Machine design

https://archive.org/details/MachineDesign Albert w. smith 1905

https://archive.org/details/ECL-255 Peter Sawchuck is required to design a two-speed gear box for a cold rolling mill coiler. He undertakes the design of a one-off unit that will satisfy the requirements. The basic gear design is governed by AGMA specs, but the remaining components are governed by reliability and economic considerations. This case study is part of the American Society for Engineering Education (ASEE) Engineering Case Library (ECL), which can be downloaded in full as a 300mb zip file. The Engineering Case Program originated at Stanford University in 1964 with the support of the National Science Foundation. The catalog was maintained by Rose-Hulman Institute of Technology and Carleton University. It continues under the sponsorship of the Design in Engineering Education Division (DEED) of the ASEE.


 * https://archive.org/details/engineeringcaselibraryasee Engineering cases from ASEE

Machinery's reference series
Machinery's reference series from the The Industrial press


 * https://archive.org/details/bevelgearing00flanrich 'Machinery's reference series' https://archive.org/search.php?query=creator%3A%22Flanders%2C+Ralph+E.+%28Ralph+Edward%29%2C+1880-1970%22  , Rules and formulas for designing spiral gears, by R.E. Flanders.--Diagrams for designing spiral gears, by F.J. Bostock.--Herringbone gears.--Calculating gears for generating spirals on hobbing machines, by G. Muffly.--The setting of the table when milling spiral gears, by G.W. Burley  ,  First principles of gearing.--Formulas for dimensions of spur gears, by A.B. Babbitt.--Internal spur gears, by R.E. Flanders.--Strength and durability of spur gears, by R.E. Flanders.--Design of spur gearing, by R.E. Flanders.--Variation of the strength of gear teeth with the velocity, by R.E. Flanders.--Simplified formulas for the strength of gears, by C.R. Whittier  https://archive.org/details/spiralgearing00flanrich (worm gear construction) is nr.6 Machinery's reference series no.6
 * https://archive.org/details/machinerysrefer03unkngoog Worm gearing by Flanders
 * https://archive.org/details/wormgearing00newyrich Worm gearing Flanders, Location of pitch circle, Hindley worm and gear, design of self-locking worm gears (C.F. Blake)
 * https://archive.org/details/bevelgearing00flanrich Bevel gearing
 * https://openlibrary.org/publishers/The_Industrial_press The Industrial press  153 books on machine element design, published "Machinery's reference series".
 * https://openlibrary.org/works/OL3717391W/Hobs_and_gear_hobbing gear hobbing, https://archive.org/details/spurgearing00babbrich spur gears, https://archive.org/details/machinerysrefer03unkngoog die casting, https://openlibrary.org/works/OL5357102W/Mechanisms_and_mechanical_movements  Mechanisms and mechanical movements


 * https://openlibrary.org/works/OL16748368W/The_extrusion_of_metals extrusion of pipes

mrpete22
https://www.youtube.com/watch?v=Dipd0ohrYzg
 * Brown and sharp tools publisher,
 * Machinery's handbook, Chicago gear works

Design tutorials
http://www.bostongear.com/pdf/gearology/all_gearology-chapters.pdf

http://engineeronadisk.com/notes_mechanic/gearsa5.html Pitch diameter, number of teeth


 * Formulas in Gearing and Practical Treatise on Gearing, published by Brown & Sharpe Mfg. co., by Providence, R.I  https://archive.org/details/formulasingeari00progoog ,
 * https://archive.org/details/practicaltreati01rigoog ''Practical treatise on gearing" referenced by Flanders book "Worm Gearing" Only reference found that explains the precise construction of worm gear Pd, throat etc.

https://archive.org/download/machinedesignam00grifgoog/machinedesignam00grifgoog.pdf  gears p.119

Trade journals
https://archive.org/download/canmachinery1907toro/canmachinery1907toro.pdf Canadian machinery and metalworking (January-December 1907) trade practice articles on shaping of cutting tools

Books and Papers Dudley, D.W., 1984. Handbook of Practical Gear Design. McGraw Hill. Maitra, G.M., 1994. Handbook of Gear Design, second ed. Tata McGraw Hill. Norton, R.L., 2006. Machine Design, third ed. Pearson. Radzevich, S.P., 2012. Dudley’s gear handbook of practical gear design and manufacture, 2nd ed. CRC Press. Shigley, J.E., 1986. Mechanical Engineering Design, first metric ed. McGraw Hill. Further Reading Shigley, J.E., Mischke, C.R., Budynas, R.G., 2004. Mechanical Engineering Design, seventh ed. McGraw Hill. Townsend, D.P., 1992. Dudley’s Gear Handbook, second ed. McGraw Hill. Standards AGMA Design manual for cylindrical wormgearing. ANSI/AGMA Standard 6022-C93. Reaffirmed 2008. AGMA Practice for enclosed cylindrical wormgear speed reducers and gearmotors. ANSI/AGMA Standard 6034-B92. Reaffirmed 2005. BS 721-1:1963. Specification for worm gearing. Imperial units. BS 721-2:1983. Specification for worm gearing. Metric units. BS ISO TR 10828:1997. Worm gears. Geometry of worm profiles. PD ISO/TR 14521:2010. Gears. Calculation of load capacity of wormgears. Web Sites At the time of going to press the world-wide-web contained useful information relating to this chapter at the following sites: www.ashokaengineering.com/ www.bandhgears.co.uk www.bellgears.co.uk www.bostongear.com/products/open/worms.html www.brentwingearcompany.co.uk www.davall.co.uk www.delroyd.com www.gearcutting.com www.gearmanufacturer.net/ www.girard-transmissions.com www.hewitt-topham.co.uk/ www.hopwoodgear.com www.hpcgears.com www.huco.com www.mmestrygears.com www.muffettgears.co.uk/ www.qtcgears.com/ www.rarodriguez.co.uk www.traceygear.com www.wmberg.com

