F O U R T H

E D I T I O N

Fundamentals of Machine Component

Design

ROBERT C. JUVINALL
Professor of Mechanical Engineering University of Michigan

KURT M. MARSHEK
Professor of Mechanical Engineering University of Texas at Austin

WILEY JOHN WILEY & SONS, INC.

Contents
PART 1 FUNDAMENTALS, 1 Chapter 1 A Broad Perspective of Mechanical Engineering Design, 3
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 An Overview of the Subject, 3 Safety Considerations, 4 Ecological Considerations, 10 Societal Considerations, 12 Overall Design Considerations, 14 Systems of Units, 15 Methodology for Solving Machine Component Problems, 19 Work and Energy, 21 Power, 23 Conservation of Energy, 24 4.2 Axial Loading, 117 4.3 Direct Shear Loading, 119 4.4 Torsional Loading, 121 4.5 Pure Bending Loading, Straight Beams, 123 4.6 Pure Bending Loading, Curved Beams, 124 4.7 Transverse Shear Loading in Beams, 130 4.8 Induced Stresses, Mohr Circle Representation, 136 4.9 Combined StressesMohr Circle Representation, 139 4.10 Stress Equations Related to Mohr's Circle, 142 4.11 Three-Dimensional Stresses, 144 4.12 Stress Concentration Factor, K, 145 4.13 Importance of Stress Concentration, 146 4.14 Residual Stresses Caused by YieldingAxial Loading, 151 4.15 Residual Stresses Caused by YieldingBending and Torsional Loading, 155 4.16 Thermal Stresses, 157 4.17 Importance of Residual Stresses, 160

Chapter 2 Force Analysis, 39

2.1 2.2 2.3 2.4 2.5 2.6 Introduction, 39 Equilibrium Equations and Free-Body Diagrams, 39 Beam Loading, 51 Locating Critical SectionsForce Flow Concept, 54 Load Division Between Redundant Supports, 56 Force Flow Concept Applied to Redundant Ductile Structures, 58

Chapter 5 Strain, Deflection, Stability, and Buckling, 174

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 Introduction, 174 Strain Definition, Measurement, and Mohr Circle Representation, 175 Analysis of StrainEquiangular Rosettes, 177 Analysis of StrainRectangular Rosettes, 179 Elastic Stress-Strain Relationships and Three-Dimensional Mohr Circles, 182 Deflection and Spring RateSimple Cases, 184 Beam Deflection, 186 Determining Elastic Deflections by Castigliano's Method, 189 Redundant Reactions by Castigliano's Method, 202 Euler Column BucklingElastic Instability, 207 Effective Column Length for Various End Conditions, 209 Column Design EquationsJ. B. Johnson Parabola, 210 Eccentric Column Loadingthe Secant Formula, 214 Equivalent Column Stresses, 216 Other Types of Buckling, 216 Finite Element Analysis, 218

Chapter 3 Materials Study, 79

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 Introduction, 79 The Static Tensile Test"Engineering" Stress-Strain Relationships, 80 Implications of the "Engineering" Stress-Strain Curve, 81 The Static Tensile Test"True" Stress-Strain Relationships, 84 Energy-Absorbing Capacity, 86 Estimating Strength Properties from Penetration Hardness Tests, 87 Use of "Handbook" Data for Material Strength Properties, 90 Machinability, 91 Cast Iron, 91 Steel, 92 Nonferrous-Alloys, 95 Plastics, 96 Material Selection Charts, 101 Engineering Material Selection Process, 105

Chapter 6 Theories of Failure, Safety Factors, and Reliability, 227

6.1 6.2 6.3 6.4 6.5 Introduction, 227 Types of Failure, 229 Fracture MechanicsBasic Concepts, 230 Fracture MechanicsApplications, 232 The "Theory" of Static Failure Theories, 242

