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1. INTRODUCTION 1.1
1.1 Introduction 1.1
1.2 Bloom's Taxonomy 1.1
1.3 Examples 1.2
1.4 Summary 1.2
1.5 References and Bibliography 1.2
1.6 Problems 1.2
1.7 Challenge Problems 1.2
2. DRAFTING 2.3
2.1 CONVENTIONAL DRAFTING 2.3
2.1.1 Manual Drafting 2.4
2.1.2 Turning Three Dimensions Into Two (Multi View Drawings) 2.5
The Glass Box 2.5
2.1.3 Lines 2.8
2.1.4 Holes 2.10
2.1.5 Special Cases 2.11
Aligned Features 2.11
Incomplete Views 2.14
2.1.6 Section Views 2.16
Full Sections 2.16
Offset Section 2.17
Half Section 2.18
Cut Away Sections 2.19
Revolved Section 2.20
Removed Section 2.20
Auxiliary Section 2.22
Thin Wall Section 2.23
Assembly Section 2.23
Special Cases 2.24
Fill Patterns 2.26
2.1.7 Auxiliary Views 2.26
Secondary Auxiliary Views 2.30
Partial Auxiliary Views 2.30
2.1.8 Descriptive Geometry 2.30
2.1.9 Isometric Views 2.31
2.1.10 Special Techniques 2.31
2.2 NOTATIONS 2.32
2.2.1 Basic Dimensions and Tolerances 2.33
2.2.2 Geometric Dimensioning and Tolerancing (GD & T) 2.33
Feature Control Symbols 2.34
Symbols and Meaning 2.35
Datums 2.40
Modifiers 2.41
2.3 WORKING DRAWINGS 2.42
2.3.1 Drawing Elements 2.42
Title Blocks 2.42
Drawing Checking 2.43
Drawing Revisions 2.43
Bill of Materials (BOM) 2.44
2.3.2 Drawing Types 2.44
Assembly Drawings 2.44
Subassembly Drawings 2.45
Exploded Assembly Drawings 2.45
Detailed Drawings 2.45
2.4 PRACTICE PROBLEMS 2.46
2.5 REFERENCES 2.46
3. METROLOGY 3.47
3.1 Introduction 3.47
3.1.1 The Role of Metrology 3.47
3.2 DEFINITIONS 3.48
3.3 STANDARDS 3.49
3.3.1 Scales 3.49
3.3.2 Calipers 3.50
3.3.3 Transfer Gauges 3.50
3.4 Instruments 3.51
3.4.1 Vernier Scales 3.51
3.4.2 Micrometer Scales 3.52
The Principle of Magnification 3.53
The Principle of Alignment 3.54
3.4.3 Dial Indicators 3.55
3.4.4 The Tool Makers Microscope 3.57
3.4.5 Metrology Summary 3.58
3.5 Surfaces 3.59
3.5.1 Measures of Roughness 3.60
3.6 Measuring Surface Roughness 3.63
3.6.1 Observation Methods 3.63
3.6.2 Stylus Equipment 3.63
3.6.3 Specifications on Drawings 3.68
3.6.4 Other Systems 3.69
3.6.5 Roundness Testing 3.72
Intrinsic Roundness Testing 3.73
Extrinsic Roundness Testing 3.76
3.7 Gage Blocks 3.78
3.7.1 Manufacturing Gauge Blocks 3.82
3.7.2 Compensating for Temperature Variations 3.85
3.7.3 Testing For Known Dimensions With Standards 3.85
3.7.4 Odd Topics 3.86
3.7.5 Limit (GO & NO GO) Gauges 3.87
Basic Concepts 3.87
GO & NO GO Gauges Using Gauge Blocks 3.89
Taylor's Theory for Limit Gauge Design 3.90
Gauge Maker's Tolerances 3.91
3.7.6 Sine Bars 3.93
Sine Bar Limitations 3.95
3.7.7 Comparators 3.96
Mechanical Comparators 3.97
Mechanical and Optical Comparators 3.98
Optical Comparators 3.99
Pneumatic Comparators 3.99
3.8 Measuring Aparatus 3.101
3.8.1 Reference Planes 3.101
Granite Surface Plates 3.102
Cast Iron Surface Plates 3.102
3.8.2 Squares 3.103
3.9 Practice Problems 3.106
4. CUTTING 4.119
4.1 Drilling 4.119
4.1.1 Drill Bits 4.122
4.1.2 Reamers 4.125
4.1.3 Boring 4.126
4.1.4 Taps 4.127
4.1.5 Process Parameters 4.128
4.1.6 The mrr For Drilling 4.130
4.2 Milling 4.131
4.2.1 Types of Milling Operations 4.131
Arbor Milling 4.133
4.2.2 Milling Cutters 4.133
4.2.3 Milling Cutting Mechanism 4.133
