Mechanical Design Engineering Handbook,

1 Design
1.1 Introduction
1.2 The design process
1.3 Design models
1.3.1 Systematic design
1.3.2 Double diamond
1.3.4 Total and blended design
1.4 Design optimisation
1.5 Design reviews
1.6 The technology base
1.7 Conclusions
References
Nomenclature

2 Mechanics of engineering materials
2.1 Introduction
2.2 Materials and mechanics basics
2.3 Loading
2.3.1 Static loading
2.3.2 Dynamic loading
2.4 Deformation and fracture
2.4.1 Deflection
2.4.2 Strain
2.4.3 Stress
2.4.4 Fatigue
2.4.5 Buckling
2.5 Engineering properties
2.5.1 Young's modulus and Poisson's ratio
2.5.2 Yield and Elastic limit
2.5.3 Hardness
2.5.4 Toughness
2.6 Conclusions
References
Nomenclature

3 Material selection for performance
3.1 Design for stiffness
3.2 Design for strength
3.3 Design for light weight
3.4 Design for endurance
3.5 Design for corrosion resistance
3.6 Design for recyclability
3.7 Materials
3.7.1 Steel
3.7.2 Aluminium
3.7.3 Plastics
3.7.4 Composites
3.7.5 Ceramics
3.7.6 Natural materials
3.8 Conclusions
References
Nomenclature

4 Tribology
4.1 Introduction
4.2 Tribology basics
4.2.1 Surface Roughness
4.2.2 Contact mechanics
4.2.2.1 Elastic contact
4.2.2.2 Contact of rough surfaces
4.2.3 Friction
4.2.3.1 Adhesion
4.2.3.2 Deformation
4.2.4 Lubrication
4.2.4.1 Oils
4.2.4.2 Greases
4.2.4.3 Solid lubricants
4.2.5 Wear
4.2.5 Abrasion
4.2.5.1 Adhesion
4.2.5.2 Surface fatigue
4.2.5.3 Tribo-corrosion
4.2.5.4 Fretting
4.3 Design for efficiency
4.3.1 Friction, lubrication and energy losses
4.3.2 Improving efficiency in mechanical elements
4.3.3 Design of efficient, smooth-running systems
4.4 Design for durability
4.4.1 Wear, surface failure and durability
4.4.1.1 Deformation
4.4.1.2 Wear
4.4.1.3 Fatigue
4.4.1.4 Corrosion
4.4.2 Failure modes
4.4.2.1 Causes of failure
4.4.2.2 Identifying failure modes
4.4.3 Design of durable systems
4.5 Conclusions
References
Nomenclature

5 Journal bearings
5.1 Introduction
5.2 Sliding bearings
5.3 Design of boundary-lubricated bearings
5.4 Design of full film hydrodynamic bearings
5.4.1 Design charts for full-film hydrodynamic bearings
5.4.2 Alternative method for the design of full film hydrodynamic bearings
5.5 Conclusions
References
Nomenclature

6 Rolling element bearings
6.1 Introduction
6.2 Bearing life and selection
6.2.1 Simple Bearing life equation
6.2.2 Modified life equation
6.3 Bearing installation
6.3.1 Radial location
6.3.2 Preload
6.4 Conclusions
References
Nomenclature

7 Shafts
7.1 Introduction to shaft design
7.2 Shaft-hub connection
7.3 Shaft-shaft connection—couplings
7.4 Cams
7.5 Critical speeds and shaft deflection
7.5.1 Macaulay’s method for calculating the deflection of beams
7.5.2 Castigliano’s theorem for calculating shaft deflections
7.6 Analysis of transmission shafting
7.7 Detailed design case study
7.8 Conclusions
References
Nomenclature

8 Gears
8.1 Introduction
8.2 Construction of gear tooth profiles
8.3 Gear trains
8.3.1 Manually shifted automotive transmissions
8.3.2 Epicyclic gear trains
8.3.3 Rack and pinion gears
8.4 Tooth systems
8.5 Force analysis
8.5.1 Introduction to gear stresses
8.5.2 Bending stresses
8.6 Simple gear selection procedure
8.7 Condition monitoring
8.8 Conclusions
References
Nomenclature

9 Spur and helical gear stressing
9.1 Introduction
9.2 Failure due to contact stresses
9.3 AGMA equations for bending and contact stress
9.4 Gear selection procedure
9.5 Conclusions
References
Nomenclature

10 Bevel gears
10.1 Introduction
10.2 Force analysis
10.3 Stress analysis
10.4 Calculation procedure summary
10.5 Conclusions
References
Nomenclature

11 Worm gears
11.1 Introduction
11.2 Force analysis
11.3 AGMA equations
11.4 Design procedure
11.5 Conclusions
References
Nomenclature

12 Belt and chain drives
12.1 Introduction
12.2 Belt drives
12.2.1 Belt selection
12.2.2 Wedge belt selection
12.2.3 Synchronous belts
12.2.4 Flat belt drives
12.3 Chain drives
12.3.1 Roller chain selection
12.4 Conclusions
References
Nomenclature

13 Clutches and brakes
13.1 Introduction
13.2 Clutches
13.2.1 Design of disc clutches
13.3 Brakes
13.3.1 Disc brakes
13.3.2 Drum brakes
13.3.3 Short-shoe external drum brakes
13.3.4 Long-shoe external drum brakes
13.3.5 Long-shoe internal drum brakes
13.3.6 Band brakes
13.4 Conclusions
References
Nomenclature

14 Seals
14.1 Introduction to seals
14.2 Static seals
14.3 Dynamic seals
14.4 Labyrinth seals
14.5 Axial and bush seals
14.6 Seals for reciprocating components
14.7 Conclusions
References
Nomenclature

15 Springs
15.1 Introduction
15.2 Helical compression springs
15.3 Helical extension springs
15.4 Helical torsion springs
15.5 Leaf springs
15.6 Belleville spring washers
15.7 Conclusions
References
Nomenclature

16 Fastening and power screws
16.1 Introduction to permanent and non-permanent fastening
16.2 Threaded fasteners
16.3 Power screws
16.4 Rivets
16.5 Adhesives
16.6 Welding
16.7 Snap fasteners
16.8 Conclusions
References
Nomenclature

17 Wire rope
17.1 Introduction
17.2 Wire rope selection
17.3 Wire rope terminations
17.4 Conclusions
References
Nomenclature

18 Pneumatics and hydraulics
18.1 Introduction
18.2 Pressure
18.3 Hydraulic pumps
18.4 Air compressors and receivers
18.5 Filters
18.6 Control valves
18.7 Pneumatic and hydraulic actuators
18.8 Conclusions
References
Nomenclature

19 Tolerancing and precision engineering
19.1 Introduction
19.2 Component tolerances
19.2.1 Standard fits for holes and shafts
19.2.2 Interference fits
19.2.3 Machine capability
19.2.4 Geometric tolerancing
19.3 Statistical tolerancing
19.3.1 Sure-fit or extreme variability
19.3.2 Linear functions or tolerance chains
19.3.3 Several independent, uncorrelated random variables
19.3.4 Statistical design techniques and quality assurance
19.4 Precision engineering
19.4.1 Axial compressor clearance case study
19.4.2 Cordless and corded hand tools case study
19.4.3 Robot transmission case study
19.5 Conclusions
References
Nomenclature

Appendix: Tables of material properties