Machine Design with CAD and Optimization

Machine Design with CAD and Optimization
Sayed M. Metwalli
Faculty of Engineering, Cairo University
Egypt
Contents
Preface xxiii
Acknowledgments xxvii
About the Companion Website xxix
Part I Introduction and Design Considerations
Introduction to Design
. Introduction
. Phases of Design
. Basic Mechanical Functions
. Design Factors
. Synthesis Approach to Design
. Product Life Cycle
. Business Measures
. Research and Development Process in Product Cycle
. Teamwork for Product or System Design
. Design and Development Case Study
. Units and Fundamentals
. Units
. Force and Mass
. Pressure
. Velocity, Acceleration, and Rotational Speed
. Moments, Work, and Power
. Weight
. Prefixes
. Unit Conversion
. Vectors and Matrices
. Summary
Problems
References
Internet Sites viii Contents
Design Considerations
. Mathematical Modeling
. Mathematical Model Initiation and Adoption
. Generalized System Modeling
. Modeling of Loads and Material Variations
. Calculation Tools
. Excel©
. MATLAB©
. Computer-Aided Design (CAD)
. Finite Element (FE)
. Design Procedure
. Manufacturing Processes
. Casting or Molding
. Deformation
. Machining
. Joining
. Surface and Heat Treatment
. D Printing or Additive Manufacturing
. Tolerances, Surface Finish, and Fits
. Tolerances
. Surface Finish
. Fits
. Fundamental Deviations
. Standard Sets and Components
. Codes and Standards
. Summary
Problems
References
Internet Links (Selected)
Part II Knowledge-Based Design
Introduction to Computer-Aided Techniques
. CAD and Geometric Modeling
. Classical Design Process
. Synthesis Design Process
. Human–Machine Characteristics
. Geometric Construction and FE Analysis
. CAD/CAM/CAE and Advanced Systems
. Virtual Reality
. Virtual Reality Process
. Virtual Reality Hardware Requirements
. Virtual Reality Interactive-Process Tools
. Virtual Reality Applications
. Summary Contents ix
Problems
References
Internet Links
Computer-Aided Design
. D Geometric Modeling and Viewing Transformation
. D Geometric Modeling
. Geometric Computations
. Topological Operations and the Euler Formula
. Geometric and Global Operations
. Procedures for Constructing a Single or a Compound Solid
. Homogeneous Coordinates Versus Cartesian Coordinates
. Point in Space
. Vectors
. Lines
. Body Geometry and Vertices
. Body Transformation
. Translation
. Rotation
. Scaling
. Zooming
. Skewing
. Perspective
. Orthographic Projection
. Body Transformation Systems
. Stereo Viewing
. D Graphics
. Parametric Modeling
. Parametric Lines
. Alternative Parametric Form
. Parametric Planes
. Parametric Bilinear Surfaces
. Parametric Curves and Surfaces
. Free-Form Parametric Curves and Surfaces
. Surface Patches and Curves
. Bezier Curves
. Bezier Surfaces or Patches
. B-Spline Curves
. B-Spline Surfaces
. NURBS
. Intersections
. Intersection of Two Lines
. Intersection of a Line with a Plane
. Intersection of Two Planes
. Intersection of Three Planes
. CAD Hardware and Software x Contents
. Rendering and Animation
. Realistic Presentations
. Color Use
. Visual Color Description
. Color Specification System
. Shading and Rendering Technique
. Methods of Shading a Polygon or a Triangle
. Computing Vertex and Surface Normals
. Rendering Process
. Diffuse Illumination
. Specular Reflection
. Transparency
. Total Rendering Effect
. D Cursor and Picking
. Data Structure
. Drawing Exchange Format (DXF)
. STL File Format
. IGES File Format
. STEP File Format
. Using CAD in D Modeling and CAM
. Summary
Problems
References
Internet Links
Optimization
. Introduction
. Formulation of Optimization Problem
. Design Vector D
. Objective Function f
. Constraints
. Problem Statement
. Dimensional Considerations in Analytical Design “Nondimensionalization”
. Classification of Optimization
. Problem Classification
. Methods of Optimization
. Optimization Fields
. Searches in One Direction
. Quadratic Interpolation
. Golden Section (Euclid)
. Newton–Raphson
. Other Methods
. Multidimensional: Classical Indirect Approach
. Unconstrained Problem
. Equality Constrained Problem
. Lagrange Multipliers
. Inequality Constraints Problem Contents xi
. Multidimensional Unconstrained Problem
. Univariate Method
. Powell’s Method of Conjugate Directions
. Linearized Ridge Path Method
. Random Search Methods
. Steepest Descent Method
. Implementation
. Fletcher–Reeves Conjugate Gradient
. Newton–Raphson Method
. Quasi-Newton Methods
. A Quadratic Optimization Technique
. Identified Quadratic Optimization Technique
. Comparison of Unconstrained Optimization Methods
. Multidimensional Constrained Problem
. Eliminating Constraints by Transformation
. Exterior Penalty Functions
. Interior Penalty Functions
. Direct Methods for Constrained Problems
. Convex–Concave Property
. Kuhn–Tucker Conditions
. Gradient Projection Method
. Heuristic Gradient Projection Method (HGP)
. Constrained Optimization Sample
. Comparison of Optimum Constrained Methods
. Applications to Machine Elements and Systems
. Summary
Problems
References
Stresses, Deformations, and Deflections
. Loads, Shear, Moment, Slope, and Deflection
. External and Internal Loads
. Pure Bending
. Beam Deflection
. Deflection by Integration
. Deflection by Superposition
. Deflection by Singularity Function
. Deflection by Other Methods
. Simple Beam Synthesis
. Comparing Stresses and Deflections in Beams
. Beam Stresses
. Beam Deflection
. Equivalent Loads on Simple Beams
. Mathematical Model
. Simple Stresses, Strains, and Deformations
. Uniform Tension and Compression
. Direct Uniform Shear xii Contents
. Pure Bending
. Shear Stress and Deformation Due to Torsion
. Transverse Shear and Shear Flow
. Shear Center
. Combined Stresses
. Plane Stress State
. Mohr’s Circle
. Principal Stresses and Principal Directions
. Vector Space and Eigenvalue Problem
. Stress Invariants I
i
. A Common Stress State
. Triaxial Stress State
. Stress Invariants I
i
. Applications in Plane Stress and Triaxial Stress States
. Thin Pressure Cylinders
. Thick Pressure Cylinders
. Press and Shrink Fits
. Contact Stresses
. Curved Beams
. Strain Energy and Deflection
. Elastic Strain
. Elastic Strain Energy
. Castigliano’s Theorem and Deflections
. Columns
. Concentric Loading
. Johnson’s Parabolic Equation
. Eccentric Loading
. Equivalent Element
. Thermal Effects
. Stress Concentration Factors
. Finite Element Method
. Axially Loaded Elements
. Prismatic Beam Element
. Constant Strain Triangle
. General D State: Linear Elasticity Problem
. General D FE Procedure
. Errors in FE Modeling and Solution
. Some Classical FE Packages
. Computer-Aided Design and Optimization
. Beam Synthesis Tablet
. Column Synthesis Tablet
. Optimum Stress Concentration
. Optimum FE Prismatic Beams
. Optimum FE Cantilever Beams
. Summary
Problems
References
Internet Links Contents xiii
Materials Static and Dynamic Strength
. Material Structure and Failure Modes
. Basic Elements of Material
. Material Failure Modes and Properties
. Tensile Properties
. Other Static Properties
. Other Time-Dependent Properties
. Numbering Systems and Designations
. Carbon and Alloy Steels
. Aluminum and Aluminum Alloys
. Other Alloys
. Copper and Copper Alloys
. Magnesium and Magnesium Alloys
. Heat Treatment and Alloying Elements
. Heat Treatment
. Case Hardening
. Effect of Alloying Elements
. Material Propertied and General Applications
. Cast Iron
. Plain and Low-Alloyed Carbon Steels
. Hot Rolled and Cold Drawn Plain-Carbon Steels
. Strength and Hardness of Annealed and Normalized Plain Carbon Steels
. Quenched and Tempered Plain Carbon Steels
. Quenched and Tempered Low-Alloy Steels
. Structural Steel
. Stainless Steel
. Tool Steel
. Other Nonferrous Metals
. Aluminum and Aluminum Alloys
. Copper and Magnesium Alloys
. Other Materials
. Plastics
. Composites
. Particular Materials for Machine Elements
. Standard Machine Elements
. Synthesized or Designed Machine Elements
. Hardness and Strength
. Failure and Static Failure Theories
. Maximum Normal Stress Theory
. Maximum Shear Stress Theory
. Maximum Distortion Energy Theory (von Mises)
. Other Failure Theories
. Comparison and Applications of Failure Theories
. Fatigue Strength and Factors Affecting Fatigue
. Fatigue Strength
