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أخواني في الله أحضرت لكم كتاب Fundamentals of Machine Component Design - Fifth 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 PART 1 FUNDAMENTALS, 1 Chapter 1 Mechanical Engineering Design in Broad Perspective, 3 1.1 An Overview of the Subject, 3 1.2 Safety Considerations, 4 1.3 Ecological Considerations, 10 1.4 Societal Considerations, 11 1.5 Overall Design Considerations, 14 1.6 Systems of Units, 15 1.7 Methodology for Solving Machine Component Problems, 19 1.8 Work and Energy, 21 1.9 Power, 23 1.10 Conservation of Energy, 24 Chapter 2 Load Analysis, 45 2.1 Introduction, 45 2.2 Equilibrium Equations and Free-Body Diagrams, 45 2.3 Beam Loading, 57 2.4 Locating Critical Sections—Force Flow Concept, 60 2.5 Load Division Between Redundant Supports, 62 2.6 Force Flow Concept Applied to Redundant Ductile Structures, 64 Chapter 3 Materials, 89 3.1 Introduction, 89 3.2 The Static Tensile Test—“Engineering” Stress–Strain Relationships, 90 3.3 Implications of the “Engineering” Stress–Strain Curve, 91 3.4 The Static Tensile Test—“True” Stress–Strain Relationships, 94 3.5 Energy-Absorbing Capacity, 96 3.6 Estimating Strength Properties from Penetration Hardness Tests, 97 3.7 Use of “Handbook” Data for Material Strength Properties, 100 3.8 Machinability, 101 3.9 Cast Iron, 101 3.10 Steel, 102 3.11 Nonferrous Alloys, 105 3.12 Plastics and Composites, 106 3.13 Materials Selection Charts, 112 3.14 Engineering Material Selection Process, 116 Chapter 4 Static Body Stresses, 131 4.1 Introduction, 131 4.2 Axial Loading, 131 4.3 Direct Shear Loading, 133 4.4 Torsional Loading, 135 4.5 Pure Bending Loading, Straight Beams, 137 4.6 Pure Bending Loading, Curved Beams, 138 4.7 Transverse Shear Loading in Beams, 144 4.8 Induced Stresses, Mohr Circle Representation, 150 4.9 Combined Stresses—Mohr Circle Representation, 153 4.10 Stress Equations Related to Mohr’s Circle, 156 4.11 Three-Dimensional Stresses, 158 4.12 Stress Concentration Factors, Kt, 162 4.13 Importance of Stress Concentration, 165 4.14 Residual Stresses Caused by Yielding—Axial Loading, 167 4.15 Residual Stresses Caused by Yielding—Bending and Torsional Loading, 171 4.16 Thermal Stresses, 173 4.17 Importance of Residual Stresses, 176 Chapter 5 Elastic Strain, Deflection, and Stability, 194 5.1 Introduction, 194 5.2 Strain Definition, Measurement, and Mohr Circle Representation, 195 5.3 Analysis of Strain—Equiangular Rosettes, 197 5.4 Analysis of Strain—Rectangular Rosettes, 199 5.5 Elastic Stress–Strain Relationships and Three-Dimensional Mohr Circles, 202 5.6 Deflection and Spring Rate—Simple Cases, 204 5.7 Beam Deflection, 206 5.8 Determining Elastic Deflections by Castigliano’s Method, 209 5.9 Redundant Reactions by Castigliano’s Method, 222 5.10 Euler Column Buckling—Elastic Instability, 227 5.11 Effective Column Length for Various End Conditions, 229 5.12 Column Design Equations—J. B. Johnson Parabola, 230 5.13 Eccentric Column Loading—the Secant Formula, 234 5.14 Equivalent Column Stresses, 236 5.15 Other Types of Buckling, 236 5.16 Finite Element Analysis, 238 Chapter 6 Failure Theories, Safety Factors, and Reliability, 248 6.1 Introduction, 248 6.2 Types of Failure, 250 ixx Contents 6.3 Fracture Mechanics—Basic Concepts, 251 6.4 Fracture Mechanics—Applications, 253 6.5 The “Theory” of Static Failure Theories, 263 6.6 Maximum-Normal-Stress Theory, 265 6.7 Maximum-Shear-Stress Theory, 265 6.8 Maximum-Distortion-Energy Theory (MaximumOctahedral-Shear-Stress Theory), 266 6.9 Mohr Theory and Modified Mohr Theory, 269 6.10 Selection and Use of Failure Theories, 270 6.11 Safety Factors—Concept and Definition, 272 6.12 Safety Factors—Selection of a Numerical Value, 274 6.13 Reliability, 276 6.14 Normal Distributions, 278 6.15 Interference Theory of Reliability Prediction, 280 Chapter 7 Impact, 288 7.1 Introduction, 288 7.2 Stress and Deflection Caused by Linear and Bending Impact, 290 7.3 Stress and Deflection Caused by Torsional Impact, 298 7.4 Effect of Stress Raisers on Impact Strength, 301 Chapter 8 Fatigue, 312 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, 337 8.12 Fatigue Life Prediction with Randomly Varying Loads, 344 8.13 Effect of Surface Treatments on the Fatigue Strength of a Part, 348 8.14 Mechanical Surface Treatments—Shot Peening and Others, 350 8.15 Thermal and Chemical Surface-Hardening Treatments (Induction Hardening, Carburizing, and Others), 351 8.16 Fatigue Crack Growth, 351 8.17 General Approach for Fatigue Design, 356 Chapter 9 Surface Damage, 372 9.1 Introduction, 372 9.2 Corrosion: Fundamentals, 372 9.3 Corrosion: Electrode and Electrolyte Heterogeneity, 375 Sœ n 9.4 Design for Corrosion Control, 376 9.5 Corrosion Plus Static Stress, 380 9.6 Corrosion Plus Cyclic Stress, 383 9.7 Cavitation Damage, 384 9.8 Types of Wear, 384 9.9 Adhesive Wear, 385 9.10 Abrasive Wear, 387 9.11 Fretting, 388 9.12 Analytical Approach to Wear, 389 9.13 Curved-Surface Contact Stresses, 392 9.14 Surface Fatigue Failures, 399 9.15 Closure, 401 PART 2 APPLICATIONS, 409 Chapter 10 Threaded Fasteners and Power Screws, 411 10.1 Introduction, 411 10.2 Thread Forms, Terminology, and Standards, 412 10.3 Power Screws, 417 10.4 Static Screw Stresses, 425 10.5 Threaded Fastener Types, 430 10.6 Fastener Materials and Methods of Manufacture, 432 10.7 Bolt Tightening and Initial Tension, 432 10.8 Thread Loosening and Thread Locking, 437 10.9 Bolt Tension with External Joint-Separating Force, 439 10.10 Bolt (or Screw) Selection for Static Loading, 444 10.11 Bolt (or Screw) Selection for Fatigue Loading: Fundamentals, 451 10.12 Bolt Selection for Fatigue Loading: Using Special Test Data, 458 10.13 Increasing Bolted-Joint Fatigue Strength, 461 Chapter 11 Rivets, Welding, and Bonding, 472 11.1 Introduction, 472 11.2 Rivets, 472 11.3 Welding Processes, 474 11.4 Welded Joints Subjected to Static Axial and Direct Shear Loading, 478 11.5 Welded Joints Subjected to Static Torsional and Bending Loading, 481 11.6 Fatigue Considerations in Welded Joints, 486 11.7 Brazing and Soldering, 489 11.8 Adhesives, 489 Chapter 12 Springs, 497 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, 504Contents xi 12.5 End Designs of Helical Compression Springs, 507 12.6 Buckling Analysis of Helical Compression Springs, 508 12.7 Design Procedure for Helical Compression Springs—Static Loading, 509 12.8 Design of Helical Compression Springs for Fatigue Loading, 513 12.9 Helical Extension Springs, 521 12.10 Beam Springs (Including Leaf Springs), 522 12.11 Torsion Springs, 528 12.12 