可任意分度的插齒機齒輪加工回轉(zhuǎn)工作臺的設(shè)計

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徐州工程學(xué)院學(xué)生畢業(yè)設(shè)計（論文）中期情況檢查表 學(xué)院名稱： 檢查日期： 年 月 日 學(xué)生姓名 專業(yè)班級 指導(dǎo)教師 設(shè)計（論文）題目 工作進度情況 是否符合任務(wù)書要求進度 能否按期完成任務(wù) 工作態(tài)度情況 (態(tài)度、紀律、出勤、主動接受指導(dǎo)等) 質(zhì)量 評價 (針對已完成的部分) 存在問題和解決辦法 檢查人簽字 學(xué)院負責(zé)人簽字 徐州工程學(xué)院 畢業(yè)設(shè)計（論文）任務(wù)書 機電工程 學(xué)院 機械設(shè)計制造及其自動化 專業(yè) 設(shè)計（論文）題目 可任意分度的插齒機齒輪加工 回轉(zhuǎn)工作臺的設(shè)計 學(xué) 生 姓 名 陳超 班 級 04機本（2）班 起 止 日 期 2008.2.25～2008.6.2 指 導(dǎo) 教 師 陳躍 教研室主任 李志 發(fā)任務(wù)書日期 2008 年 2 月 25 日 1.畢業(yè)設(shè)計的背景： 齒輪是重要的基礎(chǔ)傳動元件。近年來，隨著技術(shù)的發(fā)展，盡管采用電 氣、液壓傳動裝置日益增多，對齒輪的需求仍有增無減。目前，中國齒輪 市場的年銷售額超過了800億元。而齒輪加工機床也是結(jié)構(gòu)復(fù)雜、制造難 度大的機床產(chǎn)品之一。 插齒機作為齒輪加工機床的一種，已逐步體現(xiàn)出其加工的特殊性，在 滾齒機、銑齒機上無法加工的一些齒輪，如雙聯(lián)齒輪和內(nèi)齒輪，在插齒機 上可加工制造出來。 2.畢業(yè)設(shè)計(論文)的內(nèi)容和要求： 在本課題的設(shè)計中，采用步進電機控制回轉(zhuǎn)工作臺的轉(zhuǎn)角。在單片機 控制下，步進電機每秒鐘發(fā)出的脈沖數(shù)決定了工作臺的轉(zhuǎn)位角度，使該插 齒機實現(xiàn)可任意分度加工，進而可實現(xiàn)加工任意齒數(shù)的齒數(shù)。 設(shè)計內(nèi)容：1.工作臺機械結(jié)構(gòu)設(shè)計; 2.任意分度機構(gòu)控制電路設(shè)計。 設(shè)計要求：1. 分度誤差≤10’ 2. 最大加工法齒輪直徑250mm 3. 工作臺尺寸400mm×400mm×300mm 3.主要參考文獻： 1.邱宣懷主編，機械設(shè)計（第四版），北京：高等教育出版社，1997 2.王曉明編著，步進電機選擇，北京：北京航空航天大學(xué)出版社，1997 3.周宏甫主編，機械制造技術(shù)基礎(chǔ)，北京：高等教育出版社，2004 4.毛德謙主編，機械設(shè)計手冊，北京：化學(xué)工業(yè)出版社，2001 5.鄒麗新主編，單片機原理及應(yīng)用，蘇州：蘇州大學(xué)出版社，2001 6.范思沖主編，畫法幾何及機械制圖，北京：機械工業(yè)出版社，1996 4.畢業(yè)設(shè)計(論文)進度計劃(以周為單位)： 起 止 日 期 工 作 內(nèi) 容 備 注 第一周 第二周 第三周 第四周 第五周 第六周 第七周 第八周 第九周 第十周 第十一周 第十二周 第十三周 第十四周 第十五周 第十六周 了解設(shè)計的基本要求，查閱相關(guān)資料。 查閱相關(guān)資料，寫開題報告。 外文資料翻譯。 設(shè)計方案比較選擇。 工作臺設(shè)計計算。 工作臺設(shè)計計算。 分度部分設(shè)計計算。 分度部分設(shè)計計算。 分度控制電路設(shè)計。 分度程序設(shè)計。 繪制機械和電路圖。 繪制機械和電路圖。 撰寫畢業(yè)設(shè)計說明書。 撰寫畢業(yè)設(shè)計說明書。 答辯準備。 答辯。 教研室審查意見： 室主任 年 月 日 學(xué)院審查意見： 教學(xué)院長 年 月 日 畢業(yè)設(shè)計附本 可任意分度的插齒機齒輪加工回轉(zhuǎn)工作臺的設(shè)計 the design of gear processing rotary table on random indexing gear shaper 學(xué)生姓名 陳超 學(xué)院名稱 機電工程學(xué)院 專業(yè)名稱 機械設(shè)計制造及其自動化 指導(dǎo)教師 陳躍 2008年 6月 2日 徐州工程學(xué)院 畢業(yè)設(shè)計（論文）開題報告 課 題 名 稱： 可任意分度的插齒機齒輪加工 回轉(zhuǎn)工作臺設(shè)計 學(xué) 生 姓 名： 陳超 學(xué)號： 20040601224 指 導(dǎo) 教 師： 陳躍 職稱： 講師 所 在 學(xué) 院： 機電工程學(xué)院 專 業(yè) 名 稱： 機械設(shè)計制造及其自動化 徐州工程學(xué)院 2008年3月4日 說 明 1．根據(jù)《徐州工程學(xué)院畢業(yè)設(shè)計(論文)管理規(guī)定》，學(xué)生必須撰寫《畢業(yè)設(shè)計（論文）開題報告》，由指導(dǎo)教師簽署意見、教研室審查，學(xué)院教學(xué)院長批準后實施。 2．開題報告是畢業(yè)設(shè)計（論文）答辯委員會對學(xué)生答辯資格審查的依據(jù)材料之一。學(xué)生應(yīng)當在畢業(yè)設(shè)計（論文）工作前期內(nèi)完成，開題報告不合格者不得參加答辯。 3．畢業(yè)設(shè)計開題報告各項內(nèi)容要實事求是，逐條認真填寫。其中的文字表達要明確、嚴謹，語言通順，外來語要同時用原文和中文表達。