Chapter 4 StressesStatic Body, 117 4.1 Introduction, 117

ix

Contents

Maximum-Normal-Stress Theory, 244 Maximum-Shear-Stress Theory, 244 Maximum-Distortion-Energy Theory (MaximumOctahedral-Shear-Stress Theory), 245 6.9 Modified Mohr Theory, 248 6.10 Selection and Use of Failure Theories, 249 6.11 6.12 6.13 6.14 6.15 Safety FactorsConcept and Definition, 251 Safety FactorsSelection of a Numerical Value, 253 Reliability, 255 Normal Distributions, 257 Interference Theory of Reliability Prediction, 259

6.6 6.7 6.8

9.8 9.9 9.10 9.11 9.12 9.13

Types of Wear, 360 Adhesive Wear, 361 Abrasive Wear, 363 Fretting, 364 Analytical Approach to Wear, 365 Curved-Surface Contact Stresses, 368

9.14 Surface Fatigue Failures, 375 9.15 Closure, 376

PART 2 APPLICATIONS, 3 8 3 Chapter 10 Power Screws and Threaded Fasteners, 385

10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 Introduction, 385 Thread Forms, Terminology, and Standards, 386 Power Screws, 391 Static Screw Stresses, 399 Threaded Fastener Types, 404 Fastener Materials and Methods of Manufacture, 406 Bolt Tightening and Initial Tension, 406 Thread Loosening and Thread Locking, 411 Bolt Tension with External Joint-Separating Force, 413 Bolt (or Screw) Selection for Static Loading, 418

Chapter 7 Impact Loading, 267

7.1 7.2 7.3 7.4 Introduction, 267 Stress and Deflection Caused by Linear and Bending Impact, 269 Stress and Deflection Caused by Torsional Impact, 277 Effect of Stress Raisers on Impact Strength, 280

Chapter 8 Fatigue Loading, 290

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 Introduction, 290 Basic Concepts, 290 Standard Fatigue Strengths (S'n) for Rotating Bending, 292 Fatigue Strengths for Reversed Bending and Reversed Axial Loading, 298 Fatigue Strength for Reversed Torsional Loading, 299 Fatigue Strength for Reversed Biaxial Loading, 300 Influence of Surface and Size on Fatigue Strength, 301 Summary of Estimated Fatigue Strengths for Completely Reversed Loading, 304 Effect of Mean Stress on Fatigue Strength, 304 Effect of Stress Concentration with Completely Reversed Fatigue Loading, 312 Effect of Stress Concentration with Mean Plus Alternating Loads, 315 Fatigue Life Prediction with Randomly Varying Loads, 322 Effect of Surface Treatments on the Fatigue Strength of a Part, 326 Mechanical Surface TreatmentsShot Peening and Others, 328

10.11 Bolt (or Screw) Selection for Fatigue Loading: Fundamentals, 425 10.12 Bolt (or Screw) Selection for Fatigue Loading: Using Special Test Data, 432 10.13 Increasing Bolted-Joint Fatigue Strength, 435

Chapter 11 Joining Components and Methods, 446

11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 Introduction, 446 Rivets, 446 Welding Processes, 448 Welded Joints Subjected to Static Axial and Direct Shear Loading, 452 Welded Joints Subjected to Static Torsional and Bending Loading, 455 Fatigue Considerations in Welded Joints, 460 Brazing and Soldering, 463 Adhesives, 463

8.15 Thermal and Chemical Surface-Hardening Treatments (Induction Hardening, Carburizing, and Others), 329 8.16 Fatigue Crack Growth, 329 8.17 General Approach for Fatigue Design, 334

Chapter 12 Various Springs, 469

12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 Introduction, 469 Torsion Bar Springs, 469 Coil Spring Stress and Deflection Equations, 470 Stress and Strength Analysis for Helical Compression SpringsStatic Loading, 476 End Designs of Helical Compression Springs, 479 Buckling Analysis of Helical Compression Springs, 480 Design Procedure for Helical Compression SpringsStatic Loading, 481 Design of Helical Compression Springs for Fatigue Loading, 485 Helical Extension Springs, 493

Chapter 9 Surface Damage Causes, 348

9.1 9.2 9.3 9.4 9.5 9.6 9.7 Introduction, 348 Corrosion: Fundamentals, 348 Corrosion: Electrode and Electrolyte Heterogeneity, 352 Design for Corrosion Control, 354 Corrosion Plus Static Stress, 356 Corrosion Plus Cyclic Stress, 359 Cavitation Damage, 360

