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عدد المساهمات : 19002 التقييم : 35506 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب Make - Mechanical Engineering for Makers الخميس 23 نوفمبر 2023, 8:30 pm | |
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أخواني في الله أحضرت لكم كتاب Make - Mechanical Engineering for Makers A Hands-On Guide to Designing and Making Physical Things Brian Bunnell and Samer Najia
و المحتوى كما يلي :
Table of Contents Mechanical Engineering – A Maker’s Perspective 1 Basic Topics of Mechanical Engineering 1 Simple Machines 3 Materials 4 Stress (in the mechanical sense) 6 Static Structures and Dynamic Systems 7 Thermal/Fluid Systems 8 Electrical Engineering and Electromechanical Systems 9 Design and Design Tools 10 Manufacturing 11 Two Tales of Maker Inspiration 13 So You Have and Idea for a Project – Let’s Make It Real! 16 Project-Realization Process 17 Define the Project Idea 18 Define the Specifications 18 Conceptualize (Sketch) the Concept 20 Perform the Research 22 Fabricate the Project Idea 23 Test and Refine the Project Idea 28 Air Horn Project 29 Modularization of Design 42 Object-Oriented Programming 44 Materials Selection – Plastics, Woods, and Metals 46 Material Properties to Consider 47 Types of Materials 48 Examples of Material Shapes (Focus on Metals) 60 Protection from the Environment 62 Bonding Components Together 62 Tool Availability 63 Material Availability 63 Materials Breakdown for Brian’s Tot-Size Tank 64 Materials Breakdown for Samer’s Adult-Size Tank 73 Fasten-ating World of Fasteners & Adhesives 78 Types of Fasteners 79 Threaded Fastener Units of Measure 84 Assembly Basics 86 Corrosion 88 Fixing Fastener-related Mistakes 89 Adhesives 91 Fasteners Used in the Tot-Size Tank 93Mechanical Engineering for Makers v 5 6 7 8 9 Shaping the Ship - Giving Your Project Structure 98 Design Considerations for Structures 100 A Static Structure Example – Tot-Size Tank Body 106 A Dynamic Structure Example – Tot-Size Tank Tracks 108 Levers – Handling the Suspense 112 Classes of Levers 114 Classy Lever Contraption Project 117 The Accordion Project 127 Pulleys – Get into the Groove 132 Claw and Pulley Experiments 135 The Door Frame Clampy Claw (DFCC) Detour Project 136 Pulley Experiments Project 144 PVC Articulated Crane (PAC) Project 152 Gears and Gear Trains – Grinding, Isn't It 166 Types of Gears 168 General Gear Nomenclature – The Simplest Example (the Spur Gear) 171 Gear Ratios 172 The Humble Can Opener – A Gear Ratio Discussion and Intro to Compound Gears 175 Gear -Based Device Discussion: Differetial 176 The Cog Gear Differential (CGD) Project 179 Why Stop Now? 188 The Reality of Making vs. Engineering 189 Pneumatic Paper "Rockets" 190 Making a Pneumatic (Paper) Rocket Project 191 Pneumatic Rocket Launcher Project 194 Removable/Replaceable Model Rocket Booster Section 199 Pneumatic Cannon – Harnessing the Power of Air 202 Pneumatic Cannon – How it Works 204 Altitude Payload Dropper – Using Hobby Servos, Sensors & Microcontrollers 206 9A acrylic (plexiglass), 54 acrylonitrile butadiene styrene (ABS), 55, 64 adhesives, 91–93 Adult-Size Tank (Najia) construction and article on, 14–15 frame, 45, 64 levers, 114 materials, 73–74 prototypes, 24–27 specifications, 19, 26, 73 steering system, 45 suspension, 74, 130–31 