كتاب Fundamentals of Machine Component Design - Sixth Edition

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Fundamentals of Machine Component Design - Sixth Edition
Robert C. Juvinall
Professor of Mechanical Engineering
University of Michigan
Kurt M. Marshek
Professor of Mechanical Engineering
University of Texas at Austin

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CONTENTS
Preface v
Acknowledgments ix
Symbols xix
Part 1 Fundamentals 1
1 Mechanical Engineering Design in Broad Perspective 1
1.1 An Overview of the Subject 1
1.2 Safety Considerations 2
1.3 Ecological Considerations 7
1.4 Societal Considerations 8
1.5 Overall Design Considerations 10
1.6 Systems of Units 12
1.7 Methodology for Solving Machine Component Problems 14
1.8 Work and Energy 16
1.9 Power 18
1.10 Conservation of Energy 19
2 Load Analysis 39
2.1 Introduction 39
2.2 Equilibrium Equations and Free-Body Diagrams 39
2.3 Beam Loading 49
2.4 Locating Critical Sections—Force Flow Concept 52
2.5 Load Division Between Redundant Supports 54
2.6 Force Flow Concept Applied to Redundant Ductile Structures 56
3 Materials 84
3.1 Introduction 84
3.2 The Static Tensile Test—“Engineering” Stress–Strain Relationships 85
3.3 Implications of the “Engineering” Stress–Strain Curve 86
3.4 The Static Tensile Test—“True” Stress–Strain Relationships 89
3.5 Energy-Absorbing Capacity 90
3.6 Estimating Strength Properties from Penetration Hardness Tests 91
3.7 Use of “Handbook” Data for Material Strength Properties 94
3.8 Machinability 95
3.9 Cast Iron 95
3.10 Steel 96
3.11 Nonferrous Alloys 98
3.12 Plastics and Composites 100
3.13 Materials Selection Charts 105
3.14 Engineering Material Selection Process 107
xixii Contents
4 Static Body Stresses 121
4.1 Introduction 121
4.2 Axial Loading 121
4.3 Direct Shear Loading 123
4.4 Torsional Loading 124
4.5 Pure Bending Loading, Straight Beams 126
4.6 Pure Bending Loading, Curved Beams 127
4.7 Transverse Shear Loading in Beams 132
4.8 Induced Stresses, Mohr Circle Representation 138
4.9 Combined Stresses—Mohr Circle Representation 140
4.10 Stress Equations Related to Mohr’s Circle 143
4.11 Three-Dimensional Stresses 144
4.12 Stress Concentration Factors, Kt 148
4.13 Importance of Stress Concentration 151
4.14 Residual Stresses Caused by Yielding—Axial Loading 153
4.15 Residual Stresses Caused by Yielding—Bending and Torsional Loading 157
4.16 Thermal Stresses 159
4.17 Importance of Residual Stresses 161
5 Elastic Strain, Deflection, and Stability 178
5.1 Introduction 178
5.2 Strain Definition, Measurement, and Mohr Circle Representation 179
5.3 Analysis of Strain—Equiangular Rosettes 181
5.4 Analysis of Strain—Rectangular Rosettes 183
5.5 Elastic Stress–Strain Relationships and Three-Dimensional Mohr Circles 185
5.6 Deflection and Spring Rate—Simple Cases 187
5.7 Beam Deflection 189
5.8 Determining Elastic Deflections by Castigliano’s Method 192
5.9 Redundant Reactions by Castigliano’s Method 203
5.10 Euler Column Buckling—Elastic Instability 207
5.11 Equivalent Column Length for Various End Conditions 209
5.12 Column Design Equations—J. B. Johnson Parabola 210
5.13 Eccentric Column Loading—the Secant Formula 214
5.14 Equivalent Column Stresses 215
5.15 Other Types of Buckling 216
5.16 Finite Element Analysis 217
6 Failure Theories, Safety Factors, and Reliability 227
6.1 Introduction 227
6.2 Types of Failure 229
6.3 Fracture Mechanics—Basic Concepts 230
6.4 Fracture Mechanics—Applications 231
6.5 The “Theory” of Static Failure Theories 240
6.6 Maximum-Normal-Stress Theory 242
6.7 Maximum-Shear-Stress Theory 242
6.8 Maximum-Distortion-Energy Theory (Maximum-Octahedral-Shear-Stress
Theory) 243
6.9 Mohr Theory and Modified Mohr Theory 245
6.10 Selection and Use of Failure Theories 246
6.11 Safety Factors—Concept and Definition 248
6.12 Safety Factors—Selection of a Numerical Value 250
6.13 Reliability 252Contents xiii
6.14 Normal Distributions 253
6.15 Interference Theory of Reliability Prediction 254
7 Impact 264
7.1 Introduction 264
7.2 Stress and Deflection Caused by Linear and Bending Impact 266
7.3 Stress and Deflection Caused by Torsional Impact 273
7.4 Effect of Stress Raisers on Impact Strength 276
8 Fatigue 287
8.1 Introduction 287
8.2 Basic Concepts 287
8.3 Standard Fatigue Strengths (Sn′ ) for Rotating Bending 289
8.4 Fatigue Strengths for Reversed Bending and Reversed Axial Loading 294
8.5 Fatigue Strength for Reversed Torsional Loading 295
8.6 Fatigue Strength for Reversed Biaxial Loading 296
8.7 Influence of Surface and Size on Fatigue Strength 297
8.8 Summary of Estimated Fatigue Strengths for Completely
Reversed Loading 299
8.9 Effect of Mean Stress on Fatigue Strength 299
8.10 Effect of Stress Concentration with Completely Reversed Fatigue
Loading 308
8.11 Effect of Stress Concentration with Mean Plus Alternating Loads 310
8.12 Fatigue Life Prediction with Randomly Varying Loads 317
8.13 Effect of Surface Treatments on the Fatigue Strength of a Part 320
8.14 Mechanical Surface Treatments—Shot Peening and Others 322
8.15 Thermal and Chemical Surface-Hardening Treatments (Induction
Hardening, Carburizing, and Others) 323
8.16 Fatigue Crack Growth 323
8.17 General Approach for Fatigue Design 327
9 Surface Damage 341
9.1 Introduction 341
9.2 Corrosion: Fundamentals 341
9.3 Corrosion: Electrode and Electrolyte Heterogeneity 344
9.4 Design for Corrosion Control 345
9.5 Corrosion Plus Static Stress 348
9.6 Corrosion Plus Cyclic Stress 350
9.7 Cavitation Damage 350
9.8 Types of Wear 351
9.9 Adhesive Wear 351
9.10 Abrasive Wear 353
9.11 Fretting 354
9.12 Analytical Approach to Wear 355
9.13 Curved-Surface Contact Stresses 358
9.14 Surface Fatigue Failures 364
9.15 Closure 365
P A R T 2 APPLICATIONS 373
10 Threaded Fasteners and Power Screws 373
10.1 Introduction 373
10.2 Thread Forms, Terminology, and Standards 373xiv Contents
10.3 Power Screws 377
10.4 Static Screw Stresses 386
10.5 Threaded Fastener Types 390
10.6 Fastener Materials and Methods of Manufacture 392
10.7 Bolt Tightening and Initial Tension 392
10.8 Thread Loosening and Thread Locking 396
10.9 Bolt Tension with External Joint-Separating Force 399
10.10 Bolt (or Screw) Selection for Static Loading 403
10.11 Bolt (or Screw) Selection for Fatigue Loading: Fundamentals 409
10.12 Bolt Selection for Fatigue Loading: Using Special Test Data 415
10.13 Increasing Bolted-Joint Fatigue Strength 418
11 Rivets, Welding, and Bonding 428
11.1 Introduction 428
11.2 Rivets 428
11.3 Welding Processes 429
11.4 Welded Joints Subjected to Static Axial and Direct Shear Loading 433
11.5 Welded Joints Subjected to Static Torsional and Bending Loading 436
11.6 Fatigue Considerations in Welded Joints 441
11.7 Brazing and Soldering 443
11.8 Adhesives 443
12 Springs 450
12.1 Introduction 450
12.2 Torsion Bar Springs 450
12.3 Coil Spring Stress and Deflection Equations 451
12.4 Stress and Strength Analysis for Helical Compression
