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Some Rules for Mechanical Design
Designing stars 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 stop 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 cost. 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 of 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 tes
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