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About the Author V B Bhandari retired as Professor and Head, Department of Mechanical Engineering at Vishwakarma Institute of Technology, Pune. He holds First-Class BE and ME degrees in Mechanical Engineering from Pune University, and his teaching experience spans over 38 years in Government Colleges of Engineering at Pune, Karad and Aurangabad. He was also a postgraduate teacher of Pune University, Shivaji University and Marathwada University. Besides being a National Scholar, he has received five prizes from Pune University during his academic career. Professor Bhandari was a member of ‘Board of Studies in Mechanical Engineering’ and a member of ‘Faculty of Engineering’ of Pune University. He is a Fellow of Institution of Engineers (India), a Fellow of Institution of Mechanical Engineers (India) and a Senior Member of Computer Society of India. He was a Fellow of Institution of Production Engineers (India) and a Member of American Society of Mechanical Engineers (USA). He has presented and published twenty technical papers in national and international conferences and journals, and is also the author of Introduction to Machine Design published by Tata McGraw Hill Education Private Limited.
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Design of Machine Elements Third Edition V B BHANDARI Retired Professor and Head Department of Mechanical Engineering Vishwakarma Institute of Technology Pune Tata McGraw Hill Education Private Limited NEW DELHI McGraw-Hill Offi ces New Delhi New York St Louis San Francisco Auckland Bogotá Caracas Kuala Lumpur Lisbon London Madrid Mexico City Milan Montreal San Juan Santiago Singapore Sydney Tokyo Toronto
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Published by the Tata McGraw Hill Education Private Limited, 7 West Patel Nagar, New Delhi 110 008. Design of Machine Elements, 3e Copyright © 2010, 2007, 1994 by Tata McGraw Hill Education Private Limited. No part of this publication may be reproduced or distributed in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise or stored in a database or retrieval system without the prior written permission of the publishers. The program listing (if any) may be entered, stored and executed in a computer system, but they may not be reproduced for publication. This edition can be exported from India only by the publishers, Tata McGraw Hill Education Private Limited. ISBN (13 digits) : 978-0-07-068179-80-07-014169-8 ISBN (10 digits) : 0-07-068179-1 Managing Director: Ajay Shukla Head—Higher Education Publishing: Vibha Mahajan Manager: Sponsoring—SEM & Tech Ed: Shalini Jha Assoc. Sponsoring Editor : Suman Sen Development Editor : Devshree Lohchab Executive—Editorial Services: Sohini Mukherjee Sr Production Manager: P L Pandita General Manager: Marketing—Higher Education: Michael J Cruz Dy Marketing Manager—SEM & Tech Ed: Biju Ganesan General Manager—Production: Rajender P Ghansela Asst General Manager—Production: B L Dogra Information contained in this work has been obtained by Tata McGraw-Hill, from sources believed to be reliable. However, neither Tata McGraw-Hill nor its authors guarantee the accuracy or completeness of any information published herein, and neither Tata McGraw-Hill nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that Tata McGraw-Hill and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. Typeset at Bukprint India, B-180A, Guru Nanak Pura, Laxmi Nagar-110 092 and printed at Pashupati Printers Pvt. Ltd., 1/429/16, Gali No. 1, Friends Colony Industrial Area, G.T. Road, Shahdara, Delhi 110 095 Cover Printer: Rashtriya Printers DZXQCRCZDRLYL
