screw technology - backlash

It's a common knowledge that a good and precise machinery must be one that has as little backlash as possible. Backlash is any non-movement that occurs during axis reversals. For example, the X axis is commanded to move 10mm to the positive direction. Immediately after this X movement, the X axis is commanded to move 10mm to the negative direction. If any backlash exists in the X axis, then it will not immediately start moving in the negative direction, and the motion departure will not be precisely 1 inch.

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machine troubleshooting

To troubleshoot electrical equipment properly like an expert, problems must be solved by replacing only defective equipment or components in the least amount of time. One of the most important factors in doing this, is the approach used. An expert troubleshooter uses a system or approach that allows them to logically and systematically analyze a circuit and determine exactly what is wrong.
The approach described here is a logical, systematic approach called the 5 Step Troubleshooting Approach. It is a proven process that is highly effective and reliable in helping to solve electrical problems.
This approach differs from troubleshooting procedures. It does not actually tell you step by step how to troubleshoot a particular kind of circuit. It is more of a thinking process that is used to analyze a circuit’s behavior and determine what component or components are responsible for the faulty operation. This approach is general in nature allowing it to be used on any type of electrical circuit.
In fact, the principles covered in this approach can be applied to many other types of problem solving scenarios, not just electrical circuits.
The 5 Step Troubleshooting Approach consists of the following:
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machine installation

From my own experience, installing a machine is not as easy as you think. Even a teacher from a vocational school might not be able to do it properly if he has no clue about setting the machine level. When you need precision for your machine, the installation becomes more crucial, a slight imbalance in position imbued with fast axis travel might produce some disturbing chatter, that will be conveyed to your workpiece's surface.

Nowadays, there are a lot of improvement in measuring tool world, as implied, our capability to set-up machine is no more limited by using water level. Take this company where i work now, we just bought a digital leveling device, easier to use and have a good accuracy. I daresay it's a good price for making our setup faster.
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NC technology - safety NC code macro

Have you ever been on a machining disaster? when the program "seems" at fault. The tool travel elsewhere and make dents, machining crash, tool breakage? The greatest majority of crashes are a result of improper programming or programming that could eliminate the chance of operators making mistakes. CNC programmers often forget about Modal M-codes. They are often left active and are not canceled within the program.

What happens if an operator punches a wrong code into MDI like G18 and then starts up the program? If there was no G17 in their program then they are in trouble. I have seen this happen many times.
Often times it is difficult to determine reasoning behind a crash. One reason is when a crash happens the machine is powered down until someone inspects and troubleshoots what has happened. If powered down however; all the modal M-codes are reset back to default settings on power up and is not easily traceable to the operator. I can not tell you how many times I have heard it just take off running a normal proven program. This safety code is likely the answer as long as your operator was not lying to you.
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cutting tool technology - end mill

End mill is not something you can separate from CNC machining, especially when you're dealing with vertical machining centers (VMC). Basically there are some knowledge that an engineer should know before deciding on a process. A good tool selection will result in a better surface quality and the job might be done faster.
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machining technology - jig & fixtures

In metalworking, a jig is a type of tool used to control the location and/or motion of another tool. A jig's primary purpose is to provide repeatability, accuracy, and interchangeability in the manufacturing of products. A jig's main function is to guide the tool during machining process. A jig is often confused with a fixture; a fixture holds the work in a fixed location. A device that does both functions (holding the work and guiding a tool) is called a jig.

As the CNC technology grows rapidly, with the ability to move according to exact path generated from NC code, the use of jigs is beginning to decrease. Nevertheless, the fixtures still greatly needed to set-up the workpiece faster.
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NC technology - G codes

M codes and G codes are defined as a code telling machine what type of action to perform. The G codes specifically points toward controlling movement of one or multiple machine axes

Basically machine codes are programmed using PLC, so it is very possible that one machine have a different code than the other. Especially when it comes to milling compared to lathe. A same code can means differently according to the machine.
Here is some list of widely used G codes.
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NC technology - M codes

M codes and G codes are defined as a code telling machine what type of action to perform. The M codes specifically points toward controlling which function need to be ON / OFF


Basically machine codes are programmed using PLC, so it is very possible that one machine have a different code than the other. Some of the codes are standardized for ease of use and programming
Here is some list of widely used M codes.
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weldment technology - friction stir welding

Friction-stir welding (FSW) is a solid-state joining process (by definition that the metal is not melted during the process) and is used for applications where the original metal characteristics must remain unchanged as far as possible. This process is primarily used on aluminium, and most often on large pieces which cannot be easily heat treated post weld to recover temper characteristics.

