Steps
Step 1
Part Analysis
This step conducts in-depth analysis of mechanical engineering problems, clarifying design requirements and constraint conditions. Mechanical design requires comprehensive analysis from functional requirements, load conditions, working environment and other aspects, determining design inputs and technical specifications. Lay the foundation for subsequent scheme design through requirements analysis and failure mode analysis.
• Analyze machine functional requirements and performance specifications, including motion parameters, power parameters, accuracy requirements and life requirements
• Determine load conditions and working environment, calculate nominal load and design load, considering dynamic load, impact and fatigue effects
• Identify main failure modes (fracture, deformation, wear, corrosion, instability, etc.), determine corresponding design criteria
Deliverable: Design requirements analysis report (including functional requirements, performance specifications, load analysis, failure modes, design criteria) | Quality standard: Clear requirements, in-depth analysis, accurate loads, reasonable criteria
Step 2
Blank and Process Route
This step performs machining process planning, determining part processing methods, process routes and operation parameters. Process design is the bridge connecting product design and manufacturing, requiring improvement of production efficiency and reduction of manufacturing costs under the premise of ensuring processing quality. Comprehensively consider part structure, material, batch size and equipment conditions.
• Perform part process analysis, determine machining surfaces, accuracy requirements and blank type, select locating datums
• Develop process route, arrange machining sequence, determine machining allowance and operation dimensions for each process
• Select machine tools and tooling, determine cutting parameters and time standards, prepare process flow sheet and operation sheet
Deliverable: Process plan (including process flow sheet, operation sheet, tool sheet, measuring tool list, time standard) | Quality standard: Reasonable process, correct datums, closed dimension chain, good economics
Step 3
Operation Design
This step performs scheme design of mechanical systems or components, translating functional requirements into specific structural schemes and parameters. Mechanical design is the core of mechanical engineering, requiring balance among strength, stiffness, life, manufacturability and economy. Adopt three-stage method of conceptual design, preliminary design and detailed design, gradually refining design schemes.
• Perform overall scheme design, determine transmission scheme, structural layout and main parameters, draw mechanism kinematic diagram
• Perform component design calculation, determine dimensions and materials based on strength theory, stiffness theory and fatigue theory
• Perform 3D modeling and assembly design using SolidWorks, UG or Pro/E, check interference and motion coordination
Deliverable: Design scheme (including assembly drawing, part drawings, calculation document, BOM table, selection description) | Quality standard: Reasonable scheme, correct calculation, good manufacturability, meeting functional requirements
Step 4
Operation Dimension Calculation
This step performs detailed calculation of mechanical components, verifying design indicators such as strength, stiffness and stability. Mechanics calculation is the foundation of mechanical design, based on mechanics of materials, elasticity and mechanical design theory, ensuring components are safe and reliable under working loads. Combine analytical calculation with finite element calculation for mutual verification.
• Perform force analysis and internal force calculation, draw shear force diagram, bending moment diagram and torque diagram, determine critical sections
• Apply strength theories (first, second, third, fourth strength theory) for strength verification, calculate safety factor
• Perform stiffness calculation (deformation calculation) and stability calculation, ensuring deflection, rotation angle and critical stress meet requirements
Deliverable: Calculation document (including force analysis, internal force diagrams, strength verification, stiffness verification, stability calculation) | Quality standard: Correct calculation model, proper formula application, accurate results, sufficient safety factor
Step 5
Process Documentation and Report
This step performs machining process planning, determining part processing methods, process routes and operation parameters. Process design is the bridge connecting product design and manufacturing, requiring improvement of production efficiency and reduction of manufacturing costs under the premise of ensuring processing quality. Comprehensively consider part structure, material, batch size and equipment conditions.
• Perform part process analysis, determine machining surfaces, accuracy requirements and blank type, select locating datums
• Develop process route, arrange machining sequence, determine machining allowance and operation dimensions for each process
• Select machine tools and tooling, determine cutting parameters and time standards, prepare process flow sheet and operation sheet
Deliverable: Process plan (including process flow sheet, operation sheet, tool sheet, measuring tool list, time standard) | Quality standard: Reasonable process, correct datums, closed dimension chain, good economics