OUTLINE SERIES THEORY AND PROBLEMS OF Allen S. Hall Alfred R. Holowenko Herman G. Laughlin Covers all course fundamentals and supplements any class text Teaches effective problem-solving techniques 320 Solved Problems with complete solutions Also includes hundreds of additional problems with answersSCHAUM’S OUTLINE OF THEORY AND PROBLEMS of MACHINE DESIGN BY ALLEN §. HALL, JR, M.S.M.E, Ph.D: Professor of Mechanical Engineering, Purdue University ALFRED R. HOLOWENKO, M.S. Professor of Mechanical Engineering, Purdue University HERMAN G. LAUGHLIN, M.S.M.E. Associate Professor of Mechanical Engineering, Purdue University SCHAUM’S OUTLINE SERIES McGRAW-HILL, INC. New York St.Louis San Francisco Auckland Bogotd Caracas Hamburg Lisbon London Madrid Mexico Milan Montreal New Delhi Paris San Juan Sdéo Paulo Singapore Sydney Tokyo TorontoCopyright © 1961 by McGraw-Hill, Inc. All Rights Reserved. Printed in the United States of America, No part of this publication may be reproduced, stored im a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. ISBN 07-025595-4 20 21 22 23 24 25 26 27 28 29 30 SH SH 9876543210 Cover design by Amy E. Becker.Preface This book is designed primarily to supplement standard texts in elementary machine design, based on the belief that numerous solved problems constitute one of the best means for clarifying and fixing in mind basic principles. Moreover, the statements of theory and principle are sufficiently complete that, with suitable handling of lecture-recitation time, the book could be used as a text by itself. Each chapter begins with statements of pertinent definitions, principles and theorems together with illustrative and descriptive material. This is followed by graded sets of solved and supplementary problems, The solved problems serve to illustrate and amplify the theory and bring into sharp focus those fine points without which the student continually feels himself on unsafe ground. Numerous proofs of theorems and derivations of formulas are included among the solved problems, The supplementary problems serve as a review of the material of each chapter. Chapter topics correspond to material usually covered in standard machine design courses. It is felt that these are representative topics for illustrating the general approach to design problems. Where more than one accepted procedure for handling a problem exists, the authors have in some cases adopted what they feel to he the best; in other cases, alternative procedures are shown; and in a2 few situations there is some innovation in treatment. As a result, while this book will not mesh pre- cisely with any one text, the authors feel that it can be a very valuable adjunct to all. The following are some of the special features of this book. It contains a wide range of applied mechanics review problems. Solved problems are used to review Strength of Materials and to demon- strate the application of many previous courses to design situations, Step functions and the theorem of Castigliano are introduced as tools for determining deflections in machine members, An introduction to Vibration Studies is presented. The latest techniques as developed by Boyd and Raimondi for solv- ing lubrication problems are included. Excerpts from the latest AFBMA Standards are given for evaluating static and dynamic load ratings of radial ball bearings. Gear forces are covered in much more detail than in standard texts. A careful treatment of critical speeds of shafting is presented. An exhaustive treatment is given for determining the rigidity as well as the strength of machine mem- bers. Thirty-six design projects are presented, including flow control, automatic electrical control, quality control, and creative design problems. It is realized that competence in design rests on many factors other than scientific training — ingenuity, judgment, familiarity with empirical data, knowledge of design codes and standards, to name a few, Many of these can be fully developed only over a number of years of actual experience in industry. However, the student can be provided with what is basic, namely a good training in the logical application of theory to the design of machine elements plus some feeling for the accompany- ing assumptions and approximations, It is to this end that this book is directed. The authors are deeply indebted to many