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- Herausgeber: John Wiley & Sons
- Kategorie: Fachliteratur
- Sprache: Englisch
MACHINE DESIGN WITH CAD AND OPTIMIZATION
A guide to the new CAD and optimization tools and skills to generate real design synthesis of machine elements and systems
Machine Design with CAD and Optimization offers the basic tools to design or synthesize machine elements and assembly of prospective elements in systems or products. It contains the necessary knowledge base, computer aided design, and optimization tools to define appropriate geometry and material selection of machine elements. A comprehensive text for each element includes: a chart, excel sheet, a MATLAB® program, or an interactive program to calculate the element geometry to guide in the selection of the appropriate material.
The book contains an introduction to machine design and includes several design factors for consideration. It also offers information on the traditional rigorous design of machine elements. In addition, the author reviews the real design synthesis approach and offers material about stresses and material failure due to applied loading during intended performance. This comprehensive resource also contains an introduction to computer aided design and optimization. This important book:
- Provides the tools to perform a new direct design synthesis rather than design by a process of repeated analysis
- Contains a guide to knowledge-based design using CAD tools, software, and optimum component design for the new direct design synthesis of machine elements
- Allows for the initial suitable design synthesis in a very short time
- Delivers information on the utility of CAD and Optimization
- Accompanied by an online companion site including presentation files
Written for students of engineering design, mechanical engineering, and automotive design. Machine Design with CAD and Optimization contains the new CAD and Optimization tools and defines the skills needed to generate real design synthesis of machine elements and systems on solid ground for better products and systems.
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Seitenzahl: 2215
Veröffentlichungsjahr: 2021
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Table of Contents
Cover
Title Page
Copyright
Dedication
Preface
Acknowledgments
About the Companion Website
Part I: Introduction and Design Considerations
1 Introduction to Design
1.1 Introduction
1.2 Phases of Design
1.3 Basic Mechanical Functions
1.4 Design Factors
1.5 Synthesis Approach to Design
1.6 Product Life Cycle
1.7 Business Measures
1.8 Research and Development Process in Product Cycle
1.9 Teamwork for Product or System Design
1.10 Design and Development Case Study
1.11 Units and Fundamentals
1.12 Summary
References
Internet Sites
2 Design Considerations
2.1 Mathematical Modeling
2.2 Calculation Tools
2.3 Design Procedure
2.4 Manufacturing Processes
2.5 Standard Sets and Components
2.6 Codes and Standards
2.7 Summary
Problems
References
Internet Links (Selected)
Part II: Knowledge-Based Design
3 Introduction to Computer-Aided Techniques
3.1 CAD and Geometric Modeling
3.2 Geometric Construction and FE Analysis
3.3 CAD/CAM/CAE and Advanced Systems
3.4 Virtual Reality
3.5 Summary
Problems
References
Internet Links
4 Computer-Aided Design
4.1 3D Geometric Modeling and Viewing Transformation
4.2 Parametric Modeling
4.3 CAD Hardware and Software
4.4 Rendering and Animation
4.5 Data Structure
4.6 Using CAD in 3D Modeling and CAM
4.7 Summary
Problems
References
Internet Links
5 Optimization
5.1 Introduction
5.2 Searches in One Direction
5.3 Multidimensional: Classical Indirect Approach
5.4 Multidimensional Unconstrained Problem
5.5 Multidimensional Constrained Problem
5.6 Applications to Machine Elements and Systems
5.7 Summary
Problems
References
6 Stresses, Deformations, and Deflections
6.1 Loads, Shear, Moment, Slope, and Deflection
6.2 Mathematical Model
6.3 Simple Stresses, Strains, and Deformations
6.4 Combined Stresses
6.5 Curved Beams
6.6 Strain Energy and Deflection
6.7 Columns
6.8 Equivalent Element
6.9 Thermal Effects
6.10 Stress Concentration Factors
6.11 Finite Element Method
6.12 Computer-Aided Design and Optimization
6.13 Summary
References
Internet Links
7 Materials Static and Dynamic Strength
7.1 Material Structure and Failure Modes
7.2 Numbering Systems and Designations
7.3 Heat Treatment and Alloying Elements
7.4 Material Propertied and General Applications
7.5 Particular Materials for Machine Elements
7.6 Hardness and Strength
7.7 Failure and Static Failure Theories
7.8 Fatigue Strength and Factors Affecting Fatigue
7.9 Fracture Mechanics and Fracture Toughness
7.10 Computer-Aided Selection and Optimization
7.11 Summary
Problems
References
Internet Links
Material Selection
Material Standards
8 Introduction to Elements and System Synthesis
8.1 Introduction
8.2 Basic and Common Machine Elements
8.3 Reverse Engineering
8.4 Sample Applications
8.5 Computer-Aided Design
8.6 System Synthesis
8.7 Computer-Aided Assembly
8.8 Summary
Problems
References
Internet Links
Part III: Detailed Design of Machine Elements
Section A: Basic Joints and Machine Elements
9 Screws, Fasteners, and Permanent Joints
9.1 Standards and Types
9.2 Stresses in Threads
9.3 Bolted Connections
9.4 Bolt Strength in Static and Fatigue
9.5 Power Screws
9.6 Permanent Joints
9.7 Computer-Aided Design and Optimization
9.8 Summary
Problems
References
Internet Links
10 Springs
10.1 Types of Springs
10.2 Helical Springs
10.3 Leaf Springs
10.4 Belleville Springs
10.5 Elastomeric and Other Springs
10.6 Computer-Aided Design and Optimization
10.7 Summary
Problems
References
Internet: Information and Some Manufacturer
Internet: Images
11 Rolling Bearings
11.1 Bearing Types and Selection
11.2 Standard Dimension Series
11.3 Initial Design and Selection
11.4 Bearing Load
11.5 Detailed Design and Selection
11.6 Speed Limits
11.7 Lubrication and Friction
11.8 Mounting and Constructional Details
