SOLUTIONS MANUAL FOR
MECHANICAL
DESIGN
OF MACHINE
COMPONENTS
SECOND EDITION: SI VERSION
by
ANSEL C. UGURAL
and application of core concepts. We will also discuss the similarities and differences in these exams and how they prepare students for their respective
careers.________________________________________1. Business Exams1.1. Overview of Business EducationBusiness education prepares students for leadership and management roles in various industries. It focuses on
critical thinking, decision-making, problem-solving, and understanding organizational processes. A typical business program might cover topics like accounting, finance, marketing, management, economics, entrepreneurship,
and international business.1.2. Structure of Business ExamsBusiness exams are often a mix of theoretical knowledge and practical application. Depending on the subject area, these exams can vary significantly in format.
Common types of business exams include:Multiple Choice Questions (MCQs): These are frequently used to assess students’ understanding of business terminology, theories, and principles.Case Studies: A staple of business
exams, case studies present students with real-world business scenarios and ask them to apply their knowledge to solve complex problems. Case studies evaluate students' ability to think critically and make strategic
decisions.Essay/Short Answer Questions: These types of questions test the student’s ability to explain and analyze
, CONTENTS
.________________________________________1. Business Exams1.1. Overview of Business EducationBusiness education
Part I BASICS
Chapter 1 INTRODUCTION 1
Chapter 2 MATERIALS 16
Chapter 3 STRESS AND STRAIN 24
Chapter 4 DEFLECTION AND IMPACT 48
Chapter 5 ENERGY METHODS AND STABILITY 68
Part II FAILURE PREVENTION
Chapter 6 STATIC FAILURE CRITERIA AND RELIABILITY 100
Chapter 7 FATIGUE FAILURE CRITERIA 117
Chapter 8 SURFACE FAILURE 135
Part III APPLICATIONS
Chapter 9 SHAFTS AND ASSOCIATED PARTS 145
Chapter 10 BEARINGS AND LUBRICATION 164
Chapter 11 SPUR GEARS 176
Chapter 12 HELICAL, BEVEL, AND WORM GEARS 194
Chapter 13 BELTS, CHAINS, CLUTCHES, AND BRAKES 208
Chapter 14 MECHANICAL SPRINGS 225
Chapter 15 POWER SCREWS, FASTENERS, AND CONNECTIONS 240
Chapter 16 MISCELLANEOUS MACHINE COMPONENTS 261
Chapter 17 FINITE ELEMENT ANALYSIS IN DESIGN 278
Chapter 18 CASE STUDIES IN MACHINE DESIGN 308
vi
, DESCRIPTION OF THE MATERIAL CONTAINED IN
“MECHANICAL DESIGN of Machine Components”
careers.________________________________________1. Business Exams1.1. Overview of Business EducationBusiness education prepares students for leadership and management roles in various industries. It focuses on
critical thinking, decision-making, problem-solving, and understanding organizational processes. A typical business program might cover topics like accounting, finance, marketing, management, economics, entrepreneurship,
and international business.1.2. Structure of Business ExamsBusiness exams are often a mix of theoretical knowledge and practical application. Depending on the subject area, these exams can vary significantly in format.
Common types of business exams include:Multiple Choice Questions (MCQs): These are frequently used to assess students’ understanding of business terminology, theories, and principles.Case Studies: A staple of business
exams, case studies present students with real-world business scenarios and ask them to apply their knowledge to solve complex problems. Case studies evaluate students' ability to think critically and make strategic
decisions.Essay/Short Answer Questions: These types of questions test the student’s ability to explain and analyze business concepts in a detailed and coherent manner.1.3. Skills Tested in Business ExamsCritical Thinking
and Problem-Solving: Business exams often include case studies that
Chapter 1 attempts to present the basic concepts and an overview of the subject. Sections 1.1 through 1.8
discuss the scope of treatment, machine and mechanical design, problem formulation, factor of safety, and
units. The load analysis is normally the critical step in designing any machine or structural member (Secs.
1.8 through 1.9). The determination of loads is encountered repeatedly in subsequent chapters. Case studies
provide a number of machine or component projects throughout the book. These show that the members
must function in combination to produce a useful device. Section 1.10 review the work, energy, and power.
