Richard G. Budynas is Professor Emeritus of the Kate Gleason College of Engineering at Rochester Institute of Technology. He has over 40 years experience in teaching and practicing mechanical engineering design, He is the author of a McGraw-Hill textbook, Advanced Strength and Applied Stress Analysis, Second Edition; and co-author of a ‘McGraw-Hill reference book, Reark’s Formulas for Stress and Strain, Seventh Edition. He was awarded the BME of Union College, MSME of the University of Rochester, and the PhD. of the University of Massachusetts. He is a licensed Professional Engincer in the state of New York. J. Keith Nisbett is an Associate Professor and Associate Chair of Mechanical Engineering at the Missouri University of Science and Technology. He has over 25 years of experience with using and teaching from this classic textbook. As demonstrated by a steady stream of teaching awards, including the Governor's Award for Teaching Excellence, he is devoted to finding ways of communicating concepts to the students. He was awarded the BS, MS, and Ph.D. of the University of Texas at Arlington,viii Part 1 Rena 10 nu 12 13 4 15 16 7 18 Preface xv Introduction to Mechanical Engineering Design 3 Materials 31 Load and Stress Analysis 71 Deflection and Stiffness 147 Failure Prevention 212 Failures Resulting from Static Leading 213 Design of Mechanical Elements 358 Shafts and Shaft Components 359 Screws, Fasteners, and the Design of Nonpermanent 409 Welding, Bending, and the Design of Permanent Joints 475 Mechanical Springs 517 Rolling-Contact Bearings 569 Lubrication and Journal Bearings 617 Gears—General 673 Spur and Helical Gears 733 Bevel and Worm Gears 785 Clutches, Brakes, Couplings, and Flywheels 825 Flexible Mechanical Elements 879 n Case Study 933Part 4 9 20 Analysis Tools 952 Finite-Element Analysis 953 Statistical Considerations 977 Appendixes Useful Tables 1003 Answers to Selected Problems 1059 Index 1055Part 1 bh obs Naunenicooada Preface xv Basics 2 Introduction te Mechanical Engineering Design 3 Design 4 Mechanical Engineering Design 5 Phases and Inleractions ofthe Design Process 5 Design Tools and Resources 8 ‘The Design Bnginer’s Professional Responsibilities 10 Standards and Codes 12 Economics 12 Safety and Product Liability 15 ‘Stress and Strength 15, Uncestanty 16 Design Factor and Factor of Safety 17 Reliability 18 Dimensions and Tolerances 19 Units 21 Calculations and Significant Figures 22 Design Topic Inerdependencies 23 Power Transmission Caze Study Specifications 24 Problems 26 Materials 31 “Material Stength and Stiffness 32 ‘The Statistical Significance of Material Properties 36 Strengta and Cold Work 38 Hardness 41 Impact Properties 42 ‘Temperature Eifects 43 310 1 312 B13 3-14 w15 ‘Numbering Systems 45 Sand Casting 46 Shell Molding 47 Investment Casting 47 Powder-Metallurgy Process 47 Hot-Wotking Processes 47 Cold-Working Processes 48 ‘The Heat Treatment of Steel 49 Alloy Steels 52 Corrosion-Resistant Steels $3 Casting Materials 54 Nonferrous Metals $5 Plastics 58 Composite Materials 60 ‘Materials Selection 61 Problems 67 Load and Stress Analysis 71 ‘Equilibrium and Free-Body Diagrams 72 Shear Force and Bending Moments in Beams 77 Singularity Functions 79 Stress 79 Cartesian Stress Components 79 “Mohs Citcle for Plane Stress 80 General Three-Dimensional Stress $6 Elastic Strain 87 ‘Uniformly Distributed Stresses 88 ‘Noma Stresses for Beams in Bending 89 Shear Stresses for Beams in Bending 94 Torsion 101 Stress Concentration 110 Stresses in Pressurized Cylinders 113 Stresses in Rotating Rings 11546 a7 48 49 4-10 a1 4-12 413 414 4-15 4-16 4-17 Part 2 Press and Shrink Fits 116 “Temperature Effects 117 Curved Beams in Bending 118 Contact Stresses 122 Summary 126 Problems 127 Deflection and Stiffness 147 Spring Rates 148 ‘Tension, Compression, and Torsion 149 Deflection Due to Bending 150 Beam Deflection Methods 152 Beam Deflections by: Superposition 153 [Beam Deflections by Singularity Functions 156 Strain Energy 162 Castigliano’s