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Contents FOREWORD, xv PREFACE, xvi DESIGN IN INDUSTRY: CAE in ACTION: Skate Blades on the Cutting Edge, xviii 1 Introduction to Graphics Communication and Sketching, 1 Objectives and Overview, 1 1.1 Introduction, 2 1.2 The Importance of Graphics in the Design Process, 4 1.2.1 Visualization, 5 1.2.2 Communication, 7 1.2.3 Documentation, 7 1.3 The Traditional Design Process, 8 1.4 The Design Process Using Concurrent Engineering, 9 1.5 Standards and Conventions, 11 1.5.1 CAD Database Standards, 12 1.6 Alphabet of Lines, 12 1.7 Specialists and Technical Drawings, 13 1.8 Traditional Tools, 13 1.8.1 Pencils, 14 HISTORICAL HIGHLIGHT Leonardo da Vinci, 15 1.8.2 Drawing Paper, 16 1.8.3 Scales, 17 1.8.4 Civil Engineer's Scale, 17 1.8.5 Mechanical Engineer's Scale, 19 1.8.6 Metric Scale, 23 1.8.7 Compass, 24 1.8.8 Dividers, 25 1.8.9 Templates, 26 1.9 What You Will Learn, 27 1.10 Technical Drawing Tools, 27 3-D MODELING PROJECT Chapter 1: Stapler Modeling Project, 28 1.11 Future Trends, 29 1.11.1 Visualization Tools, 29 1.12 Computer-Aided Drawing Tools, 29 1.13 Technical Sketching, 32 1.13.1 Freehand Sketching Tools, 35 1.13.2 CAD Sketching Tools, 36 1.14 Sketching Technique, 36 1.14.1 Seeing, Imaging, Representing, 37 1.14.2 Contour Sketching, 38 1.14.3 Negative Space Sketching, 40 1.14.4 Upside-Down Sketching, 40 1.14.5 Straight Lines, 40 1.14.6 Curved Lines, 43 1.15 Proportions and Construction Lines, 45 1.16 Lettering, 49 1.16.1 Lettering Standards, 49 1.16.2 Hand Lettering, 50 1.16.3 Alternate Text Styles, 50 1.16.4 CAD Lettering Technique, 53 1.17 Text on Drawings, 55 1.18 Summary, 56 DESIGN CASE STUDY 3-D Design Pays Off for Bose Corporation, 57 Goals Review, 58 Questions for Review, 58 Further Reading, 59 DESIGN IN INDUSTRY Virtual Reality Changes the Face of Design, 59 Problems, 60 Classic Problems, 72 2 The Engineering Design Process, 73 Objectives and Overview, 73 2.1 Design, 74 2.2 The Engineering Design Process, 76 2.2.1 Traditional Engineering Design, 77 2.2.2 Concurrent Engineering Design, 77 2.2.3 Collaborative Engineering, 78 2.2.4 Virtual Product Representation, 78 2.2.5 Prototyping, 78 2.2.6 Productivity Tools, 79 2.2.7 EDM/PDM, 79 2.2.8 Internet, Intranet, and Extranet, 82 2.2.9 The Digital Enterprise, 82 2.2.10 e-Business, 82 2.2.11 Design Teams, 82 2.2.12 Members of Design Teams, 84 2.2.13 Types of Design Projects, 84 2.3 Ideation, 84 2.3.1 Problem Identification, 84 2.3.2 Preliminary Ideas Statement, 87 2.3.3 Preliminary Design, 87 2.3.4 Ideation Resources, 89 2.3.5 The Designer's Notebook, 89 2.4 Refinement, 89 2.4.1 Modeling, 93 2.4.2 Computer Simulation and Animation, 96 2.4.3 Design Analysis, 97 2.5 Design Review Meetings, 101 2.6 Implementation, 101 2.6.1 Planning, 101 2.6.2 Production, 102 2.6.3 Marketing, 103 2.6.4 Finance, 104 2.6.5 Management, 105 2.6.6 Service, 106 2.6.7 Documentation, 106 HISTORICAL HIGHLIGHT Standards, 107 2.7 Drawing Control, 113 2.7.1 Product Data Control, 113 3-D MODELING