Engineering design


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Engineering design

  1. 1. ROADMAP to ENGINEERING DESIGN 3 4 5 6 7 Define problem Gather information Concept generation Evaluate & select concept Problem statement Benchmarking Product dissection House of Quality PDS Internet Patents Technical articles Trade journals Consultants Creativity methods Brainstorming Functional models Decomposition Systematic design methods Decision making Selection criteria Pugh chart Decision matrix AHP Conceptual design 8 10 Product architecture 11 12 13 13 Configuration design Preliminary selection of materials and manufacturing processes Modeling Sizing of parts Arrangement of physical elements Modularity 8 Embodiment design Chap.1 – The Engineering Design Process Chap.2 – The Product Development Process Chap.3 – Problem Definition and Need Identification Chap.4 – Team Behavior and Tools Chap.5 – Gathering Information Chap.6 – Concept Generation Chap.7 – Decision Making and Concept Selection Chap.8 – Embodiment Design Chap.9 – Detail Design Chap.10 – Modeling and Simulation 14 15 16 9 16 Parametric design Detail design Robust design Set tolerances DFM, DFA, DFE Tolerances Engineering drawings Finalize PDS 11 12 Chap.11 – Materials Selection Chap.12 – Design with Materials Chap.13 – Design for Manufacturing Chap.14 – Risk, Reliability, and Safety Chap.15 – Quality, Robust Design, and Optimization Chap.16 – Cost Evaluation Chap.17 – Legal and Ethical Issues in Engineering Design* Chap.18 – Economic Decision Making* *see Yuliarman Electronic Library Collection Email: Padang, 22-Oct-2011 08:26 die37039_ch98_ifc.indd 1 2/25/08 7:07:02 PM
  2. 2. ENGI N EER I NG DESIGN die37039_ch00_fm.indd i 2/25/08 6:50:01 PM
  3. 3. die37039_ch00_fm.indd ii 2/25/08 6:50:01 PM
  4. 4. ENGINEERING DESIGN FOURTH EDITION George E. Dieter University of Maryland Linda C. Schmidt University of Maryland die37039_ch00_fm.indd iii 2/25/08 6:50:01 PM
  5. 5. ENGINEERING DESIGN, FOURTH EDITION Published by McGraw-Hill, a business unit of The McGraw-Hill Companies, Inc., 1221 Avenue of the Americas, New York, NY 10020. Copyright © 2009 by The McGraw-Hill Companies, Inc. All rights reserved. Previous editions © 2000, 1991, 1983. No part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written consent of The McGraw-Hill Companies, Inc., including, but not limited to, in any network or other electronic storage or transmission, or broadcast for distance learning. Some ancillaries, including electronic and print components, may not be available to customers outside the United States. This book is printed on acid-free paper. 1 2 3 4 5 6 7 8 9 0 DOC/DOC 0 9 8 ISBN 978–0–07–283703–2 MHID 0–07–283703–9 Global Publisher: Raghothaman Srinivasan Senior Sponsoring Editor: Bill Stenquist Director of Development: Kristine Tibbetts Developmental Editor: Lorraine K. Buczek Senior Project Manager: Kay J. Brimeyer Senior Production Supervisor: Laura Fuller Associate Design Coordinator: Brenda A. Rolwes Cover Designer: Studio Montage, St. Louis, Missouri Cover Illustration: Paul Turnbaugh (USE) Cover Image: Group of Students: © 2007, Al Santos, Photographer; Vacuum Roller: © Brian C. Grubel; Machinery: © John A. Rizzo/Getty Images; Gears and Machinery: © Nick Koudis/Getty Images; University Students Using Library Computers: BananaStock/ Jupiter Images Compositor: Newgen Typeface: 10.5/12 Times Roman Printer: R. R. Donnelley Crawfordsville, IN Library of Congress Cataloging-in-Publication Data Dieter, George Ellwood. Engineering design / George E. Dieter, Linda C. Schmidt. — 4th ed. p. cm. Includes bibliographical references and indexes. ISBN 978-0-07-283703-2 — ISBN 0-07-283703-9 (hard copy : alk. paper) 1. Engineering design. I. Schmidt, Linda C. II. Title. TA174.D495 2009 620Ј.0042—dc22 2007049735 die37039_ch00_fm.indd iv 2/25/08 6:50:02 PM
  6. 6. ABOUT THE AUTHORS G E O R G E E . D I E T E R is Glenn L. Martin Institute Professor of Engineering at the University of Maryland. The author received his B.S. Met.E. degree from Drexel University and his D.Sc. degree from Carnegie Mellon University. After a stint in industry with the DuPont Engineering Research Laboratory, he became head of the Metallurgical Engineering Department at Drexel University, where he later became Dean of Engineering. Professor Dieter later joined the faculty of Carnegie Mellon University as Professor of Engineering and Director of the Processing Research Institute. He moved to the University of Maryland in 1977 as professor of Mechanical Engineering and Dean of Engineering, serving as dean until 1994. Professor Dieter is a fellow of ASM International, TMS, AAAS, and ASEE. He has received the education award from ASM, TMS, and SME, as well as the Lamme Medal, the highest award of ASEE. He has been chair of the Engineering Deans Council, and president of ASEE. He is a member of the National Academy of Engineering. He also is the author of Mechanical Metallurgy, published by McGraw-Hill, now in its third edition. L I N DA C . S C H M I D T is an Associate Professor in the Department of Mechanical Engineering at the University of Maryland. Dr. Schmidt’s general research interests and publications are in the areas of mechanical design theory and methodology, design generation systems for use during conceptual design, design rationale capture, and effective student learning on engineering project design teams. Dr. Schmidt completed her doctorate in Mechanical Engineering at Carnegie Mellon University with research in grammar-based generative design. She holds B.S. and M.S. degrees from Iowa State University for work in Industrial Engineering. Dr. Schmidt is a recipient of the 1998 U.S. National Science Foundation Faculty Early Career Award for generative conceptual design. She co-founded RISE, a summer research experience that won the 2003 Exemplary Program Award from the American College Personnel Association’s Commission for Academic Support in Higher Education. die37039_ch00_fm.indd v 2/25/08 6:50:02 PM
  7. 7. vi engineer ing design Dr. Schmidt is active in engineering design theory research and teaching engineering design to third- and fourth-year undergraduates and graduate students in mechanical engineering. She has coauthored a text on engineering decision-making, two editions of a text on product development, and a team-training curriculum for faculty using engineering student project teams. Dr. Schmidt was the guest editor of the Journal of Engineering Valuation & Cost Analysis and has served as an Associate Editor of the ASME Journal of Mechanical Design. Dr. Schmidt is a member of ASME, SME, and ASEE. die37039_ch00_fm.indd vi 2/25/08 6:50:03 PM
  8. 8. BRIEF CONTENTS Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 Chapter 11 Chapter 12 Chapter 13 Chapter 14 Chapter 15 Chapter 16 Chapter 17 Chapter 18 Engineering Design Product Development Process Problem Definition and Need Identification Team Behavior and Tools Gathering Information Concept Generation Decision Making and Concept Selection Embodiment Design Detail Design Modeling and Simulation Materials Selection Design with Materials Design for Manufacturing Risk, Reliability, and Safety Quality, Robust Design, and Optimization Cost Evaluation Legal and Ethical Issues in Engineering Design Economic Decision Making 1 39 75 116 158 196 262 298 386 411 457 515 558 669 723 779 828 858 Appendices Author & Subject Indexes A-1 I-1 vii die37039_ch00_fm.indd vii 2/25/08 6:50:03 PM
  9. 9. DETAILED CONTENTS Preface Chapter 1 xxiii Engineering Design 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1 Introduction Engineering Design Process 1.2.1 Importance of the Engineering Design Process 1.2.2 Types of Designs Ways to Think About the Engineering Design Process 1.3.1 A Simplified Iteration Model 1.3.2 Design Method Versus Scientific Method 1.3.3 A Problem-Solving Methodology Considerations of a Good Design 1.4.1 Achievement of Performance Requirements 1.4.2 Total Life Cycle 1.4.3 Regulatory and Social Issues Description of Design Process 1.5.1 Phase I. Conceptual Design 1.5.2 Phase II. Embodiment Design 1.5.3 Phase III. Detail Design 1.5.4 Phase IV. Planning for Manufacture 1.5.5 Phase V. Planning for Distribution 1.5.6 Phase VI. Planning for Use 1.5.7 Phase VII. Planning for Retirement of the Product Computer-Aided Engineering Designing to Codes and Standards Design Review 1.8.1 Redesign 1.9 Societal Considerations in Engineering Design 1 3 4 5 6 6 8 10 14 14 17 18 19 19 20 21 22 23 23 23 24 26 29 30 31 viii die37039_ch00_fm.indd viii 2/25/08 6:50:03 PM
  10. 10. detailed contents 1.10 Chapter 2 Product Development Process 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Chapter 3 Introduction Product Development Process 2.2.1 Factors for Success 2.2.2 Static Versus Dynamic Products 2.2.3 Variations on the Generic Product Development Process Product and Process Cycles 2.3.1 Stages of Development of a Product 2.3.2 Technology Development and Insertion Cycle 2.3.3 Process Development Cycle Organization for Design and Product Development 2.4.1 A Typical Organization by Functions 2.4.2 Organization by Projects 2.4.3 Hybrid Organizations 2.4.4 Concurrent Engineering Teams Markets and Marketing 2.5.1 Markets 2.5.2 Market Segmentation 2.5.3 Functions of a Marketing Department 2.5.4 Elements of a Marketing Plan Technological Innovation 2.6.1 Invention, Innovation, and Diffusion 2.6.2 Business Strategies Related to Innovation and Product Development 2.6.3 Characteristics of Innovative People 2.6.4 Types of Technology Innovation Summary New Terms and Concepts Bibliography Problems and Exercises Problem Definition and Need Identification 3.1 3.2 3.3 die37039_ch00_fm.indd ix Summary New Terms and Concepts Bibliography Problems and Exercises Introduction Identifying Customer Needs 3.2.1 Preliminary Research on Customers Needs 3.2.2 Gathering Information from Customers Customer Requirements 3.3.1 Differing Views of Customer Requirements 3.3.2 Classifying Customer Requirements ix 35 36 37 37 39 39 39 43 46 46 47 47 48 50 51 53 54 55 57 58 59 60 63 63 64 64 67 68 69 71 72 72 73 75 75 77 79 80 86 87 89 2/25/08 6:50:03 PM
  11. 11. x engineer ing design 3.4 3.5 3.6 3.7 Chapter 4 Team Behavior and Tools 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 Chapter 5 Introduction What It Means to be an Effective Team Member Team Roles Team Dynamics Effective Team Meetings 4.5.1 Helpful Rules for Meeting Success Problems with Teams Problem-Solving Tools 4.7.1 Applying the Problem-Solving Tools in Design Time Management Planning and Scheduling 4.9.1 Work Breakdown Structure 4.9.2 Gantt Chart 4.9.3 Critical Path Method Summary New Terms and Concepts Bibliography Problems and Exercises Gathering Information 5.1 5.2 5.3 5.4 die37039_ch00_fm.indd x Establishing the Engineering Characteristics 3.4.1 Benchmarking in General 3.4.2 Competitive Performance Benchmarking 3.4.3 Reverse Engineering or Product Dissection 3.4.4 Determining Engineering Characteristics Quality Function Deployment 3.5.1 The House of Quality Configurations 3.5.2 Steps for Building a House of Quality 3.5.3 Interpreting Results of HOQ Product Design Specification Summary Bibliography New Terms and Concepts Problems and Exercises The Information Challenge 5.1.1 Your Information Plan 5.1.2 Data, Information, and Knowledge Types of Design Information Sources of Design Information Library Sources of Information 5.4.1 Dictionaries and Encyclopedias 5.4.2 Handbooks 5.4.3 Textbooks and Monographs 91 93 95 96 97 98 100 102 107 109 111 113 114 114 116 116 117 118 119 122 123 124 126 140 145 146 147 147 149 154 155 155 156 158 158 159 160 162 162 166 167 169 169 2/25/08 6:50:03 PM
