786-PRODUCT-DESIGN-ARC-4302-3-2-3-V-II-CHAPTER-3-converted.pptx

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PRODUCT DESIGN(CHAPTER-3)
Course Number: ARC-4302
Degree Program: BSc inArchitecture
Credits
Contact Hours
Year/Semester
: 3
:Lectures-2,Tutorials-3
:V/II
Dr. G.M.SAYEED AHMED
Associate Professor, DESIGN & MANUFACTURING DEPARTMENT
SCHOOL OF MECHANICALENGINEERING
ADAMA SCIENCE &TECHNOLOGICALUNIVERSITY

CHAPTER-3
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ADAMA SCIENCE & TECHNOLOGICALUNIVERSITY
Systematic Innovations
ETHNOGRAPHY
Definition of Ethnography
The purpose of ethnographic research is to attempt to understand what is happening
naturally in the setting and to interpret the data gathered to see what implications could be
formed from the data. Ethnographic research is also known as qualitative research.
Characteristics of Ethnographic Research
Researcher is the instrument.
Data gatheredin natural setting.
Data gathered through observations, interviews, data analysis, and questionnaires.
Data gathered using more than one of these sources and validated through cross checking.
What is ethnography in qualitative research design?
Ethnography is a type of qualitative research that gathers observations, interviews and
documentary data to produce detailed and comprehensive accounts of different social
phenomena. ... It is also aimed at those interested in considering the use of ethnographic
methods in their own research work.

TYPES OF ETHNOGRAPHIC RESEARCH
There are many forms of ethnography, such as: confessional ethnography, auto-
ethnography, ethnography in photography and video, life history, ethnographic novels,
etc.
Ethnographic research is a qualitative method where researchers observe and/or interact
with a study's participants in their real-life environment. ... The aim of an ethnographic
study within a usability project is to get 'under the skin' of a design problem (and all its
associated issues).
What are the three meanings of ethnography?
the study and systematic recording of human cultures also : a descriptive work
produced from such research. Other Words from ethnography Example Sentences
Learn More about ethnography.
Where is ethnography used?
Within the field of usability and user-centred design, ethnography is used to support a
designer's deeper understanding of the design problem — including the relevant domain,
audience(s), processes, goals and context(s) of use.
What is ethnography example?
Some examples of ethnography include traditional anthropologic texts, but also work being
done in marketing and user experience, such as conducting interviews to understand how
the user relates to products or services.
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METHODS - ETHNOGRAPHY DESIGN
Detailed observations.
Unstructured interviews.
Analysis of documents.
Cultural probes.
Interviews.
Experience sampling method.
Diary and photo studies.
Contextual inquiry.
Stages of Collection
Informal stage: Collection of data; insights used to modify data collection and refine research questions
Formal stage: sorting, organizing, and reducing the volume of the data “Thick Description” identifying
patterns, interpreting causes, consequences and relationships to understand and provide explanation
Description should be sufficiently realistic for others to see the implications
Observational Data
Rough materials collected during observation.
Obtain relevant data needed to improve and/or change systems.
Methods of recording data: written notes, audiotape, sketches, photographs, video tapes.
Who is the father ofethnography?
Franz Boaz is know as the father of American ethnography for several reasons.
Ethnography is a qualitative research study looking at the social interaction of users in a given
environment. This research provides an in-depth insight into the user's views and actions along with
the sights and sounds they encounter during their day.
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What are advantages and disadvantages of ethnographic research?
Ethnographic research has several disadvantages to consider as well. Ethnography is time consuming
and requires a well-trained researcher. It takes time to build trust with informants in order to facilitate
full and honest discourse. Short-term studies are at a particular disadvantage in this regard.
What is ethnography and its characteristics?
Ethnography is a qualitative research method which involves a detailed study of a particular cultural
group. It is a primary research method, but not limited to Anthropology which anthropologists often
document in their fieldwork. Ethnography is one of the most distinctive characteristics of
Anthropology.
How did ethnographic research develop?
Ethnographers engage in participant observation in order to gain insight into the culture in which
they are interested. These insights develop over time and in relation to the social relationships in the
field as well as through repeated analysis of many aspects of our field sites.
What are the 5 qualitative approaches?
A popular and helpful categorization separate qualitative methods into five groups: ethnography,
narrative, phenomenological, grounded theory, and case study. John Creswell outlines these five
methods in Qualitative Inquiry and Research Design.
What are the advantages of ethnographic research?
One of the main advantages associated with ethnographic research is that ethnography can help
identify and analyse unexpected issues. When conducting other types of studies, which are not based
on in-situ observation or interaction, it can very easy to miss unexpected issues.
What are the disadvantages of ethnography?
Ethnographic research has several disadvantages to consider as well. Ethnography is time consuming
and requires a well-trained researcher. It takes time to build trust with informants in order to facilitate
full and honest discourse. Short-term studies are at a particular disadvantage in this regard.