Steam engines
search for creator:"William Cawthorne Unwin" and machine design at archive.org https://archive.org/download/elementsmachine11unwigoog/elementsmachine11unwigoog.pdf, https://archive.org/download/elementsmachine09unwigoog/elementsmachine09unwigoog.pdf

gear hobbing
http://www.astronomyasylum.com/gears.html Hobbing large strip of aluminium cheaply for worm wheel. Telescope, astronomy. Large Aluminum Worm Gears Fabricated From Aluminum Strips
 * https://www.youtube.com/watch?v=7zMgJXMHcNs Sells plans for making own involute gear cutter by myfordboy

Shaft collars
http://www.andymark.com/Shaft-Items-s/481.htm

Universal joints, Bevel gears

 * http://www.abssac.co.uk/p/CURTIS+U+Joints/130/#.VbD44vkRG9c  hack this design
 * http://www.thingiverse.com/thing:112718/#comments threadless ball screw
 * http://www.youtube.com/watch?v=G5El9UynAFc Traxx company rc model
 * http://www.thingiverse.com/thing:392828 R2ZZ bearing type, see Ebay.
 * http://nathan-flynn.blogspot.com/2011/10/ball-sockets-armature-double-ball-joint.html

Youtube videos
https://www.youtube.com/watch?v=f2saYF_FLgA  DIY line boring tool

Links
http://www.mitcalc.com/en/download.htm gear calculation software

Foundry
http://www.practicalmachinist.com/vb/general/anyone-have-homemade-aluminum-foundry-r-cast-s-machinable-strength-237445/ The crucible material is important too- cannot use steel/iron pipe anywhere in the process, it will dramatically contaminate the aluminum, which is effectively a pretty good solvent for it when molten. Also consider how you're going to evaluate the alloy in your castings, which means probably you'll need to pour several molds per melt so you can cut up and test some, then repeat the process until the final alloy more or less conforms to some kind of spec adequate for the application.

For openers, use a metal of known alloy. One that has worked well is 713 (Tenzaloy™). After that are good foundry practices, degassing, keep iron away from the melt, good mold practices such as gating, risers and venting.

http://web.archive.org/web/20060214123826/http://www.aomevents.com/conferences/afi/papers/Taylor.pdf The Effect of Iron in Al-Si Casting Alloys

If you want to make a casting then you need a cast alloy. thus you melt castings, transmission cases, cylinder heads, etc. As previously stated it must be in a refractory lined vessel. DO NOT ADD OTHER CRAP. Cans and chips will burn up and create a lot of dross to be skimmed off. Sheet items, wire, etc will alter your alloy and likey prevent it from flowing and filling the mold. A layer of common table salt will reduce oxide formation. I'm sure it can be done but is it worth while? Is this an irreplaceable part?


 * http://alloyavenue.com/vb/forum.php Casting foundry discussion forum.
 * https://www.reddit.com/r/Metalfoundry/comments/37k7bb/aluminiumzinc_alloys_what_composition_gives_the/

Oxidation of melting metals
http://www.rsalloys.eu/cmsMateriali/produzioni/13/aluminium%20beriyllium%20master%20alloy.pdf Small quantities of beryllium, when introduced to magnesium and aluminum melts, provide substantial manufacturing benefits in terms of direct cost savings and pro- duct quality. When beryllium is added to the melt in small quantities much of it forms beryllium oxide. As a surface film, beryllium oxide creates a superior barrier to further oxidation. The improved barrier inhibits dross formation, limits magnesium ignition and improves metal yield. By preventing oxygen migration into the melt, the beryllium addition enhances metal cleanliness leading to improved mechanical properties and visual characteristics of the casting.

http://www.backyardmetalcasting.com/faq.html Can I use soda and/or beer cans as an aluminum source? Yes you can but there is a "trick" to using them successfully. Since the cans are so thin they easily burn and oxidize rather than melt. For this reason many people say they should not be used. But if you already have a good pool of molton aluminum in the crucible then the can can be melted efficiently by crushing them (top to bottom) and dropping them into the pool. If the dry cans are pushed below the pool's surface they will melt and be less likely to oxidise. This aluminum is almost pure (unlike car cyclinder heads which are alloys). So the metal will usually shrink more when cast. but it is extream;ly shiny making it good for small decorative castings.