11.9 Computer-Aided Design and Optimization
11.10 Summary
Problems
References
Internet
12 Journal Bearings
12.1 Lubricants
12.2 Hydrodynamic Lubrication
12.3 Journal Bearing Design Procedure
12.4 Boundary and Mixed Lubrication
12.5 Plain Bearing Materials
12.6 CAD and Optimization
12.7 Summary
Problems
References
Internet Link
Section B: Power Transmitting and Controlling Elements
13 Introduction to Power Transmission and Control
13.1 Prime Movers and Machines
13.2 Collinear and Noncollinear Transmission Elements
13.3 Power Control Elements
13.4 Computer-Aided Design of a Power Transmission System
13.5 Summary
Problems
References
14 Spur Gears
14.1 Types and Utility
14.2 Definitions, Kinematics, and Standards
14.3 Force Analysis and Power Transmission
14.4 Design Procedure
14.5 Critical Speed
14.6 CAD and Optimization
14.7 Constructional Details
14.8 Summary
Problems
References
Internet Links
15 Helical, Bevel, and Worm Gears
15.1 Helical Gears
15.2 Bevel Gears
15.3 Worm Gears
15.4 Gear Failure Regimes and Remedies
15.5 Computer-Aided Design and Optimization
15.6 Constructional Details
15.7 Summary
Problems
References
Internet Links
16 Flexible Elements
16.1 V-belts
16.2 Flat Belts
16.3 Ropes
16.4 Chains
16.5 Friction Drives
16.6 Flexible Shafts
16.7 Computer-Aided Design and Optimization
16.8 Summary
Problems
References
Internet Links
17 Shafts
Symbols
17.1 Types of Shafts and Axles
17.2 Mathematical Model
17.3 Initial Design Estimate
17.4 Detailed Design
17.5 Design for Rigidity
17.6 Critical Speed
17.7 Computer-Aided Design and Optimization
17.8 Constructional Details
17.9 Summary
Problems
References
Internet Links
18 Clutches, Brakes, and Flywheels
18.1 Classifications of Clutches and Brakes
18.2 Cone Clutches and Brakes
18.3 Disk Clutches and Brakes
18.4 Caliper Disk Brakes
18.5 Energy Dissipation and Temperature Rise
18.6 Design Process
18.7 Computer-Aided Design and Optimization
18.8 Flywheels
18.9 Constructional Details
18.10 Summary
Problems
References
Internet Links
Appendix A: Appendix AFigures and Tables
A.1 Conversion Between US and SI Units
A.2 Standard SI Prefixes
A.3 Preferred Numbers and Sizes
A.4 Standard Rods, or Bars
A.5 Standard Joining and Retaining Elements
A.6 Standard Sealing Elements
A.7 Material Properties
A.8 Standard Sections or Profiles and Section Properties
Index
End User License Agreement
List of Tables
Chapter 1
Table 1.1 Basic mechanical functions and some of their detailed elemental fun...
Table 1.2 Basic quantities, units, ratio of US to SI systems, and conversion ...
Table 1.3 Conversion ratios of selected fundamental quantities (continued fro...
Chapter 2
Table 2.1 The schematic and system graph symbol for each element of the
throug
...
Table 2.2 The schematic and system graph symbol for each element of the
effort
...
Table 2.3 The schematic and system graph symbol for each element of the
dissip
...
Table 2.4 The schematic and system graph symbol for each element of
active com
...
Table 2.5 Some manufacturing processes IT tolerance grades and surface roughn...
Table 2.6 Basic selected fits for regular cylindrical hole base, typical appl...
Chapter 5
Table 5.1 Interval of uncertainty for the number of golden ratio trials (0.61...
Table 5.2 Values of objective function of the tray (Example 5.1) at different...
Table 5.3 Values of objective function of the tray (Example 5.1) at consecuti...
Table 5.4 Values of optimum truss design (
d
*
,
h
*
), objective function
W
[lb],...
Chapter 6
Table 6.1 Singularity functions for some of the mostly used and main loading ...
Table 6.2 Thermal expansion coefficients
α
T
and modulus of elasticity
E
f...
Chapter 7
Table 7.1 Some failure modes and their main associated material properties.
Table 7.2 Selected AISI/SAE low-alloy steel designations and the associated m...
Table 7.3 General uses of plain carbon steels as a function of carbon percent...
Table 7.4 Initially selected materials for some basic machine elements.
Table 7.5 Reliability factor
K
reliab
at some conventional reliability percenta...
Chapter 8
Table 8.1 Spline dimension ratios according to the dimensions defined in Figu...
Chapter 9
Table 9.1 Selected screw threads.
Table 9.2 Classes of material strength grades of screws and bolts.
Chapter 10
Table 10.1 The adapted number of inactive end turns
N
e
, the free length
L
f
, an...
Table 10.2 Selected spring wire diameters for US units [in] and SI units [mm]...
Table 10.3 Some spring materials, their composition, standards, size range, e...
Table 10.4 Some spring materials, size range, density
ρ
, and average shea...
Table 10.5 Selected spring material standards, numbers, ultimate tensile stre...
Table 10.6 Iteration results of optimum spring index
C
for active coils and to...
Table 10.P1 The required specifications in SI and US specifications for diffe...
Chapter 12
Table 12.1 Constants for SAE lubricating oils to change the absolute or dynam...
Table 12.2
Sleeve bearings
for some applications and their projected pressure ran...
Table 12.3 Some available materials for bearings with their expected maximum ...
Chapter 14
Table 14.1 Tooth specifications for full depth spur gears.
Table 14.2 Modules [mm] in general use.
Table 14.3 Standard diametral pitches [teeth/in].
Table 14.4 Equivalent diametral pitches to modules and the closest standard d...
Table 14.5 Recommended quality numbers
Q
v
for some applications (AGMA 2000-A88...
Table 14.6 Recommended ranges of hardness, allowable bending and contact fati...
Table 14.7 Recommended load application factor
k
o
for different classes of pow...
Table 14.8 Elastic coefficients for different mating gear materials,
C
p
[MPa]
1
...
Table 14–P1 The required specifications for Problems 14.23–14.34.
Chapter 15
Table 15.1 Proportions of the main straight bevel gear parameters.
Table 15.2 The usual proportions of the main worm gear parameters.
Table 15.P1 Data for Problems 15.17–15.28.
Chapter 16
Table 16.1 Selected common V-belt types, dimensions of belt sections, minimum...
