INTRODUCTION
This text developed from classroom notes prepared in connection with junior-senior
undergraduate and first-year graduate courses in Mechanical Design, Machine Design,
Mechanical Engineering Design, and Engineering Design and Analysis. Many more topics
are covered in this book than in any other text on the subject. In addition to its applicability
to mechanical engineering, and to some extent, aerospace, agricultural, and nuclear engineering and applied engineering mechanics curricula, I have endeavored to make the
book useful to practicing engineers. The text offers a simple, comprehensive, and method-ical
presentation of the basic concepts and principles in the design and analysis of machine
and structural components. The coverage presumes a knowledge of mechanics of materials
and material properties. However, topics that are particularly significant to understanding
the subject are reviewed as they are taken up. Special effort has been made to have a book
that is as self-explanatory as possible, thus reducing the work of the instructor.
The presentation of the material in this book strikes a balance between the theory nec-essary
to gain insight into mechanics and design methods. I therefore attempt to stress
those aspects of theory and application that prepare a student for more advanced study or
professional practice in design. Above all, I made an effort to provide a visual interpreta-tion
of the equations and present the material in a form useful to a diverse audience. The
analysis presented should facilitate the use of computers and programmable calculators.
The commonality of the analytical methods needed to design a wide variety of elements
and the use of computer-aided engineering as an approach to the design are emphasized.Mechanical Design: An Integrated Approach provides unlimited opportunities for the
use of computer graphics. Computer solutions are usually preferred, because evaluation of
the design changes, and “what-if” analysis requires only a few keystrokes. Hence, many
examples, case studies, and problems in the text are solved with the aid of a computer.
Generally, solid modeling serves as a design tool that can be used to create finite element
(F.E.) models for analysis and dynamic simulation. Instructors may use a simple PC-based
F.E. program to give the students exposure to the method applied to stress concentration
and axisymmetrically loaded and plane stress problems. The website for the text (see
Supplements) allows the user to treat problems more realistically, shows tabular and graphical
trends, and demonstrates the elements of good computational practice. The text is
independent of any software package.
Traditional analysis in design, based on the methods of mechanics of materials, is given
full treatment. In some instances, the methods of the applied theory of elasticity are em-ployed.
The role of the theory of elasticity in this book is threefold: It places limitations on
the application of the mechanics of materials theory, it is used as the basis of finite element
formulation, and it provides exact solutions when configurations of loading and component
shape are simple. Plates, shells, and structural members are discussed to enable the readers
to solve real-life problems and understand interactive case studies. Website addresses of component and equipment manufacturers and open-ended web problems are given in nu-merous
chapters to provide the reader access to additional information on those topics. Also
presented is finite element analysis (FEA) in computer-aided design. The foregoing unified
methods of analysis give the reader opportunity to expand his or her ability to perform de-sign
process in a more realistic setting. The book attempts to fill what I believe to be a void
in the world of textbooks.AN INTEGRATED APPROACH
There are two major parts in this text. The fundamentals of loading, stress, strain, materials,
deflection, stiffness, buckling, fracture mechanics, failure criteria, and fatigue phenomena
are treated first. This is followed by applications to machine, miscellaneous mechanical,
and structural components. Both parts attempt to provide an integrated approach that links
together a variety of topics by means of case studies. Some chapters and sections in the text
are also carefully integrated through cross referencing. Throughout the book, case studies
provide numerous machine or component projects. They mostly present different aspects of
the same design or analysis problem in successive chapters. For instance, defining the
loading in a device in Chapter 1; calculating the stresses, deflections, or factor of safety, due
to the loading throughout in Part I; and presenting the design contents in Part II. Case
Study 1-1 on the winch crane is one such example.
Attention is given to the presentation of the fundamentals and necessary emprical in-formation
required to formulate design problems. Important principles and applications are
illustrated with numerical examples, and a broad range of practical problems is provided
for solution by the student. This volume offers numerous worked out examples and case
studies, aspects of which are presented in several sections of the book; more than 500 prob-lem
sets, most are drawn from engineering practice; and a multitude of formulas and tabu-lations
from which design calculations can be made. Most problems can be readily modi-fied
for in-class tests. References are listed at the end of each chapter. Answers to selected
problems are given at the end of the book.
A sign convention consistent with vector mechanics is used throughout for loads, in-ternal
forces (with the exception of the shear in beams), and stresses. This convention has
been carefully chosen to conform to that used in most classical mechanics of materials,
elasticity, and engineering design texts as well as to that most often employed in the nu-merical
analysis of complex machines and structures. Both the international system of
units (SI) and the U.S. customary system of units are used; but since in practice the former
is replacing the latter, this book places a greater emphasis on SI units.TEXT ARRANGEMENT
A glance at the table of contents shows the topics covered and the way in which they are
organized. Because of the extensive subdivision into a variety of topics and use of alterna-tive
design and analysis methods, the text should provide flexibility in the choice of as-signments
to cover courses of varying length and content. A discussion of the design
process and an overview of the material included in the book is given in Sections 1.1 through 1.4. Most chapters are substantially self-contained. Hence, the order of presenta-tion
can be smoothly altered to meet an instructor’s preference. It is suggested, however,
that Chapters 1 and 2 should be studied first. The sections marked with an asterisk (*) deal
with special or advanced topics. These are optional for a basic course in design and can be
deleted without destroying the continuity of the book.
This text attempts to provide synthesis and analysis that cuts through the clutter and
saves readers time. Every effort has been made to eliminate errors. I hope I’ve maintained
a clarity of presentation, as much simplicity as the subject permits, unpretentious depth, an
effort to encourage intuitive understanding, and a shunning of the irrelevant. In this con-text,
emphasis is placed on the use of fundamentals to build students’ understanding and
ability to solve more complex problems throughout.
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