第一次出現(xiàn)縮寫詞，須注出全稱。 4．本報告中，由學(xué)生本人撰寫的對課題和研究工作的分析及描述，沒有經(jīng)過整理歸納，缺乏個人見解僅僅從網(wǎng)上下載材料拼湊而成的開題報告按不合格論。 5. 課題類型填：工程設(shè)計類；理論研究類；應(yīng)用（實驗）研究類；軟件設(shè)計類；其它。 6、課題來源填：教師科研；社會生產(chǎn)實踐；教學(xué)；其它 課題 名稱 可任意分度的插齒機齒輪加工回轉(zhuǎn)工作臺設(shè)計 課題來源 模擬生產(chǎn)實際課題 課題類型 工程應(yīng)用 選題的背景及意義 選題的背景： 齒輪是重要的基礎(chǔ)傳動元件。近年來，隨著技術(shù)的發(fā)展，盡管采用電氣、液壓傳動裝置日益增多，對齒輪的需求仍有增無減。目前，中國齒輪市場的年銷售額超過了800億元。而齒輪加工機床也是結(jié)構(gòu)復(fù)雜、制造難度大的機床產(chǎn)品之一。插齒機作為齒輪加工機床的一種，已逐步體現(xiàn)出其加工的特殊性，在滾齒機、銑齒機上無法加工的一些齒輪，如雙聯(lián)齒輪和內(nèi)齒輪，在插齒機上可加工制造出來。 選題的意義： 本課題的意義就是設(shè)計出一種回轉(zhuǎn)工作臺，在由單片機控制的步進電機驅(qū)動下，可以轉(zhuǎn)過任意角度，從而帶動工件轉(zhuǎn)過任意角度，進而實現(xiàn)加工任意齒數(shù)的齒輪。 研究內(nèi)容擬解決的主要問題 設(shè)計內(nèi)容： 1. 工作臺機械結(jié)構(gòu)設(shè)計。 2. 任意分度機構(gòu)控制電路設(shè)計。 本課題的相關(guān)任務(wù)： 1.完成回轉(zhuǎn)工作臺機械結(jié)構(gòu)設(shè)計和控制電路設(shè)計 2.完成零部件的結(jié)構(gòu)設(shè)計和計算 3.可以實現(xiàn)回轉(zhuǎn)工作臺的預(yù)期工作目的 4.分析設(shè)計過程中的問題，并找出合理的解決辦法，順利完成答辯 5.對畢業(yè)答辯進行最后的修改。 用于解決以下兩個問題： 1. 如何實現(xiàn)任意分度加工，同時保證分度準確、快速。 2. 如何能使工作臺便于安裝。 研究方法技術(shù)路線 主要設(shè)計參數(shù)如下： 1. 分度誤差≤10’ 2. 最大加工法齒輪直徑250mm 3. 工作臺尺寸400mm×400mm×300mm 研究方法： 通過各種渠道，盡可能多地掌握資料，根據(jù)所掌握的資料，完成開題報告。 考慮方案的安全性、可行性和經(jīng)濟性，和導(dǎo)師對方案進行研討，確定設(shè)計的方案。 正式開始畢業(yè)設(shè)計。 技術(shù)路線： 本設(shè)計主要是用單片機作為控制系統(tǒng)來控制步進電機的轉(zhuǎn)速，通過齒輪傳動和蝸輪蝸桿傳動，將動力傳遞至蝸輪上，再由蝸輪帶動主軸的轉(zhuǎn)動，進而實現(xiàn)工件的轉(zhuǎn)動。在單片機的控制下，步進電機每秒鐘發(fā)出的脈沖數(shù)決定了工作臺的轉(zhuǎn)位角度，使該插齒機成為真正意義上的可任意分度加工，進而可實現(xiàn)加工任意齒數(shù)的齒輪。 研究的總體安排和進度計劃 第一周：了解設(shè)計的基本要求，查閱相關(guān)資料。 第二周：查閱相關(guān)資料，寫開題報告。 第三周：外文資料翻譯。 第四周：設(shè)計方案比較選擇。 第五周：工作臺設(shè)計計算。 第六周：工作臺設(shè)計計算。 第七周：分度部分設(shè)計計算。 第八周：分度部分設(shè)計計算。 第九周：分度控制電路設(shè)計。 第十周：分度程序設(shè)計。 第十一周：繪制機械和電路圖。 第十二周：繪制機械和電路圖。 第十三周：撰寫畢業(yè)設(shè)計說明書。 第十四周：撰寫畢業(yè)設(shè)計說明書。 第十五周：答辯準備。 第十六周：答辯。 主要參考 文獻 1. 邱宣懷主編，機械設(shè)計（第四版），北京：高等教育出版社，1997 2. 王曉明編著，步進電機選擇，北京：北京航空航天大學(xué)出版社，1997 3. 周宏甫主編，機械制造技術(shù)基礎(chǔ)，北京：高等教育出版社，2004 4. 毛德謙主編，機械設(shè)計手冊，北京：化學(xué)工業(yè)出版社，2001 5. 鄒麗新主編，單片機原理及應(yīng)用，蘇州：蘇州大學(xué)出版社，2001 6. 鄭堤主編，數(shù)控機床應(yīng)用與維護，北京：機械工業(yè)出版社，2005 7. 謝鐵幫等主編，互換性與技術(shù)測量，武漢：華中科技大學(xué)出版社，1998 8. 范思沖等主編，畫法幾何及機械制圖，北京：機械工業(yè)出版社，1996 指導(dǎo)教師 意 見 指導(dǎo)教師簽名： 年 月 日 教研室意見 學(xué)院意見 教研室主任簽名： 年 月 日 教學(xué)院長簽名： 年 月 日 關(guān)于畢業(yè)設(shè)計提交文件的說明 經(jīng)研究，對我院機械設(shè)計制造及其自動化專業(yè)2008屆畢業(yè)生畢業(yè)設(shè)計提交的文件有以下說明： 一、 畢業(yè)設(shè)計說明書 畢業(yè)設(shè)計說明書應(yīng)按照徐州工程學(xué)院畢業(yè)設(shè)計（論文）模板的格式，具體應(yīng)包括： 1、 畢業(yè)設(shè)計封面； 2、 徐州工程學(xué)院學(xué)位論文原創(chuàng)性聲明； 3、 摘要； 4、 目錄； 5、 正文； 6、 結(jié)論； 7、 致謝； 8、 參考文獻； 9、 附錄。 注：每個部分的字體、格式都有一定的要求，參照樣本一。 