Table 16.2 Proposed service factor
K
SF
for common V-belts for different prime ...
Table 16.3 The values of the coefficients and exponents for the evaluation of...
Table 16.4 Suggested pulley and grooves dimensions for different V-belt secti...
Table 16.5 Some selected flat-belts and round-belts materials and suggested r...
Table 16.6 Some selected fiber materials for ropes and some expected basic pr...
Table 16.7 Suggested safety factors for some applications operating wire rope...
Table 16.8 The common roller chain standard sizes or numbers, main dimensions...
Chapter 18
Table 18.1 Expected basic properties of some selected friction materials (for...
Table 18.2 Some expected additional properties of some selected friction mate...
1
Table A.1.1 Conversion between basic US and SI units including conversion rat...
Table A.1.2 Conversion ratios of selected basic quantities.
Table A.2.1 Suggested prefix symbols for SI units and adapted for the US unit...
Table A.3.1 Series of preferred dimensions (see ANSI B4.2 (2009), ANSI B4.1 (...
Table A.4.1 Properties of selected round solid steel bars or rods of main pre...
Table A.5.1 Some square and rectangular key dimensions as defined in figure.
Table A.5.2 Selected inch series of internal and external retaining ring main...
Table A.5.3 Selected metric series of internal and external retaining ring ma...
Table A.6.1 Selected metric and inch series of seals main dimensions as defin...
Table A.6.2 Selected metric and inch series of O-rings main dimensions as def...
Table A.7.1 Typical cast iron properties (gray and ductile or nodular) compil...
Table A.7.2 Typical plain carbon steel properties for hot rolled and cold dra...
Table A.7.3 Properties of selected heat treated plain carbon steel for quench...
Table A.7.4 Properties of selected heat treated low-alloy steel for quenched ...
Table A.7.5 Properties of selected structural steel.
Table A.7.6 Properties of selected stainless steel.
Table A.7.7 Properties of selected aluminum alloys.
Table A.7.8 Properties of selected plastics.
Table A.7.9 Properties of selected reinforcement fibers.
Table A.8.1 Selected metric series of round pipes main dimensions and some pr...
Table A.8.2 Selected inch series of round pipes main dimensions and some prop...
Table A.8.3 Selected metric series of square tubes main dimensions and some p...
Table A.8.4 Selected inch series of square tubes main dimensions and some pro...
Table A.8.5 Selected metric series of rectangular tubes or
hollow structural s
...
Table A.8.6 Selected inch series of rectangular tubes or hollow structural se...
Table A.8.7 Selected metric series of I-section main dimensions and some prop...
Table A.8.8 Selected inch series of S-section I-beam main dimensions and some...
Table A.8.9 Selected metric series of wide flange I-sections main dimensions ...
Table A.8.10 Selected inch series of wide flange I-sections main dimensions a...
Table A.8.11 Selected metric series of C-section or channel main dimensions a...
Table A.8.12 Selected inch series of C-section or channel main dimensions and...
Table A.8.13 Selected metric series of L-section or angle with equal legs mai...
Table A.8.14 Selected inch series of L-section or angles with equal legs main...
List of Illustrations
Chapter 1
Figure 1.1 A trans-mixer design that transports concrete from a mixing stati...
Figure 1.2 Suggested feasibility study steps to control and reiterate feedba...
Figure 1.3 Suggested initial synthesis steps to control and reiterate feedba...
Figure 1.4 Suggested detailed design steps to control and reiterate feedback...
Figure 1.5 Sketch of the usual product life cycle indicating stages of innov...
Figure 1.6 The interaction between the number of produced units and unit cos...
Figure 1.7 The infrastructures required for each step of the product cycle f...
Figure 1.8 Door handle under the maximum opening load
F
1
. The applied load i...
Chapter 2
Figure 2.1 An assembly of a shaft carrying an element through its hub and su...
Figure 2.2 Several bearing supports with the mathematical model of the beari...
Figure 2.3 External free body diagrams (
FBDs
): (a) door handle under maximum...
Figure 2.4 Main statements of a MATLAB
©
code for
n
applied loads and mo...
Figure 2.5 A multi-terminal
transformer
component: (a) schematic of an ideal...
Figure 2.6 Other
transformer
components: (a) a gearbox, (b) a shaft and a pu...
Figure 2.7 A multi-terminal
gyrator
component: (a) schematic of an ideal hyd...
Figure 2.8 Other
gyrator
components: (a) hydraulic positive displacement mot...
Figure 2.9 Schematic of an ideal
amplifier
(a), its system graph (b), and it...
Figure 2.10 A simple system of two springs assembled in parallel: (a) schema...
Figure 2.11 A simple system of two springs assembled in series: (a) schemati...
Figure 2.12 A schematic diagram in (a),
FBDs
in (b), and system graphs in (c...
Figure 2.13 Schematic diagram of frequency distributions for loading variati...
Figure 2.14 Conventional sand casting using a
pattern
– close in shape to th...
Figure 2.15 Deformation processes schematics: (a) sheet double bending, (b) ...
Figure 2.16 Machining processes schematics: (a) turning, (b) two milling ope...
Figure 2.17 Samples of
3D
printing or additive manufacturing of few parts or...
Figure 2.18 Schematic diagram of fits for hole basis cylindrical parts with ...
Figure 2.19 Interface of the available fits and tolerances computer-aided pr...
Chapter 3
Figure 3.1 Classical design process with the accustomed “CAD” systems requir...
Figure 3.2 Design synthesis paradigm in real
CAD
or computer-aided synthesis...
Figure 3.3 Different geometric modeling of a bolt: (a) the
3D
wireframe mode...
Figure 3.4 A
3D
surface model of a bolt in triangles and polygons. This mode...
Figure 3.5
3D
cantilever beam with a fixed left support and loaded at mid-ri...
Figure 3.6 Two views of a
3D
bolt in a stereographic projection that represe...
Figure 3.7 An assembly of a
stereoscope
with a simple material implementatio...
Chapter 4
Figure 4.1 Basic
3D
primitive solids, e.g. a block or parallelepiped (a), cy...
Figure 4.2 A body is made of several intersecting primitive solids in (a). O...
