www.EngineeringEBooksPdf.com ftoc.qxd 8/4/11 2:35 PM Page xiv www.EngineeringEBooksPdf.com ffirs.qxd 8/4/11 12:45 PM Page i Fifth Edition Fundamentals of Machine Component Design ROBERT C JUVINALL Professor of Mechanical Engineering University of Michigan KURT M MARSHEK Professor of Mechanical Engineering University of Texas at Austin JOHN WILEY & SONS, INC www.EngineeringEBooksPdf.com ffirs.qxd 8/4/11 12:45 PM Page ii Vice President & Executive Publisher Executive Editor Content Manager Senior Production Editor Marketing Manager Creative Director Senior Designer Production Management Services Senior Illustration Editor Editorial Assistant Media Editor Cover Photo Credit Don Fowley Linda Ratts Dorothy Sinclair Valerie A Vargas Christopher Ruel Harry Nolan James O’Shea Laserword-Maine Anna Melhorn Christopher Teja Wendy Ashenberg © -M-I-S-H-A-/iStockphoto This book was set in Times 10/12 by Laserwords, and printed and bound by RRD-JC The cover was printed by RRD-JC ~ This book is printed on acid free paper q Founded in 1807, John Wiley & Sons, Inc has been a valued source of knowledge and understanding for more than 200 years, helping people around the world meet their needs and fulfill their aspirations Our company is built on a foundation of principles that include responsibility to the communities we serve and where we live and work In 2008, we launched a Corporate Citizenship Initiative, a global effort to address the environmental, social, economic, and ethical challenges we face in our business Among the issues we are addressing are carbon impact, paper specifications and procurement, ethical conduct within our business and among our vendors, and community and charitable support For more information, please visit our website: www.wiley.com/go/citizenship Copyright © 2012, 2006 John Wiley & Sons, Inc All rights reserved No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, 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available at www.wiley.com/go/returnlabel Outside of the United States, please contact your local representative ISBN-13 9781118012895 10 www.EngineeringEBooksPdf.com fpref.qxd 8/4/11 2:49 PM Page iii Preface This book is intended as a text for first courses in Mechanical Engineering Design and as a reference for practicing engineers It is assumed that the user has had basic courses in Mechanics, Strength of Materials, and Materials Properties However, the first nine chapters of the book (Part I) serve to review as well as extend this basic background The remaining chapters (Part II) deal with the application of these fundamentals to specific machine components Features of the fifth edition of the text include: • Modern/current issues and safety considerations—New homework problems outline real world safety issues adapted from actual case studies Homework questions which help the student research, outline, and write on issues which confront the modern engineer are scattered throughout the text • Composites—A new section is presented to introduce composite materials and their properties to the student New references provide the student with a foundation of information regarding composite materials • Engineering material selection process—Ashby’s material selection charts are reviewed and discussed and are available as an aid to students in learning more about engineering materials New topics MIL-HDBK-5J and MIL-HDBK-17 are introduced which aid the student in selection and use of common engineering materials • Web site addresses and problems—Web site addresses are given throughout the text to provide the student with access to additional information on topics including industrial standards, part selection, and properties of materials Problems appear at the end of the chapter that require the student to utilize the internet in solving various machine component design problems • Three-dimensional stress—A new sample problem gives the student a powerful tool to analyze complex stress states, and new related homework problems give opportunity for the student to polish analysis skills • Wear and wear theory—Additional text on discretization wear theory outlines the use of wear models for machine parts Associated homework problems introduce the student to the unique test apparatus used to determine wear coefficients • Shaft critical speeds—This section is expanded with additional solution methods and theory discussion including explanation of both Rayleigh’s and Dunkerley’s equations New and revised homework problems accompany this section to challenge the student regarding these ideas • Appendix—Contributed appendixes have been added for using reference MIL-HDBK-5J, vectorial solution methods, normal distributions, fatigue cycle formulas, and gear terminology www.EngineeringEBooksPdf.com fpref.qxd 8/4/11 iv 2:49 PM Page iv Preface Part I Although much of Part I of the text is a review of earlier courses, we would like to call attention to several particular sections • Sections 1.2, 1.3, and 1.4 deal with three of the broadest aspects of engineering—safety, ecology, and social significance These are concerns to which today’s students are particularly responsive • Section 1.7 presents a methodology for solving machine component problems Embodied in this methodology is a sample problem format that includes a restatement, solution, and comments for the problem under the headings: known, find, schematic, decisions, assumptions, analysis, and comments Decisions are choices made by the designer Since design is an iterative decision-making process of synthesis, whenever the heading “decisions” is utilized, a design problem is presented If a solution is presented without decisions being made, the problem is one of analysis The inclusion of the category “decisions” allows the student to see clearly the difference between design and analysis Once appropriate decisions have been made, analysis can follow Assumptions, which are used in solving a problem, are statements about beliefs; for example, the material is homogeneous throughout The design engineer and the student need to understand what assumptions are made in solving a problem The listing of assumptions provides more opportunity for students of machine design to “think before doing.” Comments present key aspects of the solution and discuss how better results might be obtained by making different design decisions, relaxing certain assumptions, and so on • Sections 1.8, 1.9, and 1.10 review fundamental energy relationships Most students at this level need to gain insight and understanding concerning such basic matters as the relationship between work input to a rotating camshaft and work output at a translating follower, and the relationship between engine power, vehicle speed, and fuel consumption • Most teachers of Mechanical Engineering Design lament the weakness of their students in the area of free-body diagram analysis of loads Unless the loading on a machine component is properly established, subsequent design or analysis is of little value Section 2.2 and the associated problems are directed toward helping relieve this common deficiency • References are often an invaluable resource for the student as they provide in depth coverage of topics to which the text may only be able to devote a single paragraph As such, MIL-HDBK-17 is introduced to the student in Chapter and MIL-HDBK-5J in Appendix F These two references provide a wealth of pragmatic engineering knowledge regarding engineering materials and composites The use of these volumes along with the chapter references has the ability to dramatically enhance a student’s knowledge base • An elementary treatment of residual stresses is included in Chapter An understanding of the basic concepts involved is vital to modern stress analysis, particularly when fatigue is present • Castigliano’s method for determining elastic deflections and redundant reactions is included in Chapter This method permits ready solution of many problems not amenable to traditional elementary methods www.EngineeringEBooksPdf.com fpref.qxd 8/4/11 2:49 PM Page v v Preface • Chapter on Failure Theories, Safety Factors, Stress Intensity Factors, and Reliability includes introductory treatments of fracture mechanics and of the interference theory of statistical reliability prediction • Chapter contains a simplified, condensed, and introductory version of Fatigue Design and Fatigue Crack Growth This chapter is particularly important, and represents primarily new material for most students • Chapter deals with the various kinds of surface deterioration experienced by machine components This is of great importance because more machine parts “fail” (cease to be suitable for performing their intended function) because of surface damage than from actual breakage Part II Part II is concerned with the application of the fundamentals to specific machine components In engineering practice, problems involving the design, analysis, or application of machine members can seldom be solved by applying the fundamentals alone As critically important as a knowledge of the underlying sciences is, it is seldom sufficient Almost always some empirical information must be used and good “engineering judgment” brought to bear Actual engineering design problems seldom have only one correct answer For example, engineering staffs of competing companies arrive at different product designs as “solutions” to the same problem And these solutions change as new technology, new materials, new manufacturing methods, and new marketing conditions prevail For many students, the course based on this text will provide their first experience in dealing with these kinds of professional engineering problems Most engineers find that the above aspect of engineering adds to the interest and excitement of their profession There is a close parallel between engineers and medical doctors in this respect: Both must solve real-life problems now, making full use of the best available scientific information Engineers must design engines and build electronic apparatus even though scientists are still seeking a more complete knowledge of combustion and electricity Similarly, medical doctors cannot tell their patients to await treatment until more research has been completed Even though the fundamentals treated in Part I are seldom