附錄 1 Design of Machine Tool Designing starts with a need real Existing apparatus may need improvements in durability efficiency weight speed or cost New apparatus may be needed to perform a function previously In the design preliminary stage should allow to design the personnel fully to display the creativity not each kind of restraint Even if has had many impractical ideas also can in the design early time namely in front of the innovation the mentality Usually must propose several sets of design proposals then perform the comparison Has the possibility very much in the plan which finally designated has used certain not in plan some ideas which accepts 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 cost Optimum proportions and dimensions will be sought for each critically loaded section together with a balance between the strengths 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 static for reaction forces and for the optimum utilization or friction of dynamics for inertia acceleration and energy of elasticity and strength of materials for stress and deflection of physical behavior of materials and of fluid mechanics for lubrication and hydrodynamic drives The analyses may be made by the same engineer who conceived the arrangement of mechanisms or un a large company they may be made by a separate analysis division or research group Design is a reiterative and cooperative process whether done formally or informally and the analyst can contribute to phases other than his own Product design requires much research and development Many Concepts of an idea must be studied tried and then either used or discarded Although the content of each engineering problem is unique the designers follow the similar process to solve the problems Product liability suits designers and forced in material selection using the best program In the process of material the most common problems for five a don t understand or not use about the latest application materials to the best information b failed to foresee and consider the reasonable use material may such as possible designers should further forecast and consider due to improper use products In recent years many products liability in litigation the use of products and hurt the plaintiff accused manufacturer and won the decision c of the materials used all or some of the data data especially when the uncertainty long term performance data is so d quality control method is not suitable and unproven e by some completely incompetent persons choose materials Through to the above five questions analysis may obtain these questions is does not have the sufficient reason existence the conclusion May for avoid these questions to these questions research analyses the appearance indicating the direction Although uses the best choice of material method not to be able to avoid having the product responsibility lawsuit designs the personnel and the industry carries on the choice of material according to the suitable procedure may greatly reduce the lawsuit the quantity May see from the above discussion the choice material people should to the material nature the characteristic and the processing method have comprehensive and the basic understanding Finally a design based upon function and a prototype may be built If its tests are satisfactory 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 analyses based upon tests and experience indicate alterations Sales appeal Some Rules for Design In this section it is suggested that applied with a