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Reference:
Dieter, G. Engineering Design A Materials and Processing Approach, 4th Edition, McGraw Hill, 2009
2Ulrich, K. and Eppinger, S. Product Design and Development, McGraw-Hill, 2000
What is design?
To formulate a plan for human satisfaction
To accommodate particular need based on problem
based solutions
Examples:1.2..3
To produce a product
The process of identifying and deeply understanding a
problem or need, thinking creatively, using sound
decision-making processes to identify the best solution,
and using project management and teamwork skills to
drive the entire process, implement the solution, test it,
and modify it.
Chassis design
Steering system
Suspension system
Braking system
Power train
Final competition
Exercise 1
Think of a product.and thousands related questions
from your boss / groups members
How does it begin? And what needs to be done?
Define
Problem
Gather
Informatio
n
Concept
Generatio
n
Evaluation
of
Concepts
Product
Architectur
e
Configurati
on Design
Phase II.
Embodiment
Design
Phase I.
Conceptual
Design
Phase III.
Detail Design
Phase VII.
Planning for
Retirement
Phase VI.
Planning for
Use
Phase V.
Planning for
Distribution
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Phase IV.
Planning for
Manufacture
Parametric
Design
Phase 1
7 Phases Design Process
Define
Problem
Gather
Informati
on
Concept
Generatio
n
Phase I.
Conceptual
Design
Evaluatio
n of
Concepts
Most important steps in the engineering
design process is identifying customer needs.
The customer needs can be gained from:
Interviewing customers
Focus group
Customer survey
Customer complaints
Tools to achieve this:
Benchmarking
QFD- Quality funtion deplyoment
PDS- Product Design Specifications
Method for measuring company operation against the best company inside and outside of
the industries.
Identify the performance metrics that will be measured and used for comparison.
Compare the best in class product or process with the in house equivalent using the
performance metrics.
Question to Ponder
Who are my customer?
What does the customer want?
How can the product satisfy the customer while generating profit?
Which needs are critical? Which are secondary? How well are these needs being
currently met?
How do customers use existing products to meet these needs? What other products are
out in the market?
How do customers perceive current products relative to meeting their needs?
Why do customers use the existing products? Practical and/or emotional reasons?
1
1
(customer
requirements)
5. Target values
7.
Competitive
technical
evaluation
What
customer 1. What the
wants from customer
our product?Wants
2. How to satisfy
customer wants
(technical requirements)
Intersect both (1)
and (2)
3. Relationship
matrix
3.1 importance
ranking
Planned Tech. specs
We compare ourselves
with our competitors,
based on (2)
How we going to
meet the customer
requirements?
assessment
Customer
importance
ratings
4. Correlation matrix
Trade off
between our
ability (2),
6. Competitive
We
compare
ourselves
with our
competit
ors,
based on
(1)
Weighted
rating
Exercise 2
PDS
Frominternalmarketresearch,ithasbeendecidedthatIWCneedtodesigna
generalpurposewinchtoselltothecableandpipelayingmarketsector.The
winch should be portable but have mounting points for the end user. It is
important that the winch sits within out current range of 'Excel General
Purposewinches'.
1.0 Performance
1.1Lift/loweraloadof2.5tones(+/-10%).
1.2Drawincableinatarateof0.2m/s.
1.3 The winch drive should cut out when the load exceeds 10% of the
specifiedload.
1.4 Drive to stop lowering load when only 1.5 meters of cable remains on
winchdrum.
1.5Winchshouldoperatewithforward,reverse,stopandinchfacility.
1.6Anybrakingsystememployed,shouldproduceabrakingtorqueof 150%
thefullloadtorque.
1.7Winchshouldhaveamanualdevicetocontrolthebrakereleaseandload
descentintheeventofapowerfailure.
1.8 In the event of the winch 'overrunning',a manual safetyrelay/braking
deviceshouldoperatewithin1secondorbeforetheloadexceedsaspeedof
3m/s.
1.9 The product should be portable but with the option for permanent
mounting.
1.10 The product must use a portable power source, preferably a diesel
engine.
1.11 The weight of the product must be sufficient to aid the stability of the
product.
1.12Efficiencyoftheunitshouldbehigh,preferablyintheareaof20-30%.
1.13Thedrumshouldhold50mofcable.
2.0 Environment
2.1Thewinchdriveandpowerunitshouldbepowerunit.
2.2TheunitwillbemainlyusedinEuropeanweatherconditions.Butwecould
expectsalesofabout2%unitvolumetotheFarEast.
