Mechanical Engineer's Data Handbook

354 Pages·2003·6.22 MB·English

by  James Carvill

1'1
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JAMES CARVll !

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Mechanical Engineer’s Data Handbook

SOFTbank E-Book Center Tehran, Phone: [phone] For Educational Use.

To my daughters, Helen and Sarah

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Mechanical Engineer’s
Data Handbook

J. Carvill

IUTTERWORTH
E
I
N
E
M
A
N
N

OXFORD AMSTERDAM BOSTON LONDON NEW YORK PARIS
SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO

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Butterworth-Heinemann
An imprint of Elsevier Science
Linacre House, Jordan Hill, Oxford OX2 8DP
200 Wheeler Road, Burlington MA 01803

First published 1993
Paperback edition 1994
Reprinted 1994,1995,1996,1997,1998,1999,2000 (twice), 2001 (twice), 2003

Copyright 0 1993, Elsevier Science Ltd. All riehts reserved.

No part of this publication may be reproduced in any material form (includmg
photocopying or storing in any medium by electronic means and whether
or not transiently or incidentally to some other use of this publication) without
the written permission of the copyright holder except in accordance with the
provisions of the Copyright, Designs and Patents Act 1988 or under the terms of
a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road,
London, England WIT 4LP. Applications for the copyright holder’s written
permission to reproduce any part of this publication should be addressed
to the publishers

British Library Cataloguing in Publication Data
Carvill, James
Mechanical Engineer’s Data Handbook
I. Title
62 1

Library of Congress Cataloguing in Publication Data
Carvill, James
Mechanical engineer’s data handbook/James Carvill.
p. an.
Includes index.
1. Mechanical engineering - Handbooks, manuals, etc.
TD51 .C36
I. Title.

62 1 -dc20
92- 19069
CIP

ISBN 0 7506 1960 0

I
For information on all Butterworth-Heinemann publications
visit our website at www.bh.com
I

Typeset by Vision Typesetting, Manchester
Printed in Great Britain by Bookcraft (Bath) Ltd, Somerset

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Contents

Preface

Symbols used in text

1. Strength of materials
1.1 Types of stress
1.2 Strength of fasteners
1.3 Fatigue and stress concentration
1.4 Bending of beams
1.5 Springs
1.6 Shafts
1.7 Struts
1.8 Cylinders and hollow spheres
1.9 Contact stress
1.10 Flat plates

2. A p p l i mechanics
2.1 Basic mechanics
2.2 Belt drives
2.3 Balancing
2.4 Miscellaneous machine elements
2.5 Automobile mechanics
2.6 Vibrations
2.7 Friction
2.8 Brakes, clutches and dynamometers
2.9 Bearings
2.10 Gears

3. Tbennodyanmics and heat transfer
3.1 Heat
3.2 Perfect gases
3.3 Vapours
3.4 Data tables
3.5 Flow through nozzles
3.6 Steam plant
3.7 Steam turbines
3.8 Gas turbines
3.9 Heat engine cycles
3.10 Reciprocating spark ignition internal

3.1 1 Air compressors
combustion engines

vii

ix

1

1
8
17
24
32
38
46
48
51
53

56
56
65
68
70
77
79
83
87
90
95

102
102
I02
106
107
111
112
114
116
118

120
I24

3.12 Reciprocating air motor
3.13 Refrigerators
3.14 Heat transfer
3.15 Heat exchangers
3.16 Combustion of fuels

4. Fluid mechanics
4.1 Hydrostatics
4.2 Flow of liquids in pipes and ducts
4.3 Flow of liquids through various devices
4.4 Viscosity and laminar flow
4.5 Fluid jets
4.6 Flow of gases
4.7 Fluid machines

5. Manufacturing technology
5.1
5.2 Turning
5.3 Drilling and reaming
5.4 Milling
5.5 Grinding
5.6 Cutting-tool materials
5.7 General information on metal cutting
5.8 Casting
5.9 Metal forming processes
5.10 Soldering and brazing
5.1 1 Gas welding
5.12 Arc welding
5.13 Limits and fits

General characteristics of metal processes

6. Engineering materials
6.1 Cast irons
6.2 Carbon steels
6.3 Alloy steels
6.4 Stainless steels
6.5 British Standard specification of steels
6.6 Non-ferrous metals
6.7 Miscellaneous metals
6.8 Spring materials
6.9 Powdered metals
6.10 Low-melting-point alloys

126
127
i28
137
139

146
146
148
152
155
157
160
165

172
172
173
178
182
188
189
192
196
199
205
207
210
216

218
218
219
22 1
225
228
228
233
235
236
236

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vi
MECHANICAL ENGINEER’S DATA HANDBOOK

6.11 Miscellaneous information on metals
6.12 Corrosion of metals
6.13 Plastics
6.14 Elastomers
6.15 Wood
6.16 Adhesives
6.17 Composites
6.18 Ceramics
6.19 Cermets
6.20 Materials for special requirements
6.21 Miscellaneous information