. Estimation of Endurance Limit
. Estimation of Fatigue Strength
. Factors Affecting Fatigue Strength xiv Contents
. Surface Factor, Ksurf
. Size Factor, Ksize
. Loading Factor, Kload
. Reliability Factor, Kreliab
. Temperature Factor, Ktemp
. Fatigue Concentration Factor, Kconc
. Miscellaneous Factor, Kmiscel
. Cumulative Fatigue Strength
. Fluctuating Stresses
. Fatigue Failure Criteria
. Fracture Mechanics and Fracture Toughness
. Stress Intensity Factor KI
. Fracture Toughness: Critical Stress Intensity Factor KIC
. Crack Propagation and Life
. Crack Propagation and Real Case Study
. Computer-Aided Selection and Optimization
. Material Properties: Carbon Steel
. Fatigue Strength and Factors Affecting Fatigue: Carbon Steel
. Static Strength and Factors of Safety: Carbon Steel
. Optimization for a Specific Factor of Safety: Carbon Steel
. Summary
Problems
References
Internet Links
Material Selection
Material Standards
Introduction to Elements and System Synthesis
. Introduction
. Basic and Common Machine Elements
. Couplings
. Rigid Couplings
. Flexible Couplings
. Universal Joints
. Keys, Pins, Retaining Rings, and Splines
. Keys
. Pins and Cotter Pins
. Retaining Rings
. Splines
. Seals
. Housings, Enclosures, Frames, and Chassis
. Reverse Engineering
. Sample Applications
. Initial Bolt Synthesis
. Initial Shaft Synthesis
. Initial Bearing Synthesis
. Computer-Aided Design Contents xv
. System Synthesis
. Computer-Aided Assembly
. Summary
Problems
References
Internet Links
Producers and Providers
Standards and Codes
Part III Detailed Design of Machine Elements
Section A Basic Joints and Machine Elements
Screws, Fasteners, and Permanent Joints
. Standards and Types
. Thread Terminology and Designation
. Joining Alternative Details
. Stresses in Threads
. Bolted Connections
. Threads Under Simple Tensile Load
. Preloading Due to Tightening
. Tightening Torque
. Bolt Strength in Static and Fatigue
. Power Screws
. Torque Requirements
. Power Screw Efficiency
. Stresses in Power Screws
. Ball Screws
. Permanent Joints
. Welding
. Welding Types and Symbols
. Stresses in Welded Joints
. Welding Strength
. Resistance Welding
. Bonded Joints
. Computer-Aided Design and Optimization
. Threads Under Simple Tensile Load
. Preloading Due to Bolt Tightening
. Preloading, Bolt Tightening, and Fatigue Strength
. Power Screws
. Permanent Weldment Joints
. Optimization
. Summary
Problems
References
Internet Links xvi Contents
Springs
. Types of Springs
. Helical Springs
. Geometry, Definitions, and Configurations
. Stresses and Deflections
. Static Loading
. Dynamic Loading
. Buckling
. Resonance
. Design Procedure
. Initial Synthesis
. Detailed Design
. Extension Springs
. Torsion Springs
. Leaf Springs
. Stresses and Deflections
. Design Procedure
. Initial Synthesis
. Detailed Design
. Belleville Springs
. Elastomeric and Other Springs
. Computer-Aided Design and Optimization
. Summary
Problems
References
Internet: Information and Some Manufacturer
Internet: Images
Rolling Bearings
. Bearing Types and Selection
. Standard Dimension Series
. Boundary Dimensions
. Bearing Designation Number
. Initial Design and Selection
. Bearing Load
. Bearing Life and Reliability
. Load Distribution
. Bearing Load Rating
. Detailed Design and Selection
. Static Loading
. Combined Loading
. Tapered Roller Bearings
. Unsteady Loading
. Detailed Design Procedure
. Speed Limits
. Lubrication and Friction
. Mounting and Constructional Details Contents xvii
. Computer-Aided Design and Optimization
. Initial Ball Bearing Synthesis
. Dynamic Load Rating Estimate
. Ball Bearing Selection
. Rolling Bearing Optimization
. Summary
Problems
References
Internet
Journal Bearings
. Lubricants
. Lubricant Viscosity
. Lubricant Selection
. Stable Lubrication
. Hydrodynamic Lubrication
. Petroff’s Equation
. Journal Bearings
. Long Bearing
. Short Bearing
. Finite Length Bearing
. Journal Bearing Design Procedure
. Boundary and Mixed Lubrication
. Plain Bearing Materials
. CAD and Optimization
. CAD of Bearing Synthesis Using Knowledge Base Practice
. CAD of Bearing Synthesis Using an Optimization Approach
. Journal Bearing Synthesis Tablet
. Summary
Problems
References
Internet Link
Section B Power Transmitting and Controlling Elements
Introduction to Power Transmission and Control
. Prime Movers and Machines
. Collinear and Noncollinear Transmission Elements
. Power Control Elements
. Computer-Aided Design of a Power Transmission System
. Summary
Problems
References
Spur Gears
. Types and Utility
. Definitions, Kinematics, and Standards xviii Contents
. Force Analysis and Power Transmission
. Design Procedure
. Classical Procedure
. Initial Synthesis
. Detailed Design
. Material Set
. Bending Fatigue
. Surface Fatigue
. Critical Speed
. CAD and Optimization
. Constructional Details
. Gearboxes
. Gear Trains
. Planetary or Epicyclic Gear Trains
. Summary
Problems
References
Internet Links
Helical, Bevel, and Worm Gears
. Helical Gears
. Types and Utility
. Definitions, Kinematics, and Standards
. Force Analysis
. Design Procedure
. Initial Synthesis
. Detailed Design
. Bevel Gears
. Definitions, Kinematics, and Standards
. Force Analysis
. Design Procedure
. Initial Design
. Detailed Design
. Material Set and Safety Factor
. Worm Gears
. Definitions, Kinematics, and Standards
. Force Analysis
. Design Procedure
. Initial Synthesis
. Detailed Design
. Material Set and Safety Factor
. Gear Failure Regimes and Remedies
. Computer-Aided Design and Optimization
. Helical Gears Synthesis
. Bevel Gears Synthesis
. Worm Gears Synthesis Contents xix
. Constructional Details
. Summary
Problems
References
Internet Links
Flexible Elements
. V-belts
. V-belt Drive Relations
. Standards and Geometric Relations
. Design Procedure
. Initial Synthesis
. Detailed Design Process
. Flat Belts
. Drive Relations
. Standards and Geometry Relations
. Design Procedure
. Initial Synthesis
. Detailed Design Process
. Ropes
. Sizes and Properties
. Wire Rope Strength
. Other Wire Rope Properties
. Design Procedure
. Initial Synthesis
. Detailed Design Process
. Chains
. Standards
. Chain Size or Number
. Chain Sprockets
. Drive Relations
. Set Dimensions and Constraints
. Design Procedure
. Initial Synthesis
. Detailed Design Process
. Friction Drives
. Flexible Shafts
. Computer-Aided Design and Optimization
. V-belts Synthesis
. Wire Rope Synthesis
. Roller Chains Synthesis
. Summary
Problems
References
Internet Links xx Contents
Shafts
. Types of Shafts and Axles
. Mathematical Model
. Initial Design Estimate
. Detailed Design
. Design for Rigidity
. Critical Speed
. Computer-Aided Design and Optimization
. Shaft Materials
. Computer-Aided Design of Shafts
. Optimum Design of Shafts
. Constructional Details
. Summary
Problems
References
Internet Links
Clutches, Brakes, and Flywheels
. Classifications of Clutches and Brakes
. Cone Clutches and Brakes
. Uniform Pressure
. Uniform Wear Rate
. Disk Clutches and Brakes
. Uniform Pressure
. Uniform Wear Rate
. Multi-disk Clutch-Brake
. Uniform Pressure
. Uniform Wear Rate
. Initial Disk Clutch-Brake Synthesis
. Caliper Disk Brakes
. Energy Dissipation and Temperature Rise
. Energy Dissipation
. Temperature Rise
. Design Process
. Initial Synthesis
. Detailed Design Process
. Computer-Aided Design and Optimization
. Flywheels
. Constructional Details
. Summary
Problems
References
Internet Links Contents xxi
Appendix A Figures and Tables
A. Conversion Between US and SI Units
A. Standard SI Prefixes
A. Preferred Numbers and Sizes
A. Standard Rods, or Bars
A. Standard Joining and Retaining Elements
A. Standard Sealing Elements
A. Material Properties
A. Standard Sections or Profiles and Section Properties
Index
Index
Bold-italic numerals are for dedicated sections or variables in the text. Italic numerals are usually for variables in tables
a
Abrasion ,
Absolute system of units
Absolute viscosity ,
Acme threads ,
Addendum , – ,
Adhesive bonding ,
AGMA factors ,
allowable bending stress numbers ,
allowable contact stress number ,
bending geometry factor ,
– ,
bending strength , – ,
contact geometry factor ,
,
dynamic factor , –
elastic coefficient ,
, –
geometry factors ,
load-distribution factor ,
– , – ,
reliability factor , – ,

