ILLUSTRATED S O U R C E B O O K of MECHANICAL COMPONENTS

SECTION 21

Design Hints for Mechanical Parts 21-2

Designing for Easier Machining 21-4
How to Design for Heat Treating 21-6
More Design Hints for Heat Treating 21-8
How to Design for Better Assembly 21-10
Designing with Ribs and Beads 21-12
Design Machined Parts Properly 21-14
Innovative Detents 21-15
Cleaner lines for Control Cabinets 21-16
Flexure Devices for Economic Action 21-18
Isolating Machines from Vibration 21-20
Types of Mounts for Vibration Isolation 2 1-22
Printed-CircuitGuides 2 1-24
Hinges, Panels and Doors 21-27
Plastic Hinges 2 1 -30
Pivots Do Many Jobs 2 1-32
Dimensions for Hand Grips 2 1-34
Thirteen Ways to Use Metallic Bellows 21-36
Frictional Supports for Adiustable Parts 2 1-38
Building Strength into Brackets 2 1 -40
Adhesive Applicators for High-speed Machines 21-42
7 Basic Hoppers for Parts 2 1-44
21-2

Design Hints for Mechanical Parts

How to avoid close tolerances, and otherwise improve parts, where accurate
assembly is necessary.
Federico Strasser

High accuracy 4 Easdy machined7

Wrong Right Wrong Right

BUSHING FACE is 1nuc.11e a i e r to nia- HOLD-DOWN COVER for bearing should

chine than the hub of a large part such as have a take-up gap between the cover
a flywheel or heavy gear. flange and the bearing box,

I I

F b - 4
Wrong Right

SMOOTH-BORED HOUSINGS shown DOVETAILED parts that are to be a tight

on right let one bearing move when shaft fit are best provided with a slot and
length changes because of expansion. grooved pin where d equals b / 3 to b/4.
 Design Hints 21-3

Exfro - dose
tolerances

Right
Wrong

Wrong

Right
A
HINGE MOUNTINGS of the design
shown on the left will entail extremely
close tolerances. Let one end float.
Right
COLLARS that retain the axial position
of journal bearings should be placed a t
one end only to accommodate expansion.

Wrong Right Wrong Right

CHAMFER on pins and shafts that must CONE POINT on screw and correspond-
be driven into holes is advisable if entry ing chamfer on internal thread ensures
L to be clean and easy. quick cngagenient in blind thread.
21-4

Designing for Easier Machining

Flat working surfaces, bushings, single fits and other features simplify setups,
speed machining reduce tool replacement, and save material.
Federico Strasser

FLATS PROVIDE DRILLING SURFACES.

Wrong Right

n Riqhf

3
Wrong Fair Right High+

Much rnefol musf be remove Eccenfric hole tn Rl'fficulf fo supporf fong rods
for moch;ning female threads

Wrong

Ma/e threads con de machined

befween centers

Wrong Right
Right

4 ECCENTRIC HOLE LETS MATERIAL BE SAVED. 5 MALE THREADS ARE BEST ON LONG RODS.
 Design Hints 21-5

Cut-off pomf

Wropg Righ'

6 Wrong Riqht

PROVIDE GRIPPING SURFACES WHEN MACHINING IS TO BE DONE.

wu counter- Fjve surfaces Bushog Tbfee surfoces

Wrong Right
La Ezi

7u7 BUSHINGS REDUCE MACHINING COSTS AND AID STANDARDIZATION .

Wrong Right

. . SPLIT RINGS ALSO GIVE GOOD RESULTS.

Gops make p O f f awkward

fo clump for mil/ing

Wrong

Wrong

8
Sight

SINGLE FITS ALLOW TIGHTER TOLERANCES,

9 Right

KEEP SURFACES ON SAME PLANE FOR BETTER

CLAMPING.

>'Vo form fou/s

Ribs inierfere
7 needed

Wrong Riqht

10 DON'T LET RIBS INTERFFRE WITH MACHINING. 11 Wrong Right

DON'T CALL FOR CONTOURS THAT' NEED SPECIAL

FORM CUTTERS.
21-6

How to Design for Heat Treating

To prevent cracking and warping in heat treated parts, avoid abrupt changes
of workpiece contours.
Federico Strasser

he ideal shape for a part that is to
Tbe heat treated is a shape in which
every point of any section or surface
receives and gives back the same
amount of heat with the same speed.
Such a shape, of course, does not exist,
but it is the designer's task to come as ally to minimize stress concentrations
near to it as possible. To do this, keep during heat treatment. The other fig-
the workpiece body simple, uniform, ures show further specific ways to
and symmetrical. For example, the keep out of trouble when subjecting
first figures below show how changes parts to heat treatment. Holes, for
in c r o s section must be made gradu- example, should be correctly located.

