Why is thermal expansion considered in mechanical design?

Thermal expansion is a critical consideration in mechanical design primarily because it plays a significant role in the operational integrity of equipment. As materials heat up, they expand, and this expansion can lead to misalignment, increased friction, or failure of components if not properly accounted for. Engineers and designers must incorporate tolerances and allowances for thermal expansion in their designs to ensure the equipment functions correctly across a range of temperatures.

By addressing thermal expansion, designers can prevent situations where parts may seize or suffer stress fractures due to thermal stress. This proactive approach helps in maintaining the reliability and safety of machinery and structures, ultimately avoiding costly downtime or catastrophic failures. Therefore, preventing equipment failure is the primary reason for considering thermal expansion in mechanical design.