  12. 12. detailed contents 5.5 5.6 5.7 5.8 5.9 5.10 5.11 Chapter 6 Concept Generation 6.1 6.2 6.3 6.4 6.5 die37039_ch00_fm.indd xi 5.4.4 Finding Periodicals 5.4.5 Catalogs, Brochures, and Business Information Government Sources of Information Information From the Internet 5.6.1 Searching with Google 5.6.2 Some Helpful URLs for Design 5.6.3 Business-Related URLs for Design and Product Development Professional Societies and Trade Associations Codes and Standards Patents and Other Intellectual Property 5.9.1 Intellectual Property 5.9.2 The Patent System 5.9.3 Technology Licensing 5.9.4 The Patent Literature 5.9.5 Reading a Patent 5.9.6 Copyrights Company-Centered Information Summary New Terms and Concepts Bibliography Problems and Exercises Introduction to Creative Thinking 6.1.1 Models of the Brain and Creativity 6.1.2 Thinking Processes that Lead to Creative Ideas Creativity and Problem Solving 6.2.1 Aids to Creative Thinking 6.2.2 Barriers to Creative Thinking Creative Thinking Methods 6.3.1 Brainstorming 6.3.2 Idea Generating Techniques Beyond Brainstorming 6.3.3 Random Input Technique 6.3.4 Synectics: An Inventive Method Based on Analogy 6.3.5 Concept Map Creative Methods for Design 6.4.1 Refinement and Evaluation of Ideas 6.4.2 Generating Design Concepts 6.4.3 Systematic Methods for Designing Functional Decomposition and Synthesis 6.5.1 Physical Decomposition 6.5.2 Functional Representation 6.5.3 Performing Functional Decomposition 6.5.4 Strengths and Weaknesses of Functional Synthesis xi 169 171 171 172 174 176 178 180 181 183 184 185 187 187 189 191 192 193 194 194 194 196 197 197 201 202 202 205 208 208 210 212 213 215 217 217 219 221 222 223 225 229 232 2/25/08 6:50:04 PM
  13. 13. xii engineer ing design 6.6 6.7 6.8 6.9 Chapter 7 Decision Making and Concept Selection 7.1 7.2 7.3 7.4 Chapter 8 Introduction Decision Making 7.2.1 Behavioral Aspects of Decision Making 7.2.2 Decision Theory 7.2.3 Utility Theory 7.2.4 Decision Trees Evaluation Methods 7.3.1 Comparison Based on Absolute Criteria 7.3.2 Pugh Concept Selection Method 7.3.3 Measurement Scales 7.3.4 Weighted Decision Matrix 7.3.5 Analytic Hierarchy Process (AHP) Summary New Terms and Concepts Bibliography Problems and Exercises Embodiment Design 8.1 die37039_ch00_fm.indd xii Morphological Methods 6.6.1 Morphological Method for Design 6.6.2 Generating Concepts from Morphological Chart TRIZ: The Theory of Inventive Problem Solving 6.7.1 Invention: Evolution to Increased Ideality 6.7.2 Innovation by Overcoming Contradictions 6.7.3 TRIZ Inventive Principles 6.7.4 The TRIZ Contradiction Matrix 6.7.5 Strengths and Weaknesses of TRIZ Axiomatic Design 6.8.1 Axiomatic Design Introduction 6.8.2 The Axioms 6.8.3 Using Axiomatic Design to Generate a Concept 6.8.4 Using Axiomatic Design to Improve an Existing Concept 6.8.5 Strengths and Weaknesses of Axiomatic Design Summary New Terms and Concepts Bibliography Problems and Exercises Introduction 8.1.1 Comments on Nomenclature Concerning the Phases of the Design Process 8.1.2 Oversimplification of the Design Process Model 233 234 236 237 238 239 240 243 247 249 249 250 251 253 257 258 259 260 260 262 262 263 263 266 269 273 274 275 277 280 282 285 292 294 294 294 298 298 299 300 2/25/08 6:50:04 PM
  14. 14. detailed contents 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 die37039_ch00_fm.indd xiii Product Architecture 8.2.1 Types of Modular Architectures 8.2.2 Modularity and Mass Customization 8.2.3 Create the Schematic Diagram of the Product 8.2.4 Cluster the Elements of the Schematic 8.2.5 Create a Rough Geometric Layout 8.2.6 Define Interactions and Determine Performance Characteristics Configuration Design 8.3.1 Generating Alternative Configurations 8.3.2 Analyzing Configuration Designs 8.3.3 Evaluating Configuration Designs Best Practices for Configuration Design 8.4.1 Design Guidelines 8.4.2 Interfaces and Connections 8.4.3 Checklist for Configuration Design 8.4.4 Design Catalogs Parametric Design 8.5.1 Systematic Steps in Parametric Design 8.5.2 A Parametric Design Example: Helical Coil Compression Spring 8.5.3 Design for Manufacture (DFM) and Design for Assembly (DFA) 8.5.4 Failure Modes and Effects Analysis (FMEA) 8.5.5 Design for Reliability and Safety 8.5.6 Design for Quality and Robustness Dimensions and Tolerances 8.6.1 Dimensions 8.6.2 Tolerances 8.6.3 Geometric Dimensioning and Tolerancing 8.6.4 Guidelines for Tolerance Design Industrial Design 8.7.1 Visual Aesthetics Human Factors Design 8.8.1 Human Physical Effort 8.8.2 Sensory Input 8.8.3 Anthropometric Data 8.8.4 Design for Serviceability Design for the Environment 8.9.1 Life Cycle Design 8.9.2 Design for the Environment (DFE) 8.9.3 DFE Scoring Methods Prototyping and Testing 8.10.1 Prototype and Model Testing Throughout the Design Process 8.10.2 Building Prototypes xiii 301 303 303 305 306 307 308 309 312 315 315 316 317 321 324 325 325 326 328 336 337 337 338 338 339 340 350 355 356 357 358 359 361 364 364 365 366 368 370 370 371 372 2/25/08 6:50:04 PM
  15. 15. xiv engineer ing design 8.11 8.12 Chapter 9 Detail Design 9.1 9.2 9.3 9.4 9.5 9.6 9.7 Chapter 10 8.10.3 Rapid Prototyping 8.10.4 RP Processes 8.10.5 Testing 8.10.6 Statistical Design of Testing Design for X (DFX) Summary New Terms and Concepts Bibliography Problems and Exercises Introduction Activities and Decisions in Detail Design Communicating Design and Manufacturing Information 9.3.1 Engineering Drawings 9.3.2 Bill of Materials 9.3.3 Written Documents 9.3.4 Common Challenges in Technical Writing 9.3.5 Meetings 9.3.6 Oral Presentations Final Design Review 9.4.1 Input Documents 9.4.2 Review Meeting Process 9.4.3 Output from Review Design and Business Activities Beyond Detail Design Facilitating Design and Manufacturing with Computer-Based Methods 9.6.1 Product Lifecycle Management (PLM) Summary New Terms and Concepts Bibliography Problems and Exercises 373 374 377 378 380 382 382 383 383 386 386 387 391 391 394 395 398 399 400 402 402 403 403 403 406 407 408 408 409 409 Modeling and Simulation 411 10.1 411 412 413 414 414 423 425 429 432 434 435 439 10.2 10.3 10.4 10.5 10.6 die37039_ch00_fm.indd xiv The Role of Models in Engineering Design 10.1.1 Types of Models 10.1.2 Iconic, Analog, and Symbolic Models Mathematical Modeling 10.2.1 The Model-Building Process Dimensional Analysis 10.3.1 Similitude and Scale Models Finite-Difference Method Geometric Modeling on the Computer Finite Element Analysis 10.6.1 The Concept Behind FEA 10.6.2 Types of Elements 2/25/08 6:50:04 PM
  16. 16. detailed contents 10.7 10.8 Chapter 11 10.6.3 Steps in the FEA Process 10.6.4 Current Practice Simulation 10.7.1 Introduction to Simulation Modeling 10.7.2 Simulation Programming Software 10.7.3 Monte Carlo Simulation Summary New Terms and Concepts Bibliography Problems and Exercises xv 442 444 446 446 447 449 452 453 454 454 Materials Selection 457 11.1 457 458 460 460 461 462 463 470 471 472 474 476 476 478 479 479 482 482 482 485 486 487 488 489 494 495 496 499 503 504 504 506 508 Introduction 11.1.1 Relation of Materials Selection to Design 11.1.2 General Criteria for Selection 11.1.3 Overview of the Materials Selection Process 11.2 Performance Characteristics of Materials 11.2.1 Classification of Materials 11.2.2 Properties of Materials 11.2.3 Specification of Materials 11.2.4 Ashby Charts 11.3 The Materials Selection Process 11.3.1 Design Process and Materials Selection 11.3.2 Materials Selection in Conceptual Design 11.3.3 Materials Selection in Embodiment Design 11.4 Sources of Information on Materials Properties 11.4.1 Conceptual Design 11.4.2 Embodiment Design 11.4.3 Detail Design 11.5 Economics of Materials 11.5.1 Cost of Materials 11.5.2 Cost Structure of Materials 11.6 Overview of Methods of Materials Selection 11.7 Selection with Computer-Aided Databases 11.8 Material Performance Indices 11.8.1 Material Performance Index 11.9 Materials Selection with Decision Matrices 11.9.1 Pugh Selection Method 11.9.2 Weighted Property Index 11.10 Design Examples 11.11 Recycling and Materials Selection 11.11.1 Benefits from Recycling 11.11.2 Steps in Recycling 11.11.3 Design for Recycling 11.11.4 Material Selection for Eco-attributes die37039_ch00_fm.indd xv 2/25/08 6:50:05 PM
  17. 17. xvi engineer ing design 11.12 Summary New Terms and Concepts Bibliography Problems and Exercises Chapter 12 510 511 512 512 Design with Materials 515 12.1 12.2 515 516 518 522 523 524 525 528 529 531 536 538 539 539 541 544 544 546 547 549 549 552 553 555 556 556 556 12.3 12.4 12.5 12.6 12.7 Chapter 13 Design for Manufacturing 13.1 13.2 13.3 13.4 die37039_ch00_fm.indd xvi Introduction Design for Brittle Fracture 12.2.1 Plane Strain Fracture Toughness 12.2.2 Limitations on Fracture Mechanics Design for Fatigue Failure 12.3.1 Fatigue Design Criteria 12.3.2 Fatigue Parameters 12.3.3 Information Sources on Design for Fatigue 12.3.4 Infinite Life Design 12.3.5 Safe-Life Design Strategy 12.3.6 Damage-Tolerant Design Strategy 12.3.7 Further Issues in Fatigue Life Prediction Design for Corrosion Resistance 12.4.1 Basic Forms of Corrosion 12.4.2 Corrosion Prevention Design Against Wear 12.5.1 Types of Wear 12.5.2 Wear Models 12.5.3 Wear Prevention Design with Plastics 12.6.1 Classification of Plastics and Their Properties 12.6.2 Design for Stiffness 12.6.3 Time-Dependent Part Performance Summary New Terms and Concepts Bibliography Problems and Exercises Role of Manufacturing in Design Manufacturing Functions Classification of Manufacturing Processes 13.3.1 Types of Manufacturing Processes 13.3.2 Brief Description of the Classes of Manufacturing Processes 13.3.3 Sources of Information on Manufacturing Processes 13.3.4 Types of Manufacturing Systems Manufacturing Process Selection 13.4.1 Quantity of Parts Required 13.4.2 Shape and Feature Complexity 558 558 560 562 563 564 565 565 568 569 573 2/25/08 6:50:05 PM
  18. 18. detailed contents 13.5 13.6 13.7 13.8 13.9 13.10 13.11 13.12 13.13 13.14 13.15 13.16 die37039_ch00_fm.indd xvii 13.4.3 Size 13.4.4 Influence of Material on Process Selection 13.4.5 Required Quality of the Part 13.4.6 Cost to Manufacture 13.4.7 Availability, Lead Time, and Delivery 13.4.8 Further Information for Process Selection Design for Manufacture (DFM) 13.5.1 DFM Guidelines 13.5.2 Specific Design Rules Design for Assembly (DFA) 13.6.1 DFA Guidelines Role of Standardization in DFMA 13.7.1 Benefits of Standardization 13.7.2 Achieving Part Standardization 13.7.3 Group Technology Mistake-Proofing 13.8.1 Using Inspection to Find Mistakes 13.8.2 Frequent Mistakes 13.8.3 Mistake-Proofing Process 13.8.4 Mistake-Proofing Solutions Early Estimation of Manufacturing Cost Computer Methods for DFMA 13.10.1 DFA Analysis 13.10.2 Concurrent Costing with DFM 13.10.3 Process Modeling and Simulation Design of Castings 13.11.1 Guidelines for the Design of Castings 13.11.2 Producing Quality Castings Design of Forgings 13.12.1 DFM Guidelines for Closed-Die Forging 13.12.2 Computer-Aided Forging Design Design for Sheet-Metal Forming 13.13.1 Sheet Metal Stamping 13.13.2 Sheet Bending 13.13.3 Stretching and Deep Drawing 13.13.4 Computer-Aided Sheet Metal Design Design of Machining 13.14.1 Machinability 13.14.2 DFM Guidelines for Machining Design of Welding 13.15.1 Joining Processes 13.15.2 Welding Processes 13.15.3 Welding Design 13.15.4 Cost of Joining Residual Stresses in Design 13.16.1 Origin of Residual Stresses 13.16.2 Residual Stress Created by Quenching xvii 576 577 579 583 586 586 593 594 597 597 598 601 601 603 603 606 606 607 608 609 610 617 617 620 624 624 626 627 629 631 632 633 633 634 635 637 637 640 640 643 643 643 646 649 650 650 652 2/25/08 6:50:05 PM
  19. 19. xviii engineer ing design 13.16.3 Other Issues Regarding Residual Stresses 13.16.4 Relief of Residual Stresses 13.17 Design for Heat Treatment 13.17.1 Issues with Heat Treatment 13.17.2 DFM for Heat Treatment 13.18 Design for Plastics Processing 13.18.1 Injection Molding 13.18.2 Extrusion 13.18.3 Blow Molding 13.18.4 Rotational Molding 13.18.5 Thermoforming 13.18.6 Compression Molding 13.18.7 Casting 13.18.8 Composite Processing 13.18.9 DFM Guidelines for Plastics Processing 13.19 Summary New Terms and Concepts Bibliography Problems and Exercises Chapter 14 654 656 656 657 658 659 659 660 661 661 661 661 662 662 663 664 666 666 666 Risk, Reliability, and Safety 669 14.1 14.2 14.3 14.4 die37039_ch00_fm.indd xviii Introduction 14.1.1 Regulation as a Result of Risk 14.1.2 Standards 14.1.3 Risk Assessment Probabilistic Approach to Design 14.2.1 Basic Probability Using the Normal Distribution 14.2.2 Sources of Statistical Tables 14.2.3 Frequency Distributions Combining Applied Stress and Material Strength 14.2.4 Variability in Material Properties 14.2.5 Probabilistic Design 14.2.6 Safety Factor 14.2.7 Worst-Case Design Reliability Theory 14.3.1 Definitions 14.3.2 Constant Failure Rate 14.3.3 Weibull Frequency Distribution 14.3.4 Reliability with a Variable Failure Rate 14.3.5 System Reliability 14.3.6 Maintenance and Repair 14.3.7 Further Topics Design for Reliability 14.4.1 Causes of Unreliability 14.4.2 Minimizing Failure 14.4.3 Sources of Reliability Data 14.4.4 Cost of Reliability 669 671 672 673 674 675 677 677 679 682 684 685 685 688 688 690 692 696 699 700 701 703 703 706 706 2/25/08 6:50:05 PM