&
il Wrong Fair Good Best
Sharp corners Generous fillets
Unequal secfions Equal secfions and radii

Wrong Right Wrong Right

2 FilJefs especioJ/y needed here

/
Non-cuffing holes
I \

Right
Wrong Right

4 5
 Design Hints 21-7

Right Wrong Right

Best Best
21-8

More Design Hints for Heat Treating

Watch out for faulty designs such as thin sections, blind holes, unbalanced slots,
and other weaknesses that can cause cracking and warping in heat-treated parts.
Follow these how-to tips.
Federico Strasser

Nearly all serious failures of hardened

steel parts are caused by internal
stresses. Avoiding sudden changes of
section is one good way to ensure bal-
anced heating and cooling, the secret of
success in all heat treating. Some other
good design tips, which supplement
those in our last issue. are illustrated.

Wrong Right
m i n sections Tbicher secfions
7

2 Wrong Right Wronq

+
Right

Deep, blind ho/e poor

for quenching

4 Avoid /unctions o f holes

in steel block 7
Wrong Righi

Gr/nd punch after heaf treating 2

 Design Hints 21-9

GrJnd keyway offer heaf treating

Grind fo sharp
edge offer heat

Bo/onced s h f s and keyways

Wrong

Dubficofe
fbuf dummy/
/
warking-face

Wrong Right

Uneven coohng Divide progress;ve die p/ofes into fwo

7 \ -7
21-10

How to Design for Better Assembly

Small but important details of mechanical parts make all the difference between
mediocre and superior design.
Federico Strasser
 Design Hints 21-11

h Y ? 4 , , I) - *- *-

* - ( - , ' a

1 ; -
, . * I ,

? *
> __ .
..
2 I-

$ < I /
1 P X . *

j . ,

- 6 *
" ' WPonp " RlgM -&
-Best '

&CESS HOLES or duds shoulil'always ~

I - 1 "

b* -@raCidkd in assemblies where bdt

wads &o$M be impossible or difficutt ~
" "
I
t a reach 6 t h a wrench. ' I

I "

* I*I I II $

~ * -*

Wrong Right

PRESSURE SCREWS should Have re-

duced ends to prevent expansion of the .
threads, whieh would make removal of I

the $crews difficult.

ADJUSTABLE LlNK is -neke&ary here
where dlmtnsion a must be exdct: other-
*~
w i s e * d i e n s i o n s b, c , ~d must have ex- Whng
cessively dose tolerances. .
< - + ". < *

* e I

^ I ,

+ i

. -
- ) I

. .
a '

WITHDRAWAL B,OLTS make disassem- SHIMS for beyel gears or threaded eye-
l+y easier when,tight fits are required be- bolts are necessary where dimensian p
I
tween two parts that can nok otherwise be and the angular position 09 the eye ar&
' skptparated safely. ' ' important to the de&gn.
21-12

Designing with Ribs and Beads

The reinforcing member, stop, or spacer in your present design may be superfluous.
An embossed rib or bead may do the job better, and at the same time save weight
and add strength.
Federico Strasser

J?
S t i f f e n i n g . A s t i f f e n i n g r i b (A) c a n
increase strength 4 Zo 5 h e s in a com-
ponent subject to buckling loads. An em-
bossed corner rib @) reduces bracket
cross section as well as weight by 50%.
A
Stress relieving. internal stresses caused
by cold-working end heat-treating can
be relieved by an X rib (A). Round
ribs (B) compensate for cooling stresses
after welding heavy to light sections.

Noise reduction. Vibration-induced noise Safety. An embossed rib on a flat metal-

6 in large panels can be reduced by io

rib. The rib changes the panel frequency.
lic surface such as a floor (A) gives a
slip-proof surface even when oily. An
embossed pattern on handles and wheels
(B) can eliminate operator hand slippage.
 Design Hints 21-13

Spacers. A rib can create a small dis-

1 tance between workpieces without any ad.
ditional parts. The distance can be held
to a close tolerance by simple machining.

Temporary assemblies. In thin-walled

5
Permanent assemblies. In hollow assern-

4 blies, an inward or outward bead (A)

forms a firm, permanent joint. In sheet-
metal assemblies, small embossed beads
(6) in the thinner member aid in welding.
round parts such as bulb bases, sockets,
flashlight reflectors, s m a l l caps a n d -
other parts the rounded threads are em-
bossed so a temporary union can be made.

8 Stops. A bead formed on a rounded part

is one way to align and position a match-
ing component quickly and accurately.
9 Anchors. Sheetmetal parts that are in-
serted in a plastic molding can be ribbed
or dimpled to increase the resistance of
the part being pulled from the molding.
21-14

Design Machined Parts Properly

Ample clearances, level surfaces, square entrances, and other important details
improve parts that are to be milled, ground, and broached.
Federico Strasser

Possibi/ity o f Cufier can spa// Cuf fer has

mis- diqnmenf machined end- finish clearance \

Wrong Right diamefer

1 KEEP RADII LARGE ON ROUNDED ENDS. 2 LEAVE CLEAR4NCE FOR MILLING CUTTERS.

Wrong
Right

3 MILL KEYSLOTS PARALLEL-TO SHAFT AXIS. 4 AN ODD NUMBER OF SLOTS REQUIRES FEWER MILLING CUTS.

Wrong Right

SURFACES TO BE FINISHED SHOULD BE ON SAME PLANE.. .

