Newnes mechanical engineer's pocket book

✍ Scribed by Roger Timings

• Publisher: Elsevier/Newnes
• Year: 2006
• Tongue: English
• Leaves: 768
• Series: Newnes Pocket Books
• Edition: 3rd ed
• Category: Library

✦ Synopsis

The Newnes Mechanical Engineer's Pocket Book is a comprehensive collection of data for mechanical engineers and students of mechanical engineering. Bringing together the data and information that is required to-hand when designing, making or repairing mechanical devices and systems, it has been revised to keep pace with changes in technology and standards. The Pocket Book emphasises current engineering practice and is supported by clear accounts of the fundamental principles of mechanical engineering. Key features include the latest BSI engineering data; focus on engineering design issues; enhanced coverage of roller chain drives, pneumatic and hydraulic systems; and expanded and more accessible detail on statics, dynamics and mathematics. *

✦ Table of Contents

Front cover......Page 1
Title page......Page 4
Copyright page......Page 5
Table of contents......Page 6
Foreword......Page 20
Preface......Page 22
Acknowledgements......Page 28
1.2 Mathematical symbols......Page 30
1.3.2 Derived units......Page 31
1.3.3 Units: not SI......Page 32
1.4 Conversion factors for units......Page 33
1.4.2 SI to FPS units......Page 34
1.6.1 Plane figures......Page 35
1.6.2 Solid objects......Page 38
1.7 Powers, roots and reciprocals......Page 42
1.8.2 Geometric progressions......Page 45
1.9.1 Basic definitions......Page 46
1.9.5 Triangle formulae......Page 47
1.10 Circles: some definitions and properties......Page 48
1.10.1 Circles: areas and circumferences......Page 49
1.13.1 Basic concepts......Page 50
1.13.3 Binomial distribution......Page 51
1.13.5 Normal distribution......Page 52
1.14 Differential calculus (Derivatives)......Page 53
1.15 Integral calculus (Standard forms)......Page 55
1.18 Taylor's theorem......Page 57
2.2.2 Force......Page 58
2.2.3 Vectors......Page 59
2.2.6 Weight per unit volume......Page 60
2.2.7 Relative density......Page 61
2.2.8 Pressure (fluids)......Page 62
2.3.2 Parallelogram of forces......Page 63
2.3.4 Resolution of forces......Page 65
2.3.6 Polygon of forces: Bow's notation......Page 66
2.3.7 Non-concurrent coplanar forces (funicular link polygon)......Page 68
2.4.1 Moments of forces......Page 70
2.4.2 Principle of moments (related terminology)......Page 71
2.4.3 Principle of moments......Page 72
2.4.4 Equilibrium......Page 74
2.5.1 First-order levers......Page 76
2.5.2 Second-order levers......Page 77
2.6.2 Centre of gravity of non-uniform and composite solids......Page 78
2.6.3 Centre of gravity (lamina)......Page 80
2.6.4 Centroids of areas......Page 81
2.6.5 Equilibrium......Page 82
2.7 Friction......Page 83
2.7.3 Coefficient of friction......Page 84
2.7.5 Friction on an inclined plane......Page 86
2.7.6 Angle of repose......Page 87
2.8.1 Direct stress......Page 88
2.8.2 Shear stress......Page 89
2.8.5 Modulus of elasticity (Hooke's law)......Page 90
2.8.6 Modulus of rigidity......Page 91
2.8.7 Torsional stress......Page 92
2.8.8 Hoop stress in thin cylindrical shells......Page 93
2.8.9 Longitudinal stress in thin cylindrical shells......Page 94
2.9.1 Shearing force......Page 95
2.9.2 Bending moment......Page 96
2.9.3 Shearing force and bending moment diagrams......Page 97
2.9.4 Beams (cantilever)......Page 102
2.10.1 Bending stress and neutral axis......Page 103
2.11 Frameworks......Page 107
2.11.1 Method of sections......Page 108
2.12 Hydrostatic pressure......Page 112
2.12.1 Thrust on a submerged surface......Page 113
2.12.2 Pascal's law......Page 114
3.2 Work......Page 116