wheels, 44–45, 74 air horn project, 29–42 conceptualizing/sketching, 29 defining the idea, 29 defining the specifications, 29 fabricating, 32–39 feedback, 29 how air horns work, 30 research, 29–32 testing/refining, 39–42 walkabout to look at materials, 29–32 air manifold, 37–38 air pressure, 204 Altitude Payload Dropper, 206–9 aluminum 6061 T-6, 70–71 about, 50 anodized, 71 foil, 75 ingots made from cans, 64 T-slot extrusion, 61, 66, 69–70, 90 annealed glass, 52 Antikythera Mechanism, 1, 167 Apogee Rockets, 199–200 appliances, repurposed, 75 aramid fibers (Kevlar), 55–56 Archimedes, 116, 133 atmospheric pressure, 204 AutoCAD, 10 auto parts stores and wrecking yards, 76 210 Index INDEXB band saw, 34–35 barometric (atmospheric) pressure sensors, 207 bar stock, 60–61 batteries, 9-volt, 198 Baum, Alan, 13, 178 bevel gears, 168–69 bits for countersinks and counterbores, 85 blue foam, 57 bolted joints, 84 bolts, 81–82, 85, 96–97, 126 borosilicate glass (Pyrex), 52 bracing (triangulation), 101–2 brass, 50 Bunnell, Brian. See also Tot-Size Tank Drift Trike Industrial, 12, 178 Jacob’s ladder project, 18–19 pneumatic cannon project, 40, 42, 93 butt joints, 101 button-head screws, 95–96 C CAD (Computer-Aided Design), 10 CAM (Computer-Aided Manufacturing), 11 cannons, pneumatic, 8–9, 20–21, 40, 202–5 cantilever support, 70 car-battery corrosion, 89 carbon fibers, 56, 59 carriage bolts, 81 cast iron, 51 castle nuts, 83 catapults, 116 C-channel shape, 62 ceramic glue, 91–92 chamfering a hole, 41 chop saw, 34–35 chromoly, 51 claw hammers, 116 clearance holes, 85–86 clothes, repurposed, 75 coat hanger wire hook, 163 cogs, from plywood and dowels, 180–81 compressed gases, 202 Computer-Aided Design (CAD), 10 Computer-Aided Manufacturing (CAM), 11 computer components, repurposed, 60, 63–64, 75 Computer Numeric Controlled (CNC) machining centers, 11 conductive heat transfer, 8 conservation of energy and work, 5 construction adhesive, 91 contact adhesive, 91 containers, repurposed, 75 convective heat transfer, 8 copper, 50–51 corner (angle) joints, 101 counterbores, 85 countersinks, 85, 126 craft supply stores, 76 D deburring tools, 87 degrees of freedom (DOF) and constraints, 109–11 Delrin, 54–55 design Computer-Aided Design (CAD), 10 Computer-Aided Manufacturing (CAM), 11 cost factor, 12 defined, 10 Finite Element Analysis (FEA), 11 modularization of, 42–45 structural considerations (see under structure) differentials, 176–87 displacement, 134–35 DIY stores, 75 DOF (degrees of freedom) and constraints, 109–11 door hinges, repurposed, 63 dowels, 80 drawings, 22 drones, 206 dumpster diving, 65–66, 76 E electrical conduit (EMT tubing), 71–72 electrical engineering/electromechanical systems, 09 electronics, repurposed, 60, 63–64, 75 EMT tubing (electrical conduit), 71–72 energy and work, conservation of, 5 epicyclic gear trains (planetary gear sets), 170 Mechanical Engineering for Makers 211epoxy, 92 epoxy resin, 53 equilibrium, 115–17 Excel, 11 ExpertCAD, 10 eye bolts and eye lags, 82, 126, 158 F fabricating a project idea, 23–27 fabric glue, 91 “failure breeds success” maxim, 28 farm supply stores, 76 fasteners, 79–97 adhesives, 91–93 aluminum T-slot extrusion, 90 assembly basics, 86–87 bolts, 81–82, 85, 96–97, 126 corrosion, 88–89 dowels, 80 fixing mistakes related to, 89–90 hole