Theorem 164 Deflection of Curved Members 169 Statically Indeterminate Problems 175, Compression Members—General 181 ‘Long Columns with Central Loading 181 Intermediate-Length Columns with Central Loading 184 ‘Columns with Eccentric Loading 184 Struts or Short Compression Members 188 Elastic Stability 190 Shock and Impact 191 Problems 192 Failure Prevention 212 Failures Resulting from Static Loading 23 State Stuength 216 sitess Concentation 217 Failre Theories 219 Maximum Shear-Stess Theory for DotleMeteials 219 Distonion Energy Thery for Ductile Materials 221 5-6 5-7 5-8 59 5-10 5-11 5-12 5-13 514 1 62 63 65 67 oe 610 611 612 6-13 o14 e415 6-16 O17 6-18 Contents | xi Coulomb-Mobr Theory for Ductile Materials 228 Failure of Ductile Materials Summary 231 ‘Maximum-Normal-Stress Theory for Brittle Materials 235 ‘Modifications of the Mobr Theory for Brite Materials 235 Failure of Brittle Materials Summary 238 Selection of Failure Criteria 238 Introduction to Fracture Mechanics 239 ‘Stochastic Analysis 248 Important Design Equations 254 Problems 256 from Variable Loading 2s: Introduction to Fatigue in Metals 266 Approach to Fatigue Failure in Analysis and Design 272 Fatigue-Life Methods 273 ‘The Strest-Life Method 273 ‘The Strain-Life Method 276 ‘The Linear-Elastc Fracture Mechanics Method 278 ‘The Endurance Limit 282 Paigue Strength 283 Endurance Limit Modifying Factors 286 Stress Concentration and Notch Sensitivity 295 (Characterizing Fluctuating Stresses 300 Fatigue Failure Criteria for Fluctuating Suess 303 ‘Torsional Fatigue Strength under Fluctuating Suesses 317 Combinations of Loading Modes 317 ‘Varying, Fluctuating Stesses:; Cumulative Fatigue Damage 321 Surface Fatigue Strength 327 ‘Stochastic Analysis 330 Road Maps and Important Design Equations for the Stess-Life Method 344 Problems 348Part 3 mH 7-2 7-3 7-4 7-5 7-7 7-8 Mechanical Engineeting Design Design of Mechanical Elements 358 Shafts and Shaft Components 339 Inroduetion 360 Shaft Materials 360 Shatt Layout 361 Shaft Design fr tess 366 Deflection Considerations 379 Ciitcal Speed for Shas 383 Miscellaneous Shaft Components 388 Limits and Fits 395 Problems 400 Screws, Fasteners, and the Design of Nonpermanent Joints 409 ‘Thread Standards and Definitions 410 ‘The Mechanics of Power Screws 414 ‘Threaded Fasteners 422 Joints Fastener Stiffness 424 Joints—Member Stisness 427 Bolt Suength 432 ‘Tension Joints—The External Load 435 Relating Bol Torque to Bolt Tension 437 ‘Statically Loaded Tension Joint with Preload 440 Gasketed Joints 444 Fatigue Loading of Tension Joints 444 Bolted and Riveted Joints Loaded in Shear 451 Problems 459 Welding, Bonding, and the Design of Permanent Joints 47s Welding Symbols 475 Butt and Filet Wels 478 Siesses in Welded Joi in Tersion 482 Siesses in Welded Joins in Bending 487 SELE 10 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 10-12 10-13 10-14 10-15 5 11-6 uz 11-8 19 11-10 ‘The Swrength of Welded Joints 489 Static Loading 492 Fatigue Leading 496 Resistance Welding 498 Adhesive Bonding 498 Problems 507 Mechanical Springs 517 Steesses in Helical Springs 518 ‘The Curvature Effect 519 Dellection of Helical Springs 520 Compression Springs 520 Stability 522 Spring Materials 523 Helical Compression Spring Design for Static Service 528 Critical Frequency of Helical Springs 534 Fatigue Loading of Helical Compression Springs 536 Helical Compression Spring Design for Fatigue Loading 539 Extension Springs 542 Helical Coil Torsion Springs $50 Belleville Springs S57 Miscellaneous Springs 558 Summary 560 Problems 560 Rolling-Contact Bearings sss Bearing Types 570 Beating Life 573 Bearing Load Life at Rated Reliability 574 Beating Survival: Reliability versus Life 576 Relating Load, Life, and Reliability 577 Combined Radial and Thrust Loading 579 Variable Loading 584 Selection of Ball and Cylindrical Roller Bearings 588 Selection of Tapered Roller Bearings 590 Design Assessment for Selected Rolling-Contact Bearings 59912 12-1 12-2 12-3 12-4 12-5 12-6 12-7 12-8 12-9 