3.3.1 Conservation of energy......Page 117
3.6 Velocity and acceleration......Page 118
3.6.6 Newton's laws of motion......Page 119
3.6.7 Gravity......Page 120
3.6.9 Impact of a fluid jet on a fixed body......Page 121
3.6.11 Resisted motion......Page 122
3.7.1 The radian......Page 125
3.7.4 The relationship between angular and linear velocity......Page 126
3.7.6 Torque......Page 127
3.7.7 Work done by a torque......Page 129
3.7.8 Centripetal acceleration and centripetal force......Page 130
3.7.9 Centrifugal force......Page 131
3.8.2 Balancing co-planar masses (dynamic balance)......Page 132
3.9.1 Relative velocities (unconnected bodies)......Page 135
3.9.2 Relative velocities (connected bodies)......Page 137
3.10.1 Ballistics......Page 138
3.11.1 Universal gravitation......Page 139
3.11.4 Conic pendulum......Page 140
3.11.5 Rotation of a body about a fixed axis......Page 142
3.11.8 Angular momentum......Page 143
3.12 Simple harmonic motion......Page 145
3.12.1 Simple pendulum......Page 146
3.12.2 Natural vibration......Page 147
3.13.1 Rate of flow......Page 148
3.13.3 Energy of a fluid in motion (Bernoulli's equation)......Page 149
3.13.5 Viscosity......Page 150
3.13.7 Stoke's formula......Page 151
4.1.1 Drawing proportions......Page 152
4.1.3 Alternative screw points......Page 154
4.1.5 Application of screwed fasteners......Page 155
4.1.8 Buttress thread form......Page 156
4.1.10 Basic Whitworth (55°) thread form: parallel threads......Page 157
4.1.12 Introduction to screwed fasteners......Page 158
4.1.13 BS EN ISO 4014: 2001 Hexagon head bolts – product grades A and B......Page 161
4.1.14 BS EN ISO 4016: 2001 Hexagon head bolts – product grade C......Page 168
4.1.15 BS EN ISO 4017: 2001 Hexagon head screws – product grades A and B......Page 174
4.1.16 BS EN ISO 4018: 2001 Hexagon head screws – product grade C......Page 180
4.1.17 BS EN ISO 4032: 2001 Hexagon nuts style 1 – product grades A and B......Page 187
4.1.18 BS EN ISO 4033: 2001 Hexagon nuts style 2 – product grades A and B......Page 191
4.1.19 BS EN ISO 4034: 2001 Hexagon nuts style 1 – product grade C......Page 194
4.1.20 BS EN ISO 4035: 2001 Hexagon thin nuts (chamfered) – product grades A and B......Page 196
4.1.21 BS EN ISO 4036: 2001 Hexagon thin nuts (unchamfered) – product grade B......Page 198
4.1.22 BS EN ISO 8765: 2001 Hexagon head bolts with metric fine pitch threads – product grades A and B......Page 199
4.1.23 BS EN ISO 8676: 2001 Hexagon head screws with metric fine pitch threads – product grades A and B......Page 206
4.1.24 BS EN ISO 8673: 2001 Hexagon nuts style 1 with metric fine pitch threads – product grades A and B......Page 213
4.1.25 BS EN ISO 8674: 2001 Hexagon nuts style 2 with metric fine pitch threads – product grades A and B......Page 216
4.1.26 BS EN ISO 8675: 2001 Hexagon thin nuts with metric fine pitch threads – product grades A and B......Page 219
4.1.27 BS 7764: 1994 Hexagon slotted nuts and castle nuts......Page 221
4.1.28 BS EN ISO 898-1: 1999 Mechanical properties of fasteners: bolts, screws and studs......Page 225
4.1.29 BS EN ISO 898-1: 1999 Marking......Page 234
4.1.30 BS EN 20898-2: 1994 Mechanical properties of fasteners: nuts with specified proof load values – coarse thread......Page 238
4.1.31 BS EN ISO 898-6: 1996 Mechanical properties of fasteners: nuts with specified proof load values – fine pitch thread......Page 246
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......Page 250
4.1.33 BS EN ISO 4762: 2004 Metric hexagon socket head screws......Page 251
4.1.34 BS EN ISO 10642: 2004 Hexagon socket countersunk head screws......Page 259
4.1.35 BS4827 ISO metric screw threads, miniature series......Page 264
4.1.36 BS3643-1/2 ISO metric screw threads: constant pitch series......Page 265