The foregoing basic considerations need to be understood in order to appreciate the loading applied to a
member. The last two sections emphasize the fact that stress and strain are concepts of great importance to a
comprehension of design analysis.
Chapter 2 reviews the general properties of materials and some processes to improve the strength
of metals. Sections 2.3 through 2.14 introduce stress-strain relationships, material behavior under various
loads, modulus of resilience and toughness, and hardness, selecting materials. Since students have
previously taken materials courses, little time can be justified in covering this chapter. Much of the material
included in Chapters 3 through 5 is also a review for students. Of particular significance are the Mohr’s
circle representation of state of stress, a clear understanding of the three-dimensional aspects of stress,
influence of impact force on stress and deformation within a component, applications of Castigliano’s
theorem, energy of distortion, and Euler’s formula. Stress concentration is introduced in here, but little
applications made of it until studying fatigue (Chap.7).
The first section of Chapter 6 attempts to provide an overview of the broad subject of “failure”,
against which all machine/mechanical elements must be designed. The discipline of fracture mechanics is
introduced in Secs. 6.2 through 6.4. Yield and fracture criteria for static failure are discussed in Secs. 6.4
through 6.12. The last 3 sections deal with the method of reliability prediction in design. Chapter 7 is
devoted to the fatigue and behavior of materials under repeated loadings. The emphasis is on the Goodman
failure criterion. Surface failure is discussed in Chapter 8. Sections 8.1 through 8.3 briefly review the
corrosion and friction. Following these the surface wear is discussed. Sections 8.6 through 8.10 deal with
the surfaces contact stresses and the surface fatigue failure and its prevention. The background provided
here is directly applied to representative common machine elements in later chapters.
Sections 9.1 through 9.4 of Chapter 9 treat the stresses and design of shafts under static loads.
Emphasis is on design of shafts for fluctuating loading (Secs. 9.6 and 9.7). The last 5 sections introduce
common parts associated with shafting. Chapter 10 introduces the lubrication as well as both journal and
roller bearings. As pointed out in Sec. 8.9, rolling element bearings provide interesting applications of
contact stress and fatigue. Much of the material covered in Secs. 11.1 through 11.7 of Chapter 11 introduce
nomenclature, tooth systems, and fundamentals of general gearing. Gear trains and spur gear force analysis
are taken up in Secs. 11.6 and 11.7. The remaining sections concern with gear design, material, and
manufacture. Non-spur gearing is considered in Chapter 12. Spur gears are merely a special case of helical
gears (Secs. 12.2 through 12.5) having zero helix angle. Sections 12.6 through 12.8 deal with bevel gears.
Worm gears are fundamentally different from other gears, but have much in common with power screws to
be taken up in Chap. 15.
vii
, Chapter 13 is devoted to the design of belts, chains, clutches, and brakes. Only a few different
analyses are needed, with surface forms effecting the equations more than the functions of these devices.
Belts, clutches, and brakes are machine elements depending upon friction for their function. Design of
various springs is considered in Chapter 14. The emphasis is on helical coil springs (Secs. 14.3 through
14.9) that provide good illustrations of the static load analysis and torsional fatigue loading. Leaf springs
(Sec. 14.11) illustrate primarily bending fatigue loading. Chapter 15 attempts to present screws and
connections. Of particular importance is the load analysis of power screws and a clear understanding of the
fatigue stresses in threaded fasteners. There are alternatives to threaded fasteners and riveted or welded
joints. Modern adhesives (Secs. 15.17 and 15.18) can change traditional preferred choices.
It is important to assign at least portions of the analysis and design of miscellaneous mechanical
members treated in Chapter 16. Sections 16.3 through 16.7 concern with thick-walled cylinders, press or
shrink fits, and disk flywheels. The remaining sections concerns with the bending of curved frames, plate
and shells-like machine and structural components, and pressure vessels. Buckling of thin-walled cylinders
and spheres is also briefly discussed. Chapter 17 represents an addition to the material traditionally
covered in “Machine/Mechanical Design” textbooks. It attempts to provide an introduction to the finite
element analysis in design. Some practical case studies illustrate solutions of problems involving structural
assemblies, deflection of beams, and stress concentration factors in plates. Finally, case studies in
preliminary design of the entire crane with winch and a high-speed cutting machine are introduced in
Chapter 18.
careers.________________________________________1. Business Exams1.1. Overview of Business EducationBusiness education prepares students for leadership and management roles in various industries. It focuses on
critical thinking, decision-making, problem-solving, and understanding organizational processes. A typical business program might cover topics like accounting, finance, marketing, management, economics, entrepreneurship,
and international business.1.2. Structure of Business ExamsBusiness exams are often a mix of theoretical knowledge and practical application. Depending on the subject area, these exams can vary significantly in format.
