1'1 I. LT A I- JAMES CARVll ! Mechanical Engineer’s Data Handbook To my daughters, Helen and Sarah Mechanical Engineer’s Data Handbook J. Carvill IUTTERWORTH EINEMANN OXFORD AMSTERDAM BOSTON LONDON NEW YORK PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO Butterworth-Heinemann An imprint of Elsevier Science Linacre House, Jordan Hill, Oxford OX2 8DP 200 Wheeler Road, Burlington MA 01803 First published 1993 Paperback edition 1994 Reprinted 1994,1995,1996,1997,1998,1999,2000 (twice), 2001 (twice), 2003 Copyright 0 1993, Elsevier Science Ltd. All riehts reserved. No part of this publication may be reproduced in any material form (includmg 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 WIT 4LP. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to the publishers British Library Cataloguing in Publication Data Carvill, James Mechanical Engineer’s Data Handbook I. Title 62 1 Library of Congress Cataloguing in Publication Data Carvill, James Mechanical engineer’s data handbook/James Carvill. p. an. Includes index. 1. Mechanical engineering - Handbooks, manuals, etc. TD51 .C36 I. Title. 62 1 -dc20 92- 19069 CIP ISBN 0 7506 1960 0 I For information on all Butterworth-Heinemann publications visit our website at www.bh.com I Typeset by Vision Typesetting, Manchester Printed in Great Britain by Bookcraft (Bath) Ltd, Somerset Contents Preface Symbols used in text 1. Strength of materials 1.1 Types of stress 1.2 Strength of fasteners 1.3 Fatigue and stress concentration 1.4 Bending of beams 1.5 Springs 1.6 Shafts 1.7 Struts 1.8 Cylinders and hollow spheres 1.9 Contact stress 1.10 Flat plates 2. Appli mechanics 2.1 Basic mechanics 2.2 Belt drives 2.3 Balancing 2.4 Miscellaneous machine elements 2.5 Automobile mechanics 2.6 Vibrations 2.7 Friction 2.8 Brakes, clutches and dynamometers 2.9 Bearings 2.10 Gears 3. Tbennodyanmics and heat transfer 3.1 Heat 3.2 Perfect gases 3.3 Vapours 3.4 Data tables 3.5 Flow through nozzles 3.6 Steam plant 3.7 Steam turbines 3.8 Gas turbines 3.9 Heat engine cycles 3.10 Reciprocating spark ignition internal 3.1 1 Air compressors combustion engines vii ix 1 1 8 17 24 32 38 46 48 51 53 56 56 65 68 70 77 79 83 87 90 95 102 102 I02 106 107 111 112 114 116 118 120 I24 3.12 Reciprocating air motor 3.13 Refrigerators 3.14 Heat transfer 3.15 Heat exchangers 3.16 Combustion of fuels 4. Fluid mechanics 4.1 Hydrostatics 4.2 Flow of liquids in pipes and ducts 4.3 Flow of liquids through various devices 4.4 Viscosity and laminar flow 4.5 Fluid jets 4.6 Flow of gases 4.7 Fluid machines 5. Manufacturing technology 5.1 5.2 Turning 5.3 Drilling and reaming 5.4 Milling 5.5 Grinding 5.6 Cutting-tool materials 5.7 General information on metal cutting 5.8 Casting 5.9 Metal forming processes 5.10 Soldering and brazing 5.1 1 Gas welding 5.12 Arc welding 5.13 Limits and fits General characteristics of metal processes 6. Engineering materials 6.1 Cast irons 6.2 Carbon steels 6.3 Alloy steels 6.4 Stainless steels 6.5 British Standard specification of steels 6.6 Non-ferrous metals 6.7 Miscellaneous metals 6.8 Spring materials 6.9 Powdered metals 6.10 Low-melting-point alloys 126 127 i28 137 139 146 146 148 152 155 157 160 165 172 172 173 178 182 188 189 192 196 199 205 207 210 216 218 218 219 22 1 225 228 228 233 235 236 236 vi MECHANICAL ENGINEER’S DATA HANDBOOK 6.11 Miscellaneous information on metals 6.12 Corrosion of metals 6.13 Plastics 6.14 Elastomers 6.15 Wood 6.16 Adhesives 6.17 Composites 6.18 Ceramics 6.19 Cermets 6.20 Materials for special requirements 6.21 Miscellaneous information 7. Engineering measurements 7.1 Length measurement 7.2 Angle measurement 7.3 Strain measurement 237 240 242 248 250 25 1 257 259 259 260 263 267 267 270 27 1 7.4 Temperature measurement 7.5 Pressure measurement 7.6 Flow measurement 7.7 Velocity measurement 7.8 Rotational-speed measurement 7.9 Materials-testing measurements 8. General data 8.1 Units and symbols 