Mechanical Design: An Integrated Approach

by UGURAL

• ISBN13: 9780072421552
• ISBN10: 007242155X
• Edition: 1st
• Format: Hardcover
• Copyright: 2003-04-11
• Publisher: McGraw-Hill Science/Engineering/Math

Summary

Ugural's Mechanical Design: An Integrated Approach provides a comprehensive, unified approach to the subject of machine element design for Mechanical Engineering students and practicing engineers. The author's expertise in engineering mechanics is demonstrated in Part I (Fundamentals), where readers are given an exceptionally strong treatment of the design process, stress & strain, deflection & stiffness, energy methods, and failure/fatigue criteria. Advanced topics in mechanics (marked with an asterisk in the Table of Contents) are provided for optional use. The first 8 chapters provide the conceptual basis for Part II (Applications), where the major classes of machine components are covered. Optional coverage of finite element analysis is included, in the final chapter of the text, with selected examples and cases showing FEA applications in mechanical design. In addition to numerous worked-out examples and chapter problems, detailed Case Studies are included to show the intricacies of real design work, and the integration of engineering mechanics concepts with actual design procedures. The author provides a brief but comprehensive listing of derivations for users to avoid the "cookbook" approach many books take. Numerous illustrations provide a visual interpretation of the equations used, making the text appropriate for diverse learning styles. The approach is designed to allow for use of calculators and computers throughout, and to show the ways computer analysis can be used to model problems and explore "what if?" design analysis scenarios. An Online Learning Center website provides a wealth of resources for instructors, students and other readers; and a printed Instructor Solutions Manual is also available.

Table of Contents

PREFACE	XV
ABBREVIATIONS	XIX
SYMBOLS
ROMAN LETTERS	XX
GREEK LETTERS	XXII
PART 1 FUNDAMENTALS	2	(340)
Chapter 1 INTRODUCTION TO DESIGN	3	(35)
1.1 Scope of Treatment	4	(1)
1.2 Engineering Design	4	(1)
1.3 The Design Process	5	(3)
1.4 Design Analysis	8	(1)
1.5 Problem Formulation and Computation	9	(2)
1.6 Factor of Safety and Design Codes	11	(3)
1.7 Units and Conversion	14	(1)
1.8 Load Classification and Equilibrium	15	(2)
1.9 Load Analysis	17	(2)
1.10 Case Studies	19	(4)
1.11 Work and Energy	23	(2)
1.12 Power	25	(2)
1.13 Stress Components	27	(2)
1.14 Normal and Shear Strains	29	(2)
References	31	(1)
Problems	32	(6)
Chapter 2 MATERIALS	38	(33)
2.1 Introduction	39	(1)
2.2 Material Property Definitions	40	(1)
2.3 Static Strength	41	(4)
2.4 Hooke's Law and Modulus of Elasticity	45	(2)
2.5 Generalized Hooke's Law	47	(4)
2.6 Thermal Stress-Strain Relations	51	(1)
2.7 Temperature and Stress-Strain Properties	51	(2)
2.8 Moduli of Resilience and Toughness	53	(2)
2.9 Dynamic and Thermal Effects: Brittle-Ductile Transition	55	(2)
2.10 Hardness	57	(2)
2.11 Processes to Improve Hardness and the Strength of Metals	59	(2)
