Mechanical Engineer''''s Reference Book 2011 Part 1 potx

2 \! c Mechanical Engineer’s Reference Book Mechanical Engineer’s Reference Book Twelfth edition Edited by FI Mech E Head of Computing Services, University of Central Lancashire With specialist contributors Edward H. Smith BSC, MSC, P~D, cEng, UTTER WORTH EINEMANN Buttenvorth-Heinemann Linacre House, Jordan Hill, Oxford OX2 SDP 225 Wildwood Avenue, Woburn, MA 01801-2041 A division of Reed Educational and Professional Publishing Ltd -e A member of the Reed Elsevier group OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHl First published as Newnes Engineer's Reference Book 1946 Twelfth edition 1994 Reprinted 1995 Paperback edition 1998 Reprinted 1999,2000 0 Reed Educational and Professional Publishing Limited 1994 All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, YO Tottenham Court Road, London, England WlP OLP. Applications for the copyright holder's written permission to reproduce any part of this publication should be addressed to the publishers British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloguing in Publication Data A catalogue record for this book is available from the Library of Congress ISBN 0 7506 4218 1 Typeset by TecSet Ltd, Wallington, Surrey Printed and bound in Great Britain by The Bath Press, Bath ~~ FOR EVERY TIIU THAT WE POBUSH, EUI'IE8WORTH~HEW?MANR WU PAY POR BTCV TO PW AN0 CARE POR A IREE. Contents Preface 8 Mechanics of solids Stress and strain . Experimental techniques . Fracture mechanics . Creep of materials . Fatigue . References . Further reading 9 Tribology Basic principles . Lubricants (oils and greases) . Bearing selection . Principles and design of hydrodynamic bearings . Lubrication of industrial gears . Rolling element bearings . Materials for unlubricated sliding . Wear and surface treatment . Fretting . Surface topography . References . Further reading 10 Power units and transmission Power units . Power transmission . Further reading 11 Fuels and combustion Introduction . Major fuel groupings . Combustion . Conclusions . References General fuel types . Major property overview List of contributors 1 Mechanical engineering principles Status of rigid bodies . Strength of materials . Dynamics of rigid batdies . Vibrations . Mechanics of fluids . Principles of thermodynamics . Heat transfer . References 2 Electrical and electronics principles Basic electrica! technology . Electrical machines . Analogue and digital electronics theory . Electrical safety References . Further reading 3 Microprocessors, instrumentation and control Summary of number systems . Microprocessors . Communication standards . Interfacing of computers to systems . Instrumentation . Classical control theory and practice . Microprocessor-based control . Programmable logic controllers . The z-transform . State variable techniqiies . References . Further reading 4 Coniputers and their application IntroduNction . Types of computer . Generations of digital computers . Digital computer systems . Categories of computer systems Central processor unit . Memory . Peripherals . Output devices . Terminals . Direct input . Disk storage . Digital and analogue inputloutput . Data communications . Computer networks . Data terminal equipment . Software . Database management . Language translators . Languages 5 Coniputer-integrated engineering systems CAD/CAM: Computer-aided design and computer-aided manufacturing .Industrial robotics and automation . Computer graphics systems . References . Further reading . Drawing and graphic communications . Fits, tolerances and limits . Fasteners . Ergonomic and anthropometric data . Total quality - a company culture . References roperties and selection Engineering properties of materials . The principles underlying materials selection . Ferrous metals . Non-ferrous metals . Composites . Polymers . Elastomers . Engineering