PROJECT Chapter 2 Stapler Modeling Project, 114 2.7.2 File Management, 116 2.7.3 ISO 9000, 116 2.8 Other Engineering Design Methods, 117 DESIGN CASE STUDY The Motorola i1000 Handset Communicator, 118 Goals Review, 123 Questions for Review, 123 DESIGN IN INDUSTRY FEA and the America's Cup, 124 Further Reading, 126 3 Engineering Geometry, 134 Objectives and Overview, 134 3.1 Engineering Geometry, 135 3.2 Shape Description, 135 3.3 Coordinate Space, 136 3.3.1 Right-Hand Rule, 137 3.3.2 Polar Coordinates, 140 3.3.3 Cylindrical Coordinates, 140 3.3.4 Spherical Coordinates, 140 3.3.5 Absolute and Relative Coordinates, 141 3.3.6 World and Local Coordinate Systems, 142 3.4 Geometric Elements, 142 3.5 Points, Lines, Circles, and Arcs, 143 3.5.1 Points, 143 HISTORICAL HIGHLIGHT Gaspard Monge, 143 3.5.2 Lines, 145 3.5.3 Tangencies, 147 3.5.4 Circles, 149 3.6 Conic Curves, 150 3.6.1 Parabolas, 151 3.6.2 Hyperbolas, 151 3.6.3 Ellipses, 152 3.7 Roulettes, 156 DESIGN IN INDUSTRY New Tools Help Link Computer-Aided Industrial Design with Mechanical CAD, 156 3.7.1 Spirals, 157 3.7.2 Cycloids, 157 3.7.3 Involutes, 158 3.8 Double-Curved Lines, Including Helixes, 159 3.9 Freeform Curves, 159 3.9.1 Spline Curves, 160 3.9.2 Bezier and B-Spline Curves, 160 3.10 Angles, 161 3.11 Planes, 162 3.12 Surfaces, 162 3.12.1 Two-Dimensional Surfaces, 164 3.12.2 Ruled Surfaces, 166 3.12.3 Fractal Curves and Surfaces, 171 3.13 3-D Modeling, 172 3.13.1 Wireframe Modeling, 174 3.13.2 Surface Modeling, 175 Goals Review, 176 3-D MODELING PROJECT Chapter 3: Stapler Modeling Project, 177 Questions for Review, 177 Further Reading, 177 Problems, 178 Classic Problems, 183 4 Design Visualization, 185 Objectives and Overview, 185 4.1 Visualization for Design, 185 4.1.1 Problem Solving, 186 VISION, 187 4.2 Solid Object Features, 189 4.3 General Visualization Techniques, 191 4.3.1 Solid Object Combinations and Negative Solids, 191 4.3.2 Planar Surfaces, 192 4.3.3 Symmetry, 195 4.3.4 Surface Models (Developments), 196 4.4 Visualization Techniques for Engineering Drawings, 199 4.4.1 Image Planes, 199 4.4.2 Object-Image Plane Orientation, 200 4.4.3 Multiple Image Planes, 200 4.4.4 Choosing a View to Describe an Object, 201 4.5 Graphical Analysis of Engineering Data, 201 4.5.1 Data Visualization Elements, 202 4.5.2 Visualizations for One Independent Variable, 206 4.5.3 Visualizations for Two Independent Variables, 209 DESIGN IN INDUSTRY Sikorsky Helibus, 210 4.6 Future Directions, 211 4.7 Summary, 212 Questions for Review, 213 Further Reading, 213 Problems, 214 5 3-D Solid Modeling, 234 Objectives, 234 Introduction, 235 5.1 Model Definition, 235 5.2 Primitive Modeling, 235 5.3 Constructive Solid Geometry (CSG) Modeling, 236 5.4 Boundary Representation (B-Rep) Modeling, 240 5.5 Hybrid Modeling, 240 5.6 Constraint-Based Modeling, 241 5.6.1 Planning, 241 5.6.2 Sources of Data, 241 5.6.3 Eventual Model Use, 242 5.6.4 Modeling Standards, 242 5.7 Feature Analysis, 242 5.8 Feature Definition, 244 5.8.1 Features from