Part 1 Basics 1
1 Introduction 3
1-1 Design 5
1-2 Mechanical Engineering Design 7
1-3 Your Path to Competence 12
1-4 Technology Can Be Fragile 12
1-5 Interaction between Design Process Elements 14
1-6 Codes and Standards 17
1-7 Economics 18
1-8 Safety and Product Liability 20
1-9 The Adequacy Assessment 20
1-10 Uncertainty 22
1-11 Stress and Strength 26
1-12 Design Factors and Factors of Safety 29
1-13 Reliability 30
1-14 Numbers， Units， and Preferred Units 31
Problems 37
2 Addressing Uncertainty 47
2-1 Questions Come with the Territory 49
2-2 Estimating Statistical Parameters 50
2-3 Probability Density Function and Cumulative Distribution Function 53
2-4 Linear Regression 55
2-5 Propagation of Error 58
2-6 Simulation 61
2-7 Design Factor and Factor of Safety 63
2-8 Limits and Fits 68
2-9 Dimensions and Tolerances 71
2-10 Summary 77
Problems 79
3 Stress 93
3-1 Stress Components 94
3-2 Mohr Circles 96
3-3 Triaxial Stress 100
3-4 Uniformly Distributed Stress 102
3-5 Elastic Strain 103
3-6 Stress-Strain Relations 104
3-7 Equilibrium 104
3-8 Shear and Moment 106
3-9 Singularity Functions 108
3-10 Normal Stress in Flexure 111
3-11 Beams with Asymmetrical Sections 118
3-12 Shear Stresses in Beams 118
3-13 Shear Stresses in Rectangular-Section Beams 121
3-14 Torsion 123
3-15 Stress Concentration 129
3-16 Stresses in Cylinders 132
3-17 Rotating Rings 135
3-18 Press and Shrink Fits 135
3-19 Temperature Effects 137
3-20 Curved Members in Flexure 138
3-21 Contact Stress 144
3-22 Propagation of Error 149
3-23 Summary 154
Problems 154
4 Deflection and Stiffness 175
4-1 Spring Rates 176
4-2 Tension， Compression， and Torsion 177
4-3 Deflection Due to Bending 178
4-4 Finding Deflection by Integration 180
4-5 Finding Deflection by the Area-Moment Method 187
4-6 Finding Deflection by the Use of Singularity Functions 190
4-7 Strain Energy 193
4-8 Castigliano’s Theorem 195
4-9 Statistically Indeterminate Problems 198
4-10 Deflection of Curved Members 200
4-11 Compression Members—General 204
4-12 Long Columns with Central Loading 206
4-13 Intermediate-Length Columns with Central Loading 210
4-14 Columns with Eccentric Loading 210
4-15 Struts， or Short Compression Members 214
4-16 An Application： Round-Bar Clamps 216
4-17 Deflection of Energy-Dissipative Assemblies 220
4-18 Shock and Impact 229
4-19 Suddenly-Applied Loading 230
4-20 Propagation of Error 233
Problems 237
Part 2 Failure Prevention 253
5 Materials 255
5-1 Static Strength 256
5-2 Plastic Deformation 261
5-3 Strength and Cold Work 265
5-4 Hardness 268
5-5 Impact Properties 269
5-6 Temperature Effects 271
5-7 Numbering Systems 272
5-8 Sand Casting 274
5-9 Shell Molding 274
5-10 Investment Casting 275
5-11 Powder-Metallurgy Process 275
5-12 Hot-Working Processes 275
5-13 Cold-Working Processes 276
5-14 The Heat Treatment of Steel 277
5-15 Alloy Steels 279
5-16 Corrosion-Resistant Steels 280
5-17 Casting Materials 281
5-18 Nonferrous Metals 283
5-19 Plastics 285
5-20 Notch Sensitivity 287
5-21 Introduction to Fracture Mechanics 288
5-22 Stress-Corrosion Cracking 303
5-23 Quantitative Estimation of Properties of Cold-Worked Metals 303
5-24 Quantitative Estimation of Properties of Heat-Treated Steels 307
Problems 308
6 Failures Resulting from Static Loading 315
6-1 Static Strength 316
6-2 Stress Concentration 319
6-3 Hypotheses of Failure 322
6-4 Ductile Materials： Maximum-Shear-Stress （Tresca or Guest） Hypothesis 324
6-5 Ductile Materials：Strain-Energy Hypotheses 326
6-6 Ductile Materials：Internal-Friction Hypothesis 332
6-7 Criticism of Hypotheses by Data in Ductile Materials 334