4.1.37 BS EN ISO 228-1: 2003 Pipe threads where pressure-tight joints are not made on the threads......Page 269
4.1.38 ISO Pipe threads, tapered: basic sizes......Page 275
4.1.39 British Standard Whitworth (BSW) bolts and nuts......Page 279
4.1.40 British Standard Fine (BSF) bolts and nuts......Page 280
4.1.41 ISO unified precision internal screw threads: coarse series (UNC)......Page 281
4.1.42 ISO unified precision external screw threads: coarse series (UNC)......Page 283
4.1.43 ISO unified precision internal screw threads: fine series (UNF)......Page 285
4.1.44 ISO unified precision external screw threads: fine series (UNF)......Page 286
4.1.45 British Association thread form......Page 287
4.1.46 BA internal and external screw threads......Page 288
4.1.48 ISO metric tapping and clearance drills, coarse thread series......Page 289
4.1.50 ISO unified tapping and clearance drills, coarse thread series......Page 290
4.1.52 ISO metric tapping and clearance drills, miniature series......Page 291
4.1.55 Plain washers, bright: metric series......Page 292
4.1.56 Plain washers, black: metric series......Page 293
4.1.57 Friction locking devices......Page 294
4.1.58 Positive locking devices......Page 296
4.1.59 Single coil square section spring washers: metric series, type A......Page 298
4.1.60 Single coil rectangular section spring washers: metric series, types B and BP......Page 299
4.1.61 Double coil rectangular section spring washers: metric series, type D......Page 301
4.1.62 Toothed lock washers, metric......Page 302
4.1.63 Serrated lock washers, metric......Page 305
4.1.64 ISO metric crinkle washers: general engineering......Page 308
4.1.65 T-slot profiles......Page 309
4.1.66 Dimensions of T-bolts and T-nuts......Page 311
4.1.67 Dimensions of tenons for T-slots......Page 315
4.2.1 Typical rivet heads and shanks......Page 317
4.2.2 Typical riveted lap joints......Page 318
4.2.3 Typical riveted butt joints......Page 319
4.2.4 Proportions for hole diameter and rivet length......Page 320
4.2.5 Cold forged snap head rivets......Page 321
4.2.6 Hot forged snap head rivets......Page 322
4.2.7 Tentative range of nominal lengths associated with shank diameters......Page 323
4.2.8 POP® rivets......Page 324
4.2.9 POP® range guide......Page 325
4.2.11 Selection of POP® (or blind) rivets......Page 326
4.2.12 Design guidelines......Page 327
4.2.13 POP® 'F' series......Page 331
4.2.14 Open type aluminium 3.5% magnesium alloy......Page 334
4.2.15 Open type carbon steel......Page 342
4.2.16 Closed end type aluminium 5% magnesium alloy......Page 347
4.2.17 Blind rivet nuts......Page 349
4.2.18 POP® Nut Threaded Inserts: application......Page 350
4.2.19 POP® Nut Threaded Inserts: installation......Page 351
4.2.20 POP® Nut: Steel......Page 353
4.3.1 Self-secured joints......Page 357
4.3.2 Allowances for self-secured joints......Page 358
4.4.1 Taper pins, unhardened......Page 360
4.4.2 Circlips, external: metric series......Page 364
4.4.3 Circlips, internal: metric series......Page 367
4.5.2 Adhesives cured by ultraviolet light......Page 370
4.5.4 Adhesives cured with activator systems (modified acrylics)......Page 373
4.5.6 Epoxy adhesives......Page 374
4.5.8 Bonded joints......Page 378
5.1.1 Some typical gear drives......Page 380
5.1.2 Simple spur gear trains......Page 383
5.1.3 Compound spur gear train......Page 384
5.1.4 The involute curve......Page 385
5.1.5 Basic gear tooth geometry......Page 386
5.1.6 Gear tooth pitch......Page 390
5.1.7 Gear tooth height......Page 391
5.1.8 Standard gear tooth elements (in.)......Page 392
5.1.9 Fine pitch gear tooth elements (in.)......Page 393
5.1.10 Standard stub gear tooth elements (in.)......Page 394
