Mechanical Design

Front Cover......Page 1
Title Page......Page 5
Copyright......Page 6
Contents\n......Page 7
Preface\n......Page 17
Symbols\n......Page 19
Part I - Setting Project Methodology......Page 23
1.2 APPROACHES TO DESIGNING AND DEVELOPING THE PRODUCT......Page 25
1.3 THE MAIN ACTIVITY IN DESIGNING A PRODUCT......Page 27
1.5 CONCURRENT ENGINEERING......Page 29
1.6 LIFE CYCLE DESIGN......Page 31
1.7 DESIGN FOR X......Page 32
1.8 CORRELATING AND CHOOSING DESIGN TOOLS......Page 33
1.9 OTHER TOOLS AND DESIGN APPROACHES......Page 34
2.2 DESIGN AND ENVIRONMENTAL REQUIREMENTS......Page 37
2.3 DESIGN FOR ENVIRONMENT......Page 38
2.5 IMPLEMENTING DESIGN FOR ENVIRONMENT AND GENERAL GUIDELINES......Page 39
2.6 PRODUCT LIFE CYCLE AND ENVIRONMENTAL IMPACT......Page 40
2.7 ENVIRONMENTAL IMPACT OF THE PRODUCT......Page 41
2.8 MODELING THE LIFE CYCLE......Page 42
2.9 LIFE CYCLE ASSESSMENT......Page 45
2.10 INTRODUCING ENVIRONMENTAL FACTORS IN THE DESIGN PROCESS......Page 48
2.11 INTEGRATING LIFE CYCLE AND DESIGN......Page 49
2.12 INTEGRATING ENVIRONMENTAL ASPECTS WITH PRODUCT DEVELOPMENT......Page 51
2.13 ENVIRONMENTAL STRATEGIES FOR PRODUCT PLANNING......Page 52
2.14 METHODOLOGICAL SETUP AND DESIGN TOOLS......Page 57
2.15 THE ROLE OF DESIGN FOR X IN DESIGNING FOR ENVIRONMENTAL REQUISITES......Page 58
2.16 TOOLS FOR INTEGRATED DESIGN: OVERVIEW......Page 62
Part II - The Properties of Design Materials......Page 65
3.2 METALLIC MATERIALS AND ALLOYS......Page 67
3.3 SOLID STATE AND STRUCTURE OF METALS......Page 68
3.4 IRON–CARBON ALLOYS......Page 70
3.5 NON-FERROUS METALS AND THEIR ALLOYS......Page 78
3.6 AN OUTLINE OF POLYMERIC MATERIALS......Page 85
3.7 OUTLINE OF COMPOSITES......Page 91
3.8 OUTLINE OF CERAMIC MATERIALS......Page 96
4.1 INTRODUCTION......Page 99
4.2 TENSILE STRESS TESTS......Page 100
4.3 STATIC ELASTOPLASTIC CHARACTERIZATION......Page 101
4.4 PLASTIC CONSTITUENT LINK......Page 105
4.5 NOTES ABOUT MECHANICAL CHARACTERIZATION TESTS......Page 108
4.6 NOTES ABOUT TECHNOLOGICAL CHARACTERIZATION TESTS......Page 116
4.7 METALLURGIC TESTS......Page 123
4.8 TUBE TESTS......Page 124
4.9 TESTS ON STEEL WIRES......Page 126
4.10 FINAL INDICATIONS......Page 127
5.2 MECHANICAL BEHAVIOR OF MATERIALS......Page 129
5.3 CONDITIONS OF MECHANICAL STRESS......Page 130
6.1 GENERAL CONCEPTS......Page 149
6.2 LOAD CHARACTERISTICS......Page 151
6.3 FATIGUE DIAGRAMS......Page 153
6.4 THERMOGRAPHY TO DEFINE FATIGUE BEHAVIOR......Page 155
6.5 DETERMINING THE FATIGUE CURVE......Page 158
6.6 FATIGUE LIMIT BY THERMAL SURFACE ANALYSIS OF SPECIMEN IN MONO AXIAL TRACTION TEST......Page 160
6.7 RESIDUAL RESISTANCE OF A MECHANICAL COMPONENT......Page 162
6.8 THE FACTORS INFLUENCING FATIGUE......Page 165
6.9 SAFETY FACTOR......Page 167
6.10 STRESS CONCENTRATION FACTOR......Page 169
6.11 FATIGUE RESISTANCE OF WELDED MACHINE COMPONENTS......Page 175
6.12 INTERNAL MATERIAL DAMPING......Page 177
6.13 TEST MACHINES......Page 179
6.14 CONCLUSIONS ABOUT DESIGNING A MECHANICAL COMPONENT......Page 180
7.2 DESIGN REQUIREMENTS AND CORRELATION WITH MATERIALS......Page 183
