Valued as a standard in the course, Juvinall’s Fundamentals of Machine Component Design continues to focus on the fundamentals of component design - free body diagrams, force flow concepts, failure theories, and fatigue design, with applications to fasteners, springs, bearings, gears, clutches, and brakes. Problem-solving skills are developed by the implementation of a proven methodology which provides a structure for accurately formulating problems and clearly presenting solutions. This edition includes additional coverage of composites, the material selection process, and wear/wear theory, along with new and updated examples and homework problems.
Table of Contents
Preface v
Acknowledgments ix
Symbols xix
Part 1 Fundamentals 1
1 Mechanical Engineering Design in Broad Perspective 1
1.1 An Overview of the Subject 1
1.2 Safety Considerations 2
1.3 Ecological Considerations 6
1.4 Societal Considerations 7
1.5 Overall Design Considerations 9
1.6 Systems of Units 10
1.7 Methodology for Solving Machine Component Problems 12
1.8 Work and Energy 14
1.9 Power 16
1.10 Conservation of Energy 16
2 Load Analysis 33
2.1 Introduction 33
2.2 Equilibrium Equations and Free-Body Diagrams 33
2.3 Beam Loading 42
2.4 Locating Critical Sections - Force Flow Concept 45
2.5 Load Division Between Redundant Supports 47
2.6 Force Flow Concept Applied to Redundant Ductile Structures 48
3 Materials 70
3.1 Introduction 70
3.2 The Static Tensile Test - “Engineering” Stress–Strain Relationships 71
3.3 Implications of the “Engineering” Stress–Strain Curve 72
3.4 The Static Tensile Test - “True” Stress–Strain Relationships 74
3.5 Energy-Absorbing Capacity 75
3.6 Estimating Strength Properties from Penetration Hardness Tests 77
3.7 Use of “Handbook” Data for Material Strength Properties 79
3.8 Machinability 80
3.9 Cast Iron 80
3.10 Steel 81
3.11 Nonferrous Alloys 83
3.12 Plastics and Composites 84
3.13 Materials Selection Charts 89
3.14 Engineering Material Selection Process 90
4 Static Body Stresses 103
4.1 Introduction 103
4.2 Axial Loading 103
4.3 Direct Shear Loading 105
4.4 Torsional Loading 106
4.5 Pure Bending Loading, Straight Beams 108
4.6 Pure Bending Loading, Curved Beams 109
4.7 Transverse Shear Loading in Beams 114
4.8 Induced Stresses, Mohr Circle Representation 119
4.9 Combined Stresses - Mohr Circle Representation 121
4.10 Stress Equations Related to Mohr’s Circle 124
4.11 Three-Dimensional Stresses 125
4.12 Stress Concentration Factors, Kt 129
4.13 Importance of Stress Concentration 132
4.14 Residual Stresses Caused by Yielding - Axial Loading 133
4.15 Residual Stresses Caused by Yielding - Bending and Torsional Loading 137
4.16 Thermal Stresses 139
4.17 Importance of Residual Stresses 142
5 Elastic Strain, Deflection, and Stability 154
5.1 Introduction 154
5.2 Strain Definition, Measurement, and Mohr Circle Representation 154
5.3 Analysis of Strain - Equiangular Rosettes 156
5.4 Analysis of Strain - Rectangular Rosettes 159
5.5 Elastic Stress–Strain Relationships and Three-Dimensional Mohr Circles 161
5.6 Deflection and Spring Rate - Simple Cases 161
5.7 Beam Deflection 164
5.8 Determining Elastic Deflections by Castigliano’s Method 166
5.9 Redundant Reactions by Castigliano’s Method 177
5.10 Euler Column Buckling - Elastic Instability 180
5.11 Equivalent Column Length for Various End Conditions 182
5.12 Column Design Equations - J. B. Johnson Parabola 182
5.13 Eccentric Column Loading - the Secant Formula 186
5.14 Equivalent Column Stresses 187
5.15 Other Types of Buckling 188
5.16 Finite Element Analysis 189
6 Failure Theories, Safety Factors, and Reliability 196
6.1 Introduction 196
6.2 Types of Failure 198
6.3 Fracture Mechanics - Basic Concepts 198
6.4 Fracture Mechanics - Applications 200
6.5 The “Theory” of Static Failure Theories 209
6.6 Maximum-Normal-Stress Theory 210
6.7 Maximum-Shear-Stress Theory 210