2.12 General Properties of Metals	61	(4)
2.13 General Properties of Nonmetals	65	(3)
References	68	(1)
Problems	68	(3)
Chapter 3 STRESS AND STRAIN	71	(80)
3.1 Introduction	72	(1)
3.2 Stresses in Axially Loaded Members	72	(3)
3.3 Direct Shear and Bearing Stresses	75	(2)
3.4 Thin-Walled Pressure Vessels	77	(2)
3.5 Stress in Members in Torsion	79	(5)
3.6 Shear and Moment in Beams	84	(3)
3.7 Stresses in Beams	87	(7)
3.8 Design of Beams	94	(8)
3.9 Plane Stress	102	(6)
3.10 Combined Stresses	108	(6)
3.11 Plane Strain	114	(3)
3.12 Stress Concentration Factors	117	(1)
3.13 Importance of Stress Concentration Factors in Design	118	(2)
3.14 Contact Stress Distributions	120	(5)
3.15 Maximum Stress in General Contact	125	(3)
3.16 Three-Dimensional Stress	128	(6)
3.17 Variation of Stress Throughout a Member	134	(2)
3.18 Three-Dimensional Strain	136	(1)
References	137	(1)
Problems	138	(13)
Chapter 4 DEFLECTION AND IMPACT	151	(44)
4.1 Introduction	152	(1)
4.2 Deflection of Axially Loaded Members	152	(4)
4.3 Angle of Twist of Bars	156	(3)
4.4 Deflection of Beams by Integration	159	(3)
4.5 Beam Deflections by Superposition	162	(4)
4.6 Beam Deflection by the Moment-Area Method	166	(6)
4.7 Impact Loading	172	(1)
4.8 Longitudinal and Bending Impact	172	(5)
4.9 Torsional Impact	177	(2)
4.10 Bending of Thin Plates	179	(4)
4.11 Deflection of Plates by Integration	183	(2)
References	185	(1)
Problems	186	(9)
Chapter 5 ENERGY METHODS IN DESIGN	195	(37)
5.1 Introduction	196	(1)
5.2 Strain Energy	196	(2)
5.3 Components of Strain Energy	198	(1)
5.4 Strain Energy in Common Members	199	(4)
5.5 The Work-Energy Method	203	(1)
5.6 Castigliano's Theorem	204	(8)
5.7 Statically Indeterminate Problems	212	(4)
5.8 Virtual Work and Potential Energy	216	(1)
5.9 Use of Trigonometric Series in Energy Methods	217	(3)
5.10 The Rayleigh-Ritz Method	220	(2)
References	222	(1)
Problems	223	(9)
Chapter 6 BUCKLING DESIGN OF MEMBERS	232	(33)
6.1 Introduction	233	(1)
6.2 Buckling of Columns	233	(3)
6.3 Critical Stress in a Column	236	(6)
6.4 Initially Curved Columns	242	(2)
6.5 Eccentric Loads and the Secant Formula	244	(3)
6.6 Design of Columns Under a Centric Load	247	(2)
6.7 Design of Columns Under an Eccentric Load	249	(3)
6.8 Beam-Columns	252	(3)
6.9 Energy Methods Applied to Buckling	255	(2)
6.10 Buckling of Rectangular Plates	257	(2)
References	259	(1)
Problems	259	(6)
Chapter 7 FAILURE CRITERIA AND RELIABILITY	265	(36)
7.1 Introduction	266	(1)
7.2 Introduction to Fracture Mechanics	266	(1)
7.3 Stress-Intensity Factors	267	(1)
7.4 Fracture Toughness	268	(5)
7.5 Yield and Fracture Criteria	273	(2)
7.6 Maximum Shear Stress Theory	275	(2)
7.7 Maximum Distortion Energy Theory	277	(2)
7.8 Octahedral Shear Stress Theory	279	(3)
7.9 Comparison of the Yielding Theories	282	(1)
7.10 Maximum Principal Stress Theory	283	(1)
7.11 Mohr's Theory	284	(1)
7.12 The Coulomb-Mohr Theory	285	(3)
7.13 Reliability	288	(1)
7.14 Normal Distributions	289	(2)
7.15 The Reliability Method and Margin of Safety	291	(3)
References	294	(1)
Problems	295	(6)
Chapter 8 FATIGUE	301	(41)
8.1 Introduction	302	(1)
8.2 The Nature of Fatigue Failures	302	(2)
8.3 Fatigue Tests	304	(1)
8.4 The S-N Diagrams	305	(3)
8.5 Estimating the Endurance Limit and Fatigue Strength	308	(1)
8.6 Modified Endurance Limit	309	(1)
8.7 Endurance Limit Reduction Factors	310	(6)
8.8 Fluctuating Stresses	316	(1)
8.9 Theories of Fatigue Failure	317	(2)
8.10 Comparison of the Fatigue Criteria	319	(1)
8.11 Design for Simple Fluctuating Loads	320	(7)
8.12 Design for Combined Fluctuating Loads	327	(2)
8.13 Prediction of Cumulative Fatigue Damage	329	(1)
8.14 Fracture Mechanics Approach to Fatigue	330	(3)
8.15 Surface Fatigue Failure: Wear	333	(2)
References	335	(1)
Problems	336	(6)
PART 2 APPLICATIONS	342	(411)
Chapter 9 SHAFTS AND ASSOCIATED PARTS	343	(33)
9.1 Introduction	344	(1)
9.2 Materials Used for Shafting	345	(1)
9.3 Design of Shafts in Steady Torsion	345	(2)
9.4 Combined Static Loadings on Shafts	347	(1)
9.5 Design of Shafts for Fluctuating and Shock Loads	348	(6)
9.6 Interference Fits	354	(1)
9.7 Critical Speed of Shafts	355	(3)
9.8 Mounting Parts	358	(3)
9.9 Stresses in Keys	361	(1)
9.10 Splines	362	(2)
9.11 Couplings	364	(2)
9.12 Universal Joints	366	(3)
References	369	(1)
Problems	370	(6)
Chapter 10 BEARINGS AND LUBRICATION	376	(47)
10.1 Introduction	377	(1)
Part A Lubrication and Journal Bearings	377	(24)
10.2 Lubricants	377	(1)
10.3 Types of Journal Bearings and Lubrication	378	(4)
10.4 Lubricant Viscosity	382	(4)
10.5 Petroff's Bearing Equation	386	(2)
10.6 Hydrodynamic Lubrication Theory	388	(3)
10.7 Design of Journal Bearings	391	(6)
10.8 Methods of Lubrication	397	(2)
10.9 Heat Balance of Journal Bearings	399	(1)
10.10 Materials for Journal Bearings	400	(1)
Part B Rolling-Element Bearings	401	(106)
10.11 Types and Dimensions of Rolling Bearings	402	(6)
10.12 Rolling Bearing Life	408	(1)
10.13 Equivalent Radial Load	409	(2)
10.14 Selection of Rolling Bearings	411	(5)
10.15 Materials and Lubricants of Rolling Bearings	416	(1)
10.16 Mounting and Closure of Rolling Bearings	417	(1)
References	418	(1)
Problems	419	(4)
Chapter 11 SPUR GEARS	423	(49)
11.1 Introduction	424	(1)
11.2 Geometry and Nomenclature	425	(3)
11.3 Fundamentals	428	(2)
11.4 Gear Tooth Action and Systems of Gearing	430	(3)
11.5 Contact Ratio and Interference	433	(1)
11.6 Gear Trains	433	(3)
11.7 Transmitted Load	436	(4)
11.8 The Bending Strength of a Gear Tooth: The Lewis Formula	440	(5)
11.9 Design for the Bending Strength of a Gear Tooth: The AGMA Method	445	(7)
11.10 The Wear Strength of a Gear Tooth: The Buckingham Formula	452	(3)
11.11 Design for the Wear Strength of a Gear Tooth: The AGMA Method	455	(4)
11.12 Materials for Gears	459	(1)
11.13 Gear Manufacturing	460	(5)
References	465	(1)
Problems	466	(6)
Chapter 12 HELICAL, BEVEL, AND WORM GEARS	472	(35)
12.1 Introduction	473	(1)
12.2 Helical Gears	473	(2)
12.3 Helical Gear Geometry	475	(3)
12.4 Helical Gear Tooth Loads	478	(1)
12.5 Helical Gear-Tooth Bending and Wear Strengths	479	(6)
12.6 Bevel Gears	485	(3)
12.7 Tooth Loads of Straight Bevel Gears	488	(2)
12.8 Bevel Gear-Tooth Bending and Wear Strengths	490	(2)
12.9 Worm Gearsets	492	(4)
12.10 Worm Gear Bending and Wear Strengths	496	(2)