people. Published texts in machine design, strength of materials and dynamics of machinery have been studied and compared; all have contributed to the authors’ thinking. Members of the machine design staff at Purdue University have served to sharpen and refine the treatment of many topics. The authors are extremely grateful to them for constructive criti- cisms and suggestions,Special appreciation is expressed to E. S, Ault, Professor of Machine Design at Purdue Uni- versity, In addition to general encouragement of the authors’ efforts, Professor Ault is to be credited with the procedure presented in the chapters on Toothed Gearing for handling the Lewis formula in design calculations, Particular thanks are extended to Mr, Henry Hayden for typographical layout and art work for the figures. The realism of these figures adds greatly to the effectiveness of presentation in a sub- ject where spatial visualization plays such an important role. We would also like to thank the following for permission to publish copyrighted material: The Lincoln Electric Company, The Anti-Friction Bearing Manufacturers Association, and Mr, A. A. Raimondi and Mr. John Boyd of the Westinghouse Electric Company. A. 8. Hall, Jr. A, R, Holowenko H, G, Laughlin Purdue University June, 1961CHAPTER PAGE ew PPraunrA wD NN Ye BPP ee ee ee NRBREBBEFSSSEARARESRES INDEX INTRODUCTION ... Srresszs in SimpLe Macuine MeMBers Merat Fits anp TOLERANCES 2.2.2... 0200 c cee c cece eee eee 18 CURVED BEAMS ..... 00... c cece cree eee erent ert eeee 26 DEFLECTION AND BUCKLING OF MACHINE MEMBERS ........ 6... 37 Desicninc Macuine Mempers SupJECTED TO VARIABLE Loaps ... 72 Macuine VIBRATIONS CrivicaL SPEEDS oF SHAFTS . . PowER TRANSMISSION SHAFTING ....... eee eee ee tet e eens 113 Courting DEsicn Keys, Pins, AnD SPLINES Power ScREWS AND THREADED FASTENERS ....4.600+ 000000 «es 145 Bout Loapinc CLUTCHES 6... c cece ce cece e cee nena Brake Desien . SPRINGS 1.0... cece cece eee neers Gear Forces SPUR GEARS 00... ence te eee n nee HELICAL GEARS ....... BEVEL Gears Worm GEARS Rowuine Bearines ...Chapter 1] Introduction ENGINEERING DESIGN is the creation of plans for machines, structures, systems, or processes to perform desired functions. THE DESIGN PROCESS includes the following. (1) The recognition of a need and a statement of this need in general terms, This defines the Breblem. (2) The consideration of different schemes for solving the problem and the selection of one to be investigated in more detail. Feasibility studies, backed up by special research if necessary, ace a feature of this stage in the process. (3) A preliminary design of the machine, structure, system, or process selected. This establishes broad overall features and makes it possible to write specifications for major components. (4) Design of all components and preparation of all necessary drawings and detail specifications. In the early stages of the design process the designer is a creator. Here his ingenuity and power of imaginative thinking should be given full play. The drawings and detail specifications for a completed design are @ record of a multitude of decisions, some large and some small, The designer, in the later stages of the design process, is basically a decision maker. He must work from a sound basis of scientific principles supplemented by empirical data. However, it must be under- stood that science can only establish limits within which a decision must be made, or give a statistical picture of the effects of a partic- ular decision. The decision itself is made by the designer. Hence judgment in making de- cisions is one of the outstanding character- istics of a good designer. THE DESIGN OF A MACHINE must follow a plan somewhat as shown in the adjacent figure. After the general specifications have been set, the kinematic arrangement, or skeleton, of the machine must be established. This is followed by a force analysis (incomplete be- cause masses of moving parts are not yet known in designs where dynamics is of im- portance), With this information the components can be designed (tentatively, because forces are not known exactly). Then a more exact force analysis can be made and the design re- APPEARANCE KINEMATIC SCHEME ANALYSIS of FORCES DESIGN of COMPONENTS. for STRENGTH, RIGIDITY, etc. PRODUCIBILITY STYLING! SPACE and WEIGHT LIMITATIONS NATURE of MARKET Fig. 1-1