Springs—Static Loading 456
12.5 End Designs of Helical Compression Springs 458
12.6 Buckling Analysis of Helical Compression Springs 459
12.7 Design Procedure for Helical Compression Springs—Static Loading 460
12.8 Design of Helical Compression Springs for Fatigue Loading 463
12.9 Helical Extension Springs 471
12.10 Beam Springs (Including Leaf Springs) 472
12.11 Torsion Springs 477
12.12 Miscellaneous Springs 479
13 Lubrication and Sliding Bearings 496
13.1 Types of Lubricants 496
13.2 Types of Sliding Bearings 496
13.3 Types of Lubrication 497
13.4 Basic Concepts of Hydrodynamic Lubrication 498
13.5 Viscosity 500
13.6 Temperature and Pressure Effects on Viscosity 504
13.7 Petroff’s Equation for Bearing Friction 505
13.8 Hydrodynamic Lubrication Theory 507
13.9 Design Charts for Hydrodynamic Bearings 510
13.10 Lubricant Supply 516
13.11 Heat Dissipation and Equilibrium Oil Film Temperature 518
13.12 Bearing Materials 519
13.13 Hydrodynamic Bearing Design 521
13.14 Boundary and Mixed-Film Lubrication 526
13.15 Thrust Bearings 528
13.16 Elastohydrodynamic Lubrication 529Contents xv
14 Rolling-Element Bearings 535
14.1 Comparison of Alternative Means for Supporting Rotating Shafts 535
14.2 History of Rolling-Element Bearings 537
14.3 Rolling-Element Bearing Types 537
14.4 Design of Rolling-Element Bearings 543
14.5 Fitting of Rolling-Element Bearings 546
14.6 “Catalogue Information” for Rolling-Element Bearings 547
14.7 Bearing Selection 551
14.8 Mounting Bearings to Provide Properly for Thrust Load 558
15 Spur Gears 564
15.1 Introduction and History 564
15.2 Geometry and Nomenclature 565
15.3 Interference and Contact Ratio 573
15.4 Gear Force Analysis 576
15.5 Gear-Tooth Strength 579
15.6 Basic Analysis of Gear-Tooth-Bending Stress (Lewis Equation) 580
15.7 Refined Analysis of Gear-Tooth-Bending Strength: Basic Concepts 582
15.8 Refined Analysis of Gear-Tooth-Bending Strength: Recommended
Procedure 584
15.9 Gear-Tooth Surface Durability—Basic Concepts 590
15.10 Gear-Tooth Surface Fatigue Analysis—Recommended Procedure 593
15.11 Spur Gear Design Procedures 597
15.12 Gear Materials 601
15.13 Gear Trains 602
16 Helical, Bevel, and Worm Gears 616
16.1 Introduction 616
16.2 Helical-Gear Geometry and Nomenclature 617
16.3 Helical-Gear Force Analysis 621
16.4 Helical Gear-Tooth-Bending and Surface Fatigue Strengths 624
16.5 Crossed Helical Gears 625
16.6 Bevel Gear Geometry and Nomenclature 626
16.7 Bevel Gear Force Analysis 628
16.8 Bevel Gear-Tooth-Bending and Surface Fatigue Strengths 629
16.9 Bevel Gear Trains; Differential Gears 632
16.10 Worm Gear Geometry and Nomenclature 633
16.11 Worm Gear Force and Efficiency Analysis 635
16.12 Worm-Gear-Bending and Surface Fatigue Strengths 640
16.13 Worm Gear Thermal Capacity 642
17 Shafts and Associated Parts
(online at www.wiley.com/college/juvinall) 653
17.1 Introduction 653
17.2 Provision for Shaft Bearings 653
17.3 Mounting Parts onto Rotating Shafts 654
17.4 Rotating-Shaft Dynamics 657
17.5 Overall Shaft Design 661
17.6 Keys, Pins, and Splines 665
17.7 Couplings and Universal Joints 668
18 Clutches and Brakes
(online at www.wiley.com/college/juvinall) 681
18.1 Introduction 681xvi Contents
18.2 Disk Clutches 681
18.3 Disk Brakes 686
18.4 Energy Absorption and Cooling 687
18.5 Cone Clutches and Brakes 688
18.6 Short-Shoe Drum Brakes 690
18.7 External Long-Shoe Drum Brakes 693
18.8 Internal Long-Shoe Drum Brakes 699
18.9 Band Brakes 701
18.10 Materials 704
19 Belts, Chains, and Other Components
(online at www.wiley.com/college/juvinall) 714
19.1 Introduction 714
19.2 Flat Belts 714
19.3 V-Belts 716
19.4 Toothed Belts 720
19.5 Roller Chains 720
19.6 Inverted-Tooth Chains 722
19.7 History of Hydrodynamic Drives 724
19.8 Fluid Couplings 724
19.9 Hydrodynamic Torque Converters 727
20 Micro/Nanoscale Machine Elements
(online at www.wiley.com/college/juvinall) 737
20.1 Introduction 737
20.2 Micro and Nanoscale Actuators 738
20.3 Micro and Nanoscale Bearings 744
20.4 Micro and Nanoscale Sensors 748
20.5 Conclusions 760
21 Machine Component Interrelationships—A Case Study
(online at www.wiley.com/college/juvinall) 763
21.1 Introduction 763
21.2 Description of Original Hydra-Matic Transmission 763
21.3 Free-Body Diagram Determination of Gear Ratios and
Component Loads 766
21.4 Gear Design Considerations 769
21.5 Brake and Clutch Design Considerations 771
21.6 Miscellaneous Design Considerations 772
22 Design and Fabrication of the Mechanical Systems for a Remote Control
Car—A Design Project Case Study
(online at www.wiley.com/college/juvinall) 775
22.1 Case Study Summary 775
22.2 Project Components 776
22.3 Project Organization 778
22.4 System Design Considerations 779
22.5 RC Car Race 783
A Units 785
A-1a Conversion Factors for British Gravitational, English, and SI Units 785
A-1b Conversion Factor Equalities Listed by Physical Quantity 786
A-2a Standard SI Prefixes 788
A-2b SI Units and Symbols 789Contents xvii
A-3 Suggested SI Prefixes for Stress Calculations 790
A-4 Suggested SI Prefixes for Linear-Deflection Calculations 790
A-5 Suggested SI Prefixes for Angular-Deflection Calculations 790
B Properties of Sections and Solids 791
B-1a Properties of Sections 791
B-1b Dimensions and Properties of Steel Pipe and Tubing Sections 792
B-2 Mass and Mass Moments of Inertia of Homogeneous Solids 794
C Material Properties and Uses 795
C-1 Physical Properties of Common Metals 795
C-2 Tensile Properties of Some Metals 796
C-3a Typical Mechanical Properties and Uses of Gray Cast Iron 797
C-3b Mechanical Properties and Typical Uses of Malleable Cast Iron 798
C-3c Average Mechanical Properties and Typical Uses of Ductile (Nodular) Iron 799
C-4a Mechanical Properties of Selected Carbon and Alloy Steels 800
C-4b Typical Uses of Plain Carbon Steels 802
C-5a Properties of Some Water-Quenched and Tempered Steels 803
C-5b Properties of Some Oil-Quenched and Tempered Carbon Steels 804
C-5c Properties of Some Oil-Quenched and Tempered Alloy Steels 805
C-6 Effect of Mass on Strength Properties of Steel 806
C-7 Mechanical Properties of Some Carburizing Steels 807
C-8 Mechanical Properties of Some Wrought Stainless Steels
(Approximate Median Expectations) 808
C-9 Mechanical Properties of Some Iron-Based Superalloys 809
C-10 Mechanical Properties, Characteristics, and Typical Uses of Some
Wrought Aluminum Alloys 810
C-11 Tensile Properties, Characteristics, and Typical Uses of Some
Cast-Aluminum Alloys 811
C-12 Temper Designations for Aluminum and Magnesium Alloys 812
C-13 Mechanical Properties of Some Copper Alloys 813
C-14 Mechanical Properties of Some Magnesium Alloys 814
C-15 Mechanical Properties of Some Nickel Alloys 815
C-16 Mechanical Properties of Some Wrought-Titanium Alloys 816
C-17 Mechanical Properties of Some Zinc Casting Alloys 817
C-18a Representative Mechanical Properties of Some Common Plastics 818
C-18b Properties of Some Common Glass-Reinforced and Unreinforced
