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Engineering Design & The Design Process (Lecture #1)

Engineering Design & The Design Process

l Engineering Design l Design Process l Descriptive Design l Extended Design l Prescriptive Design l Methods in the Design Process l Design for X l Product Design and Development

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What is Computer Aided Engineering

Computer aided engineering is the performance of engineering tasks and functions with the aid of a computer. These tasks are still administrated and controlled by the engineer engineer. . CAE is a wellwell-estanlished field but it has been poorly formalized and very fragmented.

What is Computer Aided Engineering

CAE CAD covers the whole field of CAD & CAM involves computers in the design process deals with numerically controlled machine tools, automatic testing equipment and production control techniques. provides a link between design and manufacture

CAM

CIM

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Engineering Design
What is Design ? As many definitions as many there are designs because process of design is such a common human experience As per Websters Dictionary

To fashion after a plan

Is this definition complete? If Yes..What is missing in it.?

the essential fact that to design is to create something that has never been

Engineering Design
Engineering Designer, artist, sculptor, a composer, a playwright and other creative members practice design by this definition Professional practice of Engineering is concerned with Design

Then what is the Formal Definition of Design..? Design establishes and defines solutions to and pertinent structures for problems not solved before or new solutions to and which have previously been solved in a different way
Conclusion : Essence of Engineering is DESIGN

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Engineering Design
Ability to Design is both a Science and an Art Science Art Discovery : is learned through techniques and methods used : is best learned by doing design : is getting the first sight of, or first knowledge of something

We can discover what has already existed but has not been known before

Design should not be confused with Discovery Design is the product of Planning and Work
Invention:

Design may or may not involve invention as some are truly inventive but most are not

Engineering Design
What is a Good Design ?

Good design requires both Analysis and Synthesis

Analysis Decomposing problem into manageable parts
To understand performance/behavior of parts in service using appropriate discipline of science/engineering and computational tools Usually involves simplification of real world problems through models

Synthesis Identification of Design Elements that will comprise

Product Its decomposition into parts Combination of part solutions into a total workable system

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Engineering Design
What is a Real World Problem that you intend to design?
Rarely neat and defined May need many engineering (fluid, solid mechanics etc) and non-engineering discipline (economics, finance,, law etc) Input data may be best but out of the scope of the individual Constraints may be time, money, societal, environmental or energy regulations etc.

What is Final Design ?

Is it the best, most efficient. Only time will tell.!!!!! Rarely known the correct answer One is hopeful that His Design will Work

Engineering Design
Conclusion
Engineering Design extends beyond the boundaries of Science As Design Engineer during professional career you may have the opportunity
To create dozens of designs Have satisfaction of seeing them become working reality

As Scientist during professional career you may have the opportunity

To make one creative addition to human knowledge in your whole life and many never do so Can discover a new star but can not make one Have to ask an Engineer to do it for him

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Engineering Design
It is the systematic, intelligent generation and evaluation of specifications for artificats whose form and function achieve stated ojectives and satisfy specified constraints. Artifacts : human made objects Form : shape Function : the artifact is supposed to do Specification : precise description (fabrication spec.s= set of plans for making the designed artificat) (design spec.s = evaluation benchmarks)

Engineering Design
Engineering Design is the organized,
thoughtful development and testing of characteristics of new objects that have a particular configuration or perform some desired functions that meets our aims without violating any specified limitations.

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Engineering Design
Design Problems are a) OpenOpen-ended Because of having several acceptable solutions b) Illstructured Because their solutions can not normally be found by applying mathematical formulas or algorithms in a routine or structured way

The Design Process

Designers concerned with the products life cycle (purchase, support, use, and maintenance). Designers and manufacturing specialits work together, so that they are collectively and concurrently designing an artifact. It demands teamwork.
CONCURRENT ENGINEERING

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The Design Process

There are a lot of questions in simple design problem :

How is it to be used ? How much should it cost ? Is there a market for it ? Will it be made of steel, aluminum ? What is thje design load? Is the design economically feasible ? Is there a more efficient design ? And so on ...

The Design Process

Asking questions to elaborate the meaning of a clients statement is part of the design process. They can not be answered by applying usual mathematical models. There are not any equations to define the meaning of safe or marketability.

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The Design Process

Asking questions for solving them : Clarifying the objectives (color, cost) Establishing user requirements Identifying constraints Establishing functions Establishing design specifications Generating design alternatives Modeling / Analysing the design Testing & elavuating the design (test model) Refining & optimizing the design (optimize features) Documenting the completed design (fabrication specs)

The Design Process

Idea generation Feasibility study Product Yes Preliminary feasible? design No

Final design

Prototype

Process planning

Design & Manufacturing Specifications Manufacturing

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The Design Process (3(3-stages)

One of the simplest models of the design process highlights 3 3-stages. Generation : various concepts are generated. Evaluation : design is tested against the design goals. Communication : design is communicated to the manufacturers.