Generalized Sweeps, 244 5.8.2 Construction Geometry, 245 5.8.3 Sketching the Profile, 248 5.8.4 Constraining the Profile, 249 5.8.5 Completing the Feature Definition, 254 5.8.6 Feature Planning Strategies, 258 DESIGN IN INDUSTRY Design of Tollway Extension, 260 5.9 Editing Part Features, 262 5.9.1 Understanding Feature Order, 262 5.9.2 Editing Feature Properties, 264 5.10 Duplicating Part Features, 265 5.11 Viewing the Part Model, 266 5.11.1 View Camera Operation, 266 5.11.2 View Camera Strategy, 270 5.12 Application of Part Model Data, 272 5.12.1 Model Data Associativity, 273 5.12.2 Documentation, 273 5.12.3 Assembly Modeling, 275 5.12.4 Analysis, 279 5.13 Summary, 281 Goals Review, 281 Further Reading, 283 Questions for Review, 283 Problems, 284 6 Multiviews and Auxiliary Views, 297 Objectives and Overview, 297 6.1 Projection Theory, 299 6.1.1 Line of Sight (LOS), 299 6.1.2 Plane of Projection, 299 6.1.3 Parallel versus Perspective Projection, 299 6.2 Multiview Projection Planes, 301 6.2.1 Frontal Plane of Projection, 301 6.2.2 Horizontal Plane of Projection, 301 6.2.3 Profile Plane of Projection, 302 6.2.4 Orientation of Views from Projection Planes, 302 6.3 Advantages of Multiview Drawings, 302 HISTORICAL HIGHLIGHT Ivan Sutherland (1938- ), 305 6.4 The Six Principal Views, 306 6.4.1 Conventional View Placement, 307 6.4.2 First- and Third-Angle Projection, 309 6.4.3 Adjacent Views, 309 6.4.4 Related Views, 311 6.4.5 Central View, 311 6.4.6 Line Conventions, 311 6.5 Multiview Sketches, 314 6.5.1 One-View Sketches, 314 6.5.2 Two-View Sketches, 314 6.5.3 Three-View Sketches, 319 6.5.4 Multiviews from 3-D CAD Models, 320 6.6 View Selection, 321 6.7 Fundamental Views of Edges and Planes for Visualization, 325 6.7.1 Edges (Lines), 325 6.7.2 Principal Planes, 326 6.7.3 Inclined Planes, 329 6.7.4 Oblique Planes, 329 6.8 Multiview Representations for Sketches, 329 6.8.1 Points, 329 6.8.2 Planes, 329 6.8.3 Change of Planes (Edge), 332 6.8.4 Angles, 332 6.8.5 Curved Surfaces, 332 6.8.6 Holes, 333 6.8.7 Fillets, Rounds, Finished Surfaces, and Chamfers, 336 6.8.8 Runouts, 338 6.8.9 Intersecting Cylinders, 338 6.8.10 Cylinders Intersecting Prisms and Holes, 339 6.9 Multiview Drawings Visualization, 340 6.9.1 Projection Studies, 341 6.9.2 Physical Model Construction, 341 6.9.3 Adjacent Areas, 343 6.9.4 Similar Shapes, 344 6.9.5 Surface Labeling, 345 6.9.6 Missing Lines, 345 6.9.7 Vertex Labeling, 345 6.9.8 Analysis by Solids, 345 6.9.9 Analysis by Surfaces, 348 6.10 ANSI Standards for Multiview Drawings and Sketches, 349 6.10.1 Partial Views, 349 6.10.2 Revolution Conventions, 350 6.10.3 Removed Views, 351 6.11 Auxiliary View Projections, 351 6.11.1 Fold-Line Method, 352 6.11.2 Reference Plane Method, 352 DESIGN IN INDUSTRY Using Parametrics with an Agile Manufacturing Strategy, 354 6.12 Auxiliary View Classifications, 356 6.13 Auxiliary Views Using CAD, 356 3-D MODELING PROJECT, 357 6.14 Summary, 357 Goals Review, 357 Questions for Review, 358 Problems, 359 Classic Problems, 388 