12-10 12-11 12-12 12-13 12-14 12-15 Lubrication 603 ‘Mounting and Enclosure 604 Problems 608 Lubrication and Journal Bearings 517 ‘Types of Lubrication 618 Viscosity 619 Petroft’s Equation 621 Stable Lubrication 623, ‘Thick-Film Lubrication 624 Hydrodynamic Theory 625 Design Considerations 629 ‘The Relations of the Variables 631 Steady-State Conditions in Self-Contained Bearings 645 Clearance 648 Pressure-Fed Beatings 650 Loads and Materials 656 Bearing Types 658 ‘Thrust Bearings 659 Boundary-Lubricated Bearings 650 Problems 669 Gears—General 673 ‘Types of Gear 674 Nomenclature 675 Conjugete Action 677 Involute Properties 678 Fundamentals 678 Contact Ratio 684 Interference 685 ‘The Forming of Gear Teeth 687 Straight Bevel Gears 690 Parallel Helical Gears 691 ‘Worm Gears 695 Tooth Systems 696 Gar Trains 698 Force Analysis—Spur Gearing 70S Force Analysis—Bevel Gearing 709 Force Analysis—Helical Gearing 712 13-17 14 41 14-2 143 144 145 14-6 47 148 149 1410 wi 14-12 1413 1414 14-15 14-16 1417 14-18 419 15 15-1 15-2 15-3 15-4 15-5 15-6 15-7 15-8 15-9 16 16-1 16-2 Porce Analysis—Worm Gearing 714 Problems 720 Spur and Helical Gears 733 ‘The Lewis Bending Equation 734 Surface Durability 743, AGMA Stess Equations 745 AGMA Stengih Equations 747 Geometry Factors Fand J (Zj and ¥) 751 The Elastic Coeticient Cy (Zs) 756 Dynamic Factor Ky 756 Overload Factor K, 758 Surface Condition Factor Gy(Za) 758 Size Factor K, 759 Load-Distrbution Factor Km (Ki) 759 Hardness Ratio Factor Cy 761 Suess Cycle Life Factors je and Zy 762 Reliability Factor Ky (Yg) 763 ‘Temperatute Factor Kr (Vs) 764 Rim Thickness Factor Ky 764 Safety Factors Sp and Sy 765 Analysis 765 Design of a Gear Mesh 775 Problems 780 Bevel and Worm Gears 735 Bevel Gearing—General 786 Bevel-Gear Suesses and Stengths 788 AGMA Equation Factors 791 Straight-Bevel Gear Analysis 803 Design of a Straight-Bevel Gear Mesh 806 ‘Worm Gearing—AGMA Equation $09 Worm-Gear Analysis 813 Designing a Worm-Gear Mesh 817 Buckingham Wear Load 820 Problems $21 Clutches, Brakes, Couplings, and Flywheels ss Static Analysis of Catches and Brakes 827 Intemal Expanding Rim Clutches and Brakes $32xiv | Mechanical Enginesing Design 16-3 16-4 16-5 16-6 16-7 16-8 16-9 16-10 16-11 16-12 7 17-1 17-2 17-3 17-4 17-5 17-6 17-7 18 18-1 18-2 18-3 18-4 18-5 18-6 18-7 18-8 18-9 18-11 18-12 ‘External Contracting Rim Clutches and Brakes 840 Band-Type Clutches and Brakes 844 Frictional-Contact Axial Clutches 845, Disk Brakes 849 Cone Clutches and Brakes 853 ‘Energy Considerations 856 ‘Temperature Rise 857 Friction Materials 861 ‘Miscellaneous Clutches and Couplings 864 Flywheels 866 Problems 871 Flexible Mechanical Elements 379 Belts 880 Flat- and Round-Belt Drives 883 VBelts 898 ‘Timing Belts 906 Roller Chain 907 Wire Rope 916 Flexible Shafts 924 Problems 925 Power Transmission Case Study 933 Design Sequence for Power Transmission 935 Power and Tosque Requirements 936 Gear Specification 936 Shaft Layout 943, Force Analysis 945 Shaft Material Selection 945 Shall Design for Stress 945, ‘Shaft Design for Deflection 946 ‘Bearing Selection 947 Key and Retaining Ring Selection 948 Final Analysis 951 Problems 951 Part 4 19 19-1 19-2 19-3 19-4 19-5 19-6 19-7 19-8 19-9 19-10 19-11 20 20-1 20-2 20-3 20-4 20-5 Analysis Tools 952 Finite-Element Analysis 93 ‘The Finite Element Method 955 Element Geomcttes 957 The Finite Element Solon Process 959 Mesh Generation 962 Load Application 964 Boundary Conditions 965 Modcling Techniques 966 Thermal Sueses 969 Citic Bucking Load 969 Vitration Analysis 971 Summary 972 Problems 974 Statistical Considerations 977 Random Variables 978. Arithmetic Mean, Variance, and Standard Deviation 980 Probability Distibutions 985 Propagation of Error 992 Linear Regression 994 Problems 997 Appendixes Useful Tables 1003 Answers to Selected Problems 1059 Index 1085Objectives ‘This text is imtended for students beginning the study of mechanical engineering design. The focus is on blending fundamental development of concepts with practi- cal