Fundamentals of Machine Component Design

Part 1 Fundamentals Chapter 1: Mechanical Engineering design in Broad Perspective 1.1 An Overview of the Subject 1.2 Safety Considerations 1.3 Ecological Considerations 1.4 Societal Considerations, 1.5 Overall Design Considerations 1.6 Systems of Units 1.7 Methodology for Solving Machine Component Problems 1.8 Work and Energy 1.9 Power 1.10 Conservation of Energy Chapter 2: Load Analysis 2.1 Introduction 2.2 Equilibrium Equations and Free-Body Diagrams 2.3 Beam Loading 2.4 Locating Critical Sections-Force Flow Concept 2.5 Load Division Between Redundant Supports 2.6 Force Flow Concept Applied to Redundant Ductile Structures Chapter 3: Materials 3.1 Introduction 3.2 The Static Tensile Test-"Engineering" Stress-Strain Relationships 3.3 Implications of the "Engineering" Stress-Strain Curve 3.4 The Static Tensile Test-"True" Stress-Strain Relationships 3.5 Energy-Absorbing Capacity 3.6 Estimating Strength Properties from Penetration Hardness Tests 3.7 Use of "Handbook" Data for Material Strength Properties 3.8 Machinability 3.9 Cast Iron 3.10 Steel 3.11 Nonferrous Alloys 3.12 Plastics, and Composites 3.13 Material Selection Charts 3.14 Engineering Material Selection Process Chapter 4: Static Body Stresses 4.1 Introduction 4.2 Axial Loading 4.3 Direct Shear Loading 4.4 Torsional Loading, 4.5 Pure Bending Loading, Straight Beams 4.6 Pure Bending Loading, Curved Beams 4.7 Transverse Shear Loading in Beams 4.8 Induced Stresses, Mohr Circle Representation 4.9 Combined Stresses-Mohr Circle Representation 4.10 Stress Equations Related to Mohr's Circle 4.11 Three-Dimensional Stresses 4.12 Stress Concentration Factor, Kt 4.13 Importance of Stress Concentration 4.14 Residual Stresses Caused by Yielding-Axial Loading 4.15 Residual Stresses Caused by Yielding-Bending and Torsional Loading 4.16 Thermal Stresses 4.17 Importance of Residual Stresses, Chapter 5: Elastic strain, Deflection, and Stability 5.1 Introduction 5.2 Strain Definition, Measurement, and Mohr Circle Representation 5.3 Analysis of Strain-Equiangular Rosettes 5.4 Analysis of Strain-Rectangular Rosettes 5.5 Elastic Stress-Strain Relationships and Three-Dimensional Mohr Circles 5.6 Deflection and Spring Rate-Simple Cases 5.7 Beam Deflection 5.8 Determining Elastic Deflections by Castigliano's Method 5.9 Redundant Reactions by Castigliano's Method 5.10 Euler Column Buckling-Elastic Instability 5.11 Effective Column Length for Various End Conditions 5.12 Column Design Equations-J. B. Johnson Parabola 5.13 Eccentric Column Loading-the Secant Formula 5.14 Equivalent Column Stresses 5.15 Other Types of Buckling 5.16 Finite Element Analysis Chapter 6: Failure Theories, Safety Factors, and Reliability 6.1 Introduction 6.2 Types of Failure 6.3 Fracture Mechanics-Basic Concepts 6.4 Fracture Mechanics-Applications 6.5 The "Theory" of Static Failure Theories 6.6 Maximum-Normal-Stress Theory, 265 6.7 Maximum-Shear-Stress Theory, 265 6.8 Maximum-Distortion-Energy Theory (Maximum- Octahedral-Shear-Stress Theory 6.9 Modified Mohr Theory 6.10 Selection and Use of Failure Theories 6.11 Safety Factors-Concept and Definition 6.12 Safety Factors-Selection of a Numerical Value 6.13 Reliability 6.14 Normal Distributions 6.15 Interference Theory of Reliability Prediction Chapter 7: Impact 7.1 Introduction 7.2 Stress and Deflection Caused by Linear and Bending Impact 7.3 Stress and Deflection Caused by Torsional Impact 7.4 Effect of Stress Raisers on Impact Strength Chapter 8: Fatigue 8.1 Introduction, 312 8.2 Basic Concepts, 312 8.3 Standard Fatigue Strengths ( ) for Rotating Bending, 314 8.4 Fatigue Strengths for Reversed Bending and Reversed Axial Loading, 320 8.5 Fatigue Strength for Reversed Torsional Loading, 321 8.6 Fatigue Strength for Reversed Biaxial Loading, 322 8.7 Influence of Surface and Size on Fatigue Strength, 323 8.8 Summary of Estimated Fatigue Strengths for Completely Reversed Loading, 326 8.9 Effect of Mean Stress on Fatigue Strength, 326 8.10 Effect of Stress Concentration with Completely Reversed Fatigue Loading, 334 8.11 Effect of Stress Concentration with Mean Plus Alternating Loads 8.12 Fatigue