mechanical engineers pocket book

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Newnes Mechanical Engineer’s Pocket Book

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Newnes Mechanical Engineer’s Pocket Book

Third edition

Roger L Timings

AMSTERDAM• BOSTON• HEIDELBERG• LONDON • NEWYORK

OXFORD• PARIS• SANDIEGO• SANFRANCISCO• SINGAPORE

• SYDNEY• TOKYO

An imprint of Elsevier

Linacre House, Jordan Hill, Oxford OX2 8DP

30 Corporate Drive, Burlington, MA 01803

Copyright © 1990, Roger Timings and Tony May All rights reserved

Copyright © 1997, 2006 Roger Timings All rights reserved

The right of Roger Timings to be identified as the author of this work has been asserted in accordance with the Copyright, Designs and Patents Act 1988

No part of this publication may be reproduced in any material form

(including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except

in accordance with the provisions of the Copyright, Designs and

Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London, England W1T 4LP.Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to the publisher

Permissions may be sought directly from Elsevier’s Science & Technology Rights Department in Oxford, UK: phone: (
44) 1865 843830,

fax: (
44) 1865 853333, e-mail: permissions@elsevier.co.uk

You may also complete your request on-line via the Elsevier homepage(http://www.elsevier.com), by selecting ‘Customer Support’ and then

‘Obtaining Permissions’

British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library

Library of Congress Cataloguing in Publication Data

A catalogue record for this book is available from the Library of CongressISBN-13: 978-0-7506-6508-7

ISBN-10: 0-7506-6508-4

Typeset by Charon Tec Pvt Ltd, Chennai, India

Printed and bound in Great Britain

For information on all Newnes publications

visit our website at http://books.elsevier.com

1.10 Circles: some definitions and properties 19

1.13.3 Binomial distribution 22

2.3.7 Non-concurrent coplanar forces (funicular

2.6 Centre of gravity, centroids of areas and equilibrium 49

2.6.2 Centre of gravity of non-uniform and composite solids 49

2.10 Stress, strain and deflections in beams 74

3.13.3 Energy of a fluid in motion (Bernoulli’s equation) 120

4 Fastenings 123

4.1.10 Basic Whitworth (55°) thread form: parallel threads 128

4.1.13 BS EN ISO 4014: 2001 Hexagon head bolts –

4.1.14 BS EN ISO 4016: 2001 Hexagon head bolts –

4.1.15 BS EN ISO 4017: 2001 Hexagon head screws –

4.1.16 BS EN ISO 4018: 2001 Hexagon head screws –

4.1.17 BS EN ISO 4032: 2001 Hexagon nuts style 1 –

4.1.18 BS EN ISO 4033: 2001 Hexagon nuts style 2 –

4.1.19 BS EN ISO 4034: 2001 Hexagon nuts style 1 –

4.1.20 BS EN ISO 4035: 2001 Hexagon thin nuts

4.1.21 BS EN ISO 4036: 2001 Hexagon thin nuts

4.1.22 BS EN ISO 8765: 2001 Hexagon head bolts with

metric fine pitch threads – product grades A and B 170 4.1.23 BS EN ISO 8676: 2001 Hexagon head screws with

metric fine pitch threads – product grades A and B 177 4.1.24 BS EN ISO 8673: 2001 Hexagon nuts style 1 with

metric fine pitch threads – product grades A and B 184 4.1.25 BS EN ISO 8674: 2001 Hexagon nuts style 2 with

metric fine pitch threads – product grades A and B 187 4.1.26 BS EN ISO 8675: 2001 Hexagon thin nuts with

metric fine pitch threads – product grades A and B 190 4.1.27 BS 7764: 1994 Hexagon slotted nuts and castle nuts 192 4.1.28 BS EN ISO 898-1: 1999 Mechanical properties of

4.1.29 BS EN ISO 898-1: 1999 Marking 205 4.1.30 BS EN 20898-2: 1994 Mechanical properties of

fasteners: nuts with specified proof load values –

4.1.31 BS EN ISO 898-6: 1996 Mechanical properties of

fasteners: nuts with specified proof load values –

4.1.32 BS EN 20898-7: 1995 Mechanical properties of

fasteners: torsional test and minimum torques for bolts and screws with nominal diameters 1–10 mm 221 4.1.33 BS EN ISO 4762: 2004 Metric hexagon socket

