ElementsOfMechanicalDesign PDF

Introduction
Elementary rules
Essentials of thought and procedure
Some practical advice
The Elements of Mechanical Design

J.G. Skakoon, ASME Press, New York, 2008
Dr. ir. F.L.M. Delbressine, TU/e
July 19, 2010
Introduction
Elementary rules
The only thing more expensive than education is

ignorance. Benjamin Franklin
Introduction
Elementary rules
Contents:
Elementary rules of mechanical design

Essentials of thought and procedure in mechanical design
Practical advice
References
Title
Introduction
Elementary rules
Elementary rules of mechanical design
Create designs that are explicitly simple
Keep the functions of a design independent
Use exact kinematic constraint design
Plan the load paths
Triangulate parts and structures to make them stiffer
Avoid bending stress
Improve designs with self-help
Manage friction in mechanisms
Contents
Introduction
Elementary rules
Create designs that are explicitly simple, keep complexity

intrinsic
Elementary rules
Introduction
Elementary rules
Keep the functions of a design independent from one

another
Introduction
Elementary rules
Locking function independent from locating function
Introduction
Elementary rules
Indepence of all functions
Elementary rules
Introduction
Elementary rules
Use exact kinematic constraint when designing structures

and mechanisms
Advantages exactly constrained compared to over-constrained
designs:
1
No binding
No play
Repeatable position
No internal stresses
Loose-tolerance parts
Easy assembly
Robustness to wear and environment
Introduction
Elementary rules
Overconstrained design
Introduction
Elementary rules
Basic theory of exact constraint
Introduction
Elementary rules
Exact kinematic constraint diagram
Introduction
Elementary rules
Exact constraint design example
Introduction
Elementary rules
2D Single constraint design example
Introduction
Elementary rules
2D plate 2 constraint example
Introduction
Elementary rules
2D plate fully constraint example
Introduction
Elementary rules
2D constraint examples
Introduction
Elementary rules
2D Overconstrained! (Form closed!)
Introduction
Elementary rules
Applying a nesting force
Introduction
Elementary rules
The nesting force window
Introduction
Elementary rules
Curvature and surface matching
Introduction
Elementary rules
Wobbling table
Introduction
Elementary rules
Elastic constraint design
Introduction
Elementary rules
Elastic constraint design
Elementary rules
Introduction
Elementary rules
Plan the load path in parts, structures and assemblies
Introduction
Elementary rules
You want the load path to be:
Short
Direct
In a line, or barring that, in a plane
Symmetric
Non-redundant, or barring that, elastic
Locally-closed
(Easily analyzed)
Introduction
Elementary rules
Load path
Introduction
Elementary rules
Locally-closed load path
Introduction
Elementary rules
Force flow lines
Elementary rules
Introduction
Elementary rules
Triangulate parts and structures to make them stiffer
Introduction
Elementary rules
Triangulate to obtain stiffness
Introduction
Elementary rules
Flange to obtain stiffness
Introduction
Elementary rules
Ribs to obtain stiffness
Introduction
Elementary rules
Tetrahedron: 3D triangulation
Elementary rules
Introduction
Elementary rules
Avoid bending stresses. Prefer tension and compression.
Introduction
Elementary rules
Optimal material use
Introduction
Elementary rules
Optimal material use
Introduction
Elementary rules
Shear stress
Introduction
Elementary rules
Flexibility needed use: bending or non-uniform torsional

loads
Elementary rules
Introduction
Elementary rules
Improve designs with self-help
Use applied loads to improve performance:

Create new, useful forces
Transform or redirect themselves
Balance either themselves or existing loads
Help to distribute loads
Introduction
Elementary rules
Self-help that creates forces
Introduction
Elementary rules
Self-help that redirects forces
Introduction
Elementary rules
Self-help that balances forces
Introduction
Elementary rules
Self-help that distributes loads
Elementary rules
Introduction
Elementary rules
Manage friction in mechanisms
Avoid sliding friction

Maximize the length of linearly guided components
Select rotary motion over linear motion
Use rolling element bearings whenever possible
Use flexures to eliminate friction
Introduction
Elementary rules
Avoid sliding friction
Introduction
Elementary rules
Linear guided system (overconstraint design)
Introduction
Elementary rules
Use rolling elements bearing
Introduction
Elementary rules
Select rotary motion over linear motion
Introduction
Elementary rules
Use flexures to eliminate friction
Elementary rules
Introduction
Elementary rules
Essentials of thought and procedure in mechanical design

Use 3D solid models layouts
Early ideation stage: use sketches
Invert geometry to reveal new solutions
Apply inversion
Build prototypes of everything
Separate strength from stiffness
Never overlook buckling phenomena
Analyze and test for trends and relationships
Identify contingency plans
Contents
Introduction
Elementary rules
Use 3D solid models layouts
As an aid to thinking
For communicating design ideas
SOLID modelling why?

