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An integrated, case-based approach to machine design
Machine Design: An Integrated Approach, 6th Edition presents machine design in an up-to-date and thorough manner with an emphasis on design. Author Robert Norton draws on his 50-plus years of experience in mechanical engineering design, both in industry and as a consultant, as well as 40 of those years as a university instructor in mechanical engineering design.
Written at a level aimed at junior-senior mechanical engineering students, the textbook emphasizes failure theory and analysis as well as the synthesis and design aspects of machine elements. Independent of any particular computer program, the book points out the commonality of the analytical approaches needed to design a wide variety of elements and emphasizes the use of computer-aided engineering as an approach to the design and analysis of these classes of problems.
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0135214416 / 9780135214411 MODIFIED MASTERING ENGINEERING WITH PEARSON ETEXT -- ACCESS CARD -- FOR MACHINE DESIGN: AN INTEGRATED APPROACH, 6/e
PART I: FUNDAMENTALS
1. Introduction to Design
1.1 Design
Machine Design
1.2 A Design Process
1.3 Problem Formulation and Calculation
Definition Stage
Preliminary Design Stage
Detailed Design Stage
Documentation Stage
1.4 The Engineering Model
Estimation and First-Order Analysis
The Engineering Sketch
1.5 Computer-Aided Design and Engineering
Computer-Aided Design (CAD)
Computer-Aided Engineering (CAE)
Computational Accuracy
1.6 The Engineering Report
1.7 Factors of Safety and Design Codes
Factor of Safety
Choosing a Safety Factor
Design and Safety Codes
1.8 Statistical Considerations
1.9 Units
1.10 Summary
1.11 References
1.12 Web References
1.13 Bibliography
1.14 Problems
2. Materials and Processes
2.0 Introduction
2.1 Material-Property Definitions
The Tensile Test
Ductility and Brittleness
The Compression Test
The Bending Test
The Torsion Test
Fatigue Strength and Endurance Limit
Impact Resistance
Fracture Toughness
Creep and Temperature Effects
2.2 The Statistical Nature of Material Properties
2.3 Homogeneity and Isotropy
2.4 Hardness
Heat Treatment
Surface (Case) Hardening
Heat Treating Nonferrous Materials
Mechanical Forming and Hardening
2.5 Coatings and Surface Treatments
Galvanic Action
Electroplating
Electroless Plating
Anodizing
Plasma-Sprayed Coatings
Chemical Coatings
2.6 General Properties of Metals
Cast Iron
Cast Steels
Wrought Steels
Steel Numbering Systems
Aluminum
Titanium
Magnesium
Copper Alloys
2.7 General Properties of Nonmetals
Polymers
Ceramics
Composites
2.8 Selecting Materials
2.9 Summary
2.10 References
2.11 Web References
2.12 Bibliography
2.13 Problems
3. Kinematics and Load Determination
3.0 Introduction
3.1 Degree of Freedom
3.2 Mechanisms
3.3 Calculating Degree of Freedom (Mobility)
3.4 Common 1-DOF Mechanisms
Fourbar Linkage and the Grashof Condition
Sixbar Linkage
Cam and Follower
3.5 Analyzing Linkage Motion
Types of Motion
Complex Numbers as Vectors
The Vector Loop Equation
3.6 Analyzing the Fourbar Linkage
Solving for Position in the Fourbar Linkage
Solving for Velocity in the Fourbar Linkage
Angular Velocity Ratio and Mechanical Advantage
Solving for Acceleration in the Fourbar Linkage
3.7 Analyzing the Fourbar Crank-Slider
Solving for Position in the Fourbar Crank-Slider
Solving for Velocity in the Fourbar Crank-Slider