4.1.34 BS EN ISO 10642: 2004 Hexagon socket

4.1.35 BS4827 ISO metric screw threads, miniature series 235 4.1.36 BS3643-1/2 ISO metric screw threads:

4.1.37 BS EN ISO 228-1: 2003 Pipe threads where

pressure-tight joints are not made on the threads 240

4.1.39 British Standard Whitworth (BSW) bolts and nuts 250

4.1.41 ISO unified precision internal screw threads:

4.1.42 ISO unified precision external screw threads:

4.1.43 ISO unified precision internal screw threads:

4.1.44 ISO unified precision external screw threads:

4.1.48 ISO metric tapping and clearance drills,

4.1.49 ISO metric tapping and clearance drills,

4.1.50 ISO unified tapping and clearance drills,

4.1.51 ISO unified tapping and clearance drills,

4.1.52 ISO metric tapping and clearance drills,

4.1.55 Plain washers, bright: metric series 263

4.1.59 Single coil square section spring washers:

4.1.60 Single coil rectangular section spring washers:

4.1.61 Double coil rectangular section spring washers:

4.1.64 ISO metric crinkle washers: general engineering 279

4.2.7 Tentative range of nominal lengths associated with

4.5 Adhesive bonding of metals 341

4.5.3 Adhesives cured by anionic reaction (cyanoacrylates) 344 4.5.4 Adhesives cured with activator systems

5.1.12 Letter symbols for gear dimensions and calculations 368

5.2.4 Typical V-belt and synchronous-belt drive applications 376

5.2.9 V-belt pulleys complying with BS 3790 and

DIN standard 2211 for FO®-Z and ULTRAFLEX®belts.

5.2.10 V-belt pulleys complying with DIN standard 2217

5.2.11 Deep-groove pulleys 392

5.4.1 Square and rectangular parallel keys, metric series 467 5.4.2 Dimensions and tolerances for square and

5.4.3 Square and rectangular taper keys, metric series 471

5.4.4 Dimensions and tolerances for square and

5.4.8 Dimensions and tolerances of cylindrical shaft ends,

5.4.9 Dimensions of conical shaft ends with parallel keys,

5.4.10 Dimensions of conical shaft ends with diameters

above 220 mm with the keyway parallel to the shaft

5.4.11 Dimensions of conical shaft ends with

5.4.13 Straight-sided splines for cylindrical shafts, metric 488

5.6.9 Fluid power transmission design data

5.6.10 Fluid power transmission design data

5.6.11 Fluid power transmission design data

5.6.12 Fluid power transmission design data

(hydraulic fluids, seals and contamination control) 532 5.6.13 Fluid power transmission design data

5.6.14 Fluid power transmission design data

5.6.15 Fluid power transmission design data

5.6.16 Fluid power transmission design data

5.6.17 Fluid power transmission design data

5.6.18 Fluid power transmission design data

5.6.19 Fluid power transmission design data (tables and

6.1.13 Interpretation of a tensile test: secant modulus 554

6.2.2 Effect of carbon content on the composition,

6.2.9 Malleable cast irons 579

6.2.12 Composition, properties and uses of

6.3.3 Wrought copper and copper alloys: condition code 587 6.3.4 British Standards relating copper and copper alloys 587

6.3.9 Brass sheet, strip and foil: binary alloys of

6.3.10 Brass sheet, strip and foil: special alloys and

6.3.14 Copper–nickel (cupro–nickel) sheet, strip and foil 609

6.3.20 Copper alloys for casting: typical properties and

6.3.24 Aluminium alloy plate, sheet and strip:

6.3.27 Aluminium alloy bars, extruded tube and sections

6.3.28 Aluminium alloy castings, group A: general purpose 647

6.3.29 Aluminium alloy castings, group B: special purpose 648 6.3.30 Aluminium alloy castings, group C: special purpose

6.3.31 Aluminium alloy castings: mechanical properties 650

6.4.1 Metallic material sizes: introduction to BS 6722: 1986 655

6.4.3 Recommended dimensions for bar and flat products 657

7 Linear and Geometric Tolerancing of

7.2 Standard systems of limits and fits (introduction) 668

7.5 The economics of geometrical tolerancing 682

8.1.1 Typical applications of computer numerical control 684

8.1.2 Advantages and limitations of CNC 684

Appendix 1 BSI Standards: Sales Order and Enquiry Contacts 718 Appendix 2 Library Sets of British Standards in the UK 722

It is now 14 years since the first edition of the Mechanical Engineer’s Pocket Book was published in its present format Although a second edi- tion was published some 7 years ago to accommodate many updates in the British Standards incorporated in the text, no changes were made to the structure of the book.