5 .. .
OR AT LEAST PARALLEL.
 Design Hints 21-15

Innovative Detents

1
I

> t
: I 4
' : I POSITIVE DETENT HAS PUSH-
I BUVON RELEASE FOR
ST WIGHT^ RODS Section on X X
21-16

Cleaner Lines for Control Cabinets

How to improve the appearance of consoles and similar functional cabinets with
divider strips, concealed catches, recesses, baffles, and trim.
F. W. Wood

Frame
Removab/e- -Frame Frame member
ponel member
Magnet
Magnet plaie
cemenied io
panel
Sheet meiaf -
Magnet catch Magnet recessed
ottacbed to in pane/
------v
frame

n CONCEALED CATCHES permit a

clear, uncluttered exterior panel ap-
pearance. Catches not requiring close
alignment are preferable.

Thin mefa/ Stepped

or plostlc cower \
over/ay panef

Control
pane/

Edge o f ponef hidden in

shadow area
This a/lows use o f
larger tolerances 3
Cower pane/

A B C

RECESSING provides a shadow

area round the panel and effectively
~uhdursany out-of-~qiiarrncss of the
panel or adjacent surfaces.
4 OVERLAY JOINTS are particdady
useful for hiding unsightly joint linm
around control panels - you ran see
only one linc around the panel.
 Design Hints 21-17

? I AUGUST 5. 1963

ALL THE DESIGN FEATURES de-

scribed here are applied to various parts
of the data-processing console shown
in artist's conception.

Q d

,
Divider strip Spacing witbouf divider sfrip
pone/ improves oppeorance detracts from oppeorance

DIVIDER STRIP between two remov-

able panels overcomes the need for a
tight butt joint. Contrasting-finish styl- Removob/e ---__
ing is also possible. pone/

i L
corner trim-$
Bock ,,111------------(
L-- -
S/of s pro vide
Back light " odjustmenf
flnlsh
some os
pone/

LIGHT BAFFLES behind all hinging or ADJUSTABLE TRIM gives illusion o f

sliding windows prevent back-lighting a good fit between non-squared panels
from emphasizing had fits. Raffle and and frames. Open-ended slots provide
panel color should be the same. for easy assembly.
21-18

Flexure Devices for Economic Action

Advantages: Often simpler, friction and wear are virtually nil, no lubrication.
Disadvantages: Limited movement, low force capacity.
James F. Machen

-2

0 Po/ypropropy/ene integra/
P hinge is guud examp/e

BASIC FLEXURE connection (singte-strip pivot) eliminates TWO EXAMPLES of two-strip pivots
need for bearing in oscillatory linkages such as relay ar-
matures
rfrove/ /im/'ted by

"RACK AND PINION" equivalent of rolling pivots 120" Y CROSS-STRIP pivot holds center location to provide
frictionless bearing with angular spring rate

Thee for morel

skewed str&
spaced around
cifcufof disks

I
Of equd ongfes

SKEWED STRIP converts angular motion into linear motion LIGHT-DUTY UNIVERSAL JOINT is ideal for many sealed instru-
or vice versa ment actions
 Design Hints 21-19

CRW-STRIP PIVOT combines flexibility with some load- CROSS-STRIP ROLLING PtVOT maintains geared rolling
carrying eapacity contact between two cylinders - different diameters give
gear ratio

7 U .c------t

PARALLEL-MOTION linkage has varying spacing IN THIS PARALLEL-MOTIONlinkage, platform A remains level
and its height does not change with sideways oscillation

Shaft No. f
I

n
FLEXURE TRANSMITS equal But opposite, low-torque, angular
motion between parailel shafts
SINE SPRING, straight line mechanism lets point A move in
approximately a straight line for short distances.
21-20

Isolating Machines from Vibration

Here is a selection of resilient pads, spring and rubber mounts, as they are commonly
arranged to absorb vibrations.
Louis Dodge

Machine /eg
Shims o r woshers

f f maferio/

Hafd maferio/

\\',\\\\\\ \ \ \\' \ \ \\ \ \
'Sqxm? pad-
Bonded @osfic adhesive)

1' ;
t!...!h SQUARE PADS AND PLAIN FOOTING
A ROUND PADS AND SHIMMED FOOTING

BELLEVILLE SPRING MOUNT SUSPENSION-SPRING

(STIFFNESS VARIES WITH NUMBER OF WASHERS) (FOR SMALL, HIGH-SPEED MACHINERY)

Limited deflection

HOW FOUNDATIONS
ARE ISOLATED
Lateral and v e r t i c o l loads
 Design Hints 21-21