This welding process is relatively easy to tell apart from the usual welding, because unlike other welding that requires a specialized machine, FSW involves a general machine tool such as milling. The keyword for this process is "heat generated by friction"

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solidworks - weldment gap

Just for information for those with no welding-education background, a welding gap is needed, and important. There are several ways to put a welding gap into your design, the easiest one, of course is by cutting your weldment profiles using cut-extrude, more works to do, but it is correct, and will ease your welding assembly.
 There is much much easier way to do this. Actually Solidworks has anticipated your needs of gap, and therefore, equips the command with one extra numerical parameter called G1, unused by default, but can be given number, and the parameter will adjust your design.
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cutting tool technology - tool coating

New workpiece materials are being developed in response to many factors. These include ever-increasing global demand for high performance components, and higher safety standards. Development of these new alloys has always been one of the main drivers of new cutting tool technologies and grades.

Improved properties that allow parts made from these materials to perform better in their intended application also present special challenges for milling tools. Some of the key properties required for milling tools to machine these high-performance work materials include:
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spindle technology - toolholder characteristics

There are three major issues to think about when considering the proper toolholder for a high-precision application: (1) rigidity (2) accuracy (3) balance.

Much has been said in the industry today about the issue of balance, but it is important to consider the combination of all three of these issues when providing the best solution. This involves both of user and machine maker to set-up and maintain a proper quality of the machine, that the work result's quality might be satisfactory
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spindle technology - high-speed spindles and toolholders

When first designing a machine, it's ability must be defined carefully, so that every components are designed, or chosen according to the final requirements. Every machining purpose had its own characteristic, which will affect the whole machine design. The other certain thing is that spindles, related very close to the toolholders, which will hold significant part determining the quality of machining works

A machining job generally divided into two major direction : high-speed machining, or high force machining. Older machines are usually high-forced, given tough characteristic, bulky, stiff, highly capable of high metal removal rates, but usually slower. The newer machines lately grown toward high-speed, compensating low metal removal rates with a very fast feeding, so that the machining time would not differs much. High speed machines are generally more precise, since it is mostly used for contouring, that needed smooth surface as the result.
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cutting tool technology - tool geometry

Every machinists use cutting tools to make up a desired shape in a desired dimension, most of us are limited only on using it, but a little study will help to find the best method and tool to work on certain workpiece.
Most of these considerations involve cutting tool geometry :

• Lead angle is the approach angle of the cutting edge as it enters the workpiece. The lead angle controls the direction of the radial cutting force and axial cutting force.
• Rake angle is the incline of the top surface of the cutting edge that makes contact with the chip. The rake controls the degree of cutting forces and cutting edge strength.
• Clearance angle is the angled relief behind the cutting edge that eliminates interference between the cutting tool and the workpiece.
• Cutter diameter is the maximum flat surface a cutter will machine.
• Insert pitch is the distance between corresponding positions on one insert to the same position on the subsequent insert.
• Insert density is the number of inserts, or cutting edges, per inch of diameter.
• Hand of cut determines the cutter rotation direction. Milling cutters are designed to cut clockwise or counterclockwise.
• Mounting adaptation is determine by the type of machine spindle on which the rotating cutter is mounted. The method of mounting is a major factor in determining the rigidity and performance capability of the cutter.

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solidworks - viewing mates

I believe every 3d software user had at least several experience with assembly. It's easy to create, but sometimes it will take a significantly long time just to edit, when you decide to change the assembly structure, or when one of the component need to be replaced. The main cause is not in editing, but in finding the exact mate between two components that we need to edit. It might as well become a long painful journey for your tired eyes.

There are several possible solution for this,
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solidworks - delete

Most people know that you can delete lines from a sketch, or features from the Solidworks feature Manager, by pre-electing the object(s) and then simply hitting the DELETE key. But only few had known that over the last 4 years, the programmers have enhanced the intelligence behind the DELETE key, allowing it to react differently according to situations we're in.

