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PARTⅠ Principles of Design and Stress Analysis1

Appendix 1 Properties of Areas1

Appendices1

Index1

1 The Nature of Mechanical Design2

Appendix 2 Preferred Basic Sizes and Screw Threads3

The Big Picture3

You Are the Designer4

1-1 Objectives of This Chapter4

Appendix 3 Design Properties of Carbon and Alloy Steels6

1-2 The Mechanical Design Process7

Appendix 4 Properties of Heat-treated Steels8

1-4 Functions and Design Requirements9

1-3 Skills Neededin Mechanical Design9

1-5 Criteria for Evaluating Machine Design Decisions10

1-6 Example of the Integration of Machine Elements into a Mechanical Design11

1-8 Design Calculations13

1-7 Computational Aids in This Book13

1-9 Preferred Basic Sizes,Screw Threads,and Standard Shapes14

Appendix 5 Properties of Carburized Steels14

Appendix 6 Properties of Stainless Steel15

Appendix 7 Properties of Structural Steels16

Appendix 8 Design Properties of Cast Iron17

Appendix 9 Typical Properties of Aluminum18

Appendix 10 Typical Properties of Zinc Casting Alloys19

Appendix 11 Properties of Titanium Alloys20

1-10 Unit Systems20

Appendix 12 Properties of Bronzes21

1-11 Distinction among Weight,Force,and Mass22

Appendix 13 Typical Properties of Selected Plastics22

References22

Problems23

Appendix 14 Beam-Deflection Formulas23

2 Materials in Mechanical Design24

The Big Picture25

You Are the Designer26

2-1 Objectives of This Chapter26

2-2 Properties of Metals26

Appendix 15 Stress Concentration Factors32

2-3 Classification of Metals and Alloys33

2-4 Variability of Material Properties Data34

2-5 Carbon and Alloy Steel35

Appendix 16 Steel Structural Shapes36

2-6 Conditions for Steels and Heat Treatment38

Appendix 17 Aluminum Structural Shapes42

2-7 Stainless Steels42

2-10 Cast Iron43

2-9 Tool Steels43

2-8 Structural Steel43

Appendix 18 Conversion Factors44

2-11 Powdered Metals45

Appendix 19 Hardness Conversion Table45

Answers to Selected Problems46

2-12 Aluminum46

2-13 Zinc Alloys47

2-14 Titanium48

2-15 Copper,Brass,and Bronze49

2-17 Plastics50

2-16 Nickel-based Alloys50

2-18 Composite Materials52

References64

Problems65

3 Stress and Deformation Analysis67

The Big Picture68

You Are the Designer68

3-3 Representing Stresses on a Stress Element69

3-2 Philosophy of a Safe Design69

3-1 Objectives of This Chapter69

3-4 Direct Stresses:Tension and Compression70

3-5 Deformation under Direct Axial Loading72

3-6 Direct Shear Stress72

3-7 Relationship among Torque,Power,and Rotational Speed74

3-8 Torsional Shear Stress75

3-9 Torsional Deformation77

3-10 Torsion in Members Having Noncircular Cross Sections77

3-11 Torsion in Closed,Thin-walled Tubes79

3-12 Open Tubes and a Comparison with Closed Tubes80

3-13 Vertical Shearing Stress81

3-14 Special Shearing Stress Formulas83

3-15 Stress Due to Bending84

3-16 Flexural Center for Beams86

3-17 Beam Deflections87

3-18 Equations for Deflected Beam Shape89

3-19 Beams with Concentrated Bending Moments91

3-20 Combined Normal Stresses:Superposition Principle95

3-21 Stress Concentrations97

3-22 Notch Sensitivity and Strength Reduction Factor100

Problems101

References101

4 Combined Stresses and Mohr's Circle112

The Big Picture113

You Are the Designer113

4-1 Objectives of This Chapter115

4-2 General Case of Combined Stress115

4-3 Mohr's Circle122

4-4 Mohr's Circle Practice Problems128

4-5 Case When Both Principal Stresses Have the Same Sign132

4-6 Mohr's Circle for Special Stress Conditions135

4-7 Analysis of Complex Loading Conditions138

Problems139

5 Design for Different Types of Loading140

The Big Picture141

You Are the Designer142

5-1 Objectives of This Chapter143

5-2 Types of Loading and Stress Ratio143

5-4 Factors Affecting the Endurance Strength149

5-3 Endurance Strength149

5-5 Estimating Actual Endurance Strength,sn'154

5-7 Predictions of Failure157

5-6 Design for Different Types of Loading157

5-8 Design Factors159

5-9 Methods of Computing Design Factor or Design Stress160

5-10 General Design Procedure163

5-11 Design Examples167

Problems178

References178

The Big Picture189

6 Columns189

6-1 Objectives of This Chapter190

You Are the Designer190