creative attitude analyses can lead to important improvements and to the conception and perfection of alternate perhaps more functional economical and durable products To stimulate creative thought the following rules are suggested for the designer and analyst The first six rules are particularly applicable for the analyst 1 A creative use of need of physical properties and control process 2 Recognize functional loads and their significance 3 Anticipate unintentional loads 4 Devise more favorable loading conditions 5 Provide for favorable stress distribution and stiffness with minimum weigh 6 Use basic equations to proportion and optimize dimensions 7 Choose materials for a combination of properties 8 Select carefully stock and integral components 9 Modify a functional design to fit the manufacturing process and reduce cost 10 Provide for accurate location and noninterference of parts in assembly The complete design of a machine is a complex process The machine design is a creative work Project engineer not only must have the creativity in the work but also must in aspect and so on mechanical drawing kinematics engineering material materials mechanics and machine manufacture technology has the deep elementary knowledge One of the first steps in the design of any product is to select the material from which each part is to be made Numerous materials are available to today s designers The function of the product its appearance the cost of the material and the cost of fabrication are important in making a selection A careful evaluation of the properties of a material must be made prior to any calculations Careful calculations are necessary to ensure the validity of a design In case of any part failures it is desirable to know what was done in originally designing the defective components The checking of calculations and drawing dimensions is of utmost importance The misplacement of one decimal point can ruin an otherwise acceptable project All aspects of design work should be checked and rechecked The computer is a tool helpful to mechanical designers to lighten tedious calculations and provide extended analysis of available data Interactive systems based on computer capabilities have made possible the concepts of computer aided design CAD and computer aided manufacturing CAM How does the psychologist frequently discuss the machine which the people adapt to operate Design personnel basic responsibility is diligently causes the machine to adapt the people This certainly is not an easy work because certainly does not have to all people to say in fact all is the most superior operating area and the operating process Another important question project engineer must be able to carry on the exchange and the consultation with other concerned personnel In the initial stage designs the personnel to have to carry on the exchange and the consultation on the preliminary design with the administrative personnel and is approved This generally is through the oral discussion the schematic diagram and the writing material carries on If front sues the machine design goal is the production can meet the human need the product The invention the discovery and technical knowledge itself certainly not necessarily can bring the advantage to the humanity only has when they are applied can produce on the product must first determine whether the people do need this kind of product Grasps the project elementary knowledge to have to memorize some data and the formula is more important than The merely