Thermoplastic Resins 819
C-18c Typical Applications of Common Plastics 820
C-19 Material Names and Applications 821
C-20 Designer’s Subset of Engineering Materials 824
C-21 Processing Methods Used Most Frequently with Different Materials 825
C-22 Joinability of Materials 826
C-23 Materials for Machine Components 827
C-24 Relations Between Failure Modes and Material Properties 829
D Shear, Moment, and Deflection Equations for Beams
(online at www.wiley.com/college/juvinall) 830
D-1 Cantilever Beams 830
D-2 Simply Supported Beams 831
D-3 Beams with Fixed Ends 833xviii Contents
E Fits and Tolerances
(online at www.wiley.com/college/juvinall) 834
E-1 Fits and Tolerances for Holes and Shafts 834
E-2 Standard Tolerances for Cylindrical Parts 835
E-3 Tolerance Grades Produced from Machining Processes 836
F MIL-HDBK-5J, Department of Defense Handbook: Metallic Materials
and Elements for Aerospace Vehicle Structures
(online at www.wiley.com/college/juvinall) 837
F-1 Introduction 837
F-2 Overview of Data in MIL-HDBK-5J 837
F-3 Advanced Formulas and Concepts Used in MIL-HDBK-5J 838
F-4 Mechanical and Physical Properties of 2024 Aluminum Alloy 842
F-5 Fracture Toughness and Other Miscellaneous Properties 848
F-6 Conclusion 850
G Force Equilibrium: A Vectorial Approach
(online at www.wiley.com/college/juvinall) 852
G-1 Vectors: A Review 852
G-2 Force and Moments Equilibrium 853
H Normal Distributions
(online at www.wiley.com/college/juvinall) 855
H-1 Standard Normal Distribution Table 855
H-2 Converting to Standard Normal Distribution 857
H-3 Linear Combination of Normal Distributions 857
I S-N Formula
(online at www.wiley.com/college/juvinall) 858
I-1 S-N Formula 858
I-2 Illustrative Example 859
J Gear Terminology and Contact-Ratio Analysis
(online at www.wiley.com/college/juvinall) 860
J-1 Nominal Spur-Gear Quantities 860
J-2 Actual Quantities 862
J-3 Illustrative Example 863
Index 865SYMBOLS
A area, cross-sectional area, arm of planetary
gear
A point A
A
0 original unloaded cross-sectional area
a influence coefficient
a, a acceleration
a crack depth, radius of contact area of two
spheres
A
c effective clamped area
a
cr critical crack depth
A
f final area
A
r area reduction
A
t tensile stress area, tensile stress area of the
thread
B actual backlash
b section width, half width of contact area
measured perpendicular to axes of two
parallel contacting cylinders, gear face
width, band width
C spring index, overall heat transfer
coefficient, rated load capacity, heat transfer
coefficient, constant (material property)
C specific heat
c distance from the neutral axis to the extreme
fiber, half of crack length, radial clearance,
center distance, distance between shafts,
crack length
c distance from the centroidal axis to the
extreme inner fiber, actual distance between
gear and pinion centers
c
cr critical crack length
CR contact ratio
CR actual contact ratio
CG center of gravity
C
G gradient factor or gradient constant
c
i distance from the neutral axis to the extreme
inner fiber
CL
load factor
CLi life factor
c
o distance from the neutral axis to the extreme
outer fiber
CP center of aerodynamic pressure
Cp
elastic coefficient
CR
reliability factor
c
???? volumetric specific heat
C
req required value of C
Cs
surface factor
D diameter, mean coil diameter, velocity factor
d diameter, major diameter, nominal diameter,
wire diameter
d
av average diameter
db
diameter of base circle
dc
collar (or bearing) diameter
dc∕dN crack propagation rate
(dc∕dN)o crack propagation rate at (ΔK)o
dg
pitch diameter of gear
d
i minor diameter of the internal thread
dm
mean diameter
dp
pitch diameter, pitch diameter of pinion
d
r root (or minor) diameter
E modulus of elasticity, elastic proportionality
constant, tensile elastic modulus
E modulus of elasticity (tension)
Ep
plastic strain
e distance between the neutral axis and the
centroidal axis, efficiency, eccentricity, train
value, edge distance for joint, percent
elongation at break
e∕D edge margin
Eb
Young’s modulus for the bolt
Ec
Young’s modulus for clamped member,
compression modulus of elasticity
Es
secant modulus
E
t tangent modulus
F force, compressive force between the
surfaces
f relative hardenability effectiveness,
coefficient of friction
F, F force
Fa
axial force
Fb
bolt axial load
F
bru bearing ultimate strength
F
bry bearing yield strength
Fc
clamping force
fc collar (or bearing) coefficient of friction
Fd
drag force, dynamic load
xixxx Symbols
F
cy compression yield strength
Fe
equivalent radial load, equivalent static
force, external force
F
ext external force vector applied on a member
F
ga gear axial force
F
gr gear radial force
F
gt gear tangential force
Fi
initial tensile force, initial clamping force
F
int internal force vector at a cross-section
Fn
normal force
fn natural frequency
Fr
radial load, radial force
Fs
strength capacity
F
solid force when solid
F
su shear ultimate strength
Ft
thrust force, tendon force, tangential force,
thrust load
F
tu tensile ultimate strength
F
ty tensile yield strength
Fw
wear capacity
F
wa worm axial force
F
wr worm radial force
F
wt worm tangential force
G torsional or shear modulus of elasticity
g gravitational acceleration or acceleration of
gravity, grip length
gc constant of proportionality,
32.2 lbm-ft∕lb-s2
H surface hardness, time rate of heat
dissipation
h section depth, height of fall, leg length, weld
size, film thickness, height
h
0 minimum film thickness
HB
Brinell hardness number
I polar moment of inertia, moment of inertia,
geometry factor, stress invariant
i integer
Ix
moment of inertia about x axis
J polar moment of inertia, spur gear geometry
factor
K curvature factor, spring rate for angular
deflection, stress intensity factor, wear
coefficient
k spring rate, thermal conductivity, spring rate
for linear deflection, number of standard
deviations, shaft spring rate
K thermal conductivity
K′ section property
KI
stress intensity factor for tensile loading
(mode I)
KI
c critical stress intensity factor for tensile
loading (mode I)
Ka
application factor
KB
constant of proportionality
kb
spring constant for the bolt
Kc
fracture toughness or critical stress intensity
factor
k
c spring constant for clamped members
KE kinetic energy
Kf
fatigue stress concentration factor
Ki
curvature factor for inner fiber, effective
stress concentration factor for impact
loading, constant used for calculating initial
bolt-tightening force
Km
mounting factor
K
max stress intensity factor at ????max
K
min stress intensity factor at ????min
k
ms mean stress factor
Ko
curvature factor for outer fiber, overload
factor, critical stress intensity factor for
infinite plate with central crack in uniaxial
tension
Kr
life adjustment reliability factor
k
r reliability factor
Ks
stress concentration factor for static loading
Kt
theoretical or geometric stress concentration
factor
k
t temperature factor
K????