Life Prediction with Randomly Varying Loads 8.13 Effect of Surface Treatments on the Fatigue Strength of a Part 8.14 Mechanical Surface Treatments-Shot Peening and Others 8.15 Thermal and Chemical Surface-Hardening Treatments (Induction Hardening, Carburizing, and Others) 8.16 Fatigue Crack Growth 8.17 General Approach for Fatigue Design Chapter 9: Surface Damage 9.1 Introduction 9.2 Corrosion: Fundamentals 9.3 Corrosion: Electrode and Electrolyte Heterogeneity 9.4 Design for Corrosion Control 9.5 Corrosion Plus Static Stress 9.6 Corrosion Plus Cyclic Stress 9.7 Cavitation Damage 9.8 Types of Wear 9.9 Adhesive Wear 9.10 Abrasive Wear 9.11 Fretting 9.12 Analytical Approach to Wear 9.13 Curved-Surface Contact Stresses 9.14 Surface Fatigue Failures 9.15 Closure Part 2 Applications Chapter 10: Threaded Fasteners and Power Screws 10.1 Introduction 10.2 Thread Forms, Terminology, and Standards 10.3 Power Screws 10.4 Static Screw Stresses 10.5 Threaded Fastener Types 10.6 Fastener Materials and Methods of Manufacture 10.7 Bolt Tightening and Initial Tension 10.8 Thread Loosening and Thread Locking 10.9 Bolt Tension with External Joint-Separating Force 10.10 Bolt (or Screw) Selection for Static Loading 10.11 Bolt (or Screw) Selection for Fatigue Loading: Fundamentals 10.12 Bolt (or Screw) Selection for Fatigue Loading: Using Special Test Data 10.13 Increasing Bolted-Joint Fatigue Strength Chapter 11 : Rivets, Welding, and Bonding 11.1 Introduction 11.2 Rivets 11.3 Welding Processes 11.4 Welded Joints Subjected to Static Axial and Direct Shear Loading 11.5 Welded Joints Subjected to Static Torsional and Bending Loading 11.6 Fatigue Considerations in Welded Joints 11.7 Brazing and Soldering 11.8 Adhesives Chapter 12 : Springs 12.1 Introduction, 497 12.2 Torsion Bar Springs, 497 12.3 Coil Spring Stress and Deflection Equations, 498 12.4 Stress and Strength Analysis for Helical Compression Springs-Static Loading 12.5 End Designs of Helical Compression Springs 12.6 Buckling Analysis of Helical Compression Springs 12.7 Design Procedure for Helical Compression Springs-Static Loading 12.8 Design of Helical Compression Springs for Fatigue Loading 12.9 Helical Extension Springs 12.10 Beam Springs (Including Leaf Springs) 12.11 Torsion Springs 12.12 Miscellaneous Springs Chapter 13 : Lubrication and Sliding Bearings 13.1 Types of Lubricants 13.2 Types of Sliding Bearings 13.3 Types of Lubrication 13.4 Basic Concepts of Hydrodynamic Lubrication 13.5 Viscosity 13.6 Temperature and Pressure Effects on Viscosity 13.7 Petroff's Equation for Bearing Friction 13.8 Hydrodynamic Lubrication Theory 13.9 Design Charts for Hydrodynamic Bearings 13.10 Lubricant Supply 13.11 Heat Dissipation, and Equilibrium Oil Film Temperature 13.12 Bearing Materials 13.13 Hydrodynamic Bearing Design 13.14 Boundary and Mixed-Film Lubrication 13.15 Thrust Bearings 13.16 Elastohydrodynamic Lubrication Chapter 14 : Rolling-Element Bearings 14.1 Comparison of Alternative Means for Supporting Rotating Shafts 14.2 History of Rolling-Element Bearings 14.3 Rolling-Element Bearing Types 14.4 Design of Rolling-Element Bearings 14.5 Fitting of Rolling-Element Bearings 14.6 "Catalogue Information" for Rolling-Element Bearings 14.7 Bearing Selection 14.8 Mounting Bearings to Provide Properly for Thrust Load Chapter 15 : Spur Gears 15.1 Introduction and History 15.2 Geometry and Nomenclature 15.3 Interference and Contact Ratio 15.4 Gear Force Analysis 15.5 Gear-Tooth Strength 15.6 Basic Analysis of Gear-Tooth-Bending Stress (Lewis Equation) 15.7 Refined Analysis of Gear-Tooth-Bending Strength: Basic Concepts 15.8 Refined Analysis of Gear-Tooth-Bending Strength: Recommended Procedure 15.9 Gear-Tooth Surface Durability-Basic Concepts 15.10 Gear-Tooth Surface Fatigue Analysis-Recommended Procedure 15.11 Spur Gear Design Procedures 15.12 Gear Materials 15.13 Gear Trains Chapter 16 : Helical, Bevel, and Worm Gears 16.1 Introduction 16.2 Helical-Gear Geometry and Nomenclature 16.3 Helical-Gear Force Analysis 16.4 Helical-Gear-Tooth-Bending and Surface Fatigue Strengths 16.5 Crossed Helical Gears 16.6 Bevel Gear Geometry and Nomenclature 16.7 Bevel Gear