specification of components. Students of this text should find that it inherently directs them into familiarity with both the basis for decisions and the standards of industrial components, For this reason, as students transition to practicing engineers, ‘they will find that this text is indispensable as a reference text, The objectives of the text ate to + Cover the basics of machine design, including the design process, engineering ‘mechanics and materials, failure prevention under static and variable loading, and ‘characteristics of the principal types of mechanical elements, + Offer a practical approach to the subject through a wide range of real-world applica- tions and examples + Encourage readers to link design and analysis + Encourage readers to link fundamental concepts with practical component specification, New to This Edition Enhancements and modifications to the ninth edition are described in the following summaries: + New and revised end-of-chapter problems. This edition includes 1017 end-of- chapter problems, a 43 percent increase from the previous edition. Of these prob- lems, 671 are new ot revised, providing a fresh slate of problems that do not have years of previous circulation, Particular attention has been given to adding problems that provide more practice with the fundamental concepts. With an eye toward both the instructor and the students, the problems assist in the process of acquiring knowledge and practice. Multiple problems with variations arc available for the basic concepts, allowing for extra practice and for a rotation of similar problems between semesters. + Problems linked across multiple chapters. To assist in demonstrating the linkage of topics between chapters, a series of multichapter linked problems is introduced. Table 1-1 on p. 24 provides a guide to these problems. Instructors are encouraged to select several of these linked problem series each semester to use in homework assignments that continue to build upon the background knowledge gained in previous assignments, Some problems directly build upon the results of previous problems, which can either be provided by the instructor or by the students’ results from working the previous problems. Other problems simply build upon the back- ‘ground context of previous problems. In all cases, the students are encouraged to see the connectivity of a whole process. By the time a student has worked throughMechanical Enginee a series of linked problems, a substantial analysis has been achieved, addressing such things as deflection, stress, static failure, dynamic failure, and multiple component selection. Since it comes one assignment at a time, it is no more daunting than regular homework assignments. Many of the linked problems blend very nicely with the ansmission case study developed throughout the book, and detailed in Chap. 18. + Content changes. The bulk of the content changes in this edition falls into categories of pedagogy and keeping current. These changes include improved examples, clari- fied presentations, improved notations, and updated references. A detailed list of content changes is available on the resource website, www.mbhe.convshigley A few content changes warrant particular mention for the benefit of instructors familiar ‘with previous editions, + Transverse shear stress is covered in greater depth (Sec. 3-11 and Ex. 3-7) ‘The sections on strain energy and Castigliano’s method are modified in presenta- tion of equations and examples, particularly in the deflections of curved members (Sees, 4-7 through 4-9) ‘The coverage of shock and impact loading is mathematically simplified by using an ‘energy approach (Sec. 4-17), ‘The variable oz is introduced to denote a completely reversed stress, avoiding confusion with o,, which is the amplitude of alternating stress about a mean stress (Sec. 6-8). ‘The method for determining notch sensitivity for shear loading is modified to be more consistent with currently available data (Sec. 6-10). For tension-loaded