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Contents

Preface ....................................................................................................................................... ix

Introduction ................................................................................................................................. xi

Section 1. Ingenious Mechanisms .......................................................................................

1-1

1.1

Modified Geneva Drives and Special Mechanisms ...........................................................

1-2

1.2

Overriding Spring Mechanisms for Low-torque Drives ......................................................

1-4

1.3

10 Ways to Amplify Mechanical Movements .....................................................................

1-6

1.4

10 Ways to Amplify Mechanical Action .............................................................................

1-8

1.5

How to Damp Axial and Rotational Motion ........................................................................ 1-10

1.6

Make Diaphragms Work for You ....................................................................................... 1-12

1.7

4 Ways to Eliminate Backlash ........................................................................................... 1-14

1.8

4 More Ways to Prevent Backlash .................................................................................... 1-16

1.9 Limit-switch

Backlash

........................................................................................................ 1-18

Section 2. Creative Assemblies ...........................................................................................

2-1

2.1

Rotary Piston Engine ......................................................................................................... 2-2

2.2

Milk Transfer System ......................................................................................................... 2-3

2.3

Hydraulic Motor ................................................................................................................. 2-4

2.4

Slash Errors with Sensitive Balance ..................................................................................

2-5

2.5

Control-locked Thwart Vibration and Shock ......................................................................

2-6

2.6

1-way Output from Speed Reducers .................................................................................

2-8

2.7

Torque-limiters Protect Light-duty Drives .......................................................................... 2-10

2.8

6 Ways to Prevent Overloading ......................................................................................... 2-12

2.9

7 More Ways to Prevent Overloading ............................................................................... 2-14

2.10

7 Ways to Limit Shaft Rotation .......................................................................................... 2-16

2.11

Devices for Indexing or Holding Mechanical Movements .................................................. 2-18

2.12 Saw-matic

Mechanism

...................................................................................................... 2-19

2.13

Piping Assembly for Sewage Lift Station Control Vault ..................................................... 2-20

2.14

Water Bike ......................................................................................................................... 2-21

Section 3. Linkages ..............................................................................................................

3-1

3.1

8 Basic Push-pull Linkages ............................................................................................... 3-2

3.2

5 Linkages for Straight-line Motion ....................................................................................

3-4

3.3

10 Ways to Change Straight-line Direction .......................................................................

3-6

3.4

9 More Ways to Change Straight-line Direction ................................................................

3-8

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3.5

Linkage for Accelerating and Decelerating Linear Strokes ............................................... 3-10

3.6

Linkages for Multiplying Short Motions .............................................................................. 3-12

3.7

Seven Popular Types of Three-dimensional Drives .......................................................... 3-14

3.8

Power Thrust Linkages and Their Applications ................................................................. 3-18

3.9

Toggle Linkage Applications in Different Mechanisms ...................................................... 3-20

3.10

Four-bar Linkages and Typical Industrial Applications ..................................................... 3-22

Section 4. Connections ........................................................................................................

4-1

4.1

14 Ways to Fasten Hubs to Shafts ....................................................................................

4-2

4.2 At

taching Hubless Gears to Shafts ................................................................................... 4-4

4.3

10 Different Types of Splined Connections .......................................................................

4-6

4.4

Alternates for Doweled Fasteners .....................................................................................

4-8

4.5

6 More Alternates for Doweled Fastenings ....................................................................... 4-10

4.6

29 Ways to Fasten Springs ............................................................................................... 4-12

4.7

20 Tamper-proof Fasteners ............................................................................................... 4-16

4.8

Lanced Metal Eliminates Separate Fasteners ................................................................... 4-18

4.9

Joining Circular Parts without Fasteners ........................................................................... 4-20

Section 5. Locking Devices & Methods ..............................................................................

5-1

5.1

Friction Clamping Devices ................................................................................................. 5-2

5.2

Retaining and Locking Detents .........................................................................................

5-4

5.3

How Spring Clamps Hold Workpieces ..............................................................................

5-6

5.4

Holding Fixture for Workpiece ...........................................................................................

