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Design Data Data Book of_Engineers_By PSG Coll.pdf
- 2. CONTENTS MATERIALS Physical Properties. Metals I.S.Designation of Steel & Al Meehanite Castings. Properties C.I. Casting. Properties & Uses Spheroidal graphite & Grey Iron Castings. Properties High Tensile Cast Steel. Carbon Steel Casting. Properties Steel Casting for high pr & High Temp Corrosion Resistant. Heat Resistant Steel Castings Carbon Steel. Composition & Properties Carbon Steel. Typical Uses Carbon Steel. Properties Structural Steel. Strength Alloy Steel. Composition & Properties Free Cutting Steel. Composition & Properties Alloy Steel. Uses Alloy Steel. Properties Tool Steel. Hardness Tool Steel Composition Tool Steel Uses Steels. IS and their Equivalents Brasses. Bronze :Composition & Properties Bearing Alloys. Composition Bearing Alloys Uses & Pouring Temp Die Casting Steel. Composition & Uses Aluminium. Composition Aluminium Alloys. Characteristics & Uses Cast Al Alloys. Composition & Properties Cast Al Alloys. Charecteristics & Uses Hardness Number Related to Tensile Strength Gear Materials Plastics. Properties Endurance Limits of Metals HEAT TREATMENT Iron Carbon Equilibrium Diagram Structural Consituents of Iron-Carbon Alloys Choice of Annealing Treatments T T T Diagram & HardenabiIity Curves. EN 8 & C 4.0 EN 9 & C 55 EN24&40Ni2Cr 1 Mo_28 Salt Mixtures. Composition and Heating Time Annealing & Hot Working Temp. Metals Hardening & Tempering of Carbon & Alloy Steels Colour-coding of Heated Steel. during Tempering Hardness vs % Carbon. Gearing Hardening Surface Hardness thro' Induction Hardening. Grinding Allowance & Case Depth for Gears . :. Heat, Treatment - Application Progressive Induction Tempering Solid Carburiser, Liquid Nitriding. Nitriding Salts Heat Treatment - Aluminium Alloys Stress Relieving Temp, Copper Alloys, defects ii1 Heat Treatment FITS AND TOLERANCE Machining and Surface Roughness Symbols
- 3. Obtainable Surface Roughness LetterSymbol & IT Grades of Tolerances Running & Sliding Fits Location. Transition & Interference Fits Recommended Machining Process for Grades of Holes Tolerance Table Shaft Holes Mean and Variation of Fits Geometric Tolerances -do - Symbols ROLLING ELEMENT BEARING Types of Bearings Bearing Calculations - Ball & Roller Needle Equivalent Bearing Load Bearing Life - Recommended Nomogram, CIP, Ball Bearing -do- Roller Bearing Selection of Fit on Shafts -do-on Housing Tolerance on Inner Race. Radial Bearing Tolerance on Outer Race Deep Groove Ball Bearings. 60 Series Deep Groove Ball Bearings. 62 Deep Groove Ball Bearings. 63 Deep Groove Ball Bearings. 64 Self Aligning ball bearing. 22 Self Aligning ball bearing. 23 Angular Contact ball bearing. 72 Angular Contact ball bearing. 73 Double row angular contact. 33 Roller Bearings N U 22 Roller Bearings NU 23 Double Row Roller Bearing NN 30K Series Double Row Roller Bearing NNU 49 Taper Roller Bearing 322 Series Taper Roller Bearing 323 Thrust Bearing 512 Thrust Bearing 513 Double Thrust Bearing 522 Double Thrust Bearing 523 Thrust Bearing with Spherical Housing 532U Series Spherical Roller Bearing 222C Series Needle Bearing NA49 Needle Bearing NA69 Needle Bearing RNA49 & 69 Combined Needle Thrust Roller Bearing, NKXR Series Flat Cages Bearing Proportions STANDARDS It STANDARD COMPONENTS Centre Holes Threaded Centre Holes Circlip, External, Type-A. Clrclip, Internal, Type B Circlip, External. Type C Cylindrical Pin
- 4. Solid and SplitTaper Pin Threaded Taper Pin Parallel Key Tangential Key Gib Head Key Taper Key Woodruff Key Keys for Machine Tools Retaining & Jacking Screws for Key Rivet Proportions Straight sided splines Straight sided splines for m/c tools Involute sided splines Self Holding Taper Shanks External Self Holding Taper Shanks Internal Self Holding Taper Shanks External With Tang Threads for Bolts & Nuts Pipe Threads Bolt & Screw ends Thread Runout &·Undercut, External Thread Runout & Undercut. Internal Bolts, Screws. Nuts & Locknuts Countersunk Screws " Square Head Bolts & Nuts SIotted Grub Screws Hex. Socket Grub Screw Socket Head Cap Screw Studs Interference Fit, Thread ISO Metric Screw. Tolerance Trapezoidal Thread Square Thread Slotted Nut Castle Nut Cap Nut Domed Cap Nut Pitch-diam combination for ISO Metric Screw Ring Nuts Locking Washer T Slots. T Nuts T Slotted Tables Washers Relief Grooves Swing Clamp end locating plug Round and diamond locating pin Round and diamond locating stud Strap. Clamp. C Washer Set collars Vee Locator Dovetail Proportions Jig-Button. Feet Nut - Feet Button. Locating Pin Jig Bushes Knurled Plain & Tommy Nuts Handle Grip Screw and Wing Screw Pressure pad and Disc Screws for Pressure Pad. Lock Dog Cam Lever Spherical Washer and Conical Seat Ball Grip. Cap. Lever Rod Equalizer Clamp. Turning Head