Common types of business exams include:Multiple Choice Questions (MCQs): These are frequently used to assess students’ understanding of business terminology, theories, and principles.Case Studies: A staple of business
exams, case studies present students with real-world business scenarios and ask them to apply their knowledge to solve complex problems. Case studies evaluate students' ability to think critically and make strategic
decisions.Essay/Short Answer Questions: These types of questions test the student’s ability to explain and analyze business concepts in a detailed and coherent manner.1.3. Skills Tested in Business ExamsCritical Thinking
and Problem-Solving: Business exams often include case studies thatcareers.________________________________________1. Business Exams1.1. Overview of Business EducationBusiness education prepares students for
leadership and management roles in various industries. It focuses on critical thinking, decision-making, problem-solving, and understanding organizational processes. A typical business program might cover topics like
accounting, finance, marketing, management, economics, entrepreneurship, and international business.1.2. Structure of Business ExamsBusiness exams are often a mix of theoretical knowledge and practical application.
Depending on the subject area, these exams can vary significantly in format. Common types of business exams include:Multiple Choice Questions (MCQs): These are frequently used to assess students’ understanding of
business terminology, theories, and principles.Case Studies: A staple of business exams, case studies present students with real-world business scenarios and ask them to apply their knowledge to solve complex problems.
Case studies evaluate students' ability to think critically and make strategic decisions.Essay/Short Answer Questions: These types of questions test the student’s ability to explain and analyze business concepts in a detailed
and coherent manner.1.3. Skills Tested in Business ExamsCritical Thinking and Problem-Solving: Business exams often include case studies that
viii
MECHANICAL
DESIGN
OF MACHINE
COMPONENTS
SECOND EDITION: SI VERSION
by
ANSEL C. UGURAL
and application of core concepts. We will also discuss the similarities and differences in these exams and how they prepare students for their respective
careers.________________________________________1. Business Exams1.1. Overview of Business EducationBusiness education prepares students for leadership and management roles in various industries. It focuses on
critical thinking, decision-making, problem-solving, and understanding organizational processes. A typical business program might cover topics like accounting, finance, marketing, management, economics, entrepreneurship,
and international business.1.2. Structure of Business ExamsBusiness exams are often a mix of theoretical knowledge and practical application. Depending on the subject area, these exams can vary significantly in format.
Common types of business exams include:Multiple Choice Questions (MCQs): These are frequently used to assess students’ understanding of business terminology, theories, and principles.Case Studies: A staple of business
exams, case studies present students with real-world business scenarios and ask them to apply their knowledge to solve complex problems. Case studies evaluate students' ability to think critically and make strategic
decisions.Essay/Short Answer Questions: These types of questions test the student’s ability to explain and analyze
, CONTENTS
.________________________________________1. Business Exams1.1. Overview of Business EducationBusiness education
Part I BASICS
Chapter 1 INTRODUCTION 1
Chapter 2 MATERIALS 16
Chapter 3 STRESS AND STRAIN 24
Chapter 4 DEFLECTION AND IMPACT 48
Chapter 5 ENERGY METHODS AND STABILITY 68
Part II FAILURE PREVENTION
Chapter 6 STATIC FAILURE CRITERIA AND RELIABILITY 100
Chapter 7 FATIGUE FAILURE CRITERIA 117
Chapter 8 SURFACE FAILURE 135
Part III APPLICATIONS
Chapter 9 SHAFTS AND ASSOCIATED PARTS 145
Chapter 10 BEARINGS AND LUBRICATION 164
Chapter 11 SPUR GEARS 176
Chapter 12 HELICAL, BEVEL, AND WORM GEARS 194
Chapter 13 BELTS, CHAINS, CLUTCHES, AND BRAKES 208
Chapter 14 MECHANICAL SPRINGS 225
Chapter 15 POWER SCREWS, FASTENERS, AND CONNECTIONS 240
Chapter 16 MISCELLANEOUS MACHINE COMPONENTS 261
Chapter 17 FINITE ELEMENT ANALYSIS IN DESIGN 278
Chapter 18 CASE STUDIES IN MACHINE DESIGN 308
vi
, DESCRIPTION OF THE MATERIAL CONTAINED IN
“MECHANICAL DESIGN of Machine Components”
careers.________________________________________1. Business Exams1.1. Overview of Business EducationBusiness education prepares students for leadership and management roles in various industries. It focuses on
critical thinking, decision-making, problem-solving, and understanding organizational processes. A typical business program might cover topics like accounting, finance, marketing, management, economics, entrepreneurship,
and international business.1.2. Structure of Business ExamsBusiness exams are often a mix of theoretical knowledge and practical application. Depending on the subject area, these exams can vary significantly in format.