velocity or dynamic factor
Kw
Wahl factor, material and geometry factor
L length, contact length measured parallel to
the axis of contacting cylinder, lead, length
of weld, life corresponding to radial load Fr,
or life required by the application, pitch cone
length
L
0 original unloaded length
L
e equivalent length
Lf
final length, free length
LR
life corresponding to rated capacity
L
s solid height
L, ST, LT longitudinal direction, short transverse
direction, long transverse direction
M moment, internal bending moment, bending
moment
M0
redundant moment
m mass, strain-hardening exponent, module
(used only with SI or metric units)
m′ mass per unit length of belt
M
ext external moment vector applied on a member
Mf
moment of friction forcesSymbols xxi
M
int generalized internal moment vector at a
cross-section
Mn
moment of normal forces
N fatigue life, total normal load, number of
active coil turns, number of teeth, number of
friction interfaces, number of cycles
n rotating speed, number of cycles, normal
force, number of equally spaced planet
gears, index (subscript), Ramberg-Osgood
parameter
N′ virtual number of teeth
N.A. neutral axis
n
c critical speed
Ne
number of teeth
Nt
total number of turns, number of teeth in the
sprocket
P load, cumulative probability of failure,
bearing unit load, average film pressure,
radial load per unit of projected bearing area,
pitch point, diametral pitch (used only with
English units), diameter or number of teeth
of planet, band force, load (force), uniform
load
P actual pitch
p frequency of occurrence, probability of
failure, surface interface pressure, pitch, film
pressure, circular pitch, uniform level of
interface pressure, pressure
p actual circular pitch
p0 maximum contact pressure
pa axial pitch
pb base pitch
P
c tension created by centrifugal force
P
cr critical load
PE potential energy
pmax allowable pressure, maximum normal
pressure
pn circular pitch measured in a plane normal to
the teeth
Q heat energy transferred to the system, load,
total tangential force, flow rate, mass flow
rate
q number of revolutions, notch sensitivity
factor, tangential force
Qf volume of lubricant per-unit time flowing
across
Qs side leakage rate
R radius, transmission speed ratio, area ratio,
radius of curvature, diameter or number of
teeth of ring or annulus gear, ratio of gear
and pinion diameter, load ratio, fatigue cycle
stress ratio
r radius, reliability
r radial distance to the centroidal axis
ra
(max) maximum noninterfering addendum circle
radius of pinion or gear
rmax
ag
maximum allowable addendum radius on the
gear to avoid interference
rmax
ap
maximum allowable addendum radius on the
pinion to avoid interference
r
ap, rag addendum radii of the mating pinion and
gear
rb base circle radius, back cone radius
rbp, rbg base circle radii of the mating pinion and
gear
rc
chordal radius
rf friction radius
r
g actual pitch radius of gear
r
i inner radius
rp
actual pitch radius of pinion
R
m modulus of resilience
rn
radial distance to the neutral axis
ro
outer radius
S linear displacement, total rubbing distance,
Saybolt viscometer measurement in seconds,
bearing characteristic number or
Sommerfeld variable, diameter or number of
teeth of sun gear, slip
S
cr critical unit load
S
e elastic limit
S
eq equivalent stress—see Table F.4
SF safety factor
Sfe surface fatigue strength
SH
surface endurance strength
S–N fatigue stress versus cycles
S
max maximum fatigue cycle stress—see Table F.4
S
n endurance limit
S′
n standard fatigue strength for rotating bending
Sp
proof load (strength)
S
sy shear yield strength
S
u ultimate strength, ultimate tensile strength
S
uc ultimate strength in compression
S
us ultimate shear strength, ultimate torsional
shear strength
S
ut ultimate strength in tension
Sy
yield strength
S
yc yield strength in compression
S
yt yield strength in tension
T torque, brake torque, band brake torque
t time, thickness, nut thickness, throat length
Ta
alternating torque
ta
air temperature, ambient air temperature
Te
equivalent static torquexxii Symbols
Tf
friction torque
Tm
modulus of toughness, mean torque
t
o average oil film temperature, oil temperature
ts
average temperature of heat-dissipating
surfaces
U stored elastic energy, impact kinetic energy,
laminar flow velocity
U′ complementary energy
V internal transverse shear force, shear force,
volume
V, V linear velocity, gear pitch line velocity
???? velocity at impact, sliding velocity
V60 cutting speed in feet per minute for 60-min
tool life under standard cutting conditions
V
av average velocity
Vg
gear tangential velocity, pitch line velocity
of the gear
V
gt velocity of gear at contact point in tangent
direction
V
pt velocity of pinion at contact point in tangent
direction
V
gn velocity of gear at contact point in normal
direction
V
pn velocity of pinion at contact point in normal
direction
Vs
sliding velocity
Vw
worm tangential velocity
W work done, weight, volume of material worn
away, total axial load
Ẇ power
w load, load intensity, gravitational force,
width
Y Lewis form factor based on diametral pitch
or module, configuration factor
y distance from the neutral axis, Lewis form
factor
Y
cr configuration factor at critical crack size
Z section modulus
Greek Letters
???? angular acceleration, coefficient of thermal
expansion, angles measured clockwise
positive from the 0∘ gage to the principal
strain axes numbers 1 and 2, factor by which
the compressive strength is reduced through
buckling tendencies, thread angle, contact
angle, cone angle, normalized crack size
????
cr normalized critical crack size
????1 normalized crack size at c1
????2 normalized crack size at c2
????
n thread angle measured in the normal
plane
Δ deflection, material parameter important in
computing contact stress
????, ???? deflection
???? linear deflection, wear depth
ΔA change in area
ΔE change in total energy of the system
ΔKE change in kinetic energy of the system
ΔK stress intensity range
ΔK
o stress intensity range at the point o
ΔL change in length
ΔPE change in gravitational potential energy of
the system
ΔN12 number of cycles during crack growth from
c1 to c2
????
s solid deflection
????
st deflection caused by static loading (static
deflection)
ΔT temperature change
ΔU change in internal energy of the system
???? lead angle, helix angle, ratio of actual to
ideal distance between gear and pinion
centers
???? angle between the principal axes and the x
and y axes, angle giving position of
minimum film thickness, pressure angle,
angle of wrap
????n pressure angle measured in a plane normal to
the teeth
???? actual pressure angle
???? pitch cone angle
????xy, ????xz, ????yz shear strains
???? mean, viscosity
???? Poisson’s ratio—see Appendix F
???? Poisson’s ratio
???? normal strain
????1, ????2, ????3 principal strains
????f strain at fracture
????p
plastic strain
????
T “true” normal strain
????Tf true normal strain at fracture
????x
, ????
y, ????z normal strains
???? angular displacement, angular deflection,
slope
????
P
max
position of maximum film pressure
???? mass density, radial distance
???? normal stress, standard deviation, uniform
uniaxial tensile stressSymbols xxiii
????1, ????2, ????3 principal stresses in 1, 2, and 3 directions
????0 square root of strain-strengthening
proportionality constant
????
a alternating stress (or stress amplitude)
????
e equivalent stress
????
ea equivalent alternating bending stress
????
em equivalent mean bending stress
????
eq equivalent stress
????g
gross-section tensile stress
????H
surface fatigue stress
????
i maximum normal stress in the inner surface
????m
mean stress
????
max maximum normal stress
????min minimum normal stress
????
nom nominal normal stress
????
o maximum normal stress in the outer
surface
????
T “true” normal stress
????x
normal stress acting along x axis
????y
normal stress acting along y axis
???? shear stress, natural period of vibration
????a
alternating shear stress
????
av average shear stress
????initial initial shear stress
????m
mean shear stress
????
max maximum shear stress
????
nom nominal shear stress
????solid shear stress when solid
????
xy shear stress acting on an x face in the y
direction
???? kinematic viscosity
???? angular velocity, impact angular velocity
????
g angular velocity of gear
????
n natural frequency
????