- 5. Oil Seals O-Rings L TypeSpindle Nose All Types Spindle Nose Cam Lock Type Spindle Nose 7/24 Taper for Type Spindle Nose Draw Bolt End 7/24 Taper for Tool Shanks Foot Mounted Motor Flange Mounted Motor Rolled Steel. Angles Rolled Steel. I Section Rolled Steel. Channel Rolled Steel. Tee MECHANICS Properties of Sections Curved Beam Cantilever Beam Simply Supported Beam Fixed Beam Propped Beam Columns Vibration. Linear Vibration. Torsional Critical Speed Forced Vibration with Damping Natural Frequency Constants of Beams Thick Cylinders Rotating Discs AngIe of Twist and Shear Stress for Sections Bending of Circular Plate Bending of Noncircular Plate Bending of Rectangular Plate Thermal Stress in Plates, Buckling of Plates & Tubes Beams on elastic supports Membrane Stresses Location of Shear Centre MACHINE ELEMENTS Static Stresses Failure Theories Varying Stresses Allowable Stress. Variable Load Stress Concentration Factors Contact Stress Preferred Numbers Shaft Nomogram for Shaft Design (Twisting) Nomogram for Shaft design (Bending) Cylindrical Shaft Ends Short Tapered Shaft Ends Lubricants, Properties Journal Bearing Material Selection Hydrodynamic journal Bearing Hydrostatic Bearing Fluid Power Symbols Hydrostatic Air Bearings
- 6. Flat Belts Flat BeltPulley Vee Belts Vee Grooved Pulley Roller Chain Drive Chain Wheel Rim Geneva Mechanism Ratchet and Pawl Power Screws Clutch Multiple Plate Unidirectional Clutch Safety Clutch Claw Clutch Brakes Coil Springs Leaf Spring Spring Steel, Properties Flange couplings Cams Polydyne Cams Forces on Cams Displacement and Acceleration Expressions Coupling. Design Fly Wheel Connecting Rod Crankshaft Riveted Joint Bolted Joint Shoe Brake Torsion Spring Spiral Spring GEARS Gear Nomenclature Basic Rack Peripheral Speed. Backlash & Standard Gear Ratios Gear, Material. Selection Design Stresses. Gear Selection of Number of Teeth on Gears for Standard Ratios Gear ,Design Formulae & Tables Gear Geometry Gear Correction: Charts Formulae Specific Sliding & Contact Ratio Involute Functions Nomogram: Selection of Module & Face width of Spur Gears Tolerance on Centre Distance Gear Inspection Data BEVEL GEAR Nomenclature (Straight & Spiral) WORM GEAR Lewis & Buckingham Equations for Spur For helical Bevel & Worm SKEW Gear Gear Forces Reduction Gear Boxes Proportions of Large Gears Non Circular Gears
- 7. MATERIALS HANDLING Wire Ropes& Drums Hoisting Gear Proportions. Drum Groove. Sprocket for Chain Standard Sheave Grooves Point Hooks Trolley & EOT Crane Speeds for EOT Cranes Brakes for Cranes Belt Conveyor Bucket Elevator Screw Conveyor Pneumatic Conveyor CASTING Test Requirements of Grey Iron Castings Properties of unalloyed Cast Iron based on Equivalent Carbon Pattern. Materials & Shrinkage Allowance Draft Angle and General Tolerance on Castings Machining Allowances. Coloring & Marking of Patterns Minimum Section of Casting Selection of Casting Process Moulding Sand. Properties Cores. Permanent Moulds Selection of Melting Furnace Cupola Operation Casting Defects & Remedies Wall Thickness and Maximum Length of Casting Casting Design. Proportions Rules in Casting Design WELDING Weld;Symbols Stress Formulae Weld Design Data Weld Treated as a line Edge Preparation Choice of Process IS Classification of covered electrodes A WS Classification of covered electrodes Selection of covered electrodes MIG Welding TIG Welding Gas Welding Gas Cutting Gas Welding. Ferrous Metals Spot Welding MACHINING Formulae for Power and Cutting Forces Standard Spindle Speeds for mlc Tools Standard Feeds Single point Tool Geometry Tool Angles. HSS Tool Angles. Carbide Carbide Tool Classification Speeds and Feeds. Turning
- 8. Speeds and Feeds.Plannin Speeds and Feeds. Trepanning Speeds and Feeds. Boring Tool Life Nomograms Drill Geometry Speeds and Feeds. Drilling Speeds. Reaming Machine Tapping Dies for Threading Geometry. Milling Cutter Speeds in Milling Speeds in Broaching Speeds; Hacksaw Cutting and Bandsaw Cutting Designation of Grinding Wheels Speeds and Feeds. Cyl. Grinding Tool Grinding Speeds and feeds. Hobbing METAL FORMING Sheet and Wire Gauge 2 Pillar Die Set Rect. Work Area 2 Pillar Die Circular Work Area Diagonal Pillar Set Rectangular Work Area 4 Pillar Die Set. Rect. Area Die Plate Proportions Effect of Clearance on Tool Life Punch-Die Clearance Blanking Layout Application Diagram for Press Blanking. Nomogram Sheet Penetration and Trimming Allowance Deep. Drawing and Redrawing Nomogram Drawing Speed HId Ratio in Deep Drawing Deep Drawing. Rect. Box Deep Drawing. Cyl. Cup Blank Holder Force. Drawing. Nomogram Draw Die Details 90° Bend Allowance V& U Bending. Nomogram 90° Bend Allowance. Alum. Alloys. Ironing Steel Plates Bend Limit and Bend Radii, Steel Sheets Stamping and Coining. Nomogram Impact Extrusion. Nomogram Forging. Nomogram Lubricants for Press Work LIMIT GAUGES Limits and Allowances on Gauges Formulae for Gauge Dimensions Gauge Tolerance for Checking Holes Gauge Tolerance for Checking Shafts Recommended Types of Gauges