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Contents Preface xvii Visual Walkthrough xxi 1. Introduction 1 1.1 Machine Design 1 1.2 Basic Procedure of Machine Design 2 1.3 Basic Requirements of Machine Elements 3 1.4 Design of Machine Elements 4 1.5 Traditional Design Methods 8 1.6 Design Synthesis 8 1.7 Use of Standards in Design 9 1.8 Selection of Preferred Sizes 11 1.9 Aesthetic Considerations in Design 14 1.10 Ergonomic Considerations in Design 15 1.11 Concurrent Engineering 17 Short Answer Questions 19 Problems for Practice 19 2. Engineering Materials 20 2.1 Stress–Strain Diagrams 20 2.2 Mechanical Properties of Engineering Materials 23 2.3 Cast Iron 26 2.4 BIS System of Designation of Steels 29 2.5 Plain-carbon Steels 30 2.6 Free-cutting Steels 32 2.7 Alloy Steels 32 2.8 Overseas Standards 34 2.9 Heat Treatment of Steels 36 2.10 Case Hardening of Steels 37 2.11 Cast Steel 38
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vi Contents 2.12 Aluminium Alloys 39 2.13 Copper Alloys 41 2.14 Die-casting Alloys 43 2.15 Ceramics 44 2.16 Plastics 45 2.17 Fibre-reinforced Plastics 48 2.18 Natural and Synthetic Rubbers 49 2.19 Creep 50 2.20 Selection of Material 51 2.21 Weighted Point Method 51 Short Answer Questions 53 3. Manufacturing Considerations in Design 55 3.1 Selection of Manufacturing Method 55 3.2 Design Considerations of Castings 57 3.3 Design Considerations of Forgings 59 3.4 Design Considerations of Machined Parts 61 3.5 Hot and Cold Working of Metals 62 3.6 Design Considerations of Welded Assemblies 62 3.7 Design for Manufacture and Assembly (DFMA) 64 3.8 Tolerances 65 3.9 Types of Fits 66 3.10 BIS System of Fits and Tolerances 67 3.11 Selection of Fits 69 3.12 Tolerances and Manufacturing Methods 69 3.13 Selective Assembly 70 3.14 Tolerances For Bolt Spacing 72 3.15 Surface Roughness 73 Short Answer Questions 73 Problems for Practice 74 4. Design Against Static Load 76 4.1 Modes of Failure 76 4.2 Factor of Safety 77 4.3 Stress–strain Relationship 79 4.4 Shear Stress and Shear Strain 80 4.5 Stresses Due To Bending Moment 81 4.6 Stresses Due To Torsional Moment 82 4.7 Eccentric Axial Loading 83 4.8 Design of Simple Machine Parts 84 4.9 Cotter Joint 85 4.10 Design Procedure for Cotter Joint 90 4.11 Knuckle Joint 94 4.12 Design Procedure for Knuckle Joint 99 4.13 Principal Stresses 104 4.14 Theories of Elastic Failure 106
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Contents vii 4.15 Maximum Principal Stress Theory 107 4.16 Maximum Shear Stress Theory 108 4.17 Distortion-Energy Theory 110 4.18 Selection and Use of Failure Theories 112 4.19 Levers 117 4.20 Design of Levers 118 4.21 Fracture Mechanics 128 4.22 Curved Beams 130 4.23 Thermal Stresses 135 4.24 Residual Stresses 136 Short Answer Questions 137 Problems for Practice 138 5. Design Against Fluctuating Load 141 5.1 Stress Concentration 141 5.2 Stress Concentration Factors 142 5.3 Reduction of Stress Concentration 145 5.4 Fluctuating Stresses 149 5.5 Fatigue Failure 151 5.6 Endurance Limit 152 5.7 Low-cycle and High-cycle Fatigue 153 5.8 Notch Sensitivity 154 5.9 Endurance Limit—Approximate Estimation 155 5.10 Reversed Stresses—Design for Finite and Infinite Life 159 5.11 Cumulative Damage in Fatigue 166 5.12 Soderberg and Goodman Lines 167 5.13 Modified Goodman Diagrams 168 5.14 Gerber Equation 174 5.15 Fatigue Design under Combined Stresses 177 5.16 Impact Stresses 180 Short Answer Questions 182 Problems for Practice 182 6. Power Screws 184 6.1 Power Screws 184 6.2 Forms of Threads 185 6.3 Multiple Threaded Screws 187 6.4 Terminology of Power Screw 187 6.5 Torque Requirement—Lifting Load 189 6.6 Torque Requirement—Lowering Load 189 6.7 Self-locking Screw 190 6.8 Efficiency of Square Threaded Screw 190 6.9 Efficiency of Self-locking Screw 192 6.10 Trapezoidal and Acme Threads 192 6.11 Collar Friction Torque 193 6.12 Overall Efficiency 194
