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1、精选优质文档-倾情为你奉上附录英文原文Mechanical Design and Manufacturing Processes Mechanical design is the application of science and technology to devise new or improved products for the purpose of satisfying human needs. It is a vast field of engineering technology which not only concerns itself with the original
2、conception of the product in terms of its size, shape and construction details, but also considers the various factors involved in the manufacture, marketing and use of the product. People who perform the various functions of mechanical design are typically called designers, or design engineers. Mec
3、hanical design is basically a creative activity. However, in addition to being innovative, a design engineer must also have a solid background in the areas of mechanical drawing, kinematics, dynamics, materials engineering, strength ofmaterials and manufacturing processes. As stated previously, the
4、purpose of mechanical design is to produce a product which will serve a need for man. Inventions, discoveries and scientific knowledge by themselves do not necessarily benefit people; only if they are incorporated into a designed product will a benefit be derived. It should be recognized, therefore,
5、 that a human need must be identified before a particular product is designed. Mechanical design should be considered to be an opportunity to use innovative talents to envision a design of a product, to analyze the system and then make sound judgments on how the product is to be manufactured. It is
6、important to understand the fundamentals of engineering rather than memorize mere facts and equations. There are no facts or equations which alone can be used to provide all the correct decisions required to produce a good design.On the other hand, any calculations made must be done with the utmost
7、care and precision. For example, if a decimal point is misplaced, an otherwise acceptable design may not function.Good designs require trying new ideas and being willing to take a certain amount of risk, knowing that if the new idea does not work the existing method can be reinstated. Thus a designe
8、r must have patience, since there is no assurance of success for the time and effort expended. Creating a completely new design generally requires that many old and well-established methods be thrust aside. This is not easy since many people cling to familiar ideas, techniques and attitudes. A desig
9、n engineer should constantly search for ways to improve an existing product and must decide what old, proven concepts should be used and what new, untried ideas should be incorporated. New designs generally have bugs or unforeseen problems which must be worked out before the superior characteristics
10、 of the new designs can be enjoyed. Thus there is a chance for a superior product, but only at higher risk.It should be emphasized that,if a design does not warrant radical new methods, such methods should not be applied merely for the sake of change. During the beginning stages of design, creativit
11、y should be allowed to flourish without a great number of constraints.Even though many impractical ideas may arise, it is usually easy to eliminate them in the early stages of design before firm details are required by manufac- turing. In this way, innovative ideas are not inhibited. Quite often, mo
12、re than one design is developed, up to the point where they can be compared against each other.It is entirely possible that the design which is ultimately accepted will use ideas existing in one of the rejected designs that did not show as much overall promise. Psychologists frequently talk about tr
13、ying to fit people to the machines they operate. It is essentially the responsibility of the design engineer to strive to fit machines to people. This is not an easy task, since there is really no average person for which certain operating dimensions and procedures are optimum. Another important poi
14、nt which should be recognized is that a design engineer must be able to communicate ideas to other people if they are to be incorporated. Communicating the design to others is the final, vital step in the design process. Undoubtedly many great designs, inventions, and creative works have been lost t
15、o mankind simply because the originators were unable or unwilling to explain their accomplishments to others. Presentation is a selling job. The engineer, when presenting a new solution to administrative, management, or supervisory persons, is attempting to sell or to prove to them that this solutio
16、n is a better one. Unless this can be done successfully, the time and effort spent on obtaining the solution have been largely wasted. Basically, there are only three means of communication available to us. These are the written, the oral, and the graphical forms. Therefore the successful engineer w
17、ill be technically competent and versatile in all three forms of communication. A technically competent person who lacks ability in any one of these forms is severely handicapped.If ability in all three forms is lacking, no one will ever know how competent that person is! The competent engineer shou
18、ld not be afraid of the possibility of not succeeding in a presentation. In fact, occasional failure should be expected because failure or criticism seems to accompany every really creative idea. There is a great deal to be learned from a failure,and the greatest gains are obtained by those willing
19、to risk defeat. In the final analysis, the real failure would lie in deciding not to make the presentation at all. To communicate effectively, the following questions must be answered: (1) Does the design really serve a human need? (2) Will it be competitive with existing products of rival companies
20、? (3) Is it economical to produce? (4) Can it be readily maintained? (5) Will it sell and make a profit? Only time will provide the true answers to the preceding questions, but the product should be designed, manufactured and marketed only with initial affirmative answers. The design engineer also m
21、ust communicate the finalized design to manufacturing through the use of detail and assembly drawings. Quite often, a problem will occur during the manufacturing cycle3. It may be that a change is required in the dimensioning or tolerancing of a part so that it can be more readily produced. This fai
22、ls in the category of engineering changes which must be approved by the design engineer so that the product function will not be adversely affected. In other cases, a deficiency in the design may appear during assembly or testing just prior to shipping. These realities simply bear out the fact that
23、design is a living process. There is always a better way to do it and the designer should constantly strive towards finding that better way. Designing starts with a need,real or imagined.Existing apparatus may need improvements in durability, efficiently, weight, speed, or cost. New apparatus may be
24、 needed to perform a function previously done by men, such as computation, assembly, or servicing. With the objective wholly or partly defined, the next step in design is the conception of mechanisms and their arrangements that will perform the needed functions.For this, freehand sketching is of gre
25、at value, not only as a record of ones thoughts and as an aid in discussion with others, but particularly for communication with ones own mind, as a stimulant for creative ideas. When the general shape and a few dimensions of the several components become apparent, analysis can begin in earnest.The