Solving for Acceleration in the Fourbar Crank-Slider
Other Linkages
3.8 Cam Design and Analysis
The Timing Diagram
The svaj Diagram
Polynomials for the Double-Dwell Case
Polynomials for the Single-Dwell Case
Pressure Angle
Radius of Curvature
3.9 Loading Classes For Force Analysis
3.10 Free-body Diagrams
3.11 Load Analysis
Three-Dimensional Analysis
Two-Dimensional Analysis
Static Load Analysis
3.12 Two-Dimensional, Static Loading Case Studies
3.13 Three-Dimensional, Static Loading Case Study
3.14 Dynamic Loading Case Study
3.15 Vibration Loading
Natural Frequency
Dynamic Forces
3.16 Impact Loading
Energy Method
3.17 Beam Loading
Shear and Moment
Singularity Functions
Superposition
3.18 Summary
3.19 References
3.20 Web References
3.21 Bibliography
3.22 Problems
4. Stress, Strain, and Deflection
4.0 Introduction
4.1 Stress
4.2 Strain
4.3 Principal Stresses
4.4 Plane Stress and Plane Strain
Plane Stress
Plane Strain
4.5 Mohr’s Circles
4.6 Applied Versus Principal Stresses
4.7 Axial Tension
4.8 Direct Shear Stress, Bearing Stress, and Tearout
Direct Shear
Direct Bearing
Tearout Failure
4.9 Beams and Bending Stresses
Beams in Pure Bending
Shear Due to Transverse Loading
4.10 Deflection in Beams
Deflection by Singularity Functions
Statically Indeterminate Beams
4.11 Castigliano’s Method
Deflection by Castigliano’s Method
Finding Redundant Reactions with Castigliano’s Method
4.12 Torsion
4.13 Combined Stresses
4.14 Spring Rates
4.15 Stress Concentration Stress Concentration Under Static Loading
Stress Concentration Under Dynamic Loading
Determining Geometric Stress-Concentration Factors
Designing to Avoid Stress Concentrations
4.16 Axial Compression - Columns
Slenderness Ratio
Short Columns
Long Columns
End Conditions
Intermediate Columns
4.17 Stresses in Cylinders
Thick-Walled Cylinders
Thin-Walled Cylinders
4.18 Case Studies in Static Stress and Deflection Analysis
4.19 Summary
4.20 References
4.21 Bibliography
4.22 Problems
5. Static Failure Theories
5.0 Introduction
5.1 Failure of Ductile Materials Under Static Loading
The von Mises-Hencky or Distortion-Energy Theory
The Maximum Shear-Stress Theory
The Maximum Normal-Stress Theory
Comparison of Experimental Data with Failure Theories
5.2 Failure of Brittle Materials Under Static Loading
Even and Uneven Materials
The Coulomb-Mohr Theory
The Modified-Mohr Theory
5.3 Fracture Mechanics
Fracture-Mechanics Theory
Fracture Toughness Kc
5.4 Using The Static Loading Failure Theories
5.5 Case Studies in Static Failure Analysis
5.6 Summary
5.7 References
5.8 Bibliography
5.9 Problems
6. Fatigue Failure Theories
6.0 Introduction
History of Fatigue Failure
6.1 Mechanism of Fatigue Failure
Crack Initiation Stage
Crack Propagation Stage
Fracture
6.2 Fatigue-Failure Models
Fatigue Regimes
The Stress-Life Approach 3
The Strain-Life Approach
The LEFM Approach
6.3 Machine-Design Considerations
6.4 Fatigue Loads
Rotating Machinery Loading
Service Equipment Loading
6.5 Measuring Fatigue Failure Criteria
Fully Reversed Stresses
Combined Mean and Alternating Stress
Fracture-Mechanics Criteria
Testing Actual Assemblies
6.6 Estimating Fatigue Failure Criteria
Estimating the Theoretical Fatigue Strength Sf ’ or Endurance Limit Se’
Correction Factors—Theoretical Fatigue Strength or Endurance Limit
Corrected Fatigue Strength Sf or Corrected Endurance Limit Se
Creating Estimated S-N Diagrams
6.7 Notches and Stress Concentrations
Notch Sensitivity