6.8 Maximum-Distortion-Energy Theory (Maximum-Octahedral-Shear-Stress Theory) 212
6.9 Mohr Theory and Modified Mohr Theory 214
6.10 Selection and Use of Failure Theories 215
6.11 Safety Factors - Concept and Definition 216
6.12 Safety Factors - Selection of a Numerical Value 218
6.13 Reliability 219
6.14 Normal Distributions 220
6.15 Interference Theory of Reliability Prediction 221
7 Impact 230
7.1 Introduction 230
7.2 Stress and Deflection Caused by Linear and Bending Impact 232
7.3 Stress and Deflection Caused by Torsional Impact 239
7.4 Effect of Stress Raisers on Impact Strength 242
8 Fatigue 250
8.1 Introduction 250
8.2 Basic Concepts 250
8.3 Standard Fatigue Strengths (S′n ) for Rotating Bending 252
8.4 Fatigue Strengths for Reversed Bending and Reversed Axial Loading 256
8.5 Fatigue Strength for Reversed Torsional Loading 257
8.6 Fatigue Strength for Reversed Biaxial Loading 258
8.7 Influence of Surface and Size on Fatigue Strength 259
8.8 Summary of Estimated Fatigue Strengths for Completely Reversed Loading 262
8.9 Effect of Mean Stress on Fatigue Strength 262
8.10 Effect of Stress Concentration with Completely Reversed Fatigue Loading 269
8.11 Effect of Stress Concentration with Mean Plus Alternating Loads 271
8.12 Fatigue Life Prediction with Randomly Varying Loads 277
8.13 Effect of Surface Treatments on the Fatigue Strength of a Part 279
8.14 Mechanical Surface Treatments - Shot Peening and Others 281
8.15 Thermal and Chemical Surface-Hardening Treatments (Induction Hardening, Carburizing, and Others) 282
8.16 Fatigue Crack Growth 282
8.17 General Approach for Fatigue Design 286
9 Surface Damage 297
9.1 Introduction 297
9.2 Corrosion: Fundamentals 297
9.3 Corrosion: Electrode and Electrolyte Heterogeneity 300
9.4 Design for Corrosion Control 300
9.5 Corrosion Plus Static Stress 303
9.6 Corrosion Plus Cyclic Stress 305
9.7 Cavitation Damage 305
9.8 Types of Wear 306
9.9 Adhesive Wear 306
9.10 Abrasive Wear 307
9.11 Fretting 309
9.12 Analytical Approach to Wear 309
9.13 Curved-Surface Contact Stresses 312
9.14 Surface Fatigue Failures 318
9.15 Closure 319
Part 2 Applications 326
10 Threaded Fasteners and Power Screws 326
10.1 Introduction 326
10.2 Thread Forms, Terminology, and Standards 326
10.3 Power Screws 330
10.4 Static Screw Stresses 338
10.5 Threaded Fastener Types 342
10.6 Fastener Materials and Methods of Manufacture 344
10.7 Bolt Tightening and Initial Tension 345
10.8 Thread Loosening and Thread Locking 348
10.9 Bolt Tension with External Joint-Separating Force 350
10.10 Bolt (or Screw) Selection for Static Loading 353
10.11 Bolt (or Screw) Selection for Fatigue Loading: Fundamentals 359
10.12 Bolt Selection for Fatigue Loading: Using Special Test Data 364
10.13 Increasing Bolted-Joint Fatigue Strength 367
11 Rivets, Welding, and Bonding 376
11.1 Introduction 376
11.2 Rivets 376
11.3 Welding Processes 378
11.4 Welded Joints Subjected to Static Axial and Direct Shear Loading 380
11.5 Welded Joints Subjected to Static Torsional and Bending Loading 383
11.6 Fatigue Considerations in Welded Joints 388
11.7 Brazing and Soldering 389
11.8 Adhesives 390
12 Springs 395
12.1 Introduction 395
12.2 Torsion Bar Springs 395
12.3 Coil Spring Stress and Deflection Equations 396
12.4 Stress and Strength Analysis for Helical Compression Springs - Static Loading 400
12.5 End Designs of Helical Compression Springs 403
12.6 Buckling Analysis of Helical Compression Springs 404
12.7 Design Procedure for Helical Compression Springs - Static Loading 404
12.8 Design of Helical Compression Springs for Fatigue Loading 407
12.9 Helical Extension Springs 415
12.10 Beam Springs (Including Leaf Springs) 416
12.11 Torsion Springs 420
12.12 Miscellaneous Springs 422
13 Lubrication and Sliding Bearings 437
13.1 Types of Lubricants 437
13.2 Types of Sliding Bearings 437
13.3 Types of Lubrication 438
13.4 Basic Concepts of Hydrodynamic Lubrication 439
13.5 Viscosity 441