p angular velocity of pinion
???? helix angle, spiral angle
INDEX
A
ABEC see Annular Bearing Engineers’ Committee (ABEC)
Abrasive wear, 353–354, 591
ABS (acrylonitrile–butadiene–styrene), 102
Acetal, 102
Acme threads, 377
Acrylic, 102
Acrylic adhesives, 445
Actuators
displacement-based, 742–744 (online, Ch 20)
force-based, 739–741 (online, Ch 20)
Addendum, 568
Adhesive bonding, 443
Adhesive wear, 351–353, 527
AFBMA (Anti-Friction Bearing Manufacturers Association), 546
AGMA (American Gear Manufacturers Association), 564
AISC (American Institute of Steel Construction), 428
Alkyd, 103
Alloying, 100
Alloys
aluminum (see Aluminum alloys)
cast iron, 95–96
copper, 99, 293, 813
magnesium, 99, 293–294, 812, 814
nickel, 99–100, 293, 815
nonferrous alloys, 98–100
steel (see Steel alloys)
superalloys, 98–100, 809
titanium, 100, 816
zinc, 100, 817
Allyl (diallyl phthalate), 103
Alternating loads/stress, 310–315
Aluminum
anodized, 346
cavitation of, 351
connecting rod, 212–214
corrosion of, 345–347
fretting of, 354–355
notch sensitivity of, 309
Aluminum alloys, 98–99
endurance limit of, 290
fatigue strength diagrams for, 290, 293
mechanical properties/uses of, 810, 811
temper designations for, 812
American Blower Company, 724
American Gear Manufacturers Association (AGMA), 564
American Institute of Steel Construction (AISC), 428
American National Standards lnstitute (ANSI), 5
American Society for Testing and Materials (ASTM), 99, 434
American Society of Mechanical Engineers (ASME), 250, 374,
428, 722
American Welding Society (AWS), 434
Amino, 103
Anaerobic adhesives, 445
Anisotropic materials, 248
Annealing, 161, 349
Annular Bearing Engineers’ Committee (ABEC), 546
Anode, sacrificial, 343, 346
Anodized aluminum, 346
Anodizing, 345
ANSI see American National Standards lnstitute (ANSI)
Anti-Friction Bearing Manufacturers Association (AFBMA), 546
Approximations, 16
Ashby’s materials selection charts, 105–107
ASME see American Society of Mechanical Engineers
Asperity welding, 352–353
ASTM see American Society for Testing and Materials
Automatic transmission, 763 (online, Ch 21)
Automobiles
load analysis, 40–45
performance analysis, 20–23
power train components, 42–43
transmission components, 43–45
AWS (American Welding Society), 434
Axial impact, 270
Axial loads/loading, 121–123
and Castigliano’s method, 193
with power screws, 386
and residual stresses, 153–157
reversed, 294–295
with roller bearings, 552–553
sign convention for, 124
with springs, 455
with threaded fasteners, 386
B
Ball bearings
and axial loading, 553
dimensions of, 547–549
history of, 537
life requirement for, 551–552
radial, 536
rated capacities of, 549, 550
reliability requirement for, 552
865866 INDEX
Ball bearings (contd.)
rings for, 542
selection of, 551–556
shields/seals for, 541–542
and shock loading, 554
special, 544–545
surface damage to, 359–365
thrust load, mounting for, 558–559
types of, 538, 539
Ball-bearing screws, 383
Band brakes, 701–703 (online, Ch 18)
Bars
compression/tension, impacted in, 273–274
deflection/stiffness formulas for, 187
energy-absorbing capacity, effect of stress raiser
on, 278–280
stress concentration factors of, 152–153
Base units, 12
Basic design objective, 7
Basic hole system, 835 (online, Appendix E)
Beach marks, 287–288
Beam loading, 49–52
Beams
bending impact, with compound spring, 272–273
bent cantilever, deflection in, 197–198
centrally loaded, deflection in, 194–195
curved, bending of, 127–132
deflection in, 189–191, 830–833 (online, Appendix D)
deflection/stiffness formulas for, 187
extreme-fiber-bending stresses, 131–132
straight, bending of, 126–127
transverse shear loading in, 132–138
Beam springs, 472–477
Bearing(s)
ball (see Ball bearings)
bearings for shafts, 653–654 (online, Ch 17)
definition of, 744–748 (online, Ch 20)
micro and nanoscale, 744–748 (online, Ch 20)
rolling-element (see Rolling-element)
sliding (see Sliding bearings)
thrust, 528, 558–559
Bell crank, load analysis of, 46–47
Belt drive, with spur gears, 567
Belts
flat, 714–716
toothed (timing), 720
V-, 716–719
Bending
of beams, 49–50, 126–132
bevel gears, 629–632
and Castigliano’s method, 193
and fatigue strength, 289–295, 315–317
of gear teeth, 580–590
helical gears, 624–625
and residual stresses, 157–159
and shear stresses, 136–138
sign convention for, 50
worm gears, 640–642
Bending impact, 266–268, 272–273
Bevel gears, 616, 618, 626–633
bending stress with, 629–632
force analysis with, 628–629
geometry of, 626–627
large end, 626
pitch cones, 626
surface fatigue stress with, 629, 631
trains, gear, 632–633
and Tredgold’s approximation, 626
Zerol, 627
Biaxial effect (of stress raisers), 148
Biaxial loading, fatigue strength for reversed, 296–297
Biaxial stresses, 144, 146, 185
modified Mohr theory for, 245
Bioengineering, 48
Blind rivets, 429–430
Body stress(es), 121–162
from axial loading, 121–123
combined, 140–143
concentration factors, 148–151
from direct shear loading, 123–124
induced, 138–140
from pure bending loading, 126–132
residual (see Residual stresses)
thermal, 159–161
three-dimensional, 144–148
from torsional loading, 124–126
from transverse shear loading, 132–138
Bolted joint, shear load capacity of, 405–406
Bolts, 390
bracket attachment, selection for, 406–409
design for impact strength of, 278–280
fatigue loading, selection for, 409–414
fatigue strength, increasing, 418–419
initial tightening tension, 392–396, 410–412
pressure vessel flange bolts, selection of, 416–417
static loading, selection for, 403–409
tension of, with external joint-separating force, 399–403
and thread-bearing stress, 386–388
types of, 391
Bonderizing, 345
Bonding, adhesive, 443–445
Boundary lubrication, 498, 526–528
Bracket(s)
bolts for attachment of, 406–407
deflection of redundantly supported, 204–206
Brake(s), 681 (online, Ch 18)
band, 701–703 (online, Ch 18)
cone, 688–690 (online, Ch 18)
design considerations, 771–772 (online, Ch 21)
disk, 686–687 (online, Ch 18)
energy absorption/cooling with, 687–688 (online, Ch 18)
long-shoe drum, 693–699 (online, Ch 18)INDEX 867
materials for, 704–705 (online, Ch 18)
short-shoe drum, 690–693 (online, Ch 18)
Brasses, 99
Brazing, 443
Brinell hardness test, 91–94, 290
British Comets, 4
British Gravitational units, 12–14
British thermal unit, 17
British thermal units per second, 18
Brittle fracture, 229, 276
Brittle materials, 229, 252, 296
Bronzes, 99, 351
Buckingham, Earle, 592
Buckling, 207–209, 216–217
columns, 207–217
eccentric loading, secant formula for, 214–215
of helical compression springs, 460
local, 216–217
of power screws, 389
Building codes, 250
Butt welds, 434, 442
C
Cadmium, 346, 366
Camshafts
power requirement, 19–20
torque requirement, 17–18
Cantilever beams, 197–198, 830 (online, Appendix D)
Capacitive sensors, 749–750 (online, Ch 20)
Carbide, 344
Carbon fiber reinforcement, 102
Carbon nanotube–based piezoresistors, 753–754 (online, Ch 20)
Carbon nanotube–based rotary bearings, 747–748 (online, Ch 20)
Carbon steels, 96–97, 796, 800–802
Carburizing, 98, 323
Carburizing steel, 807
Cardan joint, 669 (online, Ch 17)
Case-hardening steels, 98
Castigliano, Alberto, 192
Castigliano’s method
elastic deflections determined by, 192–203
redundant reactions by, 203–206
Cast iron, 95–96
cavitation of, 351
endurance limit of, 290
fretting of, 354–355
mechanical properties/uses of (table), 797–798
surface factor for, 297, 298
Cathode, 343
Cavitation, 350–351
Cellulosics, 102
Chains
inverted-tooth, 722–723
roller, 720–722
Change, 10
Charpy test, 91, 277
Chemical surface-hardening treatments, 323
Chilling, 96
Chordal action, 721
Chrome plating, 321
Chromium, 344
Chrysler Corporation, 724
Clearance fits, 834 (online, Appendix E)
Clutch(es)
cone, 688–690 (online, Ch 18)
design considerations, 771–772 (online, Ch 21)
disk, 681–686 (online, Ch 18)
function of, 681 (online, Ch 18)
materials for, 704–705 (online, Ch 18)
Coating, 109, 112
Coining, 322
Cold rolling, 322
Column buckling, 207–217
end conditions, column length and, 209–210
equivalent stresses, 215–216
J.B. Johnson parabola for, 210–214
Column loading (of power screws), 389–390
Comb-drive actuators, 741 (online, Ch 20)
Comb-drive sensors, 749, 750 (online, Ch 20)
Combined stresses, 140–143
Compatibility, of materials, 8
Completely reversed loading, fatigue strength for,
299, 308–310
Components, mechanical, 1
Composites, 104–105
engineering, 104, 106, 821
material, 104–105
Compound springs, 272–273
Compression, 121, 122
Compression springs, helical see Helical compression springs
Concentration, stress see Stress concentration factors
Cone clutches/brakes, 688–690 (online, Ch 18)
Configuration factor, 232, 325
Conic threaded fasteners, 377
Connecting rods, determining diameter, 211–212
Conservation of energy, 19–23
Constant-force springs, 480
Constant-life fatigue diagram, 301, 304, 305
Contact modulus, 358
Contact ratio (CR), 573–575, 860–864 (online, Appendix J)
Copolymerization, 100
Copper alloys, 99, 293, 813
Copper, corrosion of, 346
Corrosion, 341–351
crevice, 345
with cyclic stress, 350–351
design for control of, 345–347
and electrode/electrolyte heterogeneity, 344–345
with static stress, 348–350
Corrosion engineering, 341
Cost(s)
of machined parts, 95868 INDEX
Cost(s) (contd.)