Here's how DELETE will act when faced on several different circumstances :
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solidworks - using derived sketch

Derived sketch is one of a good feature that often overlooked. This tool derives a sketch from another sketch that belongs to the same part, or derives a sketch from another sketch in the same assembly! When you derive a sketch from an existing sketch, you are assured that the two sketches will retain the characteristics that they share in common. Every changes that you make to the original sketch are reflected in the derived sketch. Here I will show how to derive a sketch from a sketch in the same part:
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design guide 01 - design for assembly

It is very important for a machine designer to consider a lot of things when building a component. Whether it's able to be processed (design for manufacture); able to assembled easily (design for assembly); and even sometimes whether our machine can be repaired easily (design for maintenance).
Manufacturing process done in the machining workshop, the assembly would be done by assembly workshop. It is very important for a design engineer to know what's happening on the process. At least little by little information we gather will certainly help a lot for the next possible project.

What does it means to use "design for assembly" consideration? It means that every part is designed and modified well to ease the assembly process. As we all know, assembly is very important process that must be done correctly in order to obtain the desired shape (and often, includes obtaining functionality too)
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Failure Mode & Effects Analysis [FMEA]

FMEA is a procedure in product development and operations management for analysis of potential failure modes within a system for classification by the severity and likelihood of the failures. A successful FMEA activity helps a team to identify potential failure modes based on past experience with similar products or processes, enabling the team to design those failures out of the system with the minimum of effort and resource expenditure, thereby reducing development time and costs. It is widely used in manufacturing industries in various phases of the product life cycle and is now increasingly finding use in the service industry. Failure modes are any errors or defects in a process, design, or item, especially those that affect the customer, and can be potential or actual. Effects analysis refers to studying the consequences of those failures.
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weldment design 04 - product design rules

Welding may be imperfect and there's a million ways to overcome the distortion, but the best thing to do is considering the product's design carefully so that the effort on manufacturing is kept minimum
Just like plastic molding and sand casting, each welded product must be designed thoroughly according to the process they had to undergo. There is still some chance the distortion would happen, but on a straight line of procedures and a wise design, it wouldn't spend too much energy compared to a harshly designed ones.
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weldment design 03 - welding jigs

When you're talking about welding, the use of jigs, fixtures and positioners is usually desirable, for at least four reasons:
1. To minimize distortion caused by heat of welding.
2. To permit welding in a more convenient position.
3., To increase welding efficiency and productivity.
4. To minimize fit-up problems. With a welding jig or fixture, the components of a weldment can be assembled into accurate alignment and held securely in proper relationship and with correct fit-up during positioning and during welding so that all finished parts coming from the jig or fixture will be uniform.
For high quantity production, it is very economical to design and construct an accurate, durable jigs and fixtures.
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weldment design 02 - distortion

There was a time when the welding operator used to pick up his shield and electrode holder and commenced welding a job, beginning and finishing at any place. If the completed work became distorted, it was taken for granted that it could not be avoided. The impression was that all welding caused distortion, so there would be no point in worrying.
This was purely ignorance, because distortion can be controlled and minimized by approaching the job in a correct manner. Today, welded work is being completed with minimum or no distortion. For example, large machine beds are being fabricated out of rolled steel sections and plates and welded within a tolerance of 1.5 mm.

During welding, the base metal near the arc is heated to the melting point. A few centimeters away, the temperature of the base metal is substantially lower.
This sharp temperature differential causes non uniform expansion followed by base metal movement, or metal displacement if the parts being joined are restrained. Also, the expansion of the hotter base metal (i.e., which is nearer the welding arc) is subject to restraint, due to the resistance of comparatively colder metal away from the welding arc. The metal nearer the arc expands more than that away from the arc.
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weldment design 01 - welding joints

Before an arc can be struck on metal, the product must be designed to serve its purpose, the material chosen and the method of welding determined in more or less detail. The weldment design engineer must understand the principle of welding design :
1. Approach the redesign of previously cast, forged or riveted products as a new design, on the basis of the functions to be performed.
2. Use materials, where possible, which require the least in welding precautions and least skill.
3. Welding is a means to an end, but to the designer not an end in itself. Avoid extra and unnecessary joints by flanging, bending or rolling, and use of standard sections, stampings, small castings or forgings, wher ever necessary or advisable.
4. At least mentally review all the welding processes available and applicable to various parts of the design on the basis of material, thickness, form and quantity.
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tolerances - ISO tolerances