-Sub-p/ote

/f/OOf

a LEVELING SCREW FOR UNEVEN FLOORS

COIL SPRING MOUNT
-AVOID RESONANCE FREQUENCIES

,Soft steel mof

Air
space

spr/ngs

I//BFOt/O/l
damper
fcork,
RUBBER BUSHING MOUNTS rubber)
HAVE HIGH DAMPING FACTOR

lofe

Equal s t a t i c d e f l e c t i o n for Rubber plus

V e r t i ca I d e f l e c t ion v e r t i c a l and h o r i z o n t a l loads p n e u m a t i c resilience
21-22

Types of Mounts
for Vibration Isolation
Thomas R. Finn

TRANSMISSION
OF VIBRATION from a machine or motor to the
supporting structure can be reduced by using special mountings.
Vibrations may be caused by an unbalanced rotor or reciprocating
elements of a machine. By flexibly supporting the vibrating
member, the disturbance can be greatly absorbed by the resilient
mounting.
For most effective vibration isolation, the mounting should be
very soft so that its natural frequency is low in comparison to the
frequency of the disturbance. As a rule, the disturbing frequency
should always be greater than 2.5 times the natural frequency of
the mounted system. For simple linear vibrations, the natural
frequency of the supported mass f.
can be determined by the
static deflection of the springs or mount. This is expressed by:
fn = 188 + vz (in cpm)
There are many commercial mounts available. Most of these
devices utilize rubber for resiliency; this rubber is most often
stressed in shear to obtain larger static deflection for a given
thickness. Where greater load capacity (per unit volume) is
required, rubber in compression is used.
An unrestrained body mounted on four resilient mounts, has
six modes of vibration and consequently six natural frequencies.
For single-degree translational motion of a body which is sup-
ported on more than one mount, the stiffness of each unit should
be in proportion to the weight supported. Besides motion in the
vertical plane, the natural frequency in the horizontal plane should
be also calculated. For the lowest natural frequency of the system,
mountings should be loaded close to the maximum rating given.
In applying vibration mounts, three factors are important: (1)
keep mounts far apart for better stability; ( 2 ) mounts should be
in a plane which passes through the center of gravity of the sus-
pended mass; ( 3 ) use of hold-down screws or'snubbers to limit
large motions.

STRIP-TYPE ISOLATORS

5 Goodricb Co. Finn and Co. u S. Rubber Co

Fig. 1-Rated at 80 Ib/linear in. with a
shear deflection of 1 in., this type has a
compression rating of 250 Ib/linear in. at
5/16 in. deflection. Requires drilling and
cutting to proper length.
Fig. ;?-This mount has ratings from 40 to
105 Ib/linear in. and deflects f in. Rub-
ber is stressed in shear and compression.
As a result, the load deflection c u m is
non-hear, which prevents resonance.
Fig. 3-Channel-type mounting comes in
two basic sizes: small, for vertical loads
up to 95 Ib (illustrated); large, for loads
to 420 Ib. Lengths are 1 to 7 in. Cao be io-
verted for overhead suspensions.

Fig. &For heavy, flat base, equipment several materials are
available for vibration isolation; these are most effective where
very high frequencies and disturbing sound are to be reduced.
Sheets of felt, cork, and rubber are most commonly used. (A)
Isomode pads of neoprene are 5/16 in. thick and are used at
loadings of from 10 to 60 psi. Maximum deflected height is f in.;
several Iayers can be used. (B) Vibrupad consisting of alternate
layers of cotton duck and rubber, 8 in. thick, is used for loads
up to 200 psi. (C) Elasto-rib is a combination of cork and
ribbed-rubber which is rated up to 35 psi. Minimum thickness is
1 in. @) Natural cork plates are held by a steel frame. Thick-
ness ranges from 1 to 4 in. and widths up to 24 inches
 Design Hints 21-23

INDIVIDUAL MOUNTS
I I 7 Maunfed unit - .-- 4

k--$dia. ---+I

Fig. 5-(A) Axial ratings of this standard series are: 1 to 90 Ib Ib, the rubber is solid. (B) Small mount is rated from 1/3 to 3
+
at deflections of 1/16 or in. Mounting is about twice as stiff Ib per unit. Isolates vibrations as low as 900 cpm in all direc-
radially as compared to the axial direction. For loads u p to 310 tions. Attachment is simplified by punched or tapped holes.