2.3Temperatureranges:
-28degreeCEuropean
12-44degreeC-FarEast
2.4Theproductmayexperiencehumidconditions.
2.5Corrosionresistancemaybeconsideredbytheuseofspecialmaterialsor
surfaceprotectionmethods.
2.6Any noise from the equipment should not exceed 95 dB at a distance of
1.0m.
2.7Thewinchwillbestoredinsupplierswarehousesbeforesales.
3.1Theproductshouldhaveanend-usercostof5500withinBritain.
3.2Thecostofmanufactureshouldbelessthan2750.
3.3 The cost of packaging and shipping should be no more than 15% of the
manufacturingcost.
4.0 Competition
4.1 The winch will be operating against equivalent models which include the following
companies:
Swansom-England
Oholom-Sweden
Winderhock-Germany
5.1Standardstobeadheredto:
BS5000part99MotorPerformance
BS6105andBSEN20898(1)Bolts
BS6322(2)&BS4320Nutsandwashers
BS7676andBS4517Gears
BS3019Welding
BS5989Bearings
BS2754ElectricalInsulation
BS5646pt4BearingHousing
BS4235KeysandKeyways
BS7664Painting
BS1399Seals
6.0 Testing
7.1Testingistobecarriedouton5%ofunits.
7.2AllcablesshouldbetestedtoBS3621.
Exercise 3
Think of the chosen product again (exercise 1), then write the PDS
document for that product.
Phase 1
7 Phases Design Process
Define
Problem
Gather
Informati
on
Concept
Generatio
n
Phase I.
Conceptual
Design
Evaluatio
n of
Concepts
Phase 1
7 Phases Design Process
Define
Problem
Gather
Informati
on
Concept
Generatio
n
Phase I.
Conceptual
Design
Evaluatio
n of
Concepts
Brainstorming
Functional
decomposition
Morphological chart
Brainstorming
Most common method used by design teams for
generating ideas for design concepts in conceptual
design.
Think of all the possible limitations or shortcomings of
the product.
Morphological chart
It is a table based on the function analysis
It is a visual aid used to come up with different ideas
Example: http://www.eng.fsu.edu/~
haik/design/idea_generation.htm
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1. Physical decomposition
Urban Car
Suspensio
n system
Steering
system
Chassis
Braking
system
Power
train
1.1 Tires
1.2 Springs
1.1.1??
1.2.1 Single
coilfunction??
1.2.2 Air
spring..????
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1.3 Shock
absorbers
1.3.1 Mech
damper
1.3.2 Strut
1.3.3 Absorber
1.4 Linkage
1.4.1 Anti-sway
barsfunction???
Exercise 4
Phase 1
7 Phases Design Process
Define
Problem
Gather
Informati
on
Concept
Generatio
n
Phase I.
Conceptual
Design
Evaluatio
n of
Concepts
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29
In Pughs selection method one concept may turn out to be better than
another concept.
It is preferred to choose criteria that is measurable such that for each concept a
numerical value can be considered against the criteria.
Score each concept against each design criteria using a ratio scale
Use 5 point (0-4) scale when information regarding criteria is not very detailed
Use 11 point (0-10) scale when criterion information is complete
Multiply the scores for each concept for corresponding weighting factor of
the criteria being considered.
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Material cost
Manufacturing cost
Time to produce
Durability
Reliability
Reparability
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Step 2: Determine
the design criteria
Crane hook
Cost
Mat.
Cost
Manuf.
Cost
Quality in service
Reparability
Durabilit
y
Reliabilit
y
O1= 1.0
O11= 0.6
O111=
0.3
O112=
0.5
Step 3: Determine
the weighting factor
for each of design
criteria.
O12= 0.4
O113=
0.2
O121=
0.6
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Time to
produce
O122=
0.3
The weights of
individual
categories at each
level of the tree
must add to 1.0
O123=
0.1
Step- Form
3
the decision matrix
Concept 1
Design
Criterion
Weight
factor
Concept 2
Concept 3
Units
Magnitude
Score
Rating
Magnitude
Score
Rating
Magnitude
Score
Rating
Matcost
0.18
RM/kg
60
1.44
60
1.44
50
1.62
Manuf.Cost
0.3
RM
2500
2.1
2200
2.7
3000
1.2
Reparability
0.12
Experience
Good
0.84
Excellent
1.08
Fair
0.6
Durability
0.24
Experience
High
1.92
High
1.92
Good
1.44
Reliability
0.12
Experience
Good
0.84
Excellent
1.08
Fair
0.6
0.04
Hours
40
0.28
25
0.36
60
0.2
Timetoprod.
