MACHINE DESIGN
By
Dr. N. C. Pandya & Dr. C. S. Shah
Edition : 17th Edition : 2009
ISBN : 978 - 81 - 85594-92 - 7
Size : 135 mm × 210 mm
Binding : Paperback with Four color Jacket Cover
Pages : 1064 + 16
Table of Contents
Chapter 1 : MATERIALS OF CONSTRUCTION AND
THEIR PROPERTIES
1-1 Introduction
1-2 Choice of material
Factors Affecting the choice of a Material
1-3 Materials of construction
(a) Ferrous Metals (b) Non-ferrous Metals
1-4 Structure of materials
Structure of Metalic Materials
1-5 Mechanical properties of materials of construction
1-6 Determination of mechanical properties
1-7 Fabrication characteristics and processes of fabrication
(a) FormabilityHot working precesses, Cold working process
Power metallurgy
(b) Castability, Solidfication Rate, Shrinkage, Segregation
Gas Porosity, Hot Strenghth
(c) Machinability
(d) Weldbility, Heat and cooling, Oxidation Gas
1-8 Ferrous metals - Cast iron, wrought iron and steel
1-10 Available sizes
1-11 Accuracy
1-12 Finishing processes
1-13 Non-metallic materials
1-14 Plastics
1-15 Composite Materials
1-16 Improvements in properties of materials
Examples
Chapter 2 : DESIGN CONSIDERATlONS IN MACHINE
PARTS
2-1 Loads
2-2 Stress
2-3 Strain
2-4 Stress-Strain diagram : Modulus of elasticity
2-5 Poisson’s ratio
2-6 Modulus of rigidity
2-7 Bulk modulus
2-8 Basic requirements of machine elements
(i) Strength (iii) Wear resistance
(ii) Stiffness
2-9 Factor of safety : Selection of allowable stresses
2-10 Procedure for designing a machine element
2-11 Tensile stress
2-12 Compressive stress
2-13 Shearing stress
2-14 Bearing pressure intensity
2-15 Bending (Flexure) Effect or ribs on castings
2-16 Shear stresses in a beam
2-17 Torsion
2-18 Eccentric loading
2-19 Combined stresses : Bending combined with direct load
2-20 Offset connecting links and C shaped frames
2-21 Shear stresses combined with tensile and compressive stresses
2-22 Theories of elastic failure
2-23 Designing for impact loads
2-24 Design of members subjected to impact torsion
2-25 Stress concentration
2-26 Notch sensitivity
2-27 Effect of repeated application of a load
2-28 Fluctuating stress for ductile materials Ellipse quadrant relationship
Design to avoid fatigue failure
2-29 Cummulative damage in fatigue : (Miner’s equation)
2-30 Fatigue life determined by short-term resting
2-31 Light weight and minimum dimensions
2-32 Elastic matching
2-33 Temperature stresses
Examples
Chapter 3 : CYLINDERS, TANKS AND PIPES
3-1 Introduction
3-2 Types of vessels
3-3 Design of thin cylinders
3-4 Design of a thin spherical shell
3-5 Cylindrical shell with hemi-spherical ends Cylindrical shell
Hemispherical shell, Hemispherical shell
3-6 General theory of membrane stresses in vessels under internal
pressure
3-7 Design of pipes
3-8 Design of thick cylinders, Design of hydraulic cylinder
Other design considerations
3-9 Design equation for thick cylinders
Examples
Chapter 4 : RIVETED JOINTS
4-1 Introduction
4-2 Rivets
4-3 Rivet heads
4-4 Types of riveted joints
4-5 Caulking and fullering
4-6 Design of a riveted joint for boiler construction
Design of a boiler joint
4-7 Efficiency of a riveted joint
Design of a circumferential lap point
4-8 Joints for storage tanks
4-9 Lozenge joint
4-10 Eccentric loads on riveted connections
4-11 Rules in designing riveted joints
4-12 Advantages of welding over riveting, Circular arrangement
Rectangular arrangement , Triangular arrangement
Examples
Chapter 5 : BOLTS, NUTS AND SCREWS
5-1 Introduction
5-2 Definitions
5-3 Forms of screw threads
5-4 Advantages of square threads over V threads
5-5 Screw fastenings
(i) Through bolts
(ii) Tap bolts and cap screws
(iii) Machine screws
(iv) Set Screws
(v) Studs
5-6 Locking devices for nuts
5-7 Washers
