Understand the details of size control in mechanical design | Combination of pictures and text

In mechanical design, controlling the dimensions of a product is a reflection of the designer’s ability. If you lack the necessary design skills, achieving size control can be difficult. Therefore, I would like to share with you some basic design processes and methods that can help you improve your skills.

 

01 Determine the size of outsourced functional components first

 

Firstly, when starting a design project, consider the overall requirements of the solution. Confirm the models and specifications of any outsourced functional components to get information about delivery time, cost, and design size. This information can help you evaluate the feasibility of your design solution. Additionally, the design size of purchased parts is crucial to the structural design of a product.

 

The picture above provides a general understanding of outsourced functional components. Although there are many types, these are just a few examples. These components can be bought from suppliers and product samples are used to confirm design dimensions. Suppliers provide paper and electronic samples that include two-dimensional and three-dimensional drawings of parts. For instance, pneumatic components from Japan SMC, pneumatic components from China Airtac, and products from Japan THK wait.

As a design engineer, the first step is to draw the corresponding part structure based on the supplier’s sample. After this, draw the corresponding part structure according to the model and specifications chosen. This is the primary design basis and should be accurate. If any changes are required, it implies that the design plan was flawed from the beginning.

 

As a mechanical structure design engineer, it is important to have a good understanding of the product samples provided by product-supporting suppliers. When designing a complete feed assembly drawing of a machining center, it is recommended to start from the screw rod and build outward. First, draw the screw rod, followed by the shaft end, motor base and bearings, and then other related parts. It is important to confirm the general structure and shape of the machine tool before proceeding with the design of individual parts.

Designing mechanical parts is a complex process where the size of one part affects the size of another. Hence, it is important to have a good understanding of the origin and purpose of each part to ensure that the design is well-founded and reasonable.

 

In addition to mastering the technology, it is equally important to build and maintain a network of product-supporting suppliers. This is a process of self-awakening and growth, and it is the most valuable resource and ability a design engineer can possess.

 

02 Confirm the design structure

When it comes to mechanical design structures, everyone has their own ways of thinking and habits, which can be hard to unify. However, it’s important to fully understand and master traditional structural forms, such as the various connection methods for flanges, and how to handle them effectively. Additionally, when designing parts, it’s crucial to consider not only their functional requirements but also the processing and assembly process requirements, especially for higher-end products where after-sales convenience is also a key consideration. All of these aspects together require a comprehensive skillset.

I developed a set of stamping molds for a product. During the trial, the stamping process went smoothly. However, I faced a problem when I tried to remove the parts from the mold. It turned out that the mold opening stroke was insufficient, which caused an embarrassing situation. This incident highlighted the importance of structural processing in product design. It is essential to evaluate and consider the product’s functions comprehensively before starting the structural processing. The design, procurement, outsourcing processing, assembly, debugging, production, and after-sales must be handled meticulously to ensure the product’s quality. Neglecting any of these steps can lead to serious consequences – the final product may not be perfect and can even be a complete failure.

The ability to handle structures comes with experience, observation, and imagination. It is acquired through project design experience, learning from mistakes, and guidance from an excellent teacher. A good teacher can help you achieve better results with less effort and save you time by providing valuable advice. However, finding a good teacher is not easy since others do not owe you anything. Moreover, in the workplace, others may see you as a rival and may not be willing to help. Therefore, finding a good teacher requires luck.

 

If you don’t have a good teacher in reality, then find drawings, copy them, look at them and think about them. This is the most realistic shortcut. For a design engineer, imitation is definitely a shortcut to self-growth. Don’t think about innovation from the beginning. , as long as you can master the experience of previous people, it is already an incredible ability.

The confirmed design structure here refers to both the overall structure of the product and the structure of the parts that make up the product. This is basically confirmed during the design process of the assembly drawing. This is why the design engineer who can do the scheme does not The reason why there are not many is because the comprehensive ability requires too high and cannot be mastered by just playing for a few years.

 

03 Design part drawings (wall thickness)

 

After confirming the shape of the part, how to confirm the wall thickness of the part is something that is very confusing to many people. Confirmation of the wall thickness of the part needs to consider many factors, such as the shape of the part, the material of the part, and the molding method of the part. , the heat treatment requirements of the parts, the usage intensity of the parts, the location of the cnc products, etc. Only by taking these comprehensive factors into consideration can we truly design qualified parts drawings. Of course, this is not easy.

 

It’s best to learn from existing products and parts when designing new ones. Check if your company has previously made similar products or used similar parts. Consider the relevant factors and design dimensions of previous drawings to confirm your part design. This method has the lowest error rate since others have likely already made the mistakes you could make.

 

Some suggest doing a mechanical analysis for every part, but this is not necessary and can lead to delays and cost overruns. Instead, focus on speed and cost when developing products. As you gain experience, you’ll develop your own design principles for structure, size, materials, and requirements.

 

To learn more, seek advice from those with research and development experience. They have valuable knowledge that you can learn from. People in science and engineering are often willing to share their expertise if you ask humbly. While they may not reveal all their tricks, you can still learn from basic design attempts. Communicating with experienced professionals will help you succeed in the workplace.

 

04 Confirm standard parts

 

Selecting standard parts is a simple process, similar to outsourcing parts. Once you choose the standard parts, you need to confirm their structure and size accordingly. When designing, it’s important to make full use of these cnc machined parts and ensure that the structure and size align with your design. The more standard parts you use, the more efficient your structural processing will be.

When it comes to choosing standard parts, there are a few variables to consider. Stress range, assembly method, standard parts material, and standard parts use are some of the aspects that help confirm the selected model and specifications. Once you have selected the appropriate model and specifications, you can design the corresponding drawings. Most 2D and 3D software comes with standard parts libraries that you can directly call upon, so you don’t have to draw them from scratch. However, choosing standard parts still requires some technical knowledge, although it’s relatively simpler than designing parts from scratch. If you have trouble selecting the right parts, you can always learn from others and try what has worked for them. By doing so, you can avoid falling into the same pitfalls that others have faced in the past.

 

05 Mechanical Analysis

Although we don’t use mechanical analysis in many areas of the company’s product design process, we still need to perform it whenever necessary. This is crucial for ensuring the quality and cost-effectiveness of our cnc components. We need to prioritize what needs to be done and what can be saved. We cannot overlook the importance of this process.

 

There are various ways to perform mechanical analysis. The conventional method involves looking up manuals, setting formulas, examining structures, etc., to make calculations. However, the latest way to do mechanical analysis is by using 3D design software, which can make the process quicker, more efficient, and better.

In summary, the most effective way to train individuals during the design process is by step-by-step analysis and explanation based on drawings. This is a process that cannot be substituted by any article or method. My customary training method is to allow new individuals to disassemble it following my instructions. For the parts drawing, they should first draw it based on their intention, after which I will inspect it. I will list all the issues found during the design process and then explain to them how to modify them and why they should be changed that way. Then, I asked them to correct the drawings based on my explanation. After correcting the drawings, they hand them over to me for review. If there are still issues, I will ask them to modify them again. This process is repeated several times during the product design process. As a result, a new individual can establish their preliminary design awareness and gradually cultivate their own design style and principles through numerous product design projects.

To be honest, training a qualified design engineer is not an easy task, especially when you put all your efforts into it. It can be really tiring. Every time I train someone, I tell myself that this person is like a knife. I want to sharpen them and make them an indestructible weapon in the workplace. Every time I think about this, I feel some sense of comfort in my heart.

 

 

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