Machine Elements in Mechanical Design, 6th edition

PART 1: PRINCIPLES OF DESIGN AND STRESS ANALYSIS

1. The Nature of Mechanical Design
The Big Picture
You Are the Designer
1-1 Objectives of this Chapter
1-2 The Design Process
1-3 Skills Needed in Mechanical Design
1-4 Functions, Design Requirements, and Evaluation Criteria
1-5 Example of the Integration of Machine Elements into a Mechanical Design
1-6 Computational AIDS in this Book
1-7 Design Calculations
1-8 Preferred Basic Sizes, Screw Threads, and Standard Shapes
1-9 Unit Systems
1-10 Distinction Among Weight, Force, and Mass
References
Internet Sites for General Mechanical Design
Internet Sites for Innovation and Managing Complex Design

2. Materials in Mechanical Design
The Big Picture
You Are the Designer
2-1 Objectives of this Chapter
2-2 Properties of Materials
2-3 Classification of Metals and Alloys
2-4 Variability of Material Properties Data
2-5 Carbon and Alloy Steel
2-6 Conditions for Steels and Heat Treatment
2-7 Stainless Steels
2-8 Structural Steel
2-9 Tool Steels
2-10 Cast Iron
2-11 Powdered Metals
2-12 Aluminum
2-13 Zinc Alloys and Magnesium
2-14 Nickel-Based Alloys and Titanium
2-15 Copper, Brass, and Bronze
2-16 Plastics
2-17 Composite Materials
2-18 Materials Selection
References
Internet Sites Related to Design Properties of Materials
Problems
Supplementary Problems
Internet-Based Assignments

3. Stress and Deformation Analysis
The Big Picture
You Are the Designer
3-1 Objective of This Chapter
3-2 Philosophy of a Safe Design
3-3 Representing Stresses on a Stress Element
3-4 Normal Stresses Due to Direct Axial Load
3-5 Deformation Under Direct Axial Loading
3-6 Shear Stress Due to Direct Shear Load
3-7 Torsional Load - Torque, Rotational Speed, and Power
3-8 Shear Stress Due to Torsional Load
3-9 Torsional Deformation
3-10 Torsion in Members Having Noncircular Cross Sections
3-11 Torsion in Closed, Thin-Walled Tubes
3-12 Torsion in Open Thin-Walled Tubes
3-13 Shear Stress Due to Bending
3-14 Shear Stress Due to Bending - Special Shearing Stress Formulas
3-15 Normal Stress Due to Bending
3-16 Beams with Concentrated Bending Moments
3-17 Flexural Center for Beam Bending
3-18 Beam Deflections
3-19 Equations for Deflected Beam Shapes
3-20 Curved Beams
3-21 Superposition Principle
3-22 Stress Concentrations
3-23 Notch Sensitivity and Strength Reduction Factor
References
Internet Sites Related to Stress and Deformation Analysis

4. Combined Stresses
The Big Picture
You Are the Designer
4-1 Objectives of this Chapter
4-2 General Case of Combined Stress
4-3 Stress Transformation
4-4 Mohr's Circle and Tresca and von Mises Stresses
4-5 Mohr's Circle Practice Problems
4-6 Mohr's Circle for Special Stress
4-7 Analysis of Complex Loading Conditions
Reference
Internet Sites
Problems

5. Design for Different Types of Loading
The Big Picture
You Are the Designer
5-1 Objectives of This Chapter
5-2 Types of Loading and Stress Ratio
5-3 Failure Theories
5-4 Design for Static Loading
5-5 Fatigue Strength and Endurance Strength
5-6 Estimate of Endurance Strength
5-7 Design for Cyclic Loading
5-8 Recommended Design and Processing for Fatigue Loading
5-9 Design Factors
5-10 Design Philosophy
5-11 General Design Procedure
5-12 Design Examples
5-13 Statistical Approaches to Design
5-14 Finite Life and Damage Accumulation Method

