PARTⅠ Principles of Design and Stress Analysis 1
Appendix 1 Properties of Areas 1
Appendices 1
Index 1
1 The Nature of Mechanical Design 2
Appendix 2 Preferred Basic Sizes and Screw Threads 3
The Big Picture 3
You Are the Designer 4
1-1 Objectives of This Chapter 4
Appendix 3 Design Properties of Carbon and Alloy Steels 6
1-2 The Mechanical Design Process 7
Appendix 4 Properties of Heat-treated Steels 8
1-4 Functions and Design Requirements 9
1-3 Skills Neededin Mechanical Design 9
1-5 Criteria for Evaluating Machine Design Decisions 10
1-6 Example of the Integration of Machine Elements into a Mechanical Design 11
1-8 Design Calculations 13
1-7 Computational Aids in This Book 13
1-9 Preferred Basic Sizes,Screw Threads,and Standard Shapes 14
Appendix 5 Properties of Carburized Steels 14
Appendix 6 Properties of Stainless Steel 15
Appendix 7 Properties of Structural Steels 16
Appendix 8 Design Properties of Cast Iron 17
Appendix 9 Typical Properties of Aluminum 18
Appendix 10 Typical Properties of Zinc Casting Alloys 19
Appendix 11 Properties of Titanium Alloys 20
1-10 Unit Systems 20
Appendix 12 Properties of Bronzes 21
1-11 Distinction among Weight,Force,and Mass 22
Appendix 13 Typical Properties of Selected Plastics 22
References 22
Problems 23
Appendix 14 Beam-Deflection Formulas 23
2 Materials in Mechanical Design 24
The Big Picture 25
You Are the Designer 26
2-1 Objectives of This Chapter 26
2-2 Properties of Metals 26
Appendix 15 Stress Concentration Factors 32
2-3 Classification of Metals and Alloys 33
2-4 Variability of Material Properties Data 34
2-5 Carbon and Alloy Steel 35
Appendix 16 Steel Structural Shapes 36
2-6 Conditions for Steels and Heat Treatment 38
Appendix 17 Aluminum Structural Shapes 42
2-7 Stainless Steels 42
2-10 Cast Iron 43
2-9 Tool Steels 43
2-8 Structural Steel 43
Appendix 18 Conversion Factors 44
2-11 Powdered Metals 45
Appendix 19 Hardness Conversion Table 45
Answers to Selected Problems 46
2-12 Aluminum 46
2-13 Zinc Alloys 47
2-14 Titanium 48
2-15 Copper,Brass,and Bronze 49
2-17 Plastics 50
2-16 Nickel-based Alloys 50
2-18 Composite Materials 52
References 64
Problems 65
3 Stress and Deformation Analysis 67
The Big Picture 68
You Are the Designer 68
3-3 Representing Stresses on a Stress Element 69
3-2 Philosophy of a Safe Design 69
3-1 Objectives of This Chapter 69
3-4 Direct Stresses:Tension and Compression 70
3-5 Deformation under Direct Axial Loading 72
3-6 Direct Shear Stress 72
3-7 Relationship among Torque,Power,and Rotational Speed 74
3-8 Torsional Shear Stress 75
3-9 Torsional Deformation 77
3-10 Torsion in Members Having Noncircular Cross Sections 77
3-11 Torsion in Closed,Thin-walled Tubes 79
3-12 Open Tubes and a Comparison with Closed Tubes 80
3-13 Vertical Shearing Stress 81
3-14 Special Shearing Stress Formulas 83
3-15 Stress Due to Bending 84
3-16 Flexural Center for Beams 86
3-17 Beam Deflections 87
3-18 Equations for Deflected Beam Shape 89
3-19 Beams with Concentrated Bending Moments 91
3-20 Combined Normal Stresses:Superposition Principle 95
3-21 Stress Concentrations 97
3-22 Notch Sensitivity and Strength Reduction Factor 100
Problems 101
References 101
4 Combined Stresses and Mohr's Circle 112
The Big Picture 113
You Are the Designer 113
4-1 Objectives of This Chapter 115
4-2 General Case of Combined Stress 115
4-3 Mohr's Circle 122
4-4 Mohr's Circle Practice Problems 128
4-5 Case When Both Principal Stresses Have the Same Sign 132
4-6 Mohr's Circle for Special Stress Conditions 135
4-7 Analysis of Complex Loading Conditions 138
Problems 139
5 Design for Different Types of Loading 140
The Big Picture 141
You Are the Designer 142
5-1 Objectives of This Chapter 143
5-2 Types of Loading and Stress Ratio 143
5-4 Factors Affecting the Endurance Strength 149
5-3 Endurance Strength 149
5-5 Estimating Actual Endurance Strength,sn' 154
5-7 Predictions of Failure 157
5-6 Design for Different Types of Loading 157
5-8 Design Factors 159
5-9 Methods of Computing Design Factor or Design Stress 160
5-10 General Design Procedure 163
5-11 Design Examples 167
Problems 178
References 178
The Big Picture 189
6 Columns 189
6-1 Objectives of This Chapter 190
You Are the Designer 190
6-3 End Fixity and Effective Length 191