service data and the formula is insufficient to the completely decision which makes in a good design needs On the other hand should be earnest precisely carries on all operations For example even if places wrong a decimal point position also can cause the correct design to turn wrongly Machinery design covers the following contents 1 Provides an introduction to the design process problem formulation and safety factors 2 Reviews the material properties and static and dynamic loading analysis Including beam vibration and impact loading 3 Reviews the fundamentals of stress and defection analysis 4 Introduces fatigue failure design which is commonly used in the design of rotation machinery 5 Discusses thoroughly the phenomena of wear mechanisms surface contact stresses and surface fatigue 6 Investigates shaft design using the fatigue analysis techniques 7 Discusses fluid film an rolling element bearing theory and application 8 Gives a thorough introduction to the kinematics design and stress analysis of spur gears and a simple introduction to helical bevel and worm gearing 9 Discusses spring design including compression extension and torsion springs 10 Deals with screws and fasteners including power screw and preload fasteners 11 Introduces the design and specification of disk and drum clutches and brakes A good design personnel should dare to propose the new idea moreover is willing to undertake the certain risk when the new method is not suitable use original method Therefore designs the personnel to have the patience because spends the time and the endeavor certainly cannot guarantee brings successfully A brand new design the request screen abandons absolutely many knows very well the method for the people Because many person of conservativeness does this certainly is not an easy matter A mechanical designer should unceasingly explore the improvement existing product the method should earnestly choose originally the process confirmation principle of design in this process with has not unified it after the confirmation new idea 附錄 2 機(jī)床設(shè)計(jì) 設(shè)計(jì)開始之前就要想到機(jī)器的實(shí)際性 現(xiàn)存的機(jī)器需要在耐用性 效率 重量 速度或成本上加以改進(jìn) 在設(shè)計(jì)的初始階段 應(yīng)該允許設(shè)計(jì)人員充分發(fā)揮創(chuàng)造性 不受到任何約 束 即使產(chǎn)生了許多不切實(shí)際的想法 也會(huì)在設(shè)計(jì)的早期 即在繪制圖紙之 前被改正掉 只有這樣 才不至于阻斷創(chuàng)新的思路 通常 還要提出幾套設(shè) 計(jì)方案 然后加以比較 很有可能在這個(gè)計(jì)劃最后決定中 使用了某些不在 計(jì)劃之內(nèi)的一些想法 一般的當(dāng)外型特點(diǎn)和組件部分的尺寸特點(diǎn)分析的透徹時(shí) 就可以全面的 設(shè)計(jì)和分析 接著還要客觀的分析機(jī)器性能和優(yōu)越性 以及它的安全 重量 耐用性 并且競(jìng)爭(zhēng)力的成本也要考慮在分析結(jié)果之內(nèi) 每一個(gè)至關(guān)重要的部 分優(yōu)化它的比例和尺寸 同時(shí)也要保持與其他組成部分相協(xié)調(diào) 也要選擇原 材料和處理原材料的方法 通過力學(xué)原理來分析和實(shí)現(xiàn)這些重要的特性 如 那些靜態(tài)反應(yīng)的能量和摩擦力的最佳利用 像動(dòng)力慣性 加速動(dòng)力和能量 包括彈性材料的強(qiáng)度 應(yīng)力和剛度等材料的物理特性 以及流體潤(rùn)滑和驅(qū)動(dòng) 器的流體力學(xué) 設(shè)計(jì)的過程是重復(fù)和合作的過程 無論是正式或非正式的進(jìn) 行 對(duì)設(shè)計(jì)者來說每個(gè)階段都很重要 最后 以圖樣為設(shè)計(jì)標(biāo)準(zhǔn) 并建立將 來的模型 如果它的測(cè)試時(shí)符合事先要求的 則再將對(duì)初步設(shè)計(jì)進(jìn)行某些修 改 使它能夠在制造成本上有所降低 產(chǎn)品的設(shè)計(jì)需要不斷探索和發(fā)展 許 多方案必須被研究 試驗(yàn) 完善 然后決定使用還是放棄 雖然每個(gè)工程學(xué) 問題的內(nèi)容是獨(dú)特的 但是設(shè)計(jì)師可以按照類似的步驟來解決問題 產(chǎn)品的責(zé)任訴訟迫使設(shè)計(jì)人員和公司在選擇材料時(shí) 采用最好的程序 在材料過程中 五個(gè)最常見的問題為 1 不了解或不會(huì)使用關(guān)于材料應(yīng) 用方面的最新最好的信息資料 2 未能預(yù)見和考慮材料的合理用途 3 所使用的材料的數(shù)據(jù)不完全或是有寫數(shù)據(jù)不確定 尤其是當(dāng)其性能數(shù) 據(jù)長(zhǎng)期不更新 4 質(zhì)量控制方法不適當(dāng)和未經(jīng)驗(yàn)證 5 由一些完全不 稱職的人員選擇材料 通過對(duì)上述五個(gè)問題的分析 可以得出這些問題是沒有充分理由而存在 的結(jié)論 對(duì)這些問題的研究分析可以為避免這些問題的出現(xiàn)而指明方向 盡 