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Part 1 Basics1

1 Introduction3

1-1 Design5

1-2 Mechanical Engineering Design7

1-3 Your Path to Competence12

1-4 Technology Can Be Fragile12

1-5 Interaction between Design Process Elements14

1-6 Codes and Standards17

1-7 Economics18

1-8 Safety and Product Liability20

1-9 The Adequacy Assessment20

1-10 Uncertainty22

1-11 Stress and Strength26

1-12 Design Factors and Factors of Safety29

1-13 Reliability30

1-14 Numbers， Units， and Preferred Units31

Problems37

2 Addressing Uncertainty47

2-1 Questions Come with the Territory49

2-2 Estimating Statistical Parameters50

2-3 Probability Density Function and Cumulative Distribution Function53

2-4 Linear Regression55

2-5 Propagation of Error58

2-6 Simulation61

2-7 Design Factor and Factor of Safety63

2-8 Limits and Fits68

2-9 Dimensions and Tolerances71

2-10 Summary77

Problems79

3 Stress93

3-1 Stress Components94

3-2 Mohr Circles96

3-3 Triaxial Stress100

3-4 Uniformly Distributed Stress102

3-5 Elastic Strain103

3-6 Stress-Strain Relations104

3-7 Equilibrium104

3-8 Shear and Moment106

3-9 Singularity Functions108

3-10 Normal Stress in Flexure111

3-11 Beams with Asymmetrical Sections118

3-12 Shear Stresses in Beams118

3-13 Shear Stresses in Rectangular-Section Beams121

3-14 Torsion123

3-15 Stress Concentration129

3-16 Stresses in Cylinders132

3-17 Rotating Rings135

3-18 Press and Shrink Fits135

3-19 Temperature Effects137

3-20 Curved Members in Flexure138

3-21 Contact Stress144

3-22 Propagation of Error149

3-23 Summary154

Problems154

4 Deflection and Stiffness175

4-1 Spring Rates176

4-2 Tension， Compression， and Torsion177

4-3 Deflection Due to Bending178

4-4 Finding Deflection by Integration180

4-5 Finding Deflection by the Area-Moment Method187

4-6 Finding Deflection by the Use of Singularity Functions190

4-7 Strain Energy193

4-8 Castigliano’s Theorem195

4-9 Statistically Indeterminate Problems198

4-10 Deflection of Curved Members200

4-11 Compression Members—General204

4-12 Long Columns with Central Loading206

4-13 Intermediate-Length Columns with Central Loading210

4-14 Columns with Eccentric Loading210

4-15 Struts， or Short Compression Members214

4-16 An Application： Round-Bar Clamps216

4-17 Deflection of Energy-Dissipative Assemblies220

4-18 Shock and Impact229

4-19 Suddenly-Applied Loading230

4-20 Propagation of Error233

Problems237

Part 2 Failure Prevention253

5 Materials255

5-1 Static Strength256

5-2 Plastic Deformation261

5-3 Strength and Cold Work265

5-4 Hardness268

5-5 Impact Properties269

5-6 Temperature Effects271

5-7 Numbering Systems272

5-8 Sand Casting274

5-9 Shell Molding274

5-10 Investment Casting275

5-11 Powder-Metallurgy Process275

5-12 Hot-Working Processes275

5-13 Cold-Working Processes276

5-14 The Heat Treatment of Steel277

5-15 Alloy Steels279

5-16 Corrosion-Resistant Steels280

5-17 Casting Materials281

5-18 Nonferrous Metals283

5-19 Plastics285

5-20 Notch Sensitivity287

5-21 Introduction to Fracture Mechanics288

5-22 Stress-Corrosion Cracking303

5-23 Quantitative Estimation of Properties of Cold-Worked Metals303

5-24 Quantitative Estimation of Properties of Heat-Treated Steels307

Problems308

6 Failures Resulting from Static Loading315

6-1 Static Strength316

6-2 Stress Concentration319

6-3 Hypotheses of Failure322

6-4 Ductile Materials： Maximum-Shear-Stress （Tresca or Guest） Hypothesis324

6-5 Ductile Materials：Strain-Energy Hypotheses326

6-6 Ductile Materials：Internal-Friction Hypothesis332

6-7 Criticism of Hypotheses by Data in Ductile Materials334

6-8 Brittle Materials： Maximum-Normal-Stress （Rankine） Hypothesis335

6-9 Brittle Materials： Modifications of the Mohr Hypothesis337

6-10 The Criticism of Hypotheses by Data in Brittle Materials341

6-11 What Our Failure Models Tell Us342

6-12 Interference—General343

6-13 Static or Quasi-Static Loading on a Shaft347

Problems352

7 Failure Resulting from Variable Loading359

7-1 Introduction to Fatigue in Metals360

7-2 Strain-Life Relationships361

7-3 Stress-Life Relationships367

7-4 The Endurance Limit369

7-5 Fatigue Strength372

7-6 Endurance-Limit Modifying Factors374

7-7 Stress Concentration and Notch Sensitivity383

7-8 Applying What We Have Learned about Endurance Limit and Endurance Strength387