二、 附本 除提交畢業(yè)設(shè)計說明書外，還要提交七個附本，具體有： 1、 附件一：徐州工程學(xué)院畢業(yè)設(shè)計（論文）任務(wù)書； 2、 附件二：徐州工程學(xué)院畢業(yè)設(shè)計（論文）開題報告； 3、 附件三：畢業(yè)設(shè)計（論文）進度記錄表； 4、 附件四：徐州工程學(xué)院學(xué)生畢業(yè)設(shè)計（論文）中期情況檢查表； 5、 附件五：徐州工程學(xué)院畢業(yè)設(shè)計（論文）指導(dǎo)教師評定表； 6、 附件六：徐州工程學(xué)院畢業(yè)設(shè)計（論文）評閱教師評定表； 7、 附件七：徐州工程學(xué)院畢業(yè)設(shè)計（論文）答辯及綜合成績評定表； 注：裝訂格式按照附件名的順序，參照樣本二。 樣本一與樣本二內(nèi)的附件在機電學(xué)院網(wǎng)站的教學(xué)科研欄目下載。 機電工程學(xué)院 2008年5月23日 徐州工程學(xué)院畢業(yè)設(shè)計（論文）答辯及綜合成績評定表 學(xué) 院 專業(yè)班級 學(xué)生姓名 學(xué) 號 指導(dǎo)教師 設(shè)計論文題 目 答辯時間 年 月 日 時 分至 時 分 答辯地點 答辯小組成 員 姓名 職稱 答辯 記錄 提問人 提問主要內(nèi)容 學(xué)生回答摘要 答辯記錄人簽字： 答辯 小組 意見 答辯評語： 答辯成績 答辯小組組長簽字： 綜合 成績 評定 指導(dǎo)教師評定成績 評閱教師評定成績 答辯成績 綜合評定成績 答辯委員會主任簽字： 年 月 日 徐州工程學(xué)院畢業(yè)設(shè)計（論文）評閱表 學(xué)院： 專業(yè)： 學(xué)生： 學(xué)號： 題目： 評價 項目 評價要素 成績評定 優(yōu) 良 中 及格 不及格 選題 質(zhì)量 選題方向和范圍 選題難易度 選題理論意義和實際應(yīng)用價值 能力 水平 查閱和應(yīng)用文獻資料能力 綜合運用知識能力 研究方法與手段 實驗技能和實踐能力 創(chuàng)新意識 設(shè)計 論文 質(zhì)量 內(nèi)容與寫作 結(jié)構(gòu)與水平 規(guī)范化程度 成果與成效 評閱 教師 意見 建議成績 是否同意參加答辯 評語： 評閱教師簽字： 年 月 日 編號 無錫太湖學(xué)院 畢業(yè)設(shè)計（論文） 相關(guān)資料 題目： 電池柜冷藏箱DC Tall 之箱體結(jié)構(gòu)設(shè)計 信機 系 機械工程及自動化專業(yè) 學(xué) 號： 　　　 0923222　　　　 學(xué)生姓名： 朱天柱 指導(dǎo)教師： 　 陳偉明 （職稱：教授 ） （職稱： ） 2013年5月25日 目 錄 一、畢業(yè)設(shè)計（論文）開題報告 二、畢業(yè)設(shè)計（論文）外文資料翻譯及原文 三、學(xué)生“畢業(yè)論文（論文）計劃、進度、檢查及落實表” 四、實習(xí)鑒定表 無錫太湖學(xué)院 畢業(yè)設(shè)計（論文） 開題報告 題目： 電池柜冷藏箱DC Tall 之箱體結(jié)構(gòu)設(shè)計 信機 系 機械工程及自動化 專業(yè) 學(xué) 號： 0923222 學(xué)生姓名： 朱天柱 指導(dǎo)教師： 陳偉明 （職稱：教授 ） （職稱： ） 2012年11月25日 課題來源 根據(jù)市場需求開發(fā)研制 科學(xué)依據(jù)（包括課題的科學(xué)意義；國內(nèi)外研究概況、水平和發(fā)展趨勢；應(yīng)用前景等） （1）課題科學(xué)意義 電池柜冷藏箱（DC tall）的主要結(jié)構(gòu)采用的是鈑金材料，本產(chǎn)品的主要研究目的：將電池保持一定的溫度，使得電池延長使用壽命。裝電池后產(chǎn)品重量達1.42t，保持電池柜內(nèi)部溫度251，并保持內(nèi)部溫度的均勻性。 國內(nèi)目前沒有相關(guān)類似產(chǎn)品，在國內(nèi)該產(chǎn)品屬于創(chuàng)新開發(fā)階段。國外該系列屬于起步發(fā)展階段，技術(shù)尚未全面成熟。在不久的將來，將被大量生產(chǎn)并投入使用。 （2）制冷壓縮機的研究狀況及其發(fā)展前景 目前，冷壓縮機的國際發(fā)展方向是壓縮機容量不斷增大、新型氣體密封、磁力軸承和無潤滑聯(lián)軸器相繼出現(xiàn)；高壓和小流量壓縮機產(chǎn)品不斷涌現(xiàn)；三元流動理論研究進一步深入，不僅應(yīng)用到葉輪設(shè)計，還發(fā)展到葉片擴壓器靜止元件設(shè)計中，機組效率得到提高；采用噪音防護技術(shù)，改善操作環(huán)境等。 多年來，我國壓縮機制造業(yè)在引進國外技術(shù)，消化吸收和自主開發(fā)基礎(chǔ)上，攻克不少難關(guān)，取得重大突破。但是，我國制冷壓縮機在高技術(shù)、高參數(shù)、高質(zhì)量和特殊產(chǎn)品上還不能滿足國內(nèi)需要，50%左右產(chǎn)品需要進口。另外，在技術(shù)水平、質(zhì)量、成套性上和國外還有差距。隨著石化生產(chǎn)規(guī)模不斷擴大，我國制冷壓縮機在大型化方面將面臨新的課題。 目前制冷壓縮機的發(fā)展趨勢簡述如下： (1) 創(chuàng)造新的機型。(2) 冷壓縮機內(nèi)部流動規(guī)律的研究與應(yīng)用。(3) 高速轉(zhuǎn)子動力學(xué)的研究與應(yīng)用。高速轉(zhuǎn)子的平衡、高速轉(zhuǎn)子的彎曲振動和扭轉(zhuǎn)振動、高速轉(zhuǎn)子的支承與抑振、高速轉(zhuǎn)子的軸端密封和高速轉(zhuǎn)子的使用壽命預(yù)估等。(4) 新型制造工藝技術(shù)的發(fā)展。(5) 冷壓縮機的自動控制。