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-spigot and socket, sleeve and cotter, jib and cotter joints- knuckle joints. with Case study.

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.

Stresses and deflections of helical springs – extension -compression springs – springs for fatigue loading, energy storage capacity – helical torsion springs – Flat Spiral Springs - leaf springs. Design of Rolling Contact and Sliding Contact Bearing

Design of Piston – Connecting rod – Crankshaft – Flywheel.