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
