Mechanical Design of Machine Components, Second Edition: SI Version

Analyze and Solve Real-World Machine Design Problems Using SI Units Mechanical Design of Machine Components, Second Edition: SI Version strikes a balance between method and theory, and fills a void in the world of design. Relevant to mechanical and related engineering curricula, the book is useful in college classes, and also serves as a reference for practicing engineers. This book combines the needed engineering mechanics concepts, analysis of various machine elements, design procedures, and the application of numerical and computational tools. It demonstrates the means by which loads are resisted in mechanical components, solves all examples and problems within the book using SI units, and helps readers gain valuable insight into the mechanics and design methods of machine components. The author presents structured, worked examples and problem sets that showcase analysis and design techniques, includes case studies that present different aspects of the same design or analysis problem, and links together a variety of topics in successive chapters. SI units are used exclusively in examples and problems, while some selected tables also show U.S. customary (USCS) units. This book also presumes knowledge of the mechanics of materials and material properties. New in the Second Edition: Presents a study of two entire real-life machines Includes Finite Element Analysis coverage supported by examples and case studies Provides MATLAB solutions of many problem samples and case studies included on the book’s website Offers access to additional information on selected topics that includes website addresses and open-ended web-based problems Class-tested and divided into three sections, this comprehensive book first focuses on the fundamentals and covers the basics of loading, stress, strain, materials, deflection, stiffness, and stability. This includes basic concepts in design and analysis, as well as definitions related to properties of engineering materials. Also discussed are detailed equilibrium and energy methods of analysis for determining stresses and deformations in variously loaded members. The second section deals with fracture mechanics, failure criteria, fatigue phenomena, and surface damage of components. The final section is dedicated to machine component design, briefly covering entire machines. The fundamentals are applied to specific elements such as shafts, bearings, gears, belts, chains, clutches, brakes, and springs.

Table of Contents:
BASICS Introduction Scope of the Book Mechanical Engineering Design Design Process Design Analysis Problem Formulation and Computation Factor of Safety and Design Codes Units and Conversion Loading Classes and Equilibrium Free-Body Diagrams and Load Analysis Case Studies in Engineering Work, Energy, and Power Stress Components Normal and Shear Strains Problems Materials Introduction Material Property Definitions Static Strength Hooke’s Law and Modulus of Elasticity Generalized Hooke’s Law Volume Change Thermal Stress–Strain Relations Temperature and Stress–Strain Properties Moduli of Resilience and Toughness Dynamic and Thermal Effects Hardness Processes to Improve Hardness and the Strength of Metals General Properties of Metals General Properties of Nonmetals Selecting Materials Problems Stress and Strain Introduction Stresses in Axially Loaded Members Direct Shear Stress and Bearing Stress Thin-Walled Pressure Vessels Stress in Members in Torsion Shear and Moment in Beams Stresses in Beams Design of Beams Plane Stress Combined Stresses Plane Strain Measurement of Strain; Strain Rosette Stress-Concentration Factors Importance of Stress-Concentration Factors in Design Three-Dimensional Stress Equations of Equilibrium for Stress Strain–Displacement Relations: Exact Solutions Problems Deflection and Impact Introduction Deflection of Axially Loaded Members Angle of Twist of Shafts Deflection of Beams by Integration Beam Deflections by Superposition Beam Deflection by the Moment-Area Method Impact Loading Longitudinal and Bending Impact Torsional Impact Bending of Thin Plates Deflection of Plates by Integration Problems Energy Methods and Stability Introduction Strain Energy in Common Members Work–Energy Method Castigliano’s Theorem Statically Indeterminate Problems Virtual Work Principle Use of Trigonometric Series in Energy Methods Buckling of Columns Critical Stress in a Column Initially Curved Columns Eccentric Loads and the Secant Formula Design Formulas for Columns Beam–Columns Energy Methods Applied to Buckling Buckling of Rectangular Plates Problems FAILURE PREVENTION Static Failure Criteria and Reliability Introduction