ZEIT4008 2010

Integrated Mechanical Design Semester 2

Basics
Texts
The following books have been added to the textbook list: Bosch Automotive Handbook (SAE) Milliken & Milliken, Race Car Vehicle Dynamics (SAE) These are both published by SAE, and are easiest to obtain by ordering on-line from SAE (www.sae.org), and there is a discount for Society members.

Complexity and difficulty in design

Complexity arises when there is multiple interactions between design decisions, both within and between components/assemblies. Difficulty principally arises from Uncertainty Novelty requiring invention Ignorance

Requirements
Requirements are of two kinds: Expectations: what the clients say they want by specifying. Operating environment: what the clients haven't told you, because they think you should know. It is therefore necessary for you to find out about it.

Joining, fastening and locating

Joining
Welding Produces permanent connection which is very stiff. Butt joints are better than lap joints (tension rather than shear), but distortion due to heating must be taken into consideration. Adhesive bonding Produces permanent connection which is stiff. Lap joints are essential (shear, not tension) except for low-stress and cosmetic bonding. Discrete fasteners Produce semi-permanent or removable connections with some flexibility. Rivets solid or tubular (pop). Very little distortion, do not require great skill, and good for thin materials. Joints principally in shear, but small tension component acceptable with solid rivets. Removal requires drilling-out, so not suitable when frequent disassembly or removal is required. Threaded fasteners These may be used either in shear or in tension, and there are detailed rules for design in both cases.

Locating
A principal requirement for ensuring that a machine is makeable, adjustable and repairable is that it be possible to prescribe the relative positions of components, etc. Such location is either: Setting Correcting tolerances in manufacture, etc. May only need to be done once. Adjustment To make desired changes, and compensating for unavoidable changes- wear, stretch, etc.

Locating methods
Dowelling Shimming Friction setting Screw setting