PES University · Guide: Dr. Chandrashekara C V
Computational Design of Machine Elements
Simplified the manual calculations of the design of machine elements using MATLAB. The design procedure and values were cross-verified using a Data Handbook. The implemented machine elements are shafts, springs, belt drive, chain drive, bevel gear, helical gear, spur gear, and worm gear.
Problem Statement
- Manual Bottleneck: Traditional machine element design requires repetitive handbook lookups and hand calculations, consuming hours per design iteration and introducing human error.
- Material Selection: Engineers must manually cross-reference multiple tables for material properties, standard sizes, and safety factors—a tedious and error-prone process.
- Safety Verification: Each design requires manual stress analysis against permissible values, with separate checks for wear, dynamic loading, and thermal effects depending on element type.
Methodology
This project translates standard design handbook procedures into an interactive MATLAB application, implementing computational workflows for eight fundamental machine elements with automated material selection and safety verification.
Menu-Driven Architecture
The application features a menu-driven interface that guides users through the design process. Users select a machine element type, then provide input parameters through prompted dialogs. The system supports multiple design paths—for example, shaft design can proceed with diameter known or unknown, accommodating different engineering scenarios.
Material Database Integration
A database of 22+ materials is integrated via Excel lookup tables, automatically retrieving mechanical properties (yield strength, ultimate strength, allowable stresses) based on user selection. Standard sizes for pulleys, belt widths, chain pitches, and gear modules are also retrieved from reference tables, ensuring designs conform to manufacturing standards.
Safety Verification Logic: Each design calculation includes automatic safety checks comparing computed stresses against permissible values. The system evaluates wear resistance, dynamic loading effects, and for worm gears, heat generation versus dissipation capacity with artificial cooling recommendations when needed.
Results
Successfully automated design procedures for 8 machine elements with full parameter output and built-in safety verification.
| Element | Key Outputs | Special Features |
|---|---|---|
| Shaft | Diameter (d), Torque (T), Moment of Inertia (M) | P vs N, T vs N, D vs N trend graphs; hollow shaft support |
| Belt Drive | Pulley diameters (D1, D2), Belt length (L), Width (b), Tensions (T1, T2) | Standard size selection for pulleys and belt width |
| Chain Drive | Sprocket teeth (z1, z2), Chain pitch, Center distance, Chain length | Service factor tables; safety factor verification |
| Springs | Wire diameter (d), Mean coil diameter (D), Active coils (N), Free length, Pitch | Four end-type options; Wahl correction factor |
| Bevel Gear | Module (m), Face width (b), Pitch diameters, Tooth counts | Lewis form factor; wear and dynamic load checks |
| Helical Gear | Module, Diameters, Helix angle calculations, Forces (Ft, Fa, Fr) | Virtual teeth calculation; minimum face width check |
| Spur Gear | Module, Pitch diameters, Tooth counts, Face width | Three involute systems (14.5°, 20°, 20° stub) |
| Worm Gear | Center distance, Pitch diameters, Module, Lead angle, Efficiency | Heat generation vs. dissipation analysis; artificial cooling check |
Key Achievement Automated 8 machine element designs with safety verification
All design calculations cross-verified against Data Handbook values. The system eliminates manual lookup errors and provides instant feedback on design safety margins, enabling rapid iteration through design alternatives.
Future Scope
- Add graphical output for all machine elements (currently only shaft has trend plots)
- Implement a full GUI using MATLAB App Designer for improved user experience
- Add export functionality to generate design reports in PDF format
- Include additional machine elements (couplings, clutches, brakes, bearings)
- Add optimization routines to find minimum-weight or minimum-cost designs
Skills Technical skills developed
- MATLAB Programming: Menu-driven interfaces, Excel integration via xlsread/xlswrite, plotting and visualization
- Machine Design: Handbook procedures for shafts, gears, springs, belt/chain drives
- Database Design: Material property lookup tables, standard size references
- Engineering Analysis: Safety factor calculations, stress analysis, thermal analysis
Team Contributions & credits
Sole developer. Guided by Dr. Chandrashekara C V at PES University.
Additional Information
The complete MATLAB source code and Excel lookup tables are available on GitHub.
View Source Code on GitHub