rim-thickness factor
size factor ,
surface geometry factor , –
temperature factor ,
AGMA gears
bevel gears – , –
helical gears , – , – ,
–
quality number ,
spur gears – , – ,
–
worm gears – , –
Alignment ,
Allowance ,
Alloying , – , – ,
Alloy steels
chromium , – ,
manganese , – ,
molybdenum , –
nickel , – ,
numbering system –
quenching , – ,

silicon , – ,
tempering , – , – ,
,
tungsten ,
vanadium , – ,
Alternating stresses , – ,
,
– ,
Aluminum , – ,
, – , – ,
– , – ,
,
Aluminum alloys , – ,
– , – ,
properties
Aluminum and aluminum alloys – ,
Aluminum Association (AA) ,
Aluminum brass
Index
Aluminum bronze ,
American Bearing Manufacturers Association (ABMA)
,
American Gear Manufacturers Association (AGMA) ,

approach , – , – ,
– , – , – ,
– , – , – ,
standard , – , –
American Institute of Steel Construction (AISC) ,
,
American Iron and Steel Institute (AISI) ,
, – , – , – ,
– , – , – ,
, – , – ,
, – , – ,
,
American Society of Mechanical Engineers (ASME)
,
American Society of Testing and Materials (ASTM)
,
American Welding Society (AWS) , – ,

standard –
Analysis – , – , – , – ,
– ,
force – , – , – , – , – ,
– ,
stress , – ,
Angle of articulation
Angle of twist ,
Angular contact bearing ,
,
Angular velocity ratios
Animation ,
Annealing , – ,
Anodizing
Anti-friction
Applications in plane stress and triaxial stress states
–
Applications of general materials –
Applications to machine elements and systems
– , –
A quadratic optimization technique –
Arc of contact ,
Arrow (weld symbol)
Articulation angle
ASM , – , – , – ,
– , – ,
,
ASME , – ,
, – , – , – ,
– , – , – ,
,
, – , – , – , – ,
, – , – , – , – ,
standard , – ,
ASME-elliptic (failure criteria) – , – ,
, – ,
ASM Handbook ,
Assemblies – ,
Assembly , – , – , – , – ,
– , – , – , – ,
, – ,
, – , – ,
, – , – , – ,
, – , – ,
– ,
ASTM , – , – ,
– , – ,
,
,
standard ,
Austenite – ,
Average lifetime ,
Average stress , – ,
,
Average temperature , – ,
Axial load ,
, – , – ,
– ,
Axially loaded elements –
Axial pitch , –
Axle , – ,
b
Babbitt
Backlash – , – ,
Back-to-back (mounting) – ,
Ball bearing , – ,
– , – , – , – ,
– ,
selection
synthesis , – , – , – Index
Ball screws – , –
Bars (standard)
Base circles , – , – , – ,
– , – ,
Basic and common machine elements –
Basic dynamic load rating – ,

Basic elements of material –
Basic joints and machine elements
Basic mechanical functions –
Basic mountings of bearings
Basic size (fits and tolerances) ,
Basic static load rating ,
Beam deflection – ,
Beams , – ,
– , – , – ,
, – ,
,
curved ,
deflection , – ,
deflections by singularity functions ,
– , – ,
deflections by superposition
shear force and bending moment ,
– ,
shear force and bending moment (shaft) – ,

shear stress ,
stresses ,
synthesis – , – ,
Beam stresses –
Beam synthesis tablet , –
Bearing alloys
Bearing characteristic value , . See also
Sommerfeld number
Bearing designation number –
Bearing fatigue ,
Bearing film pressure ,
Bearing film thickness , – , – ,
Bearing life – , – , – ,
– ,
recommendations for various classes of machinery

reliability and life –
Bearing life and reliability –
Bearing load –
Bearing load-life ,
Bearing load rating –
Bearing lubricant film – , – ,
Bearing maximum film pressure ,
Bearing pressure , – ,
– ,
Bearings
boundary dimensions (rolling bearings) ,
direct mounting
indirect mountings of
journal , – , – , –
reliability , – , – , – , – ,
– ,
rolling ,
– , – , – ,
,
selection , – ,
shields ,
stress – , – ,
suppliers ,
supports ,
synthesis , – , – , – , – ,
,
types – , – ,
Bearing stress ,
Bearing types and selection –
Belleville springs – ,
Belts ,
– , – , –
centrifugal tension ,
cogged
flat belts , – ,
round belts , –
synthesis – , –
tension ,
timing , – ,
V-belts – , – , –
Bending factor ,
Bending fatigue (spur gears) –
Bending moment , – ,
– , – , – , – ,
, – , – , – ,
, – , – , – , – ,
, – , – , – , – ,
– , – ,
, – , – , – ,
, –
Bending strain energy – Index
Bevel and worm gears –
bevel gear force analysis –
bevel gears – , – , – ,
synthesis (bevel gears) , –
synthesis (worm gears) – , –
worm gear force analysis –
worm gears , – , – , – ,
, – ,
Bevel gears –
synthesis –
Bezier curves –
Bezier surfaces or patches –
Blanking ,
Blending function , – , – ,
,
Body geometry and vertices
Body transformation –
Bolted connections –
Bolted joints ,
Bolt elongation
Bolt preload – ,
Bolts loosening
Bolt strength – , –
in static and fatigue –
Bolt synthesis – ,
Bolt tightening torque –
Bonded joints –
Bottom land ,
Boundary and mixed lubrication –
Boundary conditions
axisymmetric beam and bearing supports – ,
,
critical speeds
finite element analysis , – , – ,
– ,
geometric
long columns
multipoint constraint equations ,
simply supported beams – , –
Boundary dimensions (for bearings) – ,
Boundary lubrication – , – ,
Boundary representation (B-rep) , – ,
Brake lining
Brakes – , – , – ,
– , –
caliper , – , – ,
cone ,
disk or disc , – , –
materials – , – ,
optimization , –
synthesis – , –
Brake shoes
Brass – ,
Break-even point
Brinell hardness , – , – , – ,
– , – ,
Brittle Coulomb-Mohr theory , – ,
Brittle fracture , – ,
Brittle materials ,
fatigue strength
maximum-normal-stress theory – , –
modified Mohr theory , – ,
Bronze ,
tin-bronze ,
B-spline curves –
B-spline surfaces –
Bubble charts (Ashby) ,
Buckingham theory ,
Buckingham wear load ,
Buckling , – , – ,
Bushing ,
Busines measure ,
Butt weld –
c
CAD (machine elements) , – , – , – ,
– , – , – , – , – ,
– , –
CAD and geometric modeling –
CAD/CAM/CAE and advanced systems
CAD hardware and software
CAD of bearing synthesis using an optimization approach
–
CAD of bearing synthesis using knowledge base practice
–
CAD packages , – , – , – ,

CAD software – , – ,
Calculation error
Calculations and significant figures – ,
Calculation tools – ,
Caliper brakes , – , – ,
– , –
Caliper Disk Brakes – Index
Cams ,
Camshafts , – , – ,
Cap screws –
Carbon and alloy steels –
Carbon content , – , – , – ,
, – ,
Carbon steel – , – , – ,
properties –
Carburization
Case hardening – ,
Case study , –
Case study (Jib-crane) ,
–
bearing selection – , – , – ,
– , –
conceptual layout
design for stress – , – , – ,
–
force analysis –
problem specification ,
shaft layout
speed specification
synthesis – , – , – , – ,
–
Castigliano’s theorem – , –
and deflections –
Casting , – , – ,
, –
Casting materials
cast iron ,
cast steels ,
ductile and nodular cast iron ,
gray cast iron ,
malleable cast iron ,
white cast iron ,
Casting or molding –
Cast iron ,
properties
Cast steels
Catalog dynamic load rating , –
Catastrophic (failure) ,
Catenary geometry
Cementite –
Center distance , – , – ,