8.2 Fasteners 8.3 Engineering stock 8.4 Miscellaneous data Glossary of terms Index 274 279 28 1 283 284 285 288 288 293 304 308 31 1 330 Preface There are several good mechanical engineering data books on the market but these tend to be very bulky and expensive, and are usually only available in libraries as reference books. The Mechnical Engineer’s Data Handbook has been compiled with the express intention of providing a compact but comprehensive source of information of particular value to the engineer whether in the design office, drawing office, research and development department or on site. It should also prove to be of use to production, chemical, mining, mineral, electrical and building services engineers, and lecturers and students in universities, polytechnics and colleges. Although intended as a personal handbook it should also find its way into the libraries of engineering establishments and teaching institutions. The Mechanical Engineer’s Data Handbook covers the main disciplines of mechanical engineering and incorporates basic principles, formulae for easy substitution, tables of physical properties and much descriptive matter backed by numerous illustrations. It also contains a comprehensive glossary of technical terms and a full index for easy cross-reference. 1 would like to thank my colleagues at the University of Northumbria, at Newcastle, for their constructive suggestions and useful criticisms, and my wife Anne for her assistance and patience in helping me to prepare this book. J. Carvill Symbols used in text ~~ a A d b b.p. B C C Cd CP CY COP cv d D e E EL Acceleration Area Anergy Breadth Boiling point Breadth, flux density Clearance, depth of cut; specific heat capacity Couple; Spring coil index; velocity (thermodynamics); heat capacity Drag coefficient, discharge coefficient Coefficient of performance Specific heat at constant pressure Specific heat at constant volume; velocity coefficient Calorific value Depth; depth of cut; diameter; deceleration Depth; diameter; flexural rigidity Strain; coefficient of restitution; emissivity Young’s Modulus; energy; luminance; effort j J k K KE K, 1 L rn m m.p. M MA n N Ns Nu V Operator J- 1 Polar second moment of area Radius of gyration; coefficient of thermal conductivity; pipe roughness Bulk modulus; stress concentration factor Kinetic energy Wahl factor for spring Length Length Mass; mass per unit length; module of gear Mass flow rate Melting point Mass; moment; bending moment; molecular weight Mechanical advantage Index of expansion; index; number of; rotational speed Rotational speed; number of Specific speed Nusselt number Pressure; pitch Elastic limit; endurance limit P Power; force; perimeter ELONG% Percentage elongation 8 Exergy f Frequency; friction factor; feed F Force; luminous flux F, Strain gauge factor FL Fatigue limit FS Factor of safety 9 Acceleration due to gravity G Shear modulus; Gravitational constant Gr Grashof number h Height; thickness; specific enthalpy; h.t.c. Heat transfer coefficient H i slope; operator J-l I shear, heat transfer coefficient Enthalpy; height, magnetic field strength Moment of inertia; Second moment of area; luminous intensity, electric current pr PE PS Q r R Re Ro RE S S SE s, t Prandtl number Potential energy Proof stress Heat quantity; volume flow rate; metal removal rate Radius; pressure or volume ratio Radius; electric resistance; reaction, thermal resistance; gas constant Reynolds number Refrigeration effect Universal gas constant Specific entropy; stiffness Entropy, shear force, thermoelectric sensitivity Strain energy Stanton number Temperature; thickness; time [...].. .MECHANICAL ENGINEER’S DATA HANDBOOK X T TS U U UTS U V VR W W X X Y YP YS Z Z P Time; temperature; torque; tension; thrust; number of gear teeth Tensile strength Velocity; specific strain energy; specific internal... parallel to the direction of P Poisson's ratio Poisson's