6.8 Residual Stresses
6.9 Designing for High-Cycle Fatigue
6.10 Designing for Fully Reversed Uniaxial Stresses
Design Steps for Fully Reversed Stresses with Uniaxial Loading
6.11 Designing for Fluctuating Uniaxial Stresses
Creating the Modified-Goodman Diagram
Applying Stress-Concentration Effects with Fluctuating Stresses
Determining the Safety Factor with Fluctuating Stresses
Design Steps for Fluctuating Stresses
6.12 Designing for Multiaxial Stresses in Fatigue
Frequency and Phase Relationships
Fully Reversed Simple Multiaxial Stresses
Fluctuating Simple Multiaxial Stresses
Complex Multiaxial Stresses
6.13 A General Approach to High-Cycle Fatigue Design
6.14 A Case Study in Fatigue Design
6.15 Summary
6.16 References
6.17 Bibliography
6.18 Problems
7. Surface Failure
7.0 Introduction
7.1 Surface Geometry
7.2 Mating Surfaces
7.3 Friction
Effect of Roughness on Friction
Effect of Velocity on Friction
Rolling Friction
Effect of Lubricant on Friction
7.4 Adhesive Wear
The Adhesive-Wear Coefficient
7.5 Abrasive Wear
Abrasive Materials
Abrasion-Resistant Materials
7.6 Corrosion Wear
Corrosion Fatigue
Fretting Corrosion
7.7 Surface Fatigue
7.8 Spherical Contact
Contact Pressure and Contact Patch in Spherical Contact
Static Stress Distributions in Spherical Contact
7.9 Cylindrical Contact
Contact Pressure and Contact Patch in Parallel Cylindrical Contact
Static Stress Distributions in Parallel Cylindrical Contact
7.10 General Contact
Contact Pressure and Contact Patch in General Contact
Stress Distributions in General Contact
7.11 Dynamic Contact Stresses
Effect of a Sliding Component on Contact Stresses
7.12 Surface Fatigue Failure Models—Dynamic Contact
7.13 Surface Fatigue Strength
7.14 Summary
7.15 References
7.16 Problems
8. Finite Element Analysis
8.0 Introduction
Stress and Strain Computation
8.1 Finite Element Method
8.2 Element Types
Element Dimension and Degree of Freedom (DOF)
Element Order
H-Elements Versus P-Elements
Element Aspect Ratio
8.3 Meshing
Mesh Density
Mesh Refinement
Convergence
8.4 Boundary Conditions
8.5 Applying Loads
8.6 Testing the Model (Verification)
8.7 Modal Analysis
8.8 Case Studies
8.9 Summary
8.10 References
8.11 Bibliography
8.12 Web Resources
8.13 Problems
PART II: MACHINE DESIGN
9. Design Case Studies
9.0 Introduction
9.1 Case Study 8—A Portable Air Compressor
9.2 Case Study 9—A Hay-Bale Lifter
9.3 Case Study 10—A Cam-Testing Machine
9.4 Summary
9.5 References
9.6 Design Projects
10. Shafts, Keys, and Couplings
10.0 Introduction
10.1 Shaft Loads
10.2 Attachments and Stress Concentrations
10.3 Shaft Materials
10.4 Shaft Power
10.5 Shaft Loads
10.6 Shaft Stresses
10.7 Shaft Failure in Combined Loading
10.8 Shaft Design
General Considerations
Design for Fully Reversed Bending and Steady Torsion
Design for Fluctuating Bending and Fluctuating Torsion
10.9 Shaft Deflection
Shafts as Beams
Shafts as Torsion Bars
10.10 Keys and Keyways
Parallel Keys
Tapered Keys
Woodruff Keys
Stresses in Keys
Key Materials
Key Design
Stress Concentrations in Keyways
10.11 Splines
10.12 Interference Fits
Stresses in Interference Fits
Stress Concentration in Interference Fits
Fretting Corrosion
10.13 Flywheel Design
Energy Variation in a Rotating System
Determining the Flywheel Inertia
Stresses in Flywheels
Failure Criteria
10.14 Critical Speeds of Shafts
Lateral Vibration of Shafts and Beams—Rayleigh’s Method
Shaft Whirl
Torsional Vibration
Two Disks on a Common Shaft