5-8 Eye bolt
5-9 Efficiency of threads
5-10 Stresses in screw fastenings
5-11 Initial stresses
5-12 Stresses due to external forces
5-13 Stresses due to combined load
5-14 Bolts of uniform strength
5-15 Screwed boiler stays
5-16 Bolts subjected to shear
5-17 Bolts under eccentric loading
(a) When load is paralled to the bold axis
(i) Rectangular base
(ii) Circular base
(b) When load is perpendicular to the axis of the bolt
5-18 Design of a nut
5-19 Power transmitting capacity of set screws
Examples
2
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Telephone: (02692) 256237, Fax: (02692) 240089, e-mail: charotar@cphbooks.com, Website:www.cphbooks.com Back
Chapter 6 : COTTER AND KNUCKLE JOINTS
6-1 Introduction
6-2 Design of cottered joints
(a) Tension failure of the rods at diameter d
(b) Tension failure of the rod across slot
(c) Tension failure of the socket across the slot
(d) Shear failure of the cotter
(e) Shear failure of the rod end
(g) Crushing failure of the rod or the cotter
(h) Crushing failure of the socket or the cotter
6-3 Gib and cotter
6-4 Connection of a piston rod to a crosshead
6-5 Cotter foundation bolts
6-6 Introduction
6-7 Joint of suspension links
6-8 Design of a coupler or a turnbuckle
(a) Diameter of the rod
(b) Length of the screwed portion of the nut at each end
(c) Outside diameter of the coupler at the nut portion
(d) Outside diameter of the coupler at the middle
Examples
Chapter 7 : SHAFTS, KEYS AND COUPLINGS
7-1 Introduction
7-2 Materials and design stresses
7-3 Design of axles
7-4 Design of shafts on the basis of strength
(a) The maximum normal stress theory (Rankine’s theory)
(b) The maximum shear stress theory (Guest’s theory)
(c) The maximm strain theory (St. Venant’s theory)
Empirical desing of shafts
7-5 Design of shafts on the basis of rigidity
Torsional, Lateral rigidity, Critical speed
7-6 Design of hollow and non-circular shafts
7-7 Form of keys
7-8 Keys
7-9 Design of sunk keys
7-10 Effect of keyways in sunk keys
7-11 Taper pins
7-12 Feather keys and splined shafts
7-13 Force and shrink fits (Driving fits on solid shafts)
7-14 Couplings : Introduction
7-15 Sleeve couplings or muff couplings
7-16 Clamp or compression couplings
7-17 Flange couplings
7-18 Marine type of flange couplings
7-19 Flexible couplings
7-20 Bushed pin type of flexible couplings
7-21 Bibby type of flexible coupling
7-22 Leather pad type flexible coupling
7-23 Oldham’s coupling
7-24 Universal coupling
7-25 Safety couplings
7-26 Flexible shafts
Examples
Chapter 8 : SPRINGS
8-1 Introduction
8-3 Optimum design of helical springs
8-4 Helical springs of non-circular wires
8-5 Concentric helical springs
8-6 General considerations in design of compression and extension
springs
8-7 Torsion helical springs
8-8 Spiral springs (Power springs)
8-9 Leaf springs
8-10 Belleville springs
8-11 Energy-storage capacity
Examples
Chapter 9 : BEARINGS
9-1 Introduction
9-2 Bearing area
9-3 Sliding bearings : Solid journal bearings
9-4 Divided journal bearing : Plummer block
9-5 Hydrodynamic theory of lubrication
9-6 Oil grooving
9-7 Heating of bearings
9-8 Design procedure for hydrodynamic journal bearings
9-9 Bearing materials
9-10 Design of bearing caps and bolts
9-11 Foot step or pivot bearings
9-12 Collar bearings
9-13 Anti-friction bearings
9-14 Radial ball bearings
9-15 Roller bearings
9-16 Selection of ball and roller bearings
9-17 Bearing load
(a) Calculations of a bearing load in gear drives
(b) Calculations of a bearing load in belt drives
9-18 Equivalent bearing load
(a) Combined bearing load (b) Design for variable loading
9-19 Carrying capacity and life
9-20 Relationship between load and life
9-21 Requisite bearing life for different types of machines