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What is the goal of ethnographicresearch?
The goal of ethnographic research is to formulate a pattern of analysis that makes reasonable sense out of
human actions within the given context of a specific time and place.
What are the basic ethnographic techniques?
Subsequently, we discuss ethnographic methods by identifying, fieldwork, participant observation, field
notes, and interviewing as some of the key tools used in ethnographic research.
What are the characteristics ofethnography?
We identified six trademark features to be considered when embracing an ethnographic approach:
naturalism; context; multiple data sources; small case numbers; 'emic' and 'etic' perspectives, and ethical
considerations.
What is the ethnographic method?
Ethnographic methods are a research approach that looks at: people in their cultural setting; ... their
language, and the symbols, rituals and shared meanings that populate their world, with the object of
producing a narrative account of that particular culture, against a theoretical backdrop.
What is the difference between ethnography and qualitative research?
Ethnographic research shares these qualitative traits, but ethnographers more specifically seek
understanding of what participants do to create the culture in which they live, and how the culture
develops over time.
How is ethnography used in research?
It provides the researcher with an understanding of how those users see the world and how they
interact with everything around them. Ethnography methods include direct observation, diary studies,
video recordings, photography and artefact analysis such as devices that a person uses throughout the
day.

COMPUTER AIDED DRAFTING IN PRODUCT DEVELOPMENT
CAD is the use of computers (or workstations) to aid in the creation, modification,
analysis, or optimization of a design.
The CAD databases must reflect the manufacturing requirements, such as tolerances and
features, bearing in mind CAM requirements.
A Computer Aided Design (CAD) package has three components:
Design: Design refers to geometric modeling, i.e. 2-D and 3-D modeling including drafting, part
creation, creation of drawings with various views of the part, assemblies of the parts, etc.
Analysis: In general, a geometric model is first created and then the model is analyzed for loads,
stresses, moment of inertia and volume, etc.
Visualization: Visualization refers to computer graphics, which includes: rendering a model, creation
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of pie charts, contour plots, shading a model, sizing, animation, etc.
ADAMA SCIENCE & TECHNOLOGICAL UNIVERSITY

What is CAM
Process of production of objects from metals or non-metals, with or without application of
force, with or without application of heat, with or without use of machines, joining or
removing of excess material.
CAM is the next stage of CAD.
CAM-is the use of computer systems to plan, manage and control the operations of
manufacturing plant through either direct or indirect computer interface with the plant’s
production resources.
A part created in CAD can be downloaded and manufactured, without a human hand
touching the part, Involves CAD, Networking, and NC programming.
Manufacturing support applications –Use of computers in process planning, scheduling,
shop floor control, work study, tool design, quality control etc.
The application of CAM is divided in two categories:
(i) Manufacturing planning, and
(ii)Manufacturing control.
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CAM APPLICATIONS
Manufacturing Planning applications:
Computer Aided Process Planning (CAPP)
Computer Assisted NC Part Programming
Computerized Machinability Data System
Development of Work Standard
Cost Estimating
Production and InventoryPlanning
Computer Aided LineBalancing
computers are used directly to support the production function, but there is no direct
connection between the computer and the process.
The computer is used “offline” to provide information for the effective planning and
management of the production activities.
Manufacturing Control applications:
Process Monitoring and Control
Quality Control
Shop Floor Control
Inventory Control
Just in Time Production System
Development of computer supported system for implementing the manufacturing control
functions.
These control functions manage and control the physical operation in the factory.

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PRODUCT DESIGN
Product design: an iterative decision-making process which generates detailed planes of
how raw materials and purchased items are to be transformed in to useful products.
Mechanical design includes the drawing of the complete product as well as its components
and subassemblies, and the tools and fixtures required to manufacture the product.
Product development: a sequence of activities by which products are selected, designed and
prepared for full production.
Product design is the stage of product development.
PRODUCT DEVELOPMENT CYCLE
Products are selected and development is managed as a tradeoff between:
Product performance and quality (how well product fit intended use)
Development speed (how quickly new product reach the market)
Product cost (manufacturing cost )
Development program expense (spent on development)

