Machine Design Course

Lesson 1 • The Engineering Design Process

Covers iterative design stages from problem definition to final solution. Connects design methodology to real machine development workflows.

Lesson 2 • Static Equilibrium and Free Body Diagrams

Reviews static force and moment analysis applied to machine members. Provides the analytical base for subsequent stress and deflection calculations.

Lesson 3 • Material Properties and Selection

Surveys mechanical, thermal, and chemical material properties relevant to machine components. Builds the foundation for informed material selection decisions.

Lesson 4 • Design Safety and Risk Fundamentals

Introduces factor of safety, design margins, and basic risk assessment methods. Frames safety as a quantitative design requirement throughout the course.

Lesson 1 • Static Failure Theories

Compares ductile and brittle failure criteria for statically loaded components. Enables selection of the appropriate theory based on material behaviour.

Lesson 2 • Combined Loading Analysis

Applies superposition to members subjected to simultaneous axial, bending, and torsional loads. Prepares students for realistic multi-load machine component scenarios.

Lesson 3 • Deflection and Stiffness Analysis

Calculates beam and shaft deflections using integration and energy methods. Links stiffness requirements to functional performance and alignment constraints.

Lesson 4 • Stress Concentrations

Explains geometric discontinuities that amplify local stress in machine parts. Introduces stress concentration factors and their application to design calculations.

Lesson 1 • S-N Curves and Endurance Limits

Introduces stress-life diagrams and endurance limit concepts for ferrous and nonferrous materials. Provides the quantitative basis for infinite-life design.

Lesson 2 • Mean and Alternating Stress Diagrams

Uses Goodman, Gerber, and Soderberg diagrams to assess fatigue under non-zero mean stress. Enables safe-life design for components with combined static and cyclic loads.

Lesson 3 • Fatigue Failure Mechanisms

Describes crack initiation, propagation, and final fracture under cyclic stress. Connects microscopic damage mechanisms to macroscopic design implications.

Lesson 4 • Endurance Limit Modifying Factors

Applies surface finish, size, reliability, and loading correction factors to the endurance limit. Produces realistic fatigue strength estimates for actual components.

Lesson 1 • Rigid and Flexible Couplings

Compares rigid, jaw, disc, and universal joint couplings for torque and misalignment capacity. Guides coupling selection based on power, speed, and alignment conditions.

Lesson 2 • Shaft Deflection and Critical Speed

Calculates lateral and angular deflections and determines critical whirl speeds. Ensures shaft stiffness meets bearing alignment and vibration avoidance requirements.

Lesson 3 • Shaft Design for Strength and Fatigue

Applies combined bending and torsion fatigue criteria to rotating shaft design. Integrates stress concentration, endurance limit, and factor of safety into shaft sizing.

Lesson 1 • Rolling-Element Bearing Types and Geometry

Surveys ball, roller, tapered, and thrust bearing configurations and their load capabilities. Establishes geometric and kinematic relationships governing bearing performance.

Lesson 2 • Rolling Bearing Load and Life Analysis

Applies dynamic load rating and L10 life equations to bearing selection. Incorporates combined radial and thrust loads using equivalent load calculations.

Lesson 3 • Bearing Mounting and Sealing

Addresses fit selection, preload, and axial location methods for bearing assemblies. Covers seal types to prevent lubricant loss and contaminant ingress.

Lesson 4 • Lubrication Fundamentals and Lubricant Selection

Covers viscosity, viscosity index, and lubrication regimes from boundary to full film. Links lubricant properties to bearing operating conditions and service life.

Lesson 1 • Belt, Chain, and Flexible Drive Design

Designs V-belt, synchronous belt, and roller chain drives for power and speed requirements. Selects drive components using catalogue ratings and service factor adjustments.

Lesson 2 • Worm and Bevel Gear Design

Extends gear analysis to worm drives and straight or spiral bevel gears. Covers efficiency, thrust loads, and mounting considerations unique to these configurations.

Lesson 3 • Gear Surface Durability and Wear

Calculates Hertzian contact stress and compares it to allowable pitting resistance. Addresses scoring, abrasive wear, and surface hardness requirements for gear longevity.

Lesson 4 • Gear Geometry and Kinematics

Defines involute tooth geometry, pitch, pressure angle, and gear ratio relationships. Provides the geometric foundation for all subsequent gear stress and wear analyses.

Lesson 1 • Threaded Fastener Mechanics

Analyses thread geometry, torque-tension relationships, and bolt preload mechanics. Establishes the mechanical basis for all bolted joint design calculations.

Lesson 2 • Bolt Patterns Under Shear and Moment

Analyses bolt groups loaded in direct shear, eccentric shear, and combined tension-shear. Determines the critical bolt and required bolt size for complex joint geometries.

Lesson 3 • Bolted Joint Analysis Under External Load

Models joint stiffness, load sharing between bolt and members, and separation criteria. Applies the joint diagram to determine bolt fatigue load and factors of safety.

Lesson 4 • Weld Joint Design and Stress Analysis

Calculates throat stress in fillet and groove welds under axial, bending, and torsional loads. Applies weld group properties to size welds for static and fatigue conditions.

Lesson 1 • Drum and Disc Brake Analysis

Calculates braking torque, actuating force, and self-energisation for drum and disc brakes. Addresses thermal capacity and fade resistance for safe brake design.

Lesson 2 • Torsion and Leaf Springs

Analyses stress and deflection in torsion bar and multi-leaf spring configurations. Extends spring design to automotive and industrial suspension applications.

Lesson 3 • Disc and Cone Clutch Design

Derives torque capacity for disc and cone clutches under uniform pressure and wear assumptions. Selects friction materials and actuating forces for required torque transmission.

Lesson 4 • Helical Compression and Extension Springs

Applies Wahl correction factor and spring index to stress and deflection calculations. Covers buckling, natural frequency, and fatigue design for dynamic spring applications.