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1MECHANICALDESIGNABSTRACTAMACHINEISACOMBINATIONOFMECHANISMSANDOTHERCOMPONENTSWHICHTRANSFORMS,TRANSMITSEXAMPLESAREENGINES,TURBINES,VEHICLES,HOISTS,PRINTINGPRESSES,WASHINGMACHINES,ANDMOVIECAMERASMANYOFTHEPRINCIPLESANDMETHODSOFDESIGNTHATAPPLYTOMACHINESALSOAPPLYTOMANUFACTUREDARTICLESTHATARENOTTRUEMACHINESTHETERM“MECHANICALDESIGN“ISUSEDINABROADERSENSETHAN“MACHINEDESIGN“TOINCLUDETHEIRDESIGNTHEMOTIONANDSTRUCTURALASPECTSANDTHEPROVISIONSFORRETENTIONANDENCLOSUREARECONSIDERATIONSINMECHANICALDESIGNAPPLICATIONSOCCURINTHEFIELDOFMECHANICALENGINEERING,ANDINOTHERENGINEERINGFIELDSASWELL,ALLOFWHICHREQUIREMECHANICALDEVICES,SUCHASSWITCHES,CAMS,VALVES,VESSELS,ANDMIXERSKEYWORDSMECHANICALDESIGNMECHANISMSDESIGNPROCESSTHEDESIGNPROCESSDESIGNINGSTARTSWITHANEEDREALEXISTINGAPPARATUSMAYNEEDIMPROVEMENTSINDURABILITY,EFFICIENCY,WEIGHT,SPEED,ORCOSTNEWAPPARATUSMAYBENEEDEDTOPERFORMAFUNCTIONPREVIOUSLYDONEBYMEN,SUCHASCOMPUTATION,ASSEMBLY,ORSERVICINGWITHTHEOBJECTIVEWHOLLYORPARTLYINTHEDESIGNPRELIMINARYSTAGE,SHOULDALLOWTODESIGNTHEPERSONNELFULLYTODISPLAYTHECREATIVITY,NOTEACHKINDOFRESTRAINTEVENIFHASHADMANYIMPRACTICALIDEAS,ALSOCANINTHEDESIGNEARLYTIME,NAMELYINFRONTOFTHEPLANBLUEPRINTISCORRECTEDONLYTHEN,ONLYTHENDOESNOTSENDTOSTOPSUPTHEINNOVATIONTHEMENTALITYUSUALLY,MUSTPROPOSESEVERALSETSOFDESIGNPROPOSALS,THENPERFORMTHECOMPARISONHASTHEPOSSIBILITYVERYMUCHINTHEPLANWHICHFINALLYDESIGNATED,HASUSEDCERTAINNOTINPLANSOMEIDEASWHICHACCEPTSWHENTHEGENERALSHAPEANDAFEWDIMENSIONSOFTHESEVERALCOMPONENTSBECOMEAPPARENT,ANALYSISCANBEGININEARNESTTHEANALYSISWILLHAVEASITSOBJECTIVESATISFACTORYORSUPERIORPERFORMANCE,PLUSSAFETYANDDURABILITYWITHMINIMUMWEIGHT,ANDACOMPETITIVECOSTOPTIMUMPROPORTIONSANDDIMENSIONSWILLBESOUGHTFOREACHCRITICALLYLOADEDSECTION,TOGETHERWITHABALANCEBETWEENTHESTRENGTHSOFTHESEVERALCOMPONENTSMATERIALSANDTHEIRTREATMENTWILLBECHOSENTHESEIMPORTANTOBJECTIVESCANBEATTAINEDONLYBYANALYSISBASEDUPONTHEPRINCIPLESOFMECHANICS,SUCHASTHOSEOFSTATICFORREACTIONFORCESANDFORTHEOPTIMUMUTILIZATIONOFFRICTIONOFDYNAMICSFORINERTIA,ACCELERATION,ANDENERGYOFELASTICITYANDSTRENGTHOFMATERIALSFORSTRESSANDDEFLECTIONOFPHYSICALBEHAVIOROFMATERIALSANDOFFLUIDMECHANICSFORLUBRICATIONANDHYDRODYNAMICDRIVESTHEANALYSESMAYBEMADEBYTHESAMEENGINEERWHOCONCEIVEDTHEARRANGEMENTOFMECHANISMS,OR,INALARGECOMPANY,THEYMAYBEMADEBYASEPARATEANALYSISDIVISIONORRESEARCHGROUPDESIGNISAREITERATIVEANDCOOPERATIVEPROCESS,WHETHERDONEFORMALLYORINFORMALLY,ANDTHEANALYSTCANCONTRIBUTETOPHASESOTHERTHANHISOWNPRODUCTDESIGNREQUIRESMUCHRESEARCHANDDEVELOPMENTMANYCONCEPTSOFANIDEAMUSTBESTUDIED,TRIED,ANDTHENEITHERUSEDORDISCARDEDALTHOUGHTHECONTENTOFEACHENGINEERINGPROBLEMISUNIQUE,THEDESIGNERSFOLLOWTHESIMILARPROCESSTOSOLVETHEPROBLEMSPRODUCTLIABILITYSUITSDESIGNERSANDFORCEDINMATERIALSELECTION,USINGTHEBESTPROGRAMINTHEPROCESSOFMATERIAL,THEMOSTCOMMONPROBLEMSFORFIVEADONTUNDERSTANDORNOTUSEABOUTTHELATESTAPPLICATION2MATERIALSTOTHEBESTINFORMATION,BFAILEDTOFORESEEANDCONSIDERTHEREASONABLEUSEMATERIALMAYSUCHASPOSSIBLE,DESIGNERSSHOULDFURTHERFORECASTANDCONSIDERDUETOIMPROPERUSEPRODUCTSINRECENTYEARS,MANYPRODUCTSLIABILITYINLITIGATION,THEUSEOFPRODUCTSANDHURTTHEPLAINTIFFACCUSEDMANUFACTURER,ANDWONTHEDECISION,COFTHEMATERIALSUSEDALLORSOMEOFTHEDATA,DATA,ESPECIALLYWHENTHEUNCERTAINTYLONGTERMPERFORMANCEDATAISSO,DQUALITYCONTROLMETHODISNOTSUITABLEANDUNPROVEN,EBYSOMECOMPLETELYINCOMPETENTPERSONSCHOOSEMATERIALSTHROUGHTOTHEABOVEFIVEQUESTIONSANALYSIS,MAYOBTAINTHESEQUESTIONSISDOESNOTHAVETHESUFFICIENTREASONEXISTENCETHECONCLUSIONMAYFORAVOIDTHESEQUESTIONSTOTHESEQUESTIONSRESEARCHANALYSESTHEAPPEARANCEINDICATINGTHEDIRECTIONALTHOUGHUSESTHEBESTCHOICEOFMATERIALMETHODNOTTOBEABLETOAVOIDHAVINGTHEPRODUCTRESPONSIBILITYLAWSUIT,DESIGNSTHEPERSONNELANDTHEINDUSTRYCARRIESONTHECHOICEOFMATERIALACCORDINGTOTHESUITABLEPROCEDURE,MAYGREATLYREDUCETHELAWSUITTHEQUANTITYMAYSEEFROMTHEABOVEDISCUSSION,THECHOICEMATERIALPEOPLESHOULDTOTHEMATERIALNATURE,THECHARACTERISTICANDTHEPROCESSINGMETHODHAVECOMPREHENSIVEANDTHEBASICUNDERSTANDINGFINALLY,ADESIGNBASEDUPONFUNCTION,ANDAPROTOTYPEMAYBEBUILTIFITSTESTSARESATISFACTORY,THEINITIALDESIGNWILLUNDERGOCERTAINMODIFICATIONSTHATENABLEITTOBEMANUFACTUREDINQUANTITYATALOWERCOSTDURINGSUBSEQUENTYEARSOFMANUFACTUREANDSERVICE,THEDESIGNISLIKELYTOUNDERGOCHANGESASNEWIDEASARECONCEIVEDORASFURTHERANALYSESBASEDUPONTESTSANDEXPERIENCEINDICATEALTERATIONSSALESAPPEALSOMERULESFORDESIGNINTHISSECTIONITISSUGGESTEDTHAT,APPLIEDWITHACREATIVEATTITUDE,ANALYSESCANLEADTOIMPORTANTIMPROVEMENTSANDTOTHECONCEPTIONANDPERFECTIONOFALTERNATE,PERHAPSMOREFUNCTIONAL,ECONOMICAL,ANDDURABLEPRODUCTSTOSTIMULATECREATIVETHOUGHT,THEFOLLOWINGRULESARESUGGESTEDFORTHEDESIGNERANDANALYSTTHEFIRSTSIXRULESAREPARTICULARLYAPPLICABLEFORTHEANALYST1ACREATIVEUSEOFNEEDOFPHYSICALPROPERTIESANDCONTROLPROCESS2RECOGNIZEFUNCTIONALLOADSANDTHEIRSIGNIFICANCE3ANTICIPATEUNINTENTIONALLOADS4DEVISEMOREFAVORABLELOADINGCONDITIONS5PROVIDEFORFAVORABLESTRESSDISTRIBUTIONANDSTIFFNESSWITHMINIMUMWEIGHT6USEBASICEQUATIONSTOPROPORTIONANDOPTIMIZEDIMENSIONS7CHOOSEMATERIALSFORACOMBINATIONOFPROPERTIES8SELECTCAREFULLY,STOCKANDINTEGRALCOMPONENTS9MODIFYAFUNCTIONALDESIGNTOFITTHEMANUFACTURINGPROCESSANDREDUCECOST10PROVIDEFORACCURATELOCATIONANDNONINTERFERENCEOFPARTSINASSEMBLYMACHINERYDESIGNCOVERSTHEFOLLOWINGCONTENTS1PROVIDESANINTRODUCTIONTOTHEDESIGNPROCESS,PROBLEMFORMULATION,SAFETYFACTORS2REVIEWSTHEMATERIALPROPERTIESANDSTATICANDDYNAMICLOADINGANALYSIS,3INCLUDINGBEAM,VIBRATIONANDIMPACTLOADING3REVIEWSTHEFUNDAMENTALSOFSTRESSANDDEFECTIONANALYSIS4INTRODUCESFATIGUEFAILURETHEORYWITHTHEEMPHASISONSTRESSLIFEAPPROACHESTOHIGHCYCLEFATIGUEDESIGN,WHICHISCOMMONLYUSEDINTHEDESIGNOFROTATIONMACHINERY5DISCUSSESTHOROUGHLYTHEPHENOMENAOFWEARMECHANISMS,SURFACECONTACTSTRESSES,ANDSURFACEFATIGUE6INVESTIGATESSHAFTDESIGNUSINGTHEFATIGUEANALYSISTECHNIQUES7DISCUSSESFLUIDFILMANDROLLINGELEMENTBEARINGTHEORYANDAPPLICATION8GIVESATHOROUGHINTRODUCTIONTOTHEKINEMATICS,DESIGNANDSTRESSANALYSISOFSPURGEARS,ANDASIMPLEINTRODUCTIONTOHELICAL,BEVEL,ANDWORMGEARING9DISCUSSESSPRINGDESIGNINCLUDINGCOMPRESSION,EXTENSIONANDTORSIONSPRINGS10DEALSWITHSCREWSANDFASTENERSINCLUDINGPOWERSCREWANDPRELOADFASTENERS11INTRODUCESTHEDESIGNANDSPECIFICATIONOFDISKANDDRUMCLUTCHESANDBRAKESMACHINEDESIGNTHECOMPLETEDESIGNOFAMACHINEISACOMPLEXPROCESSTHEMACHINEDESIGNISACREATIVEWORKPROJECTENGINEERNOTONLYMUSTHAVETHECREATIVITYINTHEWORK,BUTALSOMUSTINASPECTANDSOONMECHANICALDRAWING,KINEMATICS,ENGINEERIGMATERIAL,MATERIALSMECHANICSANDMACHINEMANUFACTURETECHNOLOGYHASTHEDEEPELEMENTARYKNOWLEDGEONEOFTHEFIRSTSTEPSINTHEDESIGNOFANYPRODUCTISTOSELECTTHEMATERIALFROMWHICHEACHPARTISTOBEMADENUMEROUSMATERIALSAREAVAILABLETOTODAYSDESIGNERSTHEFUNCTIONOFTHEPRODUCT,ITSAPPEARANCE,THECOSTOFTHEMATERIAL,ANDTHECOSTOFFABRICATIONAREIMPORTANTINMAKINGASELECTIONACAREFULEVALUATIONOFTHEPROPERTIESOFAMATERIALMUSTBEMADEPRIORTOANYCALCULATIONSCAREFULCALCULATIONSARENECESSARYTOENSURETHEVALIDITYOFADESIGNINCASEOFANYPARTFAILURES,ITISDESIRABLETOKNOWWHATWASDONEINORIGINALLYDESIGNINGTHEDEFECTIVECOMPONENTSTHECHECKINGOFCALCULATIONSANDDRAWINGDIMENSIONSISOFUTMOSTIMPORTANCETHEMISPLACEMENTOFONEDECIMALPOINTCANRUINANOTHERWISEACCEPTABLEPROJECTALLASPECTSOFDESIGNWORKSHOULDBECHECKEDANDRECHECKEDTHECOMPUTERISATOOLHELPFULTOMECHANICALDESIGNERSTOLIGHTENTEDIOUSCALCULATIONS,ANDPROVIDEEXTENDEDANALYSISOFAVAILABLEDATAINTERACTIVESYSTEMS,BASEDONCOMPUTERCAPABILITIES,HAVEMADEPOSSIBLETHECONCEPTSOFCOMPUTERAIDEDDESIGNCADANDCOMPUTERAIDEDMANUFACTURINGCAMHOWDOESTHEPSYCHOLOGISTFREQUENTLYDISCUSSCAUSESTHEMACHINEWHICHTHEPEOPLEADAPTSTHEMTOOPERATEDESIGNSPERSONNELSBASICRESPONSIBILITYISDILIGENTLYCAUSESTHEMACHINETOADAPTTHEPEOPLETHISCERTAINLYISNOTANEASYWORK,BECAUSECERTAINLYDOESNOTHAVETOALLPEOPLETOSAYINFACTALLISTHEMOSTSUPERIOROPERATINGAREAANDTHEOPERATINGPROCESSANOTHERIMPORTANTQUESTION,PROJECTENGINEERMUSTBEABLETOCARRYONTHEEXCHANGEANDTHECONSULTATIONWITHOTHERCONCERNEDPERSONNELINTHEINITIALSTAGE,DESIGNSTHEPERSONNELTOHAVETOCARRYONTHEEXCHANGEANDTHECONSULTATIONONTHEPRELIMINARYDESIGNWITHTHEADMINISTRATIVEPERSONNEL,ANDISAPPROVEDTHISGENERALLYISTHROUGHTHEORALDISCUSSION,THESCHEMATICDIAGRAMANDTHEWRITINGMATERIALCARRIESONIFFRONTSUES,THEMACHINEDESIGNGOALISTHEPRODUCTIONCANMEETTHEHUMANNEEDTHEPRODUCTTHEINVENTION,4THEDISCOVERYANDTECHNICALKNOWLEDGEITSELFCERTAINLYNOTNECESSARILYCANBRINGTHEADVANTAGETOTHEHUMANITY,ONLYHASWHENTHEYAREAPPLIEDCANPRODUCEONTHEPRODUCTTHEBENEFITTHUS,SHOULDREALIZETOCARRIESONBEFORETHEDESIGNINASPECIFICPRODUCT,MUSTFIRSTDETERMINEWHETHERTHEPEOPLEDONEEDTHISKINDOFPRODUCTMUSTREGARDASTHEMACHINEDESIGNISTHEMACHINEDESIGNPERSONNELCARRIESONUSINGCREATIVEABILITYTHEPRODUCTDESIGN,THESYSTEMANALYSISANDAFORMULATIONPRODUCTMANUFACTURETECHNOLOGYGOODOPPORTUNITYGRASPSTHEPROJECTELEMENTARYKNOWLEDGETOHAVETOMEMORIZESOMEDATAANDTHEFORMULAISMOREIMPORTANTTHANTHEMERELYSERVICEDATAANDTHEFORMULAISINSUFFICIENTTOTHECOMPLETELYDECISIONWHICHMAKESINAGOODDESIGNNEEDSONTHEOTHERHAND,SHOULDBEEARNESTPRECISELYCARRIESONALLOPERATIONSFOREXAMPLE,EVENIFPLACESWRONGADECIMALPOINTPOSITION,ALSOCANCAUSETHECORRECTDESIGNTOTURNWRONGLYAGOODDESIGNPERSONNELSHOULDDARETOPROPOSETHENEWIDEA,MOREOVERISWILLINGTOUNDERTAKETHECERTAINRISK,WHENTHENEWMETHODISNOTSUITABLE,USEORIGINALMETHODTHEREFORE,DESIGNSTHEPERSONNELTOHAVETOHAVETOHAVETHEPATIENCE,BECAUSESPENDSTHETIMEANDTHEENDEAVORCERTAINLYCANNOTGUARANTEEBRINGSSUCCESSFULLYABRANDNEWDESIGN,THEREQUESTSCREENABANDONSOBSOLETELYMANY,KNOWSVERYWELLTHEMETHODFORTHEPEOPLEBECAUSEMANYPERSONOFCONSERVATIVENESS,DOESTHISCERTAINLYISNOTANEASYMATTERAMECHANICALDESIGNERSHOULDUNCEASINGLYEXPLORETHEIMPROVEMENTEXISTINGPRODUCTTHEMETHOD,SHOULDEARNESTLYCHOOSEORIGINALLY,THEPROCESSCONFIRMATIONPRINCIPLEOFDESIGNINTHISPROCESS,WITHHASNOTUNIFIEDITAFTERTHECONFIRMATIONNEWIDEA5机械设计摘要机器是由机械装置和其它组件组成的。