9-22 Life or Timken bearings
9-23 Influence of high temperatures on load carrying capacity
9-24 Permissible misalignment
9-25 Friction in rolling bearings
9-26 Comparison of sleeve and rolling bearings
Examples
Chapter 10 : STRUTS AND COLUMNS
10-1 Introduction
10-2 Euler’s formula
10-3 End fixity coefficients
10-4 Radius of gyration and plane of buckling
10-5 Rankine’s formula
10-6 Tetmajer’s formula
10-7 Johnson formula
10-8 Design of push rods
10-9 Eccentrically loaded columns
Examples
Chapter 11 : POWER SCREWS
11-1 Introduction
11-2 Forms of threads
11-3 Force analysis
11-4 Design of a screw
11-5 Design of a nut
11-6 Practical design of simple lifting machines (screw jack)
11-7 Compound screw
11-8 Differential screw
11-9 Ball screws
Examples
Chapter 12 : LEVERS
12-1 Introduction
12-2 General procedure for design of levers
12-3 Hand lever
12-4 Foot lever
12-5 Cranked lever
12-6 Lever of a lever loaded safety valve
12-7 Rocker arm for Diesel engines (Straight arm)
12-8 Angular levers
12-9 Design of overhung cranks
12-10 Design of a crank pin (overhung crank)
12-11 Miscellaneous examples
Examples
3
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Telephone: (02692) 256237, Fax: (02692) 240089, e-mail: charotar@cphbooks.com, Website:www.cphbooks.com Back
Chapter 13 : BRACKETS
13-1 Brackets
13-2 Hangers
13-3 Wall boxes
13-4 Design considerations
Examples
Chapter 14 : BELTS, PULLEYS AND CHAINDRIVES
14-1 Introduction
14-2 Materials for belts
14-3 Design of belts
14-4 Design procedure for flat belts
14-5 V-belt drives
14-6 Design of V-flat drives
14-7 Pulleys : Materials and types
14-8 Cast iron pulleys
14-9 Design of cast iron pulleys
14-10 Steel pulleys
14-11 Wooden pulleys
14-12 Fast and loose pulleys
14-13 Speed cones
14-14 Short centre drive : Gravity idlers
14-15 Special tension adjusting belt drives
14-16 Chain drives : (Introduction)
14-17 Roller chains
14-18 Design of chain drives
Examples
Chapter 15 : FLYWHEELS
15-1 Introduction
15-2 Determination of mass of a flywheel for a given coefficient of
fluctuation of speed
15-3 Flywheel for punches and shears
15-4 Engine flywheels
Examples
Chapter 16 : GEARS
16-1 Introduction
16-2 General characteristics
16-3 Spur gear terminology
16-4 Gear tooth forms
16-5 Accuracy of gears
16-6 Materials
16-7 Allowable stresses
16-8 Design considerations
16-9 Strength of gear teeth : Lewis equation
16-10 Dynamic tooth load
16-11 Design for wear
16-12 Gear wheel proportions
16-14 Racks
16-15 Introduction
16-16 Proportions for helical gears
16-17 Design of helical gear teeth
(a) Design for strength (c) Design for wear
(b) Design for dynamic load
16-18 Herringbone gears
16-19 Rating of machine cut spur and helical gears
Kilowatt power for strength, Kilowatt for wear
16-20 Introduction
16-21 Definitions
16-22 Strength of bevel gear teeth
16-23 Constructional details
16-24 Bearing loads
16-25 Introduction
16-26 Worm gear nomenclature
16-27 Strength of worm gear teeth
16-28 Bearing loads on the shafts
Examples
Chapter 17 : WELDED CONNECTIONS
17-1 Introduction
17-2 Welding processes
17-3 Types of welded joints
17-4 Working stresses in welds
17-5 Strength of welds
17-6 Special cases of fillet welds
17-7 Eccentric loads on welded connections
17-8 Design procedure recommended by American Welding Society
17-9 Fillet welds under varying loads
Examples
Chapter 18 : DESIGN OF MISCELLANEOUS MACHINE
PARTS I ENGINES AND BOILERS
18-1 Design of flat plates
(a) Cicular plate subjected to a uniformly distributed load of p
and supported on the outside periphery
(b) Rectangular plate subjected to uniformly distributed load p
and supported on the outside periphery
(c) Circular plant subjected to a uniformly distributed load p
