Mechanical Engineers’ Handbook Mechanical Engineers’Handbook Fourth Edition Design, Instrumentation, and Controls Edited by Myer Kutz Cover image: © denisovd / Thinkstock Cover design: Wiley This book is printed on acid-free paper. Copyright © 2014 by John Wiley & Sons, Inc. All rights reserved Published by John Wiley & Sons, Inc., Hoboken, New Jersey Published simultaneously in Canada No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, (978) 750–8400, fax (978) 646–8600, or on the web at www. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748–6011, fax (201) 748–6008, or online at www.com/go/permissions.
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Mechanical engineering–Handbooks, manuals, etc. Kutz, Myer, editor of compilation. TJ151 621–dc23 2014005952 Printed in the United States of America 10 9 8 7 6 5 4 3 2 1 To Arlene, Bill, Merrilyn, and Jayden Contents Preface ix Vision for the Fourth Edition xi Contributors xiii PART 1 DESIGN 1 1. Computer-Aided Design 3 Emory W.
Marangos, Sekar Sundararajan, and Technical Staff 2. Product Design for Manufacturing and Assembly 55 Gordon Lewis 3. Design-for-Environment Processes and Tools 75 Daniel P. Herrmann, and Peter A.
Design Optimization: An Overview 97 A. Ravi Ravindran and G. Total Quality Management in Mechanical System Design 125 B. Reliability in the Mechanical Design Process 149 B.
Product Design and Manufacturing Processes for Sustainability 177 I. Life-Cycle Design 207 Abigail Clarke and John K. Design for Maintainability 249 O. Geoffrey Okogbaa and Wilkistar Otieno 10.
Design for Remanufacturing Processes 301 Bert Bras 11. Design for Manufacture and Assembly with Plastics 329 James A. Design for Six Sigma: A Mandate for Competitiveness 341 James E. Engineering Applications of Virtual Reality 371 Wenjuan Zhu, Xiaobo Peng, and Ming C.
Physical Ergonomics 417 Maury A. Nussbaum and Jaap H. van Dieën vii viii Contents PART 2 INSTRUMENTATION, SYSTEMS, CONTROLS, AND MEMS 437 15. Electric Circuits 439 Albert J.
Signal Processing 579 John Turnbull 18. Data Acquisition and Display Systems 597 Philip C. Systems Engineering: Analysis, Design, and Information Processing for Analysis and Design 625 Andrew P. Mathematical Models of Dynamic Physical Systems 667 K.
Preston White Jr. Basic Control Systems Design 747 William J. General-Purpose Control Devices 805 James H. Kretschmann, Sujeet Chand, and Kazuhiko Yokoyama 23.
Neural Networks in Feedback Control Systems 843 K. Lewis, and Shuzhi Sam Ge 24. Mechatronics 895 Shane Farritor and Jeff Hawks 25. Introduction to Microelectromechanical Systems (MEMS): Design and Application 943 M.
Zaghloul Index 955 Preface The second volume of the fourth edition of the Mechanical Engineers’ Handbook is comprised of two parts: Part 1, Mechanical Design, with 14 chapters, and Part 2, Instrumentation, Sys- tems, Controls and MEMS, with 11 chapters. The mechanical design chapters were in Volume I in the third edition. Given the introduction of 6 new chapters, mostly on measurements, in Volume I in this edition, it made sense to move the mechanical design chapters to Volume II and to cull chapters on instrumentation to make way for the measurements chapters, which are of greater use to readers of this handbook. Moreover, the mechanical design chapters have been augmented with 4 chapters (updated as needed) from my book, Environmentally Con- scious Mechanical Design, thereby putting greater emphasis on sustainability.
The 4 chapters are Design for Environment, Life-Cycle Design, Design for Maintainability, and Design for Remanufacturing Processes. They flesh out sustainability issues that were covered in the third edition by only one chapter, Product Design and Manufacturing Processes for Sustainability. The other 9 mechanical design chapters all appeared in the third edition. Six of them have been updated.
In the second part of Volume 2, Instrumentation, Systems, Controls and MEMS, 5 of the 11 chapters were new to the third edition of the handbook, including the 3 chapters I labeled as “new departures”: Neural Networks in Control Systems, Mechatronics, and Introduc- tion to Microelectromechanical Systems (MEMS): Design and Application. These topics have become increasingly important to mechanical engineers in recent years and they are included again. Overall, 3 chapters have been updated for this edition. In addition, I brought over the Electric Circuits chapter from the fifth edition of Eshbach’s Handbook of Engineering Fun- damentals.
Readers of this part of Volume 2 will also find a general discussion of systems engineering; fundamentals of control system design, analysis, and performance modification; and detailed information about the design of servo actuators, controllers, and general-purpose control devices. All Volume 2 contributors are from North America. I would like to thank all of them for the considerable time and effort they put into preparing their chapters. ix Vision for the Fourth Edition Basic engineering disciplines are not static, no matter how old and well established they are.