ceramics and glasses . Corrosion . Non-destructive testing . References . Further reading 12 Alternative energy sources Introduction . Solar radiation . Passive solar design in the UK . Thermal power and other thermal applications . Photovoltaic energy conversion . Solar chemistry . Hydropower . Wind power . Geothermal energy Tidal power . Wave power . Biomass and energy from wastes Energy crops . References 13 Nuclear engineering Introduction . Nuclear radiation and energy . Mechanical engineering aspects of nuclear power stations and associated plant . Other applications of nuclear radiation . Elements of health physics and shielding . Further reading 14 Offshore engineering Historical review . Types of fixed and floating structures . Future development . Hydrodynamic loading . Structural strength and fatigue . Dynamics of floating systems . Design considerations and certification . References 15 Plant engineering Compressors, fans and pumps . Seals and sealing Boilers and waste-heat recovery . Heating, ventilation and air conditioning . Refrigeration . Energy management . Condition monitoring . Vibration isolation and limits . Acoustic noise . References vi Contents 16 Manufacturing methods Large-chip metal removal . Metal forming . Welding, soldering and brazing . Adhesives . Casting and foundry practice . References . Further reading 17 Engineering mathematics Trigonometric functions and general formulae . Calculus . Series and transforms . Matrices and determinants . Differential equations . Statistics . Further reading 18 Health and safety Health and safety in the European Community . Health and safety at work - law and administration in the USA . UK legislation and guidance . The Health and Safety at Work etc. Act 1974 . The Health and Safety Executive . Local Authorities . Enforcement Notices . Control of Substances Hazardous to Health Regulations 1988 . Asbestos . Control of lead at work . The Electricity at Work Regulations 1989 . The Noise at Work Regulations 1989 . Safety of machines . Personal protective equipment . Manual handling . Further reading 19 Units, symbols and constants SI units . Conversion to existing imperial terms . Abbreviations . Physical and chemical constants . Further reading Index Preface I was delighted when Butterworth-Heinemann asked me to edit a new edition of Mechanical Engineer’s Reference Book. Upon looking at its predecessor, it was clear that it had served the community well, but a major update was required. The book clearly needed to take account of modern methods and systems. The philosophy behind the book is that it will provide a qualified engineer with sufficient information so that he or she can identify the basic principles of a subject and be directed to further reading if required. There is a blurred line between this set of information and a more detailed set from which design decisions are made. One of my most important tasks has been to define this distinction, so that the aims of the book are met and its weight is minimized! I hope I have been able to do this, so that the information is neither cursory nor complex. Any book of this size will inevitably contain errors, but I hope these will be minimal. I will he pleased to receive any information from readers SO that the book can be improved. To see this book in print is a considerable personal achieve- ment, but I could not have done this without the help of others. First, I would like to thank all the authors for their tremendous hard work. It is a major task to prepare informa- tion for a hook of this type, and they have all done a magnificent job. At Butterworth-Heinemam, Duncan Enright and Deena Burgess have been a great help, and Dal Koshal of the University of Brighton provided considerable support. At the University of Central Lancashire, Gill Cooke and Sue Wright ensured that the administration ran smoothly. I hope you