7. Engineering measurements
7.1 Length measurement
7.2 Angle measurement
7.3 Strain measurement

237
240
242
248
250
25 1
257
259
259
260
263

267
267
270
27 1

7.4 Temperature measurement
7.5 Pressure measurement
7.6 Flow measurement
7.7 Velocity measurement
7.8 Rotational-speed measurement
7.9 Materials-testing measurements

8. General data
8.1 Units and symbols
8.2 Fasteners
8.3 Engineering stock
8.4 Miscellaneous data

Glossary of terms

Index

274
279
28 1
283
284
285

288
288
293
304
308

31 1

330

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Preface

There are several good mechanical engineering data books on the market but these tend to be very bulky and
expensive, and are usually only available in libraries as reference books.
The Mechnical Engineer’s Data Handbook has been compiled with the express intention of providing a
compact but comprehensive source of information of particular value to the engineer whether in the design office,
drawing office, research and development department or on site. It should also prove to be of use to production,
chemical, mining, mineral, electrical and building services engineers, and lecturers and students in universities,
polytechnics and colleges. Although intended as a personal handbook it should also find its way into the libraries
of engineering establishments and teaching institutions.
The Mechanical Engineer’s Data Handbook covers the main disciplines of mechanical engineering and
incorporates basic principles, formulae for easy substitution, tables of physical properties and much descriptive
matter backed by numerous illustrations. It also contains a comprehensive glossary of technical terms and a full
index for easy cross-reference.
1 would like to thank my colleagues at the University of Northumbria, at Newcastle, for their constructive
suggestions and useful criticisms, and my wife Anne for her assistance and patience in helping me to prepare this
book.

J. Carvill

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Symbols used in text

~~

a
A
d
b
b.p.
B

C

C

Cd

CP
CY

COP

cv
d

D
e

E

EL

Acceleration
Area
Anergy
Breadth
Boiling point
Breadth, flux density
Clearance, depth of cut; specific heat
capacity
Couple; Spring coil index; velocity
(thermodynamics); heat capacity
Drag coefficient, discharge coefficient
Coefficient of performance
Specific heat at constant pressure
Specific heat at constant volume; velocity
coefficient
Calorific value
Depth; depth of cut; diameter;
deceleration
Depth; diameter; flexural rigidity
Strain; coefficient of restitution;
emissivity
Young’s Modulus; energy; luminance;
effort

j
J
k

K

KE
K ,
1
L

rn

m
m.p.
M

MA
n

N
Ns
Nu
V

Operator J- 1
Polar second moment of area
Radius of gyration; coefficient of thermal
conductivity; pipe roughness
Bulk modulus; stress concentration
factor
Kinetic energy
Wahl factor for spring
Length
Length
Mass; mass per unit length; module of
gear
Mass flow rate
Melting point
Mass; moment; bending moment;
molecular weight
Mechanical advantage
Index of expansion; index; number of;
rotational speed
Rotational speed; number of
Specific speed
Nusselt number
Pressure; pitch
Elastic limit; endurance limit
P
Power; force; perimeter
ELONG% Percentage elongation
8
Exergy
f
Frequency; friction factor; feed
F
Force; luminous flux
F,
Strain gauge factor
FL
Fatigue limit
FS
Factor of safety
9
Acceleration due to gravity
G
Shear modulus; Gravitational constant
Gr
Grashof number
h
Height; thickness; specific enthalpy;

h.t.c.
Heat transfer coefficient
H

i
slope; operator J-l
I

shear, heat transfer coefficient

Enthalpy; height, magnetic field strength

Moment of inertia; Second moment of
area; luminous intensity, electric current

pr
PE
PS
Q

r
R

R e

Ro
RE

S
S

SE
s,
t

Prandtl number
Potential energy
Proof stress
Heat quantity; volume flow rate; metal
removal rate
Radius; pressure or volume ratio
Radius; electric resistance; reaction,
thermal resistance; gas constant
Reynolds number
Refrigeration effect
Universal gas constant
Specific entropy; stiffness
Entropy, shear force, thermoelectric
sensitivity
Strain energy
Stanton number
Temperature; thickness; time

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X
MECHANICAL ENGINEER’S DATA HANDBOOK

T

TS

U

U

UTS

V
VR

W

X

Y
YP
YS
Z

U

W

X

ZP

Time; temperature; torque; tension;
thrust; number of gear teeth
Tensile strength
Velocity; specific strain energy; specific
internal energy
Internal energy; strain energy; overall
heat transfer coefficient
Ultimate tensile stress
Velocity; specific volume
Velocity; voltage, volume
Velocity ratio
Weight; weight per unit length
Weight; load; work; power (watts)
Distance (along beam); dryness fraction
Parameter (fluid machines)
Deflection
Yield point
Yield stress
Bending modulus; impedance; number of
Polar modulus