7 Pictorial Projections, 393 Objectives and Overview, 394 7.1 Axonometric Projection, 394 7.1.1 Axonometric Projection Classifications, 394 7.2 Isometric Axonometric Projections, 397 7.2.1 Isometric Axonometric Drawings, 398 7.2.2 Standards for Hidden Lines, Center Lines, and Dimensions, 399 7.3 Isometric Pictorial Sketches, 400 HISTORICAL HIGHLIGHT Thomas Ewing French (1871-1944), 401 7.4 Isometric Ellipses, 403 7.5 Isometric Grid Paper, 406 DESIGN IN INDUSTRY Design for the Environment (DFE), 407 7.6 Oblique Planes in Isometric Views, 408 7.7 Angles in Isometric Views, 409 7.8 Irregular Curves in Isometric Views, 409 7.9 Isometric Ellipses Templates, 410 7.10 Section Views in Isometric Views, 412 7.11 Isometric Assembly Drawings, 413 DESIGN IN INDUSTRY Concept to Victory in 7 Months, 413 7.12 Oblique Projections, 414 7.12.1 Oblique Projection Theory, 414 7.12.2 Oblique Drawing Classifications, 417 7.12.3 Object Orientation Rules, 418 7.13 Oblique Pictorial Sketching, 418 7.14 Perspective Projections, 420 7.15 Perspective Projection Terminology, 421 7.16 Perspective Projection Classifications, 424 7.17 Perspective Drawing Variables Selection, 425 7.18 CAD Perspective Drawings, 425 3-D MODELING PROJECT, 428 7.19 Summary, 428 Goals Review, 428 Questions for Review, 428 Further Reading, 429 Problems, 430 Classic Problems, 436 8 Section Views, 439 Introduction and Objectives, 439 8.1 Sectioning Basics, 441 8.1.1 CAD Technique, 443 8.1.2 Visualization of Section Views, 444 8.2 Cutting Plane Lines, 445 8.2.1 Placement of Cutting Plane Lines, 447 8.3 Section Line Practices, 448 8.3.1 Material Symbols, 449 8.3.2 Sketching Techniques, 449 8.3.3 Outline Sections, 450 8.3.4 Thin Wall Sections, 451 8.4 Section View Types, 451 8.4.1 Full Sections, 452 8.4.2 Half Sections, 452 8.4.3 Broken-Out Sections, 453 8.4.4 Revolved Sections, 454 8.4.5 Removed Sections, 454 8.4.6 Offset Sections, 456 8.4.7 Assembly Sections, 457 8.4.8 Auxiliary Sections, 457 HISTORICAL HIGHLIGHT Doug Engelbart (1925- ), 460 8.5 Special Sectioning Conventions, 460 8.5.1 Ribs, Webs, and Other Thin Features, 461 8.5.2 Aligned Sections, 462 DESIGN IN INDUSTRY Adjustable Mountain Bike Suspension, 463 8.5.3 Conventional Breaks, 465 8.6 3-D CAD Techniques, 465 8.7 Summary, 466 3-D MODELING PROJECT, 467 Goals Review, 467 Questions for Review, 467 Problems, 468 9 Dimensioning and Tolerancing Practices, 477 Introduction and Objectives, 477 9.1 Dimensioning, 478 9.2 Size and Location Dimensions, 478 9.2.1 Terminology, 480 9.2.2 Basic Concepts, 482 9.2.3 Size Dimensions, 483 9.2.4 Location and Orientation Dimensions, 483 9.2.5 Coordinate Dimensions, 483 9.2.6 Standard Practices, 484 9.3 Detail Dimensioning, 488 9.3.1 Diameter versus Radius, 491 9.3.2 Holes and Blind Holes, 492 9.3.3 Counterbored Holes, 492 9.3.4 Spotfaces, 492 9.3.5 Countersinks, 492 DESIGN IN INDUSTRY Project Extranets Coordinate Engineering Projects across the Globe, 493 9.3.6 Screw Threads, 494 9.3.7 Grooves, 494 9.3.8 Manufacturers' Gages, 494 9.4 