PRODUCT DEVELOPMENT PROCESS
TYPES OF PRODUCT DESIGN
Functional design: the process of developing a working prototype of a product
from the specifications and functional requirements without regard to appearance.
Reliability and maintainability.
Industrial (form) design: focus on aesthetics and ease of use.
Design for manufacturing: key design stage for preparing a complete and
detailed definition for a product. How it will be manufactured and used.
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LINKING DESIGN AND MANUFACTURING
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For improving the product development process:
Design for manufacturing and assembly (DFM/DFA)
Design for the environment(DFE)
Consider cost implications early in the design cycle
Concurrent engineering.
DESIGN FOR MANUFACTURING (DFM)
Design for Manufacturing (DFM) is the process of designing parts, components or products
for ease of manufacturing with an end goal of making a better product at a lower cost.
This is done by simplifying, optimizing and refining the product design.
DFM/DFA generate a product definition :form, fit and structure.
Guidelines:
Reduce and simplify manufacturing process and assembly steps
Avoid unnecessarily tight tolerances or smooth surface finish
Reduce part count
Use modular or standardized components
Minimize use of fasteners
Use snap-fit fastening action
Assemble in the open and in downward direction.

DESIGN FOR THE ENVIRONMENT (DFE)
Reuse materials to remake the same product
Design new products from recycled materials
Use recyclable components and materials
Design product for ease of repair and
Design products that minimize energy use.
The simultaneous consideration of all aspects of development of a product throughout its
development cycle. Product and process development become simultaneous processes
instead of their traditional sequential nature. Facilitates design for ease of manufacturing,
ease of use and ease of service. CAD systems especially 3D modelers can play an important
role in early product development phases. to review the design during the modeling,
prototyping and soft tooling phases of development.
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PROTOTYPE
Physical Prototypes
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Tangible approximation of the product.
May exhibit un-modeled behavior.
Some behavior may be a
product of the approximation.
Often best for communication.
An approximation of the product along one or more dimensions of interest.
Four Uses of Prototypes
Learning
– answering questions aboutperformance or feasibility
–e.g., proof-of-concept model
Communication
– demonstration of product for feedback
–e.g., 3D physical models of style or function
Integration
– combination of sub-systems into system model
–e.g., alpha or betatest models
Milestones
– goal for development team’s schedule
– e.g., first testable hardware.
Analytical Prototypes
Mathematical model of the
product.
can only exhibit behavior
arising from explicitly
modeled phenomena.
Some behavior may be an
artifact of the analytical
Method and Experimental freedom than physical models.

Focused Prototypes
Implement one or a few attributes of the product.
Answer specific questions about the product design.
Generally several are required.
Comprehensive Prototypes
Implement many or all attributes of the product.
Offer opportunities for rigorous (hard) testing.
Often best for milestones and integration.
FOCUSED VS. COMPREHENSIVE PROTOTYPES
PROTOTYPING STRATEGY
Use prototypes to reduce uncertainty.
Make models with a defined purpose.
Consider multiple forms of prototypes.
Choose the timing of prototype cycles. Many early models are used to validate concepts.
Relatively few comprehensive models are necessary to test integration.
Plan time to learn from prototype cycles. Avoid the “hardware swamp”.
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PROTOTYPE TECHNOLOGIES
Traditional prototyping methods
CNC machining
Rubber molding
3D computer modeling (virtualprototyping)
Fit and assembly
Manufacturability
Form and style
Kinematics
Finite element analysis (stress, thermal)
Crash testing.
Free-form fabrication
Stereo-lithography
Using various materials including wax, resin, paper,
ceramics, and metals.
Lamination
Using paper cut, lay by layer
Rapid prototyping
Laser curing (solidifying) soft materials such as resin, layer by layer
3D printingA. DAMA SCIENCE & TECHNOLOGICALUNIVERSITY 16

