Machine Design and Mechanisms

9.

Design of Mechanical Elements

9.1.

Shafts and Axles

9.1.1.

Shaft Design Fundamentals

9.1.1.1.

9.1.1.2.

9.1.1.3.

Design Criteria

9.1.2.

Shaft Materials

9.1.2.1.

Selection Criteria

9.1.2.2.

Common Materials Used

9.1.2.3.

Heat Treatment Effects

9.1.3.

Stress Analysis in Shafts

9.1.3.1.

9.1.3.1.1.

Combined Bending and Torsion

9.1.3.1.2.

Equivalent Stress Calculations

9.1.3.2.

Fatigue Loading

9.1.3.2.1.

Fluctuating Stresses

9.1.3.2.2.

Fatigue Analysis

9.1.4.

Deflection Analysis in Shafts

9.1.4.1.

Lateral Deflection

9.1.4.1.1.

Slope and Deflection Limits

9.1.4.1.2.

Bearing Alignment

9.1.4.2.

Torsional Deflection

9.1.4.2.1.

Angle of Twist Limits

9.1.5.

Critical Speed of Shafts

9.1.5.1.

Whirling of Shafts

9.1.5.2.

Calculation Methods

9.1.5.3.

Rayleigh's Method

9.1.5.4.

Operating Speed Considerations

9.1.6.

Shaft Design Procedure

9.1.6.1.

Preliminary Sizing

9.1.6.2.

Detailed Analysis

9.1.6.3.

Design Verification

9.2.

Keys, Pins, and Splines

9.2.1.

Key Types and Applications

9.2.1.1.

9.2.1.2.

Rectangular Keys

9.2.1.3.

9.2.2.

Key Stress Analysis

9.2.2.1.

9.2.2.2.

9.2.3.

Pins and Cotter Joints

9.2.3.1.

9.2.3.2.

Stress Analysis

9.2.4.

9.2.4.1.

Involute Splines

9.2.4.2.

Straight-sided Splines

9.2.4.3.

Design and Analysis

9.3.

Fasteners and Connections

9.3.1.

Threaded Fasteners

9.3.1.1.

9.3.1.1.1.

9.3.1.1.2.

9.3.1.1.3.

9.3.1.1.4.

9.3.1.2.

Thread Standards and Specifications

9.3.1.2.1.

9.3.1.2.2.

Unified Thread Standard

9.3.1.3.

Preload and Joint Stiffness

9.3.1.3.1.

9.3.1.3.2.

Joint Stiffness Calculation

9.3.1.3.3.

9.3.1.4.

Static Loading of Bolted Joints

9.3.1.4.1.

Tension Loading

9.3.1.4.2.

9.3.1.4.3.

Combined Loading

9.3.1.5.

Fatigue Loading of Bolted Joints

9.3.1.5.1.

Stress Concentration

9.3.1.5.2.

Fatigue Analysis

9.3.1.5.3.

Preload Effects

9.3.2.

9.3.2.1.

9.3.2.1.1.

9.3.2.1.2.

9.3.2.1.3.

Plug and Slot Welds

9.3.2.2.

Welding Symbols

9.3.2.2.1.

9.3.2.2.2.

Drawing Conventions

9.3.2.3.

Stresses in Welded Joints

9.3.2.3.1.

Throat Area Calculations

9.3.2.3.2.

Stress Analysis Methods

9.3.2.4.

Fatigue of Welds

9.3.2.4.1.

Fatigue Categories

9.3.2.4.2.

Design Procedures

9.3.3.

9.3.3.1.

9.3.3.2.

Joint Configurations

9.3.3.3.

Stress Analysis

9.3.4.

Adhesive Bonding

9.3.4.1.

9.3.4.2.

9.3.4.3.

Stress Analysis

9.4.

9.4.1.

Rolling-Contact Bearings

9.4.1.1.

Types of Rolling Bearings

9.4.1.1.1.

9.4.1.1.1.1.

9.4.1.1.1.2.

Angular Contact

9.4.1.1.1.3.

Thrust Bearings

9.4.1.1.2.

Roller Bearings

9.4.1.1.2.1.

9.4.1.1.2.2.

9.4.1.1.2.3.

9.4.1.1.3.

Tapered Roller Bearings

9.4.1.2.

Bearing Life Analysis

9.4.1.2.1.

9.4.1.2.2.

Weibull Distribution

9.4.1.2.3.

Reliability Factors

9.4.1.3.

9.4.1.3.1.

Static Load Rating

9.4.1.3.2.

Dynamic Load Rating

9.4.1.3.3.

Equivalent Load Calculations

9.4.1.4.

Bearing Selection Procedures

9.4.1.4.1.

Life Requirements

9.4.1.4.2.

9.4.1.4.3.

Speed Limitations

9.4.1.4.4.

Environmental Factors

9.4.1.5.

Bearing Installation and Maintenance

9.4.1.5.1.

Mounting Methods

9.4.1.5.2.

Lubrication Requirements

9.4.1.5.3.

