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Shigley’s Mechanical Engineering Design McGRAW-HILL SERIES IN MECHANICAL ENGINEERING Alciatore/Histand: Introduction to Mechatronics and Measurement Systems Anderson: Computational Fluid Dynamics: The Basics with Applications Anderson: Fundamentals of Aerodynamics Anderson: Introduction to Flight A...

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Shigley’s Mechanical Engineering Design

McGRAW-HILL SERIES IN MECHANICAL ENGINEERING Alciatore/Histand: Anderson: Anderson: Anderson: Anderson: Barber: Beer/Johnston: Beer/Johnston: Budynas: Budynas/Nisbett: Byers/Dorf: Çengel: Çengel: Çengel/Boles: Çengel/Cimbala: Çengel/Turner: Crespo da Silva: Dieter: Dieter: Doebelin: Dunn: EDS, Inc.: Finnemore/Franzini: Hamrock/Schmid/Jacobson: Heywood: Holman: Holman: Hutton: Kays/Crawford/Weigand: Meirovitch: Norton: Palm: Reddy: Schaffer et al.: Schey: Smith/Hashemi: Turns: Ugural: Ullman: White: White: Zeid: Zeid:

Introduction to Mechatronics and Measurement Systems Computational Fluid Dynamics: The Basics with Applications Fundamentals of Aerodynamics Introduction to Flight Modern Compressible Flow Intermediate Mechanics of Materials Vector Mechanics for Engineers: Statics and Dynamics Mechanics of Materials Advanced Strength and Applied Stress Analysis Shigley’s Mechanical Engineering Design Technology Ventures: From Idea to Enterprise Heat and Mass Transfer: A Practical Approach Introduction to Thermodynamics & Heat Transfer Thermodynamics: An Engineering Approach Fluid Mechanics: Fundamentals and Applications Fundamentals of Thermal-Fluid Sciences Intermediate Dynamics Engineering Design: A Materials & Processing Approach Mechanical Metallurgy Measurement Systems: Application & Design Measurement & Data Analysis for Engineering & Science I-DEAS Student Guide Fluid Mechanics with Engineering Applications Fundamentals of Machine Elements Internal Combustion Engine Fundamentals Experimental Methods for Engineers Heat Transfer Fundamentals of Finite Element Analysis Convective Heat and Mass Transfer Fundamentals of Vibrations Design of Machinery System Dynamics An Introduction to Finite Element Method The Science and Design of Engineering Materials Introduction to Manufacturing Processes Foundations of Materials Science and Engineering An Introduction to Combustion: Concepts and Applications Mechanical Design: An Integrated Approach The Mechanical Design Process Fluid Mechanics Viscous Fluid Flow CAD/CAM Theory and Practice Mastering CAD/CAM

Shigley’s Mechanical Engineering Design Ninth Edition

Richard G. Budynas Professor Emeritus, Kate Gleason College of Engineering, Rochester Institute of Technology

J. Keith Nisbett Associate Professor of Mechanical Engineering, Missouri University of Science and Technology

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TM

SHIGLEY’S MECHANICAL ENGINEERING DESIGN, NINTH EDITION Published by McGraw-Hill, a business unit of The McGraw-Hill Companies, Inc., 1221 Avenue of the Americas, New York, NY 10020. Copyright © 2011 by The McGraw-Hill Companies, Inc. All rights reserved. Previous edition © 2008. No part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written consent of The McGraw-Hill Companies, Inc., including, but not limited to, in any network or other electronic storage or transmission, or broadcast for distance learning. Some ancillaries, including electronic and print components, may not be available to customers outside the United States. This book is printed on acid-free paper. 1 2 3 4 5 6 7 8 9 0 RJE/RJE 10 9 8 7 6 5 4 3 2 1 0 ISBN 978–0–07–352928–8 MHID 0–07–352928–1 Vice President & Editor-in-Chief: Marty Lange Vice President, EDP/Central Publishing Services: Kimberly Meriwether-David Global Publisher: Raghothaman Srinivasan Senior Sponsoring Editor: Bill Stenquist Director of Development: Kristine Tibbetts Developmental Editor: Lora Neyens Senior Marketing Manager: Curt Reynolds Project Manager: Melissa Leick Senior Production Supervisor: Kara Kudronowicz Design Coordinator: Margarite Reynolds Cover Designer: J. Adam Nisbett Senior Photo Research Coordinator: John C. Leland Compositor: Aptara®, Inc. Typeface: 10/12 Times Roman Printer: R. R. Donnelley All credits appearing on page or at the end of the book are considered to be an extension of the copyright page. Library of Congress Cataloging-in-Publication Data Budynas, Richard G. (Richard Gordon) Shigley’s mechanical engineering design / Richard G. Budynas, J. Keith Nisbett. —9th ed. p. cm. — (McGraw-Hill series in mechanical engineering) Includes bibliographical references and index. ISBN 978-0-07-352928-8 (alk. paper) 1. Machine design. I. Nisbett, J. Keith. II. Title. III. Series. TJ230.S5 2011 621.8⬘15—dc22