types, 85–86, 89 length, choosing, 86 nails, 80 nuts, 82–83, 97 overview, 5, 79–80 patching holes, 90 pins, 80 rivets, 80, 87 screws, 80–81, 84–86, 95–96 spacing, 87–88 threaded, measurement units for, 84–86 in Tot-Size Tank, 93–97 washers, 83–85, 88 FEA (Finite Element Analysis), 11 fiberglass (glass fibers), 56, 59 fiber-reinforced composites, 56 “50 Digital Wood Joints Poster,” 101 filament extruders, 64 Finite Element Analysis (FEA), 11 foam, 56–59 foam board, 58 force balance equations, 141–43 free-body diagrams (FBDs), 140–43, 150 FreeCAD, 10 fulcrum, 4 G galvanic corrosion, 89 garage sales, 76 gauge pressure, 204 gears, 167–87 can opener example, 175–76 Cog Gear Differential (CGD) project, 179–87 compound gear trains, 175–76 differentials, 176–87 gristmill example, 187 nomenclature, 171 overview, 167 ratios, 172–73 selecting, 187 types, 168 glass, 52–53 glass fibers (fiberglass), 56, 59 glue, 91 Google Sheets, 11 grip length (fasteners), 87 gusseting, 101 H hand saw, 34–35 hanger bolts, 82, 96–97 hardware cloth, 72–73 harmonics, 7 heatsinks, 208 heat transfer, 8–9 helical gears, 168 hex nuts, 82 hobby servos, 207–8 hobby shops, 76 holes chamfering, 41 deburring, 87 patching, 90 placement, 127 tapping, 40–42 types, 85–86, 89 home improvement stores, 75 hot glue, 91 hot wire cutters, 57 hypoid gears, 169 212 INDEXI I-beams, 62 idea for a project, 17–45. See also air horn project conceptualizing/sketching, 20–22 defining the idea, 18 defining the specifications, 18–20 drawings, 22 fabricating, 23–27 feedback, 23 ingenuity, 40–42 intuition, 31 modularization of design, 42–45 object-oriented programming, 44–45 outsourcing manufacturing, 25 prototyping, 24–27, 74 realization process, overview, 17 research, 22–23 scale modeling, 23–25, 27 staying on track, 24 testing/refining, 28 walkabout to look at materials, 23 ideal system, 2 idler gears, 174 inclined planes, 3, 5 inserts, 83 Instructables, 60 internet sites for materials, 76 intuition, 31 Inventor, 10 J Jacob’s ladder project (Bunnell), 18–19 jam nuts, 97 joints/joinery, 100–1, 104–5 K kernmantle rope, 144 Kevlar (aramid fibers), 55–56 L lag screws, 96 laminated glass, 52 landfill waste, reducing, 63 lap joints, 101 laptops, repurposed, 60 LCDs, repurposed, 60 LEDs (light emitting diodes), 206–7 levers, 113–31 accordion project, 127–29 Adult-Size Tank suspension, 130–31 classes, 114–17 Classy Lever Contraption, 117–25 defined, 4 equilibrium, 115–17 the law of the lever, 116 mechanical advantage, 115–17 overview, 113–14 Lexan (polycarbonate), 54, 68–69 limited-slip differentials, 178 lock nuts (nyloc nuts), 82, 88 lock washers, 83–84 L-shaped angle, 62 lubricity, 5 M machine screws, 81, 86 Make: magazine, 11, 13–14 manufacturing, 11–12, 25 materials, 47–76 acquisition, 65–66 for the Adult-Size Tank, 73–74 aesthetics, 47 aluminum foil, 75 appliances, repurposed, 75 availability, 62–63 clothes, repurposed, 75 component, 60 containers, repurposed, 75 cost, 5, 47 dumpster diving for, 65–66, 76 fastenability, 5 (see also fasteners) function, 47 glass, 52–53 lubricity, 5 Mechanical Engineering for Makers 213manufacturability, 4–5 metals, 50–51 overview, 4–6, 47 paper clips, 75 plastic milk jugs, 75 plastics, 53–55 plastic wrap/sandwich bags, 75 protection from the environment, 62 repurposed, 60, 63–64, 75–76 rubber