Dimensioning Techniques, 494 9.4.1 The Dimensioning Process, 495 9.4.2 Dimensioning Guidelines, 498 9.4.3 ASME Standard Dimensioning Rules, 499 9.5 Tolerancing, 500 9.5.1 Interchangeability, 501 9.6 Tolerance Representation, 501 9.6.1 General Tolerances, 502 9.6.2 Limit Dimensions, 502 9.6.3 Plus and Minus Dimensions, 502 9.6.4 Single Limit Dimensions, 503 9.6.5 Important Terms, 503 9.6.6 Fit Types, 504 9.6.7 Fit Type Determination, 505 9.6.8 Tolerance Costs, 506 9.6.9 Functional Dimensioning, 506 9.6.10 Tolerance Stack-Up, 506 9.6.11 Metric Limits and Fits, 507 9.6.12 Standard Precision Fits: English Units, 513 9.7 Tolerances in CAD, 518 9.7.1 Geometric Accuracy, 518 9.7.2 Associative Dimensioning, 518 9.8 Geometric Dimensioning and Tolerancing, 518 9.9 GDT Symbols, 520 9.10 GDT Rule 1, 520 9.11 Maximum Material Condition, 522 9.11.1 Material Condition Symbols, 522 9.11.2 Departure from MMC, 523 9.11.3 Perfect Form at MMC, 523 9.11.4 Separation of Control Types, 523 9.12 Datums and Datum Features, 523 9.12.1 Datum Uses, 524 9.12.2 Datums and Assembly, 524 9.12.3 Datum Feature Control, 524 9.12.4 Datum Reference Frame, 525 9.12.5 Primary Datum, 525 9.12.6 Secondary and Tertiary Datums, 525 DESIGN IN INDUSTRY Companies Collaborate to Produce Ships Faster, 526 9.12.7 Datum Feature Symbols, 526 9.13 Geometric Controls, 526 9.13.1 Perfection, 526 9.13.2 Tolerance Zones, 526 9.13.3 Virtual Condition, 526 9.13.4 Form Controls, 527 9.13.5 Orientation Controls, 530 9.13.6 Location Controls, 532 9.14 Tolerance Calculations, 537 9.14.1 Floating Fastener Tolerancing, 537 9.14.2 Fixed Fastener Tolerancing, 537 9.14.3 Hole Diameter Tolerancing, 537 9.15 Design Applications, 537 9.15.1 Five-Step GDT Process, 537 9.15.2 Application Example, 538 9.16 Summary, 539 Goals Review, 542 Questions for Review, 542 3-D MODELING PROJECT, 544 Problems, 545 10 Working Drawings and Assemblies, 557 Introduction and Objectives, 557 10.1 Basic Concepts, 558 10.2 Working Drawings, 559 10.2.1 Detail Drawings, 561 10.2.2 Assembly Drawings, 561 10.2.3 Part Numbers, 567 10.2.4 Drawing Numbers, 567 10.2.5 Title Blocks, 568 10.2.6 Parts Lists, 568 10.2.7 Part Identification, 569 10.2.8 Revision Block, 570 10.2.9 Engineering Change Orders (ECO), 570 10.2.10 Scale Specifications, 570 10.2.11 Tolerance Specifications, 571 10.2.12 Zones, 572 10.2.13 Tabular Drawings, 572 10.2.14 Working Assembly Drawing, 572 10.3 Threaded Fasteners, 573 10.3.1 Thread Notes, 573 10.3.2 Thread Specifications: Metric System , 575 10.3.3 Thread Drawings, 576 10.4 Standard Bolts, Studs, and Screws, 580 10.4.1 CAD Techniques, 581 DESIGN IN INDUSTRY Design for Assembly: Building a Simpler Computer, 581 10.5 Nonthreaded Fasteners, 582 10.5.1 Pins, 582 10.5.2 Keys, 582 10.5.3 Rivets, 582 10.6 Springs, 583 10.7 Mechanisms, 583 10.7.1 Gears, 584 10.7.2 Cams, 584 10.7.3 Linkages, 585 10.7.4 Bearings, 586 10.8 Piping, 588 10.8.1 Pipe Drawings, 589 10.9 Welding, 591 10.9.1 Weld Symbols, 591 10.10 Reprographics, 594 10.10.1 Reproduction