Mechanical Design of Machine Components: SI Version, 2nd Edition (Hardback) book cover

Mechanical Design of Machine Components

SI Version, 2nd Edition

By Ansel C. Ugural

Taylor & Francis

953 pages | 719 B/W Illus.

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Hardback: 9781498735360
pub: 2016-06-14
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pub: 2018-09-03
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Analyze and Solve Real-World Machine Design Problems Using SI Units

Mechanical Design of Machine Components, Second Edition: SI Version strikes a balance between method and theory, and fills a void in the world of design. Relevant to mechanical and related engineering curricula, the book is useful in college classes, and also serves as a reference for practicing engineers. This book combines the needed engineering mechanics concepts, analysis of various machine elements, design procedures, and the application of numerical and computational tools. It demonstrates the means by which loads are resisted in mechanical components, solves all examples and problems within the book using SI units, and helps readers gain valuable insight into the mechanics and design methods of machine components.

The author presents structured, worked examples and problem sets that showcase analysis and design techniques, includes case studies that present different aspects of the same design or analysis problem, and links together a variety of topics in successive chapters. SI units are used exclusively in examples and problems, while some selected tables also show U.S. customary (USCS) units. This book also presumes knowledge of the mechanics of materials and material properties.

New in the Second Edition:

  • Presents a study of two entire real-life machines
  • Includes Finite Element Analysis coverage supported by examples and case studies
  • Provides MATLAB solutions of many problem samples and case studies included on the book’s website
  • Offers access to additional information on selected topics that includes website addresses and open-ended web-based problems

Class-tested and divided into three sections, this comprehensive book first focuses on the fundamentals and covers the basics of loading, stress, strain, materials, deflection, stiffness, and stability. This includes basic concepts in design and analysis, as well as definitions related to properties of engineering materials. Also discussed are detailed equilibrium and energy methods of analysis for determining stresses and deformations in variously loaded members. The second section deals with fracture mechanics, failure criteria, fatigue phenomena, and surface damage of components. The final section is dedicated to machine component design, briefly covering entire machines. The fundamentals are applied to specific elements such as shafts, bearings, gears, belts, chains, clutches, brakes, and springs.


"This is a well-written and organized book. It is suitable for use in the classroom; and, should prove to be a valuable aid to a design/analytical engineer."

—Richard E. Dippery, Kettering University, Flint, Michigan, USA

"A valuable textbook for students who are interested in applying basic mechanics of materials knowledge to real-world problems. … quite comprehensive."

