Detailed Mechanical Design: A Practical Guide Book

	Preface	ix
Chapter 1.	Introduction	1
1.1	About This Book	3
1.2	The Mechanical Design Process	4
1.2.1	Market Need Identification	5
1.2.2	Product Specification	5
1.2.3	Concept Development	6
1.2.4	Detail Design	11
1.2.5	Production	12
1.2.6	Distribution	12
1.3	The Mechanical Design Process: Other Perspectives	12
1.3.1	Mechanical Design as Problem Solving	13
1.3.2	Mechanical Design as Project Management	13
1.3.3	Mechanical Design as Decision Making	13
1.4	The Mechanical Engineering Sciences	14
1.5	About Design Science	15
Chapter 2.	Principles of Mechanical Design	17
2.1	Introduction	19
2.2	Principle of Functional Independence	19
2.3	Principle of Minimum Information	22
2.4	Principle of Exact Constraint	25
2.4.1	Introduction to Exact Constraint Design	25
2.4.2	Defining Exact Constraint	26
2.4.3	Constraint Theory	27
2.4.4	Converting Constraint Theory Into Practice	34
2.4.5	Common Examples	37
2.5	Principle of Self-Help	39
2.5.1	Introduction to the Principle of Self-Help	39
2.5.2	Self-Reinforcing Self-Help (Force Manifestation)	40
2.5.3	Self-Balancing Self-Help (Force Neutralization)	42
2.5.4	Self-Protecting Self-Help (Force Distribution)	44
2.6	Principle of Convergence and Stability	46
2.7	Introduction to Suh's Design Axioms	48
2.7.1	Overview of the Independence Axiom	49
2.7.2	Overview of the Information Axiom	50
2.7.3	Corollaries and Theorems to Suh's Design Axioms	51
2.7.4	Perspectives on Suh's Design Axioms	52
Chapter 3.	Methods for Synthesis in Detail Design	53
3.1	Analogy	56
3.2	Inversion	58
3.3	Empathy	60
3.4	Composition	62
3.4.1	Composition Defined	63
3.4.2	Three-Dimensional Modeling for Composition	64
Chapter 4.	Engineering Analysis in Mechanical Design	67
4.1	Analysis: Value and Types	69
4.2	Analyzability in Design	72
4.2.1	Continuum of Analytical Methods	72
4.2.2	Analyzability Defined	73
4.2.3	Selecting the Correct Level of Analysis	74
4.3	Trends and Relationships	75
4.3.1	Trigonmetric Functions	76
4.3.2	Exponential Relationships	78
4.3.3	Parametric Relationships	81
4.3.4	Trends and Relationships From FEA	82
4.4	Force Flow Line Visualization	83
4.4.1	Purpose of Force Flow Line Visualization	84
4.4.2	Using Force Flow Lines	84
4.5	Determining Robustness	86
4.5.1	Introduction	86
4.5.2	Design Tools for Robustness Analysis	88
Chapter 5.	Design Practices	93
5.1	Triangulation	95
5.2	Minimizing Force Paths	101
5.3	Localizing Reaction Forces	102
5.4	Controlling Energy of Forces	103
5.5	Localizing Tolerances	105
5.6	Dimensioning and Tolerancing for Function	107
5.7	Optimizing Loads and Stress Distribution	110
5.8	Matching Deformations	112
5.9	Lead-Ins and Lead-Outs	115
5.10	Self-Fixturing, Self-Adjustment, and Self-Alignment	117
5.11	Guiding and Jamming	119
5.12	Using Chamfers to Reduce Stress	121
5.13	Avoiding Frictional Races	122
5.14	Sacrificial and Protective Parts	123
Chapter 6.	Materials	125
6.1	Thermoplastics	127
6.1.1	General Properties	127
6.1.2	Processing	131
6.1.3	Classification by Groups	133
6.1.4	Filler Modifications	141
6.1.5	Material Selection	142
6.1.6	Part Design Guidelines	143
6.1.7	Overview and Summary of Thermoplastics	146
6.2	Thermosets	147
6.2.1	General Properties	147
6.2.2	Processing	148
6.2.3	Thermoset Types	149
6.2.4	Part Design	150
6.3	Rubber	150
6.3.1	General Properties	150
6.3.2	Rubber Types	151
6.3.3	Processing	154
6.4	Metals	154
6.4.1	General Properties and Groups	154
6.4.2	Carbon Steel	155
6.4.3	Stainless Steel	155
6.4.4	Aluminum	156
6.4.5	Copper and Copper Alloys	157
Chapter 7.	Components	159
7.1	Screw Threads and Threaded Fasteners	162
7.1.1	Introduction	162
7.1.2	Basic Characteristics of Screw Threads and Fasteners	162
7.1.3	Preload	164
7.1.4	External Loads on Threaded Fastener Joints	166
7.1.5	Thread-Locking Methods	170
7.1.6	Selecting Standard Fasteners	171
7.2	Springs	174
7.2.1	Types of Springs	174
7.2.2	Spring Materials	177
7.2.3	Basic Performance Characteristics	178
7.2.4	Designing Springs	179
7.2.5	Fabricating Springs	185
7.3	Snap-Fits	188
7.3.1	Introduction	188
7.3.2	Designing Snap-Fits	189
7.3.3	Snap-Fit Variations	189
7.4	Adhesives and Adhesive Joints	190
7.4.1	Joints	190
7.4.2	Types of Adhesive Joint Loading	193
7.4.3	Types of Adhesives	195
Chapter 8.	Conclusion and Recommendations	197
	Bibliography	201
	About the Author	207
	Index	209