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What is included with this book?
A guide to the new CAD and optimization tools and skills to generate real design synthesis of machine elements and systems
Machine Design with CAD and Optimization offers the basic tools to design or synthesize machine elements and assembly of prospective elements in systems or products. It contains the necessary knowledge base, computer aided design, and optimization tools to define appropriate geometry and material selection of machine elements. A comprehensive text for each element includes: a chart, excel sheet, a MATLAB® program, or an interactive program to calculate the element geometry to guide in the selection of the appropriate material.
The book contains an introduction to machine design and includes several design factors for consideration. It also offers information on the traditional rigorous design of machine elements. In addition, the author reviews the real design synthesis approach and offers material about stresses and material failure due to applied loading during intended performance. This comprehensive resource also contains an introduction to computer aided design and optimization. This important book:
Written for students of engineering design, mechanical engineering, and automotive design. Machine Design with CAD and Optimization contains the new CAD and Optimization tools and defines the skills needed to generate real design synthesis of machine elements and systems on solid ground for better products and systems.
SAYED M. METWALLI, is Professor Emeritus of Machine Design and past Chair of Mechanical Design and Production Department, Cairo University, Egypt. He received a BS (Mech. Eng.) with honor from Cairo University (1965) and MS and PhD (Mech. Eng.) from State University of New York at Buffalo, USA, (1970) and (1973) respectively. Metwalli has conducted research and taught at North Carolina State University, the University of Central Florida, USA, and Kuwait University, and holds a US patent. His research interests are in design optimization theory, developing algorithms, and CAD/CAM software, with particular emphasis on optimum synthesis of mechanical components and systems including dynamics and controls for multitude of applications. He has conducted sponsored research with DOD/NRL, UNESCO, IBM-UK, NSF, EPA, USAID, and CU and has published more than 150 papers in journals and peer reviewed international conferences. His work with various manufacturers successfully implemented CAD and design optimization in their product design and development. He is an ASME Life Fellow, registered mechanical design consultant, and has been a registered PE in Florida.
MACHINE DESIGN WITH CAD & OPTIMIZATION
CONTENTS:
NOMENCLATURE
PART 1
INTRODUCTION & DESIGN CONSIDERATIONS
1. INTRODUCTION TO DESIGN
1.1. Introduction
1.2. Phases of Design
1.3. Basic Mechanical Functions
1.4. Design Factors
A. Performance
B. Constructional details
C. Safety and reliability
D. Cost and economy
1.5. Synthesis Approach to Design
1.6. Product Life Cycle
1.7. Business Measures
1.8. Research and Development Process in Product Cycle
1.9. Teamwork for Product or System Design
1.10. Design and Development Case Study.
1.11. Units and Fundamentals
1.11.1. Units
1.11.2. Unit conversion
1.11.3. Vectors and Matrices
1.12. Summary
1.13. References
1.14. Problems
2. DESIGN CONSIDERATIONS
2.1. Mathematical Modeling
2.1.1. Mathematical model initiation and adoption
2.1.2. Generalized system modeling
A. Generalized variables
B. Two terminal components
C. Multi-terminal components
2.1.3. Modeling of loading and material variations
2.2. Calculation Tools
2.2.1. Excel
2.2.2. MATLAB
2.2.3. Computer aided design (CAD)
2.2.4. Finite Element (FE)
2.3. Design Procedure
