Machine Design Databook

1332 Pages·2002·24.91 MB·English

by  K. Lingaiah

Copyrighted Material

MACHINE DESIGN

DATABOOK

K. Lingaiah, Ph.D.

Bangalore University

Professor Emeritus

Adichunchanagiri Institute of Technology

Second Edition

l\1cGraw-Hill

New York Chicago San Francisco
Lisbon London Madrid

Mexico City Milan New Delhi
San Juan Seoul

Singapore
Sydney Toronto

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Copyrighted Material

M 1.j:}pdt.fl§IQll •. l11/Ti,i .M

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ISBN: 97S-0--07-150<>49-4

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Copyrighted Material

Copyrighted Material

CONTENTS

Preface
xv

Ackuowledgments
xix

1 Pro1>erties of Engineering lVlaterials
1.1

S)~nbols
I.I

Suffixes
l.2

Abbreviations
1.2
Hardness
l.7

Wood
1.1 1

References
1.81

Bibliography
Ui2

2 Static Stresses in !Vfachine Elements
2.1

Symbols
2.L

Simple Stress and Strain
2.3

Srresses
2.4

Pure Shear
2.6

Biaxial Stresses
2.6

Biaxial Stresses Combined with Shear
2.7

Mohr's Circle
2.8
T ria.xi al Stress
2.8

Mohr's Circle
2.9

S!ress-S(rain Relations
2.10

Statistically Iudetenniuate Members
2.11

Thermal S(ress and Strain
2.12

Compo11nd Bars
2.13

Equivalent or Combined Modulus of

Elas'.icity of Compound Bars
2.14

Power
2.14

Torsion
2.15

Bending
2.16

Eccentric Loading
2.17

Column Formulas
2.17

Hertz Contact Stress
2.20

Design of Machine Elements and Structures Made of Composite
2.23

Filament Reinforced Structures
2.25
Filament Binder Composite
2.27

Filament-Overlay Composite
2.29

Formula' and Darn. for Various Cross Sections of

Machine Rlemen~5
230

Refe.rences
2.49

Bibliography
2.49

iii

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iv
Contents-

3
Dynamic Stresses in l\ilacbinc Elements
3.1

Symbols
3.1
Inertia Force
J.3

Energy Met11od
3.3

fmpact Stresses
3.4

Bcudjng Stress in Beams due to Cmpact
3.6
Torsion of Beam/llar due to Impact
3.7
Longitudinal Stre>>·Wave iu Elastic Media
3.8
Longitudinal Impact on a Long Bar
3.8

Torsional Impact 011 a Bar
3.10

Illertia in Collision of Elastic Bodies
3.12

Resilience
3.12
References
3.16

Oibliography
3.16

4
Stress Concentration and Stress Intensity

in J\'Iachine l\1embers
4.1

Symbols
4.1

Reduction or Mitigation of Stress Concentrations
4.19

Stress Intensity Factor or Fracture Toughness Factor
4.25

References
4.33

5
Design of l\il achine Elements for Strength
5.1

Symhols
5.1

Slatjc Loads
5.3

Index of Sensitivity
S.4

Surface Condit.ion
5.4

Safety Fac:.or
S.5

T heories of Frulure
5.10

Cyclic Loads
5.10

Stress-Stress and Stress-Load Relations
S.12

The Combined Stresses
5.16

Combined Stresses in Terms of Loads
5.17

Creep
5.18

Reliability
S.19

References
5.25

6
Cains
6.1

Symbols
6.1

Radius of Curvature. of Disk Cam with Roller Follower
6.2
Radius of Curvature of Disk Cam with Flat-Faced Follower
6.3

PressUl'e Angle
6.4

Radial Cam-T ranslating Roller-Follower-Force Analysis
6.6

Side Thrust
6.7

Basic Spiral Contour Cam
6.7

Basic Spiial Conrour Ca.m Constants
6.8

Her12. Contact Stresses
6.8

References
6.15

Copyrighted Material

Copyrighted Material

Contents
,.

