MAK 307 : Design and Production
Objective
Learning Engineering Design Principles
and Production Methods
Course Outline
Week
1,2
Engineering Design
2,3
Product Development Process
Materials Selection
5,6
Design with Materials, Design for Manufacturing
Part 1
ENGINEERING DESIGN
Design : A General Overview
What is design ?
- to pull together something new (synthesis)
- to arrange existing things in a new way
- to satisfy a recognized need of society
Design : A General Overview
What is design ?
Definition by Dieter & Schmidt (2013)
- to establish and to define solutions for problems not
solved before
- or new solutions to problems which have previously
been solved in a different way
Design : A General Overview
What is design ?
Design is science : Learn techniques and
methods, use the book !!
Design is art : Learn doing design: do project
work and have experience !!
Design is the product of planning and work
Design : A General Overview
What is good design ?
Analysis and Synthesis
Analysis : decompose the complex problem into parts,
understand how each part works, functions
Synthesis : identification of design elements, decomposition
into parts, combination of part solutions into a total workable
system.
Design : Challanges
Four Cs of Design
Creativity : Requires creation of something new
Complexity : Requires decisions on many
variables and parameters
Choice Requires making choices between many
possible solutions at all levels
Compromise : Requires balancing and sometimes
conflicting requirements
Engineering Design Process
Engineering design process several outcomes
- Design of products (dvd player, missile system..)
- Complex engineered systems (petrochemical plant,
electrical power generating station, )
In the course emphasis is only on Product Design
Engineering Design Process
Design process is only, 5 % of the total cost ,
95 % is materials, capital, and labor cost
BUT, decisions of design commitments effect
70-80% manufactured cost product
Decisions made in the design process have a
major effect on the cost of the product
Fig. Product cost commitment during phases of the design process
Engineering Design Process Quality and Cycle time
Quality of a product largely depends on design
Defects introduced in the design phase cannot
be compensated in manufacturing
Engineering design effects product cycle time
The design process should be conducted so as to
develop quality, cost-competitive products in the
shortest possible time
Four Types of Design
Original design or innovative design,
- innovative concept to achieve a need,
involves invention,e.g. design of microprocessor
Adaptive design different need for novel
application.
e.g. ink-jet printing to rapid prototyping
Redesign improvement in exisiting design
e.g., shape change to lower stress concentration,
new material to reduce weight or cost
Selection design selecting the parts from vendors
e.g. Using different suppliers to improve quality,cost
Engineering Design Process (Pathways)
System : combination of hardware, information, and
people necessary to accomplish some specified
task. e.g. aircraft jet engine, production steps for
gears
Systems subsystems components (parts)
Design is an iteration process to reach near optimal
values within the constraints of the system
Engineering Design Process Iteration and Optimization
Design
operation
Next
step
Feedback loop
Fig. Basic module in the design process (1962, Asimow)
Engineering Design Process
Iteration and Optimization
Iteration in design process leads to the search for best
possible technical solution
Use technically interesting and intellectually pleasent
optimization methods, BUT be aware of their limitations
especially in complex design situations
Design Method versus Scientific Method
Scientific method : a logical regression of events that leads
to the solution of scientific problems
- Scientific method is driven by curiosity
Design method : a logical regression of events that leads to
the solution of the needs of society
- Design method is driven by the needs of market
Existing knowledge
Hypothesis
Proof
Scientific method
State of the art
Conceptualization
Production
Design method
Fig. Comparison scientific method vs design method (1970, Hill)
Science and Design
Science : concerned with creating knowledge about
naturally occurring phenomena and objects
Science is based on the studies observed
Design : concerned with creating knowledge about
phenomena and objects of the artificial
Design is based on artificial concepts characterized in
terms of functions, goals, and adaptation
Problem Solving Methodology
Steps :
- Define the problem
- Gather the information
- Generate alternative solutions
- Evaluate and make decision
- Communicate the results
Definition of the Problem (analysis of the needs)
as proposed by
project sponsor
as produced by
manufacturing
as specified in the
project request
as installed at the
users site
as designed by the
senior designer
What the user wanted
Fig. Design depends on the viewpoint of the individual
who defines the problem
Definition of the Problem
Most critical step in solving a problem,
also called analysis of the needs
Write problem statement as simple as possible,
including objectives, goals, constraints and
definition of technical problems.