2.4. Manufacturing Processes
2.4.1. Casting or molding
2.4.2. Deformation
2.4.3. Machining
2.4.4. Joining
2.4.5. Surface and heat treatment
2.4.6. 3D printing or additive manufacturing
2.4.7. Tolerances, surface finish, and fits
2.5. Standard Sets and Components
2.6. Codes and Standards
2.7. Summary
2.8. References
2.9. Problems
PART 2
KNOWLEDGE-BASED DESIGN
3. INTRODUCTION TO COMPUTER AIDED TECHNIQUES
3.1. CAD and Geometric Modeling
3.1.1. Classical design process
3.1.2. Synthesis design process
3.1.3. Human-machine characteristics
3.2. Geometric Construction and FE Analysis
3.3. CAD/CAM/CAE and Advanced Systems
3.4. Virtual Reality
3.4.1. Virtual reality process
3.4.2. Virtual reality hardware requirements
3.4.3. Virtual reality interactive process tools
3.4.4. Virtual reality applications
3.5. Summary
3.6. References
3.7. Problems
4. COMPUTER AIDED DESIGN
4.1. 3-D Modeling and Transformation
4.1.1. 3D geometric modeling
A. Geometric computations
B. Topological operations and the Euler formula
C. Geometric and global operations
D. Procedures for constructing a single solid
4.1.2. Homogeneous coordinates versus Cartesian coordinates
A. Point in Space:
B. Vectors
C. Lines:
D. Body geometry and vertices
4.1.3. Body transformation
A. Translation
B. Rotation
C. Scaling
D. Zooming
E. Skewing
F. Perspective
G. Orthographic projection
H. Body transformation systems
4.1.4. Stereo viewing
4.1.5. 3D graphics
4.2. Parametric Modeling
4.2.1. Parametric lines
4.2.2. Parametric planes
4.2.3. Parametric bilinear surfaces
4.2.4. Parametric curves and surfaces
4.2.5. Free form parametric curves and surfaces
A. Surface patches and curves
B. Bezier curves
C. Bezier surfaces or patches
D. B-spline curves
E. B-spline surfaces
F. NURBS
4.2.6. Intersections
A. Intersection of two lines
B. Intersection of a line with a plane
C. Intersection of two planes
D. Intersection of three planes
4.3. CAD Hardware and Software
4.4. Rendering and Animation
4.4.1. Realistic presentations
4.4.2. Color use
A. Visual color description
B. Color specification system
4.4.3. Shading and rendering technique
4.4.4. Computing vertex and surface normals
4.4.5. Rendering process
A. Diffuse illumination
B. Specular reflection
C. Transparency
D. Total rendering effect
4.4.6. 3D cursor and picking
4.5. Data Structure
4.5.1. Drawing exchange format DXF
4.5.2. STL file format
4.5.3. IGES file format
4.5.4. STEP file format
4.6. Using CAD in 3D Modeling and CAM
4.7. Summary
4.8. References
4.9. Problems
5. OPTIMIZATION
5.1. Introduction
5.1.1. Example 5.1. “A sample demonstration problem”
5.1.2. Formulation of optimization problem
i. Design Vector D
ii. Objective Function f
iii. Constraints
iv. Problem statement
v. Dimensional considerations in analytical design “Nondimensionalization”
5.1.3. Example 5.2, “Nondimensionalization from governing equations”
5.1.4. Classification of optimization
A. Problem classification
B. Methods of optimization
C. Optimization fields
5.2. Searches in One Direction
5.2.1. Quadratic Interpolation
5.2.2. Golden Section (Euclid)
5.2.3. Newton-Raphson
5.2.4. Other Methods
5.3. Multi-Dimensional Classical Indirect Approach
5.3.1. Unconstrained problem
5.3.2. Equality constrained problem
5.3.3. Inequality constraints problem
5.4. Multi-Dimensional Unconstrained Problem
5.4.1. Univariate method
5.4.2. Powell's method of conjugate directions
5.4.3. Linearized ridge path method
5.4.4. Random search methods
5.4.5. Steepest descent method
5.4.6. Fletcher-Reeves conjugate gradient
5.4.7. Newton-Raphson method
5.4.8. Quasi-Newton methods
A. A quadratic optimization technique
B. Identified-quadratic optimization technique
5.4.9. Comparison of unconstrained optimization methods
5.5. Multi-Dimensional Constrained Problem
5.5.1. Eliminating constraints by transformation
5.5.2. Exterior penalty functions
5.5.3. Interior penalty functions
5.5.4. Direct methods for constrained problems
A. Convex–Concave property
B. Kuhn-Tucker conditions
C. Gradient projection method
D. Heuristic gradient projection method, HGP
E. Constrained optimization samples
5.5.5. Comparison of optimum constrained methods
5.6. Applications to Machine Elements and Systems
5.7. Summary
5.8. References
5.9. Problems
6. STRESSES AND DEFLECTION
6.1. Loads, Shear, Moment, Slope, and Deflection
6.1.1. External and internal loads
6.1.2. Pure bending
6.1.3. Beam deflection
A. Deflection by integration
B. Deflection by superposition
C. Deflection by singularity function
D. Deflection by other methods
6.1.4. Simple beam synthesis
6.1.5. Comparing stresses and deflection in beams
A. Beam stresses,
B. Beam deflection,
C. Equivalent loads on simple beams
6.2. Mathematical Model
6.3. Simple Stresses
6.3.1. Uniform tension and compression
6.3.2. Direct uniform shear
6.3.3. Pure bending
6.3.4. Shear stress and deformation due to torsion
6.3.5. Transverse shear and shear flow
6.4. Combined Stresses
6.4.1. Plane stress state
6.4.2. Triaxial stress state
6.4.3. Applications in plane stress and triaxial stress states
i. Thin pressure cylinders
ii. Thick pressure cylinders
iii. Press and shrink fits
iv. Contact stresses
6.5. Curved Beams
6.6. Strain Energy and Deflection
6.6.1. Elastic strain
6.6.2. Elastic strain energy
6.6.3. Castigliano’s theorem and deflections
6.7. Columns
6.7.1. Concentric loading
6.7.2. Eccentric loading
6.8. Equivalent Element
6.9. Thermal Effects
6.10. Stress Concentration Factors
6.11. Finite Element Method
6.11.1. Axially loaded elements
6.11.2. Prismatic beam element
6.11.3. Constant strain triangle
6.11.4. General 3D state - Linear elasticity problem
6.11.5. General 3D-FE procedure
6.11.6. Errors in FE modeling and solution
6.11.7. Some classical FE packages
6.12. Computer Aided Design and Optimization
6.12.1. Beam synthesis tablet
6.12.2. Column synthesis tablet
6.12.3. Optimum stress concentration
6.12.4. Optimum FE prismatic beams
6.12.5. Optimum FE cantilever beams
6.13. Summary
6.14. References
6.15. Problems
7. MATERIALS STATIC AND DYNAMIC STRENGTH
7.1. Material Structure and Failure Modes
7.1.1. Basic elements of material
7.1.2. Material failure modes and properties
7.1.3. Tensile properties
7.1.4. Other static properties
7.1.5. Other time-dependent properties
7.2. Numbering Systems and Designations
7.2.1. Carbon and alloy steels
7.2.2. Aluminum and aluminum alloys
7.2.3. Other alloys
7.3. Heat Treatment and Alloying Elements
7.3.1. Heat treatment
7.3.2. Case hardening
7.3.3. Effect of alloying elements
7.4. Material Propertied and General Applications
7.4.1. Cast iron
7.4.2. Plain and low-alloyed carbon steels
i. Hot rolled and cold drawn plain-carbon steels
ii. Strength and hardness of annealed and normalized plain-carbon steels
iii. Quenched and tempered plain-carbon steels
iv. Quenched and tempered low-alloy steels
7.4.3. Structural steel
7.4.4. Stainless steel
7.4.5. Tool steel
7.4.6. Other nonferrous metals
i. Aluminum and aluminum alloys,
ii. Copper and Magnesium alloys
7.4.7. Other materials
i. Plastics
ii. Composites
7.5. Particular Materials for Machine Elements
7.5.1. Standard machine elements
7.5.2. Synthesized or designed machine elements
7.6. Hardness and Strength
7.7. Failure and Static Failure Theories
7.7.1. Maximum normal stress theory
7.7.2. Maximum shear stress theory
7.7.3. Maximum distortion energy theory (von Mises)
7.7.4. Other failure theories
7.7.5. Comparison and applications of failure theories
7.8. Fatigue Strength and Factors Affecting Fatigue
7.8.1. Fatigue strength
7.8.2. Factors affecting fatigue strength
7.8.3. Cumulative fatigue strength
7.8.4. Fluctuating stresses
7.8.5. Fatigue failure criteria
