Introduction to the design process - factors influencing machine design, selection of materials based on mechanical properties, preferred numbers, fits and tolerances - direct, bending and torsional stress equations – impact and shock loading – calculation of principle stresses for various load combinations, eccentric loading, curved beams – crane hook and „C‟ frame -design based on strength and stiffness –factor of safety - theories of failure.

Stress concentration - theoretical stress concentration factor - Size factor - Surface limits factor - fatigue stress concentration factor - notch sensitivity - Variable and cyclic loads – Fatigue strength – S-N curve – Continued cyclic stress – Soderberg and Goodman equations. Design of cotter joints and knuckle joints. with Case study.

Straight bevel gear terminologies, tooth forces and stresses, equivalent number of teeth. Estimating the dimensions of pair of straight bevel gears. Worm Gear: Merits and demerits terminology. materials-forces and stresses, efficiency, estimating the size of the worm gear pair

Step ratio, ray diagram, kinematics layout. Design of sliding mesh gearbox, constant mesh gear box, multi speed gear box, Theory of variable speed gear box, Introduction to fluid couplings and Torque converters for automotive applications. Brakes: Design of internal and external shoe brakes, Disc brakes (self-study)

Design of Piston – Connecting rod – Crankshaft -Design of Piston – Connecting rod – Crankshaft and Flywheel – Design of Pulleys – Case study on Design and Analysis of Engine Components.