P ART I F UNDAMENTALS 1 C HAPTER 1 I NTRODUCTION TO D ESIGN 1.1 Design Machine Design Introduction to Design Machine Iteration 1.2 A Design Process 1.3 Problem Formulation and Calculation Definition Stage Preliminary Design Stage Detailed Design Stage Documentation Stage 1.4 The Engineering Model Estimation and First-Order Analysis The Engineering Sketch 1.5 Computer-Aided Design and Engineering Computer-Aided Design (CAD) Computer-Aided Engineering (CAE) Computational Accuracy 1.6 The Engineering Report 1.7 Factors of Safety and Design Codes Factor of Safety Choosing a Safety Factor Design and Safety Codes 1.

8 Statistical Considerations 1.9 Units 1.10 Summary 1.11 References 1.12 Web References 1.13 Bibliography 1.14 Problems C HAPTER 2 M ATERIALS AND P ROCESSES 2.0 Introduction 2.

1 Material-Property Definitions The Tensile Test Ductility and Brittleness The Compression Test The Bending Test The Torsion Test Fatigue Strength and Endurance Limit Impact Resistance Fracture Toughness Creep and Temperature Effects 2.2 The Statistical Nature of Material Properties 2.3 Homogeneity and Isotropy 2.4 Hardness Heat Treatment Surface (Case) Hardening Heat Treating Nonferrous Materials Mechanical Forming and Hardening 2.5 Coatings and Surface Treatments Galvanic Action Electroplating Electroless Plating Anodizing Plasma-Sprayed Coatings Chemical Coatings 2.6 General Properties of Metals Cast Iron Cast Steels Wrought Steels Steel Numbering Systems Aluminum Titanium Magnesium Copper Alloys 2.7 General Properties of Nonmetals Polymers Ceramics Composites 2.8 Selecting Materials 2.

9 Summary 2.10 References 2.11 Web References 2.12 Bibliography 2.13 Problems C HAPTER 3 L OAD D ETERMINATION 3.0 Introduction 3.1 Loading Classes 3.2 Free-body Diagrams 3.

3 Load Analysis Three-Dimensional Analysis Two-Dimensional Analysis Static Load Analysis 3.4 Two-Dimensional, Static Loading Case Studies Case Study 1A Bicycle Brake Lever Loading Analysis Case Study 2A Hand-Operated Crimping-Tool Loading Analysis Case Study 3A Automobile Scissors-Jack Loading Analysis 3.5 Three-Dimensional, Static Loading Case Study Case Study 4A Bicycle Brake Arm Loading Analysis 94 3.6 Dynamic Loading Case Study Case Study 5A Fourbar Linkage Loading Analysis 3.7 Vibration Loading Natural Frequency Dynamic Forces Case Study 5B Fourbar Linkage Dynamic Loading Measurement 3.8 Impact Loading Energy Method 107 3.9 Beam Loading Shear and Moment Singularity Functions Superposition 3.10 Summary 3.

11 References 3.12 Web References 3.13 Bibliography 3.14 Problems C HAPTER 4 S TRESS , S TRAIN , AND D EFLECTION 4.0 Introduction 4.1 Stress 4.2 Strain 4.3 Principal Stresses 4.

4 Plane Stress and Plane Strain Plane Stress Plane Strain 4.5 Mohr''s Circles 4.6 Applied Versus Principal Stresses 4.7 Axial Tension x MACHINE DESIGN - An Integrated Approach 4.8 Direct Shear Stress, Bearing Stress, and Tearout Direct Shear Direct Bearing Tearout Failure 4.9 Beams and Bending Stresses Beams in Pure Bending Shear Due to Transverse Loading 4.10 Deflection in Beams Deflection by Singularity Functions Statically Indeterminate Beams 4.11 Castigliano''s Method Deflection by Castigliano''s Method Finding Redundant Reactions with Castigliano''s Method 4.