of materials, 84
of safety factor, 251
Coulomb, C. A., 242
Coulomb-Mohr theory, 245
Countershaft, internal loads in transmission, 50–52
Couplings
fluid, 724–727
shaft, 668–671 (online, Ch 17)
CR see Contact ratio
Crack
length, 231, 323–327
propagation, 230, 233, 324, 329
Cracks, stress-corrosion, 348–350
Crevice corrosion, 3445
Critical sections, 52–54
Critical stress intensity factor, 230
Crossed helical gears, 616, 625
Cross-linked plastics, 101
Curved surfaces, contact stresses with, 358–364
Cyaniding, 98
Cyclic stress, and corrosion, 350
Cylindrical threaded fasteners, 377
D
Damper, 264
Damping, 266
Dashpot, 264
Dedendum, 568
Deflection, 178
beam, 189–191
Castigliano’s method for determining, 192–203
caused by linear/bending impact, 266–273
caused by torsional impact, 273–276
formulas for, 187–188
and redundant reactions, 203–206
of springs, 451–456
torsional, 188
DeMoivre, 253
Density, and strength, 106–107
Design, 1–12
ecological objectives of, 7–8
overall considerations in, 10–12
process, 107
safety considerations in, 2–7
societal objectives of, 8–10
Design overload, 249
“Design stress,” 248
Diallyl phthalate (allyl), 103
Dimensionally homogeneous equations, 12
Dimensions, primary/secondary, 12
Direct shear loading, 123–124
Disk brakes, 686–687 (online, Ch 18)
Disk clutches, 681–686 (online, Ch 18)
Disk sander shaft, safety factor of, 315–317
Displacement-based actuators
electrochemical actuators, 744 (online, Ch 20)
piezoelectric actuators, 743 (online, Ch 20)
shape memory alloy, 744 (online, Ch 20)
thermomechanical actuators, 742–743 (online, Ch 20)
Distortion (plastic strain), 229
Double shear, 54, 124
Drum brakes
long-shoe, 693–699 (online, Ch 18)
short-shoe, 690–693 (online, Ch 18)
Ductile (nodular) iron, 96, 799
Ductile materials, 229
fatigue strength of, 295–296, 300
machinability of, 96
Ductility, 88, 807, 829
Durability (of materials), 8
Duranickel alloys, 99
Dynamic loading see Fatigue; Impact
E
Eccentricity ratio, 214
Eccentric loading
columns, 214–215
welds, 436–441
Ecological issues, 7–8
Economic issues, 365–366
Eddy current proximity sensors, 750–751 (online, Ch 20)
Efficiency (of power screws), 382–383
Elastic instability/stability, 207–209
Elasticity, modulus of, 85
Elastic limit, notation convention for, 85
Elastic region (true stress–strain curve), 90
Elastic strains, 178 see also Strains
Elastic stress–strain relationships, 185–186
Elastohydrodynamic lubrication, 529, 590
Electrical insulators, 346
Electrical resistance strain gages, 180
Electrochemical actuators, 744 (online, Ch 20)
Electrochemical reaction, 341–344
Electrolytes, 343, 347
Electromagnetic actuator, 739–740 (online, Ch 20)
Electromagnetic (EM) microactuators, 739–740 (online, Ch 20)
Electron beam welding, 432
Electroplating, 321, 343, 366
Electroslag welding, 432
Electrostatic actuator, 740–741 (online, Ch 20)
Elongation (at fracture), 87
End-quench test, Jominy, 97
Energy
conservation of, 19–23
and work, 16–18
Energy absorption capacity
bolt design modification to increase, 278–280
of brakes, 687–688 (online, Ch 18)
effect of stress raisers on, 271–272
of materials, 90–91, 270
Engineering, 1INDEX 869
Engineering model, 16
Engineering stress–strain curve, 86–88
Engineering values, 85
English Engineering units, 12–14
Epoxies, 103, 444–445
Equations
characteristic, 147
dimensionally homogeneous, 12
equilibrium, 39–49
Equiangular rosettes, 181–183
Equilibrium
and load determination, 39
and redundant reactions, 203
and residual stresses, 161
Euler, Leonhard, 207
Euler column buckling, 207–217
F
“Fail-safe” design, 4
Failure, 227–256 see also Fatigue; Surface damage
analysis, 327, 837 (online, Appendix F)
and axial stress, 123
definition of, 229
distortion, 229
fracture, 230–240
mode, 829
theories of, 240–248
Fasteners, threaded see Threaded fasteners
Fatigue, 287–289
life prediction, 317–320
S-N formula, 307, 858–859 (online, Appendix I)
surface fatigue failures, 364–365
and surface treatments, 320–322
in welded joints, 441–442
Fatigue life prediction, 317–320
Fatigue loading
bolt selection for, 409–418
screw selection for, 409–414
spring design for, 463–471
Fatigue strength, 289–317
for completely reversed loading, 299, 308–310
concentrated stress, effect of, 308–309
definition of, 290
increasing bolted-joint, 418–419
mean stress, effect of, 299–308, 310–317
for reversed bending/reversed axial loading, 294–295
for reversed biaxial loading, 296–297
for reversed torsional loading, 395–396
for rotating bending, 289–294
and safety factors, 248–249
and surface size, 297–299
surface treatments, effect of, 320–322
Fatigue zone, 287
FCAW (flux-cored arc welding), 432
Ferrite, 344
Ferrous materials, endurance limit of, 290
Fiber-reinforced plastics, 102
Fillet welds, 434–436
Finishing, 109, 112, 113
Finite element analysis, 217–218
steps of, 217–218
Fits, 834–836 (online, Appendix E)
Flame cutting, 161
Flame hardening, 98
Flat belts, 714–716
Flexural bearings, 745–746 (online, Ch 20)
Fluid couplings, 724–727
Fluoroplastics, 102
Flux-cored arc welding (FCAW), 432
Flywheel, 18
Foot-pound force, 17
Force
units of, 14
work done by, 17
Force-based actuators
electromagnetic actuator, 739–740 (online, Ch 20)
electrostatic actuator, 740–741 (online, Ch 20)
optomechanical actuators, 741 (online, Ch 20)
Force flow
critical sections, location of, 52–54
with redundant ductile structures, 56–58
Formability, 112
Föttinger, H, 724
Fracture(s), 229–230, 287–289
Fracture mechanics, 230–240
of thick plates, 233–234
of thin plates, 231–233
Fracture toughness, 230
Free-body analysis of loads, 39
acceleration, automobile undergoing, 41–42
constant speed, automobile at, 40–41
internal loads, determination of, 45–46
power train components, automotive, 42–43
with three-force member, 46–49
transmission components, automotive, 43–45
Free-body diagram method, 766–769 (online, Ch 21)
Free-spinning locknuts, 397
Fretting, 354–355
Friction
with power screws, 381
with rolling-element bearings, 537
viscous, 505
Fusion (welding), 429
G
Galling, 353
Galvanic action, 341, 345, 347
Galvanic corrosion, 346
Galvanic series, 342