Miscellaneous Springs, 529 Chapter 13 Lubrication and Sliding Bearings, 546 13.1 Types of Lubricants, 546 13.2 Types of Sliding Bearings, 546 13.3 Types of Lubrication, 547 13.4 Basic Concepts of Hydrodynamic Lubrication, 548 13.5 Viscosity, 550 13.6 Temperature and Pressure Effects on Viscosity, 555 13.7 Petroff’s Equation for Bearing Friction, 555 13.8 Hydrodynamic Lubrication Theory, 557 13.9 Design Charts for Hydrodynamic Bearings, 561 13.10 Lubricant Supply, 568 13.11 Heat Dissipation and Equilibrium Oil Film Temperature, 571 13.12 Bearing Materials, 572 13.13 Hydrodynamic Bearing Design, 573 13.14 Boundary and Mixed-Film Lubrication, 579 13.15 Thrust Bearings, 581 13.16 Elastohydrodynamic Lubrication, 582 Chapter 14 Rolling-Element Bearings, 587 14.1 Comparison of Alternative Means for Supporting Rotating Shafts, 587 14.2 History of Rolling-Element Bearings, 591 14.3 Rolling-Element Bearing Types, 592 14.4 Design of Rolling-Element Bearings, 596 14.5 Fitting of Rolling-Element Bearings, 600 14.6 “Catalogue Information” for Rolling-Element Bearings, 601 14.7 Bearing Selection, 604 14.8 Mounting Bearings to Provide Properly for Thrust Load, 614 Chapter 15 Spur Gears, 620 15.1 Introduction and History, 620 15.2 Geometry and Nomenclature, 621 15.3 Interference and Contact Ratio, 629 15.4 Gear Force Analysis, 634 15.5 Gear-Tooth Strength, 637 15.6 Basic Analysis of Gear-Tooth-Bending Stress (Lewis Equation), 638 15.7 Refined Analysis of Gear-Tooth-Bending Strength: Basic Concepts, 640 15.8 Refined Analysis of Gear-Tooth-Bending Strength: Recommended Procedure, 642 15.9 Gear-Tooth Surface Durability—Basic Concepts, 648 15.10 Gear-Tooth Surface Fatigue Analysis—Recommended Procedure, 651 15.11 Spur Gear Design Procedures, 656 15.12 Gear Materials, 661 15.13 Gear Trains, 661 Chapter 16 Helical, Bevel, and Worm Gears, 675 16.1 Introduction, 675 16.2 Helical-Gear Geometry and Nomenclature, 678 16.3 Helical-Gear Force Analysis, 681 16.4 Helical-Gear-Tooth-Bending and Surface Fatigue Strengths, 684 16.5 Crossed Helical Gears, 685 16.6 Bevel Gear Geometry and Nomenclature, 686 16.7 Bevel Gear Force Analysis, 688 16.8 Bevel Gear-Tooth-Bending and Surface Fatigue Strengths, 690 16.9 Bevel Gear Trains; Differential Gears, 692 16.10 Worm Gear Geometry and Nomenclature, 694 16.11 Worm Gear Force and Efficiency Analysis, 696 16.12 Worm-Gear-Bending and Surface Fatigue Strengths, 701 16.13 Worm Gear Thermal Capacity, 703 Chapter 17 Shafts and Associated Parts, 716 17.1 Introduction, 716 17.2 Provision for Shaft Bearings, 717 17.3 Mounting Parts onto Rotating Shafts, 717 17.4 Rotating-Shaft Dynamics, 720 17.5 Overall Shaft Design, 725 17.6 Keys, Pins, and Splines, 730 17.7 Couplings and Universal Joints, 732 Chapter 18 Clutches and Brakes, 746 18.1 Introduction, 746 18.2 Disk Clutches, 746 18.3 Disk Brakes, 752 18.4 Energy Absorption and Cooling, 753 18.5 Cone Clutches and Brakes, 755 18.6 Short-Shoe Drum Brakes, 756 18.7 Exernal Long-Shoe Drum Brakes, 760 18.8 Internal Long-Shoe Drum Brakes, 767 18.9 Band Brakes, 769 18.10 Materials, 772xii Contents C-4b Typical Uses of Plain Carbon Steels, 824 C-5a Properties of Some Water-Quenched and Tempered Steels, 825 C-5b Properties of Some Oil-Quenched and Tempered Carbon Steels, 826 C-5c Properties of Some Oil-Quenched and Tempered Alloy Steels, 827 C-6 Effect of Mass on Strength Properties of Steel, 828 C-7 Mechanical Properties of Some Carburizing Steels, 829 C-8 Mechanical Properties of Some Wrought Stainless Steels, 830 C-9 Mechanical Properties of Some Iron-Based Superalloys, 831 C-10 Mechanical Properties, Characteristics, and Typical Uses of Some Wrought Aluminum Alloys, 832 C-11 Tensile Properties, Characteristics, and Typical Uses of Some Cast-Aluminum Alloys, 833 C-12 Temper Designations for Aluminum and Magnesium Alloys, 834 C-13 Mechanical Properties of Some Copper Alloys, 835 C-14 Mechanical Properties of Some Magnesium Alloys, 836 C-15 Mechanical Properties of Some Nickel Alloys, 837 C-16 Mechanical Properties of Some Wrought-Titanium Alloys, 838 C-17 Mechanical Properties of Some Zinc Casting Alloys, 839 C-18a Representative Mechanical Properties of Some Common Plastics, 840 C-18b Properties of Some Common Glass-Reinforced and Unreinforced Thermoplastic Resins, 841 C-18c Typical Applications of Common Plastics, 842 C-19 Material Classes and Selected Members of Each Class, 843 C-20 Designer’s Subset of Engineering Materials, 844 C-21 Processing Methods Used Most Frequently with Different Materials, 845 C-22 Joinability of Materials, 846 C-23 Materials for Machine Components, 847 C-24 Relations Between Failure Modes and Material Properties, 849 Appendix D Shear, Moment, and Deflection Equations for Beams, 850 D-1 Cantilever Beams, 850 D-2 Simply Supported Beams, 851 D-3 Beams with Fixed Ends, 853 Appendix E Fits and Tolerances, 854 E-1 Fits and Tolerances for Holes and Shafts, 854 E-2 Standard Tolerances for Cylindrical Parts, 855 E-3 Tolerance Grades Produced from Machining Processes, 856 Chapter 19 Miscellaneous Machine Components, 782 19.1 Introduction, 782 19.2 Flat Belts, 783 19.3 V-Belts, 785 19.4 Toothed Belts, 789 19.5 Roller Chains, 789 19.6 Inverted-Tooth Chains, 792 19.7 History of Hydrodynamic Drives, 793 19.8 Fluid Couplings, 794 19.9 Hydrodynamic Torque Converters, 798 Chapter 20 Machine Component Interrelationships— A Case Study (web-based chapter) (www.wiley.com/college/juvinall), 20-1 20.1 Introduction, 20-1 20.2 Description of Original Hydra-Matic Transmission, 20-2 20.3 Free-Body Diagram Determination of Gear Ratios and Component Loads, 20-5 20.4 Gear Design Considerations, 20-9 20.5 Brake and Clutch Design Considerations, 20-10 20.6 Miscellaneous Design Considerations, 20-11 Appendix A Units, 807 A-1a Conversion Factors for British Gravitational, English, and SI Units, 807 A-1b Conversion Factor Equalities Listed by Physical Quantity, 808 A-2a Standard SI Prefixes, 810 A-2b SI Units and Symbols, 811 A-3 Suggested SI Prefixes for Stress Calculations, 812 A-4 Suggested SI Prefixes for Linear-Deflection Calculations, 812 A-5 Suggested SI Prefixes for Angular-Deflection Calculations, 812 Appendix B Properties of Sections and Solids, 813 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, 817 C-1 Physical Properties of Common Metals, 817 C-2 Tensile Properties of Some Metals, 818 C-3a Typical Mechanical Properties and Uses of Gray Cast Iron, 819 C-3b Mechanical Properties and Typical Uses of Malleable Cast Iron, 820 C-3c Average Mechanical Properties and Typical Uses of Ductile (Nodular) Iron, 821 C-4a