sufficient for solving engineering problems relating to machine components, it is important that they be applied fully and consistently In particular, a special effort has been made in Part II to deal with fatigue and surface considerations in a manner consistent with the treatment given in Chapters and This sometimes results in the development of procedures that vary in detail from those given in the specialized literature, but this discrepancy is not of major importance What is of major importance is helping the student learn to approach engineering problems by applying the fundamentals and other scientific knowledge as extensively as possible, and then supplementing these with empirical data and judgment as required to get good solutions within available time limitations Few engineering schools allot sufficient time to cover all the machine components treated in Part II In addition, many components are not treated in the book, and even more are not yet in existence For these reasons, each component is treated not www.EngineeringEBooksPdf.com fpref.qxd 8/4/11 vi 2:49 PM Page vi Preface only as an end in itself, but also as a representative example of applying basic fundamentals and necessary empirical information to solve practical engineering problems Throughout Part II the reader will find numerous instances in which ingenuity, insight, and imagination are called for to deal effectively with engineering problems associated with an individual machine component The next step in the study of Mechanical Engineering Design usually involves the conception and design of a complete machine As an introduction to this “next step,” the final chapter of the book (Chapter 20) presents a “case study” of the design of the first commercially successful automotive automatic transmission This chapter can be found on the website for this text, http://www.wiley.com/college/juvinall Here, as with numerous other designs of complete machines, one cannot help being impressed and inspired by the insight, ingenuity, and imagination (as well as prolonged diligent effort) displayed by engineers Also illustrated in this case study is the way the design of any one component is often influenced by the design of related parts Because engineers will inevitably need to continue to deal with SI, British gravitational, and English engineering units, all three systems are used in the text and in the problems Recalling the NASA/JPL Mars Climate Orbiter of 1999, where the root cause of the loss of the Orbiter spacecraft was the failed translation of English units into metric units in a segment of ground-base, navigation-related mission software, should help to remind the student just how important it is to understand and apply units properly In some instances, this text has retained graphical procedures (like S–N curves and mean stress-alternating stress diagrams for fatigue analyses) rather than using equivalent mathematical expressions more quickly handled with calculators and computer programs This is done where the graphical procedure helps the student to understand and “visualize” what is going on, develop added insight about the significance of the results, and see how the design might be improved In actual practice, whenever such procedures are called for on a repetitive basis, the competent engineer will obviously employ computing facilities to full advantage ROBERT C JUVINALL KURT M MARSHEK www.EngineeringEBooksPdf.com fbetw.qxd 8/5/11 1:32 AM Page vii Acknowledgments It is impossible to give adequate recognition to the many individuals who have contributed substantially to our own professional thinking reflected in this book Five of the earliest of this distinguished group are Professor Robert R Slaymaker and Professor Daniel K Wright of Case Western Reserve University, Professor Ralph I Stephens of the University of Iowa, Professor Ali Seireg of the University of Wisconsin–Madison, and Professor Walter L Starkey of Ohio State University We have often wondered how strongly our gravitating to the area of mechanical engineering design was influenced by the fact that we first studied the subject under outstanding engineers, superb teachers, and gentlemen whom we greatly admired (Those of us in engineering education easily forget how much students are influenced by the character and the professional attitudes and practices of their instructors.) We would like to recognize with sincere thanks the several engineering authorities who reviewed individual chapters of the first edition and offered valuable suggestions Among these are Joseph Datsko (University of Michigan), Robert J Finkelston (Standard Pressed Steel Co.), Robert Frayer (Federal Mogul Corp.), Alex Gomza (Grumman Aerospace Corp.), Evan L Jones (Chrysler Corp.), Vern A Phelps (University of Michigan), Robert R Slaymaker (Case Western Reserve University), Gus S Tayeh (New Departure Hyatt Bearings), Paul R Trumpler (Trumpler Associates), Lew Wallace (Gleason Machine Div.), James E West (FAG Bearings Corp.), Charles Williams (Federal Mogul Corp.), Ward O Winer (Georgia Institute of Technology), and William Wood (Associated Spring Barnes Group) In addition to