Mechanical Engineers' Handbook: Materials and Mechanical Design, Volume 1, Third Edition

1350 Pages·2005·9.29 MB·English

Mechanical Engineers’ Handbook
Mechanical Engineers’ Handbook
Third Edition
Materials and
Mechanical Design
Edited by
Myer Kutz
JOHN WILEY & SONS, INC.
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LibraryofCongressCataloging-in-PublicationData:
Mechanicalengineers’handbook/editedbyMyerKutz.—3rded.
p.cm.
Includesbibliographicalreferencesandindex.
ISBN-13978-0-471-44990-4
ISBN-100-471-44990-3(cloth)
1. Mechanicalengineering—Handbooks,manuals,etc. I. Kutz,Myer.
TJ151.M3952005
621—dc22
2005008603
PrintedintheUnitedStatesofAmerica.
10 9 8 7 6 5 4 3 2 1
To Sol, Dorothy, and Jeanne, in Blessed Memory
Contents
Preface ix
Vision Statement xi
Contributors xiii
PART 1 MATERIALS 1
1. Carbon and Alloy Steels 3
Bruce L. Bramfitt
2. Stainless Steels 39
James Kelly
3. Aluminum Alloys 59
J. G. Kaufman
4. Copper and Copper Alloys 117
Konrad J. A. Kundig and John G. Cowie
5. Selection of Titanium Alloys for Design 221
Matthew J. Donachie
6. Nickel and Its Alloys 256
Gaylord D. Smith and Brian A. Baker
7. Magnesium and Its Alloys 278
Robert E. Brown
8. Selection of Superalloys for Design 287
Matthew J. Donachie and Stephen J. Donachie
9. Plastics: Information and Properties of Polymeric Materials 335
Edward N. Peters
10. Composite Materials 380
Carl Zweben
11. Smart Materials 418
James A. Harvey
12. Overview of Ceramic Materials, Design, and Application 433
R. Nathan Katz
13. Sources of Materials Data 450
J. G. Kaufman
14. Quantitative Methods of Materials Selection 466
Mahmoud M. Farag
PART 2 MECHANICAL DESIGN 489
15. Stress Analysis 491
Franklin E. Fisher
vii
viii Contents
16. An Introduction to the Finite-Element Method 557
Tarek I. Zohdi
17. Design for Six Sigma: A Mandate for Competitiveness 581
James E. McMunigal and H. Barry Bebb
18. TRIZ 612
James E. McMunigal, Steven Ungvari, Michael Slocum, and Ruth E. McMunigal
19. Computer-Aided Design 642
Emory W. Zimmers, Jr., and Technical Staff of Enterprise Systems Center
20. Data Exchange Using STEP 725
Martin Hardwick
21. Engineering Applications of Virtual Reality 732
Xiaobo Peng and Ming C. Leu
22. Physical Ergonomics 762
Maury A. Nussbaum and Jaap H. van Diee¨n
23. Electronic Materials and Packaging 782
Warren C. Fackler
24. Design Optimization: An Overview 819
A. Ravi Ravindran and G. V. Reklaitis
25. Design for Manufacturing and Assembly with Plastics 847
James A. Harvey
26. Failure Modes: Performance and Service Requirements for Metals 860
J. A. Collins and S. R. Daniewicz
27. Failure Analysis of Plastics 925
Vishu H. Shah
28. Failure Modes: Performance and Service Requirements for Ceramics 942
Dietrich Munz
29. Mechanical Reliability and Life Prediction for Brittle Materials 962
G. S. White, E. R. Fuller, Jr., and S. W. Freiman
30. Total Quality Management in Mechanical Design 980
B. S. Dhillon
31. Reliability in the Mechanical Design Process 1000
B. S. Dhillon
32. Lubrication of Machine Elements 1024
Bernard J. Hamrock
33. Seal Technology 1161
Bruce M. Steinetz
34. Vibration and Shock 1204
Singiresu S. Rao
35. Noise Measurement and Control 1230
George M. Diehl
36. Nondestructive Inspection 1253
Robert L. Crane and Jeremy S. Knopp
Index 1307
Preface
The first volume of the third edition of the Mechanical Engineers’Handbook is comprised
of two major parts. The first part, Materials, which has 14 chapters, covers metals,plastics,
composites, ceramics, and smart materials. The metals covered are carbon, alloy, and stain-
lesssteels;aluminumandaluminumalloys;copperandcopperalloys;titaniumalloys;nickel
and its alloys; magnesium and its alloys; and superalloys. Chapters on some of these ma-
terials, such as ceramics, smart materials, and superalloys, are updated versions of chapters
that have appeared in the Handbook of Materials Selection (Wiley, 2002), and they are
entirely new to the Mechanical Engineers’Handbook. The intent in all of the materials
chapters is to provide readers with expert advice on how particular materials are typically
used and what criteria make them suitable for specific purposes. This part of Volume I
concludes with a chapter on sources of materials data, the intent being to provide readers
with guidance on finding reliable information on materials properties, in addition to those
thatcanbefoundinthisvolume,andachapteronanalyticalmethodsofmaterialsselection,
whichisintendedtogivereaderstechniquesforspecifyingwhichmaterialsmightbesuitable
for a particular application.