6-2 Properties of the Cross Section of a Column 191
6-5 Transition Slenderness Ratio 193
6-4 Slenderness Ratio 193
6-6 Long Column Analysis:The Euler Formula 194
6-7 Short Column Analysis:The J.B.Johnson Formula 198
6-8 Column Analysis Spreadsheet 200
6-9 Efficient Shapes for Column Cross Sections 203
6-10 The Design of Columns 204
6-11 Crooked Columns 209
6-12 Eccentrically Loaded Columns 210
References 216
Problems 216
PART Ⅱ Design of a Mechanical Drive 221
7 Belt Drives and Chain Drives 225
The Big Picture 226
You Are the Designer 228
7-1 Objectives of This Chapter 228
7-2 Types of Belt Drives 228
7-3 V-Belt Drives 230
7-4 V-Belt Drive Design 233
7-5 Chain Drives 241
7-6 Design of Chain Drives 243
References 253
Problems 254
8 Kinematics of Gears 256
The Big Picture 257
You Are the Designer 261
8-1 Objectives of This Chapter 262
8-2 Spur Gear Styles 262
8-3 Spur Gear Geometry:Involute-Tooth Form 263
8-4 Spur Gear Nomenclature and Gear-Tooth Features 265
8-5 Interference between Mating Spur Gear Teeth 275
8-6 Velocity Ratio and Gear Trains 277
8-7 Helical Gear Geometry 284
8-8 Bevel Gear Geometry 289
8-9 Types of Wormgearing 294
8-10 Geometry of Worms and Wormgears 296
8-11 Typical Geometry of Wormgear Sets 299
8-12 Train Value for Complex Gear Trains 303
8-13 Devising Gear Trains 305
References 312
Problems 313
9 Spur Gear Design 318
The Big Picture 319
9-1 Objectives of This Chapter 320
You Are the Designer 320
9-2 Concepts from Previous Chapters 321
9-3 Forces on Gear Teeth 322
9-4 Gear Manufacture 325
9-5 Gear Quality 327
9-6 Allowable Stress Numbers 328
9-7 Gear Materials 330
9-8 Stresses in Gear Teeth 337
9-9 Selection of Gear Material Based on Bending Stress 346
9-10 Pitting Resistance of Gear Teeth 351
9-11 Selection of Gear Material Based on Contact Stress 355
9-12 Design of Spur Gears 360
9-13 Gear Design for the Metric Module System 365
9-14 Computer-aided Spur Gear Design and Analysis 367
9-15 Use of the Spur Gear Design Spreadsheet 371
9-16 Power-transmitting Capacity 373
9-17 Practical Considerations for Gears and Interfaces with Other Elements 383
References 386
Problems 387
10 Helical Gears,Bevel Gears,and Wormgearing 392
The Big Picture 393
10-1 Objectives of This Chapter 395
10-2 Forces on Helical Gear Teeth 395
You Are the Designer 395
10-3 Stresses in Helical Gear Teeth 398
10-4 Pitting Resistance for Helical Gear Teeth 402
10-5 Design of Helical Gears 403
10-6 Forces on Straight Bevel Gears 405
10-7 Bearing Forces on Shafts Carrying Bevel Gears 408
10-8 Bending Moments on Shafts Carrying Bevel Gears 412
10-9 Stresses in Straight Bevel Gear Teeth 412
10-10 Design of Bevel Gears for Pitting Resistance 415
10-11 Forces,Friction,and Efficiency in Wormgear Sets 417
10-12 Stress in Wormgear Teeth 423
10-13 Surface Durability of Wormgear Drives 424
References 429
Problems 430
11 Keys,Couplings,and Seals 433
The Big Picture 434
You Are the Designer 435
11-1 Objectives of This Chapter 435
11-2 Keys 436
11-3 Materials for Keys 440
11-4 Stress Analysis to Determine Key Length 440
11-5 Splines 445
11-6 Other Methods of Fastening Elements 447
to Shafts 449
11-7 Couplings 454
11-8 Universal Joints 455
11-9 Retaining Rings and Other Means of Axial 457
Location 459
11-10 Types of Seals 462
11-11 Seal Materials 465
References 469
Problems 469
12 Shaft Design 471
The Big Picture 472
You Are the Designer 473
12-1 Objectives of This Chapter 473
12-2 Shaft Design Procedure 473
12-3 Forces Exerted on Shafts by Machine Elements 476
12-4 Stress Concentrations in Shafts 480
12-5 Design Stresses for Shafts 483
12-6 Shafts in Bending and Torsion Only 487
12-7 Shaft Design Example 489
12-8 Recommended Basic Sizes for Shafts 493
12-9 Additional Design Examples 494
12-10 Spreadsheet Aid for Shaft Design 502
References 503
Problems 504
13 Tolerances and Fits 515
The Big Picture 516
You Are the Designer 517
13-1 Objectives of This Chapter 517
13-2 Factors Affecting Tolerances and Fits 518
13-3 Tolerances,Production Processes,and Cost 518
13-4 Preferred Basic Sizes 520
13-5 Clearance Fits 522
13-6 Interference Fits 526
13-7 Transition Fits 528
13-8 Robust Product Design 528
13-9 Stresses for Force Fits 529
References 533
Problems 533
14 Rolling Contact Bearings 535