Common types of business exams include:Multiple Choice Questions (MCQs): These are frequently used to assess students’ understanding of business terminology, theories, and principles.Case Studies: A staple of business
exams, case studies present students with real-world business scenarios and ask them to apply their knowledge to solve complex problems. Case studies evaluate students' ability to think critically and make strategic
decisions.Essay/Short Answer Questions: These types of questions test the student’s ability to explain and analyze business concepts in a detailed and coherent manner.1.3. Skills Tested in Business ExamsCritical Thinking
and Problem-Solving: Business exams often include case studies that
Chapter 1 attempts to present the basic concepts and an overview of the subject. Sections 1.1 through 1.8
discuss the scope of treatment, machine and mechanical design, problem formulation, factor of safety, and
units. The load analysis is normally the critical step in designing any machine or structural member (Secs.
1.8 through 1.9). The determination of loads is encountered repeatedly in subsequent chapters. Case studies
provide a number of machine or component projects throughout the book. These show that the members
must function in combination to produce a useful device. Section 1.10 review the work, energy, and power.
The foregoing basic considerations need to be understood in order to appreciate the loading applied to a
member. The last two sections emphasize the fact that stress and strain are concepts of great importance to a
comprehension of design analysis.
Chapter 2 reviews the general properties of materials and some processes to improve the strength
of metals. Sections 2.3 through 2.14 introduce stress-strain relationships, material behavior under various
loads, modulus of resilience and toughness, and hardness, selecting materials. Since students have
previously taken materials courses, little time can be justified in covering this chapter. Much of the material
included in Chapters 3 through 5 is also a review for students. Of particular significance are the Mohr’s
circle representation of state of stress, a clear understanding of the three-dimensional aspects of stress,
influence of impact force on stress and deformation within a component, applications of Castigliano’s
theorem, energy of distortion, and Euler’s formula. Stress concentration is introduced in here, but little
applications made of it until studying fatigue (Chap.7).
The first section of Chapter 6 attempts to provide an overview of the broad subject of “failure”,
against which all machine/mechanical elements must be designed. The discipline of fracture mechanics is
introduced in Secs. 6.2 through 6.4. Yield and fracture criteria for static failure are discussed in Secs. 6.4
through 6.12. The last 3 sections deal with the method of reliability prediction in design. Chapter 7 is
devoted to the fatigue and behavior of materials under repeated loadings. The emphasis is on the Goodman
failure criterion. Surface failure is discussed in Chapter 8. Sections 8.1 through 8.3 briefly review the
corrosion and friction. Following these the surface wear is discussed. Sections 8.6 through 8.10 deal with
the surfaces contact stresses and the surface fatigue failure and its prevention. The background provided
here is directly applied to representative common machine elements in later chapters.
Sections 9.1 through 9.4 of Chapter 9 treat the stresses and design of shafts under static loads.