Centipoise ,
Centrifugal castings
Centrifugal force ,
Centroidal axis , – , – ,
Cermet friction material
Chain dimensions – ,
Chains , – , –
Chain size or number –
Chain sprockets
Chain velocity , – ,
Charpy test ,
Chordal speed variation ,
Chrome silicon wire ,
Chrome vanadium wire ,
Chromium , – , – ,
,
Chromium-nickel stainless steel
Circular pitch , – , – ,
– , – , – ,
–
Classical design process
Classical FE Packages ,
Classical procedure (spur gear design) –
Classification of optimization –
Classifications of clutches and brakes
Clearance , – , – , – ,
,
– , – ,
,
diametral , – , – , – ,
– ,
radial , – ,
ratio , – ,
–
Close running fit ,
Clutch-brake – , – , – , –
energy dissipation and temperature rise –
Clutches , – , – ,
–
cone –
disk , – , –
energy dissipation and temperature rise –
friction materials – ,
multi-disk (multiple disk) – , – , –
types
Clutches, brakes, and flywheels – , –
Codes – , – ,
Codes and standards , – , Index
Coefficient of friction , – , – ,
– , – , – , – ,
, – , –
of journal bearing , – , – ,
,
of rolling bearing
Coefficient of speed fluctuation ,
Cognitive design process ,
Coining ,
Cold drawing
Cold forming
Cold rolling ,
Cold working ,
Cold working processes
Cold working tools
Collinear and noncollinear transmission elements
–
Color specification system –
Color use –
Columns , – ,
defined –
eccentric loading –
end condition – , –
Euler column formula – , –
Johnson’s parabolic equation , –
long –
secant formula – ,
synthesis ,
Column synthesis tablet
Combinations loading , – ,

Combined loading –
Combined radial and axial loading
Combined stresses –
Commercial FE packages ,
Commercial packages
Communication ,
Comparing stresses and deflection in beams –
Comparison and applications of failure theories
–
Comparison of optimum constrained methods

Comparison of unconstrained optimization methods

Composite materials , – , – ,
,
Composites –
Compression springs – , –
buckling –
design procedure –
geometry, definitions, and configurations –
resonance –
stresses and deflection –
synthesis – , –
Compressive stress , – ,
, – , – ,
Computer aided assembly
Computer aided design (CAD) – , – , –
and optimization – , – , – ,
– , – , – , – , –
of a power transmission system –
of shafts –
software ,
Computer-aided engineering (CAE) ,
Computer aided selection and optimization –
Computing vertex and surface normals –
Concentric loading – , – ,
Conceptual ,
Cone , –
Cone angle , – ,
– ,
Cone clutches –
Cone clutches and brakes –
uniform pressure –
uniform wear
Conical springs –
Conjugate direction , –
Conjugate gradient , – ,
Constant angular-velocity ratio
Constant-force springs ,
Constant strain triangle –
Constrained optimization sample –
Constructional details – , – , – ,
–
Constructive solid geometry (CSG-rep) ,
Contact fatigue strength , – ,
– , – ,
, –
Contact fatigue stress , – ,
– , – , – , – ,
Contact geometry factor ,
,
Contact ratio , – , – , –
Contact strength – , – , – , Index
Contact stresses – , – ,
,
cylindrical contact ,
spherical contact
Conversion between US and SI Units (Appendix)
–
Convex–Concave property
Coordinate transformation , – ,
Copper alloys , – , – ,
Copper and Magnesium alloys
Copper base alloys
Corrosion , – , – , – ,
, – ,
Corrosion resistant
Cost , – ,
, – ,
– ,
computational –
and economy ,
maintenance
manufacturing ,
material ,
minimum – ,
optimum , – ,
overhead
production ,
reasonable ,
reduce ,
running
specific (cost/weight)
total cost ,
unit ,
Cost and Economy
Coulomb-Mohr theory , – ,
Couplings , – ,
– , –
clutching
flexible – , – ,
rigid – ,
synthesis – ,
universal (Cardan, Hooke’s) –
Crack growth , –
Crack initiation – ,
Crack propagation and life –
Crack propagation and real case study –
Cracks ,
critical
cycles to failure , – ,
–
fatigue crack growth
fracture mechanics , –
growth , –
initial size ,
initiation – ,
instability ,
metal spraying
opening –
propagation – , – ,
quenching
sliding mode
stress intensity factor , –
tearing mode
zones I, II, III – ,
Creep , – ,
Critical buckling load ,
Critical load – ,
Critical locations ,
Critical or resonance frequency ,
Critical speed , – ,
Critical stress , – , – ,
intensity factor – ,
Critical unit load ,
Crowned pulleys –
Crowning
Crystal arrangement or structure –
C-section properties –
Cumulative fatigue damage
Cumulative fatigue strength
Cups
Curvature effect ,
Curved beams – ,
Cycles to failure , – ,
–
Cylindrical contact ,
Cylindrical or plain roller bearings , – ,

d
Damping coefficient
Data structure –
Dedendum – , – ,
Definitions, kinematics and standards
Bevel gears –
helical gears – Index
Definitions, kinematics and standards (contd.)
spur gears –
worm gears –
Deflection – , – ,
angular , – ,
beam – ,
bolt
Castigliano’s theorem – , –
critical ,
due to torsion –
maximum ,
operating , – , – ,

spring rates ,
statically indeterminate – , – , –
uniform tension and compression
Deflection by integration –
Deflection by other methods
Deflection by singularity function –
Deflection by superposition –
Deformation
Deformation (manufacturing) – ,
Deformation and beam
Deformation due to torsion –
Design and development case study
Design considerations –
Design factors –
constructional details , – , – , – ,
–
cost and economy ,
performance ,
safety and reliability ,
Design for rigidity (shafts) –
Design of a gear set
Design of power transmission system (CAD) –
Design procedure , – ,
bevel gears –
bolts (initial) –
chains –
clutches-brakes –
flat belts –
helical gears –
helical springs –
joining elements (CAD) –
journal bearings –
leaf springs –
power screws –
rolling bearings –
screws (CAD) –
shafts –
spur gears –
V-belts –
weldments (CAD) –
wire ropes –
worm gears –
Design requirements ,
Design synthesis , – , – ,
, . See also Initial
synthesis
Design tools (calculation) –
Design vector D
Detailed design –
bevel gears –
chains –
clutches-brakes
flat belts –
helical springs –
leaf springs –
machine elements –
rolling bearings –
ropes –
shafts –
spur gears –
V-belts –
worm gears
Detailed design and selection
rolling bearings –
Detailed design procedure –
Detailed design process
chains –
clutches-brakes
flat belts –
ropes –
V-belts –
Deviation
calculations
flexibility
fundamental (tolerances and fit) – , – ,
– , – ,
optimization –
standard (probability) – ,
Diameter series
Diametral clearance – , – ,
– , – , Index
Diametral pitch , – , – ,
, – , – ,
, – , – ,
– ,
Die castings ,
Diffuse illumination , –
Dimensional considerations in analytical design
“Nondimensionalization” –
Dimensions and tolerances
Directional characteristics
Direct methods for constrained problems –
Direct uniform shear ,
Discontinuities
Disk brakes ,
caliper –
uniform pressure –
uniform wear – , –
Disk clutches –
and brakes –
uniform pressure –
uniform wear rate –
Displacement , – , – , – , – ,
– , – , – ,
,
Distortion energy theory (von Mises) – ,
– , – ,

Distribution
normal ,
uniform ,
Weibull – , – ,
Double-enveloping worm gear
Double helical (herringbone gear) – , – ,

Double-helical gear , – ,
Double lap joints
Double row bearing – ,
Double thread screw
Dowel pins ,
Drawing exchange format (DXF) –
Drawings – ,
Drive relations – , – , –
Drum brake
Ductile and nodular cast iron
Ductile cast iron ,
Ductile materials , – , – ,
,
ASME elliptic for – , – ,
– ,
Coulomb-Mohr theory for , – ,
distortion-energy theory for
maximum shear stress theory , – , – ,
,
Ductility , – , – ,
Dynamic effect ,
Dynamic factor , – , –
Dynamic loading , – ,
– , – , – ,
,
Dynamic load rating estimate
Dynamic viscosity , – ,
e
Eccentricity , – , – ,
– , – , – ,
Eccentricity ratio – , – , – ,
– ,
Eccentric loading –
Economics , – ,
break-even point
standard sizes
Effect of alloying elements
Efficiency ,
belts
chains
energy
friction gears
gear set , – , –
optimization ,
planetary gears
power screw , –
power transmission – , – ,

screw , –
space
thread , –
transmission elements ,
weld joint ,
worm gears , – , –
Eigenvalue , – ,