  20. 20. detailed contents 14.5 14.6 14.7 14.8 Chapter 15 Failure Mode and Effects Analysis (FMEA) 14.5.1 Making a FMEA Analysis Defects and Failure Modes 14.7.1 Causes of Hardware Failure 14.7.2 Failure Modes 14.7.3 Importance of Failure Design for Safety 14.9.1 Potential Dangers 14.9.2 Guidelines for Design for Safety 14.9.3 Warning Labels Summary New Terms and Concepts Bibliography Problems and Exercises 707 710 712 713 713 715 715 716 717 718 718 719 719 720 Quality, Robust Design, and Optimization 15.1 15.2 15.3 15.4 15.5 15.6 15.7 15.8 die37039_ch00_fm.indd xix xix The Concept of Total Quality 15.1.1 Definition of Quality 15.1.2 Deming’s 14 Points Quality Control and Assurance 15.2.1 Fitness for Use 15.2.2 Quality-Control Concepts 15.2.3 Newer Approaches to Quality Control 15.2.4 Quality Assurance 15.2.5 ISO 9000 Quality Improvement 15.3.1 Pareto chart 15.3.2 Cause-and-Effect Diagram Process Capability 15.4.1 Six Sigma Quality Program Statistical Process Control 15.5.1 Control Charts 15.5.2 Other Types of Control Charts 15.5.3 Determining Process Statistics from Control Charts Taguchi Method 15.6.1 Loss Function 15.6.2 Noise Factors 15.6.3 Signal-to-Noise Ratio Robust Design 15.7.1 Parameter Design 15.7.2 Tolerance Design Optimization Methods 15.8.1 Optimization by Differential Calculus 15.8.2 Search Methods 15.8.3 Nonlinear Optimization Methods 15.8.4 Other Optimization Methods 723 723 724 725 726 726 727 729 729 730 730 731 732 734 738 739 739 742 743 743 744 747 748 749 749 755 755 758 762 767 770 2/25/08 6:50:05 PM
  21. 21. xx engineer ing design 15.9 Design Optimization 15.10 Summary New Terms and Concepts Bibliography Problems and Exercises Chapter 16 772 774 775 775 775 Cost Evaluation 779 16.1 16.2 16.3 16.4 16.5 779 780 784 787 789 790 790 791 795 796 797 801 802 802 803 805 808 809 809 811 814 814 818 822 823 823 823 16.6 16.7 16.8 16.9 16.10 16.11 16.12 16.13 16.14 Chapter 17 Introduction Categories of Costs Overhead Cost Activity-Based Costing Methods of Developing Cost Estimates 16.5.1 Analogy 16.5.2 Parametric and Factor Methods 16.5.3 Detailed Methods Costing Make-Buy Decision Manufacturing Cost Product Profit Model 16.8.1 Profit Improvement Refinements to Cost Analysis Methods 16.9.1 Cost Indexes 16.9.2 Cost-Size Relationships 16.9.3 Learning Curve Design to Cost 16.10.1 Order of Magnitude Estimates 16.10.2 Costing in Conceptual Design Value Analysis in Costing Manufacturing Cost Models 16.12.1 Machining Cost Model Life Cycle Costing Summary New Terms and Concepts Bibliography Problems and Exercises Legal and Ethical Issues in Engineering Design (see 17.1 Introduction 17.2 The Origin of Laws 17.3 Contracts 17.3.1 Types of Contracts 17.3.2 General Form of a Contract 17.3.3 Discharge and Breach of Contract 17.4 Liability 17.5 Tort Law die37039_ch00_fm.indd xx 828 828 829 830 830 831 832 833 834 2/25/08 6:50:06 PM
  22. 22. detailed contents xxi Product Liability 17.6.1 Evolution of Product Liability Law 17.6.2 Goals of Product Liability Law 17.6.3 Negligence 17.6.4 Strict Liability 17.6.5 Design Aspect of Product Liability 17.6.6 Business Procedures to Minimize Risk of Product Liability 17.6.7 Problems with Product Liability Law 17.7 Protecting Intellectual Property 17.8 The Legal and Ethical Domains 17.9 Codes of Ethics 17.9.1 Profession of Engineering 17.9.2 Codes of Ethics 17.9.3 Extremes of Ethical Behavior 17.10 Solving Ethical Conflicts 17.10.1 Whistleblowing 17.10.2 Case Studies 17.11 Summary New Terms and Concepts Bibliography Problems and Exercises 835 836 836 837 837 838 839 839 840 841 843 844 844 848 848 850 851 852 854 854 855 Economic Decision Making (see 858 17.6 Chapter 18 18.1 18.2 18.3 18.4 18.5 18.6 die37039_ch00_fm.indd xxi Introduction Mathematics of Time Value of Money 18.2.1 Compound Interest 18.2.2 Cash Flow Diagram 18.2.3 Uniform Annual Series 18.2.4 Irregular Cash Flows Cost Comparison 18.3.1 Present Worth Analysis 18.3.2 Annual Cost Analysis 18.3.3 Capitalized Cost Analysis 18.3.4 Using Excel Functions for Engineering Economy Calculation Depreciation 18.4.1 Straight-Line Depreciation 18.4.2 Declining-Balance Depreciation 18.4.3 Sum-of-Years-Digits Depreciation 18.4.4 Modified Accelerated Cost Recovery System (MACRS) Taxes Profitability Of Investments 18.6.1 Rate of Return 18.6.2 Payback Period 858 859 859 861 862 865 867 867 869 870 872 872 873 874 874 874 876 880 880 882 2/25/08 6:50:06 PM
  23. 23. xxii engineer ing design 18.6.3 Net Present Worth 18.6.4 Internal Rate of Return 18.7 Other Aspects of Profitability 18.8 Inflation 18.9 Sensitivity and Break-Even Analysis 18.10 Uncertainty in Economic Analysis 18.11 Benefit-Cost Analysis 18.12 Summary New Terms and Concepts Bibliography Problems and Exercises Appendices Author & Subject Indexes die37039_ch00_fm.indd xxii 882 883 887 888 891 892 894 896 898 898 898 A-1 I-1 2/25/08 6:50:06 PM
  24. 24. PREFACE TO FOURTH EDITION T h e f o u r t h e d i t i o n of Engineering Design represents the reorganization and expansion of the topics and the introduction of a coauthor, Dr. Linda Schmidt of the Mechanical Engineering Department, University of Maryland. As in previous editions, Engineering Design is intended to provide a realistic understanding of the engineering design process. It is broader in content than most design texts, but it now contains more prescriptive guidance on how to carry out design. The text is intended to be used in either a junior or senior engineering course with an integrated hands-on design project. The design process material is presented in a sequential format in Chapters 1 through 9. At the University of Maryland we use Chapters 1 through 9 with junior students in a course introducing the design process. Chapters 10 through 17 present more intense treatment of sophisticated design content, including materials selection, design for manufacturing, and quality. The complete text is used in the senior capstone design course that includes a complete design project from selecting a market to creating a working prototype. Students move quickly through the first nine chapters and emphasize chapters 10 through 17 for making embodiment design decisions. The authors recognize deterrents to learning the design process. Design is a complex process to teach in a short amount of time. Students are aware of a myriad of design texts and tools and become overwhelmed with the breadth of design approaches. One challenge of the design instructor’s task is to convey to the student that engineering design is not a mathematical equation to be solved or optimized. Another is to provide students with a cohesive structure for the design process that they can use with a variety of design methods and software packages. Toward that end, we have adopted a uniform terminology throughout and reinforced this with a new section at the end of each chapter on New Terms and Concepts. We have emphasized a cohesive eight-step engineering design process and present all material in the context of how it is applied. Regardless, we are strong in the belief that to learn design you must do design. We have found that Chapter 4, Team Behavior and Tools, is helpful to the students in this regard. Likewise, we hope that the expanded discussion of design tools like benchmarking, QFD, creativity methods, functional decomposition xxiii die37039_ch00_fm.indd xxiii 2/25/08 6:50:06 PM
  25. 25. xxiv engineer ing design and synthesis, and the decision process and decision tools will benefit the students who read this book. Many new topics have been added or expanded. These include: work breakdown structure, tolerances (including GD&T), human factors design, rapid prototyping, design against wear, the role of standardization in DFMA, mistake-proofing, Six Sigma quality, and the make-buy decision. Finally we have introduced different approaches to the steps of design so that students appreciate the range of practice and scholarship on the topic of engineering design. The authors hope that students will consider this book to be a valuable part of their professional library. In order to enhance its usefulness for that purpose, many references to the literature have been included, as well as suggestions for useful design software and references to websites. Many of the references have been updated, all of the websites from the third edition have been checked for currency, and many new ones have been added. In a book that covers such a wide sweep of material it has not always been possible to go into depth on every topic. Where expansion is appropriate, we have given a reference to at least one authoritative source for further study. Special thanks go to Amir Baz, Patrick Cunniff, James Dally, Abhijit Dasgupta, S.K. Gupta, Patrick McCloskey, and Guangming Zhang, our colleagues in the Mechanical Engineering Department, University of Maryland, for their willingness to share their knowledge with us. Thanks also go to Greg Moores of Black & Decker, Inc. for his willingness to share his industrial viewpoint on certain topics. We must also thank the following reviewers for their many helpful comments and suggestions: Charles A. Bollfrass, Texas A&M University; Peter Jones, Auburn University; Cesar A. Luongo, Florida State University; Dr. Michelle Nearon, Stony Brook University; John E. Renaud, University of Notre Dame; Robert Sterlacci, Binghamton University; Daniel T. Valentine, Clarkson University; and Savas Yavuzkurt, Penn State University. George E. Dieter and Linda C. Schmidt College Park, MD 2007 Yuliarman Electronic Library Collection Email: Padang, 22-Oct-2011 08:26 die37039_ch00_fm.indd xxiv 2/25/08 6:50:06 PM
  26. 26. 1 1 ENGINEERING DESIGN 1.1 INTRODUCTION What is design? If you search the literature for an answer to that question, you will find about as many definitions as there are designs. Perhaps the reason is that the process of design is such a common human experience. Webster’s dictionary says that to design is “to fashion after a plan,” but that leaves out the essential fact that to design is to create something that has never been. Certainly an engineering designer practices design by that definition, but so does an artist, a sculptor, a composer, a playwright, or many another creative member of our society. Thus, although engineers are not the only people who design things, it is true that the professional practice of engineering is largely concerned with design; it is often said that design is the essence of engineering. To design is to pull together something new or to arrange existing things in a new way to satisfy a recognized need of society. An elegant word for “pulling together” is synthesis. We shall adopt the following formal definition of design: “Design establishes and defines solutions to and pertinent structures for problems not solved before, or new solutions to problems which have previously been solved in a different way.” 1 The ability to design is both a science and an art. The science can be learned through techniques and methods to be covered in this text, but the art is best learned by doing design. It is for this reason that your design experience must involve some realistic project experience. The emphasis that we have given to the creation of new things in our introduction to design should not unduly alarm you. To become proficient in design is a perfectly attainable goal for an engineering student, but its attainment requires the guided experience that we intend this text to provide. Design should not be confused with discovery. Discovery is getting the first sight of, or the first knowledge of something, as 1. J. F. Blumrich, Science, vol. 168, pp. 1551–1554, 1970. 1 die37039_ch01.indd 1 2/25/08 6:50:18 PM