find the book useful. Ted Smith University of Central Lancashire, Preston. Christmas Eve, 1993 Contributors Dennis fI. Bacon BSc(Eng), MSc, CEng, MIMechE Consultant and technical author Neal Barnes BSc, PhD Formerly Manager, Pumping Technology, BHR Group Ltd John Barron BA, MA(Cantab) Lecturer, Department of Engineering, University of Cambridge Christopher Beards BSc(Eng), PhD, CEng, MRAeS, MIOA Consultant and technical author Jonh S. Bevan IEng, MPPlantE, ACIBSE Formerly with British Telecom Ronald .J. Blaen Independent consultant Tadeusz 2. Bllazynski PhD, BSc(Eng), MIMechE, CEng Formerly Reader in Applied Plasticity, Department of Mechanicaki Engineering, University of Leeds James Carvill WSc(MechE), BSc(E1ecEng) Formerly Senior Lecturer in Mechanical Engineering, University of Northumbria at Newcastle Trevor G. Clarkson BSc(Eng), PhD, CEng, MIEE, Senior Member IEEE Department of Electronic and Electrical Engineering, King's College., University of London Paul Compton BSc CEng, MCIBSE Colt International Ltd, Havant, Hants Vince Coveney PhD Senior Lecturer, Faculty of Engineering, University of the West of England Roy D. Cullurn FIED Editor, Materials and Manufacture A. Davi'es National Centre of Tribology, Risley Nuclear Development Laboratory Raymond J. H. Easton CEng, MIR4echE Chief Applications Engineer, James Walker & Co Ltd Philip Eliades BSc, AMIMechE National Centre for Tribology, UKAEA, Risley, Warrington Duncan S. T. Enright BA: MA(Oxon), CertEd, GradInstP Commissioning Editor, Butterworth-Heinemann, Oxford Charles J. Fraser BSc, PhD, CEng, FIMechE, MInstPet Reader in Mechanical Engineering Eric M. Goodger BSc(Eng), MSc, PhD, CEng, MIMechE, FInstE, FInstPet, MRAeS, MIEAust Consultant in Fuels Technology Training Edward N. Gregory CEng, FIM, FWeldI Consultant Dennis R. Hatton IEng, MIPlantE Consultant Tony G. Herraty BTech, MIMechE, CEng SKF (UK) Service Ltd, Luton, Bedfordshire Martin Hodskinson BSc, PhD, CEng, FIMechE, MIED, REngDes Senior Lecturer, Department of Engineering and Product Design. University of Central Lancashire Allan R. Hntchinson BSc, PhD, CEng, MICE Deputy Head, Joining Technology Research Centre, School of Engineering, Oxford Brookes University Jeffery D. Lewins DSc(Eng), FINucE, CEng Lecturer in Nuclear Engineering, University of Cambridge and Director of Studies in Engineering and Management, Magdalene College Michael W. J. Lewis BSc, MSc Senior Engineering Consultant, National Centre of Tribology, AE Technology, Risley, Warrington R. Ken Livesley MA, PhD, MBCS Lecturer Department of Engineering, University of Cambridge J. Cleland McVeigh MA, MSc, PhD, CEng, FIMechE, FInstE, MIEE, MCIBSE Visiting Professor, School of Engineering, Glasgow Caledonian University Gordon M. Mair BSc, DMS, CEng, MIEE, MIMgt Lecturer, Department of Design, Manufacture and Engineering Management, University of Strathclyde Fraidoon Mazda MPhil, DFH, DMS, MIMgt, CEng, FIEE Northern Telecom [...]... masses 1/ 23 1. 4 Vibrations 11 9 1. 4 .1 Single-degree-of-freedom systems 1/ 9 Further reading 1/ 15 British Standards 1/ 15 1. 4 3 Random vibratio Further reading 1/ 18 Further reading 1/ 35 1. 6 Principles of thermodynamics 1/ 35 1. 6 .1 Introduction 1/ 35 1. 6.2 The laws of thermodynamics 1/ 36 1. 6.3 Thermoeconomics 1/ 37 1. 6.4 Work, heat, property values, procecs laws and combustion 1/ 37 1. 6.5 Cycle analysis 1/ 37... 1. 0 1. 2 1. 4 1. 6 1. 8 2.0 2.2 2.4 2.6 2.8 3.0 3.2 3.4 3.6 3.8 4.0 0 0 .15 85 0. 310 8 0.4 515 0.5763 0.6827 0.7699 0.8586 0.8904 0.92 81 0.9545 0.9722 0.9836 0.9907 0.9949 0.9973 0.9986 0.9993 0.9997 0.9998 0.9999 1. 0000 0.8 415 0.6892 0.5485 0.4237 0. 317 3 0.23 01 0 .14 14 0 .10 96 0.0 719 0.0455 0.0278 0. 016 4 0.0093 0.00 51 0.0027 0.0 013 7 0.00067 0.00032 0.00 014 0.00006 Prob[-Ar x(t) Value of A > Ag] ~ X Figure 11 .29... + c2 )11 2 + a2) /12 + b2 )11 2 I,, = I,, Circular cone 1 r4 =- 3m 311 0 3m2 20 + mh’ 10 ~ 1. 