THE APPLICATION OF COMPUTERS FOR PRODUCT DESIGN
l. Geometric modeling: In computer-aided design, geometric modeling is
concerned with the computer compatible mathematical description of the geometry of an
object.
The mathematical description allows the image of the object to be displayed and
manipulated on a graphics terminal through signals from the CPU of the CAD system.
2.Engineering analysis: In the formulation of nearly any engineering design project,
some type of analysis isrequired.
The analysis may involve stress-strain calculations, heat-transfer computations, or the use of
differential equations to describe the dynamic behavior of the system being designed.
3.Design review and evaluation: Checking the accuracy of the design can be accomplished
conveniently on the graphics terminal.
Semiautomatic dimensioning and tolerance routines which assign size specifications to
surfaces indicated by the user help to reduce the possibility of dimensioning errors.
4.Automated drafting: creation of hard-copy engineering drawings directly from the CAD
data base. Indeed, CAD systems can increase productivity in the drafting function by
roughly five times over manual drafting.
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MODELING TOOLS
Sketching- The first step in creating many 3-D features is sketching a 2-D section.
Creating Parts-As the features are added the geometry of the part is enhanced.
Building Assemblies-Solid modelers can put two or more parts together in an assembly.
Documenting Designs-communicating it in a medium other than the computer monitor’s display.
export designs to other applications for analysis, manufacturing, and other forms of post-processing.
DRAWING INTERCHANGE FILES
It is necessary to export CAD data to other packages like analysis, CNC programming or other
CAD packages. One way of doing it is using neutral files STEP, IGES or DXF files.
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ADDITIVE MANUFACTURING (AM)
Additive manufacturing (AM) is the industrial production name for 3D printing, a
computer controlled process that creates three dimensional objects by depositing
materials, usually in layers.
3D printing is one form of AM. “Additive manufacturing uses data computer-aided-
design (CAD) software or 3D object scanners to direct hardware to deposit material,
layer upon layer, in precise geometric shapes. As its name implies, additive
manufacturing adds material to create an object.
Types of Additive ManufacturingProcess.
Photo-polymerization is probably one of the more visually interesting additive
manufacturing methods.
Powder Bed Fusion.
Binder Jetting (3D Printing).
Material Jetting.
Sheet Lamination.
Material Extrusion.
Directed Energy Deposition.
Creativity Comes Next.
Wire Arc AdditiveManufacturing.
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In fact, having creative freedom without worrying about cost or time penalties is
one of the primary advantages of additive manufacturing. In traditional
manufacturing, modifying a design during production can lead to significant cost
increases or time delays as tooling on a production line is changed out.
Disadvantages of AdditiveManufacturing
Currently, additively manufactured parts may require a low-temperature assembly
process, due to the range of materials currently available.
Materials. Three types of materials can be used in additive manufacturing:
polymers, ceramics and metals. All seven individual AM processes, cover the use of
these materials, although polymers are most commonly used and some additive
techniques lend themselves towards the use of certain materials over others.
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There are five industries in particular where the amazing capabilities of additive
manufacturing have transformed production:
Aerospace. Aerospace companies were some of the first to adopt additive manufacturing.
Medical.
Transportation.
Energy.
Consumer Products.
Why You Need an Additive Manufacturing Strategy. Implemented properly, additive
manufacturing can significantly reduce material waste, reduce the amount of production
steps, inventory being held, and reduce the amount of distinct parts needed for an assembly.
Between the terms 3D printing and additive manufacturing, there is no difference. 3D
printing and additive manufacturing are synonyms for the same process.
In other words, 3D printing/additive manufacturing is the process, and rapid prototyping is
the end result. When it comes to using 3D printing for manufacturing, a 3D printer will only
use the material that passes through the extruder of the printer and that is used for the
assembly of the product. In comparison to injection–molds, often there is a requirement to
use additional materials to fill the molds.
Reduced Costs: Even though the initial setup costs are higher, 3D printing has become
cheaper than cheap labor in third world countries. Furthermore, the costs of customized
products are the same for mass production products.
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How does additive manufacturing work?
What is additive manufacturing? Additive manufacturing is the process of creating an object
By building it one layer at a time. It is the opposite of subtractive manufacturing,
in which an object is created by cutting away at a solid block of material until the final
product is complete.
What are the advantages of additive manufacturing?
In fact, having creative freedom without worrying about cost or time penalties is one of the
primary advantages of additive manufacturing. In traditional manufacturing, modifying a
design during production can lead to significant cost increases or time delays as tooling on
a production line is changedout.
Where is additive manufacturing used?
Applications for metal Additive Manufacturing technology From prototyping and tooling
to direct part manufacturing in industrial sectors such as architectural, medical, dental,
aerospace, automotive, furniture and jewellery, new and innovative applications are
constantly being developed.
What is the additive manufacturing process?
Additive Manufacturing refers to a process by which digital 3D design data is used to build
up a component in layers by depositing material.
The term "3D printing" is increasingly used as a synonym for Additive Manufacturing.
Additive Manufacturing is now being used increasingly in Series Production.
