معى اليوم احبتى فى الله
كتاب Machine_Elements_In_Mechanical_Design
Fourth Etdition
Contents
PART I Principles of Design and Stress
Analysis 1
1 The Nature of Mechanical Design 2
The Big Picture 3
You Are the Designer 9
1-1 Objectives of This Chapter 9
1-2 The Mechanical Design Process 9
1-3 Skills Needed in Mechanical Design 11
1-4 Functions, Design Requirements, and
Evaluation Criteria 11
1-5 Example of the Integration of Machine
Elements into a Mechanical Design 14
1-6 Computational Aids in This Book 17
1-7 Design Calculations 17
1-8 Preferred Basic Sizes, Screw Threads, and
Standard Shapes 18
1-9 Unit Systems 24
1-10 Distinction among Weight, Force, and Mass
26
References 27
Internet Sites 27
Problems 28
2 Materials in Mechanical Design 29
The Big Picture 30
You Are the Designer 31
Objectives of This Chapter 32
Properties of Materials 32
Classification of Metals and Alloys 44
Variability of Material Properties Data 45
Carbon and Alloy Steel 46
Conditions for Steels and Heat Treatment 49
Stainless Steels 53
Structural Steel 54
2-9 Tool Steels 54
2-10 Cast Iron 54
2-11 Powdered Metals 56
2-12 Aluminum 57
2-13 Zinc Alloys 59
2-14 Titanium 60
2-15 Copper, Brass, and Bronze 60
2-16 Nickel-Based Alloys 61
2-17 Plastics 61
2-18 Composite Materials 65
2-19 Materials Selection 77
References 78
Internet Sites 79
Problems 80
3 Stress and Deformation Analysis 83
The Big Picture 84
You Are the Designer 85
3-1 Objectives of This Chapter 89
3-2 Philosophy of a Safe Design 89
3-3 Representing Stresses on a Stress Element 89
3-4 Direct Stresses: Tension and Compression 90
3-5 Deformation under Direct Axial Loading 92
3-6 Direct Shear Stress 92
3-7 Relationship among Torque, Power, and
Rotational Speed 94
3-8 Torsional Shear Stress 95
3-9 Torsional Deformation 97
3-10 Torsion in Members Having Noncircular Cross
Sections 98
3-11 Torsion in Closed, Thin-Walled Tubes 100
3-12 Open Tubes and a Comparison with Clo.sed
Tubes 100
3-13 Vertical Shearing Stress 102
3-14 Special Shearing Stress Formulas 104
VII
Vlll Contents
3-15 Stress Due to Bending 105
3-16 Flexural Center for Beams 107
3-17 Beam Deflections 108
3-18 Equations for Deflected Beam Shape 110
3-19 Beams with Concentrated Bending
Moments 1 12
3-20 Combined Normal Stresses: Superposition
Principle 1 17
3-21 Stress Concentrations 119
3-22 Notch Sensitivity and Strength Reduction
Factor 122
References 123
Internet Sites 123
Problems 123
4 Combined Stresses and
Mohr's Circle 135
The Big Picture 136
You Are the Designer 136
4-1 Objectives of This Chapter 138
4-2 General Case of Combined Stress 138
4-3 Mohr's Circle 145
4-4 Mohr's Circle Practice Problems 151
4-5 Case When Both Principal Stresses Have the
Same Sign 155
4-6 Mohr's Circle for Special Stress
Conditions 158
4-7 Analysis of Complex Loading
Conditions 161
References 162
Internet Site 162
Problems 162
5 Design for Different Types
of Loading 163
The Big Picture 164
You Are the Designer 166
5-1 Objectives of This Chapter 166
5-2 Types of Loading and Stress Ratio 166
5-3 Endurance Strength 172
5-4 Estimated Actual Endurance Strength, .v,' 173
5-5 Example Problems for Estimating Actual
Endurance Strength 181
5-6 Design Philosophy 182
5-7 Design Factors 185
5-8 Predictions of Failure 186
5-9 Design Analysis Methods 193
5-10 General Design Procedure 197
5-11 Design Examples 200
5-12 Statistical Approaches to Design 213
5-13 Finite Life and Damage Accumulafion
Method 214
References 218
Problems 219
6 Columns 229
The Big Picture 230