Figure 4.3 Generating a
3D
solid by
revolving
about the centerline of a
wire
...
Figure 4.4 Generating a
3D
solid by
lofting
or
extruding
a sketch as shown i...
Figure 4.5 A tetrahedron showing
edges
(
E
1
to
E
6
) connecting
vertices
(
P
1
to...
Figure 4.6 A simple
3D
object where the boundaries of faces are defined as
P
Figure 4.7 Object drawing (a) shows a ring
R
B
1
in a face
F
B
1
and a ring
R
B
2
...
Figure 4.8 A single solid construction of a solid body. Each node of the tre...
Figure 4.9 Constructing compound
3D
solid generated from several developed p...
Figure 4.10 Definition of the homogeneous coordinates in the
2D
Cartesian
sp...
Figure 4.11 A simple original shape of a body (a) in a plane and each of its...
Figure 4.12 A line
L
defined by its two end points
P
1
and
P
2
in
Cartesian
co...
Figure 4.13 A unit cube body attached to the origin of the coordinate system...
Figure 4.14 Plotting of the body onto the projection
x
–
y
plane. The projecti...
Figure 4.15 An example of open cube perspectives with 6° angle between the t...
Figure 4.16 Parametric representation of the line in (a) indicating the amou...
Figure 4.17 A plane surface
S
P
, its normal vector
N
P
, its normal distance fr...
Figure 4.18 A plane defined by three in-plane points with indicated directio...
Figure 4.19 Two planes that have the intersection points of (2,0,0), (0,1,0)...
Figure 4.20 Bilinear surface defined by four corner points and the center of...
Figure 4.21 A curve interpolates the control points passing through them in ...
Figure 4.22 The curve having a variation-diminishing property in (a) rather ...
Figure 4.23 A curve representing input data or control points interpolates t...
Figure 4.24 The
3D
Bezier
curve defined by four control points (in a plane) ...
Figure 4.25 Two
Bezier
surfaces in (a) and (b) with (
n
=
2
) × (
m
=
3
) in
v
a...
Figure 4.26
Bezier
surface patch, where the location of the control points a...
Figure 4.27
B
-spline curves for curve orders
k
of 3, 4, and 5 in (a), where ...
Figure 4.28 Periodic
B
-spline
curve for the curve orders
k
of 4 with its fou...
Figure 4.29 Local control of shape using
B
-
splines
. Part (a) develops sharp ...
Figure 4.30 Plot of the
B
-spline
or
Bezier
curve for the control points (4, ...
Figure 4.31 A simple MATLAB code to calculate the
3D
bicubic
B
-spline
surfac...
Figure 4.32 Plot of the
bicubic B
-spline
or
bicubic Bezier
surface and the c...
Figure 4.33 A single
NURBS
wrapping of
3D
objects with surface polygons show...
Figure 4.34 Intersection of the two lines of Example 4.6 and their plotting ...
Figure 4.35 Intersection of the two planes of Example 4.8 and their plotting...
Figure 4.36 Pictures of three shiny balls in (a) and shiny and translucent b...
Figure 4.37 Light from all directions giving
constant illumination
as shown ...
Figure 4.38 Gouraud-shaded bodies with fewer divisions produce poor behavior...
Figure 4.39 The upper small gray-filled circle and the lower gray-filled cir...
Figure 4.40 A sketch of roughly normalized eye response spectrum and fractio...
Figure 4.41 The main
RGB
(
red, green
, and
blue
) coordinates with the
black
o...
Figure 4.42 The
RGB
is an
additive
light waves system as shown in (a). Addin...
Figure 4.43 Hue, saturation, and luminance (HSL) as properties that generall...
Figure 4.44
CIE
chromaticity diagram of
x
C
and
y
C
for visible chromaticity r...
Figure 4.45 If the light source is placed at the viewer, or in the positive
Figure 4.46 Two vectors in the plane of a polygon (
x
1
, y
1
, z
1
) and (
x
2
, y
2
,
...
Figure 4.47 Diffuse and specular reflection from a glossy surface for a poin...
Figure 4.48 A reflected ray
R
S
varies as the cosine of the angle of incidenc...
Figure 4.49 The STL data file format for the
3D
tetrahedron object in Figure...
Chapter 5
Figure 5.1 A plastic tray that holds a volume of liquid
V
T
with a specific h...
Figure 5.2 A schematic of a one-dimensional problem indicating the probable ...
Figure 5.3 Two-dimensional space demonstrating the objective function contou...
Figure 5.4 A two-bar truss of a height
h
t
is supported to the ground through...
Figure 5.5 (A) Three response tables: (a) for the tube compressive stresses
Figure 5.6 A classification of the general methods of optimization.
Figure 5.7 The unknown objective function
f
is shown as a thick, grayish, an...
Figure 5.8 Two final acceptable situations for quadratic interpolation are s...
Figure 5.9 The golden section over an interval
L
that is divided by the gold...
Figure 5.10 The golden ratio is used in the stepping from either ends of the...
Figure 5.11 The contours of the objective function of Example 5.6. Two funct...
Figure 5.12 Univariate method in
2D
: (a) first option of stepping
ε
in ...
Figure 5.13 The Powell’s procedure in
2D
. Steps 1 and 2 are univariate searc...
Figure 5.14 Powell’s method generates conjugate directions; (a) two optimum ...
Figure 5.15 (a) Plot of the objective function 3
x
1
2
− 4
x
1
x
2
+
3
x
2
2
conto...
Figure 5.16 The ridge path of the function to reach the optimum locking in t...
Figure 5.17 (a) The contours of the objective function 3
x
1
2
− 4
x
1
x
2
+
3
x
Figure 5.18 Steepest descent method for
2D
problem: (a) first method using s...
Figure 5.19 (a) The contours of the Rosenbrock’s function and the starting p...
Figure 5.20 A sequence of external penalty searches with increasing
r
is per...
Figure 5.21 Interior penalty function showing that convergence takes place f...
Figure 5.22 The function is convex over a region, where between any two poin...
Figure 5.23 Two constraints showing that the
K–T
conditions are not sa...
Figure 5.24 Projecting the gradient vector ∇
f
onto the constraints tangent t...