I've been working with machine for several years, and I learned that it is principally impossible to produce machine parts with absolute dimensional accuracy. In fact, it is not necessary or useful. It is quite sufficient that the actual dimension of the part is found between two limit dimensions and a permissible deviation is kept with production to ensure correct functioning of engineering products. The required level of accuracy of production of the given part is then given by the dimensional tolerance which is prescribed in the drawing. The production accuracy is prescribed with regards to the functionality of the product and to the economy of production as well.

A coupling of two parts creates a fit whose functional character is determined by differences of their dimensions before their coupling. 

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tolerances - surface finish

Mostly in design we are talking about fulfilling a component's specification. Whether it's about dimensional tolerance, shape, or maybe the desired surface finish. As we know before, surface finish and tolerance are closely linked. A component that are manufactured precisely, would have a good surface finish, on the other hand, rough surface finish usually hold a less precise dimension

The ability of a manufacturing operation to produce a specific surface roughness depends on many factors. For example, in end mill cutting, the final surface depends on the rotational speed of the end mill cutter, the velocity of the traverse, the rate of feed, the amount and type of lubrication at the point of cutting, and the mechanical properties of the piece being machined. A small change in any of the above factors can have a significant effect on the surface produced. There are 3 components defining the surface texture, that is : lay, surface roughness, & waviness

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motoGP early schedule

Yay, my only favorite game is back. This year might give a wonderful bike-to-bike fight between Valentino Rossi aka.The Doctor VS his ex teammate Jorge Lorenzo.

These last 2 years,I've been rooting for Valentino Rossi because of a simple reason, he rides Yamaha, and so do I. But this year, I might as well vote for Rossi again, not for much reason, only because I like the combination of Italian rider and Italian motorcycle. Not much to say again.

Date                                        Grand Prix (Circuit)
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tolerances - geometric tolerance

Geometric dimensioning and tolerancing (GD&T) is used to define the nominal (theoretically perfect) geometry of parts and assemblies, to define the allowable variation in form and possibly size of individual features, and to define the allowable variation between features. Dimensioning and tolerancing and geometric dimensioning and tolerancing specifications are used as follows:

• Dimensioning specifications define the nominal, as-modeled or as-intended geometry. One example is a basic dimension.
• Tolerancing specifications define the allowable variation for the form and possibly the size of individual features, and the allowable variation in orientation and location between features. Two examples are linear dimensions and feature control frames using a datum reference (both shown above).

There are some fundamental rules that need to be applied :

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list - gruesome torture device 02

Yeah, here comes the second part, another 10 torture device. Like what was stated in previous post. I'd like to try one of this on Mr.terrorist. of course they would not be given death. cause..well, death penalty is unavailable. Let them living in pain, in the other hand, i think is a brilliant choice.
These cruel instruments were commonly used throughout history to punish criminals, exert power over others and strike fear in the immoral and corrupt. Be sure to save that meal of yours for later; this is going to make your stomach churn
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list - gruesome torture device 01

I found this list accidentally when browsing. Yeah we all know, sometimes when we heard or see crime news in TV, such as murder and terrorism, it's hard to keep yourself calm. Death penalty, of course is not available in my country. But a simple prison punishment would be too easy for the evil-doers. So are there any other  possibilities?

Torture: it is an ancient practice that still goes on today. In the middle ages torture was used for punishment, interrogation, and deterrence. It is easy to consider ourselves more humane these days, but while some of the devices listed here would lead to death, we have, in modern times, mastered the ability of inflicting extreme pain for indefinite periods of time – something which is, perhaps, worse.

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gear technology - cycloid

The word Cycloid, with its adjective Cycloidal, is derived fromHypocycloid which describes the curve traced by a point on the circumference of a smaller circle rotating inside the circumference of a larger fixed circle

GEAR RATIO CALCULATION

The reduction rate of the cycloidal drive is obtained from the following formula, where P means the number of the ring gear pins and L is the number of pins on the cycloidal disc.