The field of mechanical engineering is no exception. Movement within this broadly based disci- pline is multidimensional. Even the classic subjects, on which the discipline was founded, such as mechanics of materials and heat transfer, keep evolving. Mechanical engineers continue to be heavily involved with disciplines allied to mechanical engineering, such as industrial and manufacturing engineering, which are also constantly evolving.
Advances in other major dis- ciplines, such as electrical and electronics engineering, have significant impact on the work of mechanical engineers. New subject areas, such as neural networks, suddenly become all the rage. In response to this exciting, dynamic atmosphere, the Mechanical Engineers’ Handbook expanded dramatically, from one to four volumes for the third edition, published in November 2005. It not only incorporated updates and revisions to chapters in the second edition, pub- lished seven years earlier, but also added 24 chapters on entirely new subjects, with updates and revisions to chapters in the Handbook of Materials Selection, published in 2002, as well as to chapters in Instrumentation and Control, edited by Chester Nachtigal and published in 1990, but never updated by him.
The fourth edition retains the four-volume format, but there are several additional major changes. The second part of Volume I is now devoted entirely to topics in engineering mechan- ics, with the addition of five practical chapters on measurements from the Handbook of Mea- surement in Science and Engineering, published in 2013, and a chapter from the fifth edition of Eshbach’s Handbook of Engineering Fundamentals, published in 2009. Chapters on mechani- cal design have been moved from Volume I to Volumes II and III. They have been augmented with four chapters (updated as needed) from Environmentally Conscious Mechanical Design, published in 2007.
These chapters, together with five chapters (updated as needed, three from Environmentally Conscious Manufacturing, published in 2007, and two from Environmentally Conscious Materials Handling, published in 2009 ) in the beefed-up manufacturing section of Volume III, give the handbook greater and practical emphasis on the vital issue of sustainability. Prefaces to the handbook’s individual volumes provide further details on chapter additions, updates and replacements. The four volumes of the fourth edition are arranged as follows: Volume 1: Materials and Engineering Mechanics—27 chapters Part 1. Materials—15 chapters Part 2.
Engineering Mechanics—12 chapters Volume 2: Design, Instrumentation and Controls—25 chapters Part 1. Mechanical Design—14 chapters Part 2. Instrumentation, Systems, Controls and MEMS —11 chapters Volume 3: Manufacturing and Management—28 chapters Part 1. Manufacturing—16 chapters Part 2.
Management, Finance, Quality, Law, and Research—12 chapters xi xii Vision for the Fourth Edition Volume 4: Energy and Power—35 chapters Part 1: Energy—16 chapters Part 2: Power—19 chapters The mechanical engineering literature is extensive and has been so for a considerable period of time. Many textbooks, reference works, and manuals as well as a substantial num- ber of journals exist. Numerous commercial publishers and professional societies, particularly in the United States and Europe, distribute these materials. The literature grows continuously, as applied mechanical engineering research finds new ways of designing, controlling, mea- suring, making, and maintaining things, as well as monitoring and evaluating technologies, infrastructures, and systems.
Most professional-level mechanical engineering publications tend to be specialized, directed to the specific needs of particular groups of practitioners. Overall, however, the mechanical engineering audience is broad and multidisciplinary. Practitioners work in a variety of organizations, including institutions of higher learning, design, manufacturing, and consulting firms, as well as federal, state, and local government agencies. A rationale for a general mechanical engineering handbook is that every practitioner, researcher, and bureaucrat cannot be an expert on every topic, especially in so broad and multidisciplinary a field, and may need an authoritative professional summary of a subject with which he or she is not intimately familiar.
Starting with the first edition, published in 1986, my intention has always been that the Mechanical Engineers’ Handbook stand at the intersection of textbooks, research papers, and design manuals. For example, I want the handbook to help young engineers move from the college classroom to the professional office and laboratory where they may have to deal with issues and problems in areas they have not studied extensively in school. With this fourth edition, I have continued to produce a practical reference for the mechan- ical engineer who is seeking to answer a question, solve a problem, reduce a cost, or improve a system or facility. The handbook is not a research monograph.
Its chapters offer design tech- niques, illustrate successful applications, or provide guidelines to improving performance, life expectancy, effectiveness, or usefulness of parts, assemblies, and systems. The purpose is to show readers what options are available in a particular situation and which option they might choose to solve problems at hand. The aim of this handbook is to serve as a source of practical advice to readers. I hope that the handbook will be the first information resource a practicing engineer consults when faced with a new problem or opportunity—even before turning to other print sources, even officially sanctioned ones, or to sites on the Internet.
In each chapter, the reader should feel that he or she is in the hands of an experienced consultant who is providing sensible advice that can lead to beneficial action and results. Can a single handbook, even spread out over four volumes, cover this broad, interdisci- plinary field? I have designed the Mechanical Engineers’ Handbook as if it were serving as a core for an Internet-based information source.