Fig. &Stud-type pads am simple to at-
tach and rated in compression from 2 to
270 Ib, but limited to applications of shear
and compression forces. Pads with tapped
boles are made for cap screws.
Fig. 7-MounU are rated at 150 to 2,670
Ib at 0.15 in. deflection. The natural. fre-
quency is about 490 cpm. Sleeve ID va-
ries from 0.437 to 1.00 in. and the overall
height is from 1.75 to 4.00 in.
Fig. &All metal mount for extreme tem-
perature conditions. Woven wire is used
for resilient element. With a varying
spring rate, it has good damping effects.
Unit load ratings are from 2 to 25 Ib.

i f m Cfip holds nut

campression and
recess in mefal

._. wt nem ey Dressure _ _ _ _ _ _ - - _ _5 _- - - - - - - - - - - 4

MoNi+ Products Ca.
Fig. 9 S p e c i a l l y designed, this mount is
widely used in automotive industry. Be-
sides axial and radial resiliency, it is
used for torsional and angular motion.
General Ere Co.
Fig. 1 L F o r heavy loads, rolling joint is
useful in applications where alignment is
important. Normal ratings range from
125 to 1,500 Ib at 0.24 in. deflection.
Firrstone rue and Rubhr Ca.
Fig. 11-Metal reinforced rubber pads
are designed for loads of 250 to 1,700 Ib.
All pads have the same overall dimen-
sions. Attaching bolts are: 9, Q or 4 inch.
2 1-24

Printed-Circuit Guides
They allow easy and quick insertion, they guide accurately,
and they support the board firmly in place.
Irwin N. Schuster

%de clot

FLAT SPRING i n extrucled section pro- CHANNEL LIP allous f l n l spring to be

\,itle.; close limitation for horizontal panel- pi:tcctl to retain c i r c u i t hoard against
movement. extreme t o l e r a n c e vertically. channel side and reducc tolerancec.

Plastic
wire

SPRING WIRE a n d panel stiffener is a PLASTIC BUTTONS offer :in tiltra-siiii-

good combination where panel space is ple method of holding panels. The rcxind
n o t iit a preniiuni. huttons let pcinci \ l i c k home easily.
 Design Hints 2 1-25

EXTRUDED CHASSIS PARTS, br,ike- FORMED WIRE structure let5 cooling air
Jormcd gtittlcs, ,ind Ilat \ p i n g \ allou through mhile gripping the circuit hoard
more tolcr,incc ietlticrion in ci\wrnl>l>. ! irmly in two planes.

EXTRUDED OR HEAT-FORMED pIcistIC PLASTIC EXTRUSION here pro\ ides its

guide5 'ire incxpcnsivc a i d reduce the w n cpririg grip to support a light-weight
chance ol' 5horting t o thc metdl C:hd%i\. p i n e l in a mild cn\ironment.
21-26

Lead- in
mg/e
/

FORMED SHEETMETAL GUIDE STAMPED-IN hoard guide reduces

made of spring material, with the cntl c weight of cliassis while providing firill
off at an angle to guide the hoard. board mount. Note lead-in angle.

SMALL SECTIONS s t : i n i p C d i i i lltc cli;ts- INTEGRAL GUIDE is ideal when stiff'

sis provide locating guides f o r carcts clinssis is required and gives excellent
moiintccl in tixcd positions. lead-in characteristics.
 Design Hints 2 1-27

Hinges, Panels and Doors

Here are some low cost ways to avoid spoiling the appearance
of your equipment with hinges that show.
Frank W. Wood

-
iltornntivo n i v n t

,. . . . . ,.. , ..... ....".,. * .l.X.,.,l,I... .,. ,. ... . . . . . .,. . .,: . ,.

. .. .

..

_-.-_
x. ,

L engf h
to suif
required
pivot ocfion

. FORMED WIRE FOR DOUBLE HINGE ACTION

2 1-28

3 I
EXPOSED CATCH provides an ea\?-to-niake and lower-cost catch if the
appearance of the external fastener is not objectionable.

4 HEAVY DUTY CATCH, held by a machine screw, will retain hinged assem-
blies weighing several hundred pounds. Good initial alignnient is advisable.

f washer

5 CATCH DOUBLES A S SHIPPING LOCK when the screw is renioved and

a large washer is added between the screw head and the catch.
 Design Hints 21-29

Cublnef \

A'; \'\, h'ylon bushing w i l l prevent m e t a l - t o - m e t o l

i ' r a t t l e and b i n d i n g
I
'\
\
'\

\
\
',
\ \\
\ \
\ \
\ \
\ \
\ \
\\ , >
b'
FORMED TAB AND HOLE (vertical)

L i f f bot tom p/n A

Pu// top p/n down
fo remove door

Sma// pm pressed

7
u
Pivot action is similar to 1

HANDLE PIN AND SPRING

Beurmg wasber sbould
be used between door
and cabmef
2 1-30

Plastic Hinges
Theyll cut costs and improve your product.
You can clamp them, snap them, or otherwise
locate them with their molded-in shapes.
Irwin N. Schuster

/
Meto/ c/omp

Rigid metal section, slipped onto molded tabs,

clamps them together. Plastic material is either
polypropylene or polyethylene.

4 5
Soft plastic hinge is snapped over pin in full open Assembled similar to number four, this hinge is
position, giving maximum strength when top is fully moldable with no undercuts and can be disas-
closed; is best for containers with top handle. sembled only when fully open.