7.9. Fracture Mechanics and Fracture Toughness
7.9.1. Stress intensity factor KI
7.9.2. Fracture toughness – critical stress intensity factor KIC
7.9.3. Crack propagation and life
7.9.4. Crack propagation and real case study
7.10. Computer Aided Selection and Optimization
7.10.1. Material properties – carbon steel
7.10.2. Fatigue strength and factors affecting fatigue – carbon steel
7.10.3. Static strength and factors of safety – carbon steel
7.10.4. Optimization for a specific factor of safety – carbon steel
7.11. Summary
7.12. References
7.13. Problems
8. INTRODUCTION TO ELEMENTS AND SYSTEM SYNTHESIS
8.1. Introduction
8.2. Basic and Common Machine Elements
8.2.1. Couplings
i. Rigid couplings
ii. Flexible couplings
iii. Universal joints
8.2.2. Keys, pins, retaining rings, and splines
i. Keys
ii. Pins and cotter pins
iii. Retaining rings
iv. Splines
8.2.3. Seals
8.2.4. Housings, enclosures, frames, and chassis
8.3. Reverse Engineering
8.4. Sample Applications
8.4.1. Initial bolt synthesis
8.4.2. Initial shaft synthesis
8.4.3. Initial bearing synthesis
8.5. Computer Aided Design
8.6. System Synthesis
8.7. Computer Aided Assembly
8.8. Summary
8.9. References
8.10. Problems
PART 3
DETAILED DESIGN OF MACHINE ELEMENTS
A. BASIC JOINTS AND MACHINE ELEMENTS
9. SCREWS, FASTENERS AND PERMANENT JOINTS
9.1. Standards and Types
9.1.1. Thread terminology and designation
9.1.2. Joining alternative details
9.2. Stresses in Threads
9.3. Bolted Connections
9.3.1. Threads under simple tensile load
9.3.2. Preloading due to tightening
9.3.3. Tightening torque
9.4. Strength in Static and Fatigue
9.5. Power Screws
9.5.1. Torque requirements
9.5.2. Power screw efficiency
9.5.3. Stresses in power screws
9.5.4. Ball screws
9.6. Permanent Joints
9.6.1. Welding
9.6.2. Bonded joints
9.7. Computer Aided Design and Optimization
9.7.1. Threads under simple tensile load
9.7.2. Preloading due to bolt tightening
9.7.3. Preloading, bolt tightening, and fatigue strength
9.7.4. Power screws
9.7.5. Permanent weldment joints
9.7.6. Optimization
9.8. Summary
9.9. References
9.10. Problems
10. SPRINGS
10.1. Types of Springs
10.2. Helical Springs
10.2.1. Geometry, definitions, and configurations
10.2.2. Stresses and deflection
10.2.3. Buckling
10.2.4. Resonance
10.2.5. Design procedure
10.2.6. Extension springs
10.2.7. Torsion springs
10.3. Leaf Springs
10.3.1. Stresses and deflection
10.3.2. Design procedure
10.4. Bellville Springs
10.5. Elastomeric and Other Springs
10.6. Computer Aided Design and Optimization
10.7. Summary
10.8. References
10.9. Problems
11. ROLLING BEARINGS
11.1. Bearing Types and Selection
11.2. Standard Dimension Series
11.2.1. Boundary dimensions
11.2.2. Bearing designation number
11.3. Initial Design and Selection
11.4. Bearing Load
11.4.1. Bearing life and reliability
11.4.2. Load distribution
11.4.3. Bearing load rating
11.5. Detailed Design and Selection
11.5.1. Static loading
11.5.2. Combined loading
11.5.3. Tapered roller bearings
11.5.4. Unsteady loading
11.5.5. Detailed design procedure
11.6. Speed limits
11.7. Lubrication and Friction
11.8. Mounting and Constructional Details
11.9. Computer Aided Design and Optimization
11.9.1. Initial ball bearing synthesis
11.9.2. Dynamic load rating estimate
11.9.3. Ball bearing selection
11.9.4. Rolling bearing optimization
11.10. Summary
11.11. References
11.12. Problems
12. JOURNAL BEARINGS
12.1. Lubricants
12.1.1. Lubricant viscosity
12.1.2. Lubricant selection
12.2. Hydrodynamic Lubrication
12.2.1. Petroff’s equation
12.2.2. Journal bearings
A. Long bearing
B. Short bearing
C. Finite length bearing
12.3. Journal Bearing Design Procedure
12.4. Boundary and Mixed Lubrication
12.5. Plain Bearing Materials
12.6. Computer Aided Design and Optimization
12.6.1. CAD of bearing synthesis using knowledge base practice