Mechanical Properties of Selected Carbon and Alloy Steels, 822Contents xiii Appendix F MIL-HDBK-5J, Department of Defense Handbook: Metallic Materials and Elements for Aerospace Vehicle Structures, 857 F-1 Introduction, 857 F-2 Overview of Data in MIL-HDBK-5J, 857 F-3 Advanced Formulas and Concepts Used in MIL-HDBK-5J, 859 F-4 Mechanical and Physical Properties of 2024 Aluminum Alloy, 864 F-5 Fracture Toughness and Other Miscellaneous Properties, 869 F-6 Conclusion 873 Appendix G Force Equilibrium: A Vectorial Approach, 874 G-1 Vectors: A Review, 874 G-2 Force and Momments Equilibrium, 875 Appendix H Normal Distributions, 878 H-1 Standard Normal Distribution Table, 878 H-2 Converting to Standard Normal Distribution, 881 H-3 Linear Combination of Normal Distributions, 881 Appendix I S-N Formula, 883 I-1 S-N Formula, 883 I-2 Illustrative Example, 884 Appendix J Gear Terminology and Contact-Ratio Analysis, 885 J-1 Normal Spur-Gear Quantities, 885 J-2 Actual Quantities, 887 J-3 Illustrative Example, 888 Index 890 INDEX ABEC, see Annular Bearing Engineers’ Committee Abrasive wear, 387–388, 650 ABS (acrylonitrile–butatiene-styrene), 109 Acetal, 109 Acme threads, 415–416 Acrylic, 109 Acrylic adhesives, 491 Acrylonitrile-butatiene-styrene (ABS), 109 Addendum, 624 Adhesive bonding, 489–491 Adhesive wear, 385–387, 580 AFBMA (Anti-Friction Bearing Manufacturers Association), 600 AGMA (American Gear Manufacturers Association), 620 AISC (American Institute of Steel Construction), 472 Alkyd, 110 Alloying, 108 Alloys aluminum (see Aluminum alloys) cast iron, 101–102 copper, 105, 320, 835 magnesium, 105–106, 319, 834, 836 nickel, 106, 320, 837 nonferrous, 105–106 steel (see Steel alloys) superalloys, 105, 106, 831 titanium, 106, 838 zinc, 106, 839 Allyl (diallyl phthalate), 110 Alternating loads/stress, 337–341 Aluminum anodized, 378 cavitation of, 384 connecting rod, 233–234 corrosion of, 376–377, 378 fretting of, 388 notch sensitivity of, 335 Aluminum alloys, 105 endurance limit of, 318 fatigue strength diagrams for, 318–319 mechanical properties/uses of, 832, 833 temper designations for, 834 American Blower Company, 794 American Gear Manufacturers Association (AGMA), 620 American Institute of Steel Construction (AISC), 472 American National Standards lnstitute (ANSI), 7, 388, 389, 525 American Society for Testing and Materials (ASTM), 105–106, 478 American Society of Mechanical Engineers (ASME), 274, 414, 472, 791 American Welding Society (AWS), 478 Amino, 110 Anaerobic adhesives, 491 Anisotropic materials, 272 Annealing, 176, 382 Annular Bearing Engineers’ Committee (ABEC), 600 Anode, sacrificial, 375, 378 Anodized aluminum, 378 Anodizing, 377 ANSI, see American National Standards Institute Anti·Friction Bearing Manufacturers Association (AFBMA), 600 Approximations, 21 Ashby’s materials selection charts, 112–115 ASME, see American Society of Mechanical Engineers Asperity welding, 385–386 ASTM, see American Society for Testing and Materials Automobiles load analysis, 46–52 performance analysis, 26–28 power train components, 48–49 transmission components, 50–52 AWS (American Welding Society), 478 Axial impact, 294–295 Axial loads/loading, 131–133 and Castigliano’s method, 209–212 with power screws, 425–426 and residual stresses, 167–171 reversed, 320–321 with roller bearings, 607–608 sign convention for, 135 with springs, 502 with threaded fasteners, 425–426 Ball bearings and axial loading, 607–608 dimensions of, 601–603 history of, 591–592 life requirement for, 606 radial, 588 rated capacities of, 604, 605 reliability requirement for, 606–607 rings for, 594–595 selection of, 604–611 shields/seals for, 594 and shock loading, 608–609 special, 597–599 surface damage to, 395–401 thrust load, mounting for, 614–615 types of, 590, 593 Ball-bearing screws, 418–419 Band brakes, 769–771 Bars compression/tension, impacted in, 298–299 deflection/stiffness formulas for, 210 energy-absorbing capacity, effect of stress raiser on, 304–306 stress concentration factors of, 165–167 Base units, 16 Basic design objective, 10 Basic hole system, 854 Beach marks, 312–313 Beam loading, 57–60 Beams bending impact, with compound spring, 297–298 bent cantilever, deflection in, 215–216 centrally loaded, deflection in, 212–214 curved, bending of, 138–144 deflection in, 206–208, 850–853 deflection/stiffness formulas for, 204–205 extreme-fiber-bending stresses in, 142–144 straight, bending of, 137–138 transverse shear loading in, 144–150Index 891 Beam springs, 522–527 Bearing(s) ball (see Ball bearings) bearings for shafts, 717 definition of, 547 rolling-element (see Rolling-element) sliding (see Sliding bearings) thrust, 581–582, 614–615 Bell crank, load analysis of, 54–55 Belt drive, with spur gears, 623–624 Belts flat, 783–785 toothed (timing), 789 V-, 785–788 Bending of beams, 57–58, 137–144 bevel gears, 690–692 and Castigliano’s method, 206–208 and fatigue strength, 314–321, 342–344 of gear teeth, 638–648 helical gears, 684 and residual stress, 171–173 and shear stresses, 148–150 sign convention for, 58 worm gears, 701–703 Bending impact, 290–293, 297–298 Bevel gears, 675–676, 677, 686–694 bending stress with, 690–692 force analysis with, 688–689 geometry of, 686–688 large end of, 686 pitch cones of, 686 surface fatigue stress with, 690, 692 trains, gear, 692–694 and Tredgold’s approximation, 687 Zerol, 688 Biaxial effect (of stress raisers), 162 Biaxial loading, fatigue strength for reversed, 326 Biaxial stresses, 158, 159, 202 modified Mohr theory for, 269 Bioengineering, 55 Blind rivets, 473–474 Body stress(es), 131–177 from axial loading, 131–133 combined, 153–156 concentration factors, 162–167 from direct shear loading, 133–134 induced, 150–152 from pure bending loading, 137–144 residual (see Residual stresses) thermal, 173–176 three-dimensional, 158–161 from torsional loading, 135–136 from transverse shear loading, 144–150 Bolted joint, shear load capacity of, 446–448 Bolts, 430 bracket attachment, selection for, 448–451 design for impact strength of, 304–306 fatigue loading, selection for, 451–461 fatigue strength, increasing, 461–462 initial tightening tension, 432–437, 452–455 pressure vessel flange bolts, selection of, 459–461 static loading, selection for, 444–451 tension of, with external jointseparating force, 439–444 and thread-bearing stress, 426–427 types of, 431 Bonderizing, 377 Bonding, adhesive, 489–491 Boundary lubrication, 548, 579–581 Bracket(s) bolts for attachment of, 448–451 deflection of redundantly supported, 222–226 Brake(s), 746 band, 769–771 cone, 755–756 disk, 752–753 