You Are the Designer 231
6-1 Objectives of This Chapter 231
6-2 Properties of the Cross Section of a Column 232
6-3 End Fixity and Effective Length 232
6-4 Slenderness Ratio 234
6-5 Transition Slenderness Ratio 234
6-6 Long Column Analysis: The Euler
Formula 235
6-7 Short Column Analysis: The J. B. Johnson
Formula 239
6-8 Column Analysis Spreadsheet 241
6-9 Efficient Shapes for Column Cross
Sections 244
6-10 The Design of Columns 245
6-11 Crooked Columns 250
6-12 Eccentrically Loaded Columns 251
References 257
Problems 257
PART II Design of a Mechanical Drive 261
7 Belt Drives and Chain Drives 264
The Big Picture 265
You Are the Designer 267
7-1 Objecfives of This Chapter 267
7-2 Types of Belt Drives 268
7-3 V-Belt Drives 269
7 ^ V-Belt Drive Design 272
7-5 Chain Drives 283
7-6 Design of Chain Drives 285
References 296
Internet Sites 298
Problems 298
8 Kinematics of Gears 300
The Big Picture 301
You Are the Designer 305
8-1 Objectives of This Chapter 306
8-2 Spur Gear Styles 306
8-3 Spur Gear Geometry: Involute-Tooth Fonn 307
8-4 Spur Gear Nomenclature and Gear-Tooth
Features 308
8-5 Interference between Mating Spur Gear
Teeth 320
8-6 Velocity Ratio and Gear Trains 322
8-7 Helical Gear Geometry 329
8-8 Bevel Gear Geometry 333
8-9 Types of Wormgearing 339
8-10 Geometry of Worms and Wormgears 341
8-11 Typical Geometry of Wormgear Sets 344
8-12 Train Value for Complex Gear Trains 347
8-13 Devising Gear Trains 350
References 357
Internet Sites 357
Problems 358
9 Spur Gear Design 363
The Big Picture 364
You Are the Designer 365
9-1 Objectives of This Chapter 365
9-2 Concepts from Previous Chapters 366
9-3 Forces, Torque, and Power in Gearing 367
9 ^ Gear Manufacture 370
9-5 Gear Quality 372
9-6 Allowable Stress Numbers 378
9-7 Metallic Gear Materials 379
9-8 Stresses in Gear Teeth 385
9-9 Selection of Gear Material Based on Bending
Stress 394
9-10 Pitting Resistance of Gear Teeth 399
9-11 Selection of Gear Material Based on Contact
Stress 402
9-12 Design of Spur Gears 407
9-13 Gear Design for the Metric Module
System 413
9-14 Computer-Aided Spur Gear Design and
Analysis 415
9-15 Use of the Spur Gear Design Spreadsheet 419
9-16 Power-Transmitting Capacity 428
9-17 Practical Considerations for Gears and
Interfaces with Other Elements 430
9-18 Plastics Gearing 434
References 442
Internet Sites 443
Problems 444
10 Helical Gears, Bevel Gears,
and Wormgearing 449
The Big Picture 450
You Are the Designer 452
10-1 Objectives of This Chapter 452
10-2 Forces on Helical Gear Teeth 452
10-3 Stresses in Helical Gear Teeth 455
10-4 Pitting Resistance for Helical Gear Teeth 459
10-5 Design of Helical Gears 460
10-6 Forces on Straight Bevel Gears 463
10-7 Bearing Forces on Shafts Carrying Bevel
Gears 465
10-8 Bending Moments on Shafts Carrying Bevel
Gears 470
10-9 Stresses in Straight Bevel Gear Teeth 470
10-10 Design of Bevel Gears for Pitting
Resistance 473
10-11 Forces, Friction, and Efficiency in Wormgear
Sets 475
10-12 Stress in Wormgear Teeth 481
10-13 Surface Durability of Wormgear Drives 482
References 488
Internet Sites 488
Problems 489
Contents
11 Keys, Couplings, and Seals 491
The Big Picture 492
You Are the Designer 493
11-1 Objectives of This Chapter 493
11-2 Keys 494
11-3 Materials for Keys 498
11-4 Stress Analysis to Determine Key
Length 499
11-5 Splines 503
11-6 Other Methods of Fastening Elements to
Shafts 508
11-7 Couplings 513
11-8 Universal Joints 516
11-9 Retaining Rings and Other Means of Axial
Location 518
11-10 Types of Seals 521
