Engineers' Data Book

Clifford Mathews is an experienced engineer with worldwide knowledge of mechanical engineering.

• Foreword xi Preface xiiiIntroduction – The Role of Technical Standards xvSection 1: Engineering Careers 11.1 Introduction: what is an engineer? 11.2 A rough guide to industry breakdown 31.3 Training and professional development 41.4 Degrees of (engineering) excellence 51.5 Degrees and how to pass them 91.6 Do you have any . . . experience? 121.7 Final cut – job interviews 14Section 2: Units 182.1 The Greek alphabet 182.2 Units systems 192.3 Units and conversions 212.4 Consistency of units 322.5 Dimensional analysis 362.6 Essential engineering mathematics 382.7 Maths and the real world? 40Section 3: Engineering Design – Process and Principles 493.1 Engineering problem-solving 493.2 Problem types and methodologies 493.3 Design principles 513.4 The engineering design process 523.5 Design as a systematic activity (the 'pugh' method) 533.6 The innovation model 533.7 Creativity tools 573.8 The product design specification (PDS) 583.9 Presenting technical information 603.10 The anatomy of mechanical design 793.11 Safety in design – principles and practice 893.12 Design by nature – project toucan 105Section 4: Basic Mechanical Design 1104.1 Engineering abbreviations 1104.2 Datums and tolerances – principles 1124.3 Toleranced dimensions 1134.4 General tolerances 1144.5 Holes 1154.6 Screw threads 1164.7 Limits and fits 1174.8 Surface finish 119Section 5: Motion 1225.1 Making sense of equilibrium 1225.2 Motion equations 1235.3 Newton's laws of motion 1245.4 Simple harmonic motion (SHM) 1255.5 Understanding acceleration 1265.6 Dynamic balancing 1265.7 Vibration 1285.8 Machine vibration 1295.9 Machinery noise 130Section 6: Deformable Body Mechanics 1336.1 Quick reference – mechanical notation 1336.2 Engineering structures – so where are all the pin joints? 1356.3 Simple stress and strain 1366.4 Simple elastic bending 1386.5 Slope and deflection of beams 1406.6 Torsion 1426.7 Thin cylinders 1456.8 Cylindrical vessels with hemispherical ends 1466.9 Thick cylinders 1476.10 Buckling of struts 1486.11 Flat circular plates 1496.12 Stress concentration factors 151Section 7: Material Failure 1557.1 How materials fail 1557.2 LEFM method 1567.3 Multi-axis stress states 1577.4 Fatigue 1587.5 Factors of safety 1617.6 United states practice 1617.7 Ultimate jigsaw – what everything is made of 162Section 8: Thermodynamics and Cycles 1668.1 Quick reference: symbols – thermodynamics 1668.2 Basic thermodynamic laws 1678.3 Entropy 1698.4 Enthalpy 1698.5 Other definitions 1708.6 Cycles 1708.7 The steam cycle 1728.8 Properties of steam 1728.9 Reference information 1758.10 The gas turbine (GT) cycle 175Section 9: Basic Fluid Mechanics and Aerodynamics 1789.1 Basic properties 1789.2 Flow equations 1809.3 Flow regimes 1869.4 Boundary layers 1899.5 Isentropic flow 1919.6 Compressible one-dimensional flow 1919.7 Normal shock waves 1929.8 Axisymmetric flows 1959.9 Drag coefficients 1959.10 General airfoil theory 1979.11 Airfoil coefficients 1989.12 Pressure distributions 2009.13 Aerodynamic centre 2009.14 Centre of pressure 2019.15 Supersonic conditions 2029.16 Wing loading: semi-ellipse assumption 204Section 10: Fluid Equipment 20610.1 Turbines 20610.2 Refrigeration systems 20710.3 Diesel engines 20910.4 Heat exchangers 21010.5 Centrifugal pumps 21210.6 Impeller types 214Section 11: Pressure Vessels 21611.1 Vessel codes and standards 21611.2 Pressure vessel design features 21911.3 Cylindrical pressure vessel design stresses 22011.4 Stress categories 22111.5 Analysis of stress combinations 22211.6 Vessel certification 22311.7 Flanges 223Section 12: Materials 22512.1 Observing crystals: order and disorder 22512.2 Carbon steels 22612.3 Low-alloy steels 22712.4 Alloy steels 22712.5 Cast iron (CI) 22812.6 Stainless steels 23012.7 Non-ferrous alloys 23312.8 Nickel alloys 23312.9 Zinc alloys 23412.10 Copper alloys 23412.11 Aluminium alloys 23512.12 Titanium alloys 23612.13 Engineering plastics 23712.14 Material traceability and documentation 23812.15 Corrosion 239Section 13: Machine Elements 24413.1 Screw fasteners 24413.2 Bearings 24713.3 Ball and roller bearings 24813.4 Bearing lifetime 24913.5 Coefficient of friction 25013.6 Gear trains 25113.7 Seals 25413.8 Shaft couplings 25713.9 Cam mechanisms 25913.10 Clutches 26113.11 Pulley mechanisms 26413.12 Drive types 266Section 14: Quality Assurance and Quality Control 26714.1 Quality assurance: ISO 9001: 2008 26714.2 Quality system certification 26814.3 The ISO 9001 standard 26914.4 Taguchi methods 27114.5 Statistical process control (SPC) 27214.6 Normal distribution 27214.7 The binomial and poisson distributions 27414.8 Reliability 27414.9 Improving design reliability: main principles 27714.10 'Design for reliability' – a new approach 278Section 15: Project Engineering 28115.1 Project planning 28115.2 Critical path analysis (CPA) 28215.3 Planning with Gantt charts 28315.4 Rapid prototyping 28415.5 Value analysis 285Section 16: Welding 28616.1 Welding processes 28616.2 Weld types and orientation 28916.3 Welding symbols 29216.4 Welding defects 29516.5 Welding documentation 297Section 17: Non-Destructive Testing (NDT) 29917.1 Non-destructive testing acronyms 29917.2 Visual examination 30117.3 Dye penetrant (DP) testing 30117.4 Magnetic particle (MP) testing 30217.5 Ultrasonic testing (UT) 30317.6 Radiographic testing (RT) 313Section 18: Surface Protection 31818.1 Painting 31818.2 Galvanizing 32018.3 Chrome plating 32018.4 Rubber linings 321Section 19: Metallurgical Terms 324