Soft plastic tubing sections are snapped onto nip.
pies between both halves of this hard-plastic hinge
as they are assembled together.
w
This hinge must be used in pairs, unless three
Bower tabs are molded. Snapped in from the back,
pin cannot be removed when top is closed.
Design Hints 21-31
Stamped metal hinge with formed retaining barbs
penetrates into locating depressions in rigid foam
parts. Hinge costs little, performs well.
7
This strap, mating into itself, can loop around a
molded pin, metal rings, or other closed sections.
giving more security than a snap-on arrangnenk.
2 1-32

Pivots Do Many Jobs

Simple, easy, and inexpensive, pivots can eliminate
play in machine tools as well as scientific and measuring
instruments. Here are some ideas on how to make them,
where to apply them.
Maurice Conklin

Making a pivot In soft metals like brass a female

3 locating recess with contact lim-

ited to three constrained areas
can be made by drilling three
holes (A), a center hole (B), and
countersinking (C)around them.

Round-tipped leg, V-slot, or conical hole pivois Sheetmetaf squared ti-Qedions can be crossed fo

1 can be machined with threaded shanks for

easy installation and adjustment an a part. 4 form a knife-edge support with a n infinitely sharp
corner at the bottom of the Vee making a pivot point,

Balls used as+feetcan beepeenedinto a sleeve, A similar-reduced-area contact is made by milling

2- soldered or held by a clip. A round-headed
screw can be a suitable substitute: for the ball.
;
5 segments around a hole either plain<orcountersunk,
or a three-ribbed punch tip can forb a countersink
leaving the remaining area to [make contact.
 Design Hints 21-33

Apptying a pivot
. "

5egmenf
groove

Base
groove Tefrohe
groove

I
I *

Need to turn through an arc? A ball set into a drilled rounded t i p g f one: leg in a tefrahedral pocket and let
6 spot on the base and segment does the trick. The outer
t w o balls slide on the base andobeing set in the seg-
ment, support the outer end. Another way is to set the
the other legs slidq on a metallic surface. A third
method is to place two hemispherical-tipped feet into
and accurately grooved V-section, the third foot slides.

* >

" S S

h - Need to measure material thickness? Wow about a
block with three balls, one off-center. When-a thin
A piece of metal is slipped under the off-centered ball,
the black tips. Tap face of the block is a mirror, part
> i
I of an opticat level to indicate thickness. Anoiher meth-
od used to measure filament thickness has two balls
and a roller, The filament is slipped betweell the balls
and under tbe roller, rise of the needle gives thickness.
> * ~~ &

< > r i a

I I 1 1

* I e *

I "

' with i o force other fhan gravity, Anoher approach Is

I 1 Need to support a mirror o r other target? It's simple
with a central tension spring and three ball4ippetl
screws. One screw end fits into a tetrahedral pocket,
the second "in a V-groove, the third on the flat sur-
I face. The target 'can now be positioned accurately
i
"
to suppart two links with tension springs and &ut.
The tensionaspring eliminates backlash i n d holds the
'
assembly together; the sharplipped strut permits free
pivoting of the- mirror or target Zttacned' to tRI: links.
21-34

Dimensions for Hand Grip

To get maximum advantage from knobs and handles, use the size
suggested in these sketches.
Frank William Wood JR.

KNOBS

Thumb and Third Finger Thumb and Forefinger

IThumb, First and Second Fingers Fingertips and F l a t Grip

Open 611-hand Grip with Fingers to Edge

 Design Hints 21-35

HANDLES

I, Four Fingers Two Fingers

-y 3$ h. -
r
t-/% in.+

Po le Recessed Pull
 2 1-36

Thirteen Ways to
Use Metalk-Bellows
Sketches serve two purposes: 1) Illustrate unique as well as typical applications;
2) Show how the movement of bellows can be transferred to other elements.
E. Perry Cumming

*-pressure
Apptied

FIG 2 El
ACTUATE GAGES and switehes. FLOW CONTROL. Variations in
Pressures can be as high as 2,000 pressure adjust needle in flow valve.
psi. Maximum value should exist Also shows how bellows can be pack-
when the bellows is near free-length. less seals for valve stems and shafts.
FIG 3
METERING DEVICE. Dispensing
machines can use bellows as con-
stant or variable displacement pump
to measure and deliver predeter-
mined amounts of liquids.

Movemenf

ABSORB EXPANSION OF FJJJIDS OR
GASES. Transformer (above) uses hel-
lows to absorb increases in volume of
oil caused by thermal expansion. Single
controls of this type can operate from
-70 to 250 F or from 0 to 650 F.
FIG 7
FLEXIBLE CONNECTOR, Suitable for wide range of applications from in-
struments to jet engines and large piping. Bellows absorb movement caused
by thermal expansion, isolate vibration and noise as well as permit mis-
alignment of mating elements. Wide variety of sizes and materials are now
possible. Onits are now in use from ?/4 to 72 inches i n diameter, made
from such materials as brass, phosphor bronze, beryllium copper and
stainless steel.