6. Columns
The Big Picture
You Are the Designer
6-1 Objectives of this Chapter
6-2 Properties of the Cross Section of a Column
6-3 End Fixity and Effective Length
6-4 Slenderness Ratio
6-5 Transition Slenderness Ratio
6-6 Long Column Analysis: The Euler Formula
6-7 Short Column Analysis: The J. B. Johnson Formula
6-8 Column Analysis Spreadsheet
6-9 Efficient Shapes for Column Cross Sections
6-10 The Design of Columns
6-11 Crooked Columns
6-12 Eccentrically Loaded Columns
References
Problems

PART 2: DESIGN OF A MECHANICAL DRIVE

7. Belt Drives and Chain Drives
The Big Picture
You Are the Designer
7-1 Objectives of this Chapter
7-2 Kinematics of Belt and Chain Drive Systems
7-3 Types of Belt Drives
7-4 V-Belt Drives
7-5 Synchronous Belt Drives
7-6 Chain Drives
7-7 Wire Rope
References
Internet Sites Related to Belt Drives and Chain
Drives
Problems

8. Kinematics of Gears
The Big Picture
You Are the Designer
8-1 Objectives of This Chapter
8-2 Spur Gear Styles
8-3 Spur Gear Geometry: Involute-Tooth Form
8-4 Spur Gear Nomenclature and Gear-Tooth Features
8-5 Interference between Mating Spur Gear Teeth
8 -6 Internal Gear Geometry
8-7 Helical Gear Geometry
8-8 Bevel Gear Geometry
8-9 Types of Wormgearing
8-10 Geometry of Worms and Wormgears
8-11 Gear Manufacturing
8-12 Gear Quality
8-13 Velocity Ratio and Gear Trains
8-14 Devising Gear Trains
Reference
Internet Sites Related to Kinematics of Gears
Problems

9. Spur Gear Design
The Big Picture
You Are the Designer
9-1 Objectives of this Chapter
9-2 Concepts from Previous Chapters
9-3 Forces, Torque, and Power in Gearing
9-4 Allowable Stress Numbers
9-5 Bending Stress in Gear Teeth
9-6 Contact Stress in Gear Teeth
9-7 Metallic Gear Materials
9-8 Selection of Gear Material
9-9 Design of Spur Gears
9-10 Gear Design for the Metric Module System
9-11 Computer-Aided Spur Gear Design and Analysis
9-12 Use of the Spur Gear Design Spreadsheet
9-13 Power-Transmitting Capacity
9-14 Plastics Gearing
9-15 Practical Considerations for Gears and Interfaces with other Elements
References
Internet Sites Related to Spur Gear Design
Problems

10. Helical Gears, Bevel Gears, and Wormgearing
The Big Picture
You Are the Designer
10-1 Objectives of this Chapter
10-2 Forces on Helical Gear Teeth
10-3 Stresses in Helical Gear Teeth
10-4 Pitting Resistance for Helical Gear Teeth
10-5 Design of Helical Gears
10-6 Forces on Straight Bevel Gears
10-7 Bearing Forces on Shafts Carrying Bevel Gears
10-8 Bending Moments on Shafts Carrying Bevel Gears
10-9 Stresses in Straight Bevel Gear Teeth
10-10 Forces, Friction, and Efficiency in Wormgear Sets
10-11 Stress in Wormgear Teeth
10-12 Surface Durability of Wormgear Drives
10-13 Emerging Technology and Software for Gear Design
References
Internet Sites Related to Helical Gears, Bevel Gears, and Wormgearing
Problems

11. Keys, Couplings, and Seals
The Big Picture
You Are the Designer
11-1 Objectives of this Chapter
11-2 Keys
11-3 Materials for Keys
11-4 Stress Analysis to Determine Key Length
11-5 Splines
11-6 Other Methods of Fastening Elements to Shafts
11-7 Couplings
11-8 Universal Joints
11-9 Other Means of Axial Location
11-10 Types of Seals
11-11 Seal Materials
References
Internet Sites for Keys, Couplings, and Seals
Problems