expressing our deep gratitude to these individuals, we would like to state clearly that the responsibility for each chapter is solely ours If the reader finds errors, or points of view with which he or she disagrees, there should be no inference that these are due to anyone except the authors Moreover, we would like to state that while every effort has been made to ensure the accuracy and the conformity with good engineering practice of all the material contained in this book, there is no guarantee, stated or implied, that mechanical components designed on the basis of this text will in all instances be proper and safe Mechanical engineering design is sufficiently complex that its actual practice should always take advantage of the specialized literature in the area involved, the background of experience with related components, and, most important, appropriate tests to establish proper and safe performance in critical cases We would also like to express appreciation to Professors James Barber, Panos Papalambros, and Mohammed Zarrugh at the University of Michigan who made valuable suggestions as a result of teaching from preliminary versions of the first edition Our thanks go as well to their students and to our students, who contributed important improvements We would like to express particular thanks to Professor Emeritus Herbert H Alvord of the University of Michigan who generously permitted us the use of his extensive collection of problems, which he developed for his own classes We also thank Professors J Darrell Gibson (Rose Hulman Institute of Technology), Donald A Smith (University of Wyoming), and Petru-Aurelian Simionescu (Texas A&M—CC), and Professors Michael D Bryant, Eric P Fahrenthold, Kristin L Wood, and Rui Huang at the University of Texas who offered valuable suggestions www.EngineeringEBooksPdf.com fbetw.qxd 8/4/11 viii 12:50 PM Page viii Acknowledgments Appreciation is expressed to those who have reviewed this and previous editions: Kuang-Hua Chang, University of Oklahoma, Tim Dalrymple, University of Florida, Hamid Davoodi, North Carolina State University, Thomas Grimm, Michigan Technological University, Thomas Haas, Virginia Commonwealth University, Liwei Lin, University of California at Berkeley, Frank Owen, California Polytechnic State University, San Luis Obispo, Wendy Reffeor, Grand Valley State University, John Schueller, University of Florida, William Semke, University of North Dakota, Albert Shih, University of Michigan, Donald Smith, University of Wyoming, John Thacker, University of Virginia, and Raymond Yee, San Jose State University, Steve Daniewicz, Mississippi State University, Richard Englund, Penn State University, Ernst Kiesling, Texas Tech University, Edward R Evans Jr., Penn State Erie, The Behrend College, Thomson R Grimm, Michigan Technological University, Dennis Hong, Virginia Polytechnic Institute and State University, E William Jones, Mississippi State University, Gloria Starns, Iowa State University, and Andreas Polycarpou, University of Illinois at Urbana–Champaign We would like to personally thank Professor Roger Bradshaw, University of Louisville for contributing Appendix F as well as related sets of homework problems and solutions for Chapter and Chapter 8, and Professor Krishnan Suresh, University of Wisconsin–Madison for contributing Appendices G, H, I, and J We deeply appreciate the understanding and encouragement of our wives, Arleene and Linda, during the preparation of this book, which preempted time belonging, by all resonable standards, to important family and social activities www.EngineeringEBooksPdf.com 8/1/11 4:25 PM Page 885 APPENDIX J Gear Terminology and Contact-Ratio Analysis In this Appendix, we summarize the mathematical relationship(s) between various quantities associated with spur-gears (see Figure J.1) J.1 Nominal Spur-Gear Quantities Various quantities associated with a spur-gear set are summarized in Table J.1 below, where: • Column is the name of the quantity as described in Chapter 15 • Column is the associated symbol (see conventions below) • Column is the unit (if any) associated with the quantity • Column is the relationship of the given quantity with previously defined quantities • Column is a specific case study (see example below) ce wi dt h b t0 To p la nd Fa Fa ce Addendum ci rcle Width of space Pitch circle Bo tto m Dedendum Tooth thickness t la nd Whole depth k Working depth Circular pitch p an Addendum Fl bapp10.qxd Clearance Fillet radius FIGURE J.1 Nomenclature of gear teeth www.EngineeringEBooksPdf.com Dedendum circle Clearance circle (mating teeth extend to this circle) bapp10.qxd 8/1/11 886 4:25 PM Page 886 Appendix J ■ Gear Terminology and Contact-Ratio Analysis As in Chapter 15, we use the following conventions: • A subscript p is used to refer to the smaller gear (pinion), while g is used to refer to the larger gear Thus, for example, Np is the number of teeth in the pinion, while Ng is the number of teeth in the larger gear For quantities such as the pressure angle f that are common to pinion and gear, subscripts are not used • In addition, the subscript b is used for base radius, a for