7 Pipes, Tubes, and Cylinders
7.1

Symbols
7.1
Long Thin Tubes with lu!e.rnal Pressure
7.2

Engines aud Pressure Cylinders
7.9

Openings in Cylindrical Drums
7.9

Tbin Tubes 1\-iLh E.xtcrnal Pressure
7.10

Sl1ort Tubes with External Pressures
7. l l

Lame's Equations for Thick Cylinders
7.12

Deformation of a Thick Cylinder
7.13

Compo11nd Cyijnders
7.14

Thermal S:resses in Long Hollow Cylinders
7.14

Clavarino's Equation for Closed Cylinders
7.16

Dirnie·s Equations for Open Cylinders
7.16

Oarlow's Equation
?.Ii

References
7.20

8 Design of Pressure Vessels, Plates, and Shells
8.1

Symbols
8.1

Plates
8.7

Shells (Unfired Pressure Vessel)
8.11

Fonned Heads under Pressure o n Concave Side
8.23
Formed Heads under Pressure o n Convex- Side
8.27

Unstayed Flat Heads and Covers
8.31

Stayed F lat and Braced Pla(es or Surfaces
8.35

Openings and Reinforcem~ut
8.37

Ligamenr.s
8.60
Bolted Plange Connect.ions
8.61
Integral-Type F langes and L-00se-Type Flanges with a Hub
8.67

Loose-Type Flanges without Hub and Loose-Type F langes
with Hub Which (he Designer Chooses to Calculate
8.67

References
8.71

9 Design of Power Boilers
9.1

Symbols
9.l

Boiler Tubes and Pipes
9.2

Dished Head.•
9.7

Unstayed F lat Heads and Covers
9.&

Combustion Chamber and Furnaces
9.9
T he Maxim1011 Allowable Pressure for Special Furnaces Having

Walls Reinforced by Ribs, Rings, and Corrngations
9.14

Final Ratios
9.19

Refe.rences
9.26

10 Rotating Disks and Cylinders
10.l

Symbols
10.l

Disk of Uniform Strength Rotating at w rad/ s
10.l

Solid Disk Rotating at w rad/s
10.I

Hollow Disk Rotating at w rad/ s
10.2

Solid Cylinder Rotating at w rad /s
10.3

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vi
Contents-

Hollow Cylinder Rotating al w rad/ s
I0.3

Solid Thin Ut1iform Disk Ro'.ating at w rad/ sunder

Exrerual Pressure Po
I0.4

Hollow Cylinder of Unifonu T hickness Rotating at w rad is.

Subject to Internal (p;) and External (;oJ Pressures
10.5

Rotating Thick Disk a11d Cylinder wilh Unifom1 Thickness

Subject to Thermal Stresses
10.6
Rotating L-Ong Hollow Cylinder with Uniform Thickness Rotating

at w rad/s Subject to T hermal Stress
10.7

Deflection or a Rotating Disk of Uniform Thickness in Radial Direction

with a Ce11trnl Circular Cutout
10.7

Refe.rences
I 0.9

11 l\1etal Fits, Tolerances, and Surface Texture

Symbols
Suffixes
Press and Shrink Fi:s
lnterfereuce Fits
Tolerances and Allowances
References

12 Design of \Velded Joints

Symbols
Fillet Weld
Butt Weld
T ransverse Fillet Weld
Parallel Fillet Weld
Length of Weld
Eccentricity in a Fillet Weld
Eccentric Loads
S:resses
.Fatigue Strength
Design Stre..<s of Welds
T he St re.nglh Aiialysis of a Typical Weld Joint Subjected

to Eccentric Loading

Combined Force Due to P, , P,. and .P, at Point Q
General
Refe.re11ces
Bibliography