7.4 APPROACHES TO THE BEST CHOICE OF MATERIALS......Page 186
7.5 TOOLS FOR SELECTION OF PROPERTIES......Page 187
7.6 INTEGRATED SELECTION TOOLS......Page 192
Part III - Design of Mechanical Components and Systems......Page 201
8.2 STRESSES IN A THREE-DIMENSIONAL OBJECT......Page 203
8.3 MAIN STRESSES......Page 206
8.4 MOHR’S CIRCLES......Page 207
8.5 FAILURE HYPOTHESIS......Page 208
8.6 FAILURE HYPOTHESES: A COMPARISON......Page 217
9.1 INTRODUCTION......Page 219
9.2 APPLICATION TO ROLLING CONTACT BEARINGS......Page 231
9.3 APPROACH......Page 232
9.4 EQUIVALENT IDEAL STRESS IN HERTZIAN CONTACT......Page 234
9.5 LOADS ON THE BALL BEARINGS......Page 235
10.1 INTRODUCTION......Page 239
10.2 PRISMATIC PAIR OF INFINITE AND FINITE LENGTH......Page 242
10.3 CALCULATION OF MICHELL THRUST BEARINGS......Page 245
10.4 JOURNAL-BEARING PAIR: SETTING REYNOLDS’ EQUATION AND CLEARANCE HEIGHT......Page 248
10.5 INFINITE LENGTH JOURNAL-BEARING PAIR......Page 249
10.6 JOURNAL-BEARING PAIR OF FINITE LENGTH: SCHIEBEL’S FORMULAE......Page 254
10.7 JOURNAL-BEARING WITH FINITE LENGTH: BOSCH’S APPROXIMATE COMPUTATION......Page 258
10.8 JOURNAL-NARROW BEARING PAIR: OCVIRK’S HYPOTHESIS......Page 259
10.9 LUBRICATED JOURNAL WITH FINITE/INFINITE LENGTH: RAIMONDI–BOYD CALCULATION......Page 260
10.10 NOTES ON LUBRICANTS......Page 268
11.2 SHAFT MEASURING......Page 271
11.3 DEFORMATION LIMITS AND DETERMINATION OF ELASTIC DEFLECTIONS......Page 275
11.4 ROLLING-CONTACT BEARINGS (ANTI-FRICTION BEARINGS)......Page 279
11.6 BEARING ADJUSTMENT......Page 281
11.7 ASSEMBLY MODELS......Page 282
11.8 FRICTION BEARINGS......Page 288
12.1 SPLINED COUPLINGS......Page 293
12.2 SPLINES AND TONGUES......Page 295
12.3 TRANSVERSE SPLINES......Page 302
12.4 SPUR GEARS......Page 306
13.1 INTRODUCTION......Page 309
13.2 SPRING COMPUTATION......Page 310
13.3 BENDING SPRINGS......Page 313
13.4 TORSION SPRINGS......Page 341
13.5 COMPRESSION SPRINGS......Page 351
13.6 RESONANT SPRING CALCULATIONS......Page 355
14.2 BELTS......Page 361
14.3 SIZING BELTS......Page 362
14.4 TIMING BELTS......Page 364
14.5 PRECAUTIONS FOR TESTING DURABILITY......Page 365
Part IV - Design of Components and Mechanical Systems......Page 367
15.3 DEFINITIONS AND NOMENCLATURE......Page 369
15.4 GEAR SIZING......Page 374
15.5 CUT AND OPERATING CONDITIONS......Page 375
15.6 INVOLUTE EQUATION......Page 376
15.7 DETERMINING TOOTH THICKNESS......Page 377
15.8 TOOTH BASE FILLETS......Page 381
15.9 EULER–SAVARY THEOREM......Page 383
15.10 INTERFERENCE AND SCHIEBEL’S FILLET......Page 384
15.11 MESHING......Page 387
15.12 EXPRESSING CONTACT SEGMENT AND ACTION ARC......Page 390
15.13 CONDITION OF NON-INTERFERENCE......Page 392
15.14 REDUCTION OF THE CONTACT LINE’S USABLE SEGMENT DUE TO INTERFERENCE......Page 395
15.15 SPECIFIC CREEP......Page 400
15.16 MODIFICATED GEARS......Page 403
15.17 GERMAN NORMS ON MODIFICATED GEARING......Page 413
15.18 LOADS WHEN ENGAGING GEARS......Page 415
15.19 VERIFICATION CALCULATIONS FOR GEAR RESISTANCE......Page 416