9.4.2.

Sliding-Contact Bearings

9.4.2.1.

Lubrication Theory

9.4.2.1.1.

Reynolds Equation

9.4.2.1.2.

Hydrodynamic Lubrication

9.4.2.1.3.

Hydrostatic Lubrication

9.4.2.1.4.

Boundary Lubrication

9.4.2.1.5.

Mixed Lubrication

9.4.2.2.

Journal Bearing Analysis

9.4.2.2.1.

Sommerfeld Number

9.4.2.2.2.

Bearing Performance Parameters

9.4.2.2.3.

Friction and Power Loss

9.4.2.2.4.

Heat Generation

9.4.2.3.

Bearing Design Parameters

9.4.2.3.1.

Length-to-Diameter Ratio

9.4.2.3.2.

Clearance Ratio

9.4.2.3.3.

Material Selection

9.4.2.4.

Thrust Bearings

9.4.2.4.1.

Fixed-pad Bearings

9.4.2.4.2.

Tilting-pad Bearings

9.5.

9.5.1.

Spring Fundamentals

9.5.1.1.

Spring Functions

9.5.1.2.

9.5.1.3.

9.5.2.

Spring Materials

9.5.2.1.

Selection Criteria

9.5.2.2.

Common Materials Used

9.5.2.2.1.

9.5.2.2.2.

9.5.2.2.3.

Stainless Steel

9.5.2.2.4.

Non-ferrous Alloys

9.5.2.3.

Material Properties

9.5.3.

Helical Compression Springs

9.5.3.1.

Geometry and Terminology

9.5.3.2.

Stress Analysis

9.5.3.2.1.

Torsional Stress

9.5.3.2.2.

Direct Shear Correction

9.5.3.2.3.

Curvature Correction

9.5.3.3.

Deflection Analysis

9.5.3.4.

9.5.3.4.1.

9.5.3.4.2.

9.5.3.4.3.

9.5.3.5.

Spring Design Procedure

9.5.4.

Helical Extension Springs

9.5.4.1.

Initial Tension

9.5.4.2.

9.5.4.2.1.

9.5.4.2.2.

9.5.4.3.

Stress Analysis

9.5.4.4.

Design Considerations

9.5.5.

Helical Torsion Springs

9.5.5.1.

Stress and Deflection

9.5.5.2.

Bending vs. Torsion

9.5.5.3.

End Configurations

9.5.6.

9.5.6.1.

Single-leaf Springs

9.5.6.2.

Multi-leaf Springs

9.5.6.3.

Stress Distribution

9.5.6.4.

9.5.7.

Spring Stability

9.5.7.1.

Buckling of Compression Springs

9.5.7.2.

Buckling Criteria

9.5.7.3.

Prevention Methods

9.5.8.

Spring Surge and Resonance

9.5.8.1.

Natural Frequency

9.5.8.2.

Surge Prevention

9.6.

9.6.1.

9.6.1.1.

9.6.1.2.

9.6.1.3.

Buttress Threads

9.6.2.

9.6.2.1.

Torque Requirements

9.6.2.2.

9.6.2.3.

Self-locking Conditions

9.6.3.

Buckling of Power Screws

9.6.3.1.

9.6.3.2.

9.6.4.

9.6.4.1.

9.6.4.2.

9.6.4.3.

Selection Procedures

9.7.

9.7.1.

Gear Fundamentals

9.7.1.1.

Gear Tooth Action

9.7.1.2.

Involute Tooth Profile

9.7.1.3.

Interference and Undercutting

9.7.2.

Gear Materials and Manufacturing

9.7.2.1.

Material Selection

9.7.2.1.1.

9.7.2.1.2.

9.7.2.1.3.

Non-metallic Gears

9.7.2.2.

9.7.2.2.1.

Through Hardening

9.7.2.2.2.

9.7.2.2.3.

Surface Treatments

9.7.2.3.

Manufacturing Processes

9.7.2.3.1.

Gear Cutting Methods

9.7.2.3.2.

9.7.2.3.3.

Quality Control

9.7.3.

Spur Gear Design

9.7.3.1.

Bending Stress Analysis

9.7.3.1.1.

9.7.3.1.2.

AGMA Bending Stress Equation

9.7.3.1.3.

Geometry Factors

9.7.3.2.

Surface Durability

9.7.3.2.1.

Pitting Resistance

9.7.3.2.2.

Contact Stress Analysis

9.7.3.2.3.

AGMA Surface Durability Equation

9.7.3.3.

AGMA Design Procedures

9.7.3.3.1.

9.7.3.3.2.

9.7.3.3.3.

Reliability Factors

9.7.4.

Helical Gear Design

9.7.4.1.

Geometry and Terminology

9.7.4.2.

9.7.4.2.1.

Tangential Forces

9.7.4.2.2.

9.7.4.2.3.

9.7.4.3.

Stress Analysis

9.7.4.4.

Design Considerations

9.7.5.

Bevel Gear Design

9.7.5.1.