addendum radius, and d for dedendum radius Thus, for example, the symbol rbp is the pinion base radius, while rag is the gear addendum radius Now consider a gear-set that consists of a 16-tooth pinion and a 40-tooth gear; diametral pitch is 2, with a nominal pressure angle of 20° In the fifth column of Table J.1, we have entered this data in the first three rows, while in the remaining rows of the fifth column, we have computed the quantities using the relationship provided Observe in the table that we have used the standard addendum radii for the pinion and gear, since they are less than the corresponding maximum allowable addendum radii Given the addendum radii, one arrives at the nominal contact ratio of 1.58; these calculations are most conveniently carried out using an Excel® spreadsheet Table J.1 Nominal Quantities Associated with a Gear-Set Name Number of teeth Symbol Units Relationship Example Np Np = 16 Ng Ng = 32 Nominal Diametral pitch P per in P=2 Pressure angle f degrees f = 20° Gear ratio - Base width b Nominal pitch radius rp = Ng /Np =2 in 9/P < b < 14/P 4.5 < b < in rp = Np /(2P) rp = rg = Ng /(2P) rg = rbp = rp cos f rbp = 3.76 rbg = rg cos f rbg = 7.52 rg Base radius rbp in rbg (Np + Ng) Center distance c in c = Maximum addendum radius to avoid interference rmax ap in 2 rmax ap = 2r bp + c sin w rmax ap = 5.57 2 rmax ag = 2r bg + c sin w rmax ag = 8.56 Addendum radius rap rap = (Np + 2)/(2P) rap = 4.5 rag = (Ng + 2)/(2P) rag = 8.5 rmax ag rag in (2P) (Standard) www.EngineeringEBooksPdf.com c = 12 bapp10.qxd 8/1/11 4:25 PM Page 887 Appendix J ■ 887 Gear Terminology and Contact-Ratio Analysis Dedendum radius rdp in rdg rdp = (Np – 2.5)/(2P) rdp = 3.375 rdg = (Ng – 2.5)/(2P) rdg = 7.375 (Standard) Module m mm m = 25.4/P m = 12.7 Circular pitch p in p = /P p = 1.57 Tooth thickness t in t = /(2P) t = 0.785 Contact ratio CR ¢ p = 2r2ap - r2bp ∆p = 2.70 ¢ g = 2r2ag - r2bg ∆g = 3.96 - CR = ¢ p + ¢ g - c sin f p cos f CR = 1.58 J.2 Actual Quantities The quantities in Table J.1 are nominal quantities, i.e., they are valid when the two gears are at the nominal (ideal) center distance In practice, the center distance will be larger than the nominal center distance, and many of the above quantities will change This is captured in Table J.2 In Table J.2, we identify the specific quantities that change when the center distance increases Quantities such as number of teeth and gear ratio not depend on the center distance are therefore not listed below In order to distinguish actual quantities from their nominal counterparts in Table J.1, we use a bar above the symbol in Table J.2 For example, since c is the nominal center distance, c is the actual center distance Similarly, f is the actual pressure angle Continuing with the example of the previous section, suppose the distance between the gear-centers is 0.05 inches more than the nominal; what is the contact ratio and backlash? In the fifth column of Table J.2, we have entered the data provided in the first row, while in the remaining rows, the quantities are computed using the relationships provided Observe that the contact ratio has dropped from 1.58 in Table J.1 to 1.49 in Table J.2 Table J.2 Contact Ratio and Other Quantities at an Actual Center Distance Name Symbol Actual working distance c Ratio of center distances Actual pressure angle f Units Relationship c = 12.05 in degrees Example l = c>c = 1.004 cos f = cos f/l f = 20.64° (Continued) www.EngineeringEBooksPdf.com bapp10.qxd 8/1/11 888 4:25 PM Page 888 Appendix J ■ Gear Terminology and Contact-Ratio Analysis Actual pitch P per in P = P>l P = 1.99 Actual pitch radius rp in rp = rpl rp = 4.0167 rg = rgl rg = 8.0333 rg Actual circular pitch p in p = pl p = 1.5773 Maximum addendum radius to avoid interference rmax ap in 2 rmax ap = 2r bp + c sin w rmax ap = 5.67 2 rmax ag = 2r bg + c sin w rmax ag = 8.63 Actual contact ratio CR ¢ p = 2r2ap - r2bp CR = 1.49 rmax ag - ¢ g = 2r2ag - r2bp CR = Backlash (measured on pitch circle) B in ¢ p + ¢ g - c sin f p cos f B = 2(c - c) tan f B = 0.0377 J.3 Illustrative Example We now rework Sample Problem 15.1D (reproduced below for convenience) using the two tables above Sample Problem 15.1D Two parallel shafts with (nominal) 4-in center distance are to be connected by 6-pitch, 20° spur gears providing a velocity ratio of –3.0 (a) Determine the pitch diameters and numbers of teeth in the pinion and gear (b) Determine whether there will be interference when standard full-depth teeth are used (c) Determine the contact ratio Solution: Observe that, in this example, the number of pinion-teeth and number of gear-teeth are not provided; instead the gear ratio and the nominal center distance are provided The first objective is to determine the number of teeth from the given data (a) From the expression for gear ratio and nominal center distance in Table J.1, we have Ng/Np = and (Np + Ng)/(2P) = Further, since the pitch P is 6, we have Ng = 36 and Np = 12 We can now enter the data in the table below, and compute quantities, such as nominal pitch radius, etc (b) The standard addendum radius for the gear is rag = (Ng + 2)/(2P) = 3.17 Since this is greater