12.11 Thermal Capacity of Worm Gearsets	498	(4)
References	502	(1)
Problems	503	(4)
Chapter 13 BELTS, CHAINS, CLUTCHES, AND BRAKES	507	(52)
13.1 Introduction	508	(1)
Part A Flexible Elements	508	(23)
13.2 Belts	509	(3)
13.3 Belt Drives	512	(4)
13.4 Belt Tension Relationships	516	(2)
13.5 Design of V Belt Drives	518	(6)
13.6 Chain Drives	524	(1)
13.7 Common Chain Types	525	(6)
Part B High-Friction Devices	531	(28)
13.8 Materials for Brakes and Clutches	531	(2)
13.9 Internal Expanding Drum Clutches and Brakes	533	(1)
13.10 Disk Clutches and Brakes	534	(5)
13.11 Cone Clutches and Brakes	539	(2)
13.12 Band Brakes	541	(2)
13.13 Short-Shoe Drum Brakes	543	(3)
13.14 Long-Shoe Drum Brakes	546	(5)
13.15 Energy Absorption and Cooling	551	(2)
References	553	(1)
Problems	554	(5)
Chapter 14 SPRINGS	559	(39)
14.1 Introduction	560	(1)
14.2 Torsion Bars	561	(1)
14.3 Helical Tension and Compression Springs	562	(4)
14.4 Spring Materials	566	(4)
14.5 Helical Compression Springs	570	(2)
14.6 Buckling of Helical Compression Springs	572	(2)
14.7 Fatigue of Springs	574	(1)
14.8 Design of Helical Compression Springs for Fatigue Loading	575	(5)
14.9 Helical Extension Springs	580	(2)
14.10 Torsion Springs	582	(3)
14.11 Leaf Springs	585	(3)
14.12 Miscellaneous Springs	588	(4)
References	592	(1)
Problems	593	(5)
Chapter 15 POWER SCREWS, FASTENERS, AND CONNECTIONS	598	(61)
15.1 Introduction	599	(1)
15.2 Standard Thread Forms	600	(4)
15.3 Mechanics of Power Screws	604	(4)
15.4 Overhauling and Efficiency of Power Screws	608	(2)
15.5 Ball Screws	610	(2)
15.6 Threaded Fastener Types	612	(2)
15.7 Stresses in Screws	614	(3)
15.8 Bolt Tightening and Preload	617	(2)
15.9 Tension Joints Under Static Loading	619	(2)
15.10 Gasketed Joints	621	(1)
15.11 Determining the Joint Stiffness Constants	622	(3)
15.12 Tension Joints Under Dynamic Loading	625	(4)
15.13 Riveted and Bolted Joints Loaded in Shear	629	(5)
15.14 Shear of Rivets or Bolts Due to Eccentric Loading	634	(3)
15.15 Welding	637	(4)
15.16 Welded Joints Subjected to Eccentric Loading	641	(5)
15.17 Brazing and Soldering	646	(1)
15.18 Adhesive Bonding	647	(2)
References	649	(1)
Problems	650	(9)
Chapter 16 AXISYMMETRIC PROBLEMS IN DESIGN	659	(55)
16.1 Introduction	660	(1)
16.2 Basic Relations	660	(1)
16.3 Thick-Walled Cylinders Under Pressure	661	(5)
16.4 Compound Cylinders: Press or Shrink Fits	666	(3)
16.5 Disk Flywheels	669	(6)
16.6 Thermal Stresses in Cylinders	675	(4)
16.7 Fully Plastic Thick-Walled Cylinders	679	(3)
16.8 Stresses in Curved Beams	682	(7)
16.9 Axisymmetrically Loaded Circular Plates	689	(3)
16.10 Thin Shells of Revolution	692	(2)
16.11 Special Cases of Shells of Revolution	694	(5)
16.12 Pressure Vessels and Piping	699	(3)
16.13 The ASME Code for Conventional Pressure Vessels	702	(1)
16.14 Filament-Wound Pressure Vessels	703	(2)
16.15 Buckling of Cylindrical and Spherical Shells	705	(1)
References	706	(1)
Problems	707	(7)
Chapter 17 FINITE ELEMENT ANALYSIS IN DESIGN	714	(39)
17.1 Introduction	715	(1)
17.2 Stiffness Matrix for Axial Elements	716	(4)
17.3 Formulation of the Finite Element Method and Its Application to Trusses	720	(4)
