Machine Design and Industrial Costing Principles

Part 1: Machine Design and Costing Syllabus

Unit 1: General Considerations in Machine Design

• 1.1. General Considerations: Aesthetic considerations regarding shape, size, colour, and surface finish.
• 1.2. Material Behavior: Fatigue, endurance limit, creep, and creep curve.
• 1.3. Factor of Safety: Selection criteria and application.
• 1.4. Stress Concentration: Its causes and remedies.
• 1.5. Design Resources: Use of design data books and standards in design.
• 1.6. Failure Analysis: Types of failures.

Total Hours: 06

Unit 2: Design of Simple Machine Parts

• 2.1. Socket and spigot type cotter joint.
• 2.2. Knuckle joint.

Design of Bolt

• 2.3. Basic types of screw fastening.
• 2.4. Stresses in screwed fasteners.
• 2.5. Bolts of uniform strength.
• 2.6. Design of eyebolt.

Total Hours: 08

Unit 3: Shafts, Keys, Couplings, and Flat Belt Pulleys

Design of Shafts

• 3.1. Types of shafts, shaft materials, and standard sizes.
• 3.2. Design of solid and hollow shafts on strength and torsional rigidity basis.

Design of Keys

• 3.3. Types of keys and applications; design of saddle and sunk keys.
• 3.4. Effect of keyways on the strength of the shaft.

Design of Couplings

• 3.5. Types of coupling and applications; design of rigid type flange coupling.

Design of Pulley

• 3.6. Types of pulleys and applications; design of flat belt Cast Iron (C.I.) pulley.

Total Hours: 10

Unit 4: Design of Welded Joints

• 4.1. Types of fillet joints.
• 4.2. Strength of parallel fillet welds.
• 4.3. Strength of transverse fillet welds.
• 4.4. Axially loaded symmetrical section welded joints.
• 4.5. Merits and demerits of threaded, riveted, and welded joints.

Total Hours: 06

Unit 5: Antifriction Bearings

• 5.1. Classification and applications of bearings; comparison of sliding and rolling contact bearings; bearing materials.
• 5.2. Terminology of ball bearings: load-life relationship, static and dynamic load carrying capacity, equivalent limiting load, and limiting speed.
• 5.3. Selection of ball bearings using manufacturer’s catalogue.
• 5.4. Bearing failure: causes and remedies.

Total Hours: 06

Unit 6: Estimating and Costing

• 6.1. Introduction to estimating and costing; elements of costing.
• 6.2. Determination of weight of various parts such as simple bush, flanged pipe, lathe centre, rivet, bolt head, ring, cotter, and knuckle pin.
• 6.3. Estimation of selling price of simple engineering parts.
• 6.4. Estimation of fabricated jobs such as simple cylindrical and cuboidal tanks.

Total Hours: 06

Part 2: Detailed Syllabus Reference Breakdown

Unit 1: General Considerations in Machine Design

1.1. General considerations in machine design, aesthetic considerations regarding shape, size, colour, and surface finish.
1.2. Fatigue, endurance limit, creep, and creep curve.
1.3. Factor of safety and its selection criteria.
1.4. Stress concentration, its causes, and remedies.
1.5. Use of design data books and standards in design.
1.6. Types of failures.
06 Hours

Unit 2: Design of Simple Machine Parts

2.1. Socket and spigot type cotter joint.
2.2. Knuckle joint.
Design of Bolt:
2.3. Basic types of screw fastening.
2.4. Stresses in screwed fasteners.
08 Hours
2.5. Bolts of uniform strength.
2.6. Design of eyebolt.

Unit 3: Shafts, Keys, Couplings, and Flat Belt Pulleys

Design of Shafts:
3.1. Types of shafts, shaft materials, and standard sizes.
3.2. Design of solid shaft and hollow shaft on strength basis and torsional rigidity basis.
Design of Keys:
3.3. Types of keys and applications; design of saddle key and sunk key.
3.4. Effect of keyways on strength of shaft.
Design of Couplings:
3.5. Types of coupling and applications; design of rigid type flange coupling.
Design of Pulley:
3.6. Types of pulleys and applications; design of flat belt C.I. pulley.
10 Hours

Unit 4: Design of Welded Joints

Design of Welded Joints:
4.1. Types of fillet joints.
4.2. Strength of parallel fillet welds.
4.3. Strength of transverse fillet welds.
4.4. Axially loaded symmetrical section welded joints.
4.5. Merits and demerits of threaded joints, riveted joints, and welded joints.
06 Hours

Unit 5: Antifriction Bearings

5.1. Classification and applications of bearings; comparison of sliding contact and rolling contact bearings; bearing materials.
5.2. Terminology of ball bearings: load-life relationship, static load carrying capacity and dynamic load carrying capacity, equivalent limiting load, and limiting speed.
5.3. Selection of ball bearings using manufacturer’s catalogue.
5.4. Bearing failure: causes and remedies.
06 Hours

Unit 6: Estimating and Costing

6.1. Introduction to estimating and costing; elements of costing.
6.2. Determination of weight of various parts such as simple bush, flanged pipe, lathe centre, rivet, bolt head, ring, cotter, and knuckle pin.
6.3. Estimation of selling price of simple engineering parts.
6.4. Estimation of fabricated jobs such as simple cylindrical tank and cuboidal tank.