Multiple Disks on a Common Shaft
Controlling Torsional Vibrations
10.15 Couplings
Rigid Couplings
Compliant Couplings
10.16 Case Study 8B
Designing Driveshafts for a Portable Air Compressor
10.17 Summary
10.18 References
10.19 Problems
11. Bearings and Lubrication
11.0 Introduction
A Caveat
11.1 Lubricants
11.2 Viscosity
11.3 Types of Lubrication
Full-Film Lubrication
Boundary Lubrication
11.4 Material Combinations in Sliding Bearings
11.5 Hydrodynamic Lubrication Theory
Petroff’s Equation for No-Load Torque
Reynolds’ Equation for Eccentric Journal Bearings
Torque and Power Losses in Journal Bearings
11.6 Design of Hydrodynamic Bearings
Design Load Factor—The Ocvirk Number
Design Procedures
11.7 Nonconforming Contacts
11.8 Rolling-element Bearings
Comparison of Rolling and Sliding Bearings
Types of Rolling-Element Bearings
11.9 Failure of Rolling-element bearings
11.10 S election of Rolling-element bearings
Basic Dynamic Load Rating C
Modified Bearing Life Rating
Basic Static Load Rating C0
Combined Radial and Thrust Loads
Calculation Procedures
11.11 Bearing Mounting Details
11.12 Special Bearings
11.13 Case Study 10B
11.14 Summary
Important Equations Used in This Chapter
11.15 References
11.16 Problems
12. Spur Gears
12.0 Introduction
12.1 Gear Tooth Theory
The Fundamental Law of Gearing
The Involute Tooth Form
Pressure Angle
Gear Mesh Geometry
Rack and Pinion
Changing Center Distance
Backlash
Relative Tooth Motion
12.2 Gear Tooth Nomenclature
12.3 Interference and Undercutting
Unequal-Addendum Tooth Forms
12.4 Contact Ratio
12.5 Gear Trains
Simple Gear Trains
Compound Gear Trains
Reverted Compound Trains
Epicyclic or Planetary Gear Trains
12.6 Gear Manufacturing
Forming Gear Teeth
Machining
Roughing Processes
Finishing Processes
Gear Quality
12.7 Loading on Spur Gears
12.8 Stresses in Spur Gears
Bending Stresses
Surface Stresses
12.9 Gear Materials
Material Strengths
Bending-Fatigue Strengths for Gear Materials
Surface-Fatigue Strengths for Gear Materials
12.10 Lubrication of Gearing
12.11 Design of Spur Gears
12.12 Case Study 8C
12.13 Summary
12.14 References
12.15 Problems
13. Helical, Bevel, and Worm Gears
13.0 Introduction
13.1 Helical Gears
Helical Gear Geometry
Helical-Gear Forces
Virtual Number of Teeth
Contact Ratios
Stresses in Helical Gears
13.2 Bevel Gears
Bevel-Gear Geometry and Nomenclature
Bevel-Gear Mounting
Forces on Bevel Gears
Stresses in Bevel Gears
13.3 Wormsets
Materials for Wormsets
Lubrication in Wormsets
Forces in Wormsets
Wormset Geometry
Rating Methods
A Design Procedure for Wormsets
13.4 Case Study 9B
13.5 Summary
13.6 References
13.7 Problems
14. Spring Design
14.0 Introduction
14.1 Spring Rate
14.2 Spring Configurations
14.3 Spring Materials
Spring Wire
Flat Spring Stock
14.4 Helical Compression Springs
Spring Lengths
End Details
Active Coils
Spring Index
Spring Deflection
Spring Rate
Stresses in Helical Compression Spring Coils
Helical Coil Springs of Nonround Wire
Residual Stresses
Buckling of Compression Springs
Compression-Spring Surge
Allowable Strengths for Compression Springs
The Torsional-Shear S-N Diagram for Spring Wire
The Modified-Goodman Diagram for Spring Wire
14.5 Designing Helical Compression Springs for Static Loading
14.6 Designing Helical Compression Springs for Fatigue Loading
14.7 Helical Extension Springs
Active Coils in Extension Springs
Spring Rate of Extension Springs
Spring Index of Extension Springs
Coil Preload in Extension Springs