Exceptional visualization
Continuity of effort
Unambiguous communication
Introduction
Elementary rules
3D solid modelling
Essential thoughts
Introduction
Elementary rules
Early ideation stage: use sketches
Essential thoughts
Introduction
Elementary rules
Invert geometry to reveal new solutions
Formal techniques to generate needs, requirements, and concepts

Quality Function Deployment
Brainstorming
TRIZ
Particularly useful thought process: Inversion What happens if
I flip things around, or over, or inside-out?
Essential thoughts
Introduction
Elementary rules
Inversion
Inside outside
Right left
Above below
Symmetric asymmetric
In-line offset
Smaller larger
Parallel normal
Oblique normal or parallel
Concentric eccentric
Moving stationary
Introduction
Elementary rules
Inversion cont.
Pressure vacuum
axial radial
flat curved
bolt nut
peg hole
stiff elastic
translating rotating
2-dimensional 3D
Mirror about a plane
Introduction
Elementary rules
Inversion example
Essential thoughts
Introduction
Elementary rules
Build prototypes of everything but not all at once
Essential thoughts
Introduction
Elementary rules
Separate strength from stiffness
Strength is how much load causes yielding or breaking. If

something fails it is not strong enough! (y )
Stiffness, or rigidity, defines how much something deforms
when load is applied. (E )
If something does not break, do not assume it is stiff enough for its
purpose!
Essential thoughts
Introduction
Elementary rules
Never overlook buckling phenomena

Catastrophic failures of man-made objects are often caused by
buckling.
Essential thoughts
Introduction
Elementary rules
Analyze and test for trends and relationships
Essential thoughts
Introduction
Elementary rules
Identify contingency plans to minimize risks in design
Include as part of your design process :

a review for anything that could go awry;
anticipate possible failures and
identify corrections
Do not limit your definition of failure to hazards include:
Function, robustness, production, service, and life
Essential thoughts
Introduction
Elementary rules
Avoid press fits

Used closed sections or 3D bracing for torsional rigidity
When designing springs use: ...
Minimize and localize the tolerance path in parts and
assemblies
Include lead-ins in assembled designs
Design assembles to be . . .
Contents
Introduction
Elementary rules
Avoid press fits
Are overconstrained
Require tight tolerances
Generate uncontrolled friction
Create assembly stress
Are hard to assemble
Introduction
Elementary rules
Alternatives for press fits
Elastic fits
Snap fits
Tapered fits
Introduction
Elementary rules
Elastic fits as alternatives
Introduction
Elementary rules
Snap fit as alternative
Introduction
Elementary rules
Tapered fits
Practical advice
Introduction
Elementary rules
Used closed sections or 3D bracing for torsional rigidity
Practical advice
Introduction
Elementary rules
3D bracing for torsional rigidity
Practical advice
Introduction
Elementary rules
When designing springs use:

A low spring rate and
A high initial deflection
Why: Springs exert force and store energy!
Introduction
Elementary rules
Load-deflection diagram
Introduction
Elementary rules
Example
Introduction
Elementary rules
Why low spring rates?
Practical advice
Introduction
Elementary rules
Minimize and localize the tolerance path in parts and

assemblies
Introduction
Elementary rules
Tolerancing
Practical advice
Introduction
Elementary rules
Use mechanical amplification to reduce failures

An amplifier is any device that uses a small amount of something
to control a larger amount
Practical advice
Introduction
Elementary rules
Include lead-ins in assembled designs
The tapered end provides three functions:

Starting, or spearing the parts together
Aligning to the desired final position
Directing the applied force
Practical advice
Introduction
Elementary rules
Design assemblies to be:
Self-locating
Self-fixturing
Self-securing
Self-aligning
Self-adjusting
Self-assembling
Introduction
Elementary rules
Self locating & self-fixturing
Introduction
Elementary rules
Self-aligning
Introduction
Elementary rules
Self adjusting
Introduction
Elementary rules
Use self assembling symmetry
Introduction
Elementary rules
Identical halves
Introduction
Elementary rules
Feature detail
Practical advice
Introduction
Elementary rules
References
J.G. Skakoon, The Elements of Mechanical Design, ASME

Press, New York, 2008.

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Introduction

The Elements of Mechanical Design

July 19, 2010

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

The only thing more expensive than education is

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Elementary rules of mechanical design

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Elementary rules of mechanical design

Create designs that are explicitly simple

Keep the functions of a design independent

Use exact kinematic constraint design

Plan the load paths

Triangulate parts and structures to make them stiffer

Avoid bending stress

Improve designs with self-help

Manage friction in mechanisms

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Create designs that are explicitly simple, keep complexity

The Elements of Mechanical Design

Keep the functions of a design independent from one

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Locking function independent from locating function

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Indepence of all functions

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Use exact kinematic constraint when designing structures

Robustness to wear and environment

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Basic theory of exact constraint

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Exact kinematic constraint diagram

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Exact constraint design example

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

2D Single constraint design example

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

2D plate 2 constraint example

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

2D plate fully constraint example

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

2D Overconstrained! (Form closed!)

Dr. ir. F.L.M. Delbressine, TU/e

The Elements of Mechanical Design

Applying a nesting force