bands, 75 safety, 47, 59 shapes, 61–63 from stores and wrecking yards, 75–76 strength/durability, 47, 89 tool availability, 62 toothpicks, 75 for the Tot-Size Tank, 64–73 toys, repurposed, 75 wax paper, 75 woods, 48–49 workability, 47 MDF (Medium Density Fiberboard), 49, 59 “measure twice and cut once” adage, 24 mechanical advantage (MA) amplification vs. reduction of force, 2 calculating, 2 defined, 1 of levers, 115–17 of pulleys, 134–35, 150–51 of a wheel-and-axle, 3 mechanical engineering, overview of, 1–15 basic topics, 1–2 definition of mechanical engineering, 1 design, 10–11 (see also design) electrical engineering/electromechanical systems, 9 maker inspirations (case studies), 13–14 (see also Adult-Size Tank; Tot-Size Tank) making vs. engineering, 189 manufacturing, 11–12 materials, 4–6 (see also materials) simple machines, 1, 3–5 (see also levers; pulleys; screws) static vs. dynamic structures, 7, 99–100 stress, 6 thermal/fluid systems, 8–9 training of engineers, 1 Medium Density Fiberboard (MDF), 49, 59 metal alloys, 50 aluminum, 50 aluminum T-slot extrusion, 61, 66, 69–70, 90 bar stock, 60–61 brass, 50 cast iron, 51 chromoly, 51 copper, 50–51 corrosion, 88–89 deburring drilled holes, 87 ferrous vs. non-ferrous, 50 patching holes, 90 plate, 60 protection from the environment, 62 shapes, 60–62 sheet, 60 steel, 50–51 tube stock/pipe, 61 metric screws, 84, 86 microcontrollers, 206–9 mild carbon steel, 50–51, 62 miter gears, 172–73 modularization of design, 42–45 motors, repurposed, 60 N nails, 80 Najia, Samer, 60, 87, 130–31. See also Adult-Size Tank flight simulator project, 104–5 go-karts, 14, 45, 73 patches used by, 90 National Association of Rocketry (NAR), 198 national pipe thread taper (NPT), 40–41 Newton, Sir Isaac, 6 newtons (Ns), 6 nuts, 82–83, 97 nyloc nuts (lock nuts), 82, 88 nylon, 54–55 O object-oriented programming (OOP), 44–45 OpenSCAD, 10 outsourcing, 25 214 INDEXP paint, lead in, 59 paper clips, 75 paracord, 144 patching holes, 90 pilot holes, 89 pink foam, 57 pins, 80 pipe cutting, 33–35 PLA (polylactic acid), 55 planetary gear sets (epicyclic gear trains), 170 plastic acrylic (plexiglass), 54 bending, 67 Delrin, 54–55 epoxy resin, 53 fiber-reinforced composites, 56 foam, 56–59 nylon, 54–55 polycarbonate (Lexan), 54, 68–69 polyester resin, 53 polyvinyl chloride (PVC), 53–54 safety, 59, 67 thermoplastics, 53–55 thermosets, 53 3D printing filament, 55, 64 Ultra-high Molecular Weight Polyethylene (UHMW), 54–55, 67 plastic milk jugs, 75 plastic wrap/sandwich bags, 75 plate metal, 60 plexiglass (acrylic), 54 Plutarch, 133 plywood, 48–49, 70 pneumatic cannons, 8–9, 20–21, 40, 202–5 pneumatic paper rockets, 190–93 pneumatic rocket launchers, 194–199 polycarbonate (Lexan), 54, 68–69 polyester resin, 53 polylactic acid (PLA), 55 polyvinyl chloride pipe. See PVC pipe potato guns. See pneumatic cannons ProE, 10 prototyping, 24–27, 74 pulleys, 133–65 compound, 134 defined, 4, 133 and displacement, 134–35 Door Frame Clampy Claw (DFCC) construction, 135–43 Door Frame Clampy Claw (DFCC) force experiments, 144–49 force balance equations, 141–43 free-body diagrams (FBDs), 140–43, 150 mechanical advantage, 134–35, 150–51 overview, 133–34 PVC Articulated Crane (PAC) project, 152–65 in Tot-Size Tank, 135 PVC (polyvinyl chloride) pipe cementing, 93 cutting, 