5-8

5.5

15 Ways to Fasten Gears to Shafts ..................................................................................

5-9

5.6

8 Control Mountings .......................................................................................................... 5-14

5.7

8 Interlocking Sheetmetal Fasteners ................................................................................. 5-16

5.8

Fastening Sheet-metal Parts by Tongues, Snaps, or Clinching ........................................ 5-18

5.9

Snap Fasteners for Polyethylene ...................................................................................... 5-20

5.10

Snap Fasteners for Polystyrene ........................................................................................ 5-22

Section 6. Gears & Gearing ..................................................................................................

6-1

6.1

Nomenclature of Gears ..................................................................................................... 6-2

6.2

Graphical Representation of Gear Dimensions .................................................................

6-4

6.3

Worksheet Streamlines Bevel-gear Calculations ..............................................................

6-6

6.4

Alignment Chart for Face Gears ........................................................................................

6-8

6.5

Power Capacity of Spur Gears .......................................................................................... 6-10

6.6

Linear to Angular Conversion of Gear-tooth Index Error ................................................... 6-13

6.7

Checklist for Planetary-gear Sets ...................................................................................... 6-14

6.8

Epicyclic Gear Trains ........................................................................................................ 6-16

6.9

Cycloid Gear Mechanisms ................................................................................................ 6-18

6.10

Cardan-gear Mechanisms ................................................................................................. 6-25

6.11

Typical Methods of Providing Lubrication for Gear Systems ............................................. 6-27

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Section 7. Clutches ...............................................................................................................

7-1

7.1

Basic Types of Mechanical Clutches .................................................................................

7-2

7.2

Construction Details of Overriding Clutches ......................................................................

7-4

7.3

10 Ways to Apply Overrunning Clutches ...........................................................................

7-6

7.4

Low-cost Designs for Overrunning Clutches .....................................................................

7-8

7.5

Small Mechanical Clutches for Precise Service ................................................................ 7-10

7.6 Centrifugal

Clutches

.......................................................................................................... 7-12

7.7

Serrated Clutches and Detents ......................................................................................... 7-16

7.8

Spring Bands Grip Tightly to Drive Overrunning Clutch .................................................... 7-18

7.9

Accurate Solution for Disk-clutch Torque Capacity ........................................................... 7-19

7.10

Spring-loaded Pins Aid Sprags in One-way Clutch ........................................................... 7-20

7.11

Rolling-type Clutch ............................................................................................................ 7-20

Section 8. Chains, Sprockets & Ratchets ...........................................................................

8-1

8.1

History of Chains ............................................................................................................... 8-2

8.2

Ingenious Jobs for Roller Chain ........................................................................................

8-4

8.3

Bead Chains for Light Service ...........................................................................................

8-8

8.4

Methods for Reducing Pulsations in Chain Drives ............................................................ 8-10

8.5

Lubrication of Roller Chains .............................................................................................. 8-12

8.6

Sheet Metal Gears, Sprockets, Worms & Ratchets .......................................................... 8-14

8.7

Ratchet Layout Analyzed .................................................................................................. 8-16

8.8

No Teeth Ratchets ............................................................................................................ 8-18

8.9

One-way Drive Chain Solves Problem of Sprocket Skip ................................................... 8-20

Section 9. Belts & Belting ....................................................................................................

9-1

9.1

Ten Types of Belt Drives ................................................................................................... 9-2

9.2

Find the Length of Open and Closed Belts .......................................................................

9-4

9.3 Get

ting in Step with Hybrid Belts ....................................................................................... 9-6

9.4

Equations for Computing Creep in Belt Drives .................................................................. 9-10

9.5

Mechanisms for Adjusting Tension of Belt Drives ............................................................. 9-14

9.6

Leather Belts-hp Loss and Speeds ................................................................................... 9-16

Section 10. Shafts & Couplings ............................................................................................. 10-1

10.1

Overview of Shafts & Couplings ........................................................................................ 10-2

10.2

Critical Speeds of End Supported Bare Shafts ................................................................. 10-5

10.3

Shaft Torque: Charts Find Equivalent Sections ................................................................ 10-6

10.4

Novel Linkage for Coupling Offset Shafts ......................................................................... 10-8

10.5

Coupling of Parallel Shafts ................................................................................................ 10-10

10.6

Low-cost Methods of Coupling Small Diameter Shafts ..................................................... 10-12

