CHAPTER 2:

The Design Process

CONTENT

2.1 Introduction

2.2 The Design Process

2.3 Types of Design

2.4 Design Tools & Materials Data

2.5 Function, Materials, Shape & Process

2.6 Case Study

2.7 Factors in Materials Selection

 2.1 Introduction
Design
Mechanical
deals with the physical
principles, the proper
functioning and the production
of mechanical system.

Industrial
involves pattern, colour, texture
and consumer appeal.

Main focus ~ mechanical

design
 2.2 The Design Process

Design
An iterative process (proses lelaran / proses berulang)

Based on market need (keperluan pasaran) and product

specification (tentuan keluaran)
 2.2 The Design Process

Stages in design process:

Concept (konsep)
Embodiment
(penjelmaan)
Detail (perincian)

Refer to Figure 2.1

 Figure 2.1: The design flow chart The design proceeds from an
identification and clarification of task through concept, embodiment and
detailed analysis to a product specification.

MARKET
Define specification
NEED
Determine function structure
Seek working principles
Evaluate and select concepts
CONCEPT

Develop layout, scale, form

Model and analyse assemblies
Optimize the functions EMBODIMENT
Evaluate and select layout

Analyse components in detail DETAIL

Select processing route
Optimize performance and cost
Prepare detailed drawings PRODUCT Iterate
To do again..again..again
SPECIFICATION
 Product as technical system

Technical system consists of:

Assemblies (Pemasangan)

Sub-assemblies (Sub-
pemasangan)

Components (Komponen)

Refer Figure 2.2

 Figure 2.2: The analysis of a
Component 1.1
technical system as a
Assembly Component 1.2
breakdown into assemblies
1
and component. Material and
Component 1.3 process selection is at the
component level
Component 2.1

Technical Assembly Component 2.2

System 2 Original-in-dash Radio unit

Component 2.3

Component 3.1

Assembly Component 3.2

3

Component 3.3
 Design : input-output

System is divided into sub-sistem

All sub-systems are interrelated

and perform specific sub-
function

This arrangement is called the

function structure (struktur
fungsi) or function
decomposition (penguraian
fungsi)

Refer to Figure 2.3

 Technical System

Input Output
Function 2 Function 3
Energy Energy

Material Function 1 Function 6 Material

Information Information
Function 4 Function 5

Sub-systems

Figure 2.3: The systems approach to the analysis of a technical system, seen as
transformation of energy, materials and information (signals). This structure, when
elaborated, helps structure thinking about alternative design.
 Case study : Desktop PC

Technical System: Technical System:

Assemblies & Components Input & Output

Electricity Raw Data Blank CD

LED (Energy) (Info.) (Material)
Monitor
Switching

PCB CPU
CPU
Processor

Desktop PC Mouse Keyboard

Desktop PC
Keypad
Keyboard
Casing Monitor

Sensor
Mouse
Heat/Sound Analysis Burned CD
Buttons (Energy) (Info.) (Material)
 2.3 Types of Design

Original (Asli / Tulen)

Involves new idea or working principle. A new
material suggest new product, or a new product
demand the development of a new materials

Adaptive / Development
(Penyesuaian / Pembangunan)
develop/ enhance the existing concept from the
material aspect.

Variant (Varian / Kelainan)

A change of scale, dimension or detailing without
change of function or the method of achieving it.
Change of scale/ range of condition may require
change of material
Original (Asli / Tulen) ~ New idea / working principle

Eg. : Dynamic Skyscrapper

Suite Vollard in Curtiba, Brazil (50 m)

Completed 2001
all apartments can rotate 360
an individually spin any direction,
takes 1 hour.
Almost the entire building can rotate
 Dynamic Skyscraper
The Dynamic Tower in Dubai,
UAE (420 m)
However, as of January 2013,
construction has not started yet.
No official announcement of the
building site
Other charateristics:
New dimension of
architecture ~ time
individually varying rotating
floors
prefabricated construction
True Green building
 Fold Up Your Bathroom?!?
the shower can fold into a small
wall cabinet for easy storage
when not in use while works as
effectively as a full-scale
shower to ensure the users a
relaxed bath.

the foldable shower can be

easily installed in various types
of apartments, allowing a
comfortable bath in limited
space.
Original (Asli / Tulen)
 Adaptive / Development
(Penyesuaian / Pembangunan)

Develop the existing concept in

the aspect of materials
Old school coca-cola bottles
Metal vacuum

Vs

Polymer vacuum
Wood vs CFRP racket
 Variant
(Varian / Kelainan)

a change of scale, dimension, or

detailing without change of function or
the method of achieving it
LANCER vs INSPIRA
 Boat (fiberglass) Boat (steel)

Boiler( Cu)
Boiler (steel)
Dry conditions Low Rolling Wet conditions Snow conditions
conditions
 2.4 Design Tools & Materials
Data
Design tools are needed in order to implement the steps
in Figure 2.4

Enable the modeling and optimization of a design,

easing the routine aspects of each phase.