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What materials can be used in 3d printing?
What are the materials used to print 3D objects? Many different materials can be used for 3D printing,
such as ABS plastic, PLA, polyamide (nylon), glass filled polyamide, stereolithography materials
(epoxy resins), silver, titanium, steel, wax, photopolymers and polycarbonate.
The cheapest material for 3D printing is, of course, plastic filament. Following that are resins and
powders, which are rather similar in terms of prices. And finally, there are metal powders, which are
generally the most expensive.
Common 3D Printing Materials
Poly Lactic Acid (PLA) Filament has become one of the most common materials for 3D printing because
it is easy to print, biodegradable and bio-derived from corn and other biomaterials.
Acrylonitrile Butadiene Styrene (ABS) Filament is another common 3D printing filament.
Many different materials can be used for 3D printing, such as ABS plastic, PLA, polyamide (nylon),
glass filled polyamide, stereo-lithography materials (epoxy resins), silver, titanium, steel, wax,
photopolymers and polycarbonate.
Why is 3d printing filament so expensive?
The price of filaments for 3D printer is such a expensive, because of the raw material and equipment
costs are nowhere near the whole picture. It requires good process control, good equipment, and fairly
smart and knowledgeable people to monitor and operate the equipment.
Polycarbonate is the undisputed king of materials for desktop 3D printing. Even we were surprised at
polycarbonate's strength. In comparison to nylon at 7,000 psi, polycarbonate's tensile strength of 9,800 psi
makes it the ideal choice for high-strength, functional components.
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.
What is Rapid Prototyping?
Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or
assembly using three-dimensional computer aided design (CAD) data. Construction of the part or
assembly is usually done using 3D printing or "additive layer manufacturing" technology.
Rapid prototyping (RP) includes a variety of manufacturing technologies, although most utilise layered
additive manufacturing. While additive manufacturing is the most common RP process, other more
conventional processes can also be used to create prototypes.
In manufacturing, rapid prototyping is used to create a three-dimensional model of a part or product. In
addition to providing 3-D visualization for digitally rendered items, rapid prototyping can be used to
test the efficiency of a part or product design before it is manufactured in larger quantities.
Types of rapid prototyping techniques
Stereolithography (SLA)
Selective laser sintering (SLS)
Direct metal laser sintering(DMLS)
Fused Deposition Modelling (FDM)
Binder jetting.
Poly jetting.
The cost depends on a number of factors, including volume or size of the part or parts being created, the
surface finish, the materials used and how much post manufacture processing is required.
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One of the most important additive manufacturing technologies currently available. The
first ever commercial RP systems were resin-based systems commonly called stereo-
lithography or SLA.
The resin is a liquid photosensitive polymer that cures or hardens Stereo-lithography when
exposed to ultraviolet radiation.
This technique involves the curing or solidification of a liquid photosensitive polymer
through the use of the irradiation light source.
The source supplies the energy that is needed to induce a chemical reaction
(curing reaction), bonding large no of small molecules and forming a highly cross-linked
polymer
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Materials for FDM
The most popular material is the ABS-plus material, which can be used on all current
Stratasys FDM machines.
I Some machines also have an option for ABS blended with Polycarbonate.
Note that FDM works best with polymers that are amorphous in nature rather than the
highly crystalline polymers.
I This is because the polymers that work best are those that are extruded in a viscous paste
rather than in a lower viscosity form.
I As in amorphous polymers, there is no distinct melting point and the material increasingly
softens and viscosity lowers with increasing temperature.
I The viscosity at which these amorphous polymers can be extruded under pressure is high
enough that their shape will be largely maintained after extrusion, maintaining the
extrusion shape and enabling them to solidify quickly and easily.
Limitations of FDM
Sharp features or corners not possible to get;
I Part strength is weak perpendicular to build axis;
I More area in slices requires longer build times;
I Temperature fluctuations during production could lead to delamination
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Layer thickness: nearly 0.1 mm thick;
The part building takes place inside an enclosed chamber filled with nitrogen gas to
minimize oxidation and degradation of the powdered material;
The powder in the building platform is maintained at an elevated temperature just below
the melting point and/or glass transition temperature of the powdered material;
Infrared heaters are used to maintain an elevated temperature around the part being
formed; A focused CO2 laser beam is moved on the bed in such a way that it thermally
fuses the material to form the slice cross-section;
Surrounding powders remain loose and serve as support for subsequent layers.
Advantages vs. disadvantages ofSLS
Advantages 1) A distinct advantage of the SLS process is that because it is fully self-
supporting 2) Parts possess high strength and stiffness 3) Good chemical resistance 4)
Various finishing possibilities (e.g., metallization, stove enameling, vibratory grinding, tub
coloring, bonding, powder, coating, flocking) 5) Complex parts with interior components,
channels, can be built without trapping the material inside. 6) Fastest additive
manufacturing process.
Disadvantages SLS printed parts have surface porosity. Such porosity can be sealed by
applying sealant such as cyanoacrylate. It is the processes of extracting knowledge or
design information from anything man-made and reproducing it or reproducing anything
based on the extractedinformation.
.
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