7-9 The Distributions395

7-10 Characterizing Fluctuating Stresses396

7-11 Failure Loci under Variable Stresses398

7-12 Torsional Fatigue Strength under Pulsating Stresses408

7-13 Combinations of Loading Modes408

7-14 Stochastic Failure Loci under Fluctuating Stresses411

7-15 Cumulative Fatigue Damage414

7-16 The Fracture-Mechanics Approach421

7-17 Surface Fatigue Strength423

7-18 The Designer’s Fatigue Diagram429

7-19 An Important Design Decision： The Design Factor in Fatigue431

Problems436

Summary of Parts 1 and 2441

Part 3 Design of Mechanical Elements443

8 Screws， Fasteners， and the Design of Nonpermanent Joints445

8-1 Thread Standards and Definitions446

8-2 The Mechanics of Power Screws450

8-3 Threaded Fasteners457

8-4 Joints—Fastener Stiffness458

8-5 Joints—Member Stiffness461

8-6 Bolt Strength466

8-7 Tension Joints—The External Load470

8-8 Relating Bolt Torque to Bolt Tension471

8-9 Statistically Loaded Tension Joint—Preload477

8-10 Gasketed Joints483

8-11 Tension Joints—Dynamic Loading484

8-12 Adequacy Assessment， Specification Set，Decision Set， and Design492

8-13 Shear Joints498

8-14 Setscrews504

8-15 Pins and Keys504

Problems513

9 Welding， Brazing， Bonding，and the Design of Permanent Joints527

9-1 Welding Symbols528

9-2 Butt and Fillet Welds530

9-3 Stresses in Welded Joints in Torsion535

9-4 Stresses in Welded Joints in Bending540

9-5 The Strength of Welded Joints542

9-6 Specification Set， Adequacy Assessment，and Decision Set544

9-7 Static Loading549

9-8 Fatigue Loading554

9-9 Resistance Welding557

9-10 Bolted and Riveted Joints Loaded in Shear558

9-11 Adhesive Bonding and Design Considerations562

Problems579

10 Mechanical Springs589

10-1 Stresses in Helical Springs590

10-2 The Curvature Effect591

10-3 Deflection of Helical Springs592

10-4 Extension Springs592

10-5 Compression Springs595

10-6 Stability596

10-7 Spring Materials598

10-8 Helical Compression Springs for Static Service609

10-9 Critical Frequency of Helical Springs620

10-10 Fatigue Loading622

10-11 Helical Compression Springs for Dynamic Service625

10-12 Design of a Helical Compression Spring for Dynamic Service629

10-13 Design of Extension Springs637

10-14 Designing Helical Coil Torsion Springs664

10-15 Belleville Springs678

10-16 Miscellaneous Springs678

10-17 Summary680

Problems683

11 Rolling-Contact Bearings689

11-1 Bearing Types690

11-2 Bearing Life693

11-3 Bearing Load-Life Trade-off at Constant Reliability694

11-4 Bearing Survival： The Reliability-Life Trade-off696

11-5 Load-Life-Reliability Trade-off697

11-6 Combined Radial and Thrust Loading699

11-7 Variable Loading704

11-8 Selection of Ball and Cylindrical Roller Bearings709

11-9 Selection of Tapered Roller Bearings714

11-10 Adequacy Assessment for Selected Rolling-Contact Bearings724

11-11 Lubrication728

11-12 Mounting and Enclosure729

Problems732

12 Lubrication and Journal Bearings739

12-1 Types of Lubrication741

12-2 Viscosity741

12-3 Petroff’s Equation744

12-4 Stable Lubrication750

12-5 Thick-Film Lubrication751

12-6 Hydrodynamic Theory752

12-7 Design Considerations757

12-8 The Relations of the Variables759

12-9 Steady-State Conditions in Self-Contained Bearings722