Figure 5.25 A hypothetical constraint having convex, linear, and concave sec...
Figure 5.26 Projecting the gradient vector ∇
f
onto the constraints tangent t...
Figure 5.27 The plot of the function contours and constraints of Example 5.1...
Figure 5.28 MATLAB code for nondimensional optimum truss design. The optimum...
Figure 5.29 Plots of the optimum truss design (
d
*
,
h
*
) in [in], objective fu...
Chapter 6
Figure 6.1 External and internal loading of beams: (a) externally loaded bea...
Figure 6.2 Deformation and beam stresses: (a) extremely exaggerated deformat...
Figure 6.3 Different beam cross sections: (a) circular, (b) rectangular, and...
Figure 6.4 Exaggerated deformation of a beam (a) showing the elastic curve a...
Figure 6.5 Different bem loading and associated shear and bending diagrams: ...
Figure 6.6 Beam solution by superposition. Uniformly distributed loaded beam...
Figure 6.7 Statically indeterminate beam that is fixed at both ends and load...
Figure 6.8 (a) Beam synthesis chart for circular cross section, mid-span loa...
Figure 6.9 An assembly of a shaft carrying an element through its hub and su...
Figure 6.10 Simple cylindrical machine element subjected to (a) forces that ...
Figure 6.11 Simple cylindrical machine element subject to torsional loading:...
Figure 6.12 An element
A
of the beam at a distance
y
from the centerline in ...
Figure 6.13 A thin-section beam is transversely loaded and its section is as...
Figure 6.14 A simple beam loaded by a transverse force in (a). A small eleme...
Figure 6.15 Figure 6.14c is reproduced in (a) but sectioned by a plane at an...
Figure 6.16 A common plane stress state shown in (a) and the basic construct...
Figure 6.17 The
Mohr’s circle
of Figure 6.16 is redrawn in (a) and the...
Figure 6.18 An infinitesimal segment
A
for an inside fragment of a fully str...
Figure 6.19 The shaft is modeled similar to cylindrical element depicted in ...
Figure 6.20 Principal stresses obtained by sketching the
Mohr’s circle
Figure 6.21 (a) MATLAB codes to calculate the principal stresses and princip...
Figure 6.22 A configuration of assumed thin pressure cylinder or vessel subj...
Figure 6.23 Two cylinders pressed or shrink-fitted together. The outside dia...
Figure 6.24 Contact zones and contact stress distribution for (a) two spheri...
Figure 6.25 Curved beam of a symmetrical rectangular cross section and a cen...
Figure 6.26 Curved beams under pure bending with symmetrical cross sections:...
Figure 6.27 Curvature factors of circular –
“C”-
, rectangular –
“R
...
Figure 6.28 A plane strain where the deformation in
x
direction is
u
and the...
Figure 6.29 A general situation of an element loaded in (a) by a force
F
or ...
Figure 6.30 Simply supported beam with a uniformly distributed load. A ficti...
Figure 6.31 A column in (a) is simply supported case of an ideal end conditi...
Figure 6.32
Euler
critical buckling stresses ratio
(σ
cr
/E)
versus slen...
Figure 6.33
Euler
critical buckling stress and parabolic equation versus sle...
Figure 6.34 Critical buckling stresses for secant formula versus slenderness...
Figure 6.35 Machine element in (a) has different lengths and diameters. Equi...
Figure 6.36 A suspended shaft with two rolling bearings supporting the shaft...
Figure 6.37 A
bimetal strip
of two different metals (usually steel and brass...
Figure 6.38 A very wide (infinite) plate with an elliptical hole uniformly l...
Figure 6.39 A plate with a cylindrical hole uniformly loaded in tension and ...
Figure 6.40 A
2D
sketch of a small thickness
3D
design domain shown in (a). ...
Figure 6.41 Typical elements in
2D
and
3D
that are available in most
FE
pack...
Figure 6.42 A simple system of three elements collinearly assembled in serie...
Figure 6.43 MATLAB code to find the nodal displacements, element stresses, a...
Figure 6.44 A deformed beam and its deflection extremely exaggerated to allo...
Figure 6.45 Statically indeterminate beam fixed at both ends, loaded by an a...
Figure 6.46 An object subject to individual in-plane boundary loading
F
i
and...
Figure 6.47 Cases of
3D
objects in (a) that may represent plane stress and p...
Figure 6.48 A constant strain triangle (
CST
) with corners or nodes marked by...
Figure 6.49 External linearly distributed load or traction
T
(
x,y
) per unit a...
Figure 6.50 Finite element procedure to find deflections and stresses in an ...
Figure 6.51 Beam Synthesis Tablets: (a) US system of units and (b) SI system...
Figure 6.52 Column Synthesis Tablets: (a) US system of units and (b) SI syst...
Figure 6.53 A plate with an elliptical hole uniformly loaded in tension and ...
Figure 6.54 An optimum plate loaded in tension that had an initial circular ...
Figure 6.55 MATLAB code to find the optimum three elements collinearly assem...
Figure 6.56 Design domain, nodes, and elements of a cantilever beam. The num...
Figure 6.57 Optimum design of the cantilever beam: (a) representative optimu...
Figure 6.58 Optimum design of the cantilever beam: (a) stresses in an extrac...
Figure 6.59 Optimum design of the classical continuum cantilever beam of a r...
Chapter 7
Figure 7.1 Material properties, the link between structure and service perfo...
Figure 7.2 Tensile test: (a) essential standard dimensions of the test speci...
Figure 7.3 Spans of tensile properties of some general engineering materials...
Figure 7.4 Some material properties under time varying load: (a) impact ener...
Figure 7.5
S
–
N
(stress–number of cycles) diagram of fatigue strength versus ...
Figure 7.6 Diagram of creep rate versus time at different temperatures and h...
Figure 7.7 Selected AISI/SAE low-alloy steel designations: (a) major X and o...
Figure 7.8 Selected EN alloy steel designations: (a) the top is for plain ca...
Figure 7.9 Iron–carbon phase diagram for plain carbon steel. The heat treatm...
Figure 7.10 Selected plain carbon steel properties as functions of carbon co...
Figure 7.11 The effect of carbon percent on the ultimate strength, yield str...