bolts, the yielding factor of safety is defined and distinguished from the load factor (Sec. 8-9), ‘The presentation of fatigue loading of bolted joints now handles general fluctuating stresses, treating repeated loading as a special case (Sec. 8-11), ‘The notation for bearing life now distinguishes more clearly and consistently be- ‘ween life in revolutions versus life in hours (See. 11-3) ‘The material on tapered roller bearings is generalized to emphasize the concepts and processes, and to be less dependent on specific manufacturer's terminology (See. 11-9), + Streamlining for clarity 10 the student, There is a fine line between being compre- hensive and being cumbersome and confusing. It is a continual process to refine and maintain focus on the needs of the student. This text is first and foremost an ‘educational tool for the initial presentation of its topics to the developing engi- neering student, Accordingly, the presentation has been examined with altentive- ness to how the beginning student would likely understand it. Also recognizing that this text is a valued reference for practicing engineers, the authors have en- deavored to keep the presentation complete, accurate, properly referenced, and straightforward, Connect Engineering The Oth edition als features McGraw-Hill Connect Engineering, a Web-based assign rent and assessment platform that allows instructors to deliver assignments, quizzes, and tests easily online” Students ean practice important skills at teir own pace and on their own schadleProce | xvii Additional media offerings available at www.mhhe.com/shigley include Student Supplements + Tutorials—Presentation of major concepts, wth visuals. Among the topics covered axe pressure vessel design, press and shrink fits, contact stresses, and design for static failure + MATLAB® for machine design, Includes visual simulations and accompanying source code. The simulations are linked to examples and problem in the text and demonstrate the ways computational software can be used in mechanical design and analysis. + Fundamentals of Engineering (FE) exam questions for machine design. Interactive problems and solutions serve as effective, sli-esting problems as well as excellent preparation for the FE exam Instructor Supplements (under password protection) + Solutions manual. The instructor's manual contains solutions to most end-of-chapter nondesign problems. + PowerPoint® slides. Slides of important figures and tables from the text are provided in PowerPoint format for use in lectus + C.0.5.M.0.S. A complete online solutions manual organization system that allows instructors (0 create custom homework, quizzes, and tests using end-of-chapler problems from the text, Electronic Textbooks Ebooks are an innovative way for students to save money and create a greener environ- ‘ment at the same time. An ebook can save students about half the cost of a traditional textbook and offers unique features like a powerful search engine, highlighting, and the ability to share notes with classmates using ebooks. ‘McGraw-Hill offers this text as an ebook. To talk about the ebook options, contact, your McGraw-Hill sales rep or visit the site www.coursesmart.com to learn more. Acknowledgments ‘The authors would like to acknowledge the many reviewers who have contributed to this text over the past 40 years and cight editions. We are especially grateful to those ‘who provided input to this ninth edition: Amanda Brenner, Missouri University of Science and Technology C. Andrew Campbell, Conestoga College Gloria Stars, lowa State University Jonathon Blotter, Brigham Young University Michael Latcha, Oakland University Om P. Agrawal, Southern Illinois University Pal Molian, Jowa State University Pierre Larochelle, Florida Institute of Technology ‘Shaoping Xiao, University of Iowa eve Yurgartis, Clarkson University jothy Van Rhein, Missouri University of Science and TechnologyThis page intentionally left blankThis isa list of common symbols used in machine