5.1.11 Standard gear tooth elements (metric)......Page 395
5.1.12 Letter symbols for gear dimensions and calculations......Page 397
5.1.13 Basic spur gear calculations......Page 398
5.1.15 Miscellaneous gear equations......Page 399
5.1.16 Straight bevel gear nomenclature......Page 400
5.1.17 Worm and worm wheel nomenclature......Page 401
5.2.1 Simple flat-belt drives......Page 402
5.2.2 Compound flat-belt drives......Page 403
5.2.3 Typical belt tensioning devices......Page 404
5.2.4 Typical V-belt and synchronous-belt drive applications......Page 405
5.2.5 ULTRAFLEX® narrow-section wrapped V-belts......Page 409
5.2.6 FO®-Z heavy-duty cogged raw edge V-belts......Page 411
5.2.7 MULTIFLEX® classical-section wrapped V-belts......Page 413
5.2.8 MULTIBELT banded V-belts......Page 415
5.2.9 V-belt pulleys complying with BS 3790 and DIN standard 2211 for FO®-Z and ULTRAFLEX® belts. Rz xx refers to surface roughness......Page 417
5.2.10 V-belt pulleys complying with DIN standard 2217 Part 1 for FO®-Z and MULTIFLEX® belts......Page 419
5.2.11 Deep-groove pulleys......Page 421
5.2.12 Synchronous belt drives: introduction......Page 423
5.2.13 Synchronous belt drives: belt types and sizes......Page 427
5.2.14 Synchronous belt drives: pulleys......Page 433
5.2.15 SYNCHROBELT® HTD......Page 439
5.2.16 SYNCHROBELT® HTD synchronous (toothed) belts: tooth profiles......Page 440
5.2.17 Synchronous (toothed) belts: length measurement......Page 443
5.2.18 SYNCHROBELT® HTD toothed pulleys: preferred sizes......Page 444
5.3.1 Chain performance......Page 448
5.3.2 Wear factors......Page 450
5.3.3 Chain types......Page 451
5.3.4 International Standards......Page 452
5.3.6 Advantages of chain drives......Page 453
5.3.7 Chain selection......Page 455
5.3.8 Sprocket and chain compatibility......Page 457
5.3.9 Drive layout......Page 460
5.3.10 Selection method......Page 462
5.3.11 Rating chart construction......Page 469
5.3.12 European chain rating chart......Page 470
5.3.13 ANSI rating chart......Page 471
5.3.15 Lubrication......Page 472
5.3.16 Lubricating methods......Page 473
5.3.17 Lifting applications......Page 475
5.3.19 Influences on chain life......Page 477
5.3.20 Chain extension......Page 479
5.3.21 Matching of chain......Page 480
5.3.22 To measure chain wear......Page 481
5.3.23 Repair and replacement......Page 482
5.3.24 Chain adjustment......Page 483
5.3.25 Design ideas......Page 484
5.3.26 Table of PCD factors......Page 486
5.3.27 Simple point to point drives: Example one......Page 487
5.3.28 Simple point to point drives: Example two......Page 489
5.3.29 Simple point to point drives: Example three......Page 491
5.3.30 Safety warnings......Page 495
5.4.1 Square and rectangular parallel keys, metric series......Page 496
5.4.2 Dimensions and tolerances for square and rectangular parallel keys......Page 498
5.4.3 Square and rectangular taper keys, metric series......Page 500
5.4.4 Dimensions and tolerances for square and rectangular taper keys......Page 502
5.4.5 Woodruff keys and keyways, metric series......Page 504
5.4.6 Dimensions and tolerances for Woodruff keys......Page 506
5.4.7 Shaft ends types: general relationships......Page 508
5.4.8 Dimensions and tolerances of cylindrical shaft ends, long and short series......Page 509
5.4.9 Dimensions of conical shaft ends with parallel keys, long series......Page 511
5.4.10 Dimensions of conical shaft ends with diameters above 220 mm with the keyway parallel to the shaft surface, long series......Page 513
5.4.11 Dimensions of conical shaft ends with parallel keys, short series......Page 514
5.4.12 Transmissible torque values......Page 516
5.4.13 Straight-sided splines for cylindrical shafts, metric......Page 517