Ratio = (P - L) / L

Where P = Number of ring gear pins/rollers
             L = Number of lobes on a cycloidal disc

The method of operation is just like this :

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belt drive technology - basic belt types

A belt is a loop of flexible material used to link two or more rotating shafts mechanically. Belts may be used as a source of motion, to transmit powerefficiently, or to track relative movement. Belts are looped over pulleys. In a two pulley system, the belt can either drive the pulleys in the same direction, or the belt may be crossed, so that the direction of the shafts is opposite. As a source of motion, a conveyor belt is one application where the belt is adapted to continually carry a load between two points.

Belts are the cheapest utility for power transmission between shafts that may not be axially aligned. Power transmission is achieved by specially designed belts and pulleys. The demands on a belt drive transmission system are large and this has led to many variations on the theme. They run smoothly and with little noise, and cushion motor and bearings against load changes, albeit with less strength than gears or chains. However, improvements in belt engineering allow use of belts in systems that only formerly allowed chains or gears.
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bearing technology - rolling element bearing

A rolling-element bearing is a bearing which carries a load by placing round elements between the two pieces. The relative motion of the pieces causes the round elements to roll with very little rolling resistance and with little sliding.
Most rolling element bearings use cages to keep the balls separate. This reduces wear and friction, since it avoids the balls rubbing against each other as they roll, and precludes them from jamming
Even though some other kind of bearings are better in one or another specific attributes, many people think that it gives a pretty good tradeoff between cost, size, weight, capacity and durability. Therefore, it is one of the most widely used in machinery design
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bearing technology - plain bearing

A plain bearing, also known as a plane bearing, is the simplest type of bearing, comprising just a bearing surface and no rolling elements. Therefore the journal (i.e., the part of the shaft in contact with the bearing) slides over the bearing surface. The simplest example of a plain bearing is a shaft rotating in a hole. A simple linear bearing can be a pair of flat surfaces designed to allow motion; e.g., a drawer and the slides it rests on or the ways on the bed of a lathe.

Plain bearings, in general, are the least expensive type of bearing. They are also compact, light weight, and have a high load-carrying capacity. Read more

gear technology - harmonic drive

A Harmonic Drive (also known as "Strain Wave Gearing") is a special type of mechanical gear system that can improve certain characteristics compared to traditional gearing systems (such as Helical Gears or Planetary Gears). Basically it uses the flexibility of metal as the main component of mechanism

The mechanism is comprised of three components:
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gear technology - epicyclic/ planetary

Epicyclic gearing or planetary gearing is a gear system consisting of one or more outer gears, or planet gears, revolving about a central, orsun gear. Typically, the planet gears are mounted on a movable arm or carrier which itself may rotate relative to the sun gear. Epicyclic gearing systems also incorporate the use of an outer ring gear or annulus, which meshes with the planet gears.

The axes of all gears are usually parallel and what's more is that the sun, planet carrier and annulus axes are usually concentric
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belt drive technology - design and usage guideline

Unlike many old machines that employs gears for transmission method, Newer machines began to grow fond using belt drive, since it's cheaper, offers safety (belts will break on overload, unlike gears that take everything down with it) , easier to apply and it's easier for maintenance. One thing that we might forgot to highlight is that the belt drive efficiency actually depends a lot in heat factor.

Lifetime and performance in timing belts are greatly affected by the type of reinforcement employed. This internal component largely determines belt strength (modulus), creep, flex fatigue, and length variability (caused by humidity and temperature variation). Even though timing belt drives are generally considered to be very efficient, the operating temperatures they are exposed to can have a significant effect. Elastomers that run well hot will generally become much stiffer at low temperatures. This reduces drive efficiency as more energy is required to bend the belt around the pulleys. Elastomers that flex at lower temperatures are available, but they often wear too quickly at mid-range and elevated temperatures.
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solidworks - creating a forming tool

Not everyone interested in sheetmetal, but I've been looking at sheetmetal products likely such as stamping and curious how the SW users make the design. One thing should be noted is that whatever you bend in the sheetmetal feature, will be available in the flat pattern, so you only need to make the correct design, and you could see the flat pattern with just one click

