Engineering Design – Full Exam Answers

Engineering Design Process

The engineering design process is a step■by■step method used by engineers to create or improve
products, machines, or systems. It helps engineers move from an initial idea to a final product that
can be manufactured and used by people.

It can be used to design simple consumer products such as refrigerators, power tools, and
electronic devices, as well as complex systems like aircraft, power plants, and bridges.

Decisions made during the early stages of design strongly affect the cost, quality, and performance
of the final product. Therefore engineers carefully follow a systematic design process to achieve the
best results.

The main goal of engineering design is to develop products that have good quality, meet
performance requirements, and can be produced at a reasonable cost within the shortest possible
time.

Types of Engineering Design

Original Design: Original design is also called innovative design. In this type of design, engineers
develop a completely new concept or idea to solve a problem. These designs often involve new
inventions or technologies. Original designs are rare but can create major changes in technology. A
good example is the development of the microprocessor.

Adaptive Design: Adaptive design occurs when engineers modify an existing design to meet a
different need or application. Instead of creating a completely new idea, engineers adjust or adapt
an existing design. This type of design is very common in engineering.

Redesign: Redesign is the process of improving an existing product. Engineers may redesign a
product to reduce manufacturing cost, improve performance, increase reliability, or reduce weight.
Changes may be made to shape, material, or design parameters while keeping the basic working
principle the same.

Selection Design: Selection design involves choosing standard components that are already
available from manufacturers. Examples include selecting bearings, motors, pumps, or other
mechanical components. Engineers choose these components based on performance, quality, and
cost.

Industrial Design: Industrial design focuses on improving the appearance and user interaction of a
product. It deals with the visual appeal of the product and how easily users can operate it.

Ways to Think About the Engineering Design Process

Simplified Iteration Model: In this model, design is considered a repeating process. Engineers
identify a problem, generate possible solutions, analyze the design, test the results, and improve
the design. The process continues until the best solution is achieved.

Design Method vs Scientific Method: The scientific method is used to study natural laws and
understand how things work. It involves observation, forming a hypothesis, experimentation, and
drawing conclusions. The design method, on the other hand, focuses on creating solutions to
practical problems. In simple terms, science explains things while engineering design creates useful
products.

A Problem Solving Method: Engineering design can also be seen as a systematic problem■solving
method. Engineers define the problem clearly, gather information, develop possible solutions,
evaluate alternatives, select the best solution, build and test the design, and finally improve the
design if necessary.

Considerations of Good Design

Achievement of Performance Requirements: A good design must satisfy the required performance
of the product. The product should function properly, be reliable, and meet technical specifications.
If the product cannot perform its intended task efficiently, the design cannot be considered
successful.

Life Cycle Issues: Life cycle issues refer to all stages in the life of a product including design,
manufacturing, usage, maintenance, and disposal. Engineers must consider cost, durability,
maintenance requirements, and environmental impact during these stages.

Social and Regulatory Issues: Engineering design must also consider social responsibility and
government regulations. Products must be safe for users and should not harm the environment.
Engineers must follow safety standards, laws, and regulations during the design process.

Description of Design Process – Seven Phases

Phase I – Conceptual Design: In this phase engineers understand the problem and generate
different solution ideas. The main working principles are identified and the best concept is selected.

Phase II – Embodiment Design: The selected concept is developed into a workable design.
Engineers determine the arrangement of components, select materials, and decide the basic
structure of the product.

Phase III – Detail Design: In this phase complete details are prepared including exact dimensions,
materials, and engineering drawings. Bills of materials and technical specifications are also created.

Phase IV – Planning for Manufacture: Engineers decide how the product will be produced.
Manufacturing processes, machines, tools, and assembly methods are selected.

Phase V – Planning for Distribution: This phase involves planning packaging, storage, and
transportation so the product can reach customers safely.

Phase VI – Planning for Use: Engineers consider how the user will operate the product. Safety,
reliability, maintenance instructions, and user manuals are prepared.

Phase VII – Planning for Retirement: This phase considers the end of the product’s life. Engineers
plan recycling, reuse, or safe disposal to reduce environmental impact.
Computer Aided Engineering

Computer■Aided Engineering (CAE) refers to the use of computers and specialized software to
assist engineers in design and analysis.

In the early days engineers used programming languages like FORTRAN to perform complex
engineering calculations. Programs were executed in batch mode using punch cards.

Later, engineers could interact directly with computers using terminals. This allowed faster
calculations and easier modification of designs.

One of the greatest impacts of computer■aided engineering has been in engineering drawing and
modelling. Computer drafting systems allow engineers to create and modify designs quickly.

Modern CAE tools also allow three■dimensional modelling. Engineers can build detailed 3D
models of products and analyze their geometry and structure. These models can also be converted
into traditional 2D engineering drawings.

Computers help engineers perform repetitive calculations quickly, allowing them to focus on more
complex design problems. CAE also supports concurrent engineering where different teams work
together during product development.

Designing to Codes and Standards

Codes and standards are very important in engineering design because they ensure safety,
efficiency, and uniform quality.

A code is a collection of rules and regulations created by government or regulatory agencies to

A standard is an agreed set of procedures, dimensions, materials, or methods used in engineering

Codes usually tell engineers what must be done and are often legal requirements, while standards
explain how the work should be done.

There are two main forms of codes. Performance codes specify the performance that must be
achieved without describing the exact method. Prescriptive codes give detailed instructions and
exact procedures that must be followed.

Design standards are generally divided into three categories: performance standards, test method
standards, and codes of practice.

Design Review and Redesign

A design review is a systematic examination of a design to check whether it meets the required
specifications, safety standards, and performance goals.
During a design review, engineers from different departments analyze the design to identify errors,
weaknesses, or opportunities for improvement.

The review process helps improve design quality, reduce manufacturing problems, and prevent
costly mistakes.

Redesign refers to modifying an existing product to improve performance, reduce cost, increase
reliability, or incorporate new materials and technologies.