ThesecondpartofVolumeI,MechanicalDesign,whichhas22chapters,coversabroad
range of topics, including the fundamentals of stress analysis, the finite-element method,
vibration and shock, and noise measurement and control and then moving into modern
methodologies that engineers use to predict failures, eliminate defects, enhance quality and
reliabilityofdesigns,andoptimizedesigns.Therearechaptersonfailureanalysisanddesign
withallclassesofmaterials,includingmetals,plasticsandceramics,andcomposites.Ishould
point out that, to a large extent, the two parts of Volume I go hand in hand. After all, it is
useful to know about the properties, behavior, and failure mechanisms of all classes of
materialswhenfacedwithaproductdesignproblem.CoverageinthesecondpartofVolume
I extends to lubrication of machine elements and seals technology. Chapters in this part of
Volume I provide practitioners with techniques to solve real, practical everyday problems,
ranging from nondestructive testing to CAD (computer-aided design)to TRIZ(theacronym
in Russian for Theory of Inventive Problem Solving), STEP [theStandardfortheExchange
of Product Model Data is a comprehensive International Organization for Standardization
standard (ISO 10303) that describes how to represent and exchange digital product infor-
mation], and virtual reality. Topics of special interest include physicalergonomicsandelec-
tronic packaging.
WhilemanyofthechaptersinVolumeIareupdatesorentirelynewversionsofchapters
from the second edition of the Mechanical Engineers’Handbook and the Handbook of
Materials Selection, a number of chapters—on Six Sigma, TRIZ, and STEP—are new ad-
ditions to this family of handbooks. Contributors of the chapters in Volume I include pro-
fessors,engineersworkinginindustryandgovernmentinstallations,andconsultants,mainly
from North America, but also from Egypt, the Netherlands, and Germany.
ix
Vision for the Third Edition
Basicengineeringdisciplinesarenotstatic,nomatterhowoldandwellestablishedtheyare.
The field of mechanical engineering is no exception. Movement within this broadly based
disciplineismultidimensional.Eventheclassicsubjectsonwhichthedisciplinewasfounded,
such as mechanics of materials and heat transfer, continue to evolve. Mechanical engineers
continue to be heavily involved with disciplines allied to mechanical engineering, such as
industrial and manufacturing engineering, which are also constantly evolving. Advances in
othermajordisciplines,suchaselectricalandelectronicsengineering,havesignificantimpact
on the work of mechanical engineers. New subject areas, suchasneuralnetworks,suddenly
become all the rage.
Inresponsetothisexciting,dynamicatmosphere,theMechanicalEngineers’Handbook
is expanding dramatically, from one volume to four volumes. The third edition not only is
incorporating updates and revisions to chapters in the second edition, which was published
in1998,butalsoisadding24chaptersonentirelynewsubjectsaswell,incorporatingupdates
and revisions to chapters in the Handbook of Materials Selection, which was published in
2002, as well as to chapters in Instrumentation and Control, edited by Chester Nachtigal
and published in 1990.
The four volumes of the third edition are arranged as follows:
Volume I: Materials and Mechanical Design—36 chapters
Part 1. Materials—14 chapters
Part 2. Mechanical Design—22 chapters
Volume II: Instrumentation, Systems, Controls, and MEMS—21 chapters
Part 1. Instrumentation—8 chapters
Part 2. Systems, Controls, and MEMS—13 chapters
Volume III: Manufacturing and Management—24 chapters
Part 1. Manufacturing—12 chapters
Part 2. Management, Finance, Quality, Law, and Research—12 chapters
Volume IV: Energy and Power—31 chapters
Part 1: Energy—15 chapters
Part 2: Power—16 chapters
The mechanical engineering literature is extensive and has been so for a considerable
period of time. Many textbooks, reference works, and manuals as well as a substantial
number of journals exist. Numerous commercial publishers and professional societies, par-
ticularly in the United States and Europe, distribute these materials. The literature grows
continuously, as applied mechanical engineeringresearchfindsnewwaysofdesigning,con-
trolling, measuring, making and maintaining things, and monitoring and evaluatingtechnol-
ogies, infrastructures,and systems.