11-11 Seal Materials 525
References 526
Internet Sites 527
Problems 528
12 Shaft Design 530
The Big Picture 531
You Are the Designer 532
12-1 Objectives of This Chapter 532
12-2 Shaft Design Procedure 532
12-3 Forces Exerted on Shafts by Machine
Elements 535
12-4 Stress Concentrations in Shafts 540
12-5 Design Stresses for Shafts 543
12-6 Shafts in Bending and Torsion Only 546
12-7 Shaft Design Example 548
12-8 Recommended Basic Sizes for Shafts 552
12-9 Additional Design Examples 553
12-10 Spreadsheet Aid for Shaft Design 561
12-11 Shaft Rigidity and Dynamic
Considerations 562
12-12 Flexible Shafts 563
References 564
Internet Sites 564
Problems 565
13 Tolerances and Fits 575
The Big Picture 576
You Are the Designer 577
13-1 Objectives of This Chapter 577
13-2 Factors Affecting Tolerances and Fits 578
13-3 Tolerances, Production Processes, and Cest 578
13-4 Preferred Basic Sizes 581
13-5 Clearance Fits 581
13-6 Interference Fits 585
13-7 Transition Fits 586
13-8 Stresses for Force Fits 587
13-9 General Tolerancing Methods 591
13-10 Robust Product Design 592
References 594
Internet Sites 594
Problems 595
14 Rolling Contact Bearings 597
The Big Picture 598
You Are the Designer 599
14-1 Objectives of This Chapter 600
14-2 Types of Rolling Contact Bearings 600
14-3 Thru.st Bearings 604
14-4 Mounted Bearings 604
14-5 Bearing Materials 606
14-6 Load/Life Relationship 606
14-7 Bearing Manufacturers' Data 606
14-8 Design Life 611
14-9 Bearing Selection: Radial Loads Only 613
14-10 Bearing Selection: Radial and Thmst Loads
Combined 614
14-11 Mounting of Bearings 616
14-12 Tapered Roller Bearings 618
14-13 Practical Considerations in the Application of
Bearings 621
14-14 Importance of Oil Film Thickness in
Bearings 624
14-15 Life Prediction under Varying Loads 625
References 627
Internet Sites 627
Problems 628
Contents XI
15 Completion of the Design of a Power
Transmission 630
The Big Picture 631
15-1 Objectives of This Chapter 631
15-2 Description of the Power Transmission to Be
Designed 631
15-3 Design Alternatives and Selection of the
Design Approach 633
15-4 Design Alternatives for the Gear-Type
Reducer 635
15-5 General Layout and Design Details of the
Reducer 635
15-6 Final Design Details for the Shafts 652
15-7 Assembly Drawing 655
References 657
Internet Sites 657
PART III Design Details and Other
Machine Elements 659
16 Plain Surface Bearings 660
The Big Picture 661
You Are the Designer 663
16-1 Objectives of This Chapter 663
16-2 The Bearing Design Task 663
16-3 Bearing Parameter, [xnip 665
16-4 Bearing Materials 666
16-5 Design of Boundary-Lubricated Bearings 668
16-6 Full-Film Hydrodynamic Bearings 674
16-7 Design of Full-Film Hydrodynamically
Lubricated Bearings 675
16-8 Practical Considerations for Plain Surface
Bearings 682
16-9 Hydrostatic Bearings 683
16-10 Tribology: Fricfion, Lubrication, and Wear 687
References 691
Internet Sites 692
Problems 693
17 Linear Motion Elements 694
The Big Picture 695
You Are the Designer 698
17-1 Objectives of This Chapter 698
17-2 Power Screws 699
17-3 Ball Screws 704
17-4 Application Considerations for Power Screws
and Ball Screws 707
References 709
Internet Sites 709
Problems 709
18 Fasteners 711
The Big Picture 713
You Are the Designer 714
18-1 Objecfives of This Chapter 714
18-2 Bolt Materials and Strength 714
18-3 Thread Designations and Stress Area 717
18-4 Clamping Load and Tightening of Bolted
Joints 719
18-5 Extemally Applied Force on a Bolted Joint 722
18-6 Thread Stripping Strength 723