5.5.1 Self-holding Morse and metric 5% tapers......Page 520
5.5.2 Tapers for spindle noses......Page 528
5.5.3 Tapers for tool shanks......Page 534
5.5.4 Tool shank collars......Page 536
5.5.5 Bridgeport R8 taper......Page 537
5.6 Fluid power transmission systems......Page 538
5.6.1 A typical pneumatic system......Page 539
5.6.2 A typical hydraulic system......Page 540
5.6.3 Air compressor types......Page 542
5.6.4 Hydraulic pumps......Page 544
5.6.5 Actuators (linear)......Page 550
5.6.6 Actuators (rotary)......Page 552
5.6.8 Symbols for fluid power systems......Page 553
5.6.9 Fluid power transmission design data (general formulae)......Page 556
5.6.10 Fluid power transmission design data (hydraulic cylinders)......Page 558
5.6.11 Fluid power transmission design data (hydraulic pipes and hoses)......Page 560
5.6.12 Fluid power transmission design data (hydraulic fluids, seals and contamination control)......Page 561
5.6.13 Fluid power transmission design data (hydraulic accumulators)......Page 563
5.6.14 Fluid power transmission design data (hydraulic cooling and heating)......Page 565
5.6.15 Fluid power transmission design data (pneumatic valve flow)......Page 566
5.6.16 Fluid power transmission design data (pneumatic cylinders)......Page 567
5.6.17 Fluid power transmission design data (seals, filtration and lubrication)......Page 569
5.6.18 Fluid power transmission design data (air compressors)......Page 570
5.6.19 Fluid power transmission design data (tables and conversion factors in pneumatics)......Page 571
5.6.20 Guideline documents......Page 575
6.1.3 Shear strength......Page 577
6.1.6 Plasticity......Page 578
6.1.8 Malleability......Page 579
6.1.10 Tensile test......Page 580
6.1.11 Interpretation of a tensile test: material showing a yield point......Page 581
6.1.12 Interpretation of a tensile test: proof stress......Page 582
6.1.13 Interpretation of a tensile test: secant modulus......Page 583
6.1.15 Impact testing for toughness: Charpy test......Page 584
6.1.17 Brinell hardness test......Page 585
6.1.19 Rockwell hardness test......Page 586
6.1.20 Rockwell superficial hardness test......Page 587
6.1.21 Comparative hardness scales......Page 588
6.2.1 Ferrous metals: plain carbon steels......Page 589
6.2.3 Ferrous metals: alloying elements......Page 590
6.2.4 British standards relating to ferrous metals......Page 592
6.2.5 Some typical steels and their applications......Page 594
6.2.6 Some typical tool steels......Page 601
6.2.7 Flake (grey), cast irons......Page 603
6.2.8 BS EN 1561: 1997 Grey cast irons......Page 604
6.2.9 Malleable cast irons......Page 608
6.2.10 Spheroidal graphite cast irons......Page 611
6.2.11 Alloy cast irons......Page 613
6.2.12 Composition, properties and uses of some typical cast irons......Page 614
6.3.2 High copper content alloys......Page 615
6.3.4 British Standards relating copper and copper alloys......Page 616
6.3.5 Copper and copper alloy rods and sections......Page 617
6.3.6 Wrought copper and copper alloys......Page 619
6.3.7 Wrought copper and copper alloys......Page 624
6.3.8 Copper sheet, strip and foil......Page 626
6.3.9 Brass sheet, strip and foil: binary alloys of copper and zinc......Page 628
6.3.10 Brass sheet, strip and foil: special alloys and leaded brasses......Page 632
6.3.11 Phosphor bronze sheet, strip and foil......Page 634
6.3.12 Aluminium bronze alloys – introduction......Page 636
6.3.13 Aluminium bronze sheet, strip and foil......Page 637
6.3.14 Copper–nickel (cupro–nickel) sheet, strip and foil......Page 638
6.3.15 Nickel–silver sheet, strip and foil......Page 640
6.3.16(a) Miscellaneous wrought copper alloys......Page 642
6.3.16(b) Miscellaneous wrought copper alloys......Page 644