12.6.2. CAD of bearing synthesis using an optimization approach
12.6.3. Journal bearing synthesis tablet
12.7. Summary
12.8. References
12.9. Problems
B. POWER TRANSMITTING AND CONTROLLING ELEMENTS
13. INTRODUCTION TO POWER TRANSMISSION AND CONTROL
13.1. Prime Movers and Machines
13.2. Collinear and Noncollinear Transmission Elements
13.3. Power Control Elements
13.4. Computer Aided Design of a Power Transmission System
13.5. Summary
13.6. References
13.7. Problems
14. SPUR GEARS
14.1. Types and Utility
14.2. Definition, Kinematics and Standards
14.3. Force Analysis and Power transmission
14.4. Design Procedure
14.4.1. Classical Procedure
14.4.2. Initial Synthesis
14.4.3. Detailed Design
A. Material set
B. Bending fatigue
C. Surface fatigue
14.5. Critical Speed
14.6. Computer Aided Design and Optimization
14.7. Constructional Details
14.7.1. Gearboxes
14.7.2. Gear trains
14.7.3. Planetary or epicyclic gear trains
14.8. Summary
14.9. References
14.10. Problems
15. HELICAL, BEVEL AND WORM GEARS
15.1. Helical Gears
15.1.1. Types and Utility
15.1.2. Definition, Kinematics and Standards
15.1.3. Force Analysis
15.1.4. Design Procedure
A. Initial synthesis
B. Detailed design
15.2. Bevel Gears
15.2.1. Definition, Kinematics and Standards
15.2.2. Force Analysis
15.2.3. Design Procedure
15.3. Worm Gears
15.3.1. Definition, Kinematics and Standards
15.3.2. Force Analysis
15.3.3. Design Procedure
15.4. Gear Failure Regimes and Remedies
15.5. Computer Aided Design and Optimization
15.5.1. Helical gears synthesis
15.5.2. Bevel gears synthesis
15.5.3. Worm gears synthesis
15.6. Constructional Details
15.7. Summary
15.8. References
15.9. Problems
16. FLEXIBLE ELEMENTS
16.1. V BELTS
16.1.1. V-belts Drive Relations
16.1.2. Standards and Geometric Relations
16.1.3. Design Procedure
A. Initial Synthesis
B. Detailed design process
16.2. FLAT BELTS
16.2.1. Drive Relations
16.3. ROPES
16.3.1. Sizes and Properties
A. Wire rope strength
B. Other wire rope properties
16.3.2. Design Procedure
16.4. CHAINS
16.4.1. Standards
A. Chain size or number
B. Chain sprockets
16.4.2. Drive Relations
16.4.3. Set Dimensions and Constraints
16.4.4. Design Procedure
16.5. FRICTION DRIVES
16.6. FLEXIBLE SHAFTS
16.7. Computer Aided Design and Optimization
16.7.1. V-belts synthesis
16.7.2. Wire rope synthesis
16.7.3. Roller chains synthesis
16.8. Summary
16.9. References
16.10. Problems
17. SHAFTS
17.1. Types of Shafts and Axels
17.2. Mathematical Model
17.3. Initial Design Estimate
17.4. Detailed Design
17.5. Design for Rigidity
17.6. Critical Speed
17.7. Computer Aided Design and Optimization
17.7.1. Shaft Materials
17.7.2. Computer aided design of shafts
17.7.3. Optimum design of shafts
17.8. Constructional Details
17.9. Summary
17.10. References
17.11. Problems
18. CLUTCHES, BREAKS, AND FLYWHEELS
18.1. Introduction and Classifications
18.2. Cone Clutches and Brakes
18.2.1. Uniform pressure
18.2.2. Uniform wear rate
18.3. Disk Clutches and Brakes
18.3.1. Uniform pressure
18.3.2. Uniform wear rate
18.3.3. Multi-disk clutch-brake
A. Uniform pressure
B. Uniform wear rate
18.3.4. Initial disk clutch-brake synthesis
18.4. Caliper Disk Brakes
18.5. Energy Dissipation and Temperature Rise
18.5.1. Energy dissipation
18.5.2. Temperature rise
18.6. Design Process
18.6.1. Initial synthesis
18.6.2. Detailed design process
18.7. Computer Aided Design and Optimization
18.8. Flywheels
18.9. Constructional Details
18.10. Summary
18.11. References
18.12. Problems
APENDIXES
A1. Conversion between US and SI Units
A2. Standard SI Prefixes
A3. Preferred Numbers and Sizes
A4. Standard Rods, or Bars
A5. Standard Joining and Retaining Elements
A6. Standard Sealing Elements
A7. Material Properties
A8. Standard Sections or Profiles and Section Properties
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