energy absorption/cooling with, 753–754 long-shoe drum, 760–768 materials for, 772–773 short-shoe drum, 756–760 Brasses, 105 Brazing, 489 Brinell hardness test, 97–100, 317 British Comets, 7 British Gravitational units, 16–18 British thermal unit, 22 British thermal units per second, 23 Brittle fracture, 250–251, 302 Brittle materials, 250, 276, 322 Bronzes, 105, 384 Buckingham, Earle, 650 Buckling, 227–238 columns, 227–236 eccentric loading, secant formula for, 234–236 of helical compression springs, 508 local, 237–238 of power screws, 429 Building codes, 274 Butt welds, 478, 488–489 Cadmium, 377, 402 Camshafts power requirement, 25 torque requirement, 22–23 Cantilever beams, 215–216, 850 Carbide, 376 Carbon fiber reinforced plastics, 108 Carbon steels, 103, 818, 822–824 Carburizing, 104, 351 Carburizing steel, 829 Cardan joint, 734 Case-hardening steels, 104 Castigliano, Alberto, 210 Castigliano’s method elastic deflections determined by, 209–222 redundant reactions by, 222–226 Cast iron, 101–102 cavitation of, 384 endurance limit of, 318 fretting of, 388 mechanical properties/uses of (table), 819–820 surface factor for, 323–324 Cathode, 373 Cavitation, 384 Cellulosics, 109 Chains inverted-tooth, 792–793 roller, 789–791 Change, 13–14 Charpy test, 97, 302 Chemical surface-hardening treatments, 351 “Chilling,” 102 Chordal action, 790 Chrome plating, 349 Chromium, 376 Chrysler Corporation, 794 Clearance fits, 854 Clutch(es) cone, 755–756 disk, 746–752 function of, 746 materials for, 772–773 Coating, 118, 121 Coining, 350 Cold rolling, 350892 Index Column buckling, 227–238 end conditions, column length and, 229–230 equivalent stresses, 236 J.B. Johnson parabola for, 230–234 Column loading (of power screws), 429–430 Combined stresses, 153–156 Compatibility, of materials, 11 Completely reversed loading, fatigue strength for, 326, 334–336 Components, mechanical, 4 Composite, 111–112 engineering, 111, 112, 843 material, 111–112 Compound springs, 297–298 Compression, 131, 133 Compression springs, helical, see Helical compression springs Concentration, stress, see Stress concentration factors Cone clutches/brakes, 755–756 Configuration factor, 253, 354 Conic threaded fasteners, 416 Connecting rods, determining diameter of, 232–234 Conservation of energy, 24–28 Constant-force springs, 530 Constant-life fatigue diagram, 327, 330–331 Contact modulus, 393 Contact ratio (CR), 629–632, 885–889 Copolymerization, 108 Copper, corrosion of, 377 Copper alloys, 105, 320, 835 Corrosion, 372–383 crevice, 376 with cyclic stress, 383 design for control of, 376–379 and electrode/electrolyte heterogeneity, 375–376 with static stress, 380–382 Corrosion engineering, 372 Cost(s) of machined parts, 101 of materials, 89 of safety factor, 275–276 Coulomb, C. A., 265 Coulomb-Mohr theory, 269 Countershaft, internal loads in transmission, 58–60 Couplings fluid, 794–798 shaft, 732–735 CR. see Contact ratio Crack length, 253, 351–356 propagation, 252, 254, 352, 358 Cracks, stress-corrosion, 380–382 Crevice corrosion, 376 Critical sections, 60–62 Critical stress intensity factor, 252 Crossed helical gears, 675, 685–686 Cross-linked plastics, 108 Curved surfaces, contact stresses with, 392–399 Cyaniding, 104 Cyclic stress, and corrosion, 383 Cylindrical threaded fasteners, 416 Damper, 288 Damping, 290 Dashpot, 288 Dedendum, 624 Deflection, 194 beam, 206–209 Castigliano’s method for determining, 209–222 caused by linear/bending impact, 290–298 caused by torsional impact, 298–301 formulas for, 204–206 and redundant reactions, 222–226 of springs, 498–503 torsional, 205 DeMoivre, 278 Density, and strength, 113–114 Design, 3–15 ecological objectives of, 10–11 overall considerations in, 14–15 process, 116 safety considerations in, 4–9 societal objectives of, 11–14 Design overload, 273 “Design stress,” 272 Diallyl phthalate (allyl), 110 Dimensionally homogeneous equations, 15 Dimensions, primary/secondary, 16 Direct shear loading, 133–134 Disk brakes, 752–753 Disk clutches, 746–752 Disk sander shaft, safety factor of, 342–344 Distortion (plastic strain), 250 Double shear, 62, 134 Drum brakes long-shoe, 760–768 short-shoe, 756–760 Ductile (nodular) iron, 102, 821 Ductile materials, 250 fatigue strength of, 321–322, 325 machinability of, 102 Ductility, 93–94, 829, 849 Durability (of materials), 11 Duranickel alloys, 106 Dynamic loading. see Fatigue; Impact Eccentricity ratio, 235 Eccentric loading columns, 234–236 welds, 481–486 Ecological issues, 10–11, 376–377 Economic issues, 401–402 Efficiency (of power screws), 421–422 Elasticity, modulus of, 91 Elastic limit, notation convention for, 91 Elastic region (true stress–strain curve), 94–96 Elastic stability/instability, 227 Elastic strains, see Strain Elastic stress–strain relationships, 202–203 Elastohydrodynamic lubrication, 582, 648 Electrical insulators, 378 Electrical resistance strain gages, 196–197 Electrochemical reaction, 372–375 Electrolytes, 373, 378–379 Electron beam welding, 476 Electroplating, 349, 375, 401 Electroslag welding, 476 Elongation (at fracture), 92 End-quench test, Jominy, 103 Energy conservation of, 24 and work, 21–23 Energy absorption capacity bolt design modification to increase, 304–306 of brakes, 753–754 effect of stress raisers on, 295–296 of materials, 96–97, 294–295 Engineering, 3 Engineering model, 20 Engineering stress–strain curve, 91–94 Engineering values, 90 English Engineering units, 16–18 Epoxies, 110, 490–491 Equations characteristic, 160–161, 189–190 dimensionally homogeneous, 15 equilibrium, 45–48Index 893 Equiangular rosettes, 197–199 Equilibrium and load determination, 45–48 and redundant reactions, 222 and residual stresses, 175 Euler, Leonhard, 227 Euler column buckling, 227–229 “Fail-safe” design, 7 Failure, 248–281, see also Fatigue; Surface damage analysis, 356, 857 and axial stress, 133 definition of, 250 distortion, 250 fracture, 251–263 mode, 849 theories of, 263–272 Fasteners, threaded, see Threaded fasteners Fatigue, 312–314 life prediction, 344–347 S-N formula, 333, 883–884 surface fatigue failures, 399–401 and surface treatments, 348–351 in welded joints, 486–489 Fatigue life prediction, 344–347 Fatigue loading bolt selection for, 451–461 screw selection for, 451–457 spring design for, 513–520 Fatigue strength, 314–344 for completely reversed loading, 326, 334–336 concentrated stress, effect of, 334–344 definition of, 315 increasing bolted-joint, 461–462 mean stress, effect of, 326–334, 337–344 for reversed bending/reversed axial loading, 320–321 for reversed biaxial loading, 322 for reversed