  27. 27. 1 2 engineer ing design when Columbus discovered America or Jack Kilby made the first microprocessor. We can discover what has already existed but has not been known before, but a design is the product of planning and work. We will present a structured design process to assist you in doing design in Sec. 1.5. We should note that a design may or may not involve invention. To obtain a legal patent on an invention requires that the design be a step beyond the limits of the existing knowledge (beyond the state of the art). Some designs are truly inventive, but most are not. Look up the word design in a dictionary and you will find that it can be either a noun or a verb. One noun definition is “the form, parts, or details of something according to a plan,” as in the use of the word design in “My new design is ready for review.” A common definition of the word design as a verb is “to conceive or to form a plan for,” as in “I have to design three new models of the product for three different overseas markets.” Note that the verb form of design is also written as “designing.” Often the phrase “design process” is used to emphasize the use of the verb form of design. It is important to understand these differences and to use the word appropriately. Good design requires both analysis and synthesis. Typically we approach complex problems like design by decomposing the problem into manageable parts. Because we need to understand how the part will perform in service, we must be able to calculate as much about the part’s expected behavior as possible before it exists in physical form by using the appropriate disciplines of science and engineering science and the necessary computational tools. This is called analysis. It usually involves the simplification of the real world through models. Synthesis involves the identification of the design elements that will comprise the product, its decomposition into parts, and the combination of the part solutions into a total workable system. At your current stage in your engineering education you are much more familiar and comfortable with analysis. You have dealt with courses that were essentially disciplinary. For example, you were not expected to use thermodynamics and fluid mechanics in a course in mechanics of materials. The problems you worked in the course were selected to illustrate and reinforce the principles. If you could construct the appropriate model, you usually could solve the problem. Most of the input data and properties were given, and there usually was a correct answer to the problem. However, real-world problems rarely are that neat and circumscribed. The real problem that your design is expected to solve may not be readily apparent. You may need to draw on many technical disciplines (solid mechanics, fluid mechanics, electro magnetic theory, etc.) for the solution and usually on nonengineering disciplines as well (economics, finance, law, etc.). The input data may be fragmentary at best, and the scope of the project may be so huge that no individual can follow it all. If that is not difficult enough, usually the design must proceed under severe constraints of time and/or money. There may be major societal constraints imposed by environmental or energy regulations. Finally, in the typical design you rarely have a way of knowing the correct answer. Hopefully, your design works, but is it the best, most efficient design that could have been achieved under the conditions? Only time will tell. We hope that this has given you some idea of the design process and the environment in which it occurs. One way to summarize the challenges presented by the design environment is to think of the four C’s of design. One thing that should be clear die37039_ch01.indd 2 2/25/08 6:50:19 PM
  28. 28. cha p ter 1: Engineer ing Design 3 1 The Four C’s of Design Creativity ● Requires creation of something that has not existed before or has not existed in the designer’s mind before Complexity ● Requires decisions on many variables and parameters Choice ● Requires making choices between many possible solutions at all levels, from basic concepts to the smallest detail of shape Compromise ● Requires balancing multiple and sometimes conflicting requirements by now is how engineering design extends well beyond the boundaries of science. The expanded boundaries and responsibilities of engineering create almost unlimited opportunities for you. In your professional career you may have the opportunity to create dozens of designs and have the satisfaction of seeing them become working realities. “A scientist will be lucky if he makes one creative addition to human knowledge in his whole life, and many never do. A scientist can discover a new star but he cannot make one. He would have to ask an engineer to do it for him.” 2 1.2 ENGINEERING DESIGN PROCESS The engineering design process can be used to achieve several different outcomes. One is the design of products, whether they be consumer goods such as refrigerators, power tools, or DVD players, or highly complex products such as a missile system or a jet transport plane. Another is a complex engineered system such as an electrical power generating station or a petrochemical plant, while yet another is the design of a building or a bridge. However, the emphasis in this text is on product design because it is an area in which many engineers will apply their design skills. Moreover, examples taken from this area of design are easier to grasp without extensive specialized knowledge. This chapter presents the engineering design process from three perspectives. In Section 1.3 the design method is contrasted with the scientific method, and design is presented as a five-step problem-solving methodology. Section 1.4 takes the role of design beyond that of meeting technical performance requirements and introduces the idea that design must meet the needs of society at large. Section 1.5 lays out a cradle-to-the-grave road map of the design process, showing that the responsibility of the engineering designer extends from the creation of a design until its embodiment is 2. G. L. Glegg, The Design of Design, Cambridge University Press, New York, 1969. die37039_ch01.indd 3 2/25/08 6:50:19 PM
  29. 29. 1 4 engineer ing design disposed of in an environmentally safe way. Chapter 2 extends the engineering design process to the broader issue of product development by introducing more business– oriented issues such as product positioning and marketing. 1.2.1 Importance of the Engineering Design Process In the 1980s when companies in the United States first began to seriously feel the impact of quality products from overseas, it was natural for them to place an emphasis on reducing their manufacturing costs through automation and moving plants to lower-labor-cost regions. However, it was not until the publication of a major study of the National Research Council (NRC) 3 that companies came to realize that the real key to world-competitive products lies in high-quality product design. This has stimulated a rash of experimentation and sharing of results about better ways to do product design. What was once a fairly cut-and-dried engineering process has become one of the cutting edges of engineering progress. This text aims at providing you with insight into the current best practices for doing engineering design. The importance of design is nicely summed up in Fig. 1.1. This shows that only a small fraction of the cost to produce a product (Ϸ5 percent) is involved with the design process, while the other 95 percent of cost is consumed by the materials, capital, and labor to manufacture the product. However, the design process consists of the accumulation of many decisions that result in design commitments that affect about 70 to 80 percent of the manufactured cost of the product. In other words, the decisions made beyond the design phase can influence only about 25 percent of the total cost. If the design proves to be faulty just before the product goes to market, it will cost a great deal of money to correct the problem. To summarize: Decisions made in the design process cost very little in terms of the overall product cost but have a major effect on the cost of the product. The second major impact of design is on product quality. The old concept of product quality was that it was achieved by inspecting the product as it came off the production line. Today we realize that true quality is designed into the product. Achieving quality through product design will be a theme that pervades this book. For now we point out that one aspect of quality is to incorporate within the product the performance and features that are truly desired by the customer who purchases the product. In addition, the design must be carried out so that the product can be made without defect at a competitive cost. To summarize: You cannot compensate in manufacturing for defects introduced in the design phase. The third area where engineering design determines product competitiveness is product cycle time. Cycle time refers to the development time required to bring a new product to market. In many consumer areas the product with the latest “bells and whistles” captures the customers’ fancy. The use of new organizational methods, the widespread use of computer-aided engineering, and rapid prototyping methods are contributing to reducing product cycle time. Not only does reduced cycle time in- 3. “Improving Engineering Design,” National Academy Press, Washington, D.C., 1991. die37039_ch01.indd 4 2/25/08 6:50:19 PM
  30. 30. 5 40 Cost incurred 20 Product use Manufacturing 60 1 Cost committed Product design 80 Conceptual design Percentage of product cost committed 100 Market development cha p ter 1: Engineer ing Design 0 Time (nonlinear) FIGURE 1.1 Product cost commitment during phases of the design process. (After Ullman.) crease the marketability of a product, but it reduces the cost of product development. Furthermore, the longer a product is available for sale the more sales and profits there will be. To summarize: The design process should be conducted so as to develop quality, cost-competitive products in the shortest time possible. 1.2.2 Types of Designs Engineering design can be undertaken for many different reasons, and it may take different forms. ● ● ● die37039_ch01.indd 5 Original design, also called innovative design. This form of design is at the top of the hierarchy. It employs an original, innovative concept to achieve a need. Sometimes, but rarely, the need itself may be original. A truly original design involves invention. Successful original designs occur rarely, but when they do occur they usually disrupt existing markets because they have in them the seeds of new technology of far-reaching consequences. The design of the microprocessor was one such original design. Adaptive design. This form of design occurs when the design team adapts a known solution to satisfy a different need to produce a novel application. For example, adapting the ink-jet printing concept to spray binder to hold particles in place in a rapid prototyping machine. Adaptive designs involve synthesis and are relatively common in design. Redesign. Much more frequently, engineering design is employed to improve an existing design. The task may be to redesign a component in a product that is failing in service, or to redesign a component so as to reduce its cost of manufacture. Often redesign is accomplished without any change in the working principle or concept of the original design. For example, the shape may be changed to reduce a 2/25/08 6:50:20 PM