6-8 Brittle Materials： Maximum-Normal-Stress （Rankine） Hypothesis 335
6-9 Brittle Materials： Modifications of the Mohr Hypothesis 337
6-10 The Criticism of Hypotheses by Data in Brittle Materials 341
6-11 What Our Failure Models Tell Us 342
6-12 Interference—General 343
6-13 Static or Quasi-Static Loading on a Shaft 347
Problems 352
7 Failure Resulting from Variable Loading 359
7-1 Introduction to Fatigue in Metals 360
7-2 Strain-Life Relationships 361
7-3 Stress-Life Relationships 367
7-4 The Endurance Limit 369
7-5 Fatigue Strength 372
7-6 Endurance-Limit Modifying Factors 374
7-7 Stress Concentration and Notch Sensitivity 383
7-8 Applying What We Have Learned about Endurance Limit and Endurance Strength 387
7-9 The Distributions 395
7-10 Characterizing Fluctuating Stresses 396
7-11 Failure Loci under Variable Stresses 398
7-12 Torsional Fatigue Strength under Pulsating Stresses 408
7-13 Combinations of Loading Modes 408
7-14 Stochastic Failure Loci under Fluctuating Stresses 411
7-15 Cumulative Fatigue Damage 414
7-16 The Fracture-Mechanics Approach 421
7-17 Surface Fatigue Strength 423
7-18 The Designer’s Fatigue Diagram 429
7-19 An Important Design Decision： The Design Factor in Fatigue 431
Problems 436
Summary of Parts 1 and 2 441
Part 3 Design of Mechanical Elements 443
8 Screws， Fasteners， and the Design of Nonpermanent Joints 445
8-1 Thread Standards and Definitions 446
8-2 The Mechanics of Power Screws 450
8-3 Threaded Fasteners 457
8-4 Joints—Fastener Stiffness 458
8-5 Joints—Member Stiffness 461
8-6 Bolt Strength 466
8-7 Tension Joints—The External Load 470
8-8 Relating Bolt Torque to Bolt Tension 471
8-9 Statistically Loaded Tension Joint—Preload 477
8-10 Gasketed Joints 483
8-11 Tension Joints—Dynamic Loading 484
8-12 Adequacy Assessment， Specification Set，Decision Set， and Design 492
8-13 Shear Joints 498
8-14 Setscrews 504
8-15 Pins and Keys 504
Problems 513
9 Welding， Brazing， Bonding，and the Design of Permanent Joints 527
9-1 Welding Symbols 528
9-2 Butt and Fillet Welds 530
9-3 Stresses in Welded Joints in Torsion 535
9-4 Stresses in Welded Joints in Bending 540
9-5 The Strength of Welded Joints 542
9-6 Specification Set， Adequacy Assessment，and Decision Set 544
9-7 Static Loading 549
9-8 Fatigue Loading 554
9-9 Resistance Welding 557
9-10 Bolted and Riveted Joints Loaded in Shear 558
9-11 Adhesive Bonding and Design Considerations 562
Problems 579
10 Mechanical Springs 589
10-1 Stresses in Helical Springs 590
10-2 The Curvature Effect 591
10-3 Deflection of Helical Springs 592
10-4 Extension Springs 592
10-5 Compression Springs 595
10-6 Stability 596
10-7 Spring Materials 598
10-8 Helical Compression Springs for Static Service 609
10-9 Critical Frequency of Helical Springs 620
10-10 Fatigue Loading 622
10-11 Helical Compression Springs for Dynamic Service 625
10-12 Design of a Helical Compression Spring for Dynamic Service 629
10-13 Design of Extension Springs 637
10-14 Designing Helical Coil Torsion Springs 664
10-15 Belleville Springs 678
10-16 Miscellaneous Springs 678
10-17 Summary 680
Problems 683
11 Rolling-Contact Bearings 689
11-1 Bearing Types 690
11-2 Bearing Life 693
11-3 Bearing Load-Life Trade-off at Constant Reliability 694
11-4 Bearing Survival： The Reliability-Life Trade-off 696
11-5 Load-Life-Reliability Trade-off 697
11-6 Combined Radial and Thrust Loading 699
11-7 Variable Loading 704
11-8 Selection of Ball and Cylindrical Roller Bearings 709
11-9 Selection of Tapered Roller Bearings 714
11-10 Adequacy Assessment for Selected Rolling-Contact Bearings 724
11-11 Lubrication 728
11-12 Mounting and Enclosure 729