The only thing that bothers me, is what will we do if we have customized stamping tool,that are not available in SW library? the answer was simple, we can make it and put it in our library
This is how you do it:
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autocad - tips and trick

This is a really ancient software, i consider this as the mother of engineering software
It's simple really, and as the story goes, there's also features to make 3d designs too. I myself wouldn't recommend the 3d, but the 2d autocad is really dependable
basically it's like manual engineering drawing, but with pointer as the pen, and you can make circle without effort. the overall techniques, it's all up to you. You can decide the standards, what to view, and what you don't want to see as free as possible
To use, it's not hard, but if you want to use it nicely, a lot faster, cooler and efficiently, you gotta follow this trick
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gear technology - basic gear types

I believe almost every machinist or engineer had dealt with gears. Gear are of the workhorses of motion control systems. They can turn RPMs into muscle for a conveyor belt moving heavy boxes or convert the torque of a wind turbine into sufficient speed to drive a generator. They can completely change the direction of motion. The technology is powerful, with sufficient options to satisfy virtually every occasion - when used properly, that is. There's so much types of gear, and each have its own advantages as well as disadvantages. Let's take a look at the basic types,  the one that is used as basic for another gear-arrangements or design modification

Gear is a mechanical device that transfers power from one element to another in a system. We define the gear ratio G for two gears as the ratio of their diameters, D1 and D2
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screw technology - ballscrew vs. leadscrew

Ballscrews and lead screws are the workhorses of today's motion-centric automation environment. In that light, making the correct choice for an application is extremely important.

Ballscrew technology allows balls to roll between the screw shaft and the nut to achieve high efficiency, usually above 90%, depending on lead angle. Its required driving torque is only one third of a conventional lead screw. As a result, ballscrews are capable of converting rotational motion to straight motion and vice versa. This screw type is suitable when smooth motion, efficiency, accuracy, and precision are a priority. The rolling elements eliminate sliding friction, so smaller motors can be used to drive ballscrews. And, because rolling motion is easier to control, accuracy and precision are also easier.

Lead screws are different in that there are no recirculating elements, and they are often used for simple transfer applications when speed, accuracy, and precision, are not as critical as rigidity and the load. On a positive note, more surface contact of the threads can make for a higher load rating of the nut over ballscrews. However, their metal-to-metal contact and high friction makes lead screws more suited to applications that do not require prolonged continuous movement or high speed.
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motor technology - IP rating

Choosing a motor for drive in a system is not a hard thing to do as long as you know the specification and the environmental requirement. It means we have to define how bad the working area surrounding the motor, as dust and water are critical for the motor's lifetime.

 The IP Code (or International Protection Rating, sometimes also interpreted as Ingress Protection Rating) consists of the letters IP followed by two digits and an optional letter. As defined ininternational standard IEC 60529:

The first digit indicates degree of protection provided by the enclosure with respect to persons and solid foreign objects entering the enclosure;
The second digit indicates degree of protection provided by the enclosure with respect to harmful water ingress.

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solidworks - creating weldment library

Have you ever use standard components like frames, UNP profiles, etc.? To create arrangement of these bars is a simple thing to do in SW. Of course, basically this program has included several standard profiles.But the hard part will come when you need to arrange profiles that are not inside library. So..we must make our own library. I myself learned it just recently from a SW expert's website

Here's how you can do it:

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solidworks - creating and mating gears

This is a useful feature indeed..I meet this feature first on Inventor, and soon getting attached to it.
This feature is an add-ins, so we have to activate it beforehand. I myself set my SW so that this add-ins will instantly active whenever i use Solidworks

Here's how we can do it :
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solidworks - tips and trick

Solidworks is one of 3d design software that is used by many recently. I did use some software, but this one managed to get my attention

Part creation is simple, with auto-constraint similar to autoCad, combined with easy to use animation making, and the most important is the dimension editing that can be done, even in the 3d display.