為使冷壓縮機安全運行、調(diào)控到最佳運行工況或按產(chǎn)品生產(chǎn)過程需要改變運行工況等，均需要不斷完善自動控制系統(tǒng)。(6) 冷壓縮機的故障診斷。為使制冷壓縮機安全運行，變定期停機大修為預(yù)防性維修，采用在線監(jiān)測實時故障診斷系統(tǒng)，遇到緊急情況及時報警、監(jiān)控或聯(lián)鎖停機。(7) 實現(xiàn)國產(chǎn)化和參與國際市場競爭。許多大型的復(fù)雜冷壓縮機均已由從國外引進過渡到實現(xiàn)國產(chǎn)化，并隨著一些大型工程裝備的出口，向國外銷售，參與國際市場的競爭。 研究內(nèi)容 1.電池柜冷藏箱各個部分的設(shè)計方案與裝配方案。 蓄電池放置在擱架上，擱架必須承受住蓄電池的重量。解決擱架設(shè)計方法及強度計算。 2.強度問題： 電池柜內(nèi)部裝電池后重量達1.42t，擱架四周用到的所有螺絲必須能承受蓄電池的壓力。 擬采取的研究方法、技術(shù)路線、實驗方案及可行性分析 解決強度的設(shè)計方法及方案： （1）外部：采用高強度螺栓M8 8.8級別，材質(zhì)：鍍鋅。箱體上采用M8不銹鋼鉚螺母，并在內(nèi)部附加1mm厚的不銹鋼加強板。 （2）內(nèi)部：用側(cè)內(nèi)剪切力來分散承重的單一性，以每層12個受力點均勻分布，并在內(nèi)膽附1mm厚的加強板，材料：鍍鋅板，加強板上也有剪切力的成形設(shè)計。 研究計劃及預(yù)期成果 研究計劃： 2012年11月12日-2012年12月2日：按照任務(wù)書要求查閱論文相關(guān)參考資料，填寫畢業(yè)設(shè)計開題報告書。 2013年1月11日-2013年3月1日：填寫畢業(yè)實習(xí)報告。 2013年3月4 日-2013年3月15日：學(xué)習(xí)并翻譯一篇與畢業(yè)設(shè)計相關(guān)的英文材料。 2013年3月18日-2013年3月29日：設(shè)計箱體結(jié)構(gòu)與結(jié)構(gòu)分析。 2013年4月1日-2013年4月12日：主要結(jié)構(gòu)設(shè)計與零件尺寸計算。 2013年4月15日-2013年4月26日：配套裝配圖的設(shè)計與繪畫。 2013年4月29日-2013年 5月 10日：零件圖的設(shè)計與成型和鈑金工藝完善。 2013年5月13日-2013年5月17日：畢業(yè)論文撰寫和修改工作。 預(yù)期成果： （1）完成相關(guān)的零件圖和裝配圖，其中包括三維圖和二維圖。 （2）按學(xué)校要求完成畢業(yè)論文（不少于8000字）。 （3）完成英文翻譯（不少于3000字；英文資料翻譯要正確表達原文的含意，語句通順。 （4）設(shè)計說明書論文格式滿足學(xué)校相應(yīng)的規(guī)范要求，內(nèi)容完整，結(jié)構(gòu)安排合理，語句通順。 特色或創(chuàng)新之處 ① 使用UG編程仿真，效果明顯，能夠直觀判斷實驗結(jié)果。 ② 采用不同的材質(zhì)，與傳統(tǒng)設(shè)計想比，思路清晰，簡潔明了，行之有效。 已具備的條件和尚需解決的問題 1.防水性要求：背部拼接達到IP65等級即：浸水一米以內(nèi)不漏水； 其余拼接部分IP55級即要求能夠防雨。 2.門和箱體的防腐蝕性。 3.整個機器的保溫性及隔熱性能。防止能量損失小于整體的35%。在環(huán)境溫度35時，壓縮機輸入功率170W，制冷功率280W。保持內(nèi)部室溫25,以及內(nèi)部溫度的均勻性1。 指導(dǎo)教師意見 指導(dǎo)教師簽名： 年 月 日 教研室（學(xué)科組、研究所）意見 教研室主任簽名： 年 月 日 系意見 主管領(lǐng)導(dǎo)簽名： 年 月 日 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 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. Mechanical 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 of materials and manufacturing processes. As stated previously, the 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, 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 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 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 designer 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 design 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 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, creativity 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 manufacturing. In this way, innovative ideas are not inhibited. Quite often, more 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 trying 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 point 