During the 14 years since the first edition of the Mechanical Engineer’s Pocket Book was published, the British Engineering Industry has under- gone many changes, with the emphasis moving from manufacture to design and development At the same time manufacturing has been largely out-sourced to East Europe, Asia and the Far East in order to reduce operating costs in an increasingly competitive global market Therefore, before embarking on this third edition, the Publishers and the Author have undertaken an extensive market research exercise The main outcomes from this research have indicated that:

●The demand has changed from an engineering manufacturing driven pocket book to an engineering design driven pocket book.

●More information was requested on such topic areas as roller chain drives, pneumatic systems and hydraulic systems in the section on power transmission.

●More information was requested on selected topic areas concerning

engineering statics, dynamics and mathematics.

●Topic areas that have fallen out of favour are those related to cutting tools Cutting tool data is considered less important now that the empha- sis has move from manufacture to design Further, cutting tool data is now widely available on the web sites of cutting tool manufacturers A selection of useful web sites are included in Appendix 4.

Roger L Timings (2005)

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is no longer available in hard copy but is published on a CD.

Definitions of entries

Catalogue entries are coded as in the example shown below The various elements are labelled A–J The key explains each element Not all the elem- ents will appear in every Standard.

AMD 4171, January 1983 (Gr 0) R00000821

AMD 4795, January 1985 (Gr 2)R00000833
E

AMD 6692, January 1991 (FOC) 00000845

00000818

A BS 1361 Product identifier.

currency of the standard without full revision.

iden-tical in every detail with a corresponding European and/or international standard.

publication in all technical respects the same

as a corresponding European and/or national standard, though the wording and presenting may differ quite extensively.

publication that covers subject matters lar to that covered by a European and/or international standard The content however

simi-is short of complete identity or technical equivalence.

publication.

text No ‘R’ means the amendment is not part

of the text.

back cover of the catalogue.

pub-lished in A4 size Sizes other than A4 are listed.

All separate amendments to the date of despatch are included with any main publication ordered Prices are available on application The amend- ment is then incorporated within the next reprint of the publication and the text carries a statement drawing attention to this, and includes an indica- tion in the margin at the appropriate places on the amended pages.

Review

The policy of the BSI is for every standard to be reviewed by the technical committee responsible not more than 5 years after publication, in order to establish whether it is still current and, if it is not, to identify and set in hand appropriate action Circumstances may lead to an earlier review When reviewing a standard a committee has four options available:

●Withdrawal: indicating that the standard is no longer current.

●Declaration of Obscelence: indicating by amendment that the standard

is not recommended for use in new equipment, but needs to be retained for the servicing of existing equipment that is expected to have

a long service life.

●Revision: involving the procedure for new projects.

●Confirmation: indicating the continuing currency of the standard

with-out full revision Following confirmation of a publication, stock of copies are overstamped with the month and year of confirmation.

The latest issue of standards should always be used in new product designs and equipments However many products are still being manu- factured to obsolescent and obsolete standards to satisfy a still buoyant demand This is not only for maintenance purposes but also for current manufacture where market forces have not yet demanded an update in design This is particularly true of screwed fasteners For this reason the existing screw thread tables from the previous editions have been retained and stand alongside the new BE EN ISO requirements.

The new standards are generally more detailed and prescriptive than there predecessors, therefore there is only room to include the essential information tables in this Pocket Book as a guide Where further informa- tion is required the full standard should always be consulted and a list of libraries holding up-to-date sets of standards is included in an appendix at the end of this book The standards quoted in the Pocket Book are up-to- date at the time of publication but, in view of the BSI’s policy of regular reviews, some may become subject to revision within the life of this book.