12. Shaft Design
The Big Picture
You Are the Designer
12-1 Objectives of This Chapter
12-2 Shaft Design Procedure
12-3 Forces Exerted on Shafts by Machine Elements
12-4 Stress Concentrations in Shafts
12-5 Design Stresses for Shafts
12-6 Shafts in Bending and Torsion Only
12-7 Shaft Design Examples–Bending and Torsion Only
12-8 Shaft Design Example–Bending and Torsion with Axial Forces
12-9 Spreadsheet Aid for Shaft Design
12-10 Shaft Rigidity and Dynamic Considerations
12-11 Flexible Shafts
References
Internet Sites for Shaft Design
Problems

13. Tolerances and Fits
The Big Picture
You Are the Designer
13-1 Objectives of this Chapter
13-2 Factors Affecting Tolerances and Fits
13-3 Tolerances, Production Processes, and Cost
13-4 Preferred Basic Sizes
13-5 Clearance Fits
13-6 Interference Fits
13-7 Transition Fits
13-8 Stresses for Force Fits
13-9 General Tolerancing Methods
13-10 Robust Product Design
References
Internet Sites Related to Tolerances and Fits
Problems

14. Rolling Contact Bearings
The Big Picture
You Are the Designer
14-1 Objectives of This Chapter
14-2 Types of Rolling Contact Bearings
14-3 Thrust Bearings
14-4 Mounted Bearings
14-5 Bearing Materials
14-6 Load/Life Relationship
14-7 Bearing Manufacturers' Data
14-8 Design Life
14-9 Bearing Selection: Radial Loads Only
14-10 Bearing Selection: Radial and Thrust Loads Combined
14-11 Bearing Selection from Manufacturers' Catalogs
14-12 Mounting of Bearings
14-13 Tapered Roller Bearings
14-14 Practical Considerations in the Application of Bearings
14-15 Importance of Oil Film Thickness in Bearings
14-16 Life Prediction under Varying Loads
14-17 Bearing Designation Series
References
Internet Sites Related to Rolling Contact Bearings
Problems

15. Completion of the Design of a Power Transmission
The Big Picture
15-1 Objectives of this Chapter
15-2 Description of the Power Transmission to be Designed
15-3 Design Alternatives and Selection of the Design Approach
15-4 Design Alternatives for the Gear-Type Reducer
15-5 General Layout and Design Details of the Reducer
15-6 Final Design Details for the Shafts
15-7 Assembly Drawing
References
Internet Sites Related to Transmission Design

PART 3: DESIGN DETAILS AND OTHER MACHINE ELEMENTS

16. Plain Surface Bearings
The Big Picture
You Are the Designer
16-1 Objectives of This Chapter
16-2 The Bearing Design Task
16-3 Bearing Parameter, μn/p
16-4 Bearing Materials
16-5 Design of Boundary-Lubricated Bearings
16-6 Full-Film Hydrodynamic Bearings
16-7 Design of Full-Film Hydro-dynamically Lubricated Bearings
16-8 Practical Considerations for Plain Surface Bearings
16-9 Hydrostatic Bearings
16-10 Tribology: Friction, Lubrication, and Wear
References
Internet Sites Related to Plain Bearings and Lubrication

17. Linear Motion Elements
The Big Picture
You Are the Designer
17-1 Objectives of This Chapter
17-2 Power Screws
17-3 Ball Screws
17-4 Application Considerations for Power Screws and Ball Screws
References
Internet Sites for Linear Motion Elements
Problems

18. Springs
The Big Picture
You Are the Designer
18-1 Objectives of this Chapter
18-2 Kinds of Springs
18-3 Helical Compression Springs
18-4 Stresses and Deflection for Helical Compression Springs
18-5 Analysis of Spring Characteristics
18-6 Design of Helical Compression Springs
18-7 Extension Springs
18-8 Helical Torsion Springs
18-9 Improving Spring Performance by Shot Peening
18-10 Spring Manufacturing
References
Internet Sites Relevant to Spring Design
Problems