3 Dynamics of rigid bodies 1. 3 .1 Basic definitions 1. 3 .1. 1 Newton’s Laws of Motion First Law A particle remains at rest or continues to move in a straight line with a constant velocity unless acted on by an external force Dynamics of rigid bodies 11 5 Second Law The sum of all the external forces acting on a particle... technical author Mechanical engineering principles Beards (Section I 4.3) Peter Tucker (Section i.5 Dennis H Bacon (Sect Contents 1. 1 Statics of rigid bod 1. 2 Strength of materials 1. 3 Dynamics of rigid bodies 1. 3 .1 Basic definitions 1/ 4 1. 3.2 Linear and angular mo dimensions 1/ 6 1. 3.3 Circular motion 1/ 7 1. 3.4 Linear and angular motion in three dimensions 11 7 1. 3.5 Balancing 1/ 23 1. 3.6 Balancing of... the system Vibrations 1/ 13 No damping I Moderate damping \Cri?ical damping 1. o 30 2.0 1 o 0 3.0 2.0 4.0 Frequency ratio ( d u n ) Frequency ratio (w/w,) (a) (2) / No damping 18 0" m ( u m Critical damping H r Moderate damping 90" Q 1 2 3 0 4 1. 0 (b) Figure 1. 20 M Figure 1. 19 3.0 4.0 Frequency ratio (w/w,) (b) Frequency ratio ( d u n ) Figure 1. 18 2.0 I I I m Figure 1. 21 1 /14 Mechanical engineering... Constant 1/ 10 Mechanical engineering principles Table 1. 3 End conditions Trig equation PI1 Solutions P 21 P 31 COS pl cash 01 = 1 4.730 7.853 10 .966 x = 0, y = 0, y‘ = 0 x = 1, y“ = 0, y”’ = 0 COS pl cash pl 1. 875 4.694 7.855 x = 0, y = 0, y” = 0 x=l,y=O,y”=O sin Pl = 0 3 .14 2 6.283 9.425 x = 0, y = 0, y’ = 0 tan 3.927 7.069 10 . 210 x = 0, y = 0, y‘ = 0 + 5 x = 1, y = 0, y‘ = 0 Pl = tanh = -1 Pl x=l,y=O,y”=O... in Douglas et al (19 86) Mechanics of fluids 1/ 25 0.030 0.020 0.05 0.04 0.03 0.02 4 % ' L 0. 010 0. 01 8 + C 20.007 - % 0.008 0.006 0.004 i1 - E 7 e i 0.002 ; M m 0.0 01 0.0008 0.0006 0.0004 0.0002 0.005 0.004 0.00 01 0.003 0.00005 0.002 io3 2 3 4 5 ~ 1 02 ~ 3 4 5 7 1 0 ~ 2 3 4 5 7 1 0 ~ 2 3 4 5 7 1 0 ' Reynolds number, Re 0.0000 01 2 345 710 ~ Figure 1. A0 1. 5.4 Plow measurement 2.5.4 .1 Pipe flow One very... xlZdmg, = SSmg ylZSmg, 1 113 I Figure 1. 1 lQ 1/ 4 Mechanical engineering principles Table 1. 1 Centres of gravity and moments of inertia or second moments of area for two-dimensionalfigures Shape G I Triangular area j = hi3 IGG = bh 313 6 I,, = bh 311 2 I,, =-(a - I,, =-(a I,, I,, = m(b2 = m(c2 = m(a2 x+*4x Rectangular area Circular sector Slender rod yb: gx x = 2r sin a - 3 a Izz I’ X = h14 4 1 r4 +2 4 Torsion... said to occur A 1. 4 .1. 6 Forced damped vibrations \ \ X x1 I ‘\ \ \ I The equation of motion is given by (see Figure 1. 17(b)) mx + cx + kx = Fo sin ut or -\ t E + (c/m)i+ w t = (Fdm) sin wl The solution to this equation is in two parts: a transient part as in the undamped case which dies away, leaving a sustained vibration at the forcing frequency given by 4 m [(wf - / / Figure 1. 16 1. 4 .1. 5 Forced undamped... mass is then given by 4 ~~~ 18 00w Frequency ratio (w/w,) (a) Low damping 2 m,w2x1 i =1 If this force is zero then the assumed frequency is a natural one 1 2 3 Moderate 4damping 0 Frequency ratio (w/w,) ( b) Figure 1. 22 Figure 1. 24 Vibrations 11 15 Further reading Johnston, E R and Beer, F P.,Mechanicsfor Engineers, Volume 1, Statics; Volume 2, Dynamics, McGraw-Hill, New York (19 87) Meriam, J i.and Kraige, . thermodynamics 1/ 35 1. 3.6 Balancing of rotating masses 1/ 23 1. 6 .1 Introduction 1/ 35 1. 4 Vibrations 11 9 1. 6.3 Thermoeconomics 1/ 37 dimensions 11 7 1. 6.2 The laws of thermodynamics 1/ 36 1. 4 .1 Single-degree-of-freedom. bodies 1. 3 .1 Basic definitions 1/ 4 1. 3.2 Linear and angular mo dimensions 1/ 6 1. 3.3 Circular motion 1/ 7 1. 3.4 Linear and angular motion in three Further reading 1/ 35 1. 3.5 Balancing 1/ 23 1. 6. 1/ 9 1. 6.4 Work, heat, property values, procecs laws and Further reading 1/ 15 1. 6.5 Cycle analysis 1/ 37 British Standards 1/ 15 1. 4 3 Random vibratio Further reading 1/ 18 combustion 1/ 37