design of assembly - Statistical analysis of tolerances Mechanical reliability and factor of safety.

(Refer Chapter 4)

Design for Manufacture :

General principles of design for manufacture and assembly (DFM and DFA) - Principles of design
of castings and forgings - Design for machining - Design for powder metallurgy - Design for
welding.

(Refer Chapter 8)

UNIT - 5

Design of Gear Boxes for Machine Tool Applications :

Basic considerations in design of drives - Determination of variable speed range - Graphical

representation of speed and structure diagram - Deviation diagram - Ray diagram - Selection of
optimum ray diagram - Difference between number of teeth of successive gears in a change gear
box - Analysis of twelve speed gear box Compound ray diagram.

(Refer Chapter 5)

Aesthetic and Ergonomic Considerations in Design of Products :

Basic types of product forms - Designing for appearance - Shape, features, materials, finishes,
proportions, symmetry, contrast etc. - Morgan's colour code - Ergonomic considerations - Relation
between man, machine and environmental factors - Design of displays and controls - Practical
examples of products or equipments using ergonomic and aesthetic design principles.
(Refer Chapter 7)

UNIT - 6

Design of Material Handling Systems :

System concept - Basic principles, Objectives of material handling system - Unit load and
containerization.
Belt conveyors :
Flat belt and troughed belt conveyors - Capacity of conveyor - Rubber covered and fabric ply belts
- Belt tensions - Conveyor pulleys - Belt idlers - Tension take-up systems - Power requirement of
horizontal belt conveyors for frictional resistance of idlers and pulleys.

(Refer Chapter 6)

Preface

It gives a great pleasure to present this book on

Mechanical System Design. This book has been
written for the third course in Machine Design,
especially for the final year students of mechanical
engineering. This is the third book of the series on
Machine Design, which comprehensively covers the
design of different mechanical systems and various
aspects of system design, used in engineering
applications. The main objective of this book is to
bridge the gap between the reference books written
by the renowned international authors and the
requirements of undergraduate students.
The book has been presented in a simple language
without compromising the quality of text. The
concepts
have
been
developed
from
the
fundamentals. The main emphasis has been given on
explaining the concepts rather than merely providing
the information. Every concept is illustrated with the
help of number of solved examples, which are
arranged in the order of increasing degree of difficulty.
The list of formulae has been given at the end of each
chapter for the ready reference. This book is an
outcome of the years of classroom interaction with the
students.
I would like to express my thanks to Shri. Sachin Shah
and Shri Pradeep Lunawat of Tech-Max Publications
for their efforts in publishing this book. My thanks are
due to all those people who have directly or indirectly
contributed to this book.

Last, but not least, my special thanks go to all my

students whose continuous feedback while teaching
this subject is the source of inspiration behind this
book.
A feedback in the form of suggestions and comments
from the readers for further improvement of the book
will be highly appreciated.
1st October 2007

- R.B. Patil

To My

Daughter
Neha
&
Son Nikhil

- Author