  31. 31. 1 6 ● ● engineer ing design stress concentration, or a new material substituted to reduce weight or cost. When redesign is achieved by changing some of the design parameters, it is often called variant design. Selection design. Most designs employ standard components such as bearings, small motors, or pumps that are supplied by vendors specializing in their manufacture and sale. Therefore, in this case the design task consists of selecting the components with the needed performance, quality, and cost from the catalogs of potential vendors. Industrial design. This form of design deals with improving the appeal of a product to the human senses, especially its visual appeal. While this type of design is more artistic than engineering, it is a vital aspect of many kinds of design. Also encompassed by industrial design is a consideration of how the human user can best interface with the product. 1.3 WAYS TO THINK ABOUT THE ENGINEERING DESIGN PROCESS We often talk about “designing a system.” By a system we mean the entire combination of hardware, information, and people necessary to accomplish some specified task. A system may be an electric power distribution network for a region of the nation, a complex piece of machinery like a newspaper printing press, or a combination of production steps to produce automobile parts. A large system usually is divided into subsystems, which in turn are made up of components or parts. 1.3.1 A Simplified Iteration Model There is no single universally acclaimed sequence of steps that leads to a workable design. Different writers or designers have outlined the design process in as few as five steps or as many as 25. One of the first to write introspectively about design was Morris Asimow.4 He viewed the heart of the design process as consisting of the elements shown in Fig. 1.2. As portrayed there, design is a sequential process consisting of many design operations. Examples of the operations might be (1) exploring the alternative concepts that could satisfy the specified need, (2) formulating a mathematical model of the best system concept, (3) specifying specific parts to construct a subsystem, and (4) selecting a material from which to manufacture a part. Each operation requires information, some of it general technical and business information that is expected of the trained professional and some of it very specific information that is needed to produce a successful outcome. Examples of the latter kind of information might be (1) a manufacturer’s catalog on miniature bearings, (2) handbook data on the properties of polymer composites, or (3) personal experience gained from a trip to observe a new manufacturing process. Acquisition of information is a vital and often very dif- 4. M. Asimow, Introduction to Design Prentice-Hall, Englewood Cliffs, NJ, 1962. die37039_ch01.indd 6 2/25/08 6:50:20 PM
  32. 32. 7 cha p ter 1: Engineer ing Design 1 General information Specific information Design operation Outcome NO Feedback loop Evaluation YES GO TO THE NEXT STEP FIGURE 1.2 Basic module in the design process. (After Asimow.) ficult step in the design process, but fortunately it is a step that usually becomes easier with time. (We call this process experience.) 5 The importance of sources of information is considered more fully in Chap. 5. Once armed with the necessary information, the design team (or design engineer if the task is rather limited) carries out the design operation by using the appropriate technical knowledge and computational and/or experimental tools. At this stage it may be necessary to construct a mathematical model and conduct a simulation of the component’s performance on a computer. Or it may be necessary to construct a fullsize prototype model and test it to destruction at a proving ground. Whatever it is, the operation produces one or more alternatives that, again, may take many forms. It can be 30 megabytes of data on a memory stick, a rough sketch with critical dimensions, or a 3-D CAD model. At this stage the design outcome must be evaluated, often by a team of impartial experts, to decide whether it is adequate to meet the need. If so, the designer may go on to the next step. If the evaluation uncovers deficiencies, then the design operation must be repeated. The information from the first design is fed back as input, together with new information that has been developed as a result of questions raised at the evaluation step. We call this iteration. The final result of the chain of design modules, each like Fig. 1.2, is a new working object (often referred to as hardware) or a collection of objects that is a new system. However, the goal of many design projects is not the creation of new hardware or systems. Instead, the goal may be the development of new information that can be used elsewhere in the organization. It should be realized that few system designs are carried through to completion; they are stopped because it has become clear that the objectives of the project are not technically and/or economically feasible. Regardless, the system design process creates new information which, if stored in retrievable form, has future value, since it represents experience. The simple model shown in Fig. 1.2 illustrates a number of important aspects of the design process. First, even the most complex system can be broken down into a 5. Experience has been defined, perhaps a bit lightheartedly, as just a sequence of nonfatal events. die37039_ch01.indd 7 2/25/08 6:50:20 PM
  33. 33. 1 8 engineer ing design sequence of design objectives. Each objective requires evaluation, and it is common for this to involve repeated trials or iterations. The need to go back and try again should not be considered a personal failure or weakness. Design is an intellectual process, and all new creations of the mind are the result of trial and error. Of course, the more knowledge we have and can apply to the problem the faster we can arrive at an acceptable solution. This iterative aspect of design may take some getting used to. You will have to acquire a high tolerance for failure and the tenacity and determination to persevere and work the problem out one way or the other. The iterative nature of design provides an opportunity to improve the design on the basis of a preceding outcome. That, in turn, leads to the search for the best possible technical condition—for example, maximum performance at minimum weight (or cost). Many techniques for optimizing a design have been developed, and some of them are covered in Chap. 14. Although optimization methods are intellectually pleasing and technically interesting, they often have limited application in a complex design situation. Few designers have the luxury of working on a design task long enough and with a large enough budget to create an optimal system. In the usual situation the design parameters chosen by the engineer are a compromise among several alternatives. There may be too many variables to include all of them in the optimization, or nontechnical considerations like available time or legal constraints may have to be considered, so that trade-offs must be made. The parameters chosen for the design are then close to but not at optimum values. We usually refer to them as near-optimal values, the best that can be achieved within the total constraints of the system. 1.3.2 Design Method Versus Scientific Method In your scientific and engineering education you may have heard reference to the scientific method, a logical progression of events that leads to the solution of scientific problems. Percy Hill 6 has diagramed the comparison between the scientific method and the design method (Fig. 1.3). The scientific method starts with a body of existing knowledge based on observed natural phenomena. Scientists have curiosity that causes them to question these laws of science; and as a result of their questioning, they eventually formulate a hypothesis. The hypothesis is subjected to logical analysis that either confirms or denies it. Often the analysis reveals flaws or inconsistencies, so the hypothesis must be changed in an iterative process. Finally, when the new idea is confirmed to the satisfaction of its originator, it must be accepted as proof by fellow scientists. Once accepted, it is communicated to the community of scientists and it enlarges the body of existing knowledge. The knowledge loop is completed. The design method is very similar to the scientific method if we allow for differences in viewpoint and philosophy. The design method starts with knowledge of the state of the art. That includes scientific knowledge, but it also includes devices, components, materials, manufacturing methods, and market and economic conditions. 6. P. H. Hill, The Science of Engineering Design, Holt, Rinehart and Winston, New York, 1970. die37039_ch01.indd 8 2/25/08 6:50:20 PM
  34. 34. cha p ter 1: Engineer ing Design 1 Identification of need Hypothesis Acceptance State of the art Scientific curiosity Communication Existing knowledge 9 Conceptualization Logical analysis Feasibility analysis Proof Production Scientific method Design method FIGURE 1.3 Comparison between the scientific method and the design method. (After Percy Hill.) Rather than scientific curiosity, it is really the needs of society (usually expressed through economic factors) that provide the impetus. When a need is identified, it must be conceptualized as some kind of model. The purpose of the model is to help us predict the behavior of a design once it is converted to physical form. The outcomes of the model, whether it is a mathematical or a physical model, must be subjected to a feasibility analysis, almost always with iteration, until an acceptable product is produced or the project is abandoned. When the design enters the production phase, it begins to compete in the world of technology. The design loop is closed when the product is accepted as part of the current technology and thereby advances the state of the art of the particular area of technology. A more philosophical differentiation between science and design has been advanced by the Nobel Prize–winning economist Herbert Simon.7 He points out that science is concerned with creating knowledge about naturally occurring phenomena and objects, while design is concerned with creating knowledge about phenomena and objects of the artificial. Artificial objects are those made by humans (or by art) rather than nature. Thus, science is based on studies of the observed, while design is based on artificial concepts characterized in terms of functions, goals, and adaptation. In the preceding brief outline of the design method, the identification of a need requires further elaboration. Needs are identified at many points in a business or organization. Most organizations have research or development departments whose job it is to create ideas that are relevant to the goals of the organization. A very important 7. H. A. Simon, The Sciences of the Artificial , 3rd ed., The MIT Press, Cambridge, MA, 1996. die37039_ch01.indd 9 2/25/08 6:50:21 PM
  35. 35. 1 10 engineer ing design avenue for learning about needs is the customers for the product or services that the company sells. Managing this input is usually the job of the marketing organization of the company. Other needs are generated by government agencies, trade associations, or the attitudes or decisions of the general public. Needs usually arise from dissatisfaction with the existing situation. The need drivers may be to reduce cost, increase reliability or performance, or just change because the public has become bored with the product. 1.3.3 A Problem-Solving Methodology Designing can be approached as a problem to be solved. A problem-solving methodology that is useful in design consists of the following steps.8 ● ● ● ● ● Definition of the problem Gathering of information Generation of alternative solutions Evaluation of alternatives and decision making Communication of the results This problem-solving method can be used at any point in the design process, whether at the conception of a product or the design of a component. Definition of the Problem The most critical step in the solution of a problem is the problem definition or formulation. The true problem is not always what it seems at first glance. Because this step seemingly requires such a small part of the total time to reach a solution, its importance is often overlooked. Figure 1.4 illustrates how the final design can differ greatly depending upon how the problem is defined. The formulation of the problem should start by writing down a problem statement. This document should express as specifically as possible what the problem is. It should include objectives and goals, the current state of affairs and the desired state, any constraints placed on solution of the problem, and the definition of any special technical terms. The problem-definition step in a design project is covered in detail in Chap. 3. Problem definition often is called needs analysis. While it is important to identify the needs clearly at the beginning of a design process, it should be understood that this is difficult to do for all but the most routine design. It is the nature of the design process that new needs are established as the design process proceeds because new problems arise as the design evolves. At this point, the analogy of design as problem solving is less fitting. Design is problem solving only when all needs and potential issues with alternatives are known. Of course, if these additional needs require reworking those parts of the design that have been completed, then penalties are incurred 8. A similar process called the guided iteration methodology has been proposed by J. R. Dixon; see J. R. Dixon and C. Poli, Engineering Design and Design for Manufacturing, Field Stone Publishers, Conway, MA, 1995. A different but very similar problem-solving approach using TQM tools is given in Sec. 4.7. die37039_ch01.indd 10 2/25/08 6:50:21 PM