Contents

XI

12.10 12.11 12.12

Beam Springs (Including Leaf Springs), 494 Torsion Springs, 500 Miscellaneous Springs, 501

Chapter 16 Gears: Helical, Bevel, and Worm, 647

16.1 16.2 16.3 16.4 16.5 16.6 16.7 16.8 16.9 16.10 16.11 16.12 16.13 Introduction, 647 Helical-Gear Geometry and Nomenclature, 650 Helical-Gear Force Analysis, 653 Helical-Gear-Tooth-Bending and Surface Fatigue Strengths, 656 Crossed Helical Gears, 657 Bevel Gear Geometry and Nomenclature, 658 Bevel Gear Force Analysis, 660 Bevel-Gear-Tooth-Bending and Surface Fatigue Strengths, 662 Bevel Gear Trains; Differential Gears, 664 Worm Gear Geometry and Nomenclature, 666 Worm Gear Force and Efficiency Analysis, 668 Worm-Gear-Bending and Surface Fatigue Strengths, 673 Worm Gear Thermal Capacity, 675

Chapter 13 Bearings: Lubrication and Sliding, 517

13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 13.9 13.10 13.11 13.12 13.13 13.14 13.15 13.16 Types of Lubricants, 517 Types of Sliding Bearings, 518 Types of Lubrication, 518 Basic Concepts of Hydrodynamic Lubrication, 519 Viscosity, 522 Temperature and Pressure Effects on Viscosity, 526 Petroff's Equation for Bearing Friction, 527 Hydrodynamic Lubrication Theory, 529 Design Charts for Hydrodynamic Bearings, 532 Lubricant Supply, 540 Heat Dissipation, and Equilibrium Oil Film Temperature, 542 Bearing Materials, 544 Hydrodynamic Bearing Design, 545 Boundary and Mixed-Film Lubrication,- 551 Thrust Bearings, 553 Elastohydrodynamic Lubrication, 554

Chapter 17 Shafts and Related Parts, 688

17.1 17.2 17.3 17.4 17.5 17.6 17.7 Introduction, 688 Provision for Shaft Bearings, 689 Mounting Parts onto Rotating Shafts, 689 Rotating-Shaft Dynamics, 692 Overall Shaft Design, 694 Keys, Pins, and Splines, 699 Couplings and Universal Joints, 701

Chapter 14 Rolling-Element Bearings, 559

14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 Comparison of Alternative Means for Supporting Rotating Shafts, 559 History of Rolling-Element Bearings, 563 Rolling-Element Bearing Types, 564 Design of Rolling-Element Bearings, 568 Fitting of Rolling-Element Bearings, 572 "Catalogue Information" for Rolling-Element Bearings, 573 Bearing Selection, 576 Mounting Bearings to Provide Properly for Thrust Load, 586

Chapter 18 Brakes and Clutches, 712

18.1 18.2 18.3 18.4 18.5 18.6 18.7 18.8 18.9 18.10 Introduction, 712 Disk Clutches, 712 Disk Brakes, 718 Energy Absorption and Cooling, 719 Cone Clutches and Brakes, 721 Short-Shoe Drum Brakes, 722 Eternal Long-Shoe Drum Brakes, 726 Internal Long-Shoe Drum Brakes, 733 Band Brakes, 735 Materials, 738

Chapter 15 Gears: Spur, 591

15.1 15.2 15.3 15.4 15.5 15.6 15.7 15.8 15.9 15.10 15.11 15.12 15.13 Introduction and History, 591 Geometry and Nomenclature, 592 Interference and Contact Ratio, 601 Gear Force Analysis, 604 Gear-Tooth Strength, 608 Basic Analysis of Gear-Tooth-Bending Stress (Lewis Equation), 608 Refined Analysis of Gear-Tooth-Bending Strength: Basic Concepts, 610 Refined Analysis of Gear-Tooth-Bending Strength: Recommended Procedure, 612 Gear-Tooth Surface DurabilityBasic Concepts, 619 Gear-Tooth Surface Fatigue AnalysisRecommended Procedure, 622 Spur Gear Design Procedures, 627 Gear Materials, 632 Gear Trains, 632