and clamped on the outside edge
Project I Design of hydraulic press
Material selection, Design of a ram, Lower movable table
Upper table or Bridge piece, Packing for hydraulic ram
18-2 Design of a piston for I.C. Engines
18-3 Design of crossheads
Introduction, Wrist pin, Shoe, Guide, Crosshead bolts
Cap or keep plate
18-4 Design of connecting rods
Connecting rods and piston pins, Connectign rod type
Loads on connecting rods, Connecting rod length Connecting
rod sections, Materials, Calculations of connectingrods
18-5 Design of crankshafts
18-6 Design of a spring-loaded Hartnell governor
Introduction
(a) Spring design (c) Design of a cust steel body
(b) Design of a spindle (d) Design of a bell crand lever
18-7 Design of an eccentric, Design calculations
18-8 Compensating ring for a manhole
18-9 Design of safety valves for boilers
18-10 Design of a screw down steam stop valve
18-11 Design of cams (I.C. Engines)
18-12 Design of a valve gear for I.C. Engines
Materials, Value Design, Design of a spring, Design of a lever
or a rooker arm, Design of a push rod, Design of a camshaft
Rock arm, Fulcrum for a rocker arm, Roller end
Examples
Chapter 19 : DESIGN OF MISCELLANEOUS MACHINE
PARTS II BRAKES AND CLUTCHES
(A) Hoisting equipments
19-1 Introduction
19-2 Design of hoisting chains and drums
19-3 Design of a hoisting rope
Values of rn for various sections of curved Beams
19-6 Design of a crane hook
19-7 Introduction
19-8 Types of brakes
19-9 Design procedure for block brakes, Brake wheels, Brake shoe
Brake linings, Brake lever, Pull rods, Energy considerations in
design of brackes
19-10 Band brakes : Introduction
19-11 Design procedure for band brakes
19-12 Introduction, Friction clutches, Cone clutch
19-13 Design procedure for friction clutches
Examples
4
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Chapter 20 : DESIGN PROJECTS
20-1 Introduction
I Hand operated bench press
(1) Lever (6) Stand
(2) Torque rod (7) Frame
(3) Crank (8) Sliding head
(4) Toggle connecting rod (9) Adjustable head
(5) Toggle bars
Other considerations
Format for drawings
Surface finishes
Tolerances
Sketches and drawings
Reduction Gear
(1) Selection of materials
(2) Preliminary sketch
(3) Gears
(4) High speed shaft and bearings
(5) Low-speed shaft bearings
(6) Lubrication of gears and bearings
(7) Housing
(8) Hand operated bench press
(1) Air cylinder
(2) Compressed air receiver
(3) Pneumatic arbor press
(4) Bearing puller
(5) Toggle jack
(6) Bench vice
(7) Governor bell crank lever
(8) Bracket and bolts for tilting gear
(9) Power shaft
(10) Power shaft and a pulley
(11) Back gear of a lathe
(12) Two speed gear box
(13) Single stage speed reducer
(14) Speed reducer
(15) Winch
(16) Pulley block
(17) Jib crane
(18) Cam
(19) Combination punch and shear
(20) Drill press
(21) Globe valve design
(22) Selection of materials
(23) Specific shapes for sections
APPENDIX I Sl System
APPENDIX II Properties of Ferrous Materials
APPENDIX III Properties of Plastics
APPENDIX IV List of Indian Standards : “Testing of Materials”
APPENDIX V Indian Standards referred in the text
APPENDIX VI Preferred Numbers (Rounded values)
APPENDIX VII Deflection formulas for machine parts
APPENDIX VIII Metric threads
APPENDIX IX Common sizes of transmission shafts
(Dimensions in mm)
APPENDIX X Properties of geometrical Sections
APPENDIX XI Imperial or Legal Standard Wire Gauge
APPENDIX XII Sizes of pulleys for flat and V-belts
APPENDIX XIII Width of flat cast iron and mild steel pulleys
APPENDIX XIV Service factors for belt drives
APPENDIX XV Load carrying capacity of V-belts
APPENDIX XVI Worm data
APPENDIX XVII Basic thicknesses of sheet and diameters of
wire in millimetres
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