Most professional-level mechanical engineering publications tend to be specialized, di-
rected to the specific needs of particular groups of practitioners. Overall, however, the me-
chanical engineering audience isbroad and multidisciplinary. Practitionersworkinavariety
of organizations, including institutions of higher learning, design, manufacturing, and con-
xi
xii Vision for the Third Edition
sulting firms as well as federal, state, and local government agencies. A rationale for an
expanded general mechanical engineering handbook is that every practitioner, researcher,
and bureaucrat cannot be an expert on every topic, especially in so broad and multidiscipli-
nary a field, and may need an authoritative professional summary of a subject with which
he or she is not intimately familiar.
Starting with the first edition, which was published in 1986, our intention has always
been that the Mechanical Engineers’Handbook stand at the intersection of textbooks, re-
search papers, and design manuals. For example, we want the handbook to help young
engineers move from the college classroom to the professional office and laboratory where
they may have to deal with issues and problems in areas they have not studied extensively
in school.
With this expanded third edition, we have produced a practical reference for the me-
chanical engineer who is seeking to answer a question, solve a problem, reduce a cost, or
improve a systemorfacility. Thehandbook isnot aresearchmonograph.Thechaptersoffer
design techniques, illustrate successful applications, or provide guidelines to improving the
performance, the life expectancy, the effectiveness, or the usefulness of parts, assemblies,
and systems. The purpose is to show readers what options are available in a particular
situation and which option they might choose to solve problems at hand.
Theaimofthisexpandedhandbookistoserveasasourceofpracticaladvicetoreaders.
We hope that the handbook will be the first information resource a practicing engineer
consults when faced with a new problem or opportunity—even beforeturning tootherprint
sources, even officially sanctioned ones, or to sites on the Internet. (The second edition has
been available online on knovel.com.) In each chapter, the reader should feel that he or she
is in the hands of an experienced consultant who is providing sensible advice that can lead
to beneficial action and results.
Can a single handbook, even spread out over four volumes, cover this broad, interdis-
ciplinary field? We have designed the third edition of the Mechanical Engineers’Handbook
as if it were serving as a core for an Internet-based information source. Many chapters in
the handbook point readers to information sources on the Web dealing with the subjects
addressed. Furthermore, where appropriate, enough analytical techniques and data are pro-
vided to allow the reader to employ a preliminary approach to solving problems.
The contributors have written, to the extent their backgrounds and capabilities make
possible, in a style that reflects practical discussion informed by real-world experience. We
would like readers to feel that they are in the presence of experienced teachers and con-
sultantswhoknowaboutthemultiplicityoftechnicalissuesthatimpingeonanytopicwithin
mechanicalengineering.Atthesametime,thelevelissuchthatstudentsandrecentgraduates
can find the handbook as accessible as experienced engineers.
Contributors
Brian A. Baker George M. Diehl
Special Metals Corporation Machinery Acoustics
Huntington, West Virginia Phillipsburg, New Jersey
H. Barry Bebb Matthew J. Donachie
ASI Rennselaer at Hartford
San Diego, California Hartford, Connecticut
Bruce L. Bramfitt Stephen J. Donachie
Research Laboratories Special Metals Corporation
International Steel Group, Inc. Huntington, West Virginia
Bethlehem, Pennsylvania
Warren C. Fackler
Robert E. Brown Telesis Systems
Magnesium Monthly Review Cedar Rapids, Iowa
Prattville, Alabama
Mahmoud M. Farag
J. A. Collins The American University in Cairo
The Ohio State University Cairo, Egypt
Columbus, Ohio
Franklin E. Fisher
John G. Cowie Loyola Marymount University
Copper Development Association Los Angeles, Calaifornia
New York, New York and
Raytheon Company
Robert L. Crane El Segundo, California
Wright Patterson Air Force Base
Dayton, Ohio S. W. Freiman
National Institute of Standards and
S. R. Daniewicz Technology
Mississippi State University Gaithersburg, Maryland
Starkville, Mississippi
E. R. Fuller, Jr.
B. S. Dhillon National Institute of Standards and
University of Ottawa Technology
Ottawa, Ontario, Canada Gaithersburg, Maryland
Jaap H. van Diee¨n Bernard J. Hamrock
Vrije Universiteit The Ohio State University
Amsterdam, The Netherlands Columbus, Ohio
xiii