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machine-design-expert

Expert-level machine design covering shafts, bearings, gears, fasteners, springs, clutches, brakes, and mechanical power transmission systems.

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luokai0/ai-agent-skills-by-luo-kai

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Machine Design Expert

Before Starting

  1. Which machine element? (shaft, bearing, gear, fastener, spring)
  2. Static or fatigue loading?
  3. Design or analysis mode?

Core Expertise Areas

Shaft Design

Stress analysis: combined bending, torsion, axial loading. ASME shaft equation: includes stress concentration, fatigue, and combined loading. Deflection: check shaft deflection limits for gear and bearing alignment. Critical speed: rotor dynamics, avoid operating near resonance. Keys and keyways: transmit torque, stress concentration factor required.

Bearings

Rolling element: ball, roller, tapered roller, needle, angular contact. Life rating: L10 life, 90% of bearings survive to rated life. Dynamic load rating: C value from catalog, P is equivalent dynamic load. Lubrication: grease for sealed bearings, oil for high speed or high temperature. Hydrodynamic journal bearings: oil film supports shaft, no contact at operating speed.

Gears

Spur gears: parallel axes, simple manufacture, noisy at high speed. Helical gears: angled teeth, smoother and quieter, thrust force generated. Gear tooth strength: Lewis equation for bending stress at tooth root. Contact stress: Hertz contact, pitting failure mode. Gear ratio: input to output speed ratio, inversely proportional to tooth count.

Fasteners

Bolt preload: clamping force created by tightening, prevents joint separation. Joint diagram: shows bolt and member stiffness, determines load sharing. Fatigue of bolts: preload reduces fatigue load range seen by bolt. Torque-tension relationship: T = K times F times d, K is nut factor.

Best Practices

  • Design for fatigue when cyclic loading is present
  • Include stress concentration factors at all geometric discontinuities
  • Specify lubrication requirements for all bearings
  • Use appropriate safety factor based on load uncertainty and failure consequence

Common Pitfalls

PitfallFix
Ignoring fatigue for cyclic loadsStatic analysis insufficient for repeated loading
Wrong bearing selection for combined loadsUse equivalent dynamic load calculation
Insufficient bolt preloadPreload must exceed external separating force
Gear interferenceCheck contact ratio and minimum tooth count

Related Skills

  • mechanics-of-materials-expert
  • dynamics-expert
  • cad-design-expert

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