SOME USEFUL TIPS WHILE WORKING WITH SOLIDWORKS

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spindle technology - spindle design

A high speed spindle that will be used in a metal cutting machine tool must be designed to provide the required performance features. The major performance features include:
~ Desired Spindle Power, Peak and Continuous
~ Maximum Spindle Load, Axial and Radial
~ Maximum Spindle Speed Allowed
~ Tooling Style, Size and Capacity for ATC

High Speed Spindle Design Major Checklist 
The major components required for a high speed milling spindle design include:
* Spindle Style;   Belt Driven or Integral Motor-Spindle
* Spindle Bearings;   Type, Quantity, Mounting, and Lubrication Method
* Spindle Motor;   Belt-Type, Motor-Spindle, Capacity, Size
* Spindle Shaft;   Including Tool Retention Drawbar and Tooling System Used
* Spindle Housing;   Size, Mounting Style, Capacity

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casting design 04 - product design rules

The most important aims in designing aluminum castings are to plan components for ease of casting production and to improve casting soundness. Planning arrangements of sections so that progressive solidification is toward the heavier sections helps reach these objectives.

This principle should be adhered to when designing for joining and changing sections. Sharp corners should be filleted because fillets prevent cracks, tears and shrinkage at re-entry angles. Additionally, make corners more moldable, and reduce stress concentration in the casting when in service. Fillets should be large enough to meet engineering stress requirements and reduce stress concentration, but not so large that they cause shrinkage.
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casting design 03 - heat treatment

Many metal castings meet the specified property requirements in their as-cast form, but there are times when even the cleverest use of the casting process and alloy will leave a part lack of the requirements. In these instances, thermal treatment can change the mechanical properties to meet those critical needs.

Heat treatment consists of heating and cooling that enhances a material’s strength, consistency or ductility. The type of heat treatment required by a casting depends on the alloy and the final properties required.

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casting design 02 - casting process

The fundamental process of casting consists of five basic elements

• Molding—The mold cavity must be formed from a material that will withstand the operating temperatures and conditions of the chosen casting process and metal.
• Pouring—The molten metal is poured into the mold and travels through its passages to fill the mold cavity.
• Solidification—During the solidification process, the metal cools and becomes a solid shape.
• Mold Removal—The cooled casting is removed from the mold.
• Secondary Operations—The casting is trimmed, cleaned, heat-treated, machined, inspected, painted, etc.

These five basic elements are supported by design and fabrication of the patterns and cores for the mold, the fabrication of the mold cavity and the melting of the metal.
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casting design 01 - choosing the suitable method

Metal casting is a manufacturing process in which metal is melted and poured into molds where it solidifies into geometrically complex components.

In terms of component design, casting offers the greatest amount of flexibility of any metal forming process. The casting process is ideal because it permits the formation of streamlined, intricate, integral parts of strength and rigidity obtainable by no other method of fabrication. The shape and size of the part are primary considerations in design and in this category; the possibilities of metal castings are unsurpassed. The flexibility of cast metal design gives the engineer wide scope in converting ideas into an engineered part.

The freedom of design offered through the metalcasting process allows the designer to accomplish several tasks simultaneously. These include the following:
• Freedom of design to optimize functionality and manufacturability.
• Net or near-net shape design.
• Intricate components can be produced as single cast part.
• Few restrictions on part weight or size
• Almost all metals and alloys can be cast.
• Optimal appearance.
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standard components

A machine consists of hundreds of components. Each one must carry on its job in order for the machine to work perfectly. Every parts receives different function, load, and friction. This is what causes every component have different lifespan measured in working hour. When it's lifespan is over, it must be replaced with the same type of component. To ease yourself when designing machine as well as ease the maintenance team's work, we can use standard parts.

Since we are using standard parts, they tend to be produced in large quantity, its quality are standardized, measured and it's up to the design team to utilize them

The more standard parts you can use, the better and easier the designer's work be. Here's some component library we can use :
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greetings..it's my own blog

Nothing to do this night..guess i had a little bit of spare time and try to make..errr..what's this called? oh yeah..a blog~
So here it is, WELCOME to ST_FANUC's BLOG

After a deep consideration that i am not accustomed to writing a "diary" or daily journal, I found out one golden rule. This blog is mine, I am the King here.. So I can freely decide what to post.
Yeah, I am an engineer, such a boring profession i have here, every single day messing with machinery, new information and technology development in machining world. That's exactly why I decide to post all i know, whatever inside my head, whatever new information passed down to me, and of course every good things that i meet during my browsing times :D

Hope everyone can enjoy, If not, just go elsewhere :p