torsional loading, 321–322 for rotating bending, 314–320 and safety factors, 272–273 and surface size, 323–326 surface treatments, effect of, 348–349 Fatigue zone, 312 FCAW (flux-cored arc welding), 476 Ferrite, 376 Ferrous materials, endurance limit of, 315 Fiber-reinforced plastics, 108 Fillet welds, 478–481 Finishing, 118, 121, 123 Finite element analysis, 238–240 steps in, 238–240 Fits, 854–856 Flame cutting, 176 Flame hardening, 104 Flat belts, 783–785 Fluid couplings, 794–798 Fluoroplastics, 109 Flux-cored arc welding (FCAW), 476 Flywheels, 23 Foot-pound force, 22 Foot-pounds, 22 Force units of, 18 work done by, 21 Force flow critical sections, location of, 60–62 with redundant ductile structures, 64–67 Formability, 121 Föttinger, H., 793 Fracture mechanics, 251–263 of thick plates, 255–256 of thin plates, 253–255 Fracture(s), 250–251, 312–314 Fracture toughness, 252 Free-body analysis of loads, 45–48 acceleration, automobile undergoing, 47–48 constant speed, automobile at, 46–47 internal loads, determination of, 52–53 power train components, automotive, 48–49 with three-force member, 54–56 transmission components, automotive, 50–52 Free-spinning locknuts, 438 Fretting, 388 Friction with power screws, 419 with rolling-element bearings, 589, 591 viscous, 555–557 Fusion (welding), 474 Galling, 385 Galvanic action, 372, 376–378 Galvanic corrosion, 377–378 Galvanic series, 374 Garter springs, 530 Gas metal arc welding (GMAW), 476 Gas tungsten arc welding (GTAW), 476 Gas welding, 476 Gears, 620 bevel (see Bevel gears) helical (see Helical gears) materials for, 661 spur (see Spur gears) terminology, 885–889 worm (see Worm gears) Glass fiber reinforced plastics, 108 GMAW (gas metal arc welding), 476 Goodman lines, 330, 331 Government standards, 7 Gray iron, 101–102, 819 Greases, 546 Grinder, torsional impact in, 299–301 GTAW (gas tungsten arc welding), 476 Guest, J. J., 265–266 Guest’s law, 265–266 Hammer peening, 382 Hardness, and machinability, 101 Hardness tests Brinell, 97–100 Jominy end-quench test, 103 penetration, 97–100 Rockwell, 97–100 Hastelloys, 106 Hazard, 8 Helical compression springs, 498–520 buckling analysis of, 508 end designs of, 507–508 fatigue loading, design procedure for, 513–520 static loading, design procedure for, 509–512 stress/strength analysis for, 504–507 Helical extension springs, 521–522 Helical gears, 675, 676, 678–685. See also Spur gears angle of, 678–679 bending stress with, 684 crossed, 675, 685–686 force analysis with, 681–684 geometry of, 678–681 meshing, 682–684 pitch of, 679–680 surface fatigue stress with, 684–685 Helical threads, 412 Hencky, H., 266 Hertz, Heinrich, 394, 395 Hertz contact stresses, 394, 396, 648, 650–651 Hierarchy of needs, 13 High-carbon steels, 103 High-molecular-weight polyelhylene, 108 High-strength low-alloy (HSLA) steels, 104894 Index Holmes, Oliver Wendell, 248 Hooke’s joint, 734 Hooke’s law, 91 Hoop tension, 62 Horsepower, 23–24 HSLA (high-strength low-alloy) steels, 104 Hubs, 719 Hueber, M. T., 266 Hydraulic springs, 497 Hydrodynamic bearings design charts for, 561–568 design of, 573–579 Hydrodynamic drives, history of, 793–794 Hydrodynamic lubrication, 547–550, 557–561 Hydrodynamic torque converters, 782, 798–799 Hydrogen embrittlement, 349 Hydrostatic lubrication, 548 Impact, 288–306 bending, 290–293, 297–298 linear, 290–296 static loading vs., 288–290 torsional, 298–301 Impact factor, 276, 289, 291 Impact loading, wilh roller bearings, 607–608 Impulsive loading. see Impact Incoloy alloys, 106 Inconel alloys, 106 Induced stresses, 150–152 Induction hardening, 104, 351 Industry standards, 7 Inertia, moments of, 813 Inertia welding, 476–477 Ingenuity, 5–6 Instability, elastic, 227 Insulators, 378 Interference fits, 854 Interference points, 629–632 Interference theory of reliability prediction, 280–281 Internal loads in free-body analysis, 52–53 in transmission countershaft, 50–52 International Standards Organization (ISO), 412, 553 inverted-tooth chains, 792–793 Iron, 373, see also Cast iron Iron-based superalloys, 105, 831 ISO, see International Standards Organization ISO screw threads, 412, 414 Izod test, 97, 302 Jacks, screw-type, 417 Johnson, J. B., 230–231 Johnson column formula, 230–234 Joinability, 121, 846 Joint(s) increasing fatigue strength of bolted, 461–462 riveted, 64–67 shear load capacity of bolted, 446–448 universal, 732–735 welded (see Welded joints) Jominy, Walter, 103 Jominy end-quench test, 103 Joule, 22 Joules per second, 23 Keyways (keyseats), 717, 731 Kilowatt, 23–24 Laplace, P., 278 Laser beam welding, 476 Leaf springs, 522–527 Leonardo da Vinci, 591, 620 Lewis, Wilfred, 638 Lewis equation, 638–640 Life cycle, total, 6 Life quality index (LQI), 12–14 Limit elastic, 91 proportional, 91 Linear actuators. See Power screws Linear cumulative-damage rule, 344–346 Linear impact, 293–296 Linearly elastic stress–strain relationships, 202–203 Linear plastics, 108 Loads/loading, 45–67 axial (see Axial loads/loading) with beams, 57–60 direct shear, 133–134 dynamic, 288–290 eccentric, 234–236, 481–486 fatigue, 451–461, 513–520 and force flow, 60–62 with free bodies (see Free-body analysis of loads) impact (see Impact) pure bending, 137–144 and redundant ductile structures, 64–67 redundant supports, division between, 62–64 static, 288–290 torsional, Torsional loading transverse shear, 144–150, 428 Local buckling, 237–238 Locknuts, 438–439 Lock washers, 438 Long-shoe drum brakes, 760–768 internal long shoe, 767–768 nonpivoted long shoe, 760–766 pivoted long shoe, 766–767 Low-carbon steels, 103 Low-molecular-weight polyethylene, 107–108 LQI (life quality index), 12–14 Lubricant(s) supply of, 568–570 types of, 546 Lubrication. See also Viscosity boundary, 548, 579–581 elastohydrodynamic, 582, 648 hydrodynamic, 547–550, 557–561 hydrostatic, 548 mixed-film, 548, 580 self-, 580 Machinability, 101 Machine component problems, methodology for solving, 19–21 Magnesium, 378 fretting of, 388 notch sensitivity of, 336 Magnesium alloys, 105–106, 319 mechanical properties of, 836 temper designations for, 834 Magnesium bronze, 384 Malleable iron, 102 Manufacturing, 117–123 Margin of safety, 277 Maslow, Abraham, 13 Material properties, 116–123 Materials, 89–123. See also specific materials anisotropic, 272 for brakes/clutches, 772–773 brittle, 250, 269 classes of (table), 843–844 for clutches/brakes, 772–773 compatibility of, 11 composites, 106, 111 corrosion of (see Corrosion) database, property, 89–90 ductile, 250Index 895 ecological factors in selection of, 11 energy-absorbing capacity of, 96–97, 