10.7

Typical Methods of Coupling Rotating Shafts I ................................................................. 10-14

10.8

Typical Methods of Coupling Rotating Shafts II ................................................................ 10-16

10.9

Typical Designs of Flexible Couplings I ............................................................................. 10-18

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10.10 Typical Designs of Flexible Couplings II ............................................................................ 10-20
10.11 Typical Designs of Flexible Couplings III ........................................................................... 10-22
10.12 Ten Universal Shaft Couplings .......................................................................................... 10-24
10.13 Novel Coupling Shifts Shafts ............................................................................................. 10-26

Section 11. Threaded Components ....................................................................................... 11-1

11.1

Getting the Most from Screws ........................................................................................... 11-2

11.2

20 Dynamic Applications for Screw Threads ..................................................................... 11-4

11.3

16 Ways to Align Sheets and Plates with One Screw ....................................................... 11-8

11.4

Various Methods of Locking Threaded Members .............................................................. 11-10

11.5

How to Provide for Backlash in Threaded Parts ................................................................ 11-12

11.6

7 Special Screw Arrangements ......................................................................................... 11-14

11.7

World of Self-locking Screws ............................................................................................. 11-16

Section 12. Pins ...................................................................................................................... 12-1

12.1

Slotted Spring Pins Find Many Jobs ................................................................................. 12-2

12.2

8 Unusual Jobs for Spring Pins ......................................................................................... 12-4

12.3

8 Electrical Jobs for Spring Pins ........................................................................................ 12-6

12.4

8 More Spring Pin Applications ......................................................................................... 12-8

12.5

Uses of Split Pins .............................................................................................................. 12-10

12.6

Design Around Spiral Wrapped Pins ................................................................................. 12-12

12.7

A Penny-wise Connector: the Cotter Pin ........................................................................... 12-14

12.8

Standards of Slotted-type Spring Pins .............................................................................. 12-16

12.9

Standards of Coiled-type Spring Pins ............................................................................... 12-17

12.10 Standards of Grooved Pins ............................................................................................... 12-18
12.11 Standards of Round-head Grooved Drive Studs ............................................................... 12-19
12.12 Standards of Grooved T-head Cotter Pins ........................................................................ 12-20
12.13 Standards of Cotter Pins ................................................................................................... 12-21
12.14 Pin and Shaft of Equal Strength ........................................................................................ 12-22

Section 13. Springs ................................................................................................................. 13-1

13.1

12 Ways to Put Springs to Work ....................................................................................... 13-2

13.2

Multiple Uses of Coil Springs ............................................................................................ 13-4

13.3

Control Depth Primer Tool Employs Coil Springs ............................................................. 13-6

13.4

One Spring Returns the Hand Lever ................................................................................. 13-8

13.5

6 More One Spring Lever Return Designs ........................................................................ 13-10

13.6

How to Stiffen Bellows with Springs .................................................................................. 13-12

13.7

Springs: How to Design for Variable Rate ......................................................................... 13-14

13.8

Adjustable Extension Springs ............................................................................................ 13-16

13.9

Compression Spring Adjustment Methods I ...................................................................... 13-18

13.10 Compression Spring Adjustment Methods II ..................................................................... 13-20
13.11 Flat Springs in Mechanisms .............................................................................................. 13-22

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13.12 Flat Springs Find More Work ............................................................................................. 13-24
13.13 Pneumatic Spring Reinforcement ...................................................................................... 13-26

Section 14. Cams .................................................................................................................... 14-1

14.1

Generating Cam Curves .................................................................................................... 14-2

14.2

Cams and Gears Team Up in Programmed Motion .......................................................... 14-9

14.3

Spherical Cams: Linking Up Shafts ................................................................................... 14-11

14.4

Modifications and Uses for Basic Types of Cams ............................................................. 14-14

14.5

Nomogram for Parabolic Cam with Radically Moving Follower ......................................... 14-16

Section 15. Grommets, Spacers & Inserts ............................................................................ 15-1

15.1

A Fresh Look at Rubber Grommets .................................................................................. 15-2

15.2

These Spacers Are Adjustable .......................................................................................... 15-4

15.3

Odd Jobs for Rubber Mushroom Bumpers ........................................................................ 15-6

