Here you can find an assortment of mechanical design tools intended to help reduce the monotony of mechanical engineering. The hope is that these guides and help you located frequently need information and will help streamline your design process.
There are tables, formulas, shortcuts and advice. All these should be taken as aids, but never accepted without your own validation of the mechanical design tools within the context of your own application and your own analysis.
If there are any areas where you need further assistance, please feel free to contact us to recommend a new design tool.
Bolt Clearance Hole Sizes When a bolt passes through a part without threading into it, the hole needs to be slightly larger than the bolt diameter. How much larger depends on how precisely the holes need to align. US Bolt Clearance Holes Bolt Size Close Fit (in) Normal Fit (in) Loose Fit (in) #4 (0.112) … Read more
How It Works Structural beam analysis determines internal forces, bending moments, and deflections that develop when loads are applied to horizontal structural members. These calculations form the foundation of safe structural design by ensuring beams can support applied loads without failure or excessive deflection. Shear Force (V) represents the internal force tending to cut through … Read more
What is Tolerance Stack-Up? When multiple parts assemble together, each dimension has a tolerance. Those tolerances accumulate. Tolerance stack-up analysis tells you whether your assembly will work — or whether you’ll be forcing parts together on the shop floor. There are two fundamental approaches: Worst Case (everything goes wrong simultaneously) and RSS/Statistical (realistic probability-based analysis). … Read more
Choosing the Right Stainless Steel There are over 150 grades of stainless steel. In practice, you’ll use about five of them 90% of the time. This guide covers those five — when to use each, what to watch out for, and the trade-offs between them. The Big Five — Quick Comparison Property 304 316 303 … Read more
Common Aluminum Alloys for Engineering Not all aluminum is the same. The alloy designation tells you everything about its strength, machinability, weldability, and corrosion resistance. Here’s the practical comparison for the alloys you’ll actually encounter. Properties Comparison Table Property 6061-T6 7075-T6 2024-T3 5052-H32 Tensile Strength (ksi) 45 83 70 33 Yield Strength (ksi) 40 73 … Read more
Standard Bolt Torque Values These are recommended tightening torques for standard dry (unlubricated) bolts. If you’re using lubricant, anti-seize, or plating, reduce torque by 25–30% — lubrication dramatically changes the torque-tension relationship. Grade 5 Bolts — Torque Values Bolt Size TPI (UNC) Clamp Load (lbs) Torque Dry (ft-lbs) Torque Lubed (ft-lbs) 1/4-20 20 2,025 6.3 … Read more
Socket Head Cap Screw (SHCS) Dimensions Socket head cap screws are the go-to fastener for machine design. Their cylindrical head fits into a counterbore, allowing the screw to sit flush with or below the surface — critical when you need clearance for moving parts or a clean look. All dimensions per ASME B18.3: Screw Size … Read more
What is AS568? AS568 is the standard that defines o-ring sizes in the United States. Every standard o-ring you’ll encounter in American engineering has a “dash number” (like -214 or -028) that maps to specific inner diameter (ID) and cross-section (CS) dimensions. The dash number tells you everything: First digit = cross-section series (0XX = … Read more
What is a Static O-Ring Seal? A static o-ring seal is one where the o-ring doesn’t move during operation — it just sits in a groove and gets compressed between two mating parts. Think flanges, covers, manifolds, and housings. If you’re not familiar with standard o-ring sizing, start with AS568 O-Ring Sizes first. These guidelines … Read more
Why Hardness Matters Hardness testing is the quickest way to verify a material’s heat treatment and estimate its tensile strength without destroying the part. In practice, you’ll encounter three scales constantly: Brinell (HB), Rockwell B (HRB), and Rockwell C (HRC). Conversion Table — Steel These conversions are approximate and apply to carbon and alloy steels. … Read more