Eigenvector ,
Elastic coefficient , – ,
, – Index
Elastic deformation
Elasticity ,
composite
linear ,
matrix ,
modulus of ,
– , – , – ,
, – , – , – ,
, – , – ,
, – , – , – ,
, – ,
photoelasticity ,
rope ,
theory ,
Elastic limit – ,
Elastic loading
Elastic stability ,
Elastic strain , – ,
Elastic strain energy –
Elastohydrodynamic lubrication ,
, – ,
Elastomeric and other Springs
Electrolytic plating
Element geometry ,
Enclosures , – ,
End condition constant , – , –
End conditions ,
End configuration (spring) ,
Endurance limit , – ,
– , – , – ,
, – , – , – ,
– , – , – , – ,
– , – , – ,
estimation of
Endurance limit affecting factors – . See Fatigue
strengths and factors affecting fatigue
Energy consideration (flywheels) –
Energy dissipation ,
and temperature rise –
Energy method. See Castigliano’s theorem
Engineering stress , – ,
Engineering stress-strain diagram –
Epicyclic gear trains ,
Equations of flywheel energy –
Equilibrium , – ,
,
Equilibrium and free body diagram ,
,
Equivalent beam , – ,
Equivalent bending load , – ,
Equivalent element –
Equivalent stress ,
Equivalent von Mises stresses ,
,
Errors in FE modeling and solution
Estimation of endurance limit
Estimation of fatigue strength
Euler column –
Euler column formula
Eutectic –
Evaluation
derivative , –
design ,
digital
function –
Extension springs –
External loads ,
Extreme pressure lubricants
Extrusion , – ,
f
Face
bold (vectors) ,
cross section , –
to face – ,
shading ,
surface , – ,
tooth , –
Face load distribution factor , – , – ,
– , – , – ,
Face width (gears) , – ,
– , – , – ,
,
optimum , – , – ,
,
Factor of safety , – ,
– ,
static
Factors affecting fatigue strength –
Failure
of brittle materials
of ductile materials , Index
Failure and static failure theories –
comparison and applications of failure theories
–
Coulomb-Mohr theory , – ,
maximum distortion energy theory (von Mises)
– ,
maximum normal stress theory – ,
– ,
maximum shear stress theory – , – ,

Modified Mohr , – ,
Mohr’s theory
Failure criteria (fatigue)
Fasteners , – , – , –
Fatigue crack growth ,
Fatigue ductility coefficient ,
Fatigue ductility exponent ,
Fatigue failure , – , – ,
– , –
criteria –
cumulative ,
endurance limit , – , – , – ,
– ,
equation ,
factors affecting – , –
strain-life , –
stress-life ,
surface – ,
torsional ,
Fatigue limit. See also Endurance limit
Fatigue loading , – , –
Fatigue safety factor , . See also
Factor of safety
Fatigue strength , – . See Fatigue
strength and factors affecting fatigue
allowable (gear) –
coefficients
contact (gear) – ,
cumulative
estimation of
estimation of endurance limit
and factors affecting (carbon steel) –
and factors of safety (carbon steel) –
of a machine part ,
preloading, bolt tightening and –
spur gears –
Fatigue strength and factors affecting fatigue – ,

fatigue concentration factor –
loading factor
MATLAB code – ,
miscellaneous factor –
reliability factor
size factor –
surface factor –
temperature factor
Fatigue stress concentration factor , – ,
,
FBD . See also Free body diagram
Felt seal
Ferrite , – ,
Filler – ,
Fillet radius , –
Fillet welds – , – ,
Film pressure ,
Finishing ,
Finite element (FE) ,
,
codes or packages , –
Finite element method , – ,
about , –
axially loaded elements –
boundary conditions , – , – , – ,
– ,
element geometries
errors in FE modeling and solution
general D state: linear elasticity problem –
load application –
mesh generation –
optimization – , –
prismatic beam element –
some classical FE packages –
synthesis – ,
thermal effects , – ,
Finite length bearing – ,
Finite life ,
Fits ,
clearance ,
interference ,
preferred ,
shrink ,
and tolerances , Index
Flat belts , – ,
Fletcher-Reeves conjugate gradient , – ,
, –
Flexibility , – ,
,
Flexible couplings –
Flexible elements –
chains –
flat belts –
flexible shafts –
friction drives
ropes –
V-belts –
Flexible shafts –
Fluctuating stresses –
ASME elliptic –
equivalent von Mises
fatigue diagram
fatigue failure criteria for –
Gerber parabolic –
Goodman –
torsional fatigue
Fluid lubrication
Flywheels ,
– , – , – ,
,
energy variation –
inertia – , –
Force , – ,
, – ,
, – , – ,
Force analysis ,
bevel gears –
flat belts –
helical gears , –
MATLAB code , – ,
and power transmission –
shafts – ,
spur gears –
V-belts , –
welds
worm gears –
Force analysis and power transmission (spur gears)
–
Force fit –
Forging ,
Forming , – ,
,
Formulation of optimization problem –
Fracture mechanics , – ,
brittle fracture. See Brittle fracture
in design – ,
fracture toughness , –
safety factor ,
stress intensity factor KIC –
Fracture mechanics and fracture toughness –
crack propagation and life –
crack propagation and real case study –
fracture toughness: critical stress intensity factor
–
stress intensity factor –
Fracture toughness , – ,
– ,
Fracture toughness–critical stress intensity factor KIC
– ,
Free-body diagram , – ,
– , – , – ,
, – ,
Free cutting ,
Free form parametric curves and surfaces –
Bezier curves –
Bezier surfaces or patches –
B-spline curves –
B-spline surfaces –
NURBS –
surface patches and curves –
Free running fit ,
Frequency (natural) , – ,

Frequency distribution ,
Fretting corrosion ,
Friction coefficient , – ,
– , – , – ,
– , – , – ,
– , – , –
Friction coefficient variable (journal bearings) ,

Friction drives
Friction materials ,
Friction variable , –
Full bearing , Index
Full film lubrication
Fundamental deviation – , – ,
,
Fundamental frequency ,
Fundamentals , – , – ,
g
Gasket – ,
Gauge length ,
Gaussian or normal distribution ,
Gear bending fatigue – , –
Gearboxes , – , – ,
,
Gear failure regimes and remedies
Gear hobbing
Gear meshing
Gears –
AGMA factors. See AGMA factors
bevel – ,
contact ratio , – , –
features –
force analysis. See Force analysis
gear teeth formation , – , –
gear trains. See Gear trains
helical – ,
interference , – ,
involute profile –
spur –
stresses. See Gear bending fatigue, and Gear surface
fatigue
synthesis. See Gear synthesis
tooth specification
worm – ,
Gear surface fatigue – , –
Gear synthesis – , – , – , –
Gear teeth manufacturing –
Gear trains , – , –
Gear wear
General D FE procedure –
General D state: linear elasticity problem –
General D stress state , –
Generalized system modeling –
Generalized variables
Geometric and global operations
Geometric computations
Geometric construction and FE analysis –
Geometry, definitions, and configurations (springs)
–
Geometry factor (gears) ,
bending , – , – , – ,
,
contact (surface) , – , – ,
,
Gerber fatigue criteria – ,
Golden Section (Euclid) –
Goodman fatigue criteria – , – , – ,
– ,
Goodman line
Gradient projection method –
heuristic –
Gray cast iron ,
Grinding ,
Grip ,
Grooved pulley ,
h
Hardness , – ,
Brinell (HB), – , – , – ,
– , – ,

properties ,
Rockwell (HRB, HRC) , – , – ,
,
and strength –
Harmonic
Heading ,
Heat dissipation , – ,
Heat generation –
Heat treatment , – , – ,
, – ,
– , – ,
annealing , – ,
case hardening – ,
normalizing – ,
quenching , – , – ,
,
tempering , – , – ,
,
Heat treatment and alloying elements –
case hardening –
effect of alloying elements
heat treatment – Index
Helical gears , – , –
definitions, kinematics, and standards –
design procedure –
detailed design –
force analysis –
optimum – , –
synthesis – , –
types and utility –
Helical springs , – , – ,
buckling –
design procedure –
geometry, definitions, and configurations –
materials –
optimum – , –
resonance –
stresses and deflections –
synthesis – , – , –
Helical torsion springs , – ,
–
Helix angle
bevel gears
helical gears – , – ,
optimum ,
springs , – , – ,
threads ,
worm gears , –
Hertzian contact endurance strength ,
Hertzian stresses – ,
Heuristic gradient projection method, HGP ,
– , – , – , – ,
, –
Hexagonal nut
High-cycle fatigue ,
Hobbing ,
Hole basis (fits)
Homogeneous coordinates versus Cartesian coordinates
–
Hooke’s Law , –
Hoop stress ,
Hot melts
Hot rolled and cold drawn plain-carbon steels –
Hot working ,
Housings, enclosures, frames, and chassis ,
–
Human-machine characteristics –
Hydraulic clutch-brake
Hydrodynamic lubrication – ,
journal bearings –
Petroff’s equation –
Hydrostatic lubrication
Hypoid gears
i
Idler pulleys
IGES file format
Impact properties
Impact value ,
Inch pound second system [in lb s] ,
Inequality constraints problem –
Initial crack size ,
Initial synthesis
ball bearings –
bearings –
bolts –
chains –
disk clutch-brake – ,
flat belts –
helical gears –
journal bearings
rolling bearings –
ropes
shafts – , –
spur gears –
V-belts –
worm gears –
Initial tension (belts) , –
Injection or blow molding
Interference –
and collision , –
fits – ,
gears , – ,
splines
Internal drum shoe brake
Internal friction theory
Internal gear ,
Internal shear force , – , – ,
, – ,
International System of Units (SI) ,
International tolerance grade ,
Interpolation –
fitting, regression, or trend – , – ,
– , – , – ,
, – , – ,
, – ,
linear – ,
quadratic (optimization) – ,

shading , Index
Intersections –
a line with a plane
three planes
two lines –
two planes –
Introduction
elements and system synthesis
optimization – ,
Introduction to computer aided techniques –
Introduction to design –
Introduction to elements and system synthesis –
Investment casting ,
Involute curve
Involute helicoid – ,
Involute profile , –
Involute properties
Involute spline , – , – , – ,