33–35 fitting alignment/repositioning tricks, 123 friction fitting, 38 gauge, 61 overview, 53–54 removing pipes from fittings, 123 self-tapping with metal pipe fitting, 40–42 Pyrex (borosilicate glass), 52 R rack and pinion gears, 170 radiant heat transfer, 9 ratchet pipe cutter, 34–35 rivets, 80, 87 rivnuts, 83 rocket launchers, pneumatic, 194–199 rockets, model, 199–201 rockets, pneumatic paper, 190–93 roll pins, 80 rotating pipe cutter, 34–35 rubber bands, 75 rust, 88–89 S scalars, 140–41 scale modeling, 23–25, 27 Schrader valves, 190, 196–199 screws, 4, 80–81, 84–86, 95–96 scrounging, 64 seesaws, 114 servos, 207–8 Shaduf, 113 Mechanical Engineering for Makers 215sheet glass, 53 sheet metal, 60 sheet metal screws, 81 shoulder bolts (stripper bolts), 82 silicone adhesive, 92 simple machines, 1, 3–5. See also levers; pulleys; screws sketching, 20–22 SketchUp, 10 skinning material, 101 slotted joints, 101 solenoid sprinkler valves, 190, 196–199 SolidWorks, 10 spacers, 3D printed, 180–81 spiral bevel gears, 169 spray adhesive, 91 spreadsheets, 11 sprinkler valves, 190, 196–199 spur gears, 168, 171 steel/stainless steel, 50–51 stiffening beads, 103 stiffness-to-weight ratio, 56–57 strap joints, 101 stress, 6 structural shapes, 62 structure, 99–111 bracing (triangulation), 101–2 defined, 99 degrees of freedom (DOF) and constraints, 109–11 design overview, 100 dynamic example (Tot-Size Tank tracks), 108–9 flight simulator example, 104–5 gusseting, 101 joints, 100–1, 104–5 overbuilding, 103 skinning material, 101 static example (Tot-Size Tank body), 106–8 static vs. dynamic, 7, 99–100 stiffening beads, 103 strength, 101–5 trusses, 102 weight, 103 superglue (syanoacrylate), 92 T Tacoma Narrows Bridge, 7 tapping a hole, 40–42 tee joints, 101 tempered glass, 52 thermal/fluid systems, 8–9. See also pneumatic cannons threaded rods, cutting, 138 thread pitch (fasteners), 84, 86 3D printing filament, 55, 64 through-holes, 85 TinkerCAD, 10 tolerance, 128 toothpicks, 75 torque, 115, 143. See also gears torque wrenches, 88 Tot-Size Tank (Bunnell) construction and article on, 13–14 fasteners, 93–97 levers, 114 materials, 64–73 modules, 42–44, 64–65 pulleys, 135 sketch/model, 17 specifications, 19 steering system, 45 structure of body, 106–8 structure of tracks, 108–9 subsystems, 21–22 testing/refining, 28 toys, repurposed, 75 trailing-link suspension, 130–31 triangulation (bracing), 101–2 trusses, 102 T-slot nuts, 83 tube cutter, 34–35 tube stock/pipe, 61 tweezers, 115 two-part foam, 58 U U-channel shape, 62 Ultra-high Molecular Weight Polyethylene (UHMW), 54–55, 67 Unified National Coarse (UNC) thread, 86 Unified National Fine (UNF) thread, 86 US Customary System, 79, 84, 86 216 INDEXV vectors, 140–41 vibration, 7 voltage regulators, 208 W washers, 83–85, 88 wax paper, 75 wedges, 3–4 wheel-and-axle, 3 wheelbarrows, 114–15 white foam, 57 winches, 169–70 wood hardwoods, 48–49 Medium Density Fiberboard (MDF), 49, 59 overview, 48 patching holes, 90 plywood, 48–49, 70 pressure-treated, safety when working with, 59 protection from the environment, 62 from remodeling projects, 64 self-tapping with metal pipe fitting, 42 softwoods, 48–49 wood glue, 92 wood screws (deck screws), 81, 85 work, defined, 5 worm gears, 169–70 Y yard sales, 76
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