  36. 36. 11 cha p ter 1: Engineer ing Design As proposed by the project sponsor As specified in the project request As designed by the senior designer As produced by manufacturing As installed at the user's site 1 What the user wanted FIGURE 1.4 Note how the design depends on the viewpoint of the individual who defines the problem. in terms of cost and project schedule. Experience is one of the best remedies for this aspect of designing, but modern computer-based design tools help ameliorate the effects of inexperience. Gathering Information Perhaps the greatest frustration you will encounter when you embark on your first design project will be either the dearth or the plethora of information. No longer will your responsibility stop with the knowledge contained in a few chapters of a text. Your assigned problem may be in a technical area in which you have no previous background, and you may not have even a single basic reference on the subject. At the other extreme you may be presented with a mountain of reports of previous work, and your task will be to keep from drowning in paper. Whatever the situation, the immediate task is to identify the needed pieces of information and find or develop that information. An important point to realize is that the information needed in design is different from that usually associated with an academic course. Textbooks and articles published in the scholarly technical journals usually are of lesser importance. The need often is for more specific and current information than is provided by those sources. Technical reports published as a result of government-sponsored R&D, company reports, trade journals, patents, catalogs, and handbooks and literature published by die37039_ch01.indd 11 2/25/08 6:50:21 PM
  37. 37. 1 12 engineer ing design vendors and suppliers of material and equipment are important sources of information. The Internet is becoming a very useful resource. Often the missing piece of information can be supplied by an Internet search, or by a telephone call or an e-mail to a key supplier. Discussions with in-house experts (often in the corporate R&D center) and outside consultants may prove helpful. The following are some of the questions concerned with obtaining information: What do I need to find out? Where can I find it and how can I get it? How credible and accurate is the information? How should the information be interpreted for my specific need? When do I have enough information? What decisions result from the information? The topic of information gathering is discussed in Chap. 5. Generation of Alternative Solutions Generating alternative solutions or design concepts involves the use of creativitystimulation methods, the application of physical principles and qualitative reasoning, and the ability to find and use information. Of course, experience helps greatly in this task. The ability to generate high-quality alternative solutions is vital to a successful design. This important subject is covered in Chap. 6, Concept Generation. Evaluation of Alternatives and Decision Making The evaluation of alternatives involves systematic methods for selecting the best among several concepts, often in the face of incomplete information. Engineering analysis procedures provide the basis for making decisions about service performance. Design for manufacturing analyses (Chap. 13) and cost estimation (Chap. 16) provide other important information. Various other types of engineering analysis also provide information. Simulation of performance with computer models is finding wide usage (Chap. 10). Simulated service testing of an experimental model and testing of fullsized prototypes often provide critical data. Without this quantitative information it is not possible to make valid evaluations. Several methods for evaluating design concepts, or any other problem solution, are given in Chap. 7. An important activity at every step in the design process, but especially as the design nears completion, is checking. In general, there are two types of checks that can be made: mathematical checks and engineering-sense checks. Mathematical checks are concerned with checking the arithmetic and the equations for errors in the conversion of units used in the analytical model. Incidentally, the frequency of careless math errors is a good reason why you should adopt the practice of making all your design calculations in a bound notebook. In that way you won’t be missing a vital calculation when you are forced by an error to go back and check things out. Just draw a line through the section in error and continue. It is of special importance to ensure that every equation is dimensionally consistent. Engineering-sense checks have to do with whether the answers “seem right.” Even though the reliability of your intuition increases with experience, you can now develop the habit of staring at your answer for a full minute, rather than rushing on to do the die37039_ch01.indd 12 2/25/08 6:50:21 PM
  38. 38. cha p ter 1: Engineer ing Design 13 1 6 next calculation. If the calculated stress is 10 psi, you know something went wrong! Limit checks are a good form of engineering-sense check. Let a critical parameter in your design approach some limit (zero, infinity, etc.), and observe whether the equation behaves properly. We have stressed the iterative nature of design. An optimization technique aimed at producing a robust design that is resistant to environmental influences (water vapor, temperature, vibration, etc.) most likely will be employed to select the best values of key design parameters (see Chap. 15). Communication of the Results It must always be kept in mind that the purpose of the design is to satisfy the needs of a customer or client. Therefore, the finalized design must be properly communicated, or it may lose much of its impact or significance. The communication is usually by oral presentation to the sponsor as well as by a written design report. Surveys typically show that design engineers spend 60 percent of their time in discussing designs and preparing written documentation of designs, while only 40 percent of the time is spent in analyzing and testing designs and doing the designing. Detailed engineering drawings, computer programs, 3-D computer models, and working models are frequently among the “deliverables” to the customer. It hardly needs to be emphasized that communication is not a one-time occurrence to be carried out at the end of the project. In a well-run design project there is continual oral and written dialog between the project manager and the customer. This extremely important subject is considered in greater depth in Chap. 9. Note that the problem-solving methodology does not necessarily proceed in the order just listed. While it is important to define the problem early on, the understanding of the problem improves as the team moves into solution generation and evaluation. In fact, design is characterized by its iterative nature, moving back and forth between partial solutions and problem definition. This is in marked contrast with engineering analysis, which usually moves in a steady progression from problem setup to solution. There is a paradox inherent in the design process between the accumulation of problem (domain) knowledge and freedom to improve the design. When one is creating an original design, very little is known about its solution. As the design team proceeds with its work; it acquires more knowledge about the technologies involved and the possible solutions (Fig. 1.5). The team has moved up the learning curve. However, as the design process proceeds, the design team is forced to make many decisions about design details, technology approaches, perhaps to let contracts for longlead-time equipment, and so on. Thus, as Fig. 1.5 shows, the freedom of the team to go back and start over with their newly gained knowledge (experience) decreases greatly as their knowledge about the design problem grows. At the beginning the designer has the freedom to make changes without great cost penalty, but may not know what to do to make the design better. The paradox comes from the fact that when the design team finally masters the problem, their design is essentially frozen because of the great penalties involved with a change. The solution is for the design team to learn as much about the problem as early in the design process as it possibly can. This also places high priority on the team members learning to work independently toward a common goal (Chap. 4), being skilled in gathering information (Chap. 5), and being die37039_ch01.indd 13 2/25/08 6:50:22 PM
  39. 39. 1 14 engineer ing design 100 Percentage 80 Knowledge about the design problem 60 40 Design freedom 20 0 Time into design process FIGURE 1.5 The design paradox between design knowledge and design freedom. good at communicating relevant knowledge to their teammates. Design team members must become stewards of the knowledge they acquire. Figure 1.5 also shows why it is important to document in detail what has been done, so that the experience can be used by subsequent teams in future projects. 1.4 CONSIDERATIONS OF A GOOD DESIGN Design is a multifaceted process. To gain a broader understanding of engineering design, we group various considerations of good design into three categories: (1) achievement of performance requirements, (2) life-cycle issues, and (3) social and regulatory issues. 1.4.1 Achievement of Performance Requirements It is obvious that to be feasible the design must demonstrate the required performance. Performance measures both the function and the behavior of the design, that is, how well the device does what it is designed to do. Performance requirements can be divided into primary performance requirements and complementary performance requirements. A major element of a design is its function. The function of a design is how it is expected to behave. For example, the design may be required to grasp an object of a certain mass and move it 50 feet in one minute. Functional requirements are usually expressed in capacity measures such as forces, strength, deflection, or energy or power output or consumption. Complementary performance requirements are concerns such as the useful life of the design, its robustness to factors occurring in the die37039_ch01.indd 14 2/25/08 6:50:22 PM