—Yong Zhu, North Carolina State University, Raleigh, USA

Table of Contents



Scope of the Book

Mechanical Engineering Design

Design Process

Design Analysis

Problem Formulation and Computation

Factor of Safety and Design Codes

Units and Conversion

Loading Classes and Equilibrium

Free-Body Diagrams and Load Analysis

Case Studies in Engineering

Work, Energy, and Power

Stress Components

Normal and Shear Strains




Material Property Definitions

Static Strength

Hooke’s Law and Modulus of Elasticity

Generalized Hooke’s Law

Volume Change

Thermal Stress–Strain Relations

Temperature and Stress–Strain Properties

Moduli of Resilience and Toughness

Dynamic and Thermal Effects


Processes to Improve Hardness and the Strength of Metals

General Properties of Metals

General Properties of Nonmetals

Selecting Materials


Stress and Strain


Stresses in Axially Loaded Members

Direct Shear Stress and Bearing Stress

Thin-Walled Pressure Vessels

Stress in Members in Torsion

Shear and Moment in Beams

Stresses in Beams

Design of Beams

Plane Stress

Combined Stresses

Plane Strain

Measurement of Strain; Strain Rosette

Stress-Concentration Factors

Importance of Stress-Concentration Factors in Design

Three-Dimensional Stress

Equations of Equilibrium for Stress

Strain–Displacement Relations: Exact Solutions


Deflection and Impact


Deflection of Axially Loaded Members

Angle of Twist of Shafts

Deflection of Beams by Integration

Beam Deflections by Superposition

Beam Deflection by the Moment-Area Method

Impact Loading

Longitudinal and Bending Impact

Torsional Impact

Bending of Thin Plates

Deflection of Plates by Integration


Energy Methods and Stability


Strain Energy in Common Members

Work–Energy Method

Castigliano’s Theorem

Statically Indeterminate Problems

Virtual Work Principle

Use of Trigonometric Series in Energy Methods

Buckling of Columns

Critical Stress in a Column

Initially Curved Columns

Eccentric Loads and the Secant Formula

Design Formulas for Columns


Energy Methods Applied to Buckling

Buckling of Rectangular Plates



Static Failure Criteria and Reliability


Introduction to Fracture Mechanics

Stress–Intensity Factors

Fracture Toughness

Yield and Fracture Criteria

Maximum Shear Stress Theory

Maximum Distortion Energy Theory

Octahedral Shear Stress Theory

Comparison of the Yielding Theories

Maximum Principal Stress Theory

Mohr’s Theory

Coulomb–Mohr Theory


Normal Distributions

Reliability Method and Margin of Safety


Fatigue Failure Criteria


Nature of Fatigue Failures

Fatigue Tests

S–N Diagrams

Estimating the Endurance Limit and Fatigue Strength

Modified Endurance Limit

Endurance Limit Reduction Factors

Fluctuating Stresses

Theories of Fatigue Failure

Comparison of the Fatigue Criteria

Design for Simple Fluctuating Loads

Design for Combined Fluctuating Loads

Prediction of Cumulative Fatigue Damage

Fracture Mechanics Approach to Fatigue


Surface Failure





Wear Equation

Contact-Stress Distributions

Spherical and Cylindrical Surfaces in Contact

Maximum Stress in General Contact

Surface-Fatigue Failure

Prevention of Surface Damage



Shafts and Associated Parts


Materials Used for Shafting

Design of Shafts in Steady Torsion

Combined Static Loadings on Shafts

Design of Shafts for Fluctuating and Shock Loads

Interference Fits

Critical Speed of Shafts

Mounting Parts

Stresses in Keys



Universal Joints


Bearings and Lubrication



Types of Journal Bearings

Forms of Lubrication

Lubricant Viscosity

Petroff’s Bearing Equation

Hydrodynamic Lubrication Theory

Design of Journal Bearings

Lubricant Supply to Journal Bearings

Heat Balance of Journal Bearings

Materials for Journal Bearings

Types and Dimensions of Rolling Bearings

Rolling Bearing Life

Equivalent Radial Load

Selection of Rolling Bearings

Materials and Lubricants of Rolling Bearings

Mounting and Closure of Rolling Bearings


Spur Gears


Geometry and Nomenclature


Gear Tooth Action and Systems of Gearing

Contact Ratio and Interference

Gear Trains

Transmitted Load

Bending Strength of a Gear Tooth: The Lewis Formula

Design for the Bending Strength of a Gear Tooth: The AGMA Method

Wear Strength of a Gear Tooth: The Buckingham Formula

Design for the Wear Strength of a Gear Tooth: The AGMA Method

Materials for Gears

Gear Manufacturing


Helical, Bevel, and Worm Gears


Helical Gears

Helical Gear Geometry

Helical Gear Tooth Loads

Helical Gear Tooth Bending and Wear Strengths

Bevel Gears

Tooth Loads of Straight Bevel Gears

Bevel Gear Tooth Bending and Wear Strengths

Worm Gearsets

Worm Gear Bending and Wear Strengths

Thermal Capacity of Worm Gearsets


Belts, Chains, Clutches, and Brakes



Belt Drives

Belt Tension Relationships

Design of V-Belt Drives

Chain Drives

Common Chain Types

Materials for Brakes and Clutches

Internal Expanding Drum Clutches and Brakes

Disk Clutches and Brakes

Cone Clutches and Brakes

Band Brakes

Short-Shoe Drum Brakes

Long-Shoe Drum Brakes

Energy Absorption and Cooling


Mechanical Springs


Torsion Bars

Helical Tension and Compression Springs

Spring Materials

Helical Compression Springs

Buckling of Helical Compression Springs

Fatigue of Springs

Design of Helical Compression Springs for Fatigue Loading

Helical Extension Springs

Torsion Springs

Leaf Springs

Miscellaneous Springs


Power Screws, Fasteners, and Connections


Standard Thread Forms

Mechanics of Power Screws

Overhauling and Efficiency of Power Screws

Ball Screws

Threaded Fastener Types

Stresses in Screws

Bolt Tightening and Preload

Tension Joints under Static Loading

Gasketed Joints

Determining the Joint Stiffness Constants

Tension Joints under Dynamic Loading

Riveted and Bolted Joints Loaded in Shear

Shear of Rivets or Bolts due to Eccentric Loading


Welded Joints Subjected to Eccentric Loading

Brazing and Soldering

Adhesive Bonding


Miscellaneous Machine Components


Basic Relations

Thick-Walled Cylinders under Pressure

Compound Cylinders: Press or Shrink Fits

Disk Flywheels

Thermal Stresses in Cylinders

Exact Stresses in Curved Beams

Curved Beam Formula

Circular Plates

Thin Shells of Revolution

Special Cases of Shells of Revolution

Pressure Vessels and Piping

Filament-Wound Pressure Vessels

Buckling of Cylindrical and Spherical Shells


Finite Element Analysis in Design


Bar Element

Formulation of the Finite Element Method

Beam Element

Two-Dimensional Elements

Triangular Element

Plane Stress Case Studies


Case Studies in Machine Design


Floor Crane with Electric Winch

High-Speed Cutter



Answers to Selected Problems


About the Authors

Ansel C. Ugural has been a visiting and research professor of mechanical engineering at the New Jersey Institute of Technology. He was a National Science Foundation fellow and has taught at the University of Wisconsin. Dr. Ugural held positions at Fairleigh Dickinson University and earned his MS in mechanical engineering and PhD in engineering mechanics from the University of Wisconsin–Madison. Professor Ugural is the author of several books, including Mechanical Design of Machine Components (CRC Press, 2nd ed., 2015); and Stresses in Beams, Plates, and Shells (CRC Press, 3rd ed., 2010). In addition, he has published numerous journal articles.

Subject Categories

BISAC Subject Codes/Headings:
SCIENCE / Mechanics / General
TECHNOLOGY & ENGINEERING / Industrial Design / General