13.6 Temperature and Pressure Effects on Viscosity 444
13.7 Petroff’s Equation for Bearing Friction 445
13.8 Hydrodynamic Lubrication Theory 447
13.9 Design Charts for Hydrodynamic Bearings 449
13.10 Lubricant Supply 455
13.11 Heat Dissipation and Equilibrium Oil Film Temperature 457
13.12 Bearing Materials 459
13.13 Hydrodynamic Bearing Design 460
13.14 Boundary and Mixed-Film Lubrication 465
13.15 Thrust Bearings 466
13.16 Elastohydrodynamic Lubrication 467
14 Rolling-Element Bearings 471
14.1 Comparison of Alternative Means for Supporting Rotating Shafts 471
14.2 History of Rolling-Element Bearings 473
14.3 Rolling-Element Bearing Types 473
14.4 Design of Rolling-Element Bearings 481
14.5 Fitting of Rolling-Element Bearings 481
14.6 “Catalogue Information” for Rolling-Element Bearings 482
14.7 Bearing Selection 486
14.8 Mounting Bearings to Provide Properly for Thrust Load 493
15 Spur Gears 498
15.1 Introduction and History 498
15.2 Geometry and Nomenclature 499
15.3 Interference and Contact Ratio 506
15.4 Gear Force Analysis 509
15.5 Gear-Tooth Strength 512
15.6 Basic Analysis of Gear-Tooth-Bending Stress (Lewis Equation) 513
15.7 Refined Analysis of Gear-Tooth-Bending Strength: Basic Concepts 515
15.8 Refined Analysis of Gear-Tooth-Bending Strength: Recommended Procedure 516
15.9 Gear-Tooth Surface Durability - Basic Concepts 522
15.10 Gear-Tooth Surface Fatigue Analysis - Recommended Procedure 524
15.11 Spur Gear Design Procedures 528
15.12 Gear Materials 531
15.13 Gear Trains 532
16 Helical, Bevel, and Worm Gears 544
16.1 Introduction 544
16.2 Helical-Gear Geometry and Nomenclature 544
16.3 Helical-Gear Force Analysis 549
16.4 Helical Gear-Tooth-Bending and Surface Fatigue Strengths 551
16.5 Crossed Helical Gears 553
16.6 Bevel Gear Geometry and Nomenclature 553
16.7 Bevel Gear Force Analysis 555
16.8 Bevel Gear-Tooth-Bending and Surface Fatigue Strengths 556
16.9 Bevel Gear Trains; Differential Gears 558
16.10 Worm Gear Geometry and Nomenclature 560
16.11 Worm Gear Force and Efficiency Analysis 562
16.12 Worm-Gear-Bending and Surface Fatigue Strengths 566
16.13 Worm Gear Thermal Capacity 568
17 Shafts and Associated Parts 578
17.1 Introduction 578
17.2 Provision for Shaft Bearings 578
17.3 Mounting Parts onto Rotating Shafts 579
17.4 Rotating-Shaft Dynamics 580
17.5 Overall Shaft Design 585
17.6 Keys, Pins, and Splines 589
17.7 Couplings and Universal Joints 591
18 Clutches and Brakes 602
18.1 Introduction 602
18.2 Disk Clutches 602
18.3 Disk Brakes 607
18.4 Energy Absorption and Cooling 607
18.5 Cone Clutches and Brakes 608
18.6 Short-Shoe Drum Brakes 610
18.7 External Long-Shoe Drum Brakes 613
18.8 Internal Long-Shoe Drum Brakes 619
18.9 Band Brakes 620
18.1 Introduction 631
19.2 Flat Belts 631
19.3 V-Belts 633
19.4 Toothed Belts 636
19.5 Roller Chains 637
19.6 Inverted-Tooth Chains 639
19.7 History of Hydrodynamic Drives 640
19.8 Fluid Couplings 640
19.1 Introduction 651
20.2 Micro and Nanoscale Actuators 652
20.3 Micro and Nanoscale Bearings 657
20.4 Micro and Nanoscale Sensors 660
20.1 Introduction 674
21.2 Description of Original Hydra-Matic Transmission 674
21.3 Free-Body Diagram Determination of Gear Ratios and Component Loads 677
21.4 Gear Design Considerations 681
21.5 Brake and Clutch Design Considerations 681
21.1 Case Study Summary 685
22.2 Project Components 686
22.3 Project Organization 688
22.4 System Design Considerations 689
22.1 Introduction 747
F.2 Overview of Data in MIL-HDBK-5J 747
F.3 Advanced Formulas and Concepts Used in MIL-HDBK-5J 748
F.4 Mechanical and Physical Properties of 2024 Aluminum Alloy 752
F.5 Fracture Toughness and Other Miscellaneous Properties 756
F.1 Vectors: A Review 761
G.1 Standard Normal Distribution Table 764
H.2 Converting to Standard Normal Distribution 766
H.1 S-N Formula 767
I.1 Nominal Spur-Gear Quantities 769
J.2 Actual Quantities 771
J.3 Illustrative Example 771
Index 774