  40. 40. cha p ter 1: Engineer ing Design 15 1 service environment (see Chap. 15), its reliability (see Chap. 14), and ease, economy, and safety of maintenance. Issues such as built-in safety features and the noise level in operation must be considered. Finally, the design must conform to all legal requirements and design codes. A product is usually made up of a collection of parts, sometimes called pieceparts. A part is a single piece requiring no assembly. When two or more parts are joined it is called an assembly. Often large assemblies are composed of a collection of smaller assemblies called subassemblies. A similar term for part is component. The two terms are used interchangeably in this book, but in the design literature the word component sometimes is used to describe a subassembly with a small number of parts. Consider an ordinary ball bearing. It consists of an outer ring, inner ring, 10 or more balls depending on size, and a retainer to keep the balls from rubbing together. A ball bearing is often called a component, even though it consists of a number of parts. Closely related to the function of a component in a design is its form. Form is what the component looks like, and encompasses its shape, size, and surface finish. These, in turn, depend upon the material it is made from and the manufacturing processes that are used to make it. A variety of analysis techniques must be employed in arriving at the features of a component in the design. By feature we mean specific physical attributes, such as the fine details of geometry, dimensions, and tolerances on the dimensions.9 Typical geometrical features would be fillets, holes, walls, and ribs. The computer has had a major impact in this area by providing powerful analytical tools based on finite-element analysis. Calculations of stress, temperature, and other field-dependent variables can be made rather handily for complex geometry and loading conditions. When these analytical methods are coupled with interactive computer graphics, we have the exciting capability known as computer-aided engineering (CAE); see Sec. 1.6. Note that with this enhanced capability for analysis comes greater responsibility for providing better understanding of product performance at early stages of the design process. Environmental requirements for performance deal with two separate aspects. The first concerns the service conditions under which the product must operate. The extremes of temperature, humidity, corrosive conditions, dirt, vibration, and noise, must be predicted and allowed for in the design. The second aspect of environmental requirements pertains to how the product will behave with regard to maintaining a safe and clean environment, that is, green design. Often governmental regulations force these considerations in design, but over time they become standard design practice. Among these issues is the disposal of the product when it reaches its useful life. For more information on design for environment (DFE), see Sec. 8.9. Aesthetic requirements refer to “the sense of the beautiful.” They are concerned with how the product is perceived by a customer because of its shape, color, surface texture, and also such factors as balance, unity, and interest. This aspect of design usually is the responsibility of the industrial designer, as opposed to the engineering designer. The industrial designer is an applied artist. Decisions about the appearance of the product should be an integral part of the initial design concept. An important 9. In product development the term feature has an entirely different meaning as “an aspect or characteristic of the product.” For example, a product feature for a power drill could be a laser beam attachment for alignment of the drill when drilling a hole. die37039_ch01.indd 15 2/25/08 6:50:22 PM
  41. 41. die37039_ch01.indd 16 Oil The earth Wood Plants Wood Coal Oil Dispose Recycle Cement Paper Waste Junk Fibers Metals Chemicals Performance Service Use Process Structures Machines Devices Products Design Manufacturing Assembly Ceramics Concrete Textiles Alloys Plastics Crystals ENGINEERING MATERIALS FIGURE 1.6 The total materials cycle. (Reproduced from “Materials and Man’s Needs,” National Academy of Sciences, Washington, D.C., 1974.) Ore Mine Drill Harvest Rock Sand Ore RAW MATERIALS Extract Refine Process BULK MATERIALS 1 16 2/25/08 6:50:22 PM
  42. 42. cha p ter 1: Engineer ing Design 17 1 design consideration is adequate attention to human factors engineering, which uses the sciences of biomechanics, ergonomics, and engineering psychology to assure that the design can be operated efficiently by humans. It applies physiological and anthropometric data to such design features as visual and auditory display of instruments and control systems. It is also concerned with human muscle power and response times. The industrial designer often is responsible for considering the human factors. For further information, see Sec. 8.8. Manufacturing technology must be closely integrated with product design. There may be restrictions on the manufacturing processes that can be used, because of either selection of material or availability of equipment within the company. The final major design requirement is cost. Every design has requirements of an economic nature. These include such issues as product development cost, initial product cost, life cycle product cost, tooling cost, and return on investment. In many cases cost is the most important design requirement. If preliminary estimates of product cost look unfavorable, the design project may never be initiated. Cost enters into every aspect of the design process. Procedures for estimating costs are considered in Chap. 16 and the subject of economic decision making (engineering economics) is presented in Chap. 18.10 1.4.2 Total Life Cycle The total life cycle of a part starts with the conception of a need and ends with the retirement and disposal of the product. Material selection is a key element in shaping the total life cycle (see Chap. 11). In selecting materials for a given application, the first step is evaluation of the service conditions. Next, the properties of materials that relate most directly to the service requirements must be determined. Except in almost trivial conditions, there is never a simple relation between service performance and material properties. The design may start with the consideration of static yield strength, but properties that are more difficult to evaluate, such as fatigue, creep, toughness, ductility, and corrosion resistance may have to be considered. We need to know whether the material is stable under the environmental conditions. Does the microstructure change with temperature and therefore change the properties? Does the material corrode slowly or wear at an unacceptable rate? Material selection cannot be separated from manufacturability (see Chap. 13). There is an intimate connection between design and material selection and the manufacturing processes. The objective in this area is a trade-off between the opposing factors of minimum cost and maximum durability. Durability is the amount of use one gets from a product before it is no longer useable. Current societal issues of energy conservation, material conservation, and protection of the environment result in new pressures in the selection of materials and manufacturing processes. Energy costs, once nearly ignored in design, are now among the most prominent design considerations. Design for materials recycling also is becoming an important consideration. The life cycle of production and consumption that is characteristic of all products is illustrated by the materials cycle shown in Fig. 1.6. This starts with the mining of a 10. Chapter 18 can be found on the website for this text, die37039_ch01.indd 17 2/25/08 6:50:22 PM
  43. 43. 1 18 engineer ing design mineral or the drilling for oil or the harvesting of an agricultural fiber such as cotton. These raw materials must be processed to extract or refine a bulk material (e.g., an aluminum ingot) that is further processed into a finished engineering material (e.g., an aluminum sheet). At this stage an engineer designs a product that is manufactured from the material, and the part is put into service. Eventually the part wears out or becomes obsolete because a better product comes on the market. At this stage, one option is to junk the part and dispose of it in some way that eventually returns the material to the earth. However, society is becoming increasingly concerned with the depletion of natural resources and the haphazard disposal of solid materials. Thus, we look for economical ways to recycle waste materials (e.g., aluminum beverage cans). 1.4.3 Regulatory and Social Issues Specifications and standards have an important influence on design practice. The standards produced by such societies as ASTM and ASME represent voluntary agreement among many elements (users and producers) of industry. As such, they often represent minimum or least-common-denominator standards. When good design requires more than that, it may be necessary to develop your own company or agency standards. On the other hand, because of the general nature of most standards, a standard sometimes requires a producer to meet a requirement that is not essential to the particular function of the design. The codes of ethics of all professional engineering societies require the engineer to protect public health and safety. Increasingly, legislation has been passed to require federal agencies to regulate many aspects of safety and health. The requirements of the Occupational Safety and Health Administration (OSHA), the Consumer Product Safety Commission (CPSC), the Environmental Protection Agency (EPA), and the Department of Homeland Security (DHS) place direct constraints on the designer in the interests of protecting health, safety, and security. Several aspects of the CPSC regulations have far-reaching influence on product design. Although the intended purpose of a product normally is quite clear, the unintended uses of that product are not always obvious. Under the CPSC regulations, the designer has the obligation to foresee as many unintended uses as possible, then develop the design in such a way as to prevent hazardous use of the product in an unintended but foreseeable manner. When unintended use cannot be prevented by functional design, clear, complete, unambiguous warnings must be permanently attached to the product. In addition, the designer must be cognizant of all advertising material, owner’s manuals, and operating instructions that relate to the product to ensure that the contents of the material are consistent with safe operating procedures and do not promise performance characteristics that are beyond the capability of the design. An important design consideration is adequate attention to human factors engineering, which uses the sciences of biomechanics, ergonomics, and engineering psychology to assure that the design can be operated efficiently and safely by humans. It applies physiological and anthropometric data to such design features as visual and auditory display of instruments and control systems. It is also concerned with human muscle power and response times. For further information, see Sec. 8.8. die37039_ch01.indd 18 2/25/08 6:50:23 PM
  44. 44. 19 cha p ter 1: Engineer ing Design Define problem Gather information Concept generation Evaluation of concepts Problem statement Benchmarking QFD PDS Project planning Internet Patents Trade literature Brainstorming Functional decomposition Morphological chart 1 Pugh concept selection Decision matrices Conceptual design Product architecture Configuration design Parametric design Detail design Arrangement of physical elements to carry out function Prelim. selection matls. & mfg. Modeling/sizing of parts Robust design Tolerances Final dimen. DFM Detailed drawings and specifications Embodiment design FIGURE 1.7 The design activities that make up the first three phases of the engineering design process. 1.5 DESCRIPTION OF DESIGN PROCESS Morris Asimow 11 was among the first to give a detailed description of the complete design process in what he called the morphology of design. His seven phases of design are described below, with slight changes of terminology to conform to current practice. Figure 1.7 shows the various activities that make up the first three phases of design: conceptual design, embodiment design, and detail design. This eight-step set of design activities is our representation of the basic design process. The purpose of this graphic is to remind you of the logical sequence of activities that leads from problem definition to the detail design. 1.5.1 Phase I. Conceptual Design Conceptual design is the process by which the design is initiated, carried to the point of creating a number of possible solutions, and narrowed down to a single best concept. It is sometimes called the feasibility study. Conceptual design is the phase that requires the greatest creativity, involves the most uncertainty, and requires coordination among many functions in the business organization. The following are the discrete activities that we consider under conceptual design. 11. I. M. Asimow, Introduction to Design, Prentice-Hall, Englewood Cliffs, NJ, 1962. die37039_ch01.indd 19 2/25/08 6:50:23 PM