294–295 engineering stress-strain curve for, 91–94 ferrous, 315 for gears, 661 “handbook” data on strength properties of, 100 isotropic, 272 machinability of, 101 nonferrous (see Nonferrous metals/materials) penetration hardness tests of, 97–100 properties of, 117–118 relative durability of, 11 for rivets, 473 for screws/nuts/bolts, 432 selection charts for, 112–115 selection factor, 118–121 selection of, 116, 121–123 for sliding bearings, 572–573 for springs, 497 static tensile test for, 90–91, 94–96 strength charts for, 112–115 and stress concentration factors, 162–165 true stress-strain curve for, 94–96 value of, 89 Maximum-distortion-energy failure theory (maximum-octahedralshearstress failure theory), 266–268 Maximum-normal-stress failure theory, 265 Maximum-shear-stress failure theory, 265–266 Maxwell, James Clerk, 267 Mean stress, and fatigue strength, 326–334, 337–344 Mechanical engineering, 3 Medium-carbon steels, 103 Melamine, 110 Metal–inert gas (MIG) welding, 476 Metal plates, corrosion of, 379–380 Metals. See also specific metals corrosion of, 372–375 database for properties of, 89–90 physical properties of (table), 817 tensile properties of (table), 818 Microreyn, 551 MIG (metal-inert gas) welding, 476 MIL-HDBK-5J, 89, 129, 252, 320, 857–873 Millipascal-second, 551 Miner rule, 344 Mises, R. von, 266 Mixed-film lubrication, 548, 580 Mode I, 252 Model T Ford, 674 Modulus of elasticity, 91 Modulus of resilience, 96–97, 296 Modulus of rupture, 298 Modulus of toughness, 97, 296 Mohr, Otto, 152 Mohr circle for combined stresses, 153–156 and failure prediction, 265, 266 for induced stresses, 150–152 for strain, 195–197, 202–203 stress state representation, 156–158 three-circle diagram, 161 three-dimensional, 202–203 for two parallel cylinders, 395 Mohr theory and fatigue strength, 322 modified, 269–270 Monomers, 106, 107 Moore rotating-beam fatigue-testing machine, 314–315 National Bureau of Standards, 372 “Necking,” 92 Needle roller bearings, 593, 595, 596 Newton-meter, 22 Newton’s law of viscous flow, 551 Newton’s second law, 16, 18 Nickel, corrosion of, 376 Nickel alloys, 106, 320, 837 Nickel-based superalloys, 106 Nickel plating, 348 Nitriding, 104, 351 Nodular (ductile) iron, 102 Nominal mean stress method, 339 Nonferrous alloys, 105–106 Nonferrous metals/materials for columns, 236 electroplating, 349 endurance limit of, 318 Normal distribution, 278–279, 878–882 Notched impact tests, 302 Notches, 335, 593 Notch sensitivity factor, 335–336 Nuts locknuts, 438–439 with power screws, 417–418 and thread-bearing stress, 426–427 Nylon (polyamide), 109 Ocvirk’s short bearing approximation, 561 Oil bath, 569 Oil collar, 568 Oil grooves, 569–570 Oil holes, 569–570 Oil lubricants, 546, 568–570 Oil pump, 570 Oil ring, 568 Oldham coupling, 733 “The One-Hoss Shay,” (Oliver Wendell Holmes), 249–250 OSHA, 7 Overdesign, 248 Overhauling power screws, 420 Overload, design, 273 Oxide coatings, 377 Packaging, 11 Paints, 377 Palmgren rule, 344 Parallel loading (welds), 478–479, 481 Parkerizing, 377 Pascal-second, 551 Passivation, 376, 379 Pearlite, 376 Performance requirement, 116–123 service, 116–123 Petroff equation, 555–557 Phase transformations, 176 Phenolic, 110 Phenylene oxide, 109 Phosphate coatings, 377 Photoelastic patterns, 637 Pillow block, 444–446 Pinion, 622 Piston ring, tangential deflection of, 217–222 Pitch cones, 686 Pitch diameter, 624, 679, 695 Pitting, 399, 648, 650 Plain carbon steels, 103 Planes, principal, 152 Plane strain/stress, 252 Plasma arc welding, 476 Plastic distortion, 250 Plastics, 106–111 applications of, 842 designation of, 108 mechanical properties of, 840 reinforcement of, 108 thermoplastics, 109–110, 841 thermosets, 110–111896 Index Plastic strain-strengthening region (true stress-strain curve), 95 Plates corrosion of metal, 376–380 local buckling/wrinkling in, 237 stress concentration factors of, 168 thick, fracture mechanics of, 255–256 thin, fracture mechanics of, 253–255 Plating, 349, 373 Pneumatic springs, 497 Pole deflection, preventing, 222–224 Polyamide (nylon), 109 Polycarbonate, 109 Polyester, 109, 110 Polyethylenes, 107–108, 109 Polyimide, 109 Polymerization, 107 Polymers, 106–108 Polyphenylene sulfide, 110 Polypropylene, 110 Polystyrene, 110 Polysulfone, 110 Polyurethane, 110–111 Polyvinyl chloride (PVC), 110 Poncelet, 312 Power, 23–24 camshaft, 25 punch press motor, 42–43 Power screws, 417–425 axial load with, 425–426 column loading of, 429–430 efficiency of, 421–422 friction coefficients, values of, 419 overhauling, 420 purpose of, 417 rolling contact in, 422–423 self-locking, 420 with square thread, 419, 421 thread angle in normal plane, values of, 420 thread bearing stress with, 426–427 thread forms for, 415 thread shear stress with, 428 thread sizes for, 416 thrust collar with, 418 torque applied to nut in, 417–419 torsional stresses with, 425, 426 transverse shear loading with, 428 Power train, automotive, 48–49 Power transmission, 782–799 by belt, 783–789 by chain, 789–793 by gear (see Gears) by hydrodynamic drive, 793–799 Press, screw, 429 Pressure, and viscosity, 384 Pressure vessel flange bolts, selection of, 459–461 Prevailing-torque locknuts, 438–439 Primary dimensions, 15–16 Primers, 377 Principal planes, 152 Processing, 11 Professional engineering, 3 Proportional limit, 91 Punch press flywheel, 42–43 Punch press motor with flywheel, 42–43 without flywheel, 43 Pure bending loading, 137–144 with curved beams, 138–144 with straight beams, 137–138 PVC (polyvinyl chloride), 110 Racks, 628 Radial tension, 144 Rectangular strain rosettes, 199–202 Recycling, designing for, 10–11 Redundant ductile Structures, 64–67 Redundant reactions, 222–226 Redundant supports, 62–64 Reinforcement of plastics, 108 web, 64 Reliability, 248, 276–277 interference theory of reliability prediction, 280–281 and normal distributions, 278–279 Rene alloys, 106 Residual stresses, 167–177 and axial loading, 167–171 and bending, 171–173 and heat, 173–176 in steel, 176 and torsional loading, 171–173 Residual stress method, 339 Resilience, 96–97 modulus of, 96–97, 296 Resistance welding, 476 Reversed bending, fatigue strength for, 334–336 Reversed loading fatigue life prediction with, 344–347 fatigue strength for axial, 320–321 fatigue strength for biaxial, 326 fatigue strength for completely, 326, 334–336 fatigue strength for torsional, 321–322 Reyn, 551 Reynolds, Osborne, 551 Reynolds equation for two-dimensional flow, 560 Rigidity, test for, 90 Riveted joints, 64–67 Rivets, 472–474 blind, 473–474 cost-effectiveness of, 473 materials for, 473 