I-section properties –
Isotropic material ,
IT grade number (tolerance) ,
Izod impact
j
Johnson’s equation , – , –
Joining , – , – ,
Joints –
bolts –
bolt stiffness ,
bolt tightening
bonded , –
CAD and optimization –
gasket – ,
members – , – , – ,
– ,
optimization
riveted
separation
stresses , – , – , – ,
– , – , – ,
synthesis – , – , – ,
–
welding – , – ,
Journal bearings –
boundary and mixed lubrication –
CAD and optimization –
hydrodynamic lubrication –
journal bearing design procedure –
lubricants –
plain bearing materials –
synthesis , – , – , – ,
–
synthesis tablet –
k
Keys , – , – ,
design safety factors ,
standards
Keys, pins, retaining rings, and splines – ,
–
CAD –
keys. See Keys
pins and cotter pins –
retaining rings –
splines –
Keyway ,
Keyway dimensions ,
Kinematic viscosity ,
Kinetic energy (flywheel) , –
Kuhn-Tucker conditions – , –
lL
(life) – , – , – , –
Labyrinth seals ,
Laminates
Lapping ,
Lap-shear joints
Leaded brasses
Leaf springs , –
CAD and optimization
design procedure –
detailed design –
initial synthesis –
materials
stresses and deflections –
Leakage (side) , – ,
Length to diameter ratio , – , – ,
– , –
Lewis equation – , – ,
Lewis form factor , – , – ,
Lifetime ,
Light beam ,
Limits ,
Limits and fits
Linear elastic fracture mechanics
Linearized ridge path method – ,
Linear regression
Linear spring Index
Line elements
Line of action – , – ,
Line of contact
Lines , – , –
Load application factor – , – ,
, – , – , – ,
–
Load distribution (rolling bearings) –
Load distribution factor , – , – ,
– , – , – ,
Load eccentricity ,
Load factor , – ,

Loading factor ,
Load-life (bearing) ,
Load line – ,
Loads and stresses ,
Load-sharing ratio , –
Loads, shear, moment, slope, and deflection
–
beam deflection –
beam stresses –
comparing stresses and deflections in beams –
deflection by integration –
deflection by other methods
deflection by singularity function –
deflection by superposition –
external and internal loads –
pure bending –
simple beam synthesis –
Location clearance (fit) , – ,
Location interference (fit) – ,
Logarithmic strain
Long bearing – ,
Long columns –
Loose running fit
Loose-side force ,
Low-cycle fatigue , – ,
Lower deviation – ,
L-section properties –
Lubricants –
flow of ,
lubricant selection –
lubricant viscosity –
temperature rise , –
viscosity
Lubrication ,
boundary and mixed – ,
and friction –
journal bearings , – , – , – ,
– , – , –
roller chain
rolling bearings , –
shaft construction
spur gears
stable lubrication –
thick film
m
Machining –
Magnesium , – , – ,
,
Magnetic clutches
Major diameter , – , – ,
Malleable cast iron ,
Manganese , – , – ,
,
Manson-Coffin equation –
Manson’s discussion ,
Manufacturing processes –
casting or molding –
deformation –
joining
machining –
surface and heat treatment –
D printing or additive manufacturing –
tolerances, surface finish, and fits –
Marin relation ,
Martensite ,
Martensitic – , – ,
Material failure modes and properties
Material properties –
Material properties: carbon steel –
Material selection , – ,
Material set –
basic machine elements
bevel gears –
helical gear
shafts
spur gears –
worm gears
Materials static and dynamic strength – Index
Material structure and failure modes –
basic elements of material –
other static properties
other time-dependent properties –
Material tensile properties –
Mathematical model – , – , –
generalized system modeling –
initiation and adoption –
of loads and material variation –
Mating materials
MATLAB© –
MATLAB codes ,
– , – , – , – ,
– , – , – , – , –
Matrices –
Maximum distortion energy theory (von Mises)
Maximum film pressure ,
Maximum normal stress theory –
Maximum shear stress theory –
Mean coil diameter ,
Mechanical springs. See Springs
Median life
Medium drive (fit) –
Members (joints). See Joints members
Mesh , –
Mesh generation (FE) –
Metal spraying
Methods of optimization –
Mid-span load ,
Milling , – , – ,
Miner’s rule ,
Minimum film thickness , – , – ,
– , – ,
Minimum film thickness ratio , – ,
, – , –
Minor diameter , – ,
Misalignment – , – ,
Miscellaneous factor , – ,
,
Mixed-film lubrication , –
Modeling module , –
Modeling of loading and material variations –
Modeling technique ,
Modified Goodman – , – ,
,
Modified Goodman diagram ,
Modified Mohr theory , – ,
Module , – , – , – ,
– ,
normal ,
– ,
optimum , – , – , – ,
–
standard , – ,
,
transverse , –
Modulus of elasticity ,
, – , – ,
– , – , – ,
– ,
– , – , – ,
– , – ,
Modulus of elasticity of rope , – ,
Modulus of resilience
Modulus of rigidity , – ,
, – ,
Modulus of rupture
Mohr’s circle – , –
Mohr’s circle diagram –
Mohr’s circle for plane stress –
Mohr’s circle radius ,
Mohr’s theory (failure) –
Molded friction material ,
Molybdenum , – ,
Moment loadings
Moments ,
applied ,
bending – ,
, – , – ,

equilibrium of
external , –
internal , – ,
second area , – ,

twisting
Mounting and constructional details (rolling bearings)
–
Multidimensional classical indirect approach –
equality constrained problem –
inequality constraints problem –
unconstrained problem – Index
Multidimensional constrained problem –
comparison of optimum constrained methods
constrained optimization sample –
direct methods for constrained problems
eliminating constraints by transformation
exterior penalty functions –
gradient projection method –
heuristic gradient projection method (hgp) –
interior penalty functions –
Kuhn–tucker conditions –
Multidimensional unconstrained problem –
comparison of unconstrained optimization methods

fletcher–reeves conjugate gradient –
linearized ridge path method –
newton–raphson method –
Powell’s method of conjugate directions –
quasi-newton methods –
random search methods
steepest descent method –
univariate method –
Multi-disk clutch-brake , – ,
uniform pressure
uniform wear rate
Multiple thread ,
Multi-terminal components –
n
Natural frequencies ,
Needle bearings
Neuber constant , – , –
Neutral axis – , – , – ,
– ,
Neutral plane
Newton-Raphson method , – , –
Newton’s law for viscosity
Newton’s laws
Nickel , – ,
,
Nodes – , – , – , – ,
– ,
Noise ,
Nomenclature of worm gears –
Nominal size (pipes) , –
Noncircular cross sections –
Nondimensionalization –
Nonferrous metals ,
aluminum and aluminum alloys –
copper and copper alloys –
magnesium and magnesium alloys
Nonlinear spring
Normal circular pitch , –
Normal diametral pitch. See Diametral pitch
Normal distribution ,
Normalizing , –
Normal stresses ,
beams , – ,