Needs experience, and capability of using
computer-based design tools
Gathering Information
Two extremes : no previous background &
enormous amount of information
Identify the needed pieces of information &
find or develop the information
Textbooks, articles, technical reports, patents,
catologs, handbooks, databases and INTERNET
Important factors : Experience, Critical
knowledge, Reliability of the sources,
Generation of Alternative Solutions
or Design Concepts
- Use of creativity-stimulation methods,
- The application of physical principles,
- Qualitative reasoning,
- The ability to find and use information (!!)
For successful design generate high-quality
alternative solutions or design concepts
Evaluation of Alternatives & Decision Making
For valid, realistic evaluations :
- need to make engineering analysis which help to
make decisions about service performance,
- need to make manufacturing and cost analysis,
Simulation of performance with models,
Simulated service testing, Testing of full-sized
prototypes, all provide critical data
Communication of the Results
Purpose of the design is to satisfy the needs of customer
or client
Final design should be properly communicated :
oral presentation and a written design report
Deliverables : detailed engineering drawings, computer
programs, 3-D computer models and working models
Paradox inherent in design process : accumulation of
problem knowledge, & freedom to improve design
Description of Design Process
Phase I, Conceptual Design : needs the greatest creativity,
involves the most uncertainty, needs coordination
Phase II, Embodiment Design : decisions are made on
materials selection, size, shape
Phase III, Detail Design : missing information is added on
the arrangement, form,dimensions, tolerances, surface
properties, materials and manufacturing processes of each
part
Three Phases of Engineering Design
Fig. Design activities of engineering design process
Good Design
A good engineering design should consider :
- Achievement of performance requirements
- Life-cycle issues
- Social and regulatory issues
Performance Requirements
Performance measures both the function and the
behavior of the design. Performance requirements ;
1. Primary performance requirements :
Functional requirements related to force, strength,
deflection, energy or power consumtion
2. Complementary performance requirements :
Related to useful life, robustness, reliability, safety of
design
Life-Cycle, Social and Regulatory Issues
- Legal requirements
- Environmental requirements, service and
environmental regulations
- Aesthetic requirements
- COST requirements (v. important design rqrmnt)
- Product development costs, initial product costs,
life-cycle product cost, tooling cost, return on
invesment
Total Life Cycle
Fig. Total materials cycle
Regulatory and Social Issues
During design, use standards produced by ASTM,ASME,
DIN and others
For good design you may need to develop your own
standards
The designer has the obligation to foresee unintended
uses, should get the preventive measures
Safe operation is a must in design
Efficient and safe use by humans : human factors
engineering
Computer-aided Engineering (CAE)
The use of computers by designers help:
- organizing and handling time-consuming operations
- analyzing complex problems faster
- sharing information with the people in rapid way
e.g. Boeing 777, developed in between1990 1994,
CATIA 3-D CAD System, at its peak 7000 workstations
17 time zones, 130,000 parts fit better
Computer-Aided Engineering (CAE)
In design, CAE developed in two major domains :
- Computer graphics and modeling,
- Mathematical analysis and simulation
Computer modeling software packages :
- AutoCAD, ProE and Solid Works
- MatLAB (excellent graphic features , excellent
ability to solve differential equations)
- Other software packages in finite-element modeling,
manufacturing process modeling, statistical modeling
Design Review
Design review provides identification of problems
with design and determines future courses of action
to solve these problems
Design reviews should be held three to six times in
the life of the project (minimum 3, conceptual,
embodiment, and after final designs)
Design reviews should look two main aspects :
- technical elements of design
- business aspects of the product
Redesign
Two categories of redesigns : fixes and updates
Fix : design modification for achieving acceptable
performance after the product has been introduced
in the market
Update : adding new features and improve
performance of product during its life cycle
Redesign (eg. Update)
Fig. Design update example. Old design of railcar wheel versus
improved design
Societal Considerations in Engineering Design
Abed Code of Ethics :
Engineers shall hold paramount the safety, health, and
welfare of the public in the performance of their profession