Unit 2125: Machine Design Fundamentals

1. Introduction to Machine Design

• Definition and scope of machine design
• Importance of machine design in engineering applications
• Overview of design process and methodologies
• Types of machine elements

2. Material Selection in Machine Design

• Material properties relevant to machine design (strength, toughness, fatigue resistance)
• Common materials used: metals, polymers, composites
• Selection criteria and decision-making processes
• Case examples of material selection

3. Statics and Dynamics in Machine Design

• Principles of statics: equilibrium, free-body diagrams
• Forces and moments analysis
• Dynamics: kinematics and kinetics of machine components
• Impact of dynamic loading and vibrations

4. Mechanical Power Transmission Systems

• Types of power transmission: gears, belts, chains, couplings
• Design considerations for each system
• Efficiency and performance factors
• Maintenance and troubleshooting

5. Bearing and Lubrication Systems

• Types of bearings: plain, rolling element, fluid film
• Selection criteria and load capacity
• Lubrication principles and methods
• Bearing failures and preventive measures

6. Design of Machine Elements

• Shafts, keys, pins, springs, fasteners
• Stress analysis and factor of safety
• Design calculations and standards
• Integration of machine elements into assemblies

7. Finite Element Analysis (FEA) in Machine Design

• Introduction to FEA concepts and workflow
• Meshing, boundary conditions, and load application
• Interpretation of results: stress, deformation
• Case studies demonstrating FEA application

8. Safety and Ergonomics in Machine Design

• Design for operator safety and risk assessment
• Ergonomic principles in machine interfaces
• Standards and regulations
• Human factors engineering

9. Design for Manufacturing and Assembly (DFMA)

• Principles of DFMA
• Simplification of parts and processes
• Cost and time reduction strategies
• Impact on product quality and reliability

10. Case Studies in Machine Design

• Analysis of real-world machine design projects
• Problem identification and solution approaches
• Lessons learned and best practices
• Group discussions and presentations