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Contents

Foreword xi Preface xiii Introduction The Role of Technical Standards xv Section 1: Engineering Careers 1 1.1 Introduction: what is an engineer? 1 1.2 A rough guide to industry breakdown 3 1.3 Training and professional development 4 1.4 Degrees of (engineering) excellence 5 1.5 Degrees and how to pass them 9 1.6 Do you have any ... experience? 12 1.7 Final cut job interviews 14 Section 2: Units 18 2.1 The Greek alphabet 18 2.2 Units systems 19 2.3 Units and conversions 21 2.4 Consistency of units 32 2.5 Dimensional analysis 36 2.6 Essential engineering mathematics 38 2.7 Maths and the real world? 40 Section 3: Engineering Design Process and Principles 49 3.1 Engineering problem-solving 49 3.2 Problem types and methodologies 49 3.3 Design principles 51 3.4 The engineering design process 52 3.5 Design as a systematic activity (the 'pugh' method) 53 3.6 The innovation model 53 3.7 Creativity tools 57 3.8 The product design specification (PDS) 58 3.9 Presenting technical information 60 3.10 The anatomy of mechanical design 79 3.11 Safety in design principles and practice 89 3.12 Design by nature project toucan 105 Section 4: Basic Mechanical Design 110 4.1 Engineering abbreviations 110 4.2 Datums and tolerances principles 112 4.3 Toleranced dimensions 113 4.4 General tolerances 114 4.5 Holes 115 4.6 Screw threads 116 4.7 Limits and fits 117 4.8 Surface finish 119 Section 5: Motion 122 5.1 Making sense of equilibrium 122 5.2 Motion equations 123 5.3 Newton's laws of motion 124 5.4 Simple harmonic motion (SHM) 125 5.5 Understanding acceleration 126 5.6 Dynamic balancing 126 5.7 Vibration 128 5.8 Machine vibration 129 5.9 Machinery noise 130 Section 6: Deformable Body Mechanics 133 6.1 Quick reference mechanical notation 133 6.2 Engineering structures so where are all the pin joints? 135 6.3 Simple stress and strain 136 6.4 Simple elastic bending 138 6.5 Slope and deflection of beams 140 6.6 Torsion 142 6.7 Thin cylinders 145 6.8 Cylindrical vessels with hemispherical ends 146 6.9 Thick cylinders 147 6.10 Buckling of struts 148 6.11 Flat circular plates 149 6.12 Stress concentration factors 151 Section 7: Material Failure 155 7.1 How materials fail 155 7.2 LEFM method 156 7.3 Multi-axis stress states 157 7.4 Fatigue 158 7.5 Factors of safety 161 7.6 United states practice 161 7.7 Ultimate jigsaw what everything is made of 162 Section 8: Thermodynamics and Cycles 166 8.1 Quick reference: symbols thermodynamics 166 8.2 Basic thermodynamic laws 167 8.3 Entropy 169 8.4 Enthalpy 169 8.5 Other definitions 170 8.6 Cycles 170 8.7 The steam cycle 172 8.8 Properties of steam 172 8.9 Reference information 175 8.10 The gas turbine (GT) cycle 175 Section 9: Basic Fluid Mechanics and Aerodynamics 178 9.1 Basic properties 178 9.2 Flow equations 180 9.3 Flow regimes 186 9.4 Boundary layers 189 9.5 Isentropic flow 191 9.6 Compressible one-dimensional flow 191 9.7 Normal shock waves 192 9.8 Axisymmetric flows 195 9.9 Drag coefficients 195 9.10 General airfoil theory 197 9.11 Airfoil coefficients 198 9.12 Pressure distributions 200 9.13 Aerodynamic centre 200 9.14 Centre of pressure 201 9.15 Supersonic conditions 202 9.16 Wing loading: semi-ellipse assumption 204 Section 10: Fluid Equipment 206 10.1 Turbines 206 10.2 Refrigeration systems 207 10.3 Diesel engines 209 10.4 Heat exchangers 210 10.5 Centrifugal pumps 212 10.6 Impeller types 214 Section 11: Pressure Vessels 216 11.1 Vessel codes and standards 216 11.2 Pressure vessel design features 219 11.3 Cylindrical pressure vessel design stresses 220 11.4 Stress categories 221 11.5 Analysis of stress combinations 222 11.6 Vessel certification 223 11.7 Flanges 223 Section 12: Materials 225 12.1 Observing crystals: order and disorder 225 12.2 Carbon steels 226 12.3 Low-alloy steels 227 12.4 Alloy steels 227 12.5 Cast iron (CI) 228 12.6 Stainless steels 230 12.7 Non-ferrous alloys 233 12.8 Nickel alloys 233 12.9 Zinc alloys 234 12.10 Copper alloys 234 12.11 Aluminium alloys 235 12.12 Titanium alloys 236 12.13 Engineering plastics 237 12.14 Material traceability and documentation 238 12.15 Corrosion 239 Section 13: Machine Elements 244 13.1 Screw fasteners 244 13.2 Bearings 247 13.3 Ball and roller bearings 248 13.4 Bearing lifetime 249 13.5 Coefficient of friction 250 13.6 Gear trains 251 13.7 Seals 254 13.8 Shaft couplings 257 13.9 Cam mechanisms 259 13.10 Clutches 261 13.11 Pulley mechanisms 264 13.12 Drive types 266 Section 14: Quality Assurance and Quality Control 267 14.1 Quality assurance: ISO 9001: 2008 267 14.2 Quality system certification 268 14.3 The ISO 9001 standard 269 14.4 Taguchi methods 271 14.5 Statistical process control (SPC) 272 14.6 Normal distribution 272 14.7 The binomial and poisson distributions 274 14.8 Reliability 274 14.9 Improving design reliability: main principles 277 14.10 'Design for reliability' a new approach 278 Section 15: Project Engineering 281 15.1 Project planning 281 15.2 Critical path analysis (CPA) 282 15.3 Planning with Gantt charts 283 15.4 Rapid prototyping 284 15.5 Value analysis 285 Section 16: Welding 286 16.1 Welding processes 286 16.2 Weld types and orientation 289 16.3 Welding symbols 292 16.4 Welding defects 295 16.5 Welding documentation 297 Section 17: Non-Destructive Testing (NDT) 299 17.1 Non-destructive testing acronyms 299 17.2 Visual examination 301 17.3 Dye penetrant (DP) testing 301 17.4 Magnetic particle (MP) testing 302 17.5 Ultrasonic testing (UT) 303 17.6 Radiographic testing (RT) 313 Section 18: Surface Protection 318 18.1 Painting 318 18.2 Galvanizing 320 18.3 Chrome plating 320 18.4 Rubber linings 321 Section 19: Metallurgical Terms 324

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