bolts and threads – , –
FE, –
leaf springs
power screw – ,
shafts , – , – ,
–
welds ,
wire ropes , –
Normal tooth force , – , – ,
– , – , – , –
Notch sensitivity ,
Notch sensitivity factor ,
Numbering systems and designations (materials)
–
Number of cycles to failure ,
NURBS , – , – , –
Nuts , – , – , – ,
,
o
Objective function definition
Oil flow
Oil temperature – , – ,
Opening crack mode –
Optimization –
applications to machine elements and systems
–
multidimensional: classical indirect approach
–
multidimensional constrained problem –
multidimensional unconstrained problem –
searches in one direction –
Optimization fields –
Optimization for a specific factor of safety: carbon steel
–
Optimum design of shafts – Index
Optimum FE cantilever beams –
Optimum FE prismatic beams –
Optimum stress concentration
O-rings , – ,
Orthographic projection
Output power – ,
Overload ,
Overrunning clutches
p
Palmgren-Miner’s rule
Palmgren rule ,
Parabolic equation , – ,
,
Parallel-axis theorem –
Parametric modeling –
bilinear surfaces –
curves and surfaces –
free-form curves and surfaces –
lines –
planes –
Parent loop ,
Parent material , – ,
Paris and Erdogan law ,
Partial bearing , – ,
Particular materials for machine elements –
Partitioning , – ,
Pattern , –
Pearlite – ,
Peel stresses
Performance ,
Permanent joints –
bonded joints –
butt and fillet welds –
resistance welding ,
welding –
welding symbols –
weldments (CAD) –
Permanent mold castings –
Permissible bending stress. See AGMA factors, allowable
bending stress numbers
Permissible contact stress number. See AGMA factors,
allowable contact stress numbers
Perspective – , –
Peterson stress concentration factors ,
Petroff’s equation – , – ,
Phases of design –
Phosphor bronze , – ,
Photoelasticity ,
Piecewise polynomials splines ,
Pinion bending fatigue stress
Pinion contact fatigue stress
Pinions generation ,
Pinion shaft ,
Pinions virtual number of teeth ,
Pinions with small number of teeth
Pins and cotter pins – ,
Pitch circles – ,
Pitch cone ,
Pitch diameters , – , – , – ,
,
Pitches – ,
Pitch length ,
Pitch line velocity , – , – , – ,
,
Pitch point velocity , – , – ,
– , – , –
Pitch radius ,
Pitting , – , – ,
Pitting resistance – ,
Plain and low-alloyed carbon steels –
Plain bearing materials –
Plain bearings , –
Plain ends – ,
Plane strain fracture toughness ,
Plane stress , –
Plane stress state –
Planetary or epicyclic gear trains –
Planet carrier , – ,
Planet gears
Plastics – , – ,
Plastic strain ,
Pneumatic ,
Point in space
Point of contact
Poise ,
Poisson’s ratio , – ,
, –
Polished , –
Polymeric (adhesives)
Population (statistic)
Positioning ,
Potential energy ,
Pound force Index
Pound mass ,
Powder-metallurgy ,
Powell’s conjugate directions –
Power and speed
Power and torquer
Power control elements –
Power ratings – ,
Power screws –
ball screws –
CAD –
efficiency
stresses –
torque requirements –
Power transmission cases. See Gearboxes
Power transmitting , – ,
Preferred numbers and sizes ,
Preload , – ,
Preloading , – , – ,
,
Preloading, bolt tightening, and fatigue strength (CAD)
–
Preloading due to tightening – ,
Presentation – , – ,
Presentation editing , – ,
Press and shrink fits –
Press fitted . See also Force fit
Pressure angle , – , – ,
, – ,
– , – , – ,
Pressure cone angle – ,
Pressure sensitive adhesive
Prime movers and machines
Principal directions , – , – ,
,
Principal shear stress
Principal stresses , – , – ,
, – ,
, –
Prismatic beam element (FE) –
Probability density function
Probability distribution ,
normal (Gaussian)
Weibull –
Probability of failure ,
reliability and
Problem definition
Procedures for constructing a single solid –
Product life cycle
Proof load
Proof strength , – , – ,
,
Proportional limit ,
Pulleys , – ,
– , –
Punch press
Pure bending – , –
Pure color
Pure shear
Pure tension ,
q
Quadratic Interpolation – , – ,
,
Quality numbers ,
Quasi-Newton methods , – ,
Quenched and tempered low-alloy steels
Quenched and tempered plain carbon steels –
Quenching , – , – ,
,
Quenching and tempering , – ,

r
Rack , –
Radial clearance – , – , – ,

Radial clearance ratio ,
Random search methods
Random variables
Rating life – , – ,
Realistic presentations –
Rectangular section – , – , – ,
– ,
Regression , – ,
– , – ,
Relative velocity
Reliability , – , – ,
– , –
safety and
Reliability factor , – ,
, – ,
Reliability-life
Rendering and animation –
Rendering process – Index
Repeated stress
Research and development process in product cycle
–
Residual stresses , – ,
Resilience – ,
Resistance welding ,
Resonance –
Resultant force ,
– , – , –
Retaining rings , –
Reverse engineering
Reversing pulley
Reyn (viscosity unit) ,
Reynolds’ equation (fluid) –
Right-hand rule ,
Rigid couplings –
Rim ,
Rim thickness factor
Ring gear ,
Rivets , – ,
,
Roark’s formulas
Rockwell hardness , – , – ,
Rolled threads
Roller chain lubricant
Roller chains , – ,
standards –
synthesis –
Rolling bearings –
bearing life – , – , – ,
, – ,
bearing load –
bearing types and selection –
CAD and optimization –
catalogues
detailed design and selection –
dynamic load rating estimate
initial design and selection –
lubrication and friction –
MATLAB code , – , –
mounting and constructional details –
roller bearings – , – ,
,
Rolling bearings
taper roller bearings , – ,
,
speed limits
standard dimension series –
standards
Roll threading
Root diameter , – , – ,
, – , –
Rope core
Rotating beam (shafts)
Rotating specimen test (fatigue)
Rotation factor , –
Roughness , – , – ,
–
Round belts , –
Running fits – ,
s
SAE fasteners ,
Safety and reliability
Safety factors , – ,
, – ,
Saint Venant’s principle
Sample (optimization) –
Sample applications (synthesis) –
initial bearing synthesis –
initial bolt synthesis –
initial shaft synthesis –
Sample standard deviation – ,
Sand casting – ,
Saybolt universal seconds (SUS)
Saybolt universal viscosity (SUV)
Scaling ,
Scoring ,
Screws, fasteners, and permanent joins –
bolted connections –
bolt strength in static and fatigue –
CAD and optimization –
permanent joints –
power screws –
standards and types –
stresses in threads –
Screws, self-locking , – , –
Seals , – ,
, – , –
rolling bearings ,
standards – , –
Seam welding
Searches in one direction –
Secant formula (columns) – Index
Second-area moments , – ,
, –
Section modulus , – , – ,
, – , –
Section neutral axis location , –
Seireg relations – ,
Self-aligning bearings ,
Self-locking screws , – , –
Set dimensions and constraints (chains)
Setscrews , – ,
Shading and rendering technique
Shaft base (fits) – ,
Shaft design for rigidity –
Shaft design for stress
CAD –
constructional details , – , – ,
– , – ,
critical locations (math model) –
detailed design –
factors affecting fatigue –
fatigue and static , –
initial design estimate –
materials
optimum –
power transmission case –
Shaft joining elements ,
couplings. See Couplings
keys , – ,
pins , – ,
retaining rings , – ,
– , –
setscrews , – ,
splines. See Splines
Shaft limits and fits – ,
Shaft materials
Shafts –
Shafts critical speeds
Shafts, defined (types) –
Shaft shoulders – , – ,
Shallow objective function ,
Shaping , – ,
Shear force (internal transverse) ,
, – ,
Shear force and bending moment ,
– ,
Shear modulus of elasticity. See Modulus of rigidity
Shear strain energy (torsion)
Shear stress and deformation due to torsion –
Shear stresses ,
in beams , –
rectangular beams –
Shear yield strength , – ,
,
Sheave (pulley) diameters – , – ,
, – , –
Sheaves – ,
Shell ,
Shell molding
Shock , – ,
Short bearing (journal) –
Short column – ,
Shot peening ,
Shoulders. See Saft shoulders
Shrink fits – ,
Side leakage , – ,
Silicon , – , – ,
, – ,
Silicon bronze
Simple beam synthesis –
Simple stresses, strains, and deformations –
Sines fatigue failure ,
Single enveloping worm gear –
Single lap bonded joints
Single row bearings ,
Singularity functions – ,
Sintered material ,
Size factor , – ,