www.mhhe.com

2009049802

Dedication To my wife Joanne, my children and grandchildren, and to good friends, especially Sally and Peter. Richard G. Budynas

To Professor T. J. Lawley, who first introduced me to Shigley’s text, and who instigated in me a fascination for the details of machine design. J. Keith Nisbett

Dedication to Joseph Edward Shigley

Joseph Edward Shigley (1909–1994) is undoubtedly one of the most known and respected contributors in machine design education. He authored or co-authored eight books, including Theory of Machines and Mechanisms (with John J. Uicker, Jr.), and Applied Mechanics of Materials. He was Coeditor-in-Chief of the well-known Standard Handbook of Machine Design. He began Machine Design as sole author in 1956, and it evolved into Mechanical Engineering Design, setting the model for such textbooks. He contributed to the first five editions of this text, along with co-authors Larry Mitchell and Charles Mischke. Uncounted numbers of students across the world got their first taste of machine design with Shigley’s textbook, which has literally become a classic. Practically every mechanical engineer for the past half century has referenced terminology, equations, or procedures as being from “Shigley.” McGraw-Hill is honored to have worked with Professor Shigley for over 40 years, and as a tribute to his lasting contribution to this textbook, its title officially reflects what many have already come to call it—Shigley’s Mechanical Engineering Design. Having received a Bachelor’s Degree in Electrical and Mechanical Engineering from Purdue University and a Master of Science in Engineering Mechanics from The University of Michigan, Professor Shigley pursued an academic career at Clemson College from 1936 through 1954. This lead to his position as Professor and Head of Mechanical Design and Drawing at Clemson College. He joined the faculty of the Department of Mechanical Engineering of The University of Michigan in 1956, where he remained for 22 years until his retirement in 1978. Professor Shigley was granted the rank of Fellow of the American Society of Mechanical Engineers in 1968. He received the ASME Mechanisms Committee Award in 1974, the Worcester Reed Warner Medal for outstanding contribution to the permanent literature of engineering in 1977, and the ASME Machine Design Award in 1985. Joseph Edward Shigley indeed made a difference. His legacy shall continue.

vi

About the Authors

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, Roark’s Formulas for Stress and Strain, Seventh Edition. He was awarded the BME of Union College, MSME of the University of Rochester, and the Ph.D. of the University of Massachusetts. He is a licensed Professional Engineer 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.

vii

Brief Contents

Preface

Part 1

Basics 2

1

Introduction to Mechanical Engineering Design 3

2

Materials 31

3

Load and Stress Analysis 71

4

Deflection and Stiffness 147

Part 2

Failure Prevention 212

5

Failures Resulting from Static Loading 213

6

Fatigue Failure Resulting from Variable Loading 265

Part 3

viii

xv

Design of Mechanical Elements 358

7

Shafts and Shaft Components 359

8

Screws, Fasteners, and the Design of Nonpermanent Joints 409

9

Welding, Bonding, and the Design of Permanent Joints 475

10

Mechanical Springs 517

11

Rolling-Contact Bearings 569

12

Lubrication and Journal Bearings 617

13

Gears—General 673

14

Spur and Helical Gears 733

15

Bevel and Worm Gears 785

16

Clutches, Brakes, Couplings, and Flywheels 825

17

Flexible Mechanical Elements 879

18

Power Transmission Case Study 933

Brief Contents

Part 4

Analysis Tools 952

19

Finite-Element Analysis 953

20

Statistical Considerations 977 Appendixes

A

Useful Tables 1003

B

Answers to Selected Problems 1059 Index

1065

ix

Contents

Preface

Part 1

1

Basics

2

Introduction to Mechanical Engineering Design 3

1–1 1–2 1–3

Design 4

1–4 1–5

Design Tools and Resources 8

1–6 1–7 1–8 1–9 1–10 1–11 1–12 1–13 1–14 1–15 1–16 1–17

Mechanical Engineering Design 5 Phases and Interactions of the Design Process 5 The Design Engineer’s Professional Responsibilities 10 Standards and Codes 12 Economics 12

