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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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