15.4

Spacers Used in Jigs & Fixtures ....................................................................................... 15-8

15.5

Flanged Inserts Stabilize Multi-stroke Reloading Press .................................................... 15-9

15.6

Metal Inserts for Plastic Parts ............................................................................................ 15-10

15.7

How to Select Threaded Inserts ........................................................................................ 15-12

15.8

Applications of Helical Wire Inserts ................................................................................... 15-15

Section 16. Washers ............................................................................................................... 16-1

16.1

Ideas for Flat Washers ...................................................................................................... 16-2

16.2

Versatile Flat Washers ...................................................................................................... 16-4

16.3

Jobs for Flat Rubber Washers ........................................................................................... 16-6

16.4

Take Another Look at Serrated Washers .......................................................................... 16-8

16.5

Dished Washers Are Versatile Components ..................................................................... 16-10

16.6

Design Problems Solved with Belleville Spring Washers .................................................. 16-12

16.7

Creative Ideas for Cupped Washers ................................................................................. 16-14

16.8

SEM Applications .............................................................................................................. 16-16

16.9

SEM Standards Tables ..................................................................................................... 16-17

Section 17. O-rings ................................................................................................................. 17-1

17.1

8 Unusual Applications for O-rings .................................................................................... 17-2

17.2

16 Unusual Applications for the O-ring .............................................................................. 17-4

17.3

Look at O-rings Differently ................................................................................................. 17-6

17.4

O-rings Solve Design Problems I ...................................................................................... 17-8

17.5

O-rings Solve Design Problems II ..................................................................................... 17-10

17.6

7 More Applications for O-rings ......................................................................................... 17-12

17.7

Design Recommendations for O-ring Seals ...................................................................... 17-14

17.8

O-ring Seals for Pump Valves ........................................................................................... 17-16

Section 18. Retaining Rings ................................................................................................... 18-1

18.1

Comparisons of Retaining Rings versus Typical Fasteners .............................................. 18-2

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18.2

Retaining Rings Aid Assembly, I ....................................................................................... 18-4

18.3

Retaining Rings Aid Assembly, Il ...................................................................................... 18-6

18.4

Coupling Shafts with Retaining Rings ............................................................................... 18-8

18.5

The Versatile Retaining Ring ............................................................................................. 18-12

18.6

The Multiple-purpose Retaining Ring ................................................................................ 18-16

18.7

More Work for Round Retaining Rings .............................................................................. 18-18

18.8

Deflections of Perpendicularly Loaded Split Circular Rings .............................................. 18-20

18.9

Improve Design with Retaining Rings ............................................................................... 18-22

Section 19. Balls ..................................................................................................................... 19-1

19.1

12 Ways to Put Balls to Work ............................................................................................ 19-2

19.2

How Soft Balls Can Simplify Design .................................................................................. 19-4

19.3

Rubber Balls Find Many Jobs ........................................................................................... 19-6

19.4

Multiple Use of Balls in Milk Transfer System ................................................................... 19-8

19.5

Use of Balls in Reloading Press ........................................................................................ 19-10

19.6

Nine Types of Ball Slides for Linear Motion ...................................................................... 19-12

19.7

Stress on a Bearing Ball .................................................................................................... 19-14

19.8

Compact Ball Transfer Units ............................................................................................. 19-16

19.9

Classic Uses of Balls in Valves ......................................................................................... 19-17

Section 20. Bushings & Bearings .......................................................................................... 20-1

20.1

Going Creative with Flanged Bushings ............................................................................. 20-2

20.2

Seven Creative Ideas for Flanged Rubber Bushings ........................................................ 20-5

20.3

Rotary-linear Bearings ....................................................................................................... 20-7

20.4

Unusual Applications of Miniature Bearings ...................................................................... 20-8

20.5

Rolling Contact Bearing Mounting Units ............................................................................ 20-10

20.6

Eleven Ways to Oil Lubricate Ball Bearings ...................................................................... 20-12

20.7

Lubrication of Small Bearings ............................................................................................ 20-14

20.8

Cage Keeps Bearings in Line and Lubricated ................................................................... 20-16

Index ..........................................................................................................................................

I-1

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