Geometry and Terminology

9.7.5.2.

9.7.5.3.

Stress Analysis

9.7.5.4.

Mounting Considerations

9.7.6.

Worm Gear Design

9.7.6.1.

Geometry and Terminology

9.7.6.2.

Efficiency Analysis

9.7.6.3.

Thermal Considerations

9.7.6.4.

Lubrication Requirements

9.7.7.

Gear Trains Design

9.7.7.1.

Speed Reduction Requirements

9.7.7.2.

Torque Multiplication

9.7.7.3.

Efficiency Calculations

9.7.7.4.

Packaging Considerations

9.8.

Clutches, Brakes, and Couplings

9.8.1.

Friction Clutches

9.8.1.1.

9.8.1.1.1.

Single-plate Design

9.8.1.1.2.

Multi-plate Design

9.8.1.1.3.

Torque Capacity

9.8.1.1.4.

Pressure Distribution

9.8.1.2.

9.8.1.2.1.

Design Analysis

9.8.1.2.2.

Self-energizing Action

9.8.1.3.

Centrifugal Clutches

9.8.1.3.1.

Operating Principles

9.8.1.3.2.

Design Analysis

9.8.2.

Friction Brakes

9.8.2.1.

9.8.2.1.1.

Internal Expanding

9.8.2.1.2.

External Contracting

9.8.2.1.3.

Force and Torque Analysis

9.8.2.1.4.

Self-energizing Effects

9.8.2.2.

9.8.2.2.1.

Simple Band Brake

9.8.2.2.2.

Differential Band Brake

9.8.2.2.3.

Design Analysis

9.8.2.3.

9.8.2.3.1.

9.8.2.3.2.

9.8.2.3.3.

Heat Dissipation

9.8.3.

Energy Dissipation and Temperature Rise

9.8.3.1.

Heat Generation

9.8.3.1.1.

9.8.3.1.2.

Temperature Calculations

9.8.3.2.

Cooling Methods

9.8.3.2.1.

Natural Convection

9.8.3.2.2.

Forced Convection

9.8.3.2.3.

9.8.4.

9.8.4.1.

Rigid Couplings

9.8.4.1.1.

Flange Couplings

9.8.4.1.2.

Sleeve Couplings

9.8.4.1.3.

Design Analysis

9.8.4.2.

Flexible Couplings

9.8.4.2.1.

Universal Joints

9.8.4.2.2.

Oldham Couplings

9.8.4.2.3.

Elastomeric Couplings

9.8.4.3.

Fluid Couplings

9.8.4.3.1.

Operating Principles

9.8.4.3.2.

Performance Characteristics

9.8.4.4.

Alignment and Installation

9.8.4.4.1.

Alignment Tolerances

9.8.4.4.2.

Installation Procedures

9.9.

Flexible Mechanical Elements

9.9.1.

9.9.1.1.

9.9.1.1.1.

9.9.1.1.2.

Tension Analysis

9.9.1.1.3.

Power Transmission

9.9.1.1.4.

9.9.1.2.

9.9.1.2.1.

Belt Types and Standards

9.9.1.2.2.

9.9.1.2.3.

9.9.1.2.4.

Installation and Maintenance

9.9.1.3.

Synchronous Belts

9.9.1.3.1.

9.9.1.3.2.

9.9.1.4.

Belt Tension and Power Transmission

9.9.1.4.1.

Tight and Slack Side Tensions

9.9.1.4.2.

Centrifugal Effects

9.9.1.4.3.

9.9.2.

9.9.2.1.

9.9.2.1.1.

Chain Construction

9.9.2.1.2.

Chain Standards

9.9.2.1.3.

Sprocket Design

9.9.2.2.

9.9.2.2.1.

Construction Features

9.9.2.3.

Chain Selection and Design

9.9.2.3.1.

9.9.2.3.2.

Service Factors

9.9.2.3.3.

Chain Length Calculation

9.9.2.4.

Lubrication and Maintenance

9.9.2.4.1.

Lubrication Methods

9.9.2.4.2.

Wear Mechanisms

9.9.2.4.3.

Maintenance Procedures

9.9.3.

9.9.3.1.

Construction and Classification

9.9.3.1.1.

Wire Rope Components

9.9.3.1.2.

9.9.3.1.3.

9.9.3.2.

Materials and Properties

9.9.3.2.1.

9.9.3.2.2.

Strength Properties

9.9.3.2.3.

Flexibility Characteristics

9.9.3.3.

Stress Analysis

9.9.3.3.1.

Tension Stresses

9.9.3.3.2.

Bending Stresses

9.9.3.3.3.

Combined Stresses

9.9.3.4.

Applications and Safety

9.9.3.4.1.

Load Calculations

9.9.3.4.2.

9.9.3.4.3.

Inspection and Replacement

9.9.3.5.

Sheaves and Drums

9.9.3.5.1.

Design Requirements

9.9.3.5.2.

9.9.3.5.3.

Groove Specifications

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8. Failure Prevention

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1. Introduction to Machine Design