Introduction to Fracture Mechanics Stress–Intensity Factors Fracture Toughness Yield and Fracture Criteria Maximum Shear Stress Theory Maximum Distortion Energy Theory Octahedral Shear Stress Theory Comparison of the Yielding Theories Maximum Principal Stress Theory Mohr’s Theory Coulomb–Mohr Theory Reliability Normal Distributions Reliability Method and Margin of Safety Problems Fatigue Failure Criteria Introduction Nature of Fatigue Failures Fatigue Tests S–N Diagrams Estimating the Endurance Limit and Fatigue Strength Modified Endurance Limit Endurance Limit Reduction Factors Fluctuating Stresses Theories of Fatigue Failure Comparison of the Fatigue Criteria Design for Simple Fluctuating Loads Design for Combined Fluctuating Loads Prediction of Cumulative Fatigue Damage Fracture Mechanics Approach to Fatigue Problems Surface Failure Introduction Corrosion Friction Wear Wear Equation Contact-Stress Distributions Spherical and Cylindrical Surfaces in Contact Maximum Stress in General Contact Surface-Fatigue Failure Prevention of Surface Damage Problems APPLICATIONS Shafts and Associated Parts Introduction Materials Used for Shafting Design of Shafts in Steady Torsion Combined Static Loadings on Shafts Design of Shafts for Fluctuating and Shock Loads Interference Fits Critical Speed of Shafts Mounting Parts Stresses in Keys Splines Couplings Universal Joints Problems Bearings and Lubrication Introduction Lubricants Types of Journal Bearings Forms of Lubrication Lubricant Viscosity Petroff’s Bearing Equation Hydrodynamic Lubrication Theory Design of Journal Bearings Lubricant Supply to Journal Bearings Heat Balance of Journal Bearings Materials for Journal Bearings Types and Dimensions of Rolling Bearings Rolling Bearing Life Equivalent Radial Load Selection of Rolling Bearings Materials and Lubricants of Rolling Bearings Mounting and Closure of Rolling Bearings Problems Spur Gears Introduction Geometry and Nomenclature Fundamentals Gear Tooth Action and Systems of Gearing Contact Ratio and Interference Gear Trains Transmitted Load Bending Strength of a Gear Tooth: The Lewis Formula Design for the Bending Strength of a Gear Tooth: The AGMA Method Wear Strength of a Gear Tooth: The Buckingham Formula Design for the Wear Strength of a Gear Tooth: The AGMA Method Materials for Gears Gear Manufacturing Problems Helical, Bevel, and Worm Gears Introduction Helical Gears Helical Gear Geometry Helical Gear Tooth Loads Helical Gear Tooth Bending and Wear Strengths Bevel Gears Tooth Loads of Straight Bevel Gears Bevel Gear Tooth Bending and Wear Strengths Worm Gearsets Worm Gear Bending and Wear Strengths Thermal Capacity of Worm Gearsets Problems Belts, Chains, Clutches, and Brakes Introduction Belts Belt Drives Belt Tension Relationships Design of V-Belt Drives Chain Drives Common Chain Types Materials for Brakes and Clutches Internal Expanding Drum Clutches and Brakes Disk Clutches and Brakes Cone Clutches and Brakes Band Brakes Short-Shoe Drum Brakes Long-Shoe Drum Brakes Energy Absorption and Cooling Problems Mechanical Springs Introduction Torsion Bars Helical Tension and Compression Springs Spring Materials Helical Compression Springs Buckling of Helical Compression Springs Fatigue of Springs Design of Helical Compression Springs for Fatigue Loading Helical Extension Springs Torsion Springs Leaf Springs Miscellaneous Springs Problems Power Screws, Fasteners, and Connections Introduction Standard Thread Forms Mechanics of Power Screws Overhauling and Efficiency of Power Screws Ball Screws Threaded Fastener Types Stresses in Screws Bolt Tightening and Preload Tension Joints under Static Loading Gasketed Joints Determining the Joint Stiffness Constants Tension Joints under Dynamic Loading Riveted and Bolted Joints Loaded in Shear Shear of Rivets or Bolts due to Eccentric Loading Welding Welded Joints Subjected to Eccentric Loading Brazing and Soldering Adhesive Bonding Problems Miscellaneous Machine Components Introduction Basic Relations Thick-Walled Cylinders under Pressure Compound Cylinders: Press or Shrink Fits Disk Flywheels Thermal Stresses in Cylinders Exact Stresses in Curved Beams Curved Beam Formula Circular Plates Thin Shells of Revolution Special Cases of Shells of Revolution Pressure Vessels and Piping Filament-Wound Pressure Vessels Buckling of Cylindrical and Spherical Shells Problems Finite Element Analysis in Design Introduction Bar Element Formulation of the Finite Element Method Beam Element Two-Dimensional Elements Triangular Element Plane Stress Case Studies Problems Case Studies in Machine Design Introduction Floor Crane with Electric Winch High-Speed Cutter Problems Appendices Answers to Selected Problems References