26、analysis will have as its objective satisfactory or superior performance, plus safety and durability with minimum weight,and a competitive east. Optimum proportions and dimensions will be sought for each critically loaded section,together with a balance between the strength of the several components
27、. Materials and their treatment will be chosen. These important objectives can be attained only by analysis based upon the principles of mechanics, such as those of statics for reaction forces and for the optimum utilization of friction; of dynamics for inertia, acceleration, and energy;of elasticit
28、y and strength of materials for stress and deflection; and of fluid mechanics for lubrication and hydrodynamic drives. Finally, a design based upon function and reliability will be completed, and a prototype may be built. If its tests are satisfactory, and if the device is to be produced in quantity
29、, the initial design will undergo certain modifications that enable it to be manufactured in quantity at a lower cost. During subsequent years of manufacture and service, the design is likely to undergo changes as new ideas are conceived or as further analysis based upon tests and experience indicat
30、e alterations. Sales appeal, customer satisfaction, and manufacture cost are all related to design, and ability in design is intimately involved in the success of an engineering venture. To stimulate creative thought, the following rules are suggested for the designer. 1. Apply ingenuity to utilize
31、desired physical properties and to control undesired ones. The performance requirements of a machine are met by utilizing laws of nature or properties of matter (e. g., flexibility, strength, gravity,inertia,buoyancy,centrifugal for, principles of the lever and inclined plane, friction, viscosity, f
32、luid pressure, and thermal expansion), also the many electrical, optical, thermal, and chemical phenomena. However, what may be useful in one application may be detrimental in the next. Flexibility is desired in valve springs but not in the valve camshaft; friction is desired at the clutch face but
33、not in the clutch bearing. Ingenuity in design should be applied to utilize and control thephysical properties that are desired and to minimize those that are not desired. 2. Provide for favorable stress distribute and stiffness with minimum weight. On components subjected to fluctuating stress, par
34、ticular attention is given to a reduction in stress concentration, and to an increase of strength at fillets, threads, holes, and fits. Stress reduction are made by modification in shape, and strengthening may be done by prestressing treatments such as surface rolling and shallow hardening. Hollow s
35、hafts and tubing, and box sections give a favorable stress distribution, together with stiffness and minimum weight. Sufficient stiffness to maintain alignment and uniform pressure between contacting surfaces should be provided for crank, cam, and gear shafts, and for enclosures and frames containin
36、g bearing supports. The stiffness of shafts and other components must be suitable to avoid resonant vibrations. 3. Use &zsic equations to calculate and optimize dimensions.The fundamental equations of mechanics and the other sciences are the accepted bases for calculations. They are sometimes rearra
37、nged in special forms to facilitate the determination or optimization of dimensions, such as thebeam and surface stress equations for determining gear-tooth size. Factors may be added to a fundamental equation for conditions not analytically determinable, e. g. , on thin steel tubes, an allowance fo
38、r corrosion added to the thickness based on pressure. When it is necessary to apply a fundamental equation to shapes, materials, or conditions which only approximate the assumptions for its derivation, it is done in a manner which gives results on the safe side. In situations where data are incomple
39、te, equations of the sciences may be used as proportioning guides to extend a satisfactory design to new capacities. 4.Choose materials for a combination of properties. Materials should be chosen for a combination of pertinent properties, not only for strengths, hardness, and weight, but sometimes f
40、or resistance to impact, corrosion, and low or high temperatures. Cost and fabrication properties are factors, such as weld ability, machine ability, sensitivity to variation in heat-treating temperatures, and required coating. 5. Select carefully between stock and integral components. A previously
41、developed components is frequently selected by a designer and his company from the stocks of parts manufacturers, if the component meet the performance and reliability requirements and is adaptable without additional development costs to the particular machine being designed.However, its selection s
42、hould be carefully made with a full knowledge of its propcrties, since the reputation and liability of the company suffer if there is a failure in any one of the machines parts. In other eases the strength, reliability, and cost requirements are better met if the designer of the machine also designs
43、 the component, with the particular advantage of compactness if it is designs integral with other components, e. g., gears to be forged in clusters or integral with a shaft. 6. Provide for accurate location and non interference of parts in assembly. A good design provides for the correct locating of
44、 parts and for easy assembly and repair. Shoulders and pilot surfaces give accurate location without measurement during assembly. Shapes can be designed so that parts cannot be assembled backwards or in the wrong place. Interferences, as between screws in tapped holes, and between linkages must he f
45、oreseen and pretended. Inaccurate alignment and positioning between such assemblies must be avoided, or provision must be made to minimize any resulting detrimental displacements and stresses.The human race has distinguished itself from all other forms of life by using tools and intelligence to crea
46、te items that serve to make life easier and more enjoyable. Through the centuries, both the tools and the energy sources to power these tools have evolved to meet the increasing sophistication and complexity of mankinds ideas. In their earliest forms, tools primarily consisted of stone instruments.
47、Considering tile relative simplicity of the items being made and the materials being shaped, stone was adequate. When iron tools were invented, durable metals and more sophisticated articles could be produced. The twentieth century has seen the creation of products made from themost durable and, con
48、sequently, the most unmachinable materials in history. In an effort to meet the manufacturing challenges created by these materials, tools have now evolved to include materials such as alloy steel, carbide, diamond, and ceramics. A similar evolution has taken place with the methods used to power our
49、 tools. Initially, tools were powered by muscles; either human or animal. However as the powers of water, wind, steam, and electricity were harnessed, mankind was able to further extended manufacturing capabilities with new machines, greater accuracy, and faster machining rates. Every time new tools, tool materials, and power sources are utilized, the efficiency and capabilities of manufacturers are greatly enhanced. However as old problems are solved, new problems