2 2–1 2–2 2–3 2–4 2–5 2–6

2–7 2–8 2–9 2–10 2–11 2–12 2–13 2–14 2–15 2–16 2–17 2–18 2–19 2–20 2–21

Numbering Systems 45 Sand Casting 46 Shell Molding 47 Investment Casting 47 Powder-Metallurgy Process 47 Hot-Working Processes 47 Cold-Working Processes 48 The Heat Treatment of Steel 49 Alloy Steels 52 Corrosion-Resistant Steels 53 Casting Materials 54 Nonferrous Metals 55 Plastics 58 Composite Materials 60 Materials Selection 61 Problems

Safety and Product Liability 15

67

Stress and Strength 15 Uncertainty 16

3

Load and Stress Analysis 71

3–1

Equilibrium and Free-Body Diagrams 72

3–2

Shear Force and Bending Moments in Beams 77

Design Factor and Factor of Safety 17 Reliability 18 Dimensions and Tolerances 19 Units 21 Calculations and Significant Figures 22 Design Topic Interdependencies 23 Power Transmission Case Study Specifications 24 Problems

x

xv

26

Materials

31

Material Strength and Stiffness 32 The Statistical Significance of Material Properties 36 Strength and Cold Work 38 Hardness 41 Impact Properties 42 Temperature Effects 43

3–3 3–4 3–5 3–6 3–7 3–8 3–9 3–10 3–11 3–12 3–13 3–14 3–15

Singularity Functions 79 Stress 79 Cartesian Stress Components 79 Mohr’s Circle for Plane Stress 80 General Three-Dimensional Stress 86 Elastic Strain 87 Uniformly Distributed Stresses 88 Normal 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

Contents

3–16 3–17 3–18 3–19 3–20

Press and Shrink Fits 116 Curved Beams in Bending 118 Contact Stresses 122 Summary 126 127

Deflection and Stiffness 147

4–1 4–2 4–3 4–4 4–5

Spring Rates 148

4–6

Beam Deflections by Singularity Functions 156

Tension, Compression, and Torsion 149 Deflection Due to Bending 150 Beam Deflection Methods 152

Strain Energy 162

4–14 4–15 4–16 4–17

Columns with Eccentric Loading 184

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 Struts or Short Compression Members 188 Elastic Stability 190 Shock and Impact 191 Problems

5

5–7

Failure of Ductile Materials Summary 231

5–8

Maximum-Normal-Stress Theory for Brittle Materials 235

5–9

Modifications of the Mohr Theory for Brittle Materials 235

5–10

Failure of Brittle Materials Summary 238

5–11 5–12 5–13 5–14

Selection of Failure Criteria 238

192

Failure Prevention 212

Failures Resulting from Static Loading 213

5–1 5–2 5–3 5–4

Static Strength 216

5–5

Distortion-Energy Theory for Ductile Materials 221

6

Maximum-Shear-Stress Theory for Ductile Materials 219

Stochastic Analysis 248 Important Design Equations 254 256

Fatigue Failure Resulting from Variable Loading 265

6–1 6–2

Introduction to Fatigue in Metals 266

6–3 6–4 6–5 6–6

Fatigue-Life Methods 273

6–7 6–8 6–9 6–10

The Endurance Limit 282

6–11 6–12

Characterizing Fluctuating Stresses 300

6–13

Torsional Fatigue Strength under Fluctuating Stresses 317

6–14 6–15

Combinations of Loading Modes 317

6–16 6–17 6–18

Surface Fatigue Strength 327

Stress Concentration 217 Failure Theories 219

Introduction to Fracture Mechanics 239

Problems

Beam Deflections by Superposition 153

4–7 4–8 4–9 4–10 4–11 4–12 4–13

Part 2

Coulomb-Mohr Theory for Ductile Materials 228

Temperature Effects 117

Problems

4

5–6

xi

Approach to Fatigue Failure in Analysis and Design 272 The Stress-Life Method 273 The Strain-Life Method 276 The Linear-Elastic Fracture Mechanics Method 278 Fatigue Strength 283 Endurance Limit Modifying Factors 286 Stress Concentration and Notch Sensitivity 295 Fatigue Failure Criteria for Fluctuating Stress 303