19. Fasteners
The Big Picture
You Are the Designer
19-1 Objectives of this Chapter
19-2 Bolt Materials and Strength
19-3 Thread Designations and Stress Area
19-4 Clamping Load and Tightening of Bolted Joints
19-5 Externally Applied Force on a Bolted Joint
19-6 Thread Stripping Strength
19-7 Other Types of Fasteners and Accessories
19-8 Other Means of Fastening and Joining
References
Internet Sites Related to Fasteners
Problems

20. Machine Frames, Bolted Connections, and Welded Joints
The Big Picture
You Are the Designer
20-1 Objectives of this Chapter 6
20-2 Machine Frames and Structures
20-3 Eccentrically Loaded Bolted Joints
20-4 Welded Joints
References
Internet Sites for Machine Frames, Bolted Connections, and Welded Joints
Problems

21. Electric Motors and Controls
The Big Picture
You Are the Designer
21-1 Objectives of This Chapter
21-2 Motor Selection Factors
21-3 AC Power and General Information about AC Motors 6
21-4 Principles of Operation of AC Induction Motors
21-5 AC Motor Performance
21-6 Three-Phase, Squirrel-Cage Induction Motors
21-7 Single-Phase Motors
21-8 AC Motor Frame Types and Enclosures
21-9 Controls for AC Motors
21-10 DC Power
21-11 DC Motors
21-12 DC Motor Control
21-13 Other Types of Motors
References
Internet Sites for Electric Motors and Controls
Problems

22. Motion Control: Clutches and Brakes
The Big Picture
You Are the Designer
22-1 Objectives of this Chapter
22-2 Descriptions of Clutches and Brakes
22-3 Types of Friction Clutches and Brakes
22-4 Performance Parameters
22-5 Time Required to Accelerate a Load
22-6 Inertia of a System Referred to the Clutch Shaft Speed
22-7 Effective Inertia for Bodies Moving Linearly
22-8 Energy Absorption: Heat-Dissipation Requirements
22-9 Response Time
22-10 Friction Materials and Coefficient of Friction
22-11 Plate-Type Clutch or Brake
22-12 Caliper Disc Brakes
22-13 Cone Clutch or Brake
22-14 Drum Brakes
22-15 Band Brakes
22-16 Other Types of Clutches and Brakes
References
Internet Sites for Clutches and Brakes
Problems

23. Design Projects
23-1 Objectives of this Chapter
23-2 Design Projects

APPENDICES
Appendix 1: Properties of Areas
Appendix 2: Preferred Basic Sizes and Screw Threads
Appendix 3: Design Properties of Carbon and Alloy Steels
Appendix 4: Properties of Heat-Treated Steels
Appendix 5: Properties of Carburized Steels
Appendix 6: Properties of Stainless Steels
Appendix 7: Properties of Structural Steels
Appendix 8: Design Properties of Cast Iron–U.S. Units Basis
Appendix 8A: Design Properties of Cast Iron–SI Units Basis
Appendix 9: Typical Properties of Aluminum
Appendix 10-1: Properties of Die-Cast Zinc Alloys
Appendix 10-2: Properties of Die-Cast Magnesium Alloys
Appendix 11-1: Properties of Nickel-Based Alloys
Appendix 11-2: Properties of Titanium Alloys
Appendix 12: Properties of Bronzes, Brasses, and Other Copper Alloys
Appendix 13: Typical Properties of Selected Plastics
Appendix 14: Beam-Deflection Formulas
Appendix 15: Commercially Available Shapes Used for Load-Carrying Members
Appendix 16: Conversion Factors
Appendix 17: Hardness Conversion Table
Appendix 18: Stress Concentration Factors
Appendix 19: Geometry Factor, I, for Pitting for Spur Gears