17.4 Beam and Frame Elements	724	(6)
17.5 Properties of Two-Dimensional Elements	730	(3)
17.6 Triangular Element	733	(3)
17.7 Plane Stress Case Studies	736	(6)
17.8 Axisymmetric Element	742	(3)
References	745	(1)
Problems	746	(7)
Appendix A UNITS, PROPERTIES OF SHAPES, AND BEAM DEFLECTIONS	753	(14)
Table A.1 Conversion factors: SI units to U.S. customary units	754	(1)
Table A.2 SI prefixes	754	(1)
Table A.3 Properties of areas	755	(1)
Table A.4 Properties of some steel pipe and tubing	756	(1)
Table A.5 Properties of solids	757	(1)
Table A.6 Properties of rolled-steel (W) shapes, wide-flange sections	758	(2)
Table A.7 Properties of rolled-steel (S) shapes, American standard I beams	760	(2)
Table A.8 Properties of rolled-steel (L) shapes, angles with equal legs	762	(2)
Table A.9 Deflections and slopes of beams	764	(2)
Table A.10 Reactions and deflections of statically indeterminate beams	766	(1)
Appendix B MATERIAL PROPERTIES	767	(7)
Table B.1 Average properties of common engineering materials	768	(2)
Table B.2 Typical mechanical properties of gray cast iron	770	(1)
Table B.3 Mechanical properties of some hot-rolled (HR) and cold-drawn (CD) steels	770	(1)
Table B.4 Mechanical properties of selected heat-treated steels	771	(1)
Table B.5 Mechanical properties of some annealed (An.) and cold-worked (CW) wrought stainless steels	772	(1)
Table B.6 Mechanical properties of some aluminium alloys	772	(1)
Table B.7 Mechanical properties of some copper alloys	773	(1)
Table B.8 Selected mechanical properties of some common plastics	773	(1)
Appendix C STRESS CONCENTRATION FACTORS	774	(7)
Figure C.1 Theoretical stress-concentration factor Kt for a filleted bar in axial tension	775	(1)
Figure C.2 Theoretical stress-concentration factor for a filleted bar in bending	775	(1)
Figure C.3 Theoretical stress-concentration factor for a notched bar in axial tension	776	(1)
Figure C.4 Theoretical stress-concentration factor Kt for a notched bar in bending	776	(1)
Figure C.5 Theoretical stress-concentration factor Kt: A-for a flat bar loaded in tension by a pin through the transverse hole; B-for a flat bar with a transverse hole in axial tension	777	(1)
Figure C.6 Theoretical-stress concentration factor for a flat bar with a transverse hole in bending	777	(1)
Figure C.7 Theoretical stress-concentration factor for a shaft with a shoulder fillet in axial tension	777	(1)
Figure C.8 Theoretical stress-concentration factor for a shaft with a shoulder fillet in torsion	778	(1)
Figure C.9 Theoretical stress-concentration factor for a shaft with a shoulder fillet in bending	778	(1)
Figure C.10 Theoretical stress-concentration factor for a grooved shaft in axial tension	779	(1)
Figure C.11 Theoretical stress-concentration factor for a grooved shaft in torsion	779	(1)
Figure C.12 Theoretical stress-concentration factor for a grooved shaft in bending	780	(1)
Figure C.13 Theoretical stress-concentration factor for a shaft with a transverse hole in axial tension, bending, and torsion	780	(1)
Appendix D SOLUTION OF THE STRESS CUBIC EQUATION	781	(2)
ANSWERS TO SELECTED PROBLEMS	783	(8)
Index	791