Varying, Fluctuating Stresses; Cumulative Fatigue Damage 321 Stochastic Analysis 330 Road Maps and Important Design Equations for the Stress-Life Method 344 Problems

348

xii

Mechanical Engineering Design

Part 3

7 7–1 7–2 7–3 7–4 7–5 7–6 7–7 7–8

Shafts and Shaft Components 359 Shaft Materials 360 Shaft Layout 361 Shaft Design for Stress 366 Deflection Considerations

8–1 8–2 8–3 8–4 8–5 8–6 8–7 8–8 8–9 8–10 8–11 8–12

9

9–1 9–2 9–3 9–4

379

Critical Speeds for Shafts 383 Miscellaneous Shaft Components 388 Limits and Fits 395 400

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 Stiffness 427 Bolt Strength 432 Tension Joints—The External Load 435

Static Loading 492 Fatigue Loading 496 Resistance Welding 498 Adhesive Bonding

Statically Loaded Tension Joint with Preload 440

10–1 10–2 10–3 10–4 10–5 10–6 10–7

Stresses in Helical Springs 518

10–8 10–9

Critical Frequency of Helical Springs 534

459

Welding, Bonding, and the Design of Permanent Joints

475

Stresses in Welded Joints in Torsion 482 Stresses in Welded Joints in Bending 487

The Curvature Effect 519 Deflection of Helical Springs 520 Compression Springs 520 Stability 522 Spring Materials 523 Helical Compression Spring Design for Static Service 528 Fatigue Loading of Helical Compression Springs 536 Helical Compression Spring Design for Fatigue Loading 539

10–11 10–12 10–13 10–14 10–15

Extension Springs 542 Helical Coil Torsion Springs 550 Belleville Springs 557 Miscellaneous Springs 558 Summary 560 Problems

560

Rolling-Contact Bearings 569

11–1 11–2 11–3 11–4

Bearing Types 570

11–5 11–6 11–7 11–8

Relating Load, Life, and Reliability 577

Welding Symbols 476 Butt and Fillet Welds 478

517

10–10

Gasketed Joints 444 Bolted and Riveted Joints Loaded in Shear 451

507

Mechanical Springs

11

Fatigue Loading of Tension Joints 444

498

10

Relating Bolt Torque to Bolt Tension 437

Problems

The Strength of Welded Joints 489

Problems

Introduction 360

Problems

8

9–5 9–6 9–7 9–8 9–9

Design of Mechanical Elements 358

11–9 11–10

Bearing Life 573 Bearing Load Life at Rated Reliability 574 Bearing Survival: Reliability versus Life 576 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

xiii

Contents

11–11 11–12

13–17

Lubrication 603 Mounting and Enclosure 604 Problems

Problems

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 and Journal Bearings 617 Types of Lubrication 618 Viscosity 619 Petroff’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 Bearings 650 Loads and Materials 656 Bearing Types 658 Thrust Bearings 659 Boundary-Lubricated Bearings 660 Problems

669

14–1 14–2 14–3 14–4 14–5 14–6 14–7 14–8 14–9 14–10 14–11 14–12 14–13 14–14 14–15 14–16 14–17 14–18 14–19

Spur and Helical Gears

13–1 13–2 13–3 13–4 13–5 13–6 13–7 13–8 13–9 13–10 13–11 13–12 13–13 13–14 13–15 13–16

Gears—General

673

Types of Gear 674 Nomenclature 675 Conjugate 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

15 15–1 15–2 15–3 15–4 15–5 15–6 15–7 15–8 15–9

Surface Durability 743 AGMA Stress Equations 745 AGMA Strength Equations 747 Geometry Factors I and J (ZI and YJ) The Elastic Coefficient Cp (ZE) Dynamic Factor K v

756

Overload Factor Ko

758

Tooth Systems 696 Gear Trains 698

16

Force Analysis—Spur Gearing 705 Force Analysis—Bevel Gearing 709 Force Analysis—Helical Ge...