ratio v = strain in direction of load strain at right angles to load 6BIB eB ~L/L=< Note: $ e , is positive, eB is negative I P 2 MECHANICAL ENGINEER’SDATA HANDBOOK Bending stress MY Bending stress a = - I P where: M = bending moment I =second moment of area of section y = distance from centroid to the point considered V MYm Maximum stress am=I... more bars of different materials rigidly joined The stress when loaded depends on the cross-sectional areas (A, and Ab) areas and Young’s moduli (E, and Eb) of the components Stresses 4 MECHANICAL ENGINEER’S DATA HANDBOOK Failure may be due to any one of the following stresses Strains e, = a,/E,; e,, = ab/E,, (note that e, = e,,) (1 ) Tensile in rod a, =4P/nDZ a F F (2) Tensile in eye 6, P/(Do- D,)b... (general case) Edt2=(d,t:+d2t:+ .Zdt3=(dlt:+dzt:+ Z , ) k 0.5 1.02 DJD, W,JW, 0.783 eje, 0.979 0.6 0.7 0.8 0.9 1.047 0.702 0.955 1.095 0.613 0.913 1.192 0.516 0.839 1.427 0.387 0.701 8 MECHANICAL ENGINEER’S DATA HANDBOOK 1.2 Strength of fasteners I.2 I Bolts and bolted joints Bolts, usually in conjunction with nuts, are the most widely used non-permanent fastening The bolt head is usually hexagonal... Spring lock nut (compression stop nut) Typical metric sizes (mm) D=lOO R = 0 6 A-160 F=80 H=100 K = 5 5 UTaccording to application Hexagon socket head screw Elastic stop nut (Nyloc nut) 10 MECHANICAL ENGINEER’SDATA HANDBOOK + @- Helical spring lock washer and two-coil spring lock washer t Bolted joint in tension The bolt shown is under tensile load plus an initial tightening load Three members are shown... pivot point Shear stress t=4P/7tD2 P,=Pda,/(a:+a:+a:+ Tensile stress o1= P , / A ) Double shear Shear stress t = 2P/nD2 12 MECHANICAL ENGINEER'SDATA HANDBOOK I I I \ +,MI P P f 0 I P Efficiency of joint: PI2 I] = P Butt joint PI2 I Crushing stress Q, least of P P P P 4 x 1 ~ % QpPt The rivet is in 'double shear', therefore P, =z,nD2/2 per row In practice, P, is nearer to TJC- 3D2 8 =P/Dt I 2.4 Rivets... =constant x t Z = l/ymax bending modulus = Resultant stress ( T ~ is the vector sum of T~ and T ~ r;is ) chosen to give highest value of T ~ From T, the value oft is found, and hence w 14 MECHANICAL ENGINEER’S DATA HANDBOOK Y A - A X X -X Y I 2.6 Properties of weld groups treated as lines - welds Symbols used: Z =bending modulus about axis XX J =polar second moment of area t =weld throat size [ ( Z... Z = (2bd+d2/3)t;J = (2b3+ 6bd2+d3)t/6 Y b 3 b 1 P (density) ‘ E Solid disk X- d Maximum tangential and radial stress (a,) + ut=u, =pu2(3 v)/8 at r =0 where: v =Poisson’s ratio, u =rw 16 MECHANICAL ENGINEER’S DATA HANDBOOK No of spokes Value of constant c 4 6 8 Annular wheel For axial length assumed ‘small’: where: u=rzw 2Ar Tensile stress in spokes us=-.pu2 3cA, Long thick cylinder Maximum tangential... number of stress reversals N ’ is specified 0 Combined steady and alternating stress The average value is urnwith a superimposed alternating stress of range Q, oFs alloy N’ N (log scale) 18 MECHANICAL ENGINEER’SDATA HANDBOOK Soderberg diagram vor steel) I Endurance limit and fatigue stress 32 for various materials Alternating stress is plotted against steady stress , Actual failures occur above the line... concentration and possible failure Great care must be taken in welds subject to fluctuating loads to prevent unnecessary stress concentration Some examples are given below of bad cases penetration 20 MECHANICAL ENGINEER’S DATA HANDBOOK Incomplete penetration I Incomplete penetration n Cracking Slag inclusions (due to poor weldability) Porosity Bad profile Improved profile Incomplete weld 1.3.4 Stress concentration . I- JAMES CARVll ! Mechanical Engineer’s Data Handbook To my daughters, Helen and Sarah Mechanical Engineer’s Data Handbook J. Carvill IUTTERWORTH. Publication Data Carvill, James Mechanical Engineer’s Data Handbook I. Title 62 1 Library of Congress Cataloguing in Publication Data Carvill, James Mechanical