Up-Cut Milling 4.134
Down-Cut Milling 4.135
4.3 Feeds and Speeds 4.136
4.3.1 The mrr for Milling 4.139
4.3.2 Process Planning for Prismatic Parts 4.139
4.3.3 Indexing 4.139
4.4 Lathes 4.142
4.4.1 Machine tools 4.145
Production Machines 4.146
4.4.2 Toolbits 4.147
4.4.3 Thread Cutting On A Lathe 4.150
4.4.4 Cutting Tapers 4.152
4.4.5 Turning Tapers on Lathes 4.153
4.4.6 Feeds and Speeds 4.155
4.4.7 The mrr for Turning 4.156
4.4.8 Process Planning for Turning 4.157
4.5 Cutting Speeds, Feeds, Tools, and Times 4.158
4.6 Cutting Power 4.159
4.7 Examples 4.164
4.8 Summary 4.164
4.9 References and Bibliography 4.164
4.10 Problems 4.164
4.11 Challenge Problems 4.164
4.12 Practice Problems 4.165
5. JOINING 5.182
5.1 Introduction 5.182
5.2 ADHESIVE BONDING 5.183
5.3 ARC WELDING 5.184
5.4 GAS WELDING 5.186
5.5 SOLDERING AND BRAZING 5.187
5.6 PLASTIC WELDING 5.188
5.7 Examples 5.193
5.8 Summary 5.193
5.9 References and Bibliography 5.193
5.10 Problems 5.193
5.11 Challenge Problems 5.194
6. ROTATIONS 6.195
6.1 Introduction 6.195
6.2 Rotational Masses and Inertia 6.195
6.3 Motor Models 6.203
6.3.1 Basic Brushed DC Motors 6.203
6.4 Tachometers 6.210
6.4.1 Angular Displacement 6.210
Potentiometers 6.210
6.4.2 Encoders 6.211
Tachometers 6.215
6.5 Examples 6.216
6.6 Summary 6.216
6.7 References and Bibliography 6.216
6.8 Problems 6.216
6.9 Challenge Problems 6.216
7. FEEDBACK CONTROL REVIEW 7.217
7.1 Introduction 7.217
7.2 OpAmps 7.221
7.3 Examples 7.225
7.4 Summary 7.225
7.5 References and Bibliography 7.225
7.6 Problems 7.225
7.7 Challenge Problems 7.225
8. MECHANICAL POWER TRANSMISSION 8.226
8.1 Mechanisms 8.226
8.1.1 Locking/Engaging 8.227
8.1.2 Motion Transmission/Transformation 8.230
8.1.3 Four Bar Linkages 8.230
8.1.4 Reciprocating 8.232
8.1.5 Six Bar Linkages 8.234
8.2 Mechanical Advantage 8.236
8.3 Gears 8.238
8.3.1 Spur Gears 8.238
8.3.2 Involute Profiles 8.243
8.3.3 Design of Gears 8.245
8.3.4 Design Issues 8.248
Undercutting and Contact Ratios 8.248
Changing the Center Distance 8.250
8.3.5 Helical Gears 8.250
Design of Helical Gears 8.251
Perpendicular Helical Gears 8.254
8.3.6 Bevel Gears 8.256
Design of Bevel Gears 8.257
8.3.7 Other Bevelled Gears 8.258
8.3.8 Worm Gears 8.258
8.3.9 Harmonic Drives 8.261
8.3.10 Design With Gears 8.261
Gear Trains 8.262
Examples - Fixed Axis Gears 8.263
Examples - Moving Axis Gears 8.267
Epicyclic Gear Trains 8.267
Differentials 8.270
8.3.11 Gear Forces and Torques 8.272
8.4 Cams 8.274
8.4.1 Using Cams in Mechanisms 8.287
8.5 Examples 8.287
8.6 Summary 8.287
8.7 References and Bibliography 8.287
8.8 Problems 8.287
8.9 Challenge Problems 8.290
9. MECHANICAL ISSUES 9.291
9.1 Introduction 9.291
9.2 Friction 9.291
9.3 Friction 9.293
9.4 Contact Points And Joints 9.294
9.4.1 Switching 9.295
9.4.2 Deadband 9.296
9.4.3 Saturation and Clipping 9.299
9.4.4 Hysteresis and Slip 9.299
9.4.5 Delays and Lags 9.300
9.5 Wheeled Vehicles 9.301
9.6 Examples 9.301
9.7 Summary 9.301
9.8 References and Bibliography 9.301
9.9 Problems 9.301
9.10 Challenge Problems 9.301
10. SENSORS 10.302
10.1 INTRODUCTION 10.302
10.2 SENSOR WIRING 10.302
10.2.1 Switches 10.303
10.2.2 Transistor Transistor Logic (TTL) 10.303
10.2.3 Sinking/Sourcing 10.304
