Mechanical Engineering Design

Principles and Concepts

SIRAJ AHMED
Professor and Head
Department of Mechanical Engineering
Maulana Azad National Institute of Technology
Bhopal

PHI Learning PGteO IWK

Delhi-110092
2014
 Contents

Foreword xvii

Preface xix

Acknowledgements xxi

List of Symbols xxiii

1. Engineering Design 3-25

1.1 Introduction 3

1.2 Design Process 3

1.2.1 Recognition of Need 3

1.2.2 Definition of the Problem 4

1.2.3 Synthesis 5
1.2.4 Analysis and Optimization 5

1.2.5 Finite Element Analysis (FEA) 5

1.2.6 Evaluation 6

1.2.7 Presentation 7
1.3 Machine Design 8
1.4 Factor of Safety 8
1.5 Fail-Safe Design 10

1.6 Safe-Life Design 11

1.7 Design Considerations 11

1.8 Tolerances 16
1.9 Fits 17
1.10 Material Selection 19
1.10.1 Methods of Material Selection 23
vii
Viii Contents

1.10.2 Economical and Practical Consideration 24

1.10.3 in Material Selection 24
Steps
Review 25
Questions

2. Product Design 26-46

2.1 Introduction 26
2.2 Product Design 27
2.2.1 Product
Design Steps 27
2.3 Types of
Design 30
2.4 Modelling 32
2.5 Simulation 36
2.6 Design Standards 36
2.7 Creativity and Problem Solving 36
2.7.1 Brainstorming 37
2.7.2 Problem Solving 37
2.7.3 Innovation 38
2.8 Reliability inDesign 38
2.8.1 Reliability Theory 38
2.9 Embodiment Design 39
2.10 Detailed Design 40
2.11 40
Design for Manufacture (DFM)
2.12 Value Analysis 40

2.13 Need Analysis 41

2.14 41
Concept Selection Technique
2.15 Industrial Design 42

2.15.1 Aesthetic 42

2.16 Concurrent 43
Engineering
2.17 Reverse Engineering 44

Review Questions 46

3. Ergonomics: Human Factor Engineering 47-56

3.1 Introduction 47

3.2 Body Posture and Movement 48

3.2.1 Sitting Posture 48
3.2.2 Standing Posture 49

3.3 Principles of Biomechanics 50

3.4 Physiological Principles 55

3.5 Anthropometric Principles 55

Review Questions 56

4. Economic Consideration 57-61

4.1 Introduction 57

Time Value of 57
4.2 Money
 Contents M ix

4.3 Cost Evaluation 58

4.4 Life Cycle Costing (LCC) 61

Review Questions 61

5. Theories of Elastic Failure 62-74

5.1 Introduction 62
5.2 Maximum Principal Stress Theory 62
5.3 Maximum Shear Stress Theory 64

5.4 Maximum Principal Strain Theory 65

5.5 Maximum Strain Energy Theory 66

5.6 Maximum Shear Strain Energy Theory 67

5.7 Graphical Representation of Failure Theories 68

Review Questions 73

6. Impact Load 75-91

6.1 Introduction 75
6.2 Suddenly Applied Loads 77
6.3 Strain Energy 77
6.4 Impact Load: Axial Application 78
6.5 Impact Load: Bending Applications 83
Review Questions 89

7. Contact Stresses 92-98

7.1 Introduction 92
7.2 Cases of Contact Stresses 93
7.2.1 Contact Stress in Two Curved Surfaces 93
7.2.2 Contact Stress between Two Parallel Cylinders 94
7.2.3 Contact of Gears 96
Review Questions 98

8. Residual Stress 99-107

8.1 Introduction 99
8.2 Reasons of Residual Stresses 100
8.2.1 Mechanical Processes 100
8.2.2 Machining 101
8.2.3 Chemical Treatment 102
8.2.4 Heat Treatment 103
8.2.5 Welds 104
8.2.6 Castings 105
8.3 Measurement of Residual Stress 105
8.3.1 Hole-Drilling Method 105
8.3.2 X-Ray Diffraction 106
Review Questions 107
X Contents