12 Torsion 4.13 Combined Stresses 4.14 Spring Rates 4.15 Stress Concentration Stress Concentration Under Static Loading Stress Concentration Under Dynamic Loading Determining Geometric Stress-Concentration Factors Designing to Avoid Stress Concentrations 4.16 Axial Compression - Columns Slenderness Ratio Short Columns Long Columns End Conditions Intermediate Columns Eccentric Columns 4.17 Stresses in Cylinders Thick-Walled Cylinders Thin-Walled Cylinders 4.18 Case Studies in Static Stress and Deflection Analysis Case Study 1B Bicycle Brake Lever Stress and Deflection Analysis Case Study 2B Crimping-Tool Stress and Deflection Analysis Case Study 3B Automobile Scissors-Jack Stress and Deflection Analysis Case Study 4B Bicycle Brake Arm Stress Analysis 4.19 Summary 4.

20 References 4.21 Bibliography 4.22 Problems C HAPTER 5 S TATIC F AILURE T HEORIES 5.0 Introduction 5.1 Failure of Ductile Materials Under Static Loading The von Mises-Hencky or Distortion-Energy Theory The Maximum Shear-Stress Theory The Maximum Normal-Stress Theory Comparison of Experimental Data with Failure Theories 5.2 Failure of Brittle Materials Under Static Loading Even and Uneven Materials The Coulomb-Mohr Theory The Modified-Mohr Theory 5.3 Fracture Mechanics Fracture-Mechanics Theory Fracture Toughness K c 5.4 Using The Static Loading Failure Theories 5.

5 Case Studies in Static Failure Analysis Case Study 1C Bicycle Brake Lever Failure Analysis Case Study 2C Crimping Tool Failure Analysis Case Study 3C Automobile Scissors-Jack Failure Analysis Case Study 4C Bicycle Brake Arm Factors of Safety 5.6 Summary 5.7 References 5.8 Bibliography 5.9 Problems C HAPTER 6 F ATIGUE F AILURE T HEORIES 6.0 Introduction History of Fatigue Failure 6.1 Mechanism of Fatigue Failure Crack Initiation Stage Crack Propagation Stage Fracture 6.2 Fatigue-Failure Models Fatigue Regimes The Stress-Life Approach The Strain-Life Approach The LEFM Approach 6.

3 Machine-Design Considerations 6.4 Fatigue Loads Rotating Machinery Loading Service Equipment Loading 6.5 Measuring Fatigue Failure Criteria Fully Reversed Stresses Combined Mean and Alternating Stress Fracture-Mechanics Criteria Testing Actual Assemblies 6.6 Estimating Fatigue Failure Criteria Estimating the Theoretical Fatigue Strength Sf'' or Endurance Limit Se'' Correction Factors to the Theoretical Fatigue Strength Calculating the Corrected Fatigue Strength Sf Creating Estimated S-N Diagrams 6.7 Notches and Stress Concentrations Notch Sensitivity 6.8 Residual Stresses 6.9 Designing for High-Cycle Fatigue 6.10 Designing for Fully Reversed Uniaxial Stresses Design Steps for Fully Reversed Stresses with Uniaxial Loading: 6.

11 Designing for Fluctuating Uniaxial Stresses Creating the Modified-Goodman Diagram Applying Stress-Concentration Effects with Fluctuating Stresses Determining the Safety Factor with Fluctuating Stresses Design Steps for Fluctuating Stresses 6.12 Designing for Multiaxial Stresses in Fatigue Frequency and Phase Relationships Fully Reversed Simple Multiaxial Stresses Fluctuating Simple Multiaxial Stresses Complex Multiaxial Stresses 6.13 A General Approach to High-Cycle Fatigue Design 6.14 A Case Study in Fatigue Design Case Study 6 Redesign of a Failed Laybar for a Water-Jet Power Loom 6.15 Summary 6.16 References 6.17 Bibliography 6.18 Problems C HAPTER 7 S URFACE F AILURE 7.

0 Introduction 7.1 Surface Geometry 7.2 Mating Surfaces 7.3 Friction Effect of Roughness on Friction Effect of Velocity on Friction Rolling Friction Effect of Lubricant on Friction 7.4 Adhesive Wear The Adhesive-Wear Coefficient 7.5 Abrasive Wear Abrasive Materials Abrasion-Resistant Materials 7.6 Corrosion Wear Corrosion Fatigue Fretting Corrosion 7.7 Surface Fatigue 7.

8 Spherical Contact Contact Pressure and Contact Patch in Spherical Contact 438 Static Stress Distributions in Spherical Contact 440 Ch 00 4ed Final 12 7/26.