Deflection of Extension Springs
Coil Stresses in Extension Springs
End Stresses in Extension Springs
Surging in Extension Springs
Material Strengths for Extension Springs
Design of Helical Extension Springs
14.8 Helical Torsion Springs
Terminology for Torsion Springs
Number of Coils in Torsion Springs
Deflection of Torsion Springs
Spring Rate of Torsion Springs
Coil Closure
Coil Stresses in Torsion Springs
Material Parameters for Torsion Springs
Safety Factors for Torsion Springs
Designing Helical Torsion Springs
14.9 Belleville Spring Washers
Load-Deflection Function for Belleville Washers
Stresses in Belleville Washers
Static Loading of Belleville Washers
Dynamic Loading
Stacking Springs
Designing Belleville Springs
14.10 Case Study 10C
14.11 Summary
14.12 References
14.13 Problems
15. Screws and Fasteners
15.0 Introduction
15.1 Standard Thread Forms
Tensile Stress Area
Standard Thread Dimensions
15.2 Power Screws
Square, Acme, and Buttress Threads
Power Screw Application
Power Screw Force and Torque Analysis
Friction Coefficients
Self-Locking and Back-Driving of Power Screws
Screw Efficiency
Ball Screws
15.3 Stresses in Threads
Axial Stress
Shear Stress
Torsional Stress
15.4 Types of Screw Fasteners
Classification by Intended Use
Classification by Thread Type
Classification by Head Style
Nuts and Washers
15.5 Manufacturing Fasteners
15.6 Strengths of Standard Bolts and Machine Screws
15.7 Preloaded Fasteners in Tension
Preloaded Bolts Under Static Loading
Preloaded Bolts Under Dynamic Loading
15.8 Determining the Joint Stiffness Factor
Joints With Two Plates of the Same Material
Joints With Two Plates of Different Materials
Gasketed Joints
15.9 Controlling Preload
The Turn-of-the-Nut Method
Torque-Limited Fasteners
Load-Indicating Washers
Torsional Stress Due to Torquing of Bolts
15.10 Fasteners in Shear
Dowel Pins
Centroids of Fastener Groups
Determining Shear Loads on Fasteners
15.11 Case Study 8D
15.12 Summary
15.13 References
15.14 Bibliography
15.15 Problems
16. Weldments
16.0 Introduction
16.1 Welding Processes
Types of Welding in Common Use
Why Should a Designer Be Concerned with the Welding Process?
16.2 Weld Joints and Weld Types
Joint Preparation
Weld Specification
16.3 Principles of Weldment Design
16.4 Static Loading of Welds
16.5 Static Strength of Welds
Residual Stresses in Welds
Direction of Loading
Allowable Shear Stress for Statically Loaded Fillet and PJP Welds
16.6 Dynamic Loading of Welds
Effect of Mean Stress on Weldment Fatigue Strength
Are Correction Factors Needed For Weldment Fatigue Strength?
Effect of Weldment Configuration on Fatigue Strength
Is There an Endurance Limit for Weldments?
Fatigue Failure in Compression Loading?
16.7 Treating a Weld as a Line
16.8 Eccentrically Loaded Weld Patterns
16.9 Design Considerations for Weldments in Machines
16.10 Summary
16.11 References
16.12 Problems
17. Clutches and Brakes
17.0 Introduction
17.1 Types of Brakes and Clutches
17.2 Clutch/Brake Selection and Specification
17.3 Clutch and Brake Material
17.4 Disk Clutches
Uniform Pressure
Uniform Wear
17.5 Disk Brakes
17.6 Drum Brakes
Short-Shoe External Drum Brakes
Long-Shoe External Drum Brakes
Long-Shoe Internal Drum Brakes
17.7 Summary
17.8 References
17.9 Bibliography
17.10 Problems
Appendices
A Material Properties
B Beam Tables
C Stress-Concentration Factors
D Answers to Selected Problems
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