Figure 7.12 The effect of carbon percent on the yield strength, ultimate str...
Figure 7.13 The effect of tempering temperatures on heat treated plain carbo...
Figure 7.14 The effect of carbon percent on the yield strength and
Brinell
h...
Figure 7.15 Ultimate tensile strength,
Rockwell
hardness (
HRB
,
HRC
), and
Bri
...
Figure 7.16 Point
A
in (a) representing an inside fragment of a fully stress...
Figure 7.17 The failure of a bar of chalk under manual bending in (a). The f...
Figure 7.18 The
maximum normal stress
theory in
2D
stress state, where the b...
Figure 7.19 (a) The
maximum shear stress
theory in
2D
stress state, where th...
Figure 7.20 The
2D
ellipse of the
von Mises
distortion energy theory is plot...
Figure 7.21 Different failure strength in tension, compression, and torsion ...
Figure 7.22 Anticipated typical internal stress loading shown in (a) due to ...
Figure 7.23
S
–
N
diagram of fatigue strength versus the number of loading cyc...
Figure 7.24 Values of surface factor
K
surf
for different manufacturing proce...
Figure 7.25 Values of
Neuber
number (
a
N
)
1/2
as a function of the ultimate te...
Figure 7.26 Values of
Neuber
number (
a
N
)
1/2
as a function of the ultimate te...
Figure 7.27 The fatigue diagram showing the failure limiting criteria of mod...
Figure 7.28 The fatigue
strain life
in reversals to failure (2
N
Cf
) is relate...
Figure 7.29 The elliptical hole of Figure 6.38 is reproduced in (a) with min...
Figure 7.30 General approximate spans of fracture toughness against tensile ...
Figure 7.31 Plots of crack growth rates in the propagation zone only without...
Figure 7.32 Seriously cracked arm of a microwave turntable coupler drive is ...
Figure 7.33 MATLAB code to calculate the material properties for carbon stee...
Figure 7.34 MATLAB code to calculate the material properties for carbon stee...
Figure 7.35 MATLAB code to calculate the SI and US fatigue strength
S
f
of pl...
Figure 7.36 MATLAB code to calculate the factors affecting fatigue strength ...
Figure 7.37 MATLAB code to calculate the equivalent fatigue stresses. It als...
Figure 7.38 MATLAB code to iteratively optimize the part diameter for a need...
Chapter 8
Figure 8.1 Sketches of a rigid coupling main dimensions on sectional view in...
Figure 8.2 Rigid coupling main dimensions as functions of the shaft diameter...
Figure 8.3 Sketches of a double-cone clamping coupling showing the main dime...
Figure 8.4 Sketches of two other rigid couplings. (a) Simple sleeve coupling...
Figure 8.5 Sketches of two flexible couplings: (a) bush pin flanged coupling...
Figure 8.6 Outline of a universal joint coupling in a perspective view. The ...
Figure 8.7 Images of some
3D
joining and fastening elements: (a) a parallel ...
Figure 8.8 Retaining rings mounting dimensions: (a) external retaining ring ...
Figure 8.9 Spline shaft and mating part side view: (a)
3D
shaft with 6 splin...
Figure 8.10 Spline shaft lengths as functions of the ratio of the torque to ...
Figure 8.11 Sketches of involute spline shafts of 30° pressure angle and mat...
Figure 8.12 A sketch of a sectional view for a gearbox showing one gasket fi...
Figure 8.13 Sketches of some common static seals. (a)
Gasket
between an encl...
Figure 8.14 Sketches of some common non-rubbing seals. (a)
Close clearance
(...
Figure 8.15 Sketches of some common rubbing seals. (a)
Felt ring
(checkered ...
Figure 8.16 Collar seal and O-ring mounting dimensions: (a) collar seal and ...
Figure 8.17 A conceptual
Jib crane
demonstrating the possible extensive use ...
Figure 8.18 Free body diagrams of the Jib-crane main modules sketches with l...
Figure 8.19 Preliminary bolt size estimation as a function of the tensile lo...
Figure 8.20 Estimate of shaft size synthesis as a function of rotational spe...
Figure 8.21 Estimate of bearing synthesis as a function of nominal bearing d...
Figure 8.22 Computer-aided synthesis of connected elements. One code include...
Figure 8.23 Redesign of a rigid coupling: main dimension in (a) and expanded...
Figure 8.24 A legacy
PanDesign CAD
software interfaces: (a) components of Pa...
Chapter 9
Figure 9.1 Screw fastener and thread. (a) The end of a short-threaded bolt a...
Figure 9.2 The square threads are shown in (a), and the Acme or trapezoidal ...
Figure 9.3 Few joining alternatives such as a set screw in (a), different sc...
Figure 9.4 A bolted joint tying two members in (a). The load deflection diag...
Figure 9.5 Member stiffness by using a cone frustum starting at the washer c...
Figure 9.6 Fatigue diagram for a constant preload and a fluctuating load. Th...
Figure 9.7 Sketch of a portion of power screw in (a). The force balance for ...
Figure 9.8 A sketch of the power screw with a collar to handle the thrust in...
Figure 9.9 A sketch of a power screw sections in (a) and their stress state ...
Figure 9.10 A sketch of a ball screw. The ball recirculation is usually off ...
Figure 9.11 Sketches of frequently used butt welding types and simplified we...
Figure 9.12 Sketches of some fillet welding types and simplified welding sym...
Figure 9.13 Sketches of loaded butt and fillet welds showing assumed dimensi...
Figure 9.14 Sketches of different types of lap joints with grayish and
exagg
...
Figure 9.15 MATLAB code to calculate the needed bolt material yield strength...
Figure 9.16 MATLAB code to calculate the bolt and the joint members stiffnes...
Figure 9.17 MATLAB code to calculate the fatigue loading and stresses of the...
Figure 9.18 (a) MATLAB code to calculate power screw geometry, loads, stress...
Figure 9.19 (a) A MATLAB code for the calculation of weldment in
jib-crane h
...
Chapter 10
Figure 10.1 Common springs showing (a) frequently encountered springs and (b...
Figure 10.2 Common cylindrical helical spring showing basic geometrical para...