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viii Contents 6.13 Coefficient of Friction 194 6.14 Design of Screw and Nut 194 6.15 Design of Screw Jack 206 6.16 Differential and Compound Screws 214 6.17 Recirculating Ball Screw 215 Short-Answer Questions 216 Problems for Practice 217 7. Threaded Joints 219 7.1 Threaded Joints 219 7.2 Basic Types of Screw Fastening 220 7.3 Cap Screws 222 7.4 Setscrews 223 7.5 Bolt of Uniform Strength 224 7.6 Locking Devices 225 7.7 Terminology of Screw Threads 227 7.8 ISO Metric Screw Threads 228 7.9 Materials and Manufacture 230 7.10 Bolted Joint—Simple Analysis 231 7.11 Eccentrically Loaded Bolted Joints in Shear 233 7.12 Eccentric Load Perpendicular to Axis of Bolt 235 7.13 Eccentric Load on Circular Base 242 7.14 Torque Requirement for Bolt Tightening 248 7.15 Dimensions of Fasteners 249 7.16 Design of Turnbuckle 251 7.17 Elastic Analysis of Bolted Joints 254 7.18 Bolted Joint under Fluctuating Load 257 Short-Answer Questions 269 Problems for Practice 269 8. Welded and Riveted Joints 272 8.1 Welded Joints 272 8.2 Welding Processes 273 8.3 Stress Relieving of Welded Joints 274 8.4 Butt Joints 274 8.5 Fillet Joints 275 8.6 Strength of Butt Welds 276 8.7 Strength of Parallel Fillet Welds 277 8.8 Strength of Transverse Fillet Welds 278 8.9 Maximum Shear Stress in Parallel Fillet Weld 281 8.10 Maximum Shear Stress in Transverse Fillet Weld 282 8.11 Axially Loaded Unsymmetrical Welded Joints 284 8.12 Eccentric Load in the Plane of Welds 285 8.13 Welded Joint Subjected to Bending Moment 290 8.14 Welded Joint Subjected to Torsional Moment 294 8.15 Strength of Welded Joints 295
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Contents ix 8.16 Welded Joints Subjected to Fluctuating Forces 296 8.17 Welding Symbols 297 8.18 Weld Inspection 298 8.19 Riveted Joints 298 8.20 Types of Rivet Heads 301 8.21 Types of Riveted Joints 303 8.22 Rivet Materials 305 8.23 Types of Failure 306 8.24 Strength Equations 306 8.25 Efficiency of Joint 307 8.26 Caulking and Fullering 307 8.27 Longitudinal Butt Joint for Boiler Shell 311 8.28 Circumferential Lap Joint for Boiler Shells 318 8.29 Eccentrically Loaded Riveted Joint 321 Short-Answer Questions 325 Problems for Practice 325 9. Shafts, Keys and Couplings 330 9.1 Transmission Shafts 330 9.2 Shaft Design on Strength Basis 331 9.3 Shaft Design on Torsional Rigidity Basis 333 9.4 ASME Code for Shaft Design 334 9.5 Design of Hollow Shaft on Strength Basis 342 9.6 Design of Hollow Shaft on Torsional Rigidity Basis 344 9.7 Flexible Shafts 346 9.8 Keys 346 9.9 Saddle Keys 347 9.10 Sunk Keys 348 9.11 Feather Key 349 9.12 Woodruff Key 350 9.13 Design of Square and Flat Keys 350 9.14 Design of Kennedy Key 352 9.15 Splines 354 9.16 Couplings 356 9.17 Muff Coupling 357 9.18 Design Procedure for Muff Coupling 357 9.19 Clamp Coupling 359 9.20 Design Procedure for Clamp Coupling 360 9.21 Rigid Flange Couplings 362 9.22 Design Procedure for Rigid Flange Coupling 364 9.23 Bushed-pin Flexible Coupling 368 9.24 Design Procedure for Flexible Coupling 371 9.25 Design for Lateral Rigidity 376 9.26 Castigliano’s Theorem 380
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x Contents 9.27 Area Moment Method 382 9.28 Graphical Integration Method 383 9.29 Critical Speed of Shafts 385 Short-Answer Questions 388 Problems for Practice 389 10. Springs 393 10.1 Springs 393 10.2 Types of Springs 393 10.3 Terminology of Helical Springs 395 10.4 Styles of End 396 10.5 Stress and Defl ection Equations 397 10.6 Series and Parallel Connections 399 10.7 Spring Materials 401 10.8 Design of Helical Springs 403 10.9 Spring Design—Trial-and-Error Method 405 10.10 Design against Fluctuating Load 405 10.11 Concentric Springs 425 10.12 Optimum Design of Helical Spring 430 10.13 Surge in Spring 432 10.14 Helical Torsion Springs 433 10.15 Spiral Springs 435 10.16 Multi-Leaf Spring 437 10.17 Nipping of Leaf Springs 439 10.18 Belleville Spring 441 10.19 Shot Peening 443 Short-Answer Questions 443 Problems for Practice 444 11. Friction Clutches 448 11.1 Clutches 448 11.2 Torque Transmitting Capacity 450 11.3 Multi-disk Clutches 456 11.4 Friction Materials 459 11.5 Cone Clutches 461 11.6 Centrifugal Clutches 465 11.7 Energy Equation 467 11.8 Thermal Considerations 469 Short-Answer Questions 470 Problems for Practice 471 12. Brakes 472 12.1 Brakes 472 12.2 Energy Equations 472 12.3 Block Brake with Short Shoe 475 12.4 Block Brake with Long Shoe 480