18-7 Other Types of Fasteners and Accessories 724
18-8 Other Means of Fastening and Joining 726
References 727
Internet Sites 727
Problems 728
19 Springs 729
The Big Picture 730
You Are the Designer 731
19-1 Objectives of This Chapter 732
19-2 Kinds of Springs 732
19-3 Helical Compression Springs 735
19-4 Stresses and Deflection for Helical
Compression Springs 744
19-5 Analysis of Spring Characteristics 746
19-6 Design of Helical Compression Springs 749
19-7 Extension Springs 757
19-8 Helical Torsion Springs 762
19-9 Improving Spring Performance by Shot
Peening 769
19-10 Spring Manufacturing 770
References 770
Internet Sites 770
Problems 771
XII Contents
20 Machine Frames, Bolted Connections,
and Welded Joints 773
The Big Picture 774
You Are the Designer 775
20-1 Objectives of This Chapter 775
20-2 Machine Frames and Structures 776
20-3 Eccentrically Loaded Bolted Joints 780
20-4 Welded Joints 783
References 792
Internet Sites 792
Problems 793
21 Electric Motors and Controls 795
The Big Picture 796
You Are the Designer 797
21-1 Objecfives of This Chapter 797
21-2 Motor Selection Factors 798
21-3 AC Power and General Information about AC
Motors 799
2 1 ^ Principles of Operation of AC Induction
Motors 800
21-5 AC Motor Performance 802
21-6 Three-Phase, Squirrel-Cage Induction
Motors 803
21-7 Single-Phase Motors 806
21-8 AC Motor Frame Types and Enclosures 808
21-9 Controls for AC Motors 811
21-10 DC Power 820
21-11 DC Motors 821
21-12 DC Motor Control 824
21-13 Other Types of Motors 824
References 826
Internet Sites 827
Problems 827
22 Motion Control: Clutches
and Brakes 830
The Big Picture 831
You Are the Designer 833
22-1 Objectives of This Chapter 833
22-2 Descriptions of Clutches and Brakes 833
22-3 Types of Friction Clutches and Brakes 835
22-4 Performance Parameters 840
22-5 Time Required to Accelerate a Load 841
22-6 Inertia of a Sy.stem Referred to the Clutch Shaft
Speed 844
22-7 Effective Inertia for Bodies Moving
Lineariy 845
22-8 Energy Absorption: Heat-Dissipation
Requirements 846
22-9 Response Time 847
22-10 Friction Materials and Coefficient
of Friction 849
22-11 Plate-Type Clutch or Brake 851
22-12 Caliper Disc Brakes 854
22-13 Cone Clutch or Brake 854
22-14 Drum Brakes 855
22-15 Band Brakes 860
22-16 Other Types of Clutches and Brakes 862
References 864
Internet Sites 864
Problems 865
23 Design Projects 867
23-1 Objectives of This Chapter 868
23-2 Design Projects 868
Appendices A-1
Appendix 1 Properties of Areas A-1
Appendix 2 Preferred Basic Sizes and Screw
Threads A-3
Appendix 3 Design Properties of Carbon and Alloy
Steels A-6
Appendix 4 Properties of Heat-Treated Steels A-8
Appendix 5 Properties of Carburized Steels A-11
Appendix 6 Properties of Stainless Steels A-12
Appendix 7 Properties of Structural Steels A-13
Appendix 8 Design Properties of Cast Iron A-14
Appendix 9 Typical Properties of Aluminum A-15
Appendix 10 Typical Properties of Zinc Casfing
Alloys A-16
Appendix 11 Properties of Titanium Alloys A-16
Contents Xlll
Appendix 12 Properties of Bronzes A-17
Appendix 13 Typical Properties of Selected Plastics
A-17
Appendix 14 Beam-Deflection Formulas A-18
Appendix 15 Stress Concentration Factors A-27
Appendix 16 Steel Structural Shapes A-31
Appendix 17 Aluminum Structural Shapes A-37
Appendix 18 Conversion Factors A-39
Appendix 19 Hardness Conversion Table A—10
Appendix 20 Geometry Factor / for Pitting for Spur
Gears A-+1
Answers to Selected Problems A-44
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