For this reason the validity of the standards quoted should always be fied The BSI helpline should be consulted.

veri-This Pocket Book has been prepared as an aid to mechanical engineers engaged in the design, development and manufacture of engineering products and equipment It is also a useful source book for others who require a quick, day-to-day reference of engineering information For easy reference this book is divided into 8 main sections, namely:

7 Linear and geometrical tolerancing

8 Computer aided engineering.

Within these main sections the material has been assembled in a logical sequence for easy reference and numbered accordingly This enables the reader to be lead directly to the item required by means of a comprehen- sive list contents and the inclusion of a comprehensive alphabetical index This Pocket Book is not a text book but a compilation of useful informa- tion Therefore in the sections concerned with mathematics, statics and dynamics worked examples are only included where anomalies might oth- erwise occur The author is indebted to the British Standards Institution and to all the industrial and commercial companies in the UK and abroad who have co-operated in providing up-to-date data in so many technical areas Unfortunately, limitations of space have allowed only abstracts to be included from amongst the wealth of material provided Therefore the reader is strongly recommended to consult the complete standards, indus- trial manuals, design manuals or catalogues after an initial perusal of the tables of data found in this book To this end, an appendix is provided with the names and addresses of the contributors to this book They all have useful web sites where additional information may be found.

The section on computer-aided manufacture has been deleted from this edition as it was too brief to be of much use and could not be expanded with in the page count available Specialist texts are available on applica- tion from the publishers of this Pocket Book on such topic areas as:

●Computer numerical control

●Computer-aided drawing and design

●Industrial robots

●Flexible manufacturing systems

●Programmable logic controllers

●Manufacturing management

●Project management.

Within the constraints of commercial viability, it is the continuing tion of the author and publisher to update this book from time to time Therefore, the author would appreciate (via the publishers) suggestions from the users of this book for additions and/or deletions to be taken into account when producing new editions.

inten-Roger L Timings (2005)

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David Brown Engineering Ltd (Section 5.1.1).

Henkel Loctite Adhesives Ltd (Sections 4.5.1–4.5.9).

IMI Norgren Ltd (Section 5.6.19).

National Broach & Machine Co (Sections 5.1.4–5.1.17).

Renold plc (Sections 5.3–5.4, 5.3.10–5.3.13, 5.3.16, 5.3.18–5.3.19, 5.3.21–5.3.22, 5.3.27–5.3.30).

Emhart Teknologies (Tucker Fasteners Ltd.) (Sections 4.2.8–4.2.18) Butterworth Heinemann for allowing us to reproduce material from

Higgins, R A., Properties of Materials in Sections 6.2.2, and 6.2.3.

Butterworth Heinemann for allowing us to reproduce material from Parr,

Andrew, Hydraulics and Pneumatics in Sections 5.6.1–5.6.4.

Newnes for allowing us to reproduce material from Stacey, Chris, Practical

Pneumatics in Section 5.6.3.

Pearson Education Ltd., for allowing us to reproduce material from

Timings, R L., Materials Technology volumes 1 and 2 in Sections

6.1.1–6.1.21 and 7.1–7.5.

Extracts from British Standards are reproduced with permission of BSI Complete copies of these documents can be obtained by post from BSI Sales, Linford Wood, Milton Keynes, Bucks., MK14 6LE.

Further information concerning the above companies can be found in the Appendix 3 at the end of this Pocket Book.

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Engineering Mathematics

Capital Lower case

alpha A
Angles, angular acceleration, various coefficientsbeta B  Angles, coefficients

gamma
 Shear strain, surface tension, kinematic viscositydelta   Differences, damping coefficient

epsilon E  Linear strain

eta H  Dynamic viscosity, efficiency

theta   Angles, temperature, volume strain

lambda   Wavelength, thermal conductivity

mu M Poisson’s ratio, coefficient of friction

sigma   Normal stress, standard deviation, sum of

phi   Angles, heat flow rate, potential energy

psi   Helix angle (gears)

omega  Angular velocity, solid angle () electrical resistance ( )

dx df , df/dx, f(x)

1.3 Units: SI

The International System of Units (SI) is based on nine physical quantities

Thermodynamic temperature kelvin K

By dimensionally appropriate multiplication and/or division of the units shown above,

Physical quantity Unit name Unit symbol Derivation

Electric capacitance farad F (A2s4)/(kg m2)

Electric conductance siemens S (A2s3)/(kg m2)Electric potential difference volt V (kg m2)/(A s3)Electrical resistance ohm (kg m2)/(A2s3)

Inductance henry H (kg m2)/(A2s2)

Magnetic flux weber Wb (kg m2)/(A s2)Magnetic flux density tesla T kg/(A s2)

Some other derived units not having special names.

