Introduction to 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 principal 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 finish 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 - Fits & tolerances – Detailed study on GD&T with industrial case studies.

Design of solid and hollow shafts for strength and rigidity – Design of shafts for combined bending and axial loads – shaft sizes. Design of couplings – Rigid – Muff, Split muff and Flange couplings - Flexible – Rigid Flange couplings.

Design of helical, leaf and torsional springs under constant and variable loads Design of Rolling Contact and Sliding Contact Bearing

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