管采用最好的材料選擇方法也不能避免發(fā)生產(chǎn)品責(zé)任訴訟 設(shè)計(jì)人員和工業(yè) 界按照適當(dāng)?shù)某绦蜻M(jìn)行材料選擇 可以大大減少訴訟的數(shù)量 從以上的討論可以看出 材料選擇的人們應(yīng)該對(duì)材料的性質(zhì) 特點(diǎn)和加 工方法有一個(gè)全面而基本的了解 在隨后生產(chǎn)和售后服務(wù)的幾年中 要接受新觀念的變化 或者由試驗(yàn)和 經(jīng)驗(yàn)為基礎(chǔ) 進(jìn)一步分析并改進(jìn) 一些設(shè)計(jì)規(guī)則 在本節(jié)中 建議運(yùn)用創(chuàng)造性的態(tài)度來替代和改進(jìn) 也許會(huì)創(chuàng)造出更實(shí)用 更經(jīng)濟(jì) 更耐用的產(chǎn)品 為了激發(fā)創(chuàng)造性思維 下列是設(shè)計(jì)和分析的建議和規(guī)則 前六個(gè)規(guī)則對(duì) 設(shè)計(jì)者來說特別適用 1 要有創(chuàng)造性的利用所需要的物理性質(zhì)和控制過程 2 認(rèn)識(shí)負(fù)載產(chǎn)生的影響及其意義 3 預(yù)測(cè)沒有想到的負(fù)載 4 創(chuàng)造出對(duì)載荷更為有利的條件 5 提供良好的應(yīng)力分布和最小的剛度條件 6 運(yùn)用最簡(jiǎn)單的方程來優(yōu)化體積和面積 7 選擇組合材料 8 仔細(xì)選擇所備的原料和不可缺少的組件 9 調(diào)整有效的設(shè)計(jì)方案 以適應(yīng)生產(chǎn)過程和降低成本 10 規(guī)定好準(zhǔn)確的位置條件為了使組件安裝時(shí)不干涉 一臺(tái)完整機(jī)器的設(shè)計(jì)是一個(gè)復(fù)雜的過程 機(jī)械設(shè)計(jì)是一項(xiàng)創(chuàng)造性的工作 設(shè)計(jì)工程師不僅在工作上要有創(chuàng)造性 還必須在機(jī)械制圖 運(yùn)動(dòng)學(xué) 工程材 料 材料力學(xué)和機(jī)械制造工藝學(xué)等方面具有深厚的知識(shí)基礎(chǔ) 任何產(chǎn)品在設(shè)計(jì)時(shí)第一步就是選擇產(chǎn)品每個(gè)部分的構(gòu)成材料 許多的材 料被今天的設(shè)計(jì)師所使用 對(duì)產(chǎn)品的功能 它的外觀 材料的成本 制造的 成本做出必要的選擇是十分重要的 對(duì)材料的特性必須事先做出仔細(xì)的評(píng)估 仔細(xì)精確的計(jì)算是必要的 以確保設(shè)計(jì)的有效性 在任何失敗的情況下 最好知道在最初設(shè)計(jì)中有缺陷的部件 計(jì)算檢查時(shí)非常重要的 一個(gè)小數(shù)點(diǎn) 的位置放錯(cuò) 就可以導(dǎo)致一個(gè)本可以完成的項(xiàng)目失敗 設(shè)計(jì)工作的各個(gè)方面 都應(yīng)該檢查和復(fù)查 計(jì)算機(jī)是一種工具 它能夠幫助機(jī)械設(shè)計(jì)師減輕繁瑣的計(jì)算 并對(duì)現(xiàn)有 數(shù)據(jù)提供進(jìn)一步的分析 互動(dòng)系統(tǒng)基于計(jì)算機(jī)的能力 已經(jīng)使計(jì)算機(jī)輔助設(shè) 計(jì) CAD 和計(jì)算機(jī)輔助制造 CAM 成為了可能 心理學(xué)家經(jīng)常談?wù)撊?何使人們適應(yīng)他們所操作的機(jī)器 設(shè)計(jì)人員的基本職責(zé)是努力使計(jì)算機(jī)來適 應(yīng)他們 這并不是一項(xiàng)容易的工作 因?yàn)閷?shí)際上并不存在著一個(gè)對(duì)所有人來 說都是最優(yōu)的操作范圍和操作流程 另一個(gè)重要問題 設(shè)計(jì)工程師必須能夠 同其他有關(guān)人員進(jìn)行交流和磋商 在開始階段 設(shè)計(jì)人員必須就初步設(shè)計(jì)同 管理人員進(jìn)行交流 并得到批準(zhǔn) 這一般是通過口頭討論 草圖和文字材料 進(jìn)行的 如前所述 機(jī)械設(shè)計(jì)的目的是生產(chǎn)能夠滿足人類需求的產(chǎn)品 發(fā)明 發(fā) 現(xiàn)和科技知識(shí)本身并不一定能給人類帶來好處 只有當(dāng)他們被應(yīng)用在產(chǎn)品上 才能產(chǎn)生效益 因而 應(yīng)該認(rèn)識(shí)到在一個(gè)特定的產(chǎn)品進(jìn)行設(shè)計(jì)之前 必須先 確定人們是否需要這種產(chǎn)品 掌握工程基礎(chǔ)知識(shí)要比熟記一些數(shù)據(jù)和公式更為重要 僅僅使用數(shù)據(jù)和 公式是不足以在一個(gè)好的設(shè)計(jì)中做出所需要的全部決定的 另一方面 應(yīng)該 認(rèn)證精確的進(jìn)行所有的運(yùn)算 例如 即使講一個(gè)小數(shù)點(diǎn)的位置放錯(cuò) 也會(huì)使 正確的設(shè)計(jì)變成錯(cuò)誤的 機(jī)械設(shè)計(jì)包括以下內(nèi)容 1 對(duì)設(shè)計(jì)過程 設(shè)計(jì)所需要公式以及安全系數(shù)進(jìn)行介紹 2 回顧材料特性 靜態(tài)和動(dòng)態(tài)載荷分析 包括梁 振動(dòng)和沖擊載荷 3 回顧應(yīng)力的基本規(guī)律和失效分析 4 介紹靜態(tài)失效理論和靜態(tài)載荷下機(jī)械斷裂分析 5 介紹疲勞失效理論并強(qiáng)調(diào)在壓力條件下接近高循環(huán)的疲勞設(shè)計(jì) 這 通常用在旋轉(zhuǎn)機(jī)械的設(shè)計(jì)中 6 深入探討機(jī)械磨損機(jī)理 表面接觸應(yīng)力和表面疲勞現(xiàn)象 7 使用疲勞分析技術(shù)校核軸的設(shè)計(jì) 8 討論潤(rùn)滑油膜與滾動(dòng)軸承的理論和應(yīng)用 9 深入介紹直齒圓柱齒輪的動(dòng)力學(xué) 設(shè)計(jì)和應(yīng)力分析 并簡(jiǎn)單介紹斜 齒輪 錐齒輪和渦輪有關(guān)方面的問題 10 討論彈簧設(shè)計(jì) 螺桿等緊固件的設(shè)計(jì) 包括傳動(dòng)螺桿和預(yù)緊固件 11 介紹盤式和鼓式離合器及制動(dòng)器的設(shè)計(jì)和技術(shù)說明 一個(gè)好的設(shè)計(jì)人員應(yīng)該勇于提出新的想法 而且愿意承擔(dān)一定的風(fēng)險(xiǎn) 當(dāng)新的方法不適用時(shí) 就使用原來的方法 因此 設(shè)計(jì)人員必須要有耐心 因?yàn)樗ㄙM(fèi)的時(shí)間和努力并不能保證帶來成功 一個(gè)全新的設(shè)計(jì) 要求摒棄 許多陳舊的 為人們所熟知的方法 由于許多人墨守成規(guī) 這樣做并不是一 件容易事 一位機(jī)械設(shè)計(jì)師應(yīng)該不斷地探索改進(jìn)現(xiàn)有的產(chǎn)品的方法 在此過 程中應(yīng)該認(rèn)證選擇原有的 進(jìn)過驗(yàn)證的設(shè)計(jì)理論 將其與未經(jīng)過驗(yàn)證的新觀 念結(jié)合起來 新設(shè)計(jì)本身會(huì)有許多缺陷和未能預(yù)料的問題發(fā)生 只有當(dāng)這些缺陷和問 題被解決之后 才能體現(xiàn)出新產(chǎn)品的優(yōu)越性 因此 一個(gè)性能優(yōu)越的產(chǎn)品誕 生的同時(shí) 也伴隨著較高的風(fēng)險(xiǎn) 應(yīng)該強(qiáng)調(diào)的是 如果設(shè)計(jì)本身不要求采用 全新的方法 就沒有必要僅僅為了變革的目的而采用新方法