standards for, 472 threaded fasteners vs., 473 tubular, 473, 474 Rockwell hardness test, 97–100 Rods connecting, 232–234 deflection/stiffness formulas for, 204 energy-absorbing capacity, effect of stress raiser on, 295–296 straight, impacted in compression/tension, 293–294 Roller chains, 789–791 Rolling-element bearings, 587–615. See also Ball bearings and axial loading, 607–608 catalogue information for, 601–604 cylindrical, 593, 594–595 design of, 596–600 dimensions of, 601–603 fitting of, 600–601 friction with, 589, 591 history of, 591–592 life requirement for, 606 needle, 593, 595, 596 rated capacities of, 605 reliability requirement for, 606–607 rings for, 594–596 selection of, 604–610 and shock loading, 608–609 sliding bearings vs., 587, 589 spherical, 593, 595 surface damage to, 395–401 tapered, 593, 594, 595 thrust load, mounting for, 614–615 types of, 592–586 Rotating bending, fatigue strength for, 314–321 Rotating machine components, power transmitted by, 23–24 Rubber, energy absorption capacity of, 295 Rupture, modulus of, 298 Rust, 373Index 897 Sacrificial anode, 375, 378 Safety/safety factors, 4–9, 272–274 awareness of, 5 definition of, 272–274 estimation of, for steel pan, 270–272 and ingenuity, 5–6 and margin of safety, 276 nontechnical aspects of, 9 selection of numerical value for, 274–276 techniques/guidelines for ensuring, 6–8 SAW (submerged arc welding), 476 Saybolt seconds, 552 Scoring, 385 Screw press, 429 Screw(s), 430–431. See also Power screws ball-bearing, 418–419 fatigue loading, selection for, 451–457 fatigue strength, increasing, 461–462 static loading, selection for, 444–451 tamper-resistant, 431 types of, 431 Scuffing, 385 Secant formula, 234–236 Secondary dimensions, 15–16 Sections, properties of, 813–815 Self-locking power screws, 420 Self-locking screws, 437–439 Self-loosening (of screws), 437–439 Self-lubrication, 580 Sems, 430 Shaft(s), 716–735 bearings for, 717 definition of, 716 deflections in, 206–209 design considerations with, 725–729 dynamics of rotating, 720–724 fatigue with, 339–341 joining of, 730–732 mounting parts onto rotating, 717–720 rigid couplings for, 732–735 stresses in, 153–156 torque-transmitting connections with, 730–732 torsional stress/deflection of, 299–301 transmission countershaft, internal loads, 58–60 universal joints with, 732 Shear modulus of elasticity, and viscosity, 550–551 Shear/shear loading direct, 133–134 double, 62, 134 in load analysis, 57–60 and sign convention, 57–58 sign convention for, 135 Shear strains, 195–197 Shear stresses in beams, 144–150 and bending stresses, 148–150 and distortion, 250 Shielded metal arc welding (SMAW), 475 Shock, see Impact Shock absorber, 288 Short-shoe drum brakes, 756–760 Shot peening, 350, 382 Significant strength, 273, 277 Significant stress, 273, 277 Silicone, 111 Sinclair, Harold, 793–794 SI units, 16–18, 771–776 Size and corrosion, 377 and fatigue strength, 323–326 Slenderness ratio (of column), 228–229, 231 Sliding bearings hydrodynamic bearings, 561–568, 573–575 materials for, 572–573 oil film temperature with, 571–572 rolling-element bearings vs., 587, 589 types of, 546–547 SMAW (shielded metal arc welding), 475 Snapfit assembly, 472 Snap rings, 719 S-N curves, 315–322, 330–336,869–870 formula, 883–884 Snowmobile track drive shaft, 726–729 Societal objectives, 11–14 Society of Automotive Engineers (SAE), 414, 432 , 552 Soldering, 489 Solids, mass/moments of inertia of homogeneous, 816 Solid-state welding, 476 Solutions, engineering, 3 Spalling, 399, 650 Spindles, 716 Spin welding, 477 “Splash,” 569 Splines, 720, 730–732 Split ring, tangential deflection of, 217–222 Spring rate (spring constant/spring scale), 204–206 Spring(s), 497–530. See also Helical compression springs beam, 522–527 compound, 297–298 constant-force, 530 definition of, 497 flat, 522 garter, 530 helical extension, 521–522 hydraulic, 497 leaf, 522–527 materials for, 497 pneumatic, 497 redundant supports using, 62–64 torsion, 528–529 torsion bar, 497–498 volute, 530 washers, spring, 529–530 wire forms, 530 Spur gears, 620–665. See also Helical gears belt drive with, 623–624 contact ratio for, 629–632, 885–889 design procedures for, 656–660 force analysis with, 634–637 geometry of, 621–629 interference with, 629–632 and law of conjugate gear-tooth action, 621 manufacture of, 628–629 materials for, 661 with racks, 628 standards for, 626–629 strength, gear-tooth-bending, 637–646 stress, gear-tooth-bending, 638–640 surface durability, gear-tooth, 648–651 surface fatigue, gear-tooth, 651–656 trains, gear, 661–665 Square thread (power screws), 419, 421 S.S. Schenectady, 251 Stability, 194 elastic, 227 Stainless steels, 104 cavitation of, 384 corrosion of, 377 fretting of, 388 mechanical properties of, 830 Standards, government/industry, 7 Standard tensile test, 264 Static failure theories, 263–272 Static loading bolt/screw selection for, 444–451 impact vs., 288–290 Static stress and corrosion, 380–382 on springs, 498–503, 509–512898 Index Static tensile test and “engineering” stress-strain relationships, 91–94 and true stress–strain relationships, 94–96 Statistics, normal distribution, 278–279, 878–882 Steel, 102–105. See also Stainless steels brittle fracture in, 250–251 carburizing, 829 cathodic protection of, 374 cavitation of, 384 connecting rod, diameter of, 232–234 corrosion of, 372 electroplating, 349, 375, 401 energy absorption capacity of, 294 fatigue in, 331–334 hardness test for, 98–100, 101 mass and strength of, 828 notch sensitivity of, 335–336 oil-quenched, 826, 827 pipe/tubing sections, 814–815 residual stresses in, 176 stress-strain in, 93–94 water-quenched/tempered, 825 Steel alloys, 103–104 fatigue strength diagram for, 328 mechanical properties of, 817, 822–823 Stellite, 384 Stepped-shaft deflection, 206–209 Stiffness, 194 and redundant supports, 63–64 and strength, 111–112 Strain elastic stress–strain relationships, 202–203 engineering vs. true, 94 equiangular rosette analysis, 197–199 measurement of, 195 Mohr circle for, 195–197, 203 notation convention for, 90 rectangular rosette analysis, 199–202 state of, Mohr circle for, 203 and stress (see Stress–strain relationships) Strain gages, 196–197 electrical resistance, 196 online guide to, 197 Strain peening, 350 Strength. See also Fatigue strength ceramics, charts for, 112–115 composites, charts for, 112–115 and density, 113–114 elastomers, charts for, 112–115 gear-tooth-bending, 638–648 metals, charts for, 112–115 notation convention for, 90 penetration hardness tests of, 97–100 polymers, charts for, 112–115 