Covers All 18 Chapters
SOLUTIONS MANUAL
, CONTENTS
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
, NOTES TO THE INSTRUCTOR
The Solutions Manual to accompany the text MECHANICAL DESIGN of Machine Components
supplements the study of machine design developed in the book. The main objective of the manual is to
provide efficient solutions for problems in design and analysis of variously loaded mechanical components.
In addition, this manual can serve to guide the instructor in the assignment of problems, in grading these
problems, and in preparing lecture materials as well as examination questions. Every effort has been made
to have a solutions manual that cuts through the clutter and is self –explanatory as possible thus reducing
the work on the instructor. It is written and class tested by the author.
As indicated in its preface, the text is designed for the junior-senior courses in machine or
mechanical design. However, because of the number of optional sections which have been included,
MECHANICAL DESIGN of Machine Components may also be used to teach an upper level course. In
order to accommodate courses of varying emphases, considerably more material has been presented in the
book than can be covered effectively in a single three-credit-hour course. Machine/mechanical design is one
of the student’s first courses in professional engineering, as distinct from basic science and mathematics.
There is never enough time to discuss all of the required material in details.
To assist the instructor in making up a schedule that will best fit his classes, major topics that will
probably be covered in every machine design course and secondary topics which may be selected to
complement this core to form courses of various emphases are indicated in the following Sample
Assignment Schedule. The major topics should be covered in some depth. The secondary topics, because
of time limitations and/or treatment on other courses, are suggested for brief coverage. We note that the
topics which may be used with more advanced students are marked with asterisks in the textbook.
The problems in the sample schedule have been listed according to the portions of material they
illustrate. Instructor will easily find additional problems in the text to amplify a particular subject in
discussing a problem assigned for homework. Answers to selected problems are given at the end of the text.
Space limitations preclude our including solutions to open-ended web problems. Since the integrated
approach used in this text differs from that used in other texts, the instructor is advised to read its preface,
where the author has outlined his general philosophy. A brief description of the topics covered in each
chapter throughout the text is given in the following. It is hoped that this material will help the instructor in
organizing his course to best fit the needs of, his students.
Ansel C. Ugural
Holmdel, N.J.
vii
, DESCRIPTION OF THE MATERIAL CONTAINED IN
“MECHANICAL DESIGN of Machine Components”
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.
viii
SOLUTIONS MANUAL
, CONTENTS
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
, NOTES TO THE INSTRUCTOR
The Solutions Manual to accompany the text MECHANICAL DESIGN of Machine Components
supplements the study of machine design developed in the book. The main objective of the manual is to
provide efficient solutions for problems in design and analysis of variously loaded mechanical components.
In addition, this manual can serve to guide the instructor in the assignment of problems, in grading these
problems, and in preparing lecture materials as well as examination questions. Every effort has been made
to have a solutions manual that cuts through the clutter and is self –explanatory as possible thus reducing
the work on the instructor. It is written and class tested by the author.
As indicated in its preface, the text is designed for the junior-senior courses in machine or
mechanical design. However, because of the number of optional sections which have been included,
MECHANICAL DESIGN of Machine Components may also be used to teach an upper level course. In
order to accommodate courses of varying emphases, considerably more material has been presented in the
book than can be covered effectively in a single three-credit-hour course. Machine/mechanical design is one
of the student’s first courses in professional engineering, as distinct from basic science and mathematics.
There is never enough time to discuss all of the required material in details.
To assist the instructor in making up a schedule that will best fit his classes, major topics that will
probably be covered in every machine design course and secondary topics which may be selected to
complement this core to form courses of various emphases are indicated in the following Sample
Assignment Schedule. The major topics should be covered in some depth. The secondary topics, because
of time limitations and/or treatment on other courses, are suggested for brief coverage. We note that the
topics which may be used with more advanced students are marked with asterisks in the textbook.
The problems in the sample schedule have been listed according to the portions of material they
illustrate. Instructor will easily find additional problems in the text to amplify a particular subject in
discussing a problem assigned for homework. Answers to selected problems are given at the end of the text.
Space limitations preclude our including solutions to open-ended web problems. Since the integrated
approach used in this text differs from that used in other texts, the instructor is advised to read its preface,
where the author has outlined his general philosophy. A brief description of the topics covered in each
chapter throughout the text is given in the following. It is hoped that this material will help the instructor in
organizing his course to best fit the needs of, his students.
Ansel C. Ugural
Holmdel, N.J.
vii
, DESCRIPTION OF THE MATERIAL CONTAINED IN
“MECHANICAL DESIGN of Machine Components”
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.
viii