t-

PRESSURE COMPENSATOR. Effect of ambient pressure can he eliminated Bellows used instead of piston and
in a pressure measuring system by matching the area of a pressure bellows cylinder arrangement. Eliminates ef-
with that of an aneroid and combining the two into a single assembly. fects of leakage and friction. Long
Errors caused by ambient pressure can be held to a max of one percent. stroke can be provMed with sensitive
Present materials permit aneroid operation from -70 to 450 F. response.
 Design Hints 21-37

FIG 4
FLEXIBLE COUPLING. Bellows can transmit torque
through oblique shafts with negligible amount of back-
lash or can be used to transmit circular motion through
the wall of a sealed container as shown above.
HERMETIC SWITCH. Bellows provide a gas tight
flexible member through which motion can be trans-
mitted into a sealed assembly. Flexibility and long life
are important characteristics of these elements.

i
FIG
n ,I Bulb

SEALED ADJUSTMENT. Accurately calibrated adjnst-
ments inside sealed instruments are possible by means of
single or compound threads. To meet varied installation
requirements, bellows are available with ends prepared
for ring or disk end plates of standard or special design.
These plates are fastened by brazing or welding tech-
niques.
VAPOR PRESSURE THERMOSTAT. Small dia bellows
offer large movement over a relatively small, adjustable
temperature range. Can be filled so a s to be unaffected
by over-runs in temperature. Compensation for changes
in ambient temperature is unnecessary whether this
temperature is above or below the value selerted for con-
trol purposes.

I
SlOM.

t
f0Sl

FIG
TIME DELAY MECHANISM. A cheek
bdACMT
FIG 13

valve and proper size bleed hole be-
tween two liquid filled bellows allows
fast motion in one direction and slow
motion in the other direetion.
bdb
AMBIENT TEMPERATURE COMPENSATION. Two methods are shown.
The left one uses two bellows i n the actuating system. One is driven by the
compensating assembly and correctly positions the actuating bellows as
ambient temperature ehanges. The other method uses a floating lever whose
mid-point is positioned by both the actuating and compensating bellows.
21-38

Frictional Su ports
for Adjustab e Parts
L. Kasper
P
Frictional supports permitting relative longitudinal and rotational adjustment
between a rod and a clamping member have wide application because of their simpli-
city of design and the ease and rapidity with which they can be adjusted. Possibili-
ties of design are endlees, as indicated by the accompanying group of designs.
Illustrations include typea having slight and strong resistance to friction,
types in which the frictional resistance can be varied to suit conditions, typea
that have greater resistance in one direction than the other, and types that
have positive detents for certain positiona. The sketches are self-explanatory.

Spfii sleeve of
soft rnaieriah
such u s fiber,

FIG. 4

FIG.3
FIG. 1

spiii s/eeve o f /
-soft material
such a s hber la?

FIG. 5 FIG. 6 F16.7 FIG. 0

 Design Hints 21-39

\
\ R o d is ffaffeene+---- Pin---
\ fo receive spring,,'
\
\

\\/'

FlG.9 FIG. 10
,
\

P e r m i f s change of-?,
angu/ar re/ufion ship
of r o d
FIG. I I

Tapered sp/if
c- .--collar qrips
rod

longifudinuf fricfron
downward greafer
fhun upward
& ___---- - --%-
-----.--__
,-d?---- __ T a u f yire
k >

FIG. 12

Inner tube sd1a'e.r fn w f e r fube-.,

t

Spring for f r i c i i o n a l r---Four s/ofs in inner fube

Rod-.-' Tighfening screw

_._ &<&xpered collar expands inner fube and arz)jusfs -si8 func.
focks rod fo movemenf
FIG. 15 FIG. 16
2 1-40
Building Strength into Brackets
They must meet specific requirements-stability, light weight, and the like.
Heres your guide.
S. Warren Kaye
F o r stability, a good bracket must be able to carry
load in three directions at right angles to each other-
vertical, fore and aft, and sideways. Besides being able
to withstand regular acceleration and operating loads, it
must often be rugged enough to avoid damage from
handling and accidental loads-for example, if it is
stepped on, or used as a handhold, as in aircraft and
missiles.
Space Age requirements also point up the frequent
need to minimize weight of brackets. One way to do
this is to place the equipment they support as near as
Poor design
Improved design
1 M O U N T I N G LUGS should be either kept short or
have rivet locations that reduce twisting.
possible to suitable attachment points on the basic
structure. (Sometimes, in fact, by a minor rearrange-
ment, such as shifting a stiffener or frame, the equip-
ment can be attached directly ,to t h e structure, and the
bracket eliminated.)
Other general rules for designing brackets: Avoid
tension loads on riveted joints, do not combine rivets
and bolts in the same local area; avoid using aluminum
bolts in tension wherever possible; in a rivet pattern,
avoid smaller rivets in the outer row; and dont over-
load first rivet or first row of rivets.
This rivef group not
This rivef
overloaded
Poor design
ndle
shear only fensile loads
Improved design
2 SPECIAL M O U N T I N G is best for cantilever bracket
where large moments cause high tensile stress at
mounting. If possible, design a one-piece bracket.
 Design Hints 21-41

Rigid frame members

Web

3 STIFFENERS carry moment loads to rigid frame, 4 SHELF SHEET can be thinner and lighter if stiff-
prevent unsupported web from oilcanning. eners are provided. Lightening holes are flanged
where possible.