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Contents xi 12.5 Pivoted Block Brake with Long Shoe 482 12.6 Internal Expanding Brake 485 12.7 Band Brakes 490 12.8 Disk Brakes 493 12.9 Thermal Considerations 496 Short-Answer Questions 496 Problems for Practice 497 13. Belt Drives 499 13.1 Belt Drives 499 13.2 Belt Constructions 501 13.3 Geometrical Relationships 503 13.4 Analysis of Belt Tensions 504 13.5 Condition for Maximum Power 507 13.6 Condition for Maximum Power (Alternative Approach) 507 13.7 Characteristics of Belt Drives 509 13.8 Selection of Flat-belts from Manufacturer’s Catalogue 514 13.9 Pulleys for Flat Belts 517 13.10 Arms of Cast-iron Pulley 520 13.11 V-belts 522 13.12 Selection of V-belts 534 13.13 V-grooved Pulley 535 13.14 Belt-Tensioning Methods 540 13.15 Ribbed V-belts 540 Short-Answer Questions 542 Problems for Practice 542 14. Chain Drives 544 14.1 Chain Drives 544 14.2 Roller Chains 546 14.3 Geometric Relationships 548 14.4 Polygonal Effect 549 14.5 Power Rating of Roller Chains 549 14.6 Sprocket Wheels 551 14.7 Design of Chain Drive 553 14.8 Chain Lubrication 555 14.9 Silent Chain 562 Short-Answer Questions 562 Problems for Practice 563 15. Rolling Contact Bearings 564 15.1 Bearings 564 15.2 Types of Rolling-contact Bearings 565 15.3 Principle of Self-aligning Bearing 568 15.4 Selection of Bearing-type 569 15.5 Static Load Carrying Capacity 569
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xii Contents 15.6 Stribeck’s Equation 569 15.7 Dynamic Load Carrying Capacity 571 15.8 Equivalent Bearing Load 571 15.9 Load-Life Relationship 572 15.10 Selection of Bearing Life 572 15.11 Load Factor 573 15.12 Selection of Bearing from Manufacturer’s Catalogue 573 15.13 Selection of Taper Roller Bearings 580 15.14 Design for Cyclic Loads and Speeds 588 15.15 Bearing with Probability of Survival other than 90 Per Cent 592 15.16 Needle Bearings 595 15.17 Bearing Failure—Causes and Remedies 596 15.18 Lubrication of Rolling Contact Bearings 596 15.19 Mounting of Bearing 597 Short-Answer Questions 598 Problems for Practice 599 16. Sliding Contact Bearings 601 16.1 Basic Modes of Lubrication 601 16.2 Viscosity 604 16.3 Measurement of Viscosity 605 16.4 Viscosity Index 605 16.5 Petroff’s Equation 606 16.6 McKee’s Investigation 607 16.7 Viscous Flow through Rectangular Slot 608 16.8 Hydrostatic Step Bearing 609 16.9 Energy Losses in Hydrostatic Bearing 611 16.10 Reynold’s Equation 619 16.11 Raimondi and Boyd Method 622 16.12 Temperature Rise 624 16.13 Bearing Design—Selection of Parameters 625 16.14 Bearing Constructions 634 16.15 Bearing Materials 635 16.16 Sintered Metal Bearings 637 16.17 Lubricating Oils 637 16.18 Additives for Mineral Oils 639 16.19 Selection of Lubricants 640 16.20 Greases 641 16.21 Bearing Failure—Causes and Remedies 641 16.22 Comparison of Rolling and Sliding Contact Bearings 642 Short-Answer Questions 643 Problems for Practice 644 17. Spur Gears 646 17.1 Mechanical Drives 646 17.2 Gear Drives 647
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Contents xiii 17.3 Classifi cation of Gears 647 17.4 Selection of Type of Gears 648 17.5 Law of Gearing 649 17.6 Terminology of Spur Gears 650 17.7 Standard Systems of Gear Tooth 653 17.8 Gear Trains 656 17.9 Interference and Undercutting 657 17.10 Backlash 658 17.11 Force Analysis 658 17.12 Gear Tooth Failures 665 17.13 Selection of Material 666 17.14 Gear Blank Design 667 17.15 Number of Teeth 670 17.16 Face Width 671 17.17 Beam Strength of Gear Tooth 672 17.18 Permissible Bending Stress 673 17.19 Effective Load on Gear Tooth 674 17.20 Estimation of Module Based on Beam Strength 677 17.21 Wear Strength of Gear Tooth 678 17.22 Estimation of Module Based on Wear Strength 680 17.23 Internal Gears 688 17.24 Gear Lubrication 690 Short-Answer Questions 690 Problems for Practice 690 18. Helical Gears 694 18.1 Helical Gears 694 18.2 Terminology of Helical Gears 694 18.3 Virtual Number of Teeth 695 18.4 Tooth Proportions 696 18.5 Force Analysis 697 18.6 Beam Strength of Helical Gears 702 18.7 Effective Load on Gear Tooth 702 18.8 Wear Strength of Helical Gears 703 18.9 Herringbone Gears 706 18.10 Crossed Helical Gears 708 Short-Answer Questions 709 Problems for Practice 710 19. Bevel Gears 711 19.1 Bevel Gears 711 19.2 Terminology of Bevel Gears 713 19.3 Force Analysis 715 19.4 Beam Strength of Bevel Gears 720 19.5 Wear Strength of Bevel Gears 722 19.6 Effective Load on Gear Tooth 722