  45. 45. 1 20 ● ● ● ● ● ● ● engineer ing design Identification of customer needs: The goal of this activity is to completely understand the customers’ needs and to communicate them to the design team. Problem definition: The goal of this activity is to create a statement that describes what has to be accomplished to satisfy the needs of the customer. This involves analysis of competitive products, the establishment of target specifications, and the listing of constraints and trade-offs. Quality function deployment (QFD) is a valuable tool for linking customer needs with design requirements. A detailed listing of the product requirements is called a product design specification (PDS). Problem definition, in its full scope, is treated in Chap. 3. Gathering information: Engineering design presents special requirements over engineering research in the need to acquire a broad spectrum of information. This subject is covered in Chap. 5. Conceptualization: Concept generation involves creating a broad set of concepts that potentially satisfy the problem statement. Team-based creativity methods, combined with efficient information gathering, are the key activities. This subject is covered in Chap. 6. Concept selection: Evaluation of the design concepts, modifying and evolving into a single preferred concept, are the activities in this step. The process usually requires several iterations. This is covered in Chap. 7. Refinement of the PDS: The product design specification is revisited after the concept has been selected. The design team must commit to achieving certain critical values of design parameters, usually called critical-to-quality (CTQ) parameters, and to living with trade-offs between cost and performance. Design review: Before committing funds to move to the next design phase, a design review will be held. The design review will assure that the design is physically realizable and that it is economically worthwhile. It will also look at a detailed productdevelopment schedule. This is needed to devise a strategy to minimize product cycle time and to identify the resources in people, equipment, and money needed to complete the project. 1.5.2 Phase II. Embodiment Design Structured development of the design concept occurs in this engineering design phase. It is the place where flesh is placed on the skeleton of the design concept. An embodiment of all the main functions that must be performed by the product must be undertaken. It is in this design phase that decisions are made on strength, material selection, size, shape, and spatial compatibility. Beyond this design phase, major changes become very expensive. This design phase is sometimes called preliminary design. Embodiment design is concerned with three major tasks—product architecture, configuration design, and parametric design. ● die37039_ch01.indd 20 Product architecture: Product architecture is concerned with dividing the overall design system into subsystems or modules. In this step we decide how the physical components of the design are to be arranged and combined to carry out the functional duties of the design. 2/25/08 6:50:23 PM
  46. 46. cha p ter 1: Engineer ing Design ● ● 21 1 Configuration design of parts and components: Parts are made up of features like holes, ribs, splines, and curves. Configuring a part means to determine what features will be present and how those features are to be arranged in space relative to each other. While modeling and simulation may be performed in this stage to check out function and spatial constraints, only approximate sizes are determined to assure that the part satisfies the PDS. Also, more specificity about materials and manufacturing is given here. The generation of a physical model of the part with rapid prototyping processes may be appropriate. Parametric design of parts: Parametric design starts with information on the configuration of the part and aims to establish its exact dimensions and tolerances. Final decisions on the material and manufacturing processes are also established if this has not been done previously. An important aspect of parametric design is to examine the part, assembly, and system for design robustness. Robustness refers to how consistently a component performs under variable conditions in its service environment. The methods developed by Dr. Genichi Taguchi for achieving robustness and establishing the optimum tolerance are discussed in Chap. 15. Parametric design also deals with determining the aspects of the design that could lead to failure (see Chap. 14). Another important consideration in parametric design is to design in such a way that manufacturability is enhanced (see Chap. 13). 1.5.3 Phase III. Detail Design In this phase the design is brought to the stage of a complete engineering description of a tested and producible product. Missing information is added on the arrangement, form, dimensions, tolerances, surface properties, materials, and manufacturing processes of each part. This results in a specification for each special-purpose part and for each standard part to be purchased from suppliers. In the detail design phase the following activities are completed and documents are prepared: ● ● ● ● ● ● ● die37039_ch01.indd 21 Detailed engineering drawings suitable for manufacturing. Routinely these are computer-generated drawings, and they often include three-dimensional CAD models. Verification testing of prototypes is successfully completed and verification data is submitted. All critical-to-quality parameters are confirmed to be under control. Usually the building and testing of several preproduction versions of the product will be accomplished. Assembly drawings and assembly instructions also will be completed. The bill of materials for all assemblies will be completed. A detailed product specification, updated with all the changes made since the conceptual design phase, will be prepared. Decisions on whether to make each part internally or to buy from an external supplier will be made. With the preceding information, a detailed cost estimate for the product will be carried out. Finally, detail design concludes with a design review before the decision is made to pass the design information on to manufacturing. 2/25/08 6:50:24 PM
  47. 47. 1 22 engineer ing design Phases I, II, and III take the design from the realm of possibility to the real world of practicality. However, the design process is not finished with the delivery of a set of detailed engineering drawings and specifications to the manufacturing organization. Many other technical and business decisions must be made that are really part of the design process. A great deal of thought and planning must go into how the design will be manufactured, how it will be marketed, how it will be maintained during use, and finally, how it will be retired from service and replaced by a new, improved design. Generally these phases of design are carried out elsewhere in the organization than in the engineering department or product development department. As the project proceeds into the new phases, the expenditure of money and personnel time increases greatly. One of the basic decisions that must be made at this point is which parts will be made by the product developing company and which will be made by an outside vendor or supplier. This often is called the “make or buy” decision. Today, one additional question must be asked: “Will the parts be made and/or assembled in the United States or in another country where labor rates are much lower?” 1.5.4 Phase IV. Planning for Manufacture A great deal of detailed planning must be done to provide for the production of the design. A method of manufacture must be established for each component in the system. As a usual first step, a process sheet is created; it contains a sequential list of all manufacturing operations that must be performed on the component. Also, it specifies the form and condition of the material and the tooling and production machines that will be used. The information on the process sheet makes possible the estimation of the production cost of the component.12 High costs may indicate the need for a change in material or a basic change in the design. Close interaction with manufacturing, industrial, materials, and mechanical engineers is important at this step. This topic is discussed more fully in Chap. 13. The other important tasks performed in phase IV are the following: ● ● ● ● ● ● Designing specialized tools and fixtures Specifying the production plant that will be used (or designing a new plant) and laying out the production lines Planning the work schedules and inventory controls (production control) Planning the quality assurance system Establishing the standard time and labor costs for each operation Establishing the system of information flow necessary to control the manufacturing operation All of these tasks are generally considered to fall within industrial or manufacturing engineering. 12. Precise calculation of manufacturing costs cannot be made until the process sheet is known. However, reasonable part cost estimates are made in conceptual and embodiment design. These are important elements for decision making at early stages of design. For more detail on costs, see Chap. 16. die37039_ch01.indd 22 2/25/08 6:50:24 PM
  48. 48. cha p ter 1: Engineer ing Design 23 1 1.5.5 Phase V. Planning for Distribution Important technical and business decisions must be made to provide for the effective distribution to the consumer of the products that have been produced. In the strict realm of design, the shipping package may be critical. Concepts such as the shelf life of the product may also be critical and may need to be addressed in the earlier stages of the design process. A system of warehouses for distributing the product may have to be designed if none exists. The economic success of the design often depends on the skill exercised in marketing the product. If it is a consumer product, the sales effort is concentrated on advertising in print and video media, but highly technical products may require that the marketing step be a technical activity supported by specialized sales brochures, performance test data, and technically trained sales engineers. 1.5.6 Phase VI. Planning for Use The use of the product by the consumer is all-important, and considerations of how the consumer will react to the product pervade all steps of the design process. The following specific topics can be identified as being important user-oriented concerns in the design process: ease of maintenance, durability, reliability, product safety, convenience in use (human factors engineering), aesthetic appeal, and economy of operation. Obviously, these consumer-oriented issues must be considered in the design process at its very beginning. They are not issues to be treated as afterthoughts. Phase VI of design is less well defined than the others, but it is becoming increasingly important with the growing concerns for consumer protection and product safety. More strict interpretation of product liability laws is having a major impact on design. An important phase VI activity is the acquisition of reliable data on failures, service lives, and consumer complaints and attitudes to provide a basis for product improvement in the next design cycle. 1.5.7 Phase VII. Planning for Retirement of the Product The final step in the design process is the disposal of the product when it has reached the end of its useful life. Useful life may be determined by actual deterioration and wear to the point at which the design can no longer function, or it may be determined by technological obsolescence, in which a competing design performs the product’s functions either better or cheaper. In consumer products, it may come about through changes in fashion or taste. In the past, little attention has been given in the design process to product retirement. This is rapidly changing, as people the world over are becoming concerned about environmental issues. There is concern with depletion of mineral and energy resources, and with pollution of the air, water, and land as a result of manufacturing and technology advancement. This has led to a formal area of study called industrial ecology. Design for the environment, also called green design, has become an important consideration in design (Sec. 8.9). As a result, the design of a product should include a die37039_ch01.indd 23 2/25/08 6:50:24 PM
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