Emphasis is on design of shafts for fluctuating loading (Secs. 9.6 and 9.7). The last 5 sections introduce
common parts associated with shafting. Chapter 10 introduces the lubrication as well as both journal and
roller bearings. As pointed out in Sec. 8.9, rolling element bearings provide interesting applications of
contact stress and fatigue. Much of the material covered in Secs. 11.1 through 11.7 of Chapter 11 introduce
nomenclature, tooth systems, and fundamentals of general gearing. Gear trains and spur gear force analysis
are taken up in Secs. 11.6 and 11.7. The remaining sections concern with gear design, material, and
manufacture. Non-spur gearing is considered in Chapter 12. Spur gears are merely a special case of helical
gears (Secs. 12.2 through 12.5) having zero helix angle. Sections 12.6 through 12.8 deal with bevel gears.
Worm gears are fundamentally different from other gears, but have much in common with power screws to
be taken up in Chap. 15.
vii
, Chapter 13 is devoted to the design of belts, chains, clutches, and brakes. Only a few different
analyses are needed, with surface forms effecting the equations more than the functions of these devices.
Belts, clutches, and brakes are machine elements depending upon friction for their function. Design of
various springs is considered in Chapter 14. The emphasis is on helical coil springs (Secs. 14.3 through
14.9) that provide good illustrations of the static load analysis and torsional fatigue loading. Leaf springs
(Sec. 14.11) illustrate primarily bending fatigue loading. Chapter 15 attempts to present screws and
connections. Of particular importance is the load analysis of power screws and a clear understanding of the
fatigue stresses in threaded fasteners. There are alternatives to threaded fasteners and riveted or welded
joints. Modern adhesives (Secs. 15.17 and 15.18) can change traditional preferred choices.
It is important to assign at least portions of the analysis and design of miscellaneous mechanical
members treated in Chapter 16. Sections 16.3 through 16.7 concern with thick-walled cylinders, press or
shrink fits, and disk flywheels. The remaining sections concerns with the bending of curved frames, plate
and shells-like machine and structural components, and pressure vessels. Buckling of thin-walled cylinders
and spheres is also briefly discussed. Chapter 17 represents an addition to the material traditionally
covered in “Machine/Mechanical Design” textbooks. It attempts to provide an introduction to the finite
element analysis in design. Some practical case studies illustrate solutions of problems involving structural
assemblies, deflection of beams, and stress concentration factors in plates. Finally, case studies in
preliminary design of the entire crane with winch and a high-speed cutting machine are introduced in
Chapter 18.
careers.________________________________________1. Business Exams1.1. Overview of Business EducationBusiness education prepares students for leadership and management roles in various industries. It focuses on
critical thinking, decision-making, problem-solving, and understanding organizational processes. A typical business program might cover topics like accounting, finance, marketing, management, economics, entrepreneurship,
and international business.1.2. Structure of Business ExamsBusiness exams are often a mix of theoretical knowledge and practical application. Depending on the subject area, these exams can vary significantly in format.
Common types of business exams include:Multiple Choice Questions (MCQs): These are frequently used to assess students’ understanding of business terminology, theories, and principles.Case Studies: A staple of business
exams, case studies present students with real-world business scenarios and ask them to apply their knowledge to solve complex problems. Case studies evaluate students' ability to think critically and make strategic
decisions.Essay/Short Answer Questions: These types of questions test the student’s ability to explain and analyze business concepts in a detailed and coherent manner.1.3. Skills Tested in Business ExamsCritical Thinking
and Problem-Solving: Business exams often include case studies thatcareers.________________________________________1. Business Exams1.1. Overview of Business EducationBusiness education prepares students for
leadership and management roles in various industries. It focuses on critical thinking, decision-making, problem-solving, and understanding organizational processes. A typical business program might cover topics like
accounting, finance, marketing, management, economics, entrepreneurship, and international business.1.2. Structure of Business ExamsBusiness exams are often a mix of theoretical knowledge and practical application.
Depending on the subject area, these exams can vary significantly in format. Common types of business exams include:Multiple Choice Questions (MCQs): These are frequently used to assess students’ understanding of
business terminology, theories, and principles.Case Studies: A staple of business exams, case studies present students with real-world business scenarios and ask them to apply their knowledge to solve complex problems.
Case studies evaluate students' ability to think critically and make strategic decisions.Essay/Short Answer Questions: These types of questions test the student’s ability to explain and analyze business concepts in a detailed
and coherent manner.1.3. Skills Tested in Business ExamsCritical Thinking and Problem-Solving: Business exams often include case studies that
viii