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xiv Contents 19.7 Spiral Bevel Gears 727 Short-Answer Questions 728 Problems for Practice 728 20. Worm Gears 730 20.1 Worm Gears 730 20.2 Terminology of Worm Gears 731 20.3 Proportions of Worm Gears 733 20.4 Force Analysis 735 20.5 Friction in Worm Gears 737 20.6 Selection of Materials 741 20.7 Strength Rating of Worm Gears 742 20.8 Wear Rating of Worm Gears 744 20.9 Thermal Considerations 745 Short-Answer Questions 747 Problems for Practice 747 21. Flywheel 749 21.1 Flywheel 749 21.2 Flywheel and Governor 750 21.3 Flywheel Materials 750 21.4 Torque Analysis 751 21.5 Coefficient of Fluctuation of Energy 752 21.6 Solid Disk Flywheel 753 21.7 Rimmed Flywheel 755 21.8 Stresses in Rimmed Flywheel 756 Short-Answer Questions 767 Problems for Practice 767 22. Cylinders and Pressure Vessels 768 22.1 Thin Cylinders 768 22.2 Thin Spherical Vessels 769 22.3 Thick Cylinders—Principal Stresses 770 22.4 Lame’s Equation 771 22.5 Clavarino’s and Birnie’s Equations 772 22.6 Cylinders with External Pressure 774 22.7 Autofrettage 775 22.8 Compound Cylinder 775 22.9 Gaskets 779 22.10 Gasketed Joint 780 22.11 Unfi red Pressure Vessels 783 22.12 Thickness of Cylindrical and Spherical Shells 785 22.13 End Closures 785 22.14 Openings in Pressure Vessel 791 Short-Answer Questions 794 Problems for Practice 794
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Contents xv 23. Miscellaneous Machine Elements 796 23.1 Oil Seals 796 23.2 Wire Ropes 797 23.3 Stresses in Wire Ropes 800 23.4 Rope Sheaves and Drums 804 23.5 Buckling of Columns 806 Short-Answer Questions 812 Problems for Practice 812 24. Statistical Considerations in Design 814 24.1 Frequency Distribution 814 24.2 Characteristics of Frequency Curves 816 24.3 Measures of Central Tendency and Dispersion 817 24.4 Probability 819 24.5 Probability Distribution 819 24.6 Normal Curve 821 24.7 Population Combinations 823 24.8 Design and Natural Tolerances 825 24.9 Reliability 829 24.10 Probabilistic Approach to Design 830 Short-Answer Questions 840 Problems for Practice 841 25. Design of IC Engine Components 843 25.1 Internal Combustion Engine 843 25.2 Cylinder and Cylinder Liner 844 25.3 Bore and Length of Cylinder 845 25.4 Thickness of Cylinder Wall 845 25.5 Stresses in Cylinder Wall 846 25.6 Cylinder Head 847 25.7 Design of Studs for Cylinder Head 847 25.8 Piston 853 25.9 Piston Materials 854 25.10 Thickness of Piston Head 854 25.11 Piston Ribs and Cup 855 25.12 Piston Rings 856 25.13 Piston Barrel 857 25.14 Piston Skirt 858 25.15 Piston Pin 858 25.16 Connecting Rod 867 25.17 Buckling of Connecting Rod 868 25.18 Cross-section for Connecting Rod 869 25.19 Big and Small End Bearings 871
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xvi Contents 25.20 Big End Cap and Bolts 873 25.21 Whipping Stress 875 25.22 Crankshaft 880 25.23 Design of Centre Crankshaft 881 25.24 Centre Crankshaft at Top-Dead Centre Position 881 25.25 Centre Crankshaft at Angle of Maximum Torque 883 25.26 Side Crankshaft at Top-Dead Centre Position 892 25.27 Side Crankshaft at Angle of Maximum Torque 895 25.28 Valve-Gear Mechanism 903 25.29 Design of Valves 904 25.30 Design of Rocker Arm 906 25.31 Design of Valve Spring 910 25.32 Design of Push Rod 911 Short-Answer Questions 922 Problems for Practice 923 References 927 Index 930
