Machine Design and Mechanisms

Machine Design and Mechanisms is a cornerstone discipline within mechanical engineering that integrates the study of motion (kinematics) with the principles of creating robust mechanical systems. It involves the analysis and synthesis of mechanisms—such as linkages, cams, and gears—to produce desired movements and transmit forces, while also applying principles of stress analysis, material science, and failure theories to select and size individual machine elements like shafts, bearings, fasteners, and springs. The ultimate goal is to design and build functional, safe, and reliable machines and devices that can withstand operational loads and environments throughout their intended lifespan.

1. Introduction to Machine Design
   1. Overview of Machine Design
      1. Definition and Scope
      2. Historical Development
      3. Role of Machine Design in Engineering
      4. Relationship to Other Engineering Disciplines
   2. The Design Process
      1. Problem Identification and Specification
         1. Defining the Design Problem
         2. Establishing Functional Requirements
         3. Setting Design Constraints
         4. Creating Design Specifications
         5. Market and User Analysis
      2. Conceptual Design and Synthesis
         1. Generating Design Concepts
         2. Brainstorming Techniques
         3. Morphological Analysis
         4. Feasibility Assessment
         5. Concept Selection Methods
         6. Decision Matrices
      3. Analysis and Optimization
         1. Preliminary Calculations
         2. Design Variables and Parameters
         3. Design Optimization Techniques
         4. Sensitivity Analysis
         5. Trade-off Studies
      4. Detailed Design
         1. Component Sizing
         2. Material Selection
         3. Tolerance Assignment
         4. Interface Design
      5. Prototyping and Testing
         1. Types of Prototypes
         2. Rapid Prototyping Methods
         3. Testing Procedures
         4. Design Iteration and Improvement
         5. Validation and Verification
      6. Documentation and Communication
         1. Engineering Drawings and Schematics
         2. Bill of Materials
         3. Technical Reports
         4. Design Review and Presentation
         5. Design History Files
   3. Engineering Materials and Selection
      1. Properties of Materials
         1. Mechanical Properties
            1. Strength
            2. Toughness
            3. Hardness
            4. Ductility
            5. Fatigue Resistance
            6. Creep Resistance
            7. Impact Resistance
         2. Physical Properties
            1. Density
            2. Thermal Conductivity
            3. Electrical Conductivity
            4. Thermal Expansion
            5. Magnetic Properties
         3. Chemical Properties
            1. Corrosion Resistance
            2. Oxidation Resistance
            3. Chemical Compatibility
      2. Material Categories
         1. Metals and Alloys
            1. Ferrous Metals
            2. Non-ferrous Metals
            3. Heat Treatment Effects
         2. Polymers and Plastics
            1. Thermoplastics
            2. Thermosets
            3. Elastomers
         3. Ceramics and Composites
            1. Engineering Ceramics
            2. Fiber-reinforced Composites
            3. Metal Matrix Composites
      3. Standard Shapes and Sizes
         1. Bars and Rods
         2. Plates and Sheets
         3. Tubes and Pipes
         4. Structural Sections
         5. Standard Fasteners
      4. Material Selection Process
         1. Material Selection Charts
         2. Ashby Charts
         3. Performance Indices
         4. Cost Considerations
         5. Environmental Impact
         6. Availability and Supply Chain
   4. Manufacturing Considerations in Design
      1. Design for Manufacturing
         1. Minimizing Manufacturing Complexity
         2. Material Utilization
         3. Process Selection
         4. Tooling Considerations
         5. Production Volume Effects
      2. Design for Assembly
         1. Reducing Part Count
         2. Simplifying Assembly Operations
         3. Error-Proofing
         4. Assembly Sequence Planning
      3. Tolerances and Fits
         1. Types of Tolerances
         2. Geometric Dimensioning and Tolerancing
         3. Types of Fits
            1. Clearance Fits
            2. Interference Fits
            3. Transition Fits
         4. Surface Finish Requirements
         5. Tolerance Stack-up Analysis
      4. Manufacturing Processes Overview
         1. Machining Processes
         2. Forming Processes
         3. Joining Processes
         4. Surface Treatment Processes
   5. Codes, Standards, and Safety
      1. Role of Standards in Design
         1. International Standards
         2. National Standards
         3. Industry-Specific Standards
         4. Company Standards
      2. Factor of Safety
         1. Definition and Purpose
         2. Selection Criteria
         3. Application in Design
         4. Reliability Considerations
      3. Product Liability and Ethics
         1. Legal Responsibilities
         2. Ethical Considerations in Design
         3. Risk Assessment and Mitigation
         4. Safety Regulations and Compliance
         5. Product Recalls and Liability