10.2.4 Solid State Relays 10.311
10.3 PRESENCE DETECTION 10.312
10.3.1 Contact Switches 10.312
10.3.2 Reed Switches 10.312
10.3.3 Optical (Photoelectric) Sensors 10.313
10.3.4 Capacitive Sensors 10.320
10.3.5 Inductive Sensors 10.324
10.3.6 Ultrasonic 10.326
10.3.7 Hall Effect 10.326
10.3.8 Fluid Flow 10.326
10.4 SUMMARY 10.327
10.5 PRACTICE PROBLEMS 10.327
10.6 PRACTICE PROBLEM SOLUTIONS 10.331
10.7 ASSIGNMENT PROBLEMS 10.337
11. ACTUATORS 11.339
11.1 INTRODUCTION 11.339
11.2 SOLENOIDS 11.339
11.3 VALVES 11.340
11.4 CYLINDERS 11.342
11.5 HYDRAULICS 11.344
11.6 PNEUMATICS 11.346
11.7 MOTORS 11.347
11.8 COMPUTERS 11.348
11.9 OTHERS 11.348
11.10 SUMMARY 11.348
11.11 PRACTICE PROBLEMS 11.349
11.12 PRACTICE PROBLEM SOLUTIONS 11.349
11.13 ASSIGNMENT PROBLEMS 11.350
12. PROJECT MANAGEMENT 12.351
12.1 Introduction 12.351
12.2 An Academic View of Design Revisited 12.351
12.3 Project Management 12.355
12.3.1 Timeline - Tentative 12.355
12.3.2 Teams 12.355
12.3.3 Conceptual Design 12.356
12.3.4 Progress Reports 12.356
12.3.5 Design Proposal 12.357
12.3.6 The Final Report 12.358
12.3.7 Gantt Charts 12.359
12.3.8 Drawings 12.359
12.3.9 Budgets and Bills of Material 12.359
12.3.10 Calculations 12.360
12.3.11 Presentations 12.360
12.4 Examples 12.361
12.5 Summary 12.361
12.6 References and Bibliography 12.361
12.7 Problems 12.361
12.8 Challenge Problems 12.361
12.9 Forms 12.361
13. MOTION CONTROL 1.363
13.1 INTRODUCTION 1.363
13.2 MOTION PROFILES 1.364
13.2.1 Velocity Profiles 1.364
13.2.2 Position Profiles 1.373
13.3 MULTI AXIS MOTION 1.376
13.3.1 Slew Motion 1.377
Interpolated Motion 1.378
1.3.2 Motion Scheduling 1.379
1.4 PATH PLANNING 1.381
1.5 CASE STUDIES 1.383
1.6 SUMMARY 1.385
1.7 PRACTICE PROBLEMS 1.385
1.8 PRACTICE PROBLEM SOLUTIONS 1.386
1.9 ASSIGNMENT PROBLEMS 1.387
2. LABORATORIES 1.389
2.1 Lab - Lab Safety 1.390
2.1.1 Theory 1.390
2.1.2 Procedure 1.390
2.2 Lab - Soldering 1.391
2.2.1 Theory 1.391
2.2.2 Procedure 1.391
2.3 Lab - Motors and Tachometers 1.392
2.3.1 Theory 1.392
2.3.2 Procedure 1.393
2.4 Lab - Machining 1.396
2.4.1 Theory 1.396
2.4.2 Procedure 1.396
2.5 Lab - Feedback Control 1.397
2.5.1 Theory 1.397
2.5.2 Procedure 1.398
2.6 Lab - Basic AVR Board 1.399
2.6.1 Theory 1.399
2.6.2 Procedure 1.399
2.7 Lab - ASCII I/O 1.400
2.7.1 Theory 1.400
2.7.2 Procedure 1.400
2.8 Lab - Welding Qualification 1.401
2.8.1 Theory 1.401
2.8.2 Procedure 1.401
2.9 Lab - Microcontroller Based Feedback Control 1.402
2.9.1 Theory 1.402
2.9.2 Procedure 1.402
2.10 Lab - Music (or Stepper Motor) 1.403
2.10.1 Theory 1.403
2.10.2 Procedure 1.403
2.11 Lab - Part Production 1.404
2.11.1 Theory 1.404
2.11.2 Procedure - ECE 1.404
2.11.3 Procedure - PDM / MO / ME 1.404
2.12 Lab - Pneumatics and Sensors 1.405
2.12.1 Theory 1.405
2.12.2 Procedure 1.405
2.13 Lab - Analog I/O 1.406
2.13.1 Theory 1.406
2.13.2 Procedure 1.406
2.14 Lab - Structured Programming 1.407
2.14.1 Theory 1.407
2.14.2 Procedure 1.407
2.15 Lab - LCD Control 1.408
2.15.1 Theory 1.408
2.15.2 Procedure 1.408
2.16 Lab - Mechanical Component Demos 1.409
2.16.1 Theory 1.409
2.16.2 Procedure 1.409
3. Projects 1.410
3.1 NOTEBOOK ENTRIES 1.412
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