15.20 NOTES ON THE “AMERICAN” NORMS FOR CALCULATING TOOTHING (AGMA)......Page 424
15.21 DESIGN PHASES FOR A GEARING......Page 427
16.2 FIXING FLYWHEEL COMPONENTS......Page 429
16.3 FORCED HUB-SHAFT SHRINKING......Page 436
16.4 THE RELATIONSHIP BETWEEN INTERFERENCE AND THERMAL VARIATION......Page 443
17.2 SIZING AND VERIFYING PIPE STRENGTH......Page 445
17.3 STRENGTH VERIFICATION FOR PRESSURIZED VESSELS......Page 448
17.4 SOME OIL PIPE CONSIDERATIONS......Page 449
17.4 INSTABILITY IN EXTERNALLY PRESSED PIPES......Page 450
17.5 CALCULATIONS FOR FLANGE BOLTS......Page 453
17.6 FIXED FLANGE CALCULATIONS......Page 454
17.7 FREE FLANGE CALCULATION......Page 456
17.8 FLANGE BOLTS......Page 457
17.9 NOTES ON HOT METAL CREEP......Page 458
17.10 BRIEF NOTES ON TESTING CREEP......Page 464
18.1 INTRODUCTION......Page 465
18.2 WELDING DEFECTS......Page 466
18.3 WELD TESTS......Page 468
18.5 STATIC CALCULATION......Page 469
18.7 STATIC CALCULATION—HEAD AND COMPLETE PENETRATION WELD......Page 470
18.8 STATIC CALCULATION—WELDS WITH CORNER BEADS......Page 471
18.9 LOADS ON THE BEAD......Page 473
18.10 FATIGUE CALCULATION......Page 475
18.11 FATIGUE CALCULATION ACCORDING TO NORM CNR-UNI 10011......Page 476
18.12 SPOT WELDING......Page 478
18.13 RIVETED JOINT......Page 481
19.1 PRELIMINARY NOTIONS AND TYPES OF JOINTS......Page 489
19.2 RIGID JOINTS......Page 490
19.3 FIXED SEMI ELASTIC AND ELASTIC JOINTS......Page 497
19.4 PEG JOINTS......Page 500
19.5 SPRING JOINTS......Page 502
19.6 MOBILE JOINTS......Page 512
20.2 FRICTION CLUTCHES......Page 523
20.3 FLAT PLATE CLUTCHES......Page 528
20.4 CONE AND DOUBLE CONE CLUTCHES......Page 532
20.5 RADIAL BLOCK CLUTCHES......Page 534
20.6 SURPLUS CLUTCHES......Page 539
20.7 SAFETY CLUTCHES......Page 542
20.8 CENTRIFUGAL CLUTCHES......Page 543
21.1 INTRODUCTORY CONCEPTS......Page 551
21.2 DISC BRAKES......Page 552
21.3 PERFORMANCE AND DIMENSION ANALYSES......Page 556
21.4 DRUM BRAKES......Page 567
21.5 RIBBON BRAKES......Page 579
21.6 DIFFERENTIAL RIBBON BRAKES......Page 582
22.1 INTRODUCTION......Page 585
22.2 REVIEW FOR THE GEARS PROJECT......Page 586
22.3 DIMENSIONING OF THE BEVEL GEARS......Page 588
22.4 PROJECT OF PLANETARY REDUCER......Page 592
22.5 DIFFERENTIAL GEAR DIMENSIONS......Page 595
22.6 MEASUREMENT OF TIME GEARING......Page 597
22.7 DIMENSIONING OF THE SHAFT PINION AND CHOICE OF THE BEARINGS......Page 605
22.8 CHOICE OF THE DIFFERENTIAL BEARINGS BOX......Page 615
22.9 DIMENSIONING OF THE PINS......Page 618
22.10 DIMENSIONING OF THE BOX SCREWS......Page 622
22.11 DIMENSIONING OF THE SEMI-SHAFT......Page 623
APPENDIX......Page 628
CHAPTER 2......Page 639
CHAPTER 4......Page 640
CHAPTER 5......Page 641
CHAPTER 6......Page 643
CHAPTER 7......Page 645
PART III CHAPTER 8......Page 646
CHAPTER 9......Page 647
CHAPTER 10......Page 650
CHAPTER 11......Page 652
CHAPTER 13......Page 653
CHAPTER 15......Page 656
CHAPTER 17......Page 658
CHAPTER 18......Page 660
PART IV CHAPTER 19......Page 663
CHAPTER 20......Page 665
CHAPTER 21......Page 667
REFERENCES FOR THE SETTING PROJECT METHODOLOGY......Page 671