7.42
8.58
5.66
Step 6: Total
ratings
Preliminary Design.
Decisions are made in this design phase: strength,
material selection, size, shape, and spatial
compatibility.
Any major changes beyond this design phase become
very expensive.
Product
Architectur
e
Configurati
on Design
Parametric
Design
3 major activities:
Phase II.
1.Product architecture
Embodiment
Arrangement of the physical functions
Design
Dividing the overall system into subsystem module
How the physical components of the design are to be arranged and combined?
2.Configuration design
Preliminary selection of materials, modelings and sizing of parts
What features (e.g., holes, ribs, splines and curves) will be present and those
features are to be arranged in space relative to each other?
3.Parametric design
Involves the information on the part configuration and aims to establish its exact
dimensions and tolerances
Important aspect of parametric design is to examine the part, assembly and system
for design robustness
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Phase II
41
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42
Product
Architectur
e
Configurati
on Design
Phase II.
Embodiment
Design
Parametric
Design
Integral Architecture
The implementation of function uses only
one or few chunks.
Component perform multiple function: so
called function sharing
E.g., wrench, screw driver
1 physical element save large number of
function
Changes made to any component tend to
propagate to other (or many physical
elements)
Often adopted when there is a constraint of
weight, space or cost
Modular Architecture
The chunk implement only one or a few
function.
Accomplish overall function through
combination of building block/modules
Interaction between chunks are well defined
E.g., computer
Advantages:
Components can be manufacture in
higher quantity (reduce cost)
Shortening product development cycles
(mod. develops independently)
Easier to evolve over time
To adapt to needs of different customers
To replaced components as they wear
out or used up
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45
Product
Architectur
e
Configurati
on Design
Phase II.
Embodiment
Design
Parametric
Design
Modeling
Represent physical appearance of the design
ideas
Engineers use model for thinking,
communicating, predicting, controlling, and
training
various types (e.g., scale models, prototype,
equtions, CAD/CAE modeling)
Simulation
Model subject to various input or
environmental condition
To observe how they behave
Analysis
Involves calculation form understanding of
mathematical and engineering fundamental
Ensuring the design concept are able and
reliable to performed and manufactured
Finite-element analysis solves wide range of
engineering problems area such as stress,
thermal, flow, etc
Several type of software (Nastran, Abacus,
Lusas, Ansys)
*However, understanding the fundamentals
are important
Materials Selection
An important aspect of design for mechanical,
electrical, thermal, chemical or other
application is selection of the best materials
Systematic selection of the best material for a
given application begins with properties and
costs of candidate materials.
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47
Product
Architectur
e
Configurati
on Design
Phase II.
Embodiment
Design
Parametric
Design
48
ssembly Guidelines
y-minimize part number, part variety, simplify assembly sequences and component handling and inse
dize-On material usage
widest possible tolerance
material that suit function and production process
e non value added operations
ork
number of parts
hat the remaining parts are easy to assemble
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Provide chamfers
Provide clearance
Standardize
50
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52
53
54
Process Selection
55
Liberal tolerance
Design part so that many operation can be carried out without reposition it
Simplicity
56
Rough machine
250
100
Standard machining
125
200
63
440
32
720
16
1400
2400
Lapping, burnishing
polishing
4500
57
Process
Dimensional Tolerance
(in)
Rough machining
0.03
100
Standard machining
0.005
200
0.001
300
0.0005
600
0.0002
1000
0.00005
3000
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Phase III.
Detail Design
Phase III
Detail Design : the process in which the precise shape, dimension, and tolerances are specified,
the material selection is confirmed, and the method of manufacture is considered for every
individual component of the product
Detail Engineering Drawing - First task to be complete in detail design
Gives details of product specification in size and layout/views
Should also be understandable to production or customer
Drawing of each:
Component
Subassembly
Assembly
Information on details drawing include:
Standard views of orthogonal projection (top, front, side views)
Auxiliary views such as section, enlarge views or isometric views that aid in
visualizing the component and clarifying the details
Dimensions (Presented according to the standard)
Tolerances
Materials specification, and any special processing instructions
Manufacturing details; such as parting line location, draft angle, surface finish
Title block-with drawing title, scale, type of projection, name, logo, file location,
etc.
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NOTE: While many consider that the engineering design process ends with detail
design, there are many issues that must be resolved before a product can be shipped
to the customer. These additional phases of design are often folded into what is
called the product development process.
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