Force Analysis 16.8 Bevel-Gear-Tooth-Bending and Surface Fatigue Strengths 16.9 Bevel Gear Trains; Differential Gears 16.10 Worm Gear Geometry and Nomenclature 16.11 Worm Gear Force and Efficiency Analysis 16.12 Worm-Gear-Bending and Surface Fatigue Strengths 16.13 Worm Gear Thermal Capacity Chapter 17 : Shafts and Associated Parts 17.1 Introduction 17.2 Provision for Shaft Bearings 17.3 Mounting Parts onto Rotating Shafts 17.4 Rotating-Shaft Dynamics 17.5 Overall Shaft Design 17.6 Keys, Pins, and Splines 17.7 Couplings and Universal Joints Chapter 18 : Clutches and Brakes 18.1 Introduction 18.2 Disk Clutches 18.3 Disk Brakes 18.4 Energy Absorption and Cooling 18.5 Cone Clutches and Brakes 18.6 Short-Shoe Drum Brakes 18.7 Eternal Long-Shoe Drum Brakes 18.8 Internal Long-Shoe Drum Brakes 18.9 Band Brakes Chapter 19 : Miscellaneous Machine Components 19.1 Introduction 19.2 Flat Belts 19.3 V-Belts 19.4 Toothed Belts 19.5 Roller Chains 19.6 Inverted-Tooth Chains 19.7 History of Hydrodynamic Drives 19.8 Fluid Couplings 19.9 Hydrodynamic Torque Converters Chapter 20: Machine Component Interrelationships (ONLINE ONLY) Appendix A: Units A-1a Conversion Factors for British Gravitational, English, and SI Units A-1b Conversion Factor Equalities Listed by Physical Quantity A-2a Standard SI Prefixes A-2b SI Units and Symbols A-3 Suggested SI Prefixes for Stress Calculations A-4 Suggested SI Prefixes for Linear-Deflection Calculations A-5 Suggested SI Prefixes for Angular-Deflection Calculations Appendix B: Properties of Sections and Solids B-1a Properties of Sections, 813 B-1b Dimensions and Properties of Steel Pipe and Tubing Sections, 814 B-2 Mass and Mass Moments of Inertia of Homogeneous Solids, 816 Appendix C: Material Properties and Uses C-1 Physical Properties of Common Metals C-2 Tensile Properties of Some Metals C-3a Typical Mechanical Properties and Uses of Gray Cast Iron C-3b Mechanical Properties and Typical Uses of Malleable Cast Iron C-3c Average Mechanical Properties and Typical Uses of Ductile (Nodular) Iron C-4a Mechanical Properties of Selected Carbon and Alloy Steels C-4b Typical Uses of Plain Carbon Steels C-5a Properties of Some Water-Quenched and Tempered Steels C-5b Properties of Some Oil-Quenched and Tempered Carbon Steels C-5c Properties of Some Oil-Quenched and Tempered Alloy Steels C-6 Effect of Mass on Strength Properties of Steel C-7 Mechanical Properties of Some Carburizing Steels C-8 Mechanical Properties of Some Wrought Stainless Steels C-9 Mechanical Properties of Some Iron-Based Superalloys C-10 Mechanical Properties, Characteristics, and Typical Uses of Some Wrought Aluminum Alloys C-11 Tensile Properties, Characteristics, and Typical Uses of Some Cast-Aluminum Alloys C-12 Temper Designations for Aluminum and Magnesium Alloys C-13 Mechanical Properties of Some Copper Alloys C-14 Mechanical Properties of Some Magnesium Alloys C-15 Mechanical Properties of Some Nickel Alloys C-16 Mechanical Properties of Some Wrought-Titanium Alloys C-17 Mechanical Properties of Some Zinc Casting Alloys C-18a Representative Mechanical Properties of Some Common Plastics C-18b Properties of Some Common Glass-Reinforced and Unreinforced Thermoplastic Resins C-18c Typical Applications of Common Plastics C-19 Material Classes and Selected Members of Each Class C-20 Designer's Subset of Engineering Materials C-21 Processing Methods Used Most Frequently with Different Materials C-22 Joinability of Materials C-23 Materials for Machine Components C-24 Relations Between Failure Modes and Material Properties Appendix D: Shear, Moment, and Deflection Equations for Beams D-1 Cantilever Beams D-2 Simply Supported Beams D-3 Beams with Fixed Ends Appendix E: Fits and Tolerances E-1 Fits and Tolerances for Holes and Shafts E-2 Standard Tolerance for Holes and Shafts E-1 Tolerance Grades Produced from Machining Processes Appendix F: MIL-HDBK-5J, Department of Defense Handbook: Metallic Materials and Elements For Aerospace Vehicle Structures, Appendix G: Force Equilibrium: A Vectorial Approach Appendix H: Normal Distributions Appendix I : SN-Formula Appendix J : Gear Terminology and Contact-Ratio Analysis