Acceleration metre per second squared m/s2

Angular velocity radian per second rad/s

Current density ampere per square metre A/m2

Density kilogram per cubic metre kg/m3

Dynamic viscosity pascal second Pa sElectric charge density coulomb per cubic metre C/m3

Electric field strength volt per metre V/mEnergy density joule per cubic metre J/m3

Heat flux density watt per square metre W/m2

Kinematic viscosity square metre per second m2/sLuminance candela per square metre cd/m2

Magnetic field strength ampere per metre A/m

Specific volume cubic metre per kilogram m3/kgSurface tension newton per metre N/mThermal conductivity watt per metre kelvin W/(m K)

Some of the units which are not part of the SI system, but which are recognized for tinued use with the SI system, are as shown

con-Physical quantity Unit name Unit symbol Definition

Celsius temperature degree Celsius °C K  273.2 (For K see 1.3.1)Dynamic viscosity poise P 101Pa s

Fahrenheit temperature degree Fahrenheit °F (9)°C 32

Section 1.3.3 (continued )

Kinematic viscosity stokes St 104m2/s

Pressure millimetre of mercury mm Hg 133.322 Pa

Thermodynamic temperature degree Rankine °R °F 459.7

(a) Symbols should be in roman type lettering: thus cm, not cm.

(b) Symbols should remain unaltered in the plural: thus cm, not cms

(c) There should be a space between the product of two symbols: thus N m, not Nm.(d) Index notation may be used: thus m/s may be written as m s1and W/(m K) as

W m1K1

For quantities which are much larger or much smaller than the units so far given, decimalmultiples of units are used

Internationally agreed multiples are as shown

For small quantities For large quantities

(a) A prefix is used with the gram, not the kilogram: thus Mg, not kkg

(b) A prefix may be used for one or more of the unit symbols: thus kN m, N mm and

kN mm are all acceptable

(c) Compound prefixes should not be used: thus ns, not m s.

1.4 Conversion factors for units

The conversion factors shown below are accurate to five significant figures where FPS is

1.5 Preferred numbers

When one is buying, say, an electric lamp for use in the home, the normal range of lampsavailable is 15, 25, 40, 60, 100 W and so on These watt values approximately follow ageometric progression, roughly giving a uniform percentage change in light emissionbetween consecutive sizes In general, the relationship between the sizes of a commodity

is not random but based on a system of preferred numbers.

Preferred numbers are based on R numbers devised by Colonel Charles Renard The principal

series used are R5, R10, R20, R40 and R80, and subsets of these series The values within aseries are approximate geometric progressions based on common ratios of 5–––1–0, 10–1–0, 20–1–0,

40–1–0 and 80–1–0, representing changes between various sizes within a series of 58% for the

R5 series, 26% for the R10, 12% for the R20, 6% for the R40 and 3% for the R80 series.Further details on the values and use of preferred numbers may be found in BS 2045:1965.The rounded values for the R5 series are given as 1.00, 1.60, 2.50, 4.00, 6.30 and 10.00;these values indicate that the electric lamp sizes given above are based on the R5 series.Many of the standards in use are based on series of preferred numbers and these includesuch standards as sheet and wire gauges, nut and bolt sizes, standard currents (A) androtating speeds of machine tool spindles

Rectangle

b

h

8 Mechanical Engineer’s Pocket Book

Sector of circle

s

r u

a

Area Perimeter Ellipse

u

d

s r

x2

x1q

b

Arc length s

(u is in radians)

Several methods are used to find the shaded area, such as the mid-ordinate rule, the oidal rule and Simpson’s rule As an example of these, Simpson’s rule is as shown Divide

trapez-x1x2into an even number of equal parts of width d Let p, q, r, … be the lengths of cal lines measured from some datum, and let A be the approximate area of the irregular

verti-plane, shown shaded Then:

In general, the statement of Simpson’s rule is:

where first, last, evens, odds refer to ordinate lengths and d is the width of the equal parts

of the datum line

10 Mechanical Engineer’s Pocket Book

Cone

Total surface area

h l

R

Zone of sphere

r1

Where r is the radius of the sphere

8 Mechanical Engineer’s Pocket Book< /p>

Sector of circle

s

r u

a

Area... class="text_page_counter">Trang 39

10 Mechanical Engineer’s Pocket Book< /p>

Cone

Total surface area

h l

R