design and in this book. Specialized use in a subject-matter area often attracts fore and post subscripts and superscripts. To make the table brief enough (o be useful, the symbol kernels are listed. See Table 14-1, pp. 735-736 for spur and helical gearing symbols, and Table 15-1, pp. 789-790 for bevel-gear symbols come eas ee & arm CDF 8 g wos BE ggEs agus mace * 8 Area, coefficient ‘Area variate Distance, regression constant Regression constant estimate Distance variate Coefficient Brinell hardness Variate Distance, Weibull shape parameter, range number, regression constant, ‘width Regression constant estimate Distance variate Basic load rating, bolted-joint constant, center distance, coefficient of variation, column end condition, correction factor, specific heat capacity, spring index Distance, viscous damping, velocity coefficient Cumulative distribution function Coefficient of variation Distance variate Helix diameter Diameter, distance ‘Modulus of elasticity, energy, ettor Distance, eccentricity, efficiency, Naperian logarithmic base Force, fundamental dimension force Coefficient of friction, frequency, function Figure of merit Torsional modulus of elasticity Acceleration due to gravity, function Heat, power Brinell hardness Rockwell C-scale hardness Distance, film thickness Combined overall coefficient of convection and radiation heat transfer Integral, linear impulse, mass moment of inertia, second moment of area Index Unit vector in x-direction xixchancel Eaginoeing Desig mos PDF NO NES RHR REE PEE SEG OT ENS MoT BRED ‘Mechanical equivalent of heat, polar second moment of area, geometry factor Unit vector in the y-direction Service factor, stress-concentration factor, stress-augmentation factor, torque coefficient ‘Marin endurance limit modifying factor, spring rate variate, unit vector in the z-direction Length, life, fundamental dimension length Life in hours Lognormal distribution Length Fundamental dimension mass, moment ‘Moment vector, moment variate ‘Mass, slope, strain-strengthening exponent Normal force, number, rotational speed Normal distribution Load factor, rotational speed, safety factor Design factor Force, pressure, diametral pitch Probability density function Pitch, pressure, probability First moment of area, imaginary force, volume Distributed load, notch sensitivity Radius, reaction force, reliability, Rockwell hardness, stress ratio ‘Vector reaction force Correlation coefficient, radius Distance vector Sommerfeld number, strength S variate Distance, sample standard deviation, stress ‘Temperature, tolerance, torque, fundamental dimension time ‘Torque vector, torque variate Distance, Student's t-statistic, time, tolerance Strain energy Uniform distribution Strain energy per unit volume Linear velocity, shear force Linear velocity Cold-work factor, load, weight ‘Weibull distribution Distance, gap, load intensity ‘Vector distance Coordinate, truncated number Coordinate, true value of a number, Weibull parameter x variate Coordinate Coordinate, deflection y variate Coordinate, section modulus, viscosity Standard deviation of the unit normal distribution ‘Variate of zeer amr e pe 8 ga zee oe eanag ist of Symbols | sexi Coefficient, coefficient of linear thermal expansion, end-condition for springs, thread angle Bearing angle, coefficient Change, deflection Deviation, elongation Eccentricity ratio, engineering (normal) strain Normal distribution with a mean of 0 and a standard deviation of s ‘True or logarithmic normal strain Gamma function Pitch angle, shear strain, specific weight Slenderness ratio for springs Unit lognormal with a mean of | and a standard deviation equal to COV Absolute viscosity, population mean Poisson ratio Angular velocity, circular frequency Angle, wave length Slope integral Radius of curvature ‘Normal stress Von Mises stress Normal stress variate Standard deviation Shear stress. Shear stress variate Angle, Weibull characteristic parameter Cost per unit weight CostThis page intentionally left blank