\! 2 c Mechanical Engineer’s Reference Book Mechanical Engineer’s Reference Book Twelfth edition Edited by Edward H. Smith BSC, MSC, P~Dc,E ng, FI Mech E Head of Computing Services, University of Central Lancashire With specialist contributors UTTER W O R T H E I N E M A N N Buttenvorth-Heinemann Linacre House, Jordan Hill, Oxford OX2 SDP 225 Wildwood Avenue, Woburn, MA 01801-2041 A division of Reed Educational and Professional Publishing Ltd -e A member of the Reed Elsevier group OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHl First published as Newnes Engineer's Reference Book 1946 Twelfth edition 1994 Reprinted 1995 Paperback edition 1998 Reprinted 1999,2000 0 Reed Educational and Professional Publishing Limited 1994 All rights reserved. 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, YO Tottenham Court Road, London, England WlP OLP. 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 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 Congress ISBN 0 7506 4218 1 Typeset by TecSet Ltd, Wallington, Surrey Printed and bound in Great Britain by The Bath Press, Bath FOR EVERY TIIU THAT WE POBUSH, EUI'IE8WOR~~T H~HEW?MANR W UPA Y POR BTCV TO P WAN 0 CARE POR A IREE. Contents Preface 8 Mechanics of solids Stress and strain . Experimental techniques . Fracture List of contributors mechanics . Creep of materials . Fatigue . References . Further reading 1 Mechanical engineering principles 9 Tribology Status of rigid bodies . Strength of materials . Dynamics of Basic principles . Lubricants (oils and greases) . Bearing rigid batdies . Vibrations . Mechanics of fluids . Principles of selection . Principles and design of hydrodynamic bearings . thermodynamics . Heat transfer . References Lubrication of industrial gears . Rolling element bearings . 2 Electrical and electronics principles Materials for unlubricated sliding . Wear and surface treatment . Fretting . Surface topography . References . Basic electrica! technology . Electrical machines . Analogue Further reading and digital electronics theory . Electrical safety References . Further reading 10 Power units and transmission 3 Microprocessors, instrumentation and control Power units . Power transmission . Further reading Summary of number systems . Microprocessors . Communication standards . Interfacing of computers to 11 Fuels and combustion systems . Instrumentation . Classical control theory and Introduction General fuel types . Major property overview practice . Microprocessor-based control . Programmable . Major fuel groupings . Combustion . Conclusions . logic controllers . The z-transform . State variable References techniqiies . References . Further reading 4 Coniputers and their application 12 Alternative energy sources IntroduNction . Types of computer . Generations of digital Introduction . Solar radiation . Passive solar design in the computers . Digital computer systems . Categories of UK . Thermal power and other thermal applications . computer systems Central processor unit . Memory . Photovoltaic energy conversion . Solar chemistry . Peripherals . Output devices . Terminals . Direct input . Hydropower . Wind power . Geothermal energy Tidal Disk storage . Digital and analogue inputloutput . Data power . Wave power . Biomass and energy from wastes communications . Computer networks . Data terminal Energy crops . References equipment . Software . Database management . Language translators . Languages 13 Nuclear engineering Introduction . Nuclear radiation and energy . Mechanical 5 Coniputer-integrated engineering systems engineering aspects of nuclear power stations and associated CAD/CAM: Computer-aided design and computer-aided plant . Other applications of nuclear radiation . Elements of manufacturing .Industrial robotics and automation . health physics and shielding . Further reading Computer graphics systems . References . Further reading 14 Offshore engineering . Drawing and graphic Historical review . Types of fixed and floating structures . Future development . Hydrodynamic loading . Structural communications . Fits, tolerances and limits . Fasteners . strength and fatigue . Dynamics of floating systems . Design Ergonomic and anthropometric data . Total quality - a considerations and certification . References company culture . References roperties and selection 15 Plant engineering Engineering properties of materials . The principles Compressors, fans and pumps . Seals and sealing Boilers underlying materials selection . Ferrous metals . and waste-heat recovery . Heating, ventilation and air Non-ferrous metals . Composites . Polymers . Elastomers . conditioning . Refrigeration . Energy management . Engineering ceramics and glasses . Corrosion . Condition monitoring . Vibration isolation and limits . Non-destructive testing . References . Further reading Acoustic noise . References vi Contents 16 Manufacturing methods 19 Units, symbols and constants Large-chip metal removal . Metal forming . Welding, SI units . Conversion to existing imperial terms . soldering and brazing . Adhesives . Casting and foundry Abbreviations . Physical and chemical constants . Further practice . References . Further reading reading 17 Engineering mathematics Index Trigonometric functions and general formulae . Calculus . Series and transforms . Matrices and determinants . Differential equations . Statistics . Further reading 18 Health and safety Health and safety in the European Community . Health and safety at work - law and administration in the USA . UK legislation and guidance . The Health and Safety at Work etc. Act 1974 . The Health and Safety Executive . Local Authorities . Enforcement Notices . Control of Substances Hazardous to Health Regulations 1988 . Asbestos . Control of lead at work . The Electricity at Work Regulations 1989 . The Noise at Work Regulations 1989 . Safety of machines . Personal protective equipment . Manual handling . Further reading Preface I was delighted when Butterworth-Heinemann asked me to To see this book in print is a considerable personal achieve- edit a new edition of Mechanical Engineer’s Reference Book. ment, but I could not have done this without the help of Upon looking at its predecessor, it was clear that it had served others. First, I would like to thank all the authors for their the community well, but a major update was required. The tremendous hard work. It is a major task to prepare informa- book clearly needed to take account of modern methods and tion for a hook of this type, and they have all done a magnificent systems. job. At Butterworth-Heinemam, Duncan Enright and Deena The philosophy behind the book is that it will provide a Burgess have been a great help, and Dal Koshal of the qualified engineer with sufficient information so that he or she University of Brighton provided considerable support. At the can identify the basic principles of a subject and be directed to University of Central Lancashire, Gill Cooke and Sue Wright further reading if required. There is a blurred line between ensured that the administration ran smoothly. this set of information and a more detailed set from which I hope you find the book useful. design decisions are made. One of my most important tasks has been to define this distinction, so that the aims of the book are met and its weight is minimized! I hope I have been able to do this, so that the information is neither cursory nor complex. Any book of this size will inevitably contain errors, but I Ted Smith hope these will be minimal. I will he pleased to receive any University of Central Lancashire, Preston. information from readers SO that the book can be improved. Christmas Eve, 1993 Contributors Dennis fI. Bacon BSc(Eng), MSc, CEng, MIMechE Duncan S. T. Enright BA: MA(Oxon), CertEd, GradInstP Consultant and technical author Commissioning Editor, Butterworth-Heinemann, Oxford Neal Barnes BSc, PhD Charles J. Fraser BSc, PhD, CEng, FIMechE, MInstPet Formerly Manager, Pumping Technology, BHR Group Ltd Reader in Mechanical Engineering John Barron BA, MA(Cantab) Eric M. Goodger BSc(Eng), MSc, PhD, CEng, MIMechE, Lecturer, Department of Engineering, University of FInstE, FInstPet, MRAeS, MIEAust Cambridge Consultant in Fuels Technology Training Christopher Beards BSc(Eng), PhD, CEng, MRAeS, MIOA Edward N. Gregory CEng, FIM, FWeldI Consultant and technical author Consultant Jonh S. Bevan IEng, MPPlantE, ACIBSE Dennis R. Hatton IEng, MIPlantE Formerly with British Telecom Consultant Ronald .J. Blaen Tony G. Herraty BTech, MIMechE, CEng Independent consultant SKF (UK) Service Ltd, Luton, Bedfordshire Tadeusz 2. Bllazynski PhD, BSc(Eng), MIMechE, CEng Martin Hodskinson BSc, PhD, CEng, FIMechE, MIED, Formerly Reader in Applied Plasticity, Department of REngDes Mechanicaki Engineering, University of Leeds Senior Lecturer, Department of Engineering and Product Design. University of Central Lancashire James Carvill WSc(MechE), BSc(E1ecEng) Formerly Senior Lecturer in Mechanical Engineering, Allan R. Hntchinson BSc, PhD, CEng, MICE University of Northumbria at Newcastle Deputy Head, Joining Technology Research Centre, School of Engineering, Oxford Brookes University Trevor G. Clarkson BSc(Eng), PhD, CEng, MIEE, Senior Member IEEE Jeffery D. Lewins DSc(Eng), FINucE, CEng Department of Electronic and Electrical Engineering, King's Lecturer in Nuclear Engineering, University of Cambridge College., University of London and Director of Studies in Engineering and Management, Magdalene College Paul Compton BSc CEng, MCIBSE Colt International Ltd, Havant, Hants Michael W. J. Lewis BSc, MSc Senior Engineering Consultant, National Centre of Vince Coveney PhD Tribology, AE Technology, Risley, Warrington Senior Lecturer, Faculty of Engineering, University of the West of England R. Ken Livesley MA, PhD, MBCS Lecturer Department of Engineering, University of Roy D. Cullurn FIED Cambridge Editor, Materials and Manufacture J. Cleland McVeigh MA, MSc, PhD, CEng, FIMechE, A. Davi'es FInstE, MIEE, MCIBSE National Centre of Tribology, Risley Nuclear Development Visiting Professor, School of Engineering, Glasgow Laboratory Caledonian University Raymond J. H. Easton CEng, MIR4echE Gordon M. Mair BSc, DMS, CEng, MIEE, MIMgt Chief Applications Engineer, James Walker & Co Ltd Lecturer, Department of Design, Manufacture and Engineering Management, University of Strathclyde Philip Eliades BSc, AMIMechE National Centre for Tribology, UKAEA, Risley, Fraidoon Mazda MPhil, DFH, DMS, MIMgt, CEng, FIEE Warrington Northern Telecom