than the maximum allowable addendum radius of rmax ag = 3.13 (see Table J.3), there will be interference if standard full-depth teeth are used Instead, as explained in Sample Problem 15.1D, we shall use a nonstandard addendum of rag = rg + 0.06 = 3.06 and rap = rp + 0.29 = 1.29 (c) With this choice, one can now compute the contact ratio as illustrated in Table J.3 www.EngineeringEBooksPdf.com bapp10.qxd 8/1/11 4:25 PM Page 889 Appendix J ■ 889 Gear Terminology and Contact-Ratio Analysis Table J.3 Solution to Sample Problem 15.1D Name Number of teeth Symbol Units Relationship Example Np Np = 12 Ng Ng = 36 Nominal diametral pitch P per in P=6 Nominal pressure angle f degrees f = 20° Gear ratio Base width b Nominal pitch radius rp Nominal base radius rbp Nominal center distance c Maximum addendum radius to avoid interference rmax ap =3 in 9/P < b < 14/P 1.5 < b < 2.33 in rp = Np/(2P) rp = rg = Ng/(2P) rg = rbp = rp cos f rbp = 0.939 rbg = rg cos f rbg = 2.82 rg in rbg in in rmax ag rap Standard addendum radius = Ng/Np in rag c = (Np + Ng) c=4 (2P) 2 rmax ap = 2r bp + c sin w rmax ap = 1.66 2 rmax ag = 2r bg + c sin w rmax ag = 3.13 rap = (Np + 2)/(2P) rap = 1.17 rag = (Ng + 2)/(2P) rag = 3.17 (Interference) Addendum radius rap in (Non-standard) rap = 1.29 rag rdp Standard dedendum radius rag = 3.06 in rdg rdp = (Np – 2.5)/(2P) rdp = 0.792 rdg = (Ng – 2.5)/(2P) rdg = 2.792 (Standard) Nominal module m mm m = 25.4/P m = 4.23 Nominal circular pitch p in p = /P p = 0.523 Nominal tooth thickness t in t = /(2P) t = 0.262 CR Nominal contact ratio ¢ p = 2r 2ap - r2bp ¢g = CR = www.EngineeringEBooksPdf.com 2r2ag - r2bg ¢ p + ¢ p - c sin f p cos f CR = 1.43 bindex.qxd 8/4/11 12:22 PM Page 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 www.EngineeringEBooksPdf.com 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, 144–150 bindex.qxd 8/4/11 12:22 PM Page 891 891 Index 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, 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 www.EngineeringEBooksPdf.com 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, 350 bindex.qxd 8/4/11 892 12:22 PM Page 892 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, 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 www.EngineeringEBooksPdf.com 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, 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, 45–48 bindex.qxd 8/4/11 12:22 PM Page 893 893 Index 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, 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) www.EngineeringEBooksPdf.com 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, 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, 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, 104 bindex.qxd 8/4/11 894 12:22 PM Page 894 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, 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, 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 www.EngineeringEBooksPdf.com 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, 250 bindex.qxd 8/4/11 12:22 PM Page 895 895 Index 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, 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 www.EngineeringEBooksPdf.com 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, 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, 110–111 bindex.qxd 8/4/11 896 12:22 PM Page 896 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, 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 www.EngineeringEBooksPdf.com 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, 373 bindex.qxd 8/4/11 12:22 PM Page 897 897 Index Sacrificial anode, 375, 378 Safety/safety factors, 4–9, 272–274 awareness of, definition of, 272–274 estimation of, for steel pan, 270–272 and ingenuity, 5–6 and margin of safety, 276 nontechnical aspects of, 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, 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 www.EngineeringEBooksPdf.com 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, 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, 509–512 bindex.qxd 8/4/11 898 12:22 PM Page 898 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 www.EngineeringEBooksPdf.com 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, 425–426 bindex.qxd 8/4/11 12:22 PM Page 899 899 Index 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, 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, 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 www.EngineeringEBooksPdf.com 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 ... www.EngineeringEBooksPdf.com ffirs.qxd 8/4/11 12:45 PM Page i Fifth Edition Fundamentals of Machine Component Design ROBERT C JUVINALL Professor of Mechanical Engineering University of Michigan KURT M MARSHEK Professor... remaining chapters (Part II) deal with the application of these fundamentals to specific machine components Features of the fifth edition of the text include: • Modern/current issues and safety... Five of the earliest of this distinguished group are Professor Robert R Slaymaker and Professor Daniel K Wright of Case Western Reserve University, Professor Ralph I Stephens of the University of