6.3.17(a) Copper alloys for casting: group A......Page 646
6.3.17(b) Further copper alloys for casting: group A......Page 647
6.3.18(a) Copper alloys for casting: group B......Page 649
6.3.18(b) Further copper alloys for casting: group B......Page 651
6.3.19(a) Copper alloys for casting: group C......Page 653
6.3.19(b) Further copper alloys for casting: group C......Page 655
6.3.20 Copper alloys for casting: typical properties and hardness values......Page 657
6.3.22 British Standards......Page 661
6.3.23 Unalloyed aluminium plate, sheet and strip......Page 663
6.3.24 Aluminium alloy plate, sheet and strip: non-heat-treatable......Page 665
6.3.25 Aluminium alloy plate, sheet and strip: heat-treatable......Page 668
6.3.26 Aluminium and aluminium alloy bars, extruded tube and sections for general engineering: non-heat-treatable......Page 671
6.3.27 Aluminium alloy bars, extruded tube and sections for general engineering: heat-treatable......Page 673
6.3.28 Aluminium alloy castings, group A: general purpose......Page 676
6.3.29 Aluminium alloy castings, group B: special purpose......Page 677
6.3.30 Aluminium alloy castings, group C: special purpose and of limited application......Page 678
6.3.31 Aluminium alloy castings: mechanical properties......Page 679
6.3.32 BS EN 29453: 1993......Page 680
6.3.34 Silver soldering (hard soldering)......Page 682
6.3.35 Group AG: silver brazing filler metals......Page 683
6.4.1 Metallic material sizes: introduction to BS 6722: 1986......Page 684
6.4.2 Recommended diameters of wires, metric......Page 685
6.4.4 Recommended widths and lengths of flat products......Page 686
6.4.5 Mass of metric round and square bars......Page 687
6.4.6 Hexagon bar sizes for screwed fasteners, metric......Page 689
6.4.7 Gauge sizes and equivalents......Page 690
6.5.1 Polymeric (plastic) materials – introduction......Page 691
6.5.2 Some important thermosetting polymers......Page 693
6.5.3 Some important thermoplastic polymers......Page 694
7.1.1 Limits and fits......Page 695
7.1.3 Accuracy......Page 696
7.2.1 Application of tables of limits and fits......Page 697
7.2.2 Selection of tolerance grades......Page 699
7.3 Geometric tolerancing......Page 701
7.3.1 Geometrical tolerance (principles)......Page 703
7.3.3 Geometrical tolerance......Page 706
7.3.5 Geometrical reference frame......Page 707
7.3.6 Applications of geometrical tolerances......Page 708
7.4 Virtual size......Page 710
7.5 The economics of geometrical tolerancing......Page 711
8.1.2 Advantages and limitations of CNC......Page 713
8.1.3 Axes of control for machine tools......Page 714
8.1.4 Control systems......Page 716
8.1.6 Word (or letter) address format......Page 717
8.1.7 Coded information......Page 718
8.1.10 Cutter diameter compensation: milling......Page 721
8.1.11 Programming techniques: milling and drilling......Page 724
8.1.12 Programming example: milling......Page 725
8.1.13 Tool offsets: lathe......Page 727
8.1.14 Tool nose radius compensation: lathe......Page 728
8.1.15 Programming techniques: lathe......Page 729
8.1.16 Programming example: lathe......Page 731
8.1.17 Glossary of terms......Page 733
8.2.1 An introduction to computer-aided design......Page 735
8.2.2 CAD system hardware......Page 737
8.2.3 CAD system software......Page 739
8.2.4 Computer-aided design and manufacture......Page 740
8.3.1 An introduction to robotics......Page 741
8.3.3 Robot arm geometry......Page 742
Appendix 1 BSI Standards: Sales Order and Enquiry Contacts......Page 747
Appendix 2 Library Sets of British Standards in the UK......Page 751
Appendix 3 Contributing Companies......Page 755
Appendix 4 Useful References......Page 757
Index......Page 758