Chapter 19 Various Machine Components, 748

19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8 19.9 Introduction, 748 Rat Belts, 749 V-Belts,751 Toothed Belts, 755 Roller Chains, 755 Inverted-Tooth Chains, 758 History of Hydrodynamic Drives, 759 Fluid Couplings, 760 Hydrodynamic Torque Converters, 764

Appendix A Units, A-l A-la Conversion Factors for British Gravitational, English, and SI Units, A-l

Xll

Contents

A-lb Conversion Factor Equalities Listed by Physical Quantity, A-2 * A-2a Standard SI Prefixes, A-4 A-2b SI Units and Symbols, A-5 A-3 A-4 A-5 Suggested SI Prefixes for Stress Calculations, A-6 Suggested SI Prefixes for Linear-Deflection Calculations, A-6 Suggested SI Prefixes for Angular-Deflection Calculations, A-6

Appendix B Properties of Sections and Solids, A-7

B-la Properties of Sections, A-7 B-lb Dimensions and Properties of Steel Pipe and Tubing Sections, A-8 B-2 Mass and Mass Moments of Inertia of Homogeneous Solids, A-10

Appendix C Material Properties and Uses, A-11

C-l Physical Properties of Common Metals, A-11 C-2 Tensile Properties of Some Metals, A-12 C-3a Typical Mechanical Properties and Uses of Gray Cast Iron, A-13 C-3b Mechanical Properties and Typical Uses of Malleable Cast Iron, A-14 C-3c Average Mechanical Properties and Typical Uses of Ductile (Nodular) Iron, A-15 C-4a Mechanical Properties of Selected Carbon and Alloy Steels, A-16 C-4b Typical Uses of Plain Carbon Steels, A-18 C-5a Properties of Some Water-Quenched and Tempered Steels, A-19 C-5b Properties of Some Oil-Quenched and Tempered Carbon Steels, A-20 C-5c Properties of Some Oil-Quenched and Tempered Alloy C-6 C-7 C-8 C-9 Steels, A-21 Effect of Mass on Strength Properties of Steel, A-22 Mechanical Properties of Some Carburizing Steels, A-23 Mechanical Properties of Some Wrought Stainless Steels, A-24 Mechanical Properties of Some ton-Based Superalloys, A-25

C-10 Mechanical Properties, Characteristics, and Typical Uses of Some Wrought Aluminum Alloys, A-26 C-ll Tensile Properties, Characteristics, and Typical Uses of Some Cast-Aluminum Alloys, A-27 C-12 Temper Designations for Aluminum and Magnesium Alloys, A-28 C-13 Mechanical Properties of Some Copper Alloys, A-29 C-14 Mechanical Properties of Some Magnesium Alloys, A-30 C-15 Mechanical Properties of Some Nickel Alloys, A-31 C-16 Mechanical Properties of Some Wrought-Titanium Alloys, A-32 C-17 Mechanical Properties of Some Zinc Casting Alloys, A-33 C-18a Representative Mechanical Properties of Some Common Plastics, A-34 C-18b Properties of Some Common Glass-Reinforced and Unreinforced Thermoplastic Resins, A-35 C-18c Typical Applications of Common Plastics, A-36 C-19 Material Classes and Selected Members of Each Class, A-37 C-20 Designer's Subset of Engineering Materials, A-38 C-21 Processing Methods Used Most Frequently with Different Materials, A-39 C-22 Joinability of Materials, A-40 C-23 Materials for Machine Components, A-41 C-24 Relations Between Failure Modes and Material Properties, A-43

Appendix D Shear, Moment, and Deflection Equations for Beams, A-44

D-l D-2 D-3 D-4 Cantilever Beams, A-44 Simply Supported Beams, A-45 Beams with Fixed Ends, A-47 Program for Determining Elastic Deflections of Stepped Shafts, A-48

Appendix E
E-l

Fits and Tolerances, A-52

Fits and Tolerances for Holes and Shafts, A-52

Index

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