它是一种用来转换或传递能量的装置，例如发动机、涡轮机、车辆、起重机、印刷机、洗衣机、照相机和摄影机等。许多原则和设计方法不但适用于机器的设计，也适用于非机器的设计。术语中的“机械装置设计”的含义要比“机械设计”的含义更为广泛一些，机械装置设计包括机械设计。在分析运动及设计结构时，要把产品外型以及以后的保养也要考虑在机械设计中。在机械工程领域中，以及其它工程领域中，所有这些都需要机械设备，比如开关、凸轮、阀门、船舶以及搅拌机等。关键词设计流程设计规则机械设计设计流程设计开始之前就要想到机器的实际性，现存的机器需要在耐用性、效率、重量、速度，或者成本上得到改善。新的机器必需具有以前机器所能执行的功能。在设计的初始阶段，应该允许设计人员充分发挥创造性，不要受到任何约束。即使产生了许多不切实际的想法，也会在设计的早期，即在绘制图纸之前被改正掉。只有这样，才不致于阻断创新的思路。通常,还要提出几套设计方案，然后加以比较。很有可能在这个计划最后决定中,使用了某些不在计划之内的一些设想。一般的当外型特点和组件部分的尺寸特点分析得透彻时，就可以全面的设计和分析。接着还要客观的分析机器性能的优越性，以及它的安全、重量、耐用性，并且竞争力的成本也要考虑在分析结果之内。每一个至关重要的部分要优化它的比例和尺寸，同时也要保持与其它组成部分相协调。也要选择原材料和处理原材料的方法。通过力学原理来分析和实现这些重要的特性，如那些静态反应的能量和摩擦力的最佳利用，像动力惯性、加速动力和能量；包括弹性材料的强度、应力和刚度等材料的物理特性，以及流体润滑和驱动器的流体力学。设计的过程是重复和合作的过程，无论是正式或非正式的进行，对设计者来说每个阶段都很重要。最后，以图样为设计的标准，并建立将来的模型。如果它的测试是符合事先要求的，则再将对初步设计进行某些修改，使它能够在制造成本上有所降低。产品的设计需要不断探索和发展。许多方案必须被研究、试验、完善，然后决定使用还是放弃。虽然每个工程学问题的内容是独特的，但是设计师可以按照类似的步骤来解决问题。产品的责任诉讼迫使设计人员和公司在选择材料时，采用最好的程序。在材料过程中，五个最常见的问题为（A）不了解或者不会使用关于材料应用方面的最新最好的信息资料；B未能预见和考虑材料的合理用途（如有可能，设计人员还应进一步预测和考虑由于产品使用方法不当造成的后果。在近年来的许多产品责任诉讼案件中，由于错误地使用产品而受到伤害的原告控告生产厂家，并且赢得判决）；C所使用的材料的数据不全或是有些数据不确定，尤其是当其性能数据长期不更新；D质量控制方法不适当和未经验证；E由一些完全不称职的人员选择材料。通过对上述五个问题的分析，可以得出这些问题是没有充分理由而存在的结论。对这些问题的研究分析可以为避免这些问题的出现而指明方向。尽管采用最好的材料选择方法也不能避免发生产品责任诉讼，设计人员和工业界按照适当的程序进行材料选择，可以大大减少诉讼的数量。6从以上的讨论可以看出，选择材料的人们应该对材料的性质，特点和加工方法有一个全面而基本的了解。在随后生产和售后服务的几年中，要接受新观念的变化，或者由试验和经验为基础，进一步分析并改进。一些设计规则在本节中，建议要运用创造性的态度来替代和改进。也许会创造出更实用、更经济、更耐用的产品。为了激发创造性思维，下列是设计和分析的建议规则。前六个规则对设计者来说特别适用。1要有创造性的利用所需要的物理性质和控制过程。2认识负载产生的影响及其意义。3预测没有想到的负载。4创造出对载荷更为有利的条件。5提供良好的应力分布和最小的刚度条件。6运用最简单的方程来优化体积和面积。7选择组合材料。8仔细选择所备的原料和不可缺少的组件。9调整有效的设计方案，以适应生产过程和降低成本。10规定好准确的位置条件为了使组件安装时不干涉。机械设计包括一下内容1对设计过程、设计所需要公式以及安全系数进行介绍。2回顾材料特性、静态和动态载荷分析，包括梁、振动和冲击载荷。3回顾应力的基本规律和失效分析。4介绍静态失效理论和静态载荷下机械断裂分析。5介绍疲劳失效理论并强调在压力条件下接近高循环的疲劳设计，这通常用在旋转机械的设计中。6深入探讨机械磨损机理、表面接触应力和表面疲劳现象。7使用疲劳分析技术校核轴的设计。8讨论润滑油膜与滚动轴承的理论和应用。9深入介绍直齿圆柱齿轮的动力学、设计和应力分析，并
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