Garter springs, 480
Gas metal arc welding (GMAW), 431
Gas tungsten arc welding (GTAW), 431–432870 INDEX
Gas welding, 432
Gears, 564
bevel (see Bevel gears)
design considerations, 769–771 (online, Ch 21)
helical (see Helical gears)
materials for, 601
spur (see Spur gears)
terminology, 860–864 (online, Appendix J)
worm (see Worm gears)
Gear system, 763 (online, Ch 21)
Glass fiber reinforced plastics, 102
GMAW (gas metal arc welding), 431
Goodman lines, 304, 305
Government standards, 4–5
Graphene-based nanoelectromechanical resonators, 760
(online, Ch 20)
Gray iron, 95, 797
Greases, 496
Grinder, torsional impact in, 274–276
GTAW (gas tungsten arc welding), 431–432
Guest, J. J., 243
Guest’s law, 243
H
Hall effect sensors, 751 (online, Ch 20)
Hammer peening, 349
Hardness, and machinability, 95
Hardness tests
Brinell, 91–94
Jominy end-quench test, 97
penetration, 91–94
Rockwell, 91–94
Hastelloys, 99–100
Hazard, 5–6
Helical compression springs, 451–471
buckling analysis of, 459–460
end designs of, 458–459
fatigue loading, design procedure for, 463–471
static loading, design procedure for, 460–463
stress/strength analysis for, 456–458
Helical extension springs, 471–472
Helical gears, 617–625, 771 (online, Ch 21)
see also Spur gears
angle of, 617, 618
bending stress with, 624, 625
crossed, 616, 625
force analysis with, 621–624
geometry of, 617–621
meshing, 622–624
pitch of, 617, 618, 620, 621
surface fatigue stress with, 625
Helical threads, 373, 374
Hencky, H., 243
Hertz, Heinrich, 359, 362
Hertz contact stresses, 359, 362, 590, 592
Hierarchy of needs, 10
High-carbon steels, 96
High-molecular-weight polyethylene, 100
High-performance interferometers, 757 (online, Ch 20)
High-strength low-alloy (HSLA) steels, 97
Holmes, Oliver Wendell, 227
Hooke’s joint, 669 (online, Ch 17)
Hooke’s law, 85
Hoop tension, 54
Horsepower, 18, 19
HSLA (high-strength low-alloy) steels, 97
Hubs, 654 (online, Ch 17)
Hueber, M. T., 243
Hydra-Matic transmission
basic components, 764 (online, Ch 21)
design features, 766 (online, Ch 21)
power flow and gear ratios, 764, 765 (online,
766 (online, Ch 21)
Hydraulic control system, 763 (online, Ch 21)
Hydraulic springs, 450
Hydrodynamic bearings
design charts for, 510–516
design of, 521–526
Hydrodynamic drives, history of, 724
Hydrodynamic lubrication, 497–500, 507–509
Hydrodynamic torque converters, 714, 727–729
Hydrogen embrittlement, 321
Hydrostatic lubrication, 498
I
Impact, 264–280
bending, 266–268, 272–273
linear, 266–273
static loading vs., 264–266
torsional, 273–276
Impact factor, 252, 266
Impact loading, with roller bearings, 552–553
Impulsive loading see Impact
Inconel alloys, 100
Induced stresses, 138–140
Induction hardening, 98, 323
Inductive sensors, 750–751 (online, Ch 20)
Industry standards, 4–5
Inertia, moments of, 791
Inertia welding, 432
Ingenuity, 3–4
Instability, elastic, 207–209
Insulators, 346
Interference fits, 834 (online, Appendix E)
Interference points, 573–575
Interference theory of reliability prediction, 254–256
Internal loads
in free-body analysis, 45–46
in transmission countershaft, 50–52
International Standards Organization (ISO), 373, 503
Inverted-tooth chains, 722–723
Iron, 343 see also Cast ironINDEX 871
Iron-based superalloys, 98, 809
ISO see International Standards Organization
ISO screw threads, 373–374
Izod test, 91, 277
J
Jacks, screw-type, 377
Johnson, J. B., 210–211
Johnson column formula, 210–214
Joinability, 112, 826
Joint(s)
increasing fatigue strength of bolted, 418–419
riveted, 56–58
shear load capacity of bolted, 405–406
universal, 668–671 (online, Ch 17)
welded (see Welded joints)
Jominy, Walter, 97
Jominy end-quench test, 97
Joule, 17
Joule heating, 742 (online, Ch 20)
Joules per second, 18
K
Keyways (keyseats), 654, 667 (online, Ch 17)
Kilowatt, 18
L
Laplace, P., 253
Laser beam welding, 432
Leaf springs, 472–477
Leonardo da Vinci, 537, 564
Lewis, Wilfred, 580
Lewis equation, 580–582
Life cycle, total, 4
Life quality index (LQI), 9–10
Limit
elastic, 85
proportional, 85
Linear actuators see Power screws
Linear cumulative-damage rule, 317–318
Linear impact, 269–272
Linearly elastic stress–strain relationships, 185–186
Linear plastics, 101
Linear variable differential transformers (LVDTs), 750
(online, Ch 20)
Loads/loading, 39–58
axial (see Axial loads/loading)
with beams, 49–52
direct shear, 123–124
dynamic, 264, 265
eccentric, 214–215, 436–441
fatigue, 409–418, 463–471
and force flow, 52–54
with free bodies (see Free-body analysis of loads)
impact (see Impact)
pure bending, 126–132
and redundant ductile structures, 56–58
redundant supports, division between, 54–56
static, 264, 265
torsional loading, 124–126
transverse shear, 132–138, 389
Local buckling, 216–217
Locknuts, 397–398
Lock washers, 397
Long-shoe drum brakes, 693–699 (online, Ch 18)
internal long shoe, 699–701 (online, Ch 18)
nonpivoted long shoe, 693–699 (online, Ch 18)
pivoted long shoe, 699 (online, Ch 18)
Low-carbon steels, 96
Low-molecular-weight polyethylene, 100
LQI (Life quality index), 9–10
Lubricant(s)
supply of, 516–518
types of, 496
Lubrication see also Viscosity
boundary, 498, 526–528
elastohydrodynamic, 529, 590
hydrodynamic, 497–500, 507–509
hydrostatic, 498
mixed-film, 498, 527
self-, 527
M
Machinability, 95
Machine component problems, methodology for solving, 14–16
Machine components, 763 (online, Ch 21)
Magnesium, 346
fretting of, 354–355
notch sensitivity of, 309
Magnesium alloys, 99, 293
mechanical properties of, 814
temper designations for, 812
Magnesium bronze, 351
Malleable iron, 96
Manufacturing, 108–110, 113
Margin of safety, 252
Maslow, Abraham, 10
Material properties, 107–114
Materials, 84–114 see also specific materials
anisotropic, 248
for brakes/clutches, 704–705 (online, Ch 18)
brittle, 229, 245
for clutches/brakes, 704–705 (online, Ch 18)
compatibility of, 8
composites, 100, 104–105
corrosion of (see Corrosion)
database, property, 84
ductile, 229
ecological factors in selection of, 8
energy absorption capacity of, 90–91, 270
engineering stress–strain curve for, 86–88
ferrous, 290872 INDEX
Materials, (contd.)