13 Riveted Joints

Symbols
Pressure \ 7 essels
Pitches
Margin
Cover Plaies
Strength Analy~is of Typical Riveted Joint
Efficiency of the RiveLed Joint.
T he Length of the Shank of Rivet

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11.1

I I.I
I I.I
I l.2
11.4
I 1.6

11.33

12.l

12.1
12.2
12.2
12.3
12.3
12.4
12.4
12.5
12.5
12.6
12.7

12.7

12.10
12.11
12.11
12.11

13.1

13.1
13.2
13.2
13.6
13.6
13.8
U.9
13.9

14

15

Structural Joint
Riveted Bracker
References
Bibliography

Design of Shafts
Symbols
Suffixes
Solid Shafts
Hollow Shafts

Copyrighted Material

Comparison Bet.ween Diamerers of Solid and Hollow Shafts of Same Lengrlt
Stiffness
Rigidity
Effect of Keyways
The Buckling Factor
Shafts Subjected to Various Stresses
GeneJ'al
Refere11ces
Bibliography

Flywheels
Symbols
Kinetic Energy
Flywheel Effect or Polar Moment of Inertia
Stres.<es in Rim
Stresses in Anns
Rim Dimensions
Arms
References

16 Packings and Seals
Symbols
Elastic Packing
Friction
Metallic Gaskets
Self-Scaling Packing
Paclcingless Seals
S:raight-01!. Sealings
V-Ring Packing
Bolt Loads in Gasket Joint According to ASilfE Boil~,.

a1Jd PreJSure Vessd Lode

Flange Design Dolt Load W
References

17 Keys, Pins, Cotters, and Joints

Symbols
Suffixes
Round or Pin Keys

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13.IO
13.IO
13.11
13. l l

14.l

14.l
14.2
14.2
14.5
14.9

14.IO
14.IO
14.IO
14.10
14.10
14.16
14.17
14.17

15.1

15.I
15.2
15.3
15.3
15.4
15.4
15.5
15.5

16.l

16.l
16.2
16.2
16.2
16.3
16.4
16.4
16.5

16.6
16.7

16.34

17.l

17.1
17.2
17.2

Contents
vii

vil i
Cont~nts

Strength of Keys
Taper Key
Friction of Feather Keys
Splines
Indian Standard
Pins
Colter
References

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17.2
17.4
17.7
17.10
t 7.16
17.20
17.24
17.26

18 Threaded Fasteners and Screws for Power Trans1nission
18.1

Symbols
S11ffixes
Screws
Tension Bolled Joint under Exte.rnal L-0ad
Preloaded Bolt
Gasket .Joints
Preloaded Bolts 1111der Dynamic Loading
Loading
General
References

19 Couplings, Clutches, and Brakes

Symbols
Suffixes
19.1 Couplings
Common Flange Co11pling
Marine Type of Flange Coupling
Pulley Flange Coupling
Pin or Busl1 Type Flexible Coupling
Oldham Coupling
Muff or Sleeve Co11pling
Fairbairn's Lap-Box Coupling
Split Muff Coupling
Slip Couplhtg
Sellers' Cone Coupling
Hydraulic Couplings
19.2 O utches
Positive Clutd1es
Frictjoo Clutches
Disk Clmches
Dimensions of Disks
Design of a Typical Clutch Operati11g Lever
BxpandJng-R.ing Outches
Rim Clutd1es
Centrifugal Clutch
Overrunning Clutches
1.9.3 llrakes
Energy EqlJations
Brake Formulas

Copyrighted Material

18.1
18.3
l&.3
l&.5
18.6
L8.7
l&.7

18.13
18.20
18.76

19.l

19.L
19.4
19.4
19.4
19.7
19.9
19.1 1
19.12
19.14
19.15
19.15
19.16
19.17
19.17
19.19
19 19
19.20
19.21
19.22
19 23
19.24
19.24
19.25
19.27
19.29
19.29
19.31