Figure 10.3 Spring end configurations: (a) plain end, (b) plain ground end, ...
Figure 10.4 Helical springs with each having a different spring index
C
of 5...
Figure 10.5 Helical springs at free length, initially loaded length, operati...
Figure 10.6 Free body diagram of a spring showing the torque
T
and the direc...
Figure 10.7 Distribution of shear stresses on the circular cross section of ...
Figure 10.8 The critical buckling factor
K
cr
against the free length to coil...
Figure 10.9 The wire diameter
d
w
for the maximum applied solid force
F
s
for ...
Figure 10.10 The Number of active turns
N
a
for different spring index
C
agai...
Figure 10.11
Helical Spring Synthesis Tablet
providing the solution to Examp...
Figure 10.12.
Helical Spring Synthesis Tablet
providing the solution to Exam...
Figure 10.13 The torsional fatigue and the
modified Goodman
diagram for fati...
Figure 10.14 Extension spring characteristics indicating initial tension
F
it
Figure 10.15 Constant strength–constant thickness triangular beam (a), simil...
Figure 10.16 An equivalent leaf spring configuration relative to the origina...
Figure 10.17
Belleville
spring and its sectional view showing main geometry ...
Figure 10.18
Belleville
springs stacked in combined form: (a) for the same f...
Figure 10.19 Representative characteristics of
Belleville
springs in nondime...
Figure 10.20 Other springs: (a) three different elastomeric spring blocks, (...
Figure 10.21 Iteration results of optimum spring index
C
for active coils ma...
Chapter 11
Figure 11.1 Images of a simple
3D
rolling bearings with cages and inner ring...
Figure 11.2 Some of main types of
ball
bearings. Deep groove ball bearing is...
Figure 11.3 Some of the main types of
roller
bearings showing simple sketche...
Figure 11.4 Dimension series for radial bearings of same bore diameter. It i...
Figure 11.5 A sketch of a sectional view for a
gearbox
showing deep groove
b
...
Figure 11.6 (Similar to Figure 8.21) Estimate of radial bearing synthesis as...
Figure 11.7 Estimate of thrust bearing synthesis as a function of nominal be...
Figure 11.8 A sketch of expanded bearing reliability at low guarantied beari...
Figure 11.9 A sketch of load distribution among rolling elements.
Figure 11.10 Sketch of main terminologies and dimensions of a tapered roller...
Figure 11.11 Sketch of tapered roller bearing mountings and applied loads. F...
Figure 11.12 Sketches of basic mountings of bearings on shafts in housings. ...
Figure 11.13 Sketches of bearing mounting or assembly needs. Assembly of bea...
Figure 11.14 MATLAB code for initial synthesis of rolling bearings. The inpu...
Figure 11.15 MATLAB code for initial synthesis of rolling bearings. The inpu...
Figure 11.16 MATLAB code for required synthesis of rolling bearings. The inp...
Figure 11.17 MATLAB code for rolling bearings selection safety. The input is...
Chapter 12
Figure 12.1 Friction phenomenon and force development. Dry or
Coulomb
coeffi...
Figure 12.2 Simplified friction force development.
Coulomb
, dry, or static c...
Figure 12.3 Lubricant film between the stationary base or
bearing
and the mo...
Figure 12.4 Coefficient of friction variation as a function of bearing chara...
Figure 12.5 A concentric lightly loaded bearing used to derive
Petroff’s
...
Figure 12.6 The lubricant film in between the journal and the bearing has an...
Figure 12.7 Small element (
dx dy
) in the lubricant film with forces due to p...
Figure 12.8 Short bearing showing the projected pressure distribution sketch...
Figure 12.9 The regression curves of the Sommerfeld number
S
N
for
l
J
/d
J
rati...
Figure 12.10 (Similar to Figures 8.21 and 11.6) Estimate of practical journa...
Figure 12.11 Estimate of practical journal bearing synthesis as a function o...
Figure 12.12 The practical journal bearing designs are characterized by clea...
Figure 12.13 A more realistic projected pressure distribution is not usually...
Figure 12.14 (Similar to Figure 8.17b) The conceptual
Jib crane
uses standar...
Figure 12.15 (a) MATLAB code for journal bearings – 180 bearing; (a) applied...
Figure 12.16 The optimum viscosity criterion as a function of the clearance ...
Figure 12.17
CAD
tablet to synthesize both
practice
and
optimum
knowledge ba...
Chapter 13
Figure 13.1 Power transmission elements between a prime mover and a machine....
Figure 13.2 Flowchart of power transmission elements carried by input and ou...
Figure 13.3 Simplified outlines of some power transmission elements. From (a...
Figure 13.4 Torque and preliminary shaft synthesis for power transmission el...
Figure 13.5 Dynamic shaft synthesis process for power transmission of SI sys...
Figure 13.6 Dynamic shaft synthesis process for power transmission of US sys...
Chapter 14
Figure 14.1 Gears showing (a) spur gear and pinion that have cylindrical sha...
Figure 14.2 Gear train sets of linked spur or other gears (a) for high speed...
Figure 14.3 Involute tooth profile for spur gears (a) and (b) shows the two ...
Figure 14.4 Components along the line of action of the normal velocities
v
P
...
Figure 14.5 A part of a spur gear sketch where some basic gear features and ...
Figure 14.6 The gear main geometrical parameters, dimensions, and tooth form...
Figure 14.7 The recommended minimum backlash for SI system indicating the fi...
Figure 14.8 The recommended minimum backlash for the US system indicating th...
Figure 14.9 Forces developed between teeth of mating gears. The main force
F
Figure 14.10 For the derivation of
Lewis
equation, (a) the tooth is loaded a...
Figure 14.11 The modified
Lewis
form factor
Y
L
is shown with an indicated ap...
Figure 14.12 The optimum module
m
n
* in [mm] for a large span of input torque...
Figure 14.13 The optimum number of pinion teeth
N
P
* against the allowable be...
Figure 14.14 The optimum face width
f
g
* in [mm] against the input torque
T
in
Figure 14.15 Bending geometry factor evaluation: (a) value of geometry facto...
Figure 14.16 The dynamic or velocity factor
K
v
as function of pitch line vel...
