Mechanical Design Handbook 2nd Edition

This Second Edition of the Mechanical Design Handbook has been completely reorganized from its previous edition and includes seven chapters from the Mechanical Design and Systems Handbook, the precursor to the First Edition. The twenty-two chapters contained in this new edition are divided into three main sections: Mechanical Design Fundamentals, Mechanical System Analysis, and Mechanical Subsystem Components. It is hoped that this new edition will meet the needs of practicing engineers providing the critical resource of information needed in their mechanical designs.

The first section, Part I, Mechanical Design Fundamentals, includes seven chapters covering the foundational information in mechanical design. Chapter 1, Classical Mechanics, is one of the seven chapters included from the Second Edition of the Mechanical Design and Systems Handbook, and covers the basic laws of dynamics and the motion of rigid bodies so important in the analysis of machines in three-dimensional motion. Comprehensive information on topics such as stress, strain, beam theory, and an extensive table of shear and bending moment diagrams, including deflection equations, is provided in Chap. 2. Also in Chap. 2 are the equations for the design of columns, plates, and shells, as well as a complete discussion of the finite-element analysis approach. Chapter 3, Kinematics of Mechanisms, contains an endless number of ways to achieve desired mechanical motion. Kinematics, or the geometry of motion, is probably the most important step in the design process, as it sets the stage for many of the other decisions that will be made as a successful design evolves. Whether it’s a particular multi-bar linkage, a complex cam shape, or noncircular gear combinations, the information for its proper design is provided. Chapter 4, Mechanical Vibrations, provides the basic equations governing mechanical vibrations, including an extensive set of tables compiling critical design information such as, mechanical impedances, mechanical-electrical analogies, natural frequencies of basic systems, torsional systems, beams in flexure, plates, shells, and several tables of spring constants for a wide variety of mechanical configurations. Design information on both static and dynamic failure theories, for ductile and brittle materials, is given in Chap. 5, Static and Fatigue Design, while Chap. 6, Properties of Engineering Materials, covers the issues and requirements for material selection of machine elements. Extensive tables and charts provide the experimental data on heat treatments, hardening, high-temperature and low-temperature applications, physical and mechanical properties, including properties for ceramics and plastics. Chapter 7, Friction, Lubrication, and Wear, gives a basic overview of these three very important areas, primarily directed towards the accuracy requirements of the machining of materials.

The second section, Part II, Mechanical System Analysis, contains six chapters, the first four of which are from the Second Edition of the Mechanical Design and Systems Handbook. Chapter 8, Systems Dynamics, presents the fundamentals of how a complex dynamic system can be modeled mathematically. While the solution of such systems will be accomplished by computer algorithms, it is important to have a solid foundation on how all the components interact—this chapter provides that comprehensive analysis. Chapter 9, Continuous Time Control Systems, expands on the material in Chap. 8 by introducing the necessary elements in the analysis when there is a time-dependent input to the mechanical system. Response to feedback loops, particularly for nonlinear damped systems, is also presented. Chapter 10, Digital Control Systems, continues with the system analysis presented in Chaps. 8 and 9 of solving the mathematical equations for a complex dynamic system on a computer. Regardless of the hardware used, from personal desktop computers to supercomputers, digitalization of the equations must be carefully considered to avoid errors being introduced by the analog to digital conversion. A comprehensive discussion of the basics of optics and the passage of light through common elements of optical systems is provided in Chap. 11, Optical Systems, and Chap. 12, Machine Systems, presents the dynamics of mechanical systems primarily from an energy approach, with an extensive discussion of Lagrange’s equations for three-dimensional motion. To complete this section, Chap. 13, System Reliability, provides a system approach rather than addressing single mechanical elements. Reliability testing is discussed along with the Weibull distribution used in the statistical analysis of reliability.

The third and last section, Part III, Mechanical Subsystem Components, contains nine chapters covering the most important elements of a mechanical system. Cam layout and geometry, dynamics, loads, and the accuracy of motion are discussed in Chap. 14 while Chap. 15, Rolling-Element Bearings, presents ball and roller bearing, materials of construction, static and dynamic loads, friction and lubrication, bearing life, and dynamic analysis. Types of threads available, forces, friction, and efficiency are covered in Chap. 16, Power Screws. Chapter 17, Friction Clutches, and Chap. 18, Friction Brakes, both contain an extensive presentation of these two important mechanical subsystems. Included are the types of clutches and brakes, materials, thermal considerations, and application to various transmission systems. The geometry of belt assemblies, flat and v-belt designs, and belt dynamics is explained in Chap. 19, Belts, while chain arrangements, ratings, and noise are dealt with in Chap. 20, Chains. Chapter 21, Gearing, contains every possible gear type, from basic spur gears and helical gears to complex hypoid bevel gears sets, as well as the intricacies of worm gearing. Included is important design information on processing and manufacture, stresses and deflection, gear life and power-loss predictions, lubrication, and optimal design considerations. Important design considerations for helical compression, extension and torsional springs, conical springs, leaf springs, torsion-bar springs, power springs, constant-force springs, and Belleville washers are presented in Chap. 22, Springs.

This second edition of the Mechanical Design Handbook contains two new appendices not in the first edition: App. A, Analytical Methods for Engineers, and App. B, Numerical Methods for Engineers. They have been provided so that the practicing engineer does not have to search elsewhere for important mathematical information needed in mechanical design.

It is hoped that this Second Edition continues in the tradition of the First Edition, providing relevant mechanical design information on the critical topics of interest to the engineer. Suggestions for improvement are welcome and will be appreciated.