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Preface It was really a pleasure to receive an overwhelming response to the textbook Design of Machine Elements since it was published first in 1994. In fact, whenever I visit an engineering college in any part of the country, students and staff members of the Mechanical Engineering Department know me as the ‘Machine Design author’ and the book has become my identity. Machine design occupies a prominent position in the curriculum of Mechanical Engineering. It consists of applications of scientific principles, technical information and innovative ideas for the development of a new or improved machine. The task of a machine designer has never been easy, since he has to consider a number of factors, which are not always compatible with the present-day technology. In the context of today’s techni- cal and social climate, the designer’s task has become increasingly difficult. Today’s designer is required to account for many factors and considerations that are almost impossible for one individual to be thoroughly conversant with. At the same time, he cannot afford to play a role of something like that of a music director. He must have a special competence of his own and a reasonable knowledge of other ‘instruments.’ New to this Edition After the publication of the second edition in 2007, it was observed that there was a need to incorporate a broader coverage of topics in the textbook to suit the content of ‘Machine Design’ syllabi of various uni- versities in our country. One complete chapter on ‘Design of Engine Components’ (Chapter 25) and half a chapter on ‘Design of Riveted Joints’ (Chapter 8) are added to fulfill this requirement. Design of Engine Components includes cylinders, pistons, connecting rods, crankshafts and valve-gear mechanism. Design of Riveted Joints includes strength equations, eccentrically loaded joints and riveted joints in boiler shells. Another important feature of the current edition is changing the style of solutions to numerical examples. A ‘step-by-step’ approach is incorporated in all solved examples of the book. This will further simplify and clarify the understanding of the examples. Target Audience This book is intended to serve as a textbook for all the courses in Machine Design. It covers the syllabi of all universities, technical boards and professional examining bodies such as Institute of Engineers in the country. It is also useful for the preparation of competitive examinations like UPSC and GATE. This textbook is particularly written for the students of the Indian subcontinent, who find it difficult to adopt the textbooks written by foreign authors. Salient Features The main features of the book are the following: (i) SI system of units used throughout the book (ii) Indian standards used throughout the book for materials, tolerances, screw threads, springs, gears, wire ropes and pressure vessels
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xviii Preface (iii) The basic procedure for selection of a machine component from the manufacturer’s catalogue discussed with a particular reference to Indian products (iv) Step by step approach of problem solving Organization The book is divided into 25 chapters. Chapter 1 is an introductory chapter on machine design and discusses the various procedures, requirements, design methods and ergonomic considerations for design. Chapter 2 is on engineering materials and describes the different kinds of irons, steels and alloys used in engineering design. Chapter 3 explains in detail the manufacturing considerations in design. Chapters 4 and 5 discuss the various procedures for design against static load and fluctuating load correspondingly. Chapter 6 describes power screws in detail while chapters 7 and 8 specify the features and varieties of threaded joints, and welded and riveted joints in that order. Similarly, chapters 9 to 22 are each devoted to a particular design element, that is, shafts, keys and couplings; springs; friction clutches; brakes; belt drives; chain drives; rolling contact bearings; sliding contact bearings; spur gears; helical gears; bevel gears; worm gears; flywheel; cylinders and pressure vessels respectively. Chapter 23 describes miscellaneous machine elements like oil seals, wire ropes, rope sheaves and drums. Chapter 24 details the various statistical considerations in design. Finally, Chapter 25 explains the design of IC engine components. Web Resources The readers should note