Cone Brakes
Considering the Lever
Disk Drakes
Internal Expanding-Rim Brake
External Contracting-Rim Brake
Heating of Brakes
Reiereuces

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19.34
19.34
19.35
19.35
19 37
19.38
19.42

20 Springs
20. l

Symbols
20.I

Suffixes
20 .2

Leaf Springs
20.2

Laminated Spring
20.4

Laminated Springs with Initial Curvature
20.5

Disk Springs (Belleville Springs)
20.6

lleLlcal Springs
20.9

Spring Sea le
20.10

Resilience
20.10

Rectangular Section Springs
20.10

Square Sectjon Spring
20. 13

Selection of Maltrials and Stresses for Springs
20.14

Design of Helical Compression Springs
20.15
$(ability of Helical Springs
20.21

Repeated Loading
20.22
Concentric Spr in g.~
20.24

Vibration of Helical Springs
20.24

S:ress Wave Propagation in Cylindrical Springs under Impact Load
20.26

Helical E.xtension Springs
20.27

Conical Springs
20.28

1\oumetallic Springs
20.29

Torsio11 Springs
20.29

References
20.33

Bibliography
20.33

21.
Flexible l\tlacbine Elements
21.1

Symbols
Suffixes
Belts
Belt Lengths and Contact Angles for Open and Crossed Belts
Pulleys
Indian Standard Specification
V-Belt
Minimum Allowances for Adjustment of Centers for
Two Transmission Pulleys

Initial Tension
Syncb.ronous Belt Drive Analysis
c:onveyor
Short. Center Urive
Ropes

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21.l
21.4
21.4

21.14
21.16
21.17
21.22

21.35
21.35
21.35
21.43
21.44
21.45

Cont.cnts
ix

X
Contents

Hoisting Tackle
Drums

Copyrighted Material

Iloldiug Capacity of Wire Rope Reels
Wire Rope Construction
Chains
Check for Actual Safety Factor
Reierences

22 J\1echaoical Vibrations

21 .46
21.49
21.50
21 .50
21.50
21.&3
21.100

22.l

S)~ubols
22.l

Simple Harmonic Motion
22.2
Energy
22.4

Logarithmic Decrement
22.7

Equivalent Spring Consr.antS
22.7

Unbala11ce due to Rotating Mass
22.10
Whipping of Rotating Shaft
22.12

Excitatfon of a System by Motion of Support
22.12

Instrument for Vibration Measuring
22.13

Isolation of Vibration
22.13

Undamped Two-Degree-ol~Freedom System \\~tit.out Ex:erual Force
22.15

Dynamic Vibration Absorber
22.15

Torsional Vibrating Systems
22.16

References
22.25

23 Design of Bearings and Tribology
23.l

23.1 Slicling Contact Bearings
23.1

Symbols
21.1

Sllear Stress
23.5

Viscosity
23.5

Hagen-Poiseuille Law
23.12

Vertical Shaft Rotating in a Guide Dearing
23.13

Dearing Pressure
23.17

Idealized Journal Bearing
23.21

Influence of Misalignment of Shaft in Bearing
23.33

Power Loss
23.34

Partial Journal Bearing
23.37

Influence of End Leakage
23.38

Friction in a Full Journal Bearing with End Leakage from B''<lring
23.45

Oil Flow through Journal Bearing
23.47
T hermal Equilibrium of Journal Bearing
23.49

