CHAPTER 1 INTRODUCTION TO DESIGN

1.1

Design ............................................................................................................... 3

Machine Design

3

Machine

4

Iteration

5

1.2

A Design Process ............................................................................................. 5

1.3

Problem Formulation and Calculation .............................................................. 8

Definition Stage

8

Preliminary Design Stage

8

Detailed Design Stage

9

Documentation Stage

9

1.4

The Engineering Model ..................................................................................... 9

Estimation and First-Order Analysis

10

The Engineering Sketch

10

1.5

Computer-Aided Design and Engineering ...................................................... 11

Computer-Aided Design (CAD)

11

Computer-Aided Engineering (CAE)

14

Computational Accuracy

16

1.6

The Engineering Report .................................................................................. 16

1.7

Factors of Safety and Design Codes .............................................................. 16

Factor of Safety

17

Choosing a Safety Factor

18

Design and Safety Codes

19

1.8

Statistical Considerations ............................................................................. 20

1.9

Units ............................................................................................................... 21

1.10 Summary ....................................................................................................... 25

1.11 References ..................................................................................................... 26

1.12 Web References .............................................................................................. 27

1.13 Bibliography ................................................................................................... 27

1.14 Problems ........................................................................................................ 28

 

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MACHINE DESIGN -

An Integrated Approach

CHAPTER 2 MATERIALS AND PROCESSES _________________________________ 29

2.0

Introduction ...................................................................................................29

2.1

Material-Property Definitions .......................................................................... 29

The Tensile Test

31

Ductility and Brittleness

33

The Compression Test

35

The Bending Test

35

The Torsion Test

35

Fatigue Strength and Endurance Limit

37

Impact Resistance

38

Fracture Toughness

40

Creep and Temperature Effects

40

2.2

The Statistical Nature of Material Properties .................................................41

2.3

Homogeneity and Isotropy .............................................................................42

2.4

Hardness ........................................................................................................42

Heat Treatment

44

Surface (Case) Hardening

45

Heat Treating Nonferrous Materials

46

Mechanical Forming and Hardening

46

2.5

Coatings and Surface Treatments ..................................................................48

Galvanic Action

49

Electroplating

50

Electroless Plating

50

Anodizing

51

Plasma-Sprayed Coatings

51

Chemical Coatings

51

2.6

General Properties of Metals ...........................................................................52

Cast Iron

52

Cast Steels

53

Wrought Steels

53

Steel Numbering Systems

54

Aluminum

56

Titanium

58

Magnesium

59

Copper Alloys

59

2.7

General Properties of Nonmetals ....................................................................60

Polymers

60

Ceramics

62

Composites

62

2.8

Selecting Materials .........................................................................................63

2.9

Summary ........................................................................................................64

2.10 References ......................................................................................................68

2.11 Web References ..............................................................................................68

2.12 Bibliography ...................................................................................................68

2.13 Problems ........................................................................................................69

 

ix