Sizes and properties (ropes) –
Skewing ,
Sleeves – , –
Slenderness ratio , – ,
Slenderness ratio limit , – ,
Sliding bearings
Sliding location (fits) ,
Sliding velocity
Slug , – ,
Smith-Dolan
Smith-Dolan failure criteria
S-N diagram (fatigue) ,
Society of Automotive Engineers (SAE) ,
Soderberg criteria
Software (some) , – , – , – ,
, – , – ,
Solid circular cross sections Index
Solid elements –
Solid film lubricants
Some classical FE packages –
Sommerfeld number , – , – ,
– , – ,
Specification grades of bolts
Specific strength ,
Specular reflection
Speed limits (rolling bearings)
Speed ratio , – , – , – ,
, – ,
Speed reduction ratio , – ,
– , –
Spherical contact
Spherical roller bearings –
Spiral bevel gears ,
Spiral groove seal –
Splines , – ,
synthesis
Spot welding
Spring ends , – ,
Spring index , – , – , – ,
, – ,
Spring materials , –
Springs – . See also Belleville springs,
Compression springs, Conical springs,
Constant-force springs, Design procedure and
Detailed design (helical springs) (leaf springs),
Elastomeric and other Springs, Extension springs,
Helical torsion springs, Helical springs, Leaf
springs,
critical surge frequency. See Spring surge
curvature effect –
fatigue loading (dynamic) –
stability (buckling) –
stresses and deflection in helical springs –
stresses and deflection in leaf springs –
Spring stiffness , – , – ,
,
Spring surge – , – , – ,
Spring types ,
Sprockets , – , –
Spur gears – . See also AGMA gears, Fatigue
strength, Bending fatigue (spur gears, Definitions,
kinematics and standards, Design procedure,
Detailed design, Fatigue strength, Force analysis,
Force analysis and power transmission, Initial
synthesis, Lubrication, Material set
geometry factors ,
Lewis bending. See Lewis equation
surface durability ,
surface fatigue –
Squared ends (springs) – , – , –
Square keys
Square threads ,
Stability in springs (buckling) –
Stable lubrication –
Stainless steel – ,
Stamping ,
standard ,
Standard deviation – ,
Standard dimension series –
Standard machine elements
Standards , – , – ,
, – , – , – ,
– , – , – , – ,
ISO ,
material
US ,
Standards (chains) –
Standards and codes. See Codes, Codes and standards
Standards and geometric relations
flat belts –
V-belts –
Standard sets and components
Standard sizes (preferred) ,
Statically indeterminate ,
Statically loaded (spring)
Static conditions
Static equilibrium. See Equilibrium
Static factor of safety
Static load(ing) , – ,
, – , – , – ,
, –
Static loading (rolling bearing) –
Static strength – ,
Statistical material property quote
Statistical model – ,
mean value ,
probability distribution ,
random variables
standard deviation – ,
Statistical tolerance definition
Steady-state case ,
Steady stress (mean) ,
Steel (casting) , Index
Steels. See also Alloy steel, Carbon and alloy steels, Hot
rolled and cold drawn plain-carbon steels, Plain
and low-alloyed carbon steels, Quenched and
tempered plain carbon steels, Quenched and
tempered low-alloy steels
cast steels
fatigue strength – , –
hardness and strengths –
heat treatment –
numbering system –
properties , –
Steepest descent method –
STEP file format
Stereo viewing – , –
Stiffness
bolt and members , –
element and global matrices , – , – ,
, – ,
material ,
pressure-cone – ,
spring. See Spring stiffness
torsional equivalent –
Stiffness ratio – , – , – , –
STL file format
Stochastic model ,
Stokes – ,
Straight bevel gears , –
bending fatigue –
contact fatigue
definitions, kinematics, and standards –
detailed design –
force analysis –
initial design
material set and safety factor –
synthesis
Strain energy ,
bending
and deflection –
density ,
distortion ,
elastic –
element –
hydrostatic ,
normal load
operating ,
torsion
total ,
Strain energy and deflection –
Strain hardening , – ,
Strain-life method ,
Strength ,
alternating load ,
bolt –
proof , – ,

property , –
static and dynamic –
welding , – ,
Strength and hardness of annealed and normalized
plain-carbon steels –
Stress components ,
Stress concentration
and notch sensitivity ,
optimum
of threaded fasteners
Stress-concentration factors – ,

Stress distributions , – ,
Stresses
beam –
combined –
comparing in beams –
concentration factors –
contact –
and deflection in beams –
and deflection in helical springs –
and deflection in leaf springs –
deformation and deflection –
fluctuating –
in interference fits –
in power screws –
principal –
shear due to torsion –
simple –
in thick pressure cylinders –
in thin pressure cylinder –
in threads –
in welded joints –
Stresses in power screws –
Stress intensity factor KI –
Stress life method
Stress raisers ,
Stress ratio ,
Stress relieving , Index
Stress-strain diagram ,
Stress values ,
Structural adhesives – ,
Structural steel – ,
Studs ,
Sun gear , – ,
Superposition ,
Surface and heat treatment –
Surface condition factor
Surface durability ,
Surface elements
Surface factor , – ,

Surface fatigue (spur gears) –
Surface fatigue strength
Surface patches and curves –
Surface stresses
Synthesis. See Initial synthesis
Synthesis approach to design –
Synthesis design process –
Synthesis tablets – , – , – ,
– , – ,
Synthesized or designed machine elements
–
System synthesis –
t
Tangential stress , –
Tapered roller bearings , – ,
– ,
Teamwork for product or system design
Tearing mode
Temperature
average film , – ,
difference ,
high , – ,

Temperature effect
Temperature factor , – ,
, – ,
Temperature rise , – , – ,
– , – , – , – ,
,
Temper carbon (cast iron)
Tempering , – , – ,
,
Tensile properties – ,
Tensile strength , – , –
ultimate , –
yield ,
Tensile-stress area , – ,
Tension, compression, and torsion , –
Tension test ,
Theoretical stress-concentration factor
Thermal effects –
Thermal stresses ,
Thermoplastics ,
Thermosets ,
Thick film lubrication
Thick pressure cylinders –
Thin film lubrication ,
Thin pressure cylinders –
Threaded fasteners ,
Thread standards – , –
Threads under simple tensile load – , –
Thread terminology and designation –
D Cursor and picking
D Geometric modeling –
D Geometric modeling and viewing transformation
–
D Graphics –
D Printing or additive manufacturing –
Three-parameter Weibull distribution , –
Thrust bearings , – ,
Tightening torque –
Tight-side force , – , – ,
Timing belts , – ,
Timken rolling bearings – , – ,
Tin bronzes ,
Titanium ,
Tolerances , – ,
, – ,
,
Tolerances, surface finish, and fits –
Tool steel –
Toothed wheels (sprockets)
Tooth thickness , – ,
– ,
Top land , – , –
Topological operations and the Euler formula –
Torque ,
, – , – ,
, –
Torque coefficient (tightening) , Index
Torque requirements –
Torque transmission ,
Torque-twist diagram
Torque vector ,
Torsion , – , – ,
Torsional fatigue ,
Torsional strain energy
Torsional stress , –
Torsional yield strength
Torsion springs –
Total rendering effect –
Translation (transformation) ,
Transmitted load
Transparency ,
Transverse circular pitch – ,
Transverse shear and shear flow –
Transverse shear stress , – ,
Tresca theory ,
Triaxial stress state –
True strain ,
True stress ,
True stress-strain diagram
Tungsten , – ,
Two-parameter Weibull distribution – ,
Two terminal components –
Two-way bending , – ,
Types and utility (helical gears) –
Types and utility (spur gears) –
Types of shafts and axles –
Types of springs
u
Ultimate strength ,
Ultimate tensile strength (rope) –
Uncertainty , – ,
Unconstrained problem –
Undercut ,
Unified Numbering System (UNS) ,
Uniform distribution , –
Uniform pressure – , –
Uniform tension and compression –
Uniform wear rate , – ,
Unit conversion – ,
Unit load ,
Units , – ,
Units and fundamentals –
Univariate method –
Universal joints –
Unstable lubrication –
Unsteady loading
UNS thread type
Upper deviation –
Using CAD in D modeling and CAM
U S units (customary) [in lb s] , – , – ,
v
Vanadium , – , –
Variable speed ,
Variable transmission (continuously, CVT) ,
V belts , – , – , –
CAD synthesis –
design procedure –
detailed design process –
drive relations –
initial synthesis –
standards and geometry – , –
Vectors – ,
Vectors and matrices –
Velocity factor , – , – , – ,
, – , – ,
Velocity gradient ,
Vibration analysis ,
Virtual number of teeth ,
Virtual reality – ,
Viscosity ,
Visual color description –
Volute spring
von Mises-Hencky
von Mises stress (equivalent) ,
,

w
Wahl factor , –
Washers , – ,
Wear , – ,
Wear factor
Weibull distribution – , – ,
three-parameter , –
two-parameter – ,
Weibull distribution curve
Welded joints
CAD , –
MATLAB code Index
standards ,
strength
stress in –
Welding –
under bending and torsion –
CAD –
MATLAB code
resistance
strength
stresses in joints –
symbols –
types and symbols –
Weld throat , – , – , –
White cast iron ,
Whole depth , – ,
Width series –
Wire diameter ,
Wire rope , – ,
detailed design process –
fatigue – ,
initial synthesis –
lay type –
modulus of elasticity ,
other properties
safety factor
sizes and properties –
strength –
tension
wear resistance
Worm axis ,
Worm gears –
CAD –
definition, kinematics, and standards –
design procedure
detailed design
efficiency ,
force analysis –
initial design –
material set and safety factor –
synthesis –
Woven friction material ,
Wrought alloys
y
Yield point – ,
Yield strength ,
,
shear , – ,
,
von Mises equivalent ,
Yield stress (torsional) –
Young’s modulus ,
z
Zerol bevel gear
Zero velocity
Zooming ,

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