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 to 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 solution 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 will 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 should 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 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? (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 must communicate the finalized design to manufacturing through the use of detail and assembly drawings. Quite often, a problem will occur during the manufacturing cycle [3]. 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 fails 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 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 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 great value, not only as a record of one's thoughts and as an aid in discussion with others, but particularly for communication with one's 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 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. 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 elasticity 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, 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 indicate 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 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, fluid 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 not in the clutch bearing. Ingenuity in design should be applied to utilize and control the physical 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, particular 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 shafts 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 containing bearing supports. The stiffness of shafts and other components must be suitable to avoid resonant vibrations. 3. Use equations to calculate and optimize dimensions. The fundamental equations of mechanics and the other sciences are the accepted bases for calculations. They are sometimes rearranged in special forms to facilitate the determination or optimization of dimensions, such as the Beam 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 for 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 incomplete, 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 for 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 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 should be carefully made wi'th a full knowledge of its properties, since the reputation and liability of the company suffer if there is a failure in any one of the machine's parts. In other eases the strength, reliability, and cost requirements are better met if the designer of the machine also designs 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 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 foreseen 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 create 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 mankind's ideas. In their earliest forms, tools primarily consisted of stone instruments. 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 the Most durable , consequently, 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 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 and challenges arise so that the manufacturers of today are faced with tough questions such as the following: How do you drill a 2 mm diameter hole 670 mm deep without experiencing taper or run out? Is there a way to efficiently deburr passageways inside complex castings and guarantee 100 % that no burrs were missed? Is there a welding process that can eliminate the thermal damage now occurring to my product? Since the 1940s, a revolution in manufacturing has been taking place that once again allows manufacturers to meet the demands imposed by increasingly sophisticated designs and durable, but in many cases nearly unmachinable, materials. This manufacturing revolution is now, as it has been in the past, centered on the use of new tools and new forms of energy. The result has been the introduction of new manufacturing processes used for material removal, forming, and joining, known today as nontraditional manufacturing processes. The conventional manufacturing processes in use today for material removal primarily rely on electric motors and hard tool materials to perform tasks such as sawing, drilling, an broaching. Conventional forming operations are performed with the energy from electric motors, hydraulics, and gravity. Likewise, material joining is conventionally accomplished with thermal energy sources such as burning gases and electric arcs. In contrast, nontraditional manufacturing processes harness energy sources considered unconventional by yesterday's standards. Material removal can now be accomplished with electrochemical reactions, high-temperature plasmas, and high-velocity jets of liquids and abrasives. Materials that in the past have been extremely difficult to form, are now formed with magnetic fields, explosives, and the shock waves from powerful electric sparks. Material-joining capabilities have been expanded with the use of high-frequency sound waves and beams of