Bearing Cap
23.55

External Pressurized Bearing or Hydros:atic Bearing: Journal Bearing
23.56

Idealized Slider Bearing
23.59

Design of Vertical, Pivot, and Collar Bearing
23.61

Plain Thrust Dearing
23.64

Oil Fihn T hickness
23.66

Coeffi.(,~ent of Fri(.iion
23.67

Hydrosrar.ic Bearing: Step-Bearing
23.67

Spnerical Ilea rings
23. 75

~
23.M

Copyrighted Material

23.2 Rolling Contact Be.arings
Symbols
Rolling Elements Beariugs
Speed
Gear-Tooth Load
Static Loadiug

Copyrighted Material

Basic Static Load R.atillg as per Indian Standards
Thnist Bearings
Catalogue Information from FAG for the Selection of Bearing
Dynamic Load Rating of Bearings
Life
Basic Dynamic Load Rating as per FAG Catalogue
Life Adj1L~ tment Factors
Basic Dynamic Load Rating of Bearings as per Indian Standards
Thrust Bearings
The Equivalen: Dynamic Load for Angular Contact Ball Bearings
The Bquivalne~ Dynamic Load for Tapered Roller Boariug's
Dimensions, Basic Load Rating Capacity, Fatigue Load Limit,

and Maximum PennL'5ible Speed of Rolling Contact Bearings

Needle Bearing Load Capacity
Pressure
Hertz-Con:act Pressure
Selection of Fi: for Bearings
23.3 Friction and Wear
Symbols
Frictjon
Wear and Abra<ion
General
Refe.rences
Bibliography

24 l\1iscellaneous l\1lachine Elements

24 .. 1 Crankshafts
S}1nbols
Suffixes
Force Analysis
Side Crank
llollow Crankpin
Dimension of Crankshaft Main Bearing
Proportions of Crankshafts
Center era n.k
Equivalen L Shafts
Empirical Proporuons
24.2 Cun·ed Beam
Symbols
Suffixes
General
Approximate Empirical Equation for Curved Beams

S~resses in Rings
Deffection

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23.77
23.77
23.&0
23.80
23.82
23.&4
23.&4
23.86
23.&8
23.90
23.90
23.90

23.101
23.!05
23.!08
23.117
23.119

23.119
23.120
23.120
23.121
23.150
23.154
23.154
23.156
23.158
23.167
23.173
23.174

24.l

24.1
24.l
24.2
24.2
24.3
24.4
24.5
24.6
24.7
24.9
24.9
24.12
24.12
24.12
24.13
24.15
24.15
24.16

Cont.cnts
xi

xii
Conl•n1S

Link
Cra11e Hook of Circular Section
24.3 Connecting and Coupling Rod
Symbols
Design of Connecting Rod
Design of Small and Big Ends
Design of Bolts for Big-End Cap
Design of Coupling Rod
24.4 Piston and Piston Rings

S)~ubols
Steam Engine Pistons

Copyrighted Material

Proportions for Preliminary Layout for Plate Pistons
S;res.<es
Pisrnos for lnremal-Comb1L5rion Engines
Commonly Used Empirical Formulas in the Design of
Trnnk Pistons for Automotive-Type Engines
24.5 Design of Speed Reduction Gears and Variable-Speed Dri•cs
Symbols
Planetary Reduction Gears
Conditions of Proper Assembly of Planetary Gear Transmission
Wave-Type Reduction Gears
Variable-Speed Drives
Dissipation of Hear in Reduction Gear Drives
Minimum and Total Weight Equation for Gear Systems
24.6 Fl'ic.tion Gearin~

S)~ubols
Spur Fricrfon Gears
Bevel Friction Gears
Disk Friction Gears
Bearing Loads of Frictio11 Gearing
24. 7 Mecl1anics of Vehicles
Symbols
Suffixes
Calculation of Power
Transmission Gearbox
Hydraulic Coupling

Hydro<l~rnmic Torque Converter
Tractive Effort Curves for Cars, Trucks, and Ciry Buses
24.8 lntetmitteot-Motion Mechanisms

S~ubols
Pawl and Ratchet
24.9 Geneva Mechanism
Symbols
External Geneva Wheel
Displacement
Velocity
Acceleration
Snock or Jerk
Torque Acting on ShaftS of Geoeva Wheel and Driver
Instantaneous Power

Copyrighted Material

24.16
24.16
24.19
24. 19
24.20
24.22
24.22
24.24
24.26
24.26
24.27
24.28
24.28
2430