9. Fatigue ,
108-129

9.1 Introduction 108

109
9.2 Fatigue Testing
9.2.1 S-N Curve 110

9.3 of
Loading 112
Types
9.4 Endurance Limit Modifying Factors 114

9.5 Stress Concentration and Notch Sensitivity 116

9.5.1 Stress Concentration 116

9.6 Effect of Mean Stress 118

9.7 Design against Fatigue 119

9.8 Multi-axial Stress 122

9.9 Cumulative
Fatigue Damage ,
123

9.10 Combating Fatigue 124

Review 126
Questions

10. Fracture Mechanics 130-136

10.1 Introduction 130

10.2 Stress Concentration 130

10.3 Three Modes 131

10.4 Energy Variation in Cracked Bodies 132

10.4.1 Constant Displacement 132

10.4.2 Constant Loading 133

10.5 Linear Elastic Fracture Mechanics (LEFM) 134

10.5.1 Griffith's Criterion for Fracture 134

10.5.2 Irwin's Analysis 135

Review Questions 136

11. 137-160
Creep
11.1 Introduction 137

11.2 Creep Test 137

11.3 Presentation of Creep Data 143

11.4 Stress-Rupture Test 146

11.4.1 Time to Rupture 146

11.5 Creep under Bi-axial Stresses 148

11.6 Parameter Methods 149

11.6.1 Larson-Miller Parameter 150

11.6.2 Sherby-Dorn Parameter <

150

11.6.3 Manson-Haferd Parameter 153

11.7 Stress Relaxation 154

11.8 Creep-Resistant Alloys 156

11.9 Super Alloys 157

Review 158
Questions
 Contents H xi

12. Wear 161-169

12.1 Introduction 161

162
12.2 Type of Wear
12.2.1 Adhesive Wear 162

12.2.2 Abrasive Wear 163

12.2.3 Erosive Wear 164
12.2.4 Fretting 166
12.2.5 Corrosive Wear 166

12.2.6 Wear 167

Fatigue
12.3 Identifying the Wear Process 167

12.4 Steps for Wear Analysis 168

12.4.1 Physical Measurements 168

Review Questions 169

13. Mechanical Vibration 170-191

13.1 Introduction 170

13.2 Simple Harmonic Motion 170

13.3 Free Vibrations 172

13.3.1 Free Longitudinal Vibrations 173

13.4 Damped Vibrations 176

13.4.1 Logarithmic Decrement 179

13.5 Forced Vibrations 180

13.5.1 Graphical Solution 182

13.6 Vibration Isolation and Transmissibility 184

13.7 Transverse Vibrations 185

13.7.1Single Concentrated Load 185

13.7.2Uniformly Loaded Shaft 186

13.8 Shaft Carrying Several Loads 188

13.8.1 Dunkerley's Method 188

13.8.2 Energy Method 188

13.9 Whirling of Shaft 189

Review Question 191

192-206
14. Optimization of Design
14.1 Introduction 192

14.2 Optimization Methods 193

14.2.1 Differential Calculus 194

14.2.2 Lagrange Multipliers 195

14.2.3 Linear Programming 198

14.3 Search Methods 199

14.3.1 Uniform Search 199

Xii Contents

14.3.2 Fibonacci Search 200

14.3.3 Rosen Brock's Method 200

Method 203
14.4 Non-linear Programming
Review Questions 206

15. Key and Coupling 209-217

15.1 Introduction 209

15.2 209
Key
15.2.1 Spline 211

15.3 Flange Coupling 211

Review Questions 216

16. Knuckle Joint 218-221

16.1 Introduction 218

16.2 Knuckle Joint 218
Review Questions 220

17. Welded Joint 222-236

17.1 Introduction 222

17.2 of Welded Joints 222

Types
17.3 Strength of Welded Joints 223

223
17.3.1 Strength of Butt Welded Joint
17.3.2 Strength of Parallel Fillet Welded Joint 224

17.3.3 Strength of Transverse Fillet Welded Joint 226

17.3.4 Maximum Shear Stress in Parallel Fillet Weld 227
17.3.5 Maximum Shear Stress in Transverse Fillet Weld 227

Loaded Welded Joint 227

17.3.6 Axially Unsymmetrical
17.3.7 Eccentrically Loaded Weld Joint 229
17.3.8 Welded Joint Subjected to Bending Moment 232
17.3.9 Welded Joint Subjected to Torsion 234
Review Questions 235

18. Crane Hook 237-243

18.1 Introduction 237

18.2 Crane Hook Design 237

18.2.1 Analysis of Hook Sections 238
18.2.2 Crane Shank 240
18.2.3 of Crane Hook 240
Eye
Review Questions 243
 Contents M Xltt

19. Power Screw 244-255

19.1 Introduction 244

19.2 Design of Power Screw 244

19.2.1 Stresses in Screw and Nut 245

19.3 Design of Screw Jack 247

19.3.1 Efficiency of Screw Jack 248
19.3.2 Friction Torque in Collar 250
19.3.3 Material of Screw and Nut 250
Review Questions 255

20. Belt, Rope and Chain 256-268

20.1 Introduction 256

20.2 Belt Drive 256
20.3 Rope Drive 261
20.3.1 Wire Rope 261
20.4 Roller Chain 264
Review Questions 267

21. Clutches, Brakes and Flywheel ...269-286

21.1 Introduction 269

21.2 Clutch 269
21.2.1 Disc Clutch 270
21.2.2 Cone Clutch 273
21.3 Brakes 276
21.3.1 Single Block Brake 276
21.3.2 Double Block Brake 277
21.3.3 Internal Expanding Shoe Brake 277
21.3.4 Band Brake 278
21.4 Heat Generation 280
21.5 Flywheel '. 284
Review Questions 285