Angle; coefficient of linear expansion;
angular acceleration; thermal diffusivity ;
Resistance temperature coefficient
Angle; coefficient of superficial expansion
Angle; coefficient of volumetric
expansion; ratio of specific heats
Angle
Permittivity
Efficiency
Angle; temperature
Wavelength
Absolute viscosity; coefficient of friction
Poisson’s ratio; kinematic viscosity
Density; resistivity; velocity ratio
Resistivity
Stress; Stefan-Boltzmann constant
Shear stress
Friction angle; phase angle; shear strain;
pressure angle of gear tooth
Angular velocity

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II
Strengths of materials

1.1
Types of stress

Engineering design involves the correct determination
of the sizes of components to withstand the maximum
stress due to combinations ofdirect, bending and shear
loads. The following deals with the different types of
stress and their combinations. Only the case of two-

dimensional stress is dealt with, although many cases
of three-dimensional stress combinations occur. The
theory is applied to the special case of shafts under
both torsion and bending.

I. I. I

Tensile and compressive stress (direct stresses)

Direct, shear and bending stress

load
P
Stress o=-=- area A

extension
x
original length =z
Strain e=

Stress a
P L
- -Young's modulus, E . Thus E =-
Strain e
Ax

Poisson's ratio

strain in direction of load
strain at right angles to load

6BIB eB

Poisson's ratio v =

--
- ~ L / L = <

Note: $e, is positive, eB is negative.

Shear stress

P
Shear stress T = -
A

Shear strain 4=:,
where G=Shear modulus
G

Note: A is parallel to the direction of P .

I
P

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2
MECHANICAL ENGINEER’S DATA HANDBOOK

Bending stress

MY
Bending stress a = -
I

where:
M = bending moment
I = second moment of area of section
y = distance from centroid to the point considered

MYm
Maximum stress am=-
I

where y , =maximum value of y for tensile and com-
pressive stress.

E l
Radius of curvature R = -
M

Bending modulus Z = I/ym and u,,, = M / Z

T

NA = neutral axis

Combined bending and direct stresses

I
a, = PIA M / Z where Z = -
Ylll

Hydrostatic (three-dimensional) stress

U V
Volumetric strain e, = -
V
Bulk modulus K =pie,
where p = pressure and V= volume.

P

V

Relationship between elastic constants

Compound stress

For normal stresses u, and ay with shear stress 5 :
Maximum principal stress a1 = (a, + ay)/2 +
Minimum principal stress a2 = (a, + aJ2
-t,,,

e= 112 tan-‘ (+I

Combined bending and torsion

For solid and hollow circular shafts the following can
be derived from the theory for two-dimensional (Com-
pound) stress. If the shaft is subject to bending moment

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STRENGTHS OF MATERIALS
3

M and torque T, the maximum direct and shear
stresses, a, and 7,,, are equal to those produced by
‘equivalent’ moments Me
and T, where

5, = T,/Z, and a, = M,/Z

where Z , = polar modulus

T, = ,/m
and M e = (M + T,)/2

nD3
K (D4-d4)
Z=-
(solid shaft) or -
~
(hollow shaft)
32
32
D

I[ (D4-d4) (hollow shaft)
Z,=-
(solid shaft) or - -
nD3

16
16
D

See section 1.1.7.

M b
I. I .2
Impact stress

In many components the load may be suddenly
applied to give stresses much higher than the steady
stress. An example of stress due to a falling mass is
given.

Maximum tensile stress in bar

a,=a,[l +J-

where :
a, = steady stress = mgiA
x, = steady extension = w L / A E
h = height fallen by mass m.

Stress due to a ‘suddenly applied’ load (h=O)

urn = 2a,

Stress due to a mass M moving at velocity v

I. I .3
Compound bar in tension

A compound bar is one composed of two or more bars
of different materials rigidly joined. The stress when
loaded depends on the cross-sectional areas (A, and
Ab) areas and Young’s moduli (E, and Eb) of the
components .

Stresses

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4
MECHANICAL ENGINEER’S DATA HANDBOOK

Strains

e, = a,/E,; e,, = ab/E,, (note that e, = e,,)

a

F
F

I. I .4
Stresses in knuckle joint

The knuckle joint is a good example of the application
of simple stress calculations. The various stresses
which occur are given.

Symbols used:
P = load
a, = tensile stress
a,, = bending stress
a, =crushing stress

7 =shear stress
D = rod diameter
D, = pin diameter
Do = eye outer diameter
a=thickness of the fork
b = the thickness of the eye i

Failure may be due to any one of the following
stresses.

(1 ) Tensile in rod a, = 4P/nDZ

(2) Tensile in eye 6, = P/(Do - D,)b

(3) Shear in eye z=P/(D,-D,)b
p-$gPp
9
approx

(4) Tensile in fork a, = P/(Do - D,)2a

a
a

(5) Shear in fork T = P/(Do-Dp)2a