for gears, 601
“handbook” data on strength properties of, 94
isotropic, 248
machinability of, 95
names of (table), 821–823
nonferrous (see Nonferrous metals/materials)
penetration hardness tests, 91–94
properties of, 108–109
relative durability of, 8
for rivets, 429
for screws/nuts/bolts, 392
selection charts for, 105–107
selection factors, 109–112
selection of, 107
selection procedure, 112–114
for sliding bearings, 519–520
for springs, 450
static tensile test for, 85–86, 89–90
strength charts for, 106–107
and stress concentration factors, 148–151
true stress–strain curve for, 89–90
value of, 84
Maximum-distortion-energy failure theory
(maximum-octahedral-shear-stress failure theory), 243–245
Maximum-normal-stress failure theory, 242
Maximum-shear-stress failure theory, 242–243
Maxwell, James Clerk, 243–244
Mean stress, and fatigue strength, 299–308, 310–317
Mechanical engineering, 1
Medium-carbon steels, 96
Melamine, 103
MEMS sensors, 748, 749 (online, Ch 20)
Metal-inert gas (MIG) welding, 431
Metal plates, corrosion of, 347–348
Metals see also specific metals
corrosion of, 341–344
database for properties of, 84
physical properties of (table), 795
tensile properties of (table), 796
Microactuators, 738–744 (online, Ch 20)
Microelectromechanical systems (MEMS) devices, flexural
bearings in, 745–746 (online, Ch 20)
Micro/nanoscale machine elements
description, 737 (online, Ch 20)
low-cost production, 737 (online, Ch 20)
Microreyn, 500
Microscale piezoelectric actuator, 743 (online, Ch 20)
MIG (metal-inert gas) welding, 431
MIL-HDBK-5J, 84, 230, 295, 837–851 (online, Appendix F)
Millipascal-second, 500
Miner rule, 317
Mises, R. von, 243
Mixed-film lubrication, 498, 527
Mode I, 230
Modern gear-cutting machines, 771 (online, Ch 21)
Modulus of elasticity, 85
Modulus of resilience, 91, 272
Modulus of rupture, 273
Modulus of toughness, 91, 272
Mohr, Otto, 140
Mohr circle
combined stresses, 140–143
and failure prediction, 242–243
for induced stresses, 138–140
for strain, 179–181, 185–186
stress state representation, 143–144
three-circle diagram, 148
three-dimensional, 185–186
for two parallel cylinders, 362
Mohr theory
and fatigue strength, 297
modified, 245–246
Monomers, 100
Moore rotating-beam fatigue-testing machine, 289–290
N
Nanoscale actuators, 738–744 (online, Ch 20)
Nanoscale flexural bearings, 746 (online, Ch 20)
National Bureau of Standards, 341
Necking, 87
Needle bearings, 774 (online, Ch 21)
Needle roller bearings, 539, 542, 543
Newton • meter, 17
Newton’s law of viscous flow, 500
Newton’s second law, 12–14
Nickel alloys, 99–100, 293, 815
Nickel-based superalloys, 99–100
Nickel, corrosion of, 344
Nickel plating, 321
Nitriding, 98, 323
Nodular (ductile) iron, 96
Nominal mean stress method, 313
Non-feedback tunneling sensors, 757–758 (online, Ch 20)
Nonferrous alloys, 98–100
Nonferrous metals/materials
for columns, 216
electroplating, 321
endurance limit of, 290
Normal distribution, 253–254, 855–857 (online, Appendix H)
Notched impact tests, 277
Notches, 308, 539
Notch sensitivity factor, 309
Nuts
locknuts, 397
with power screws, 377–380
and thread-bearing stress, 386–388
Nylon (polyamide), 102
O
Ocvirk’s short bearing approximation, 509
Oil bath, 516INDEX 873
Oil collar, 516
Oil grooves, 517
Oil holes, 517
Oil lubricants, 496, 516–518
Oil pump, 517–518
Oil ring, 516, 517
Oldham coupling, 669 (online, Ch 17)
“The One-Hoss Shay,” (Oliver Wendell Holmes), 227–229
Optical heterodyne interferometers, 756–757 (online, Ch 20)
Optical sensors, 756–757 (online, Ch 20)
Optomechanical actuators, 741 (online, Ch 20)
OSHA, 4–5
Overdesign, 227
Overhauling power screws, 381
Overload, design, 249
Oxide coatings, 345
P
Packaging, 8
Paints, 346
Palmgren rule, 317
Parallel loading (welds), 433–436
Parallel plate actuators, 740–741 (online, Ch 20)
Parallel plate capacitive sensors, 749, 750 (online, Ch 20)
Parkerizing, 345
Pascal-seconds, 500
Passivation, 344, 347
Pearlite, 344
Performance
requirement, 107, 108
service, 109–110
Petroff’s equation, 505–506
Phase transformations, 161
Phenolic, 104
Phenylene oxide, 102
Phosphate coatings, 345
Photoelastic patterns, 579
Piezoelectric actuators, 743 (online, Ch 20)
Piezoelectric bimorph actuator, 743 (online, Ch 20)
Piezoelectric sensors, 754–755 (online, Ch 20)
Piezoresistive sensors, 751–755 (online, Ch 20)
Pillow block, 403–405
Pinion, 566
Piston ring, tangential deflection of, 198–203
Pitch cones, 626
Pitch diameter, 569, 620, 633, 634
Pitting, 364, 590, 592
Plain carbon steels, 96–97
Planes, principal, 139
Plane strain/stress, 230
Planet bearings, 773 (online, Ch 21)
Plasma arc welding, 432
Plastic distortion, 229
Plastics, 100–104
applications of, 820
designation of, 101
mechanical properties of, 818
reinforcement of, 102
thermoplastics, 102–103, 819
thermosets, 102–104
Plastic strain-strengthening region (true stress-strain curve), 90
Plates
corrosion of metal, 345–348
local buckling/wrinkling in, 216
stress concentration factors of, 154
thick, fracture mechanics of, 233–234
thin, fracture mechanics of, 231–233
Plating, 321, 343
Pneumatic springs, 450
Pole deflection, preventing, 203–204
Polyamide (nylon), 102
Polycarbonate, 103
Polyester, 103, 104
Polyethylenes, 100, 101, 103
Polyimide, 103
Polymerization, 100
Polymers, 100–101
Polyphenylene sulfide, 103
Polypropylene, 103
Polystyrene, 103
Polysulfone, 103
Polyurethane, 103, 104
Polyvinyl chloride (PVC), 103
Poncelet, 287
Power, 18–19
camshafts, 19–20
punch press motor, 36, 37
Power screws, 377–385
axial load with, 386
column loading of, 389–390
efficiency of, 382–383
friction coefficients, values of, 381
overhauling, 381–382
purpose of, 377
rolling contact in, 383–385
self-locking, 381–382
with square thread, 380, 382
thread angle in normal plane, values of, 381
thread bearing stress with, 386–388
thread forms for, 377
thread shear stress with, 388–389
thread sizes for, 377
thrust collar with, 380
torque applied to nut in, 377–380
torsional stresses with, 386
transverse shear loading with, 389
Power train, automotive, 42–43
Power transmission, 714–729
by belt, 714–716
by chain, 720–722
by gear (see Gears)
by hydrodynamic drive, 724874 INDEX
Press, screw, 389
Pressure, and viscosity, 350–351
Pressure vessel flange bolts, selection of, 416–417
Prevailing-torque locknuts, 397
Primary dimensions, 12
Primers, 346
Principal planes, 139
Processing, 8
Professional engineering, 1
Proportional limit, 85
Punch press flywheel, 36, 37
Punch press motor
with flywheel, 36, 37
without flywheel, 37
Pure bending loading, 126–132
with curved beams, 127–132
with straight beams, 126–127
PVC (polyvinyl chloride), 103
R
Racks, 571
Radial tension, 132
Rectangular strain rosettes, 183–185
Recycling, designing for, 7–8
Redundant ductile structures, 56–58
Redundant reactions, 203–206
Redundant supports, 54–56
Reinforcement
of plastics, 102
web, 55
Reliability, 227, 252–253
interference theory of reliability prediction, 254–256
and normal distributions, 253–254
Rene alloys, 100
Residual stresses, 153–159
and axial loading, 153–157
and bending, 157–159
and heat, 159–161
in steel, 161
and torsional loading, 157–159
Residual stress method, 312
Resilience
modulus of, 91, 272
Resistance welding

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