6-3 End Fixity and Effective Length191

6-2 Properties of the Cross Section of a Column191

6-5 Transition Slenderness Ratio193

6-4 Slenderness Ratio193

6-6 Long Column Analysis:The Euler Formula194

6-7 Short Column Analysis:The J.B.Johnson Formula198

6-8 Column Analysis Spreadsheet200

6-9 Efficient Shapes for Column Cross Sections203

6-10 The Design of Columns204

6-11 Crooked Columns209

6-12 Eccentrically Loaded Columns210

References216

Problems216

PART Ⅱ Design of a Mechanical Drive221

7 Belt Drives and Chain Drives225

The Big Picture226

You Are the Designer228

7-1 Objectives of This Chapter228

7-2 Types of Belt Drives228

7-3 V-Belt Drives230

7-4 V-Belt Drive Design233

7-5 Chain Drives241

7-6 Design of Chain Drives243

References253

Problems254

8 Kinematics of Gears256

The Big Picture257

You Are the Designer261

8-1 Objectives of This Chapter262

8-2 Spur Gear Styles262

8-3 Spur Gear Geometry:Involute-Tooth Form263

8-4 Spur Gear Nomenclature and Gear-Tooth Features265

8-5 Interference between Mating Spur Gear Teeth275

8-6 Velocity Ratio and Gear Trains277

8-7 Helical Gear Geometry284

8-8 Bevel Gear Geometry289

8-9 Types of Wormgearing294

8-10 Geometry of Worms and Wormgears296

8-11 Typical Geometry of Wormgear Sets299

8-12 Train Value for Complex Gear Trains303

8-13 Devising Gear Trains305

References312

Problems313

9 Spur Gear Design318

The Big Picture319

9-1 Objectives of This Chapter320

You Are the Designer320

9-2 Concepts from Previous Chapters321

9-3 Forces on Gear Teeth322

9-4 Gear Manufacture325

9-5 Gear Quality327

9-6 Allowable Stress Numbers328

9-7 Gear Materials330

9-8 Stresses in Gear Teeth337

9-9 Selection of Gear Material Based on Bending Stress346

9-10 Pitting Resistance of Gear Teeth351

9-11 Selection of Gear Material Based on Contact Stress355

9-12 Design of Spur Gears360

9-13 Gear Design for the Metric Module System365

9-14 Computer-aided Spur Gear Design and Analysis367

9-15 Use of the Spur Gear Design Spreadsheet371

9-16 Power-transmitting Capacity373

9-17 Practical Considerations for Gears and Interfaces with Other Elements383

References386

Problems387

10 Helical Gears,Bevel Gears,and Wormgearing392

The Big Picture393

10-1 Objectives of This Chapter395

10-2 Forces on Helical Gear Teeth395

You Are the Designer395

10-3 Stresses in Helical Gear Teeth398

10-4 Pitting Resistance for Helical Gear Teeth402

10-5 Design of Helical Gears403

10-6 Forces on Straight Bevel Gears405

10-7 Bearing Forces on Shafts Carrying Bevel Gears408

10-8 Bending Moments on Shafts Carrying Bevel Gears412

10-9 Stresses in Straight Bevel Gear Teeth412

10-10 Design of Bevel Gears for Pitting Resistance415

10-11 Forces,Friction,and Efficiency in Wormgear Sets417

10-12 Stress in Wormgear Teeth423

10-13 Surface Durability of Wormgear Drives424

References429

Problems430

11 Keys,Couplings,and Seals433

The Big Picture434

You Are the Designer435

11-1 Objectives of This Chapter435

11-2 Keys436

11-3 Materials for Keys440

11-4 Stress Analysis to Determine Key Length440

11-5 Splines445

11-6 Other Methods of Fastening Elements447

to Shafts449

11-7 Couplings454

11-8 Universal Joints455

11-9 Retaining Rings and Other Means of Axial457

Location459

11-10 Types of Seals462

11-11 Seal Materials465

References469

Problems469

12 Shaft Design471

The Big Picture472

You Are the Designer473

12-1 Objectives of This Chapter473

12-2 Shaft Design Procedure473

12-3 Forces Exerted on Shafts by Machine Elements476

12-4 Stress Concentrations in Shafts480

12-5 Design Stresses for Shafts483

12-6 Shafts in Bending and Torsion Only487

12-7 Shaft Design Example489

12-8 Recommended Basic Sizes for Shafts493

12-9 Additional Design Examples494

12-10 Spreadsheet Aid for Shaft Design502

References503

Problems504

13 Tolerances and Fits515

The Big Picture516

You Are the Designer517

13-1 Objectives of This Chapter517

13-2 Factors Affecting Tolerances and Fits518

13-3 Tolerances,Production Processes,and Cost518

13-4 Preferred Basic Sizes520

13-5 Clearance Fits522

13-6 Interference Fits526

13-7 Transition Fits528

13-8 Robust Product Design528

13-9 Stresses for Force Fits529

References533

Problems533