Problems 732
12 Lubrication and Journal Bearings 739
12-1 Types of Lubrication 741
12-2 Viscosity 741
12-3 Petroff’s Equation 744
12-4 Stable Lubrication 750
12-5 Thick-Film Lubrication 751
12-6 Hydrodynamic Theory 752
12-7 Design Considerations 757
12-8 The Relations of the Variables 759
12-9 Steady-State Conditions in Self-Contained Bearings 722
12-10 Clearance 781
12-11 Pressure-Fed Bearings 792
12-12 Loads and Materials 803
12-13 Bearing Types 805
12-14 Thrust Bearings 806
12-15 Boundary-Lubricated Bearings 807
Problems 823
13 Gearing-General 831
13-1 Types of Gears 832
13-2 Nomenclature 833
13-3 Tooth Systems 835
13-4 Conjugate Action 837
13-5 Involute Properties 838
13-6 Fundamentals 839
13-7 Contact Ratio 844
13-8 Interference 845
13-9 The Forming of Gear Teeth 848
13-10 Straight Bevel Gears 850
13-11 Parallel Helical Gears 851
13-12 Worm Gears 855
13-13 Gear Trains 856
13-14 Force Analysis—Spur Gearing 860
13-15 Force Analysis—Bevel Gearing 863
13-16 Force Analysis—Helical Gearing 866
13-17 Force Analysis—Worm Gearing 869
13-18 Gear Ratios and Numbers of Teeth 874
13-19 Gear-Shaft Speeds and Bearings 878
Problems 883
14 Spur and Helical Gears 897
14-1 The Lewis Bending Equation 898
14-2 Surface Durability 907
14-3 AGMA Stress Equations 909
14-4 AGMA Strength Equations 910
14-5 Geometry Factors I and J （ZI and YI ） 915
14-6 Elastic Coefficient C p（Z E） 920
14-7 Dynamic Factor K ’V 920
14-8 Overload Factor K O 922
14-9 Surface Condition Factors Cf and Z R 922
14-10 Size Factor K s 923
14-11 Load-Distribution Factor K m or K H 923
14-12 Hardness-Ratio Factor C H 924
14-13 Load Cycles Factors YN and Z N 926
14-14 Reliability Factors KR and Y Z 927
14-15 Temperature Factors KT and Y θ 928
14-16 Rim-Thickness Factor KB 928
14-17 Safety Factors SF and SH 929
14-18 Analysis 929
14-19 An Adequacy Assessment of a Gear Mesh 940
14-20 Design of a Gear Mesh 942
Problems 947
15 Bevel and Worm Gears 951
15-1 Bevel Gearing—General 952
15-2 Bevel-Gear Stresses and Strengths 954
15-3 AGMA Equation Factors 957
15-4 Straight-Bevel Gear Analysis 969
15-5 Design of a Straight-Bevel Gear Mesh 972
15-6 Worm Gearing—AGMA Equation 974
15-7 Worm-Gear Analysis 978
15-8 Designing a Worm-Gear Mesh 980
15-9 Buckingham Wear Load 985
Problems 986
16 Clutches， Brakes， Couplings， and Flywheels 991
16-1 Rudiments of Brake Analysis 993
16-2 Internal Expanding Rim Clutches and Brakes 999
16-3 External Contracting Rim Clutches and Brakes 1008
16-4 Band-Type Clutches and Brakes 1011
16-5 Friction-Contact Axial Clutches 1013
16-6 Disk Brakes 1016
16-7 Cone Clutches and Brakes 1022
16-8 Self-Locking Tapers and Torque Capacity 1024
16-9 Energy Considerations 1026
16-10 Temperature Rise 1027
16-11 Friction Materials 1031
16-12 Miscellaneous Clutches and Couplings 1032
16-13 Flywheels 1034
16-14 Adequacy Assessment for Clutches and Brakes 1039
Problems 1040
17 Flexible Mechanical Elements 104917-1 Belts 1050
17-2 Flat- and Round-Belt Drives 1053
17-3 V Belts 1069
17-4 Timing Belts 1077
17-5 Roller Chain 1079
17-6 Wire Rope 1088
17-7 Flexible Shafts 1097
Problems 1098
18 Shafts and Axles 1107
18-1 Introduction 1108
18-2 Sufficing Geometric Constraints 1111
18-3 Sufficing Strength Constraints 1120
18-4 The Adequacy Assessment 1128
18-5 Shaft Materials 1134
18-6 Hollow Shafts 1135
18-7 Critical Speeds 1135
18-8 Shaft Design 1141
18-9 Computer Considerations 1142
Problems 1146
Appendixes 1153
A Statistical Relations 1153
B Linear Regression 1161
C Propagation of Error Relations 1163
D Simulation 1165
E Useful Tables 1169
F Solutions to Selected Problems 1231
Index 1237