significant, 273, 277 and speed of loading, 289 and stiffness, 112–113 and temperature, 114–115 tensile, and safety factors, 270–272 test data vs. “handbook” data for calculation of, 100 test for, 90–91 ultimate, 289, 317–318 yield, 91, 290 Stress concentration factors, 162–171 completely reversed fatigue loading, 334–336 of cracks, 251–252 importance of, 165–167 mean plus alternating loads, 337–341 theoretical (geometric), 165 Stress–corrosion cracks, 380–382 Stress(es). See also Body stresses average vs. maximum, 131–133 biaxial (see Biaxial stresses) column, 236 combined, 153–156 fluctuating, 326 induced, 150–152 from linear/bending impact, 290–298 maximum/minimum, 326 measurability of, 194 notation convention for, 90, 95–96 principle normal, 159–161 principle shear, 160–161 residual (see Residual stresses) reversed, 320–322, 326 shear (see Shear stresses) significant, 273, 277 state of, Mohr circle for, 203 static (see Static stress) from torsional impact, 298–301 three-dimensional, 158–161 uniaxial, 158 zero principal, 158, 159 Stress gradient, 162 Stress intensity factor, 257–263, 351–352, 357–358 Stress invariants, 160–161 Stress raisers, 162, 301–306 Stress–strain relationships elastic, 202–203 “engineering,” 91–94 true, 94–96 Submerged arc welding(SAW), 476 Sudden loading, see impact Superalloys iron-based, 105, 831 nickel-based, 106 Superposition, method of, 206 Surface and fatigue strength, 348–351 gear-tooth, 648–656 Surface damage, 372–402 from cavitation, 384 from corrosion (see Corrosion) from curved-surface contact stresses, 392–399 fatigue failure, surface, 399–401 from wear, 384–392 Surface fatigue, 384 Surface fatigue stress bevel gears, 690, 692 failure, surface fatigue, 399–401 helical gears, 684–685 worm gears, 701–703 Surface treatments, and fatigue strength, 348–351 Tamper-resistant screws, 431 Tangent modulus, 64 Tapered roller bearings, 593, 594, 595 Temperature and corrosion, 378 and strength, 114–115 stresses, thermal, 173–176 transition, 250, 301–302 viscosity, effect on, 571–572 Temperature gradients, 175–176 Tensile loading, 252 Tensile strength, 272 Tensile test standard, 264 static, 91–96 Tension, 131 hoop, 62 radial, 144 T-head, stress concentration factors of, 169 Thermal capacity (of worm gears), 703–708 Thermal stresses, 173–176 Thermal surface-hardening treatments, 351 Thermoplastics, 108–110, 477, 843 Thermosets, 108, 110–111 Thermosetting adhesives, 490–491 Thread angle (power screws), 420 Thread-bearing (compressive) stress, 426–427 Threaded fasteners, 411–417. See also Bolts; Nuts; Screws axial load with, 425–426Index 899 bearing stress, thread, 426–427 cylindrical vs. conic, 416 design considerations with, 411 design of threads for, 414–416 geometry of threads on, 412, 414 helical thread wound on, 412 initial tension of, 432–437 manufacture of, 432 materials for, 432 rivets vs., 473 self-loosening/locking of, 437–439 shear loading, transverse, 428 shear stress, thread, 428 standards for, 412–414 torsional stresses with, 425, 432, 434–437 types of, 430–431 Thread shear stress, 428 Three-dimensional stresses, 158–161 Three-force member, load analysis for, 54–56 “Through-hardening” steels, 104 Thrust bearings, 581–582, 614–615 Thrust collar (power screws), 418 TIG (tungsten-inert gas) welding, 476 Timing (toothed) belts, 789 Timoshenko, S. P., 266 Tin, 373 Titanium, 320 corrosion of, 377 fretting of, 388 Titanium alloys, 106, 838 Tolerances, 854–856 Toothed (timing) belts, 789 Torque camshaft, 22–23 punch press motor, 42–43 transmission of (see Power transmission) Torsion and Castigliano’s method, 211–213 notation convention for, 90 with power screws, 425, 426 with threaded fasteners, 425, 432, 434–437 Torsional deflection, formulas for, 205 Torsional impact, 298–301 Torsional loading, 135–136 fatigue strength for reversed, 321–322 and residual stress, 171–173 Torsion bar springs, 497–498 Torsion springs, 528–529 Total life cycle, 6 Toughness, 97 fracture, 252 modulus of, 97, 296 Tower, Beauchamp, 557–558 Trains, gear, 661–665, 692–694 Transitional fits, 854 Transition region (true stress-strain curve), 96 Transition temperature, 250, 301–302 Translation screws, see Power screws Transmission, 50–52. See also Power transmission countershaft, internal loads in, 58–60 Transverse shear loading, 144–150, 428 in beams, 144–150 and Castigliano’s method, 211–214 in welds, 478–481 Tredgold’s approximation, 687 Tresca theory, 265 Triaxial effect (of stress raisers), 162 Triple-riveted butt joint, 64–67 True stress–strain curve, 94–96 Tubes, local buckling in, 237 Tubular rivets, 473, 474 Tungsten-inert gas (T1G) welding, 476 Udimet alloys, 106 Ultimate strength and fatigue strength, 318–319 and speed of loading, 289 Ultrasonic welding, 477 UNC thread, 413–414 UNF thread, 413–414 Uniaxial stresses, 158, 203 Unified screw threads, 413–414 Units, 15–18 conversion factors for, 807–810 SI prefixes, standard, 810–812 Universal joints, 732–735 Urea, 110 Urethane adhesives, 491 User needs, 9 Value, of materials, 89 V-belts, 785–788 Vectors, 874–877 Vibration, 289 with power screws, 420 Vibration welding, 477 Vidosic, Joseph, 276 Viscosity, 550–555 friction, viscous, 555–557 kinematic, 552–554 measurement of, 552 and shear modulus of elasticity, 550–551 standards for, 553 temperature/pressure effects on, 555 units of, 551 Volute springs, 530 Vulcan-Werke A. G., 793 Warning information, 7–8 Washers, 430 spring, 529–530 Watt, 23–24 Wear, 384–392 abrasive wear, 387–388, 651 adhesive wear, 385–387, 580 analytical approach to, 389–392 coefficients, 387, 389–392 discretization theory, 392 fretting, 388 surface similarity, 392 “Weathering” Steels, 377 Web reinforcement, 64 Welded joints, 478–489 fatigue considerations with, 486–489 static axial and direct shear loading, subject to, 478–481 static torsional and bending loading, subject, 481–486 Welding, 474–477 and adhesive wear, 385 asperity, 385–386 and residual tension, 176–177 White iron, 102 Wire forms, 530 Wood beams, 297–298 Work, 21–23 “Working stress,” 272 Worm gears, 676, 677–678, 694–708 bending stress with, 701–703 force/efficiency analysis with, 696–701 geometry of, 694–696 pitch diameter of, 695–696 “recess action” with, 696 surface fatigue strength for, 702 thermal capacity of, 703–708 Wrinkling, 237 Yield point, 91 Yield strength, 91 notation convention for, 90, 91 and speed of loading, 290 Yoke connections, 60–62 Young’s modulus, 91, 95, 112 Zerol bevel gears, 688 Zero principal stress, 158, 159 Zinc, 373–374 Zinc alloys, 106, 839
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