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Mechanical Design Practice

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Magnesium Alloys in Machine Design: Weight Savings, Flammability Risk, and Handling

Magnesium is the material that generates the most nervous questions in a design review of anything I specify. Someone al...
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Copper and Brass Alloys: Electrical, Thermal, and Machinability Trade-offs

Copper and Brass Alloys: Electrical, Thermal, and Machinability Trade-offs. Covers Electrical Conductivity Applications, Thermal Conductivity Applications.
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Reading a Mill Test Report: Verifying Material Certification for Critical Parts

Reading a Mill Test Report: Verifying Material Certification for Critical Parts. Covers Chemical Composition Section, Mechanical Properties Section.
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Titanium in Mechanical Design: Properties, Machining Challenges, and Where It Pays Off

Titanium has a reputation that precedes it into almost every design review I have sat in over the past twenty years: exp...
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Fracture Toughness and Brittle Failure: Why Ductile Materials Sometimes Fail Suddenly

I remember the first time I saw a fractured part from a "ductile" steel component that had failed with almost no visible...
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Hardness Testing Methods: Rockwell, Brinell, and Vickers Explained for Designers

I have spent twenty years as a contract mechanical designer embedded at large manufacturers in Japan, and if there is on...
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Ball Spline Selection: Rotary and Linear Motion Combined in One Component

I first specified a ball spline on a project where the customer wanted a shaft that could both rotate under servo contro...
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Creep in Mechanical Design: When Materials Deform Under Sustained Load and Temperature

Early in my career I designed a support bracket for a piece of process equipment that ran hot — not glowing hot, just co...
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Ratchet and Pawl Mechanisms: Design Rules for Reliable One-Way Motion

Ratchet and Pawl Mechanisms: Design Rules for Reliable One-Way Motion. Covers Spring Selection for the Pawl, Backlash and Positioning Accuracy.
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Timing Belt and Pulley Design: Synchronous Drives for Precision Positioning

I have used timing belts on everything from simple conveyor indexing to servo-driven linear stages where the customer wa...