22. Springs 287-311

22.1 Introduction 287

22.2 Helical
Spring: Stress
Equation 288
22.2.1Spring Index 288
22.3 Helical Spring: Deflection Equation 289
22.3.1 Styles of End of Spring 292
22.4 Design against Static Load 293
22.4.1 Initial Tension 293
22.5 Design against Fluctuating Load 296
22.6 Helical Torsion Spring 299
Xiv Contents

22.7 Leaf Spring 302

22.7.1 StressAnalysis of Leaf Spring 303
306
22.7.2 Nipping of Leaf Spring
22.8 Material 309
Spring
Review Questions 311

23. Gear Design 312-347

23.1 Introduction 312

23.2 Different Types of Gears 312
23.2.1 Transmission Shafts Parallel to Each Other 312
23.2.2 Transmission Shafts Inclined to Each Other 314
23.2.3 Transmission Shafts Non-parallel and Non-intersecting 316
23.3 Gear Terminology 317
23.4 326
Design of Gears
23.5 Helical Gear 338
23.5.1 Force Analysis 339
23.5.2 Helical Gear Design 341
23.6 Gear Train 342
23.7 Manufacturing of Gear Teeth 345
23.8 Gear Lubrication 345

23.9 Gear Failure 346

Review Questions 346

24. Gear Box 348-369

24.1 Introduction 348

24.2 Gear Box Layout 351

24.3 Four Speed Gear Box 355

24.4 Overall Evaluation of Ray Diagram 362

24.5 Number of Teeth in Gears 363
Review Questions 369

25. Journal Bearing 370-395

25.1 Introduction 370

25.2 Lubrication Regimes 373
25.3 Formation of Film 377
25.4 Journal
Bearing Design 380
25.5 Hydrostatic Bearing Design 390
25.6 Boundary Lubricated Bearing Design 392
25.7 Bearing Materials 393
Review Questions 394

26. Rolling Contact Bearing 396-413

26.1 Introduction 396

26.2 Classification 396
 Contents <i XV

26.3 Design Considerations 399

26.4 Selection of Ball and Roller Bearing 405
26.5 Selection of Tapered Roller Bearing 409
Review Questions 413

27. Shaft 414-424

27.1 Introduction 414

27.2 Design for Static Loads 414

27.3 ASME
Approach 415

27.4 Reversed
Bending and Steady Torsion 417

27.5 The Soderberg Approach 418

Review Questions 422

28. Pressure Vessels 425-449

28.1 Introduction 425

28.2 Thin Cylinder under Internal Pressure 425
28.3 Thin Spherical Shell under Internal Pressure 426
28.4 Cylindrical Vessel with Hemispherical Ends 426
28.5 Volumetric Strain 428
28.6 Winding of Thin Cylinders
Wire 429
28.7 Centrifugal Stress in Thin Cylinder 432
28.8 Thick Cylinders 433
28.8.1 Internal Pressure Only 434
28.9 Thick Spherical Shells 437
28.10 Compound Tubes 438
28.11 Stresses in Interference Fits 439
28.12 Classification 443
28.13 Cylinder Heads and Cover Plates 444
28.14 Pipes and Tubes 445
28.15 Design Considerations 446
Review Questions 448

29. Internal Combustion Engine 450-490

29.1 Introduction 450

29.2 New Technological Options 451
29.3 Geometrical Properties 451
29.4 Engine Performance 454
29.5 Engine Design Tasks 462
29.6 Piston 463
29.7 Piston
Design 463
29.8 Connecting Rod 468
29.9 Crank Shaft 477
XVi Contents

478
29.10 Design Analysis
29.10.1 Crank at Angle of Maximum Bending Moment 478
29.10.2 Crank at Angle of Maximum Torsional Moment 480
29.10.3 Empirical Rules for Dimensions 483
Review Questions 488

30. Design of Centrifugal Pump 491-535

30.1 Introduction 491

30.2 Basic Theory 497

30.2.1 Ideal Head Equation 499

30.3 Classification of Pumps 503

30.4 Losses in Pump 507

30.5 Suction Head 507

30.6 of Centrifugal Pump 507

Design
of Impeller 508
30.7 Design
30.8 Design of Vane 512
30.8.1 Tangent Circular Arcs Method 513
30.8.2 Polar Coordinate Method 514
30.9 Design of Volute Casing 516
30.10 Design of Diffuser ...519

30.11 Multi-staging 520

30.12 Other Pump Impeller 520

30.13 Casing 521
30.14 Priming 521
30.15 Disc Stresses 521
30.16 Critical Speed 522
30.17 Selection of Materials 523

30.18 Design Example 523

30.18.1 Design of Impeller 524
30.18.2 Design of Vanes 528
30.18.3 Design of Volute Casing 531

30.18.4 Diffuser Design 533

Review Questions 534

31. Introduction to Machine Tool Design 536-542

31.1 Introduction 536

31.2 Machine Tool Drives 537
31.3 Machine Tool Design Overview 542

Appendix A: Statistics and Reliability 547-549

Appendix B: Material Properties 550-551

Appendix C: SI Units 552

Bibliography 553-554

Index 555-564