Figure 14.17 The image of the
Spur Gear Synthesis Tablet
. It also shows a sy...
Figure 14.18 The correction factor
K
IN
to be multiplied by geometry factor
I
Figure 14.19 More geometry and performance parameters and variables are show...
Figure 14.20 A schematic diagram (a) and
FBD
and system graph (b) of a mathe...
Figure 14.21 Optimization iteration for initially synthesized case to reduce...
Figure 14.22 Optimization iteration for initially synthesized case to reduce...
Figure 14.23 Initial iteration of reducing both the allowable bending fatigu...
Figure 14.24 Initial iteration of reducing both the allowable bending fatigu...
Figure 14.25 An assembly drawing that defines the main requirements and cons...
Figure 14.26 A single sectional view for the physical substance implementati...
Figure 14.27 A two-stage gear train schematically represented in (a) with a ...
Chapter 15
Figure 15.1 Simple diagrammatic sketches of helical, bevel, and worm gears: ...
Figure 15.2 Helical gears in
3D
isometric view: (a) frequently encountered h...
Figure 15.3 Other compound helical gears in
3D
isometric view: (a) double he...
Figure 15.4
Involute helicoid
simulated generation. (a) The grayish sheet ha...
Figure 15.5 Helical gear parameters for the normal (
n
) section A–A, transver...
Figure 15.6 Helical gear forces. The grayish cylinder lines represent the be...
Figure 15.7 The optimum module
m
n
* for helical gears. The grayish markers re...
Figure 15.8 The optimum number of teeth
N
p
* for helical gears. The grayish m...
Figure 15.9 The optimum face width
f
g
*
for helical gears. The grayish marker...
Figure 15.10 Two main types of bevel gears: (a) straight bevel gear set and ...
Figure 15.11 Main geometrical parameters and basic designations of straight ...
Figure 15.12 Forces on straight bevel gear tooth. The radial and axial compo...
Figure 15.13 A sketch of a single-enveloping worm gear set showing the worm,...
Figure 15.14 A schematic of worm forces, where forces are not proportional f...
Figure 15.15 Worm gearbox approximate characteristic torque versus speed rat...
Figure 15.16 MATLAB code for synthesis of single stage helical gearbox. The ...
Figure 15.17 MATLAB code for synthesis of single stage helical gearbox. The ...
Figure 15.18 MATLAB code for synthesis of single stage helical gearbox. The ...
Figure 15.19 MATLAB code for synthesis of single stage helical gearbox. The ...
Figure 15.20 MATLAB code for synthesis of single stage worm gear set. The sy...
Figure 15.21 MATLAB code for synthesis of single stage worm gear set. The sy...
Figure 15.22 A sectional view for the assembly of a single stage helical gea...
Figure15.23 A sectional view for the assembly of a single stage herringbone ...
Chapter 16
Figure 16.1 Isometric sketches of V-belt sections and a pulley on which the ...
Figure 16.2 Simple diagrammatic sketches of a belt connecting two pulleys. (...
Figure 16.3 Simple diagrammatic sketches of free body diagrams of a single p...
Figure 16.4 Simple sketch of the stress diagram of the wrapped V-belt. Tensi...
Figure 16.5 Pulley diameter estimated from the knowledge of the
rated power
...
Figure 16.6 Simple diagrammatic sketches of flat belt drives. (a) Regular op...
Figure 16.7 Some ropes with different sizes, structure, and materials.
Figure 16.8 Wire rope sketches with different structure and lays. (a) Cress-...
Figure 16.9 Wire rope breaking-strength force and weight per unit length. (a...
Figure 16.10 Simple sketches of the common roller chain components and assem...
Figure 16.11 A draft of the roller chain engaging the driving sprocket and i...
Figure 16.12 Roller chains characteristics and trend lines for maximum power...
Figure 16.13 A spring member having a very large number of coils and a small...
Figure 16.14 MATLAB code for the synthesis of V-belts (part 1). The main inp...
Figure 16.15 MATLAB code for the synthesis of V-belts (part 2). Center dista...
Figure 16.16 MATLAB code for the synthesis of V-belts (part 3). Calculating ...
Figure 16.17 MATLAB code for the synthesis of wire ropes (part 1). The main ...
Figure 16.18 MATLAB code for the synthesis of wire ropes (part 2). The main ...
Figure 16.19 MATLAB code for the synthesis of wire ropes (part 3). The main ...
Figure 16.20 MATLAB code for the synthesis of roller chains (part 1). The ma...
Figure 16.21 MATLAB code for the synthesis of wire ropes (part 2). The main ...
Figure 16.22 MATLAB code for the synthesis of wire ropes (part 3). The main ...
Chapter 17
Figure 17.1 Isometric views of few different shafts: (a) legacy railway axle...
Figure 17.2 External and internal free body diagrams (
FBD
) of a simple shaft...
Figure 17.3 MATLAB code to find the
3D
external reactions for a loaded shaft...
Figure 17.4 MATLAB code to find the internal shear forces and moments for th...
Figure 17.5 Shaft Synthesis Tablets for the US and SI systems of units.
Figure 17.6 Some methods of improving the stress concentration factor and fa...
Figure 17.7 A sketch of a left end assembly of a shaft. This end is supporte...
Chapter 18
Figure 18.1 Out of scale sketches of a cone clutch or a cone brake. (a)
3D
c...
Figure 18.2 Sketch of a disk clutch or disk brake with one friction surface....
Figure 18.3 Schematic diagrams of multiple friction surface clutch-brake. (a...
Figure 18.4 Charts of initial clutch-brake synthesis noting the safety facto...
Figure 18.5 Outline of caliper disk brake with main components identified. (...
Figure 18.6 A simple joining model of clutch-brake connecting an input inert...
Figure 18.7 Clutch-brake synthesis tablets for (a) SI and (b) US systems of ...
Figure 18.8 Torque fluctuation on crankshaft of a single-cylinder engine. SI...
Figure 18.9 Half-sectional view of a hydraulically operated multi-disk clutc...
Guide
Cover
Table of Contents
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Machine Design with CAD and Optimization
Sayed M. Metwalli
Faculty of Engineering, Cairo UniversityEgypt
This edition first published 2021