Material selection is very important and enters at every

stage of the design.

Complete and precise information about materials are

required to enable the selection process.
 Design Tools Market
need
Function modeling Material Selection
Viability studies
Concept All Materials
Approximate analysis (low precision data)
Geometric modeling
Simulation Embodiment Subset of Materials
(higher precision data)
Optimization methods
Cost modeling Detail One Material
Component modeling (best available precision
Finite element analysis data)
Product

Figure 2.4: The design flow chart. shows how design tools and materials
selection enter the procedure information about materials is needed at
each stage at very different levels of breadth and precision.
2.5 Function, Materials, Shape & Process

FUNCTION
Transmit load, heat
Contain pressure
Store energy, etc,
at minimum mass,
or at minimum cost,
or with minimum
environmental effect

Material Shape

Process
2.6 Case Study: Devices to open corked bottles

Market need ~ A device is required to

allow access to water in a corked bottle cork

Additional requirements :
with convenience
at modest cost
without contaminating the water

Figure 2.6: wine in a corked

bottle (Ashby, 1999)
 Figure 2.7: Five possible concepts, illustrating physical
principles, to fill the need expressed by Figure 2.6

a) Axial traction / pulling

b) Shear traction

c) Push from below (a) (b) (c)

d) Pulverize

e) Bypass ~ eg. knocking

(d) (e)
Problems with option (d) and (e) water might be contaminated!
Figure 2.8: Working principles for implementing the first
three concepts of Figure 2.7

a) A screw is threaded into

the cork which an axial pull
is applied

b) Slender elastic blades

inserted down the sides of
the cork apply shear
tractions when pulled

c) Cork pierced by hollow

needle through which a gas
is pumped to push it out
 Figure 2.9: Cork removers which employ the working principles (a) direct-pull; (b)
gear lever screw-assisted pull; (c) spring-assisted pull (a spring in the body is
compressed as the screw is driven into the cork); (d) shear blade systems; (e)
pressure-induced removal systems.
(a) (b) (c)

(d)
(e)
 spring-assisted pull
direct-pull gear lever screw-assisted pull

pressure-induced

shear blade
 Figure 2.10: The function structure and
working principles of cork removers

Apply Force
Generate Force Transmit Force
To Cork

Direct Pull
Shaft Screw
Levered Pull

Geared Pull Linkage Shear blades

Direct Push
Gas Injection Gas pressure
Levered Push
 Figure 2.11: Embodiment sketches for four mechanisms of axial traction concept:
direct-pull, levered pull, geared pull dan spring-assisted pull.
Each system is made up of components perform a sub-function. The requirements
of these sub-functions are the inputs to the material selection method.

Direct pull Levered pull

Geared pull Spring-assisted pull

 2.7 Factors in Materials Selection

Factors In Materials Selection

Interrelated Constraints

Criteria & Tools

 Interrelated Constraints
(Kekangan Berhubungkait)

1. Physical factors
size, shape &
weight of material
 Interrelated Constraints
(Kekangan Berhubungkait)

2. Mechanical
factors
the ability of the
materials to
withstand the type of
stresses (tensile,
compression,
bending and cyclic)
imposed on it.
 Interrelated Constraints
(Kekangan Berhubungkait)

3. Processing &
Fabricability
the ability to form or
shape the material
(different material
different method of
processing).
 Interrelated Constraints
(Kekangan Berhubungkait)

4. Life of
Component
factors
the length of time the
materials perform their
intended function in
the environment to
which they are
exposed.
 Interrelated Constraints
(Kekangan Berhubungkait)

5. Cost and
availability
market-driven
economy, quantity
and
standardization.
 Interrelated Constraints
(Kekangan Berhubungkait)

6. Code
technical requirements
that are imposed on
the material or the
component (usually
set by the customer),
eg. ASTM, ASME,
SAE etc.
 Interrelated Constraints
(Kekangan Berhubungkait)
7. Statutory & Other
Factors
relate to local, state
and federal
regulations about the
materials and
processes used or the
disposal of the
material, eg. OSHA,
JAS etc.
Criteria & Tools for materials selection
(Ciri & Peralatan Pemilihan Bahan)

The process used to extract the materials

from its ore and then to bring it to its
usable form
Total energy spent during use of
component (in transport industry)
Recoverable energy after its use
 Sustainable Design

Four key environmental

indicators are considered:
1. carbon footprint,

2. total energy consumed,

3. impacts as to air, and

4. impacts to water.
 FURTHER READING
Michael F. Ashby (1999) Materials
Selection in Mechanical Design, 2nd ed.,
Butterworth-Heinemann, p8 19.

Pat L. Mangonon (1999) The Principles of

Materials Selection for Engineering
Design, Prentice hall, p429 436.