Poor design Improved design

5 CHANNELS are best for spacing mounted equipment sufficient t o withstand bending from side loads. If
from attachment wall. Channel thickness must be necessary, extra stiffening should be provided.
2 1-42

Adhesive Applicators
for High-speed Machines
T H K> r ~ ~ r ~ ~o or i Ai'i'i.YIxC:
>s LIQIJII) AUHF:SI\ ES that a r e illirstrated here
include rotary applicators on movable axes and otherwise movahlc
1)etwwn adhesive pick-up po.iition and applying position, endless I x l t
:ipplii~ators, applicators in the form of rnoring daul)cr~.plate.. arid thc.

m \ \ \
like. reciprocating dies exuding measureti quantities o f c'rmrnt. a n d spray
iiozzl~:.~. 4 II o f these rneclianis~nsare used or are cil)plical)le on pri)duc.-
tion rrracliines suvh as for making p s t c h o a r d boxes or c'urtonh, pasting
labels or envelopes, and making shires o r other prodirctr; involving the
u + e of l i i p i d adhesive..

,-Label stack

'brush
W n t e r vessel in p / m e when
is nof use
in

FIG. 3-Brush applicator i s f e d througli

passages between bristle t u f t s b y spring
Pa f 2,25a785 operuted plunger

FIG. 1 - Bottom lubei is spread with glue by tico ubirttiiig glue-could picker plutes,
which sepurute during contact wirh lube1 stuck, then curry lube1 t o bottle

L o w e r die s/ides
under upper d t e - - -

Section A-A

mafching supplied in
upper d e measured
pfafes qucvn+/ity
FIG. 2 - Measured qciuntities OJ cement are forced through perforutions in speciully FIG. 4-Shoulder on ralve stern in glue
designed u p p e r und lower die plates, which are closed hydraulically ocer zippers. chamber retains glue until presslire 011
Lower die only is shoten tip opens bottorn calve
 Design Hints 2 1-43

from edge o f l a b e / staik FIG. 10 - Datiber asscmbly is m o i - d

P a f 2,206,964 horizontully between gliie pot c i n d work
by eccentric pin on gecir. Vertirul m o w -
FIG. 9 - Paste belt upplicutor passe. uroiind ments are produced b y crank operutrd
pulley iri pastcpot and slidrs over lube1 stuck bar. o i w duiiber shaft
21-44

7 Basic Hoppers for Parts

Hoppers, feeding single parts to an assembly station, speed up many
operations. Reviewed here are some devices that may not be familiar
to all design engineers.
Peter C. Noy

Hopper/ tube

2
Centerboard selector . ..
is similar to reciprocating feed. The centerboard top can be milled
to various section shapes to pick up moderately complex parts. It
Reciprocating feed ...
for spheres or short cylinders is perhaps the
works best, however, with cylinders too long to be fed with the
reciprocating hopper. Feed can be continuous or a s required.
simplest feed mechanism. Either the hopper
or the tube reciprocates. The hopper must be
be kept topped-up with parts unless the tube
can be adiusted to the parts level.

3
Rotary centerblades ...
catch small U-shaped parts effectively if their legs are not
too long. Parts must also be resilient enough to resist perma-
nent set from displacement forces as blades cut through
pile of ports. Feed is usually continuous.

Part
4 Rotary screw-feed
Paddle wheel ...
is effective for disk-shaped parts if they are stable
enough. Thin, weak parts wou!d bend and jam. Such
designs must be avoided if possible-especially
outornotic assembly methods will be employed.
(See pp. 750, 151.)
long-cylinder feeder ...
is a variation of the first two hoppers. If the'
cylinders have similar ends, the part can be
fed without pre-positioning, thus assisting
outornotic assembly. (See pp. 150, 151.) A
cylinder with differently shaped ends requires
extra machinery to orientate the part before
it can be assembled.
Design Hints 2 1-45
5 ...
handles screws, headed pins, shouldered shafts ond
similar parts. 13 most hopper feeds, random selec-
tion of chance-orientated parts necessitates further
machinery if parts must be fed in only one specific
if
position. Here, however, all screws are fed in
the same orientotion (except for slot position)
without separaie machinery.
7
Barrel hopper ...
is most useful if parts tend to tangle. The parts drop free of the rotating-
barrel sides. By chance selection some of them fall onto the vibrating rack
and ore fed out of the barrel. Paris should be stiff enough to resist excessive
bending because the tumbling action can subject parts to relatively severe
loads. The tumbling sometimes helps to remove sharp burrs.