14 Rolling Contact Bearings535

The Big Picture536

You Are the Designer537

14-2 Types of Rolling Contact Bearings538

14-1 Objectives of This Chapter538

14-3 Thrust Bearings542

14-4 Mounted Bearings542

14-5 Bearing Materials544

14-6 Load/Life Relationship544

14-7 Bearing Manufacturers' Data545

14-8 Design Life549

14-9 Bearing Selection:Radial Loads Only551

14-10 Bearing Selection:Radial and Thrust Loads Combined552

14-11 Mounting of Bearings554

14-12 Tapered Roller Bearings556

14-13 Practical Considerations in the Application of Bearings558

14-14 Importance of Oil Film Thickness in Bearings562

14-15 Life Prediction under Varying Loads563

References564

Problems565

15 Completion of the Design of a Power Transmission567

The Big Picture568

15-1 Objectives of This Chapter568

15-2 Description of the Power Transmission to Be Designed568

15-3 Design Alternatives and Selection of the Design Approach570

15-5 General Layout and Design Details of the Reducer572

15-4 Design Alternatives for the Gear-Type Reducer572

15-6 Final Design Details for the Shafts592

15-7 Assembly Drawing595

References597

PART Ⅲ Design Details and Other Machine Elements599

16 Plain Surface Bearings600

The Big Picture601

You Are the Designer603

16-1 Objectives of This Chapter603

16-2 The Bearing Design Task603

16-3 Bearing Parameter,μn/p605

16-4 Bearing Materials606

16-5 Design of Boundary-lubricated Bearings608

16-6 Full-Film Hydrodynamic Bearings614

16-7 Design of Full-Film Hydrodynamically Lubricated Bearings615

16-8 Practical Considerations for Plain Surface Bearings621

16-9 Hydrostatic Bearings622

References625

Problems626

17 Power Screws and Ball Screws627

The Big Picture628

You Are the Designer629

17-1 Objectives of This Chapter630

17-2 Power Screws630

17-3 Ball Screws636

References639

Problems639

18 Fasteners641

The Big Picture642

You Are the Designer644

18-2 Other Types of Fasteners and Accessories644

18-1 Objectives of This Chapter644

18-3 Bolt Materials and Strength646

18-4 Thread Designations648

18-5 Performance of Bolted Joints650

18-6 Other Means of Fastening653

References654

Problems654

19 Springs655

The Big Picture656

You Are the Designer657

19-1 Objectives of This Chapter657

19-2 Kinds of Springs658

19-3 Helical Compression Springs661

19-4 Stresses and Deflection for Helical Compression Springs670

19-5 Analysis of Spring Characteristics672

19-6 Design of Helical Compression Springs674

19-7 Extension Springs683

19-8 Helical Torsion Springs687

References694

Problems695

20 Machine Frames,Bolted Connections,and Welded Joints697

The Big Picture698

You Are the Designer699

20-1 Objectives of This Chapter699

20-2 Machine Frames and Structures699

20-3 Eccentrically Loaded Bolted Joints704

20-4 Welded Joints707

References715

Problems716

21 Electric Motors719

The Big Picture720

You Are the Designer721

21-1 Objectives of This Chapter721

21-2 Motor Selection Factors722

21-3 AC Power and General Information about AC Motors723

21-4 Principles of Operation of AC Induction Motors724

21-5 AC Motor Performance726

21-6 Three-Phase,Squirrel-Cage Induction Motors727

21-7 Single-Phase Motors730

21-8 AC Motor Frame Types and Enclosures733

21-9 Controls forAC Motors736

21-10 DC Power744

21-11 DC Motors745

21-12 DC Motor Control748

21-13 Other Types of Motors750

References751

Problems751

22 Motion Control:Clutches and Brakes754

The Big Picture755

22-2 Descriptions of Clutches and Brakes757

22-1 Objectives of This Chapter757

You Are the Designer757

22-3 Types of Friction Clutches and Brakes759

22-4 Performance Parameters763

22-5 Time Required to Accelerate a Load765

22-6 Inertia of a System Referred to the Clutch Shaft Speed767

22-7 Effective Inertia for Bodies Moving Linearly769

22-8 Energy Absorption:Heat-Dissipation Requirements770

22-9 Response Time771

22-10 Friction Materials and Coefficient of Friction773

22-11 Plate-Type Clutch or Brake774

22-12 Caliper Disc Brakes776

22-13 Cone Clutch or Brake776

22-14 Drum Brakes778

22-15 Band Brakes782

22-16 Other Types of Clutches and Brakes784

Problems786

References786

23 Design Projects789

23-2 Design Projects790

23-1 Objectives of This Chapter790