The Big Picture 536
You Are the Designer 537
14-2 Types of Rolling Contact Bearings 538
14-1 Objectives of This Chapter 538
14-3 Thrust Bearings 542
14-4 Mounted Bearings 542
14-5 Bearing Materials 544
14-6 Load/Life Relationship 544
14-7 Bearing Manufacturers' Data 545
14-8 Design Life 549
14-9 Bearing Selection:Radial Loads Only 551
14-10 Bearing Selection:Radial and Thrust Loads Combined 552
14-11 Mounting of Bearings 554
14-12 Tapered Roller Bearings 556
14-13 Practical Considerations in the Application of Bearings 558
14-14 Importance of Oil Film Thickness in Bearings 562
14-15 Life Prediction under Varying Loads 563
References 564
Problems 565
15 Completion of the Design of a Power Transmission 567
The Big Picture 568
15-1 Objectives of This Chapter 568
15-2 Description of the Power Transmission to Be Designed 568
15-3 Design Alternatives and Selection of the Design Approach 570
15-5 General Layout and Design Details of the Reducer 572
15-4 Design Alternatives for the Gear-Type Reducer 572
15-6 Final Design Details for the Shafts 592
15-7 Assembly Drawing 595
References 597
PART Ⅲ Design Details and Other Machine Elements 599
16 Plain Surface Bearings 600
The Big Picture 601
You Are the Designer 603
16-1 Objectives of This Chapter 603
16-2 The Bearing Design Task 603
16-3 Bearing Parameter,μn/p 605
16-4 Bearing Materials 606
16-5 Design of Boundary-lubricated Bearings 608
16-6 Full-Film Hydrodynamic Bearings 614
16-7 Design of Full-Film Hydrodynamically Lubricated Bearings 615
16-8 Practical Considerations for Plain Surface Bearings 621
16-9 Hydrostatic Bearings 622
References 625
Problems 626
17 Power Screws and Ball Screws 627
The Big Picture 628
You Are the Designer 629
17-1 Objectives of This Chapter 630
17-2 Power Screws 630
17-3 Ball Screws 636
References 639
Problems 639
18 Fasteners 641
The Big Picture 642
You Are the Designer 644
18-2 Other Types of Fasteners and Accessories 644
18-1 Objectives of This Chapter 644
18-3 Bolt Materials and Strength 646
18-4 Thread Designations 648
18-5 Performance of Bolted Joints 650
18-6 Other Means of Fastening 653
References 654
Problems 654
19 Springs 655
The Big Picture 656
You Are the Designer 657
19-1 Objectives of This Chapter 657
19-2 Kinds of Springs 658
19-3 Helical Compression Springs 661
19-4 Stresses and Deflection for Helical Compression Springs 670
19-5 Analysis of Spring Characteristics 672
19-6 Design of Helical Compression Springs 674
19-7 Extension Springs 683
19-8 Helical Torsion Springs 687
References 694
Problems 695
20 Machine Frames,Bolted Connections,and Welded Joints 697
The Big Picture 698
You Are the Designer 699
20-1 Objectives of This Chapter 699
20-2 Machine Frames and Structures 699
20-3 Eccentrically Loaded Bolted Joints 704
20-4 Welded Joints 707
References 715
Problems 716
21 Electric Motors 719
The Big Picture 720
You Are the Designer 721
21-1 Objectives of This Chapter 721
21-2 Motor Selection Factors 722
21-3 AC Power and General Information about AC Motors 723
21-4 Principles of Operation of AC Induction Motors 724
21-5 AC Motor Performance 726
21-6 Three-Phase,Squirrel-Cage Induction Motors 727
21-7 Single-Phase Motors 730
21-8 AC Motor Frame Types and Enclosures 733
21-9 Controls forAC Motors 736
21-10 DC Power 744
21-11 DC Motors 745
21-12 DC Motor Control 748
21-13 Other Types of Motors 750
References 751
Problems 751
22 Motion Control:Clutches and Brakes 754
The Big Picture 755
22-2 Descriptions of Clutches and Brakes 757
22-1 Objectives of This Chapter 757
You Are the Designer 757
22-3 Types of Friction Clutches and Brakes 759
22-4 Performance Parameters 763
22-5 Time Required to Accelerate a Load 765
22-6 Inertia of a System Referred to the Clutch Shaft Speed 767
22-7 Effective Inertia for Bodies Moving Linearly 769
22-8 Energy Absorption:Heat-Dissipation Requirements 770
22-9 Response Time 771
22-10 Friction Materials and Coefficient of Friction 773
22-11 Plate-Type Clutch or Brake 774
22-12 Caliper Disc Brakes 776
22-13 Cone Clutch or Brake 776
22-14 Drum Brakes 778
22-15 Band Brakes 782
22-16 Other Types of Clutches and Brakes 784
Problems 786
References 786
23 Design Projects 789
23-2 Design Projects 790
23-1 Objectives of This Chapter 790