Techniques, 595 10.10.2 Digital Technologies, 596 10.11 Summary, 597 Goals Review, 597 3-D MODELING PROJECT Chapter 10: Stapler Modeling Project, 598 Questions for Review, 598 Further Reading, 598 Problems, 599 Classic Problems, 638 APPENDIXES, A-1 1. Metric Equivalents, A-3 2. Trigonometry Functions, A-4 3. ANSI Running and Sliding Fits (RC), A-5 4. ANSI Clearance Locational Fits (LC), A-6 5. ANSI Transition Locational Fits (LT), A-7 6. ANSI Interference Locational Fits (LN), A-8 7. ANSI Force and Shrink Fits (FN), A-9 8. Description of Preferred Metric Fits, A-10 9. ANSI Preferred Hole Basis Metric Clearance Fits, A-11 10. ANSI Preferred Hole Basis Transition and Interference Fits, A-12 11. ANSI Preferred Shaft Basis Metric Clearance Fits, A-13 12. ANSI Preferred Shaft Basis Metric Transition and Interference Fits, A-14 13. Unified Standard Screw Thread Series, A-15 14. Thread Sizes and Dimensions, A-16 15. Tap Drill Sizes for American National Thread Forms, A-17 16. Hex Cap Screws (Finished Hex Bolts), A-17 17. Socket Head Cap Screws (1960 Series), A-18 18. Square Head Bolts, A-19 19. Hex Nuts and Hex Jam Nuts, A-20 20. Square Nuts, A-21 21. ANSI Metric Hex Jam Nuts and Heavy Hex Nuts, A-22 22. ANSI Metric Hex Nuts, Styles 1 and 2, A-22 23. ANSI Metric Slotted Hex Nuts and Hex Flange Nuts, A-23 24. ANSI Square and Hexagon Machine Screw Nuts and Flat Head Machine Screws, A-24 25. ANSI Slotted Flat Countersunk Head Cap Screws, A-25 26. ANSI Slotted Round and Fillister Head Cap Screws, A-25 27. Drill and Counterbore Sizes for Socket Head Cap Screws, A-26 28. ANSI Hexagon and Spline Socket Head Cap Screws, A-26 29. ANSI Hexagon Socket Head Shoulder Screws, A-27 30. Drill and Counterbore Sizes for Metric Socket Head Cap Screws, A-27 31. ANSI Socket Head Cap Screws-Metric Series, A-28 32. ANSI Metric Hex Bolts, A-28 33. ANSI Metric Hex Cap Screws, A-29 34. ANSI Hex and Hex Flange Head Metric Machine Screws, A-30 35. ANSI Slotted Flat Head Metric Machine Screws, A-31 36. ANSI Slotted Headless Set Screws, A-32 37. ANSI Hexagon and Spline Socket Set Screws, A-32 38. ANSI Hexagon and Spline Socket Set Screw Optional Cup Points, A-33 39. ANSI Square Head Set Screws, A-34 40. ANSI Taper Pipe Threads (NPT), A-35 41. ANSI Metric Plain Washers, A-36 42. ANSI Type A Plain Washers-Preferred Sizes, A-37 43. ANSI Type A Plain Washers-Additional Selected Sizes, A-37 44. ANSI Type B Plain Washers, A-38 45. ANSI Helical Spring Lock Washers, A-39 46. ANSI Internal and External Tooth Lock Washers, A-40 47. ANSI Keyseat Dimensions for Woodruff Keys, A-41 48. ANSI Standard Woodruff Keys, A-42 49. Key Size versus Shaft Diameter-Key Size and Keyway Depth, A-43 50. ANSI Standard Plain and Gib Head Keys, A-43 51. ANSI Chamfered, Square End, and Taper Pins, A-44 52. British Standard Parallel Steel Dowel Pins-Metric Series, A-45 53. ANSI Cotter and Clevis Pins, A-46 54. Welding Symbols, A-47 GLOSSARY, G-1 INDEX, I-1
Library of Congress Subject Headings for this publication: Engineering graphics