that there is a website of this textbook which can be accessed at http://www.mhhe.com/bhandari/dme3e that contains the following. For Instructors: (i) Solution Manual (ii) Power Point Lecture Slides For Students: (i) Interactive 643 Objective Type Questions (ii) 803 Short Answer Questions (iii) Glossary (iv) Bibliography The above additional information will be useful for students in preparing for competitive examinations. Acknowledgements For this textbook, information has been collected from various sources such as textbooks, handbooks, cata- logues and journals. I would like to express my gratitude to the authors, publishers and firms who have per- mitted me to use their valuable material in this textbook. The following firms and individuals need special mention: 1. A A Raimondi of Westinghouse Electric Corporation, USA for the data on ‘Dimensionless Performance Parameters of Hydrodynamic Bearings’ 2. George Sines, University of California, USA for the ‘Notch Sensitivity Charts’ in Fatigue Design 3. B K Sollars, President, Diamond Chain Company, USA, for his valuable suggestions and design data related to the selection of roller chains 4. McGraw-Hill Education, USA, for their permission to include the table of ‘Reliability Factors’ from their publication Mechanical Engineering Design by J E Shigley and ‘Surface Finish Factors’ in Fatigue Design from Engineering Considerations of Stress, Strain and Strength by R C Juvinall 5. Associated Bearing Company Limited, Mumbai, for their permission to include different tables for the selection of SKF bearings
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Preface xix 6. The Dunlop Rubber Co. (India) Ltd., Kolkata, for their permission to include data for the ‘Selection of Dunlop belts’ 7. The Bureau of Indian Standards, New Delhi, for its permission to include extracts from standards- IS-4218, IS-7008, IS-919, IS-1570, IS-2644, IS- 733, IS-2403, IS-3681, IS-2266, IS-3973, IS-5129, IS-4454, IS-4694, IS-210, IS-1030, IS-617, IS-813, IS-25, IS-2825, IS-2365, IS-2494 and IS-7443 I acknowledge with a deep sense of gratitude, the encouragement and inspiration received from my stu- dents, readers and teachers. I would also like to thank the following reviewers of this edition whose names are given below. A Bhattacharya Institute of Technology, Banaras Hindu University Banaras, Uttar Pradesh A D Bhatt Motilal Nehru National Institute of Technology, Allahabad Allahabad, Uttar Pradesh Pratesh Jayaswal Madhav Institute of Technology and Science Gwalior, Madhya Pradesh Shivabrata Mojumdar Dr B C Roy Engineering College Durgapur, West Bengal Shashidhar K Kudari D Y Patil College of Engineering and Technology Kolhapur, Maharashtra P M Bapat Manohar Lal Patel Institute of Engineering and Technology Nagpur, Maharashtra A D Diwate Sinhagad Institute of Technology Pune, Maharashtra R Sesharajan Bharat Heary Electricals Limited Vela Murali College of Engineering, Guindy Guindy, Tamil Nadu K S Seetharama Adichunchanagiri Institute of technology Chikmagalur, Karnataka K Mallikarjuna Rao Jawaharlal Nehru Technological University College of Engineering Kakinada, Andhra Pradesh A C S Kumar Jawaharlal Nehru Technological University College of Engineering Hyderabad, Andhra Pradesh A special thanks to the Editorial and Production teams of Tata McGraw-Hill headed by Vibha Mahajan and her enthusiastic team members—Shalini Jha, Suman Sen, Devshree Lohchab, Sohini Mukherjee and P L Pandita.
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xx Preface Feedback Suggestions and comments for improvement of the book will be appreciated. They can be sent either to the publisher or to me at bhandariprof@gmail.com . V B BHANDARI Publisher’s Note Do you have a feature request? A suggestion? We are always open to new ideas (the best ideas come from you!). You may send your comments to tmh.mechfeedback@gmail.com (kindly mention the title and author name in the subject line). Piracy-related issues may also be reported.
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