24.30
24.47
24.47
24.50
24.51
24.52
24.52
24.54
24.56
24.58
24.58
24.58
24.60
24.62
24.65
24.67
24.67
24.68
24.68
24.70
24.73
24.74
24.75
24.79
24.79
24 79
24.82
24.82
24.&3
24.&4
24.84
24.85
24.86
24.87
24.87

Copyrighted Material

Contents
xiii

Forces at the Point of Contact
24.89

Iitternal Gene.va Wheel
24.89

24.10 Uni<ersal Joint
24.91

Symbols
24.91

Single Universal Joint
24.91

Double Universal Joint
24.92

24.11 Unsynunetric.al Bending and Tor.sion of Nondrmlar

Cross-Section Machine Elemeuts
24.97

Symbols
24.97

Shear Center
24.98

Unsymmetrical Bending
24.98

Torsion
24.9&

Narrow R ectartgnlar Cros.5 Sect.ion.<
24.99

Composire Sections
24.!03

Hollow Thi11-Walled Tubes
24.104

Bending Stresses Caused by Torsion
24.105

Transverse L-Oad o n Deam of Channel Section not through

Shear Center
24.106

References
24.116

25 Elements of l\1;1cltinc Tool Design
25.1

Symbols
25.1

25.1 Metal Cutting Tool Design
25.4

Forces ou a Single-Poin: Metal Cutting Tool
25.4

Merchant's Circle for 0..tting Forces

for a Single-Point Metal Cutting Tool
25.5

Power
25.8

Speeillc Power or Unit Power Cou:mmption
25.8

Tool Design
25.9

Tool Signature~
25.9

Tool Life
25.10

25.2 Machine Tools
25.15
Lathe Turning
25.17

DrilLing Machine
25.19

Taps and Tapping
25.25

Broachii1g Machine
25.2&

Milling M achines
25.31

References
25.103

26 Retaining Rings and Circlips
26.1

Symbols
26.1

Retaining Rings and Circlips:
26.2

References
26.13

27 Applied Elasticity
27.l

Symbols
27.1

Stress ar a Point.
27.3

Equations of Equilibrium
27.6

Transformation of Stress
27.6

Copyrighted Material

xiv
Cont"'1ts

Principal Stresses
S(rain

Copyrighted Material

T hree-Dimensional Stress-Strain System
Biaxial Stress-Strain System
Shear Strains
Strain and Displaceme11t
Boundary Conditions
Compatibility
General Hooke's Law
A.iry's Stress Function
Cylindrical CoordinaLes SysLem
Strain Components
Airy's Stress Function in Polar Coordinates
Solution of £lastici1.y Problems Using A.iry's Stress Punction
Application of Stress Function
S(ress Distribution in a Flat Plate with Holes or Cutouts under
Different Types of Loads

Rotating Solid Disk with Unifonn T ltickness
Rotating Disk -.ilh a Central Qrcular Hole of Unifonu
Thickness

Rotating Disk of Variable Thickness
l\eutral Holes (Mansfield Theory)
Complex Variable Method Applied to Elasticity
Strain Combinations
Plane Strain
Boundary Conditions
Force and Couple Resultant.s around the Boundary
Generalized Plane Stress
Conditions along a Stress-free Boundary
Sol111ion fo,•olving Circular Boundaries
Applicat:ion of Conformal Transformation
Muskhelishvili's Direct Medtod
Torsio11
T orsio11 of Circular Shafi of Variable Diameter
Plates

Index

Copyrighted Material

27.&

27.10
27.10
27. 11
27.11
27.12
27.15
27.15
27.16
27.21
27.22
27.23
27.24
27.25
27.27

27.28
27.32

27.33
27.35
27.36
27.39
27.40
27.41
27.41
27.42
27.42
27.43
27.43
27.44
27.52
27.59
27.68
27.70

T. l