12-10 Clearance781

12-11 Pressure-Fed Bearings792

12-12 Loads and Materials803

12-13 Bearing Types805

12-14 Thrust Bearings806

12-15 Boundary-Lubricated Bearings807

Problems823

13 Gearing-General831

13-1 Types of Gears832

13-2 Nomenclature833

13-3 Tooth Systems835

13-4 Conjugate Action837

13-5 Involute Properties838

13-6 Fundamentals839

13-7 Contact Ratio844

13-8 Interference845

13-9 The Forming of Gear Teeth848

13-10 Straight Bevel Gears850

13-11 Parallel Helical Gears851

13-12 Worm Gears855

13-13 Gear Trains856

13-14 Force Analysis—Spur Gearing860

13-15 Force Analysis—Bevel Gearing863

13-16 Force Analysis—Helical Gearing866

13-17 Force Analysis—Worm Gearing869

13-18 Gear Ratios and Numbers of Teeth874

13-19 Gear-Shaft Speeds and Bearings878

Problems883

14 Spur and Helical Gears897

14-1 The Lewis Bending Equation898

14-2 Surface Durability907

14-3 AGMA Stress Equations909

14-4 AGMA Strength Equations910

14-5 Geometry Factors I and J （ZI and YI ）915

14-6 Elastic Coefficient C p（Z E）920

14-7 Dynamic Factor K ’V920

14-8 Overload Factor K O922

14-9 Surface Condition Factors Cf and Z R922

14-10 Size Factor K s923

14-11 Load-Distribution Factor K m or K H923

14-12 Hardness-Ratio Factor C H924

14-13 Load Cycles Factors YN and Z N926

14-14 Reliability Factors KR and Y Z927

14-15 Temperature Factors KT and Y θ928

14-16 Rim-Thickness Factor KB928

14-17 Safety Factors SF and SH929

14-18 Analysis929

14-19 An Adequacy Assessment of a Gear Mesh940

14-20 Design of a Gear Mesh942

Problems947

15 Bevel and Worm Gears951

15-1 Bevel Gearing—General952

15-2 Bevel-Gear Stresses and Strengths954

15-3 AGMA Equation Factors957

15-4 Straight-Bevel Gear Analysis969

15-5 Design of a Straight-Bevel Gear Mesh972

15-6 Worm Gearing—AGMA Equation974

15-7 Worm-Gear Analysis978

15-8 Designing a Worm-Gear Mesh980

15-9 Buckingham Wear Load985

Problems986

16 Clutches， Brakes， Couplings， and Flywheels991

16-1 Rudiments of Brake Analysis993

16-2 Internal Expanding Rim Clutches and Brakes999

16-3 External Contracting Rim Clutches and Brakes1008

16-4 Band-Type Clutches and Brakes1011

16-5 Friction-Contact Axial Clutches1013

16-6 Disk Brakes1016

16-7 Cone Clutches and Brakes1022

16-8 Self-Locking Tapers and Torque Capacity1024

16-9 Energy Considerations1026

16-10 Temperature Rise1027

16-11 Friction Materials1031

16-12 Miscellaneous Clutches and Couplings1032

16-13 Flywheels1034

16-14 Adequacy Assessment for Clutches and Brakes1039

Problems1040

17 Flexible Mechanical Elements 104917-1 Belts1050

17-2 Flat- and Round-Belt Drives1053

17-3 V Belts1069

17-4 Timing Belts1077

17-5 Roller Chain1079

17-6 Wire Rope1088

17-7 Flexible Shafts1097

Problems 1098

18 Shafts and Axles1107

18-1 Introduction1108

18-2 Sufficing Geometric Constraints1111

18-3 Sufficing Strength Constraints1120

18-4 The Adequacy Assessment1128

18-5 Shaft Materials1134

18-6 Hollow Shafts1135

18-7 Critical Speeds1135

18-8 Shaft Design1141

18-9 Computer Considerations1142

Problems1146

Appendixes1153

A Statistical Relations1153

B Linear Regression1161

C Propagation of Error Relations1163

D Simulation1165

E Useful Tables1169

F Solutions to Selected Problems1231

Index1237