The Design Process (3 (3-stages) Descriptive = linear =

Synthesis Client Statement
Look for different concept schemes to achieve the clients objectives

Conceptual design
Several competing concepts

Analyses

Preliminary design
Final choise from among them

Detailed design

Final Design

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The Conceptual Design

Schemes is used as an outline solution having the spatial and structural relationship of the principle components. Estimating costs, weights and overall dimensins
Synthesis Client Statement

Conceptual design

Analyses

Preliminary design Final Design

Detailed design

OUTPUT several competing concepts

The Conceptual Design

The first creative stage of any design concepts such as the choice between gasoline or electric powered vehicles. The most important rule in conceptual design stage is to generate a few concepts and then select the best.
Synthesis Client Statement Conceptual design

Analyses

Preliminary design Final Design

Detailed design

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The Conceptual Design

Typically the hardest part of design so involves Brainstorming Functional decomposition Diagramming or Morphological charts
Synthesis

Concept Generation

Client Statement

Conceptual design

Analyses

Preliminary design Final Design

Detailed design

The Conceptual Design

Conceptual design Is design feasible ? yes no

s
no
Build/model/ simulate/prototype Will concept work?

Is there an unkown or vague component

yes
Add detail research discard design

no

yes
Acceptable concept Discard concept

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The Conceptual Design

DO NOT MARRY YOUR FIRST DESIGN IDEA !! No sufficient data to desicard any concepts.

The Descriptive Design Process

It is the embodiment of schemes. Design concepts with their most important attributes are embodied and endowed. Selection and sizing the major subsystems, based on lowerlower-level concerns
Synthesis Client Statement

Conceptual design

Analyses

Preliminary design Final Design

Detailed design

(taking into account the performance specifications and the operating requirements)

OUTPUT final choise from among them

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The Descriptive Design Process

Detailed Design : It is the third & final stage of the process with refining the choices down to down to specific part types and dimensions. Specific rules : formulas, algorithms
Synthesis Client Statement

Conceptual design

Analyses

Preliminary design Final Design

Detailed design

OUTPUT final design

R e f l e c t t h e d e s i g n e r s e x p e r i e n c e

The Design Process (5(5-stages)

The 33-stage model can be formally extended to a 5 5-stage model. It is a linear model. PrePre -processing : problem definition identifying the work done with the clients statementstatementPostPost -processing : design communication identifying the work done after detailed designdesign -

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The Design Process (5 (5-stages) Extended = linear =

Client Statement Problem Definition

Conceptual design

Preliminary design Detailed design

Fabrication specs & documentation

Design Communication

Final Design

The Design Process (5 (5-stages) Prescriptive

Clients statement : documented to the client 10 design tasks identified within the 55-stages. Problem definition : clarifying the objectives Output detailed objectives + contraints Conceptual design : generation of concepts Output scheme + design specifications Preliminary design : identification of the principal attributes. Output a selected design Detailed design : refinement and detailed definition Output final design review Design communication : documenting the fabrication specs. Output fabrication specifications

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The Design Process (5 (5-stages) Prescriptive

Client Statement
#5 establish design specs #6 generate alternatives #7 model / analyze design #8 test & evaluate design

Problem Definition

#1 clarify objectives #2 establish user reqir.s #3 identify contraints

Conceptual design

#4 establish functions

Preliminary design Detailed design

Fabrication specs & documentation

#9 refine & optimize design

#10 document design

Design Communication

Final Design

The Design Process (5(5-stages) Prescriptive =with feedback=

Two important elements in design are thinking and behaviour. The first of them is feedback feedback. . The other is iteration iteration. . 1st feedback loop (internal) internal) The results of performing the test and evaluation task are fed back into the preliminary design stage to verify that the design perfoms. 2nd feedback loop (external) external) User feedback provides validation for the design.

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The Design Process (5 (5-stages) Prescriptive with Feedback

Verification

Client Statement

Problem Definition
Validation

Conceptual design

Preliminary design

Product
Detailed design

Design Communication

Final Design

Methods In The Design Process

Problem Definition
Input Sources Tasks Methods Means Output : clients statement : codes & regualtions, experts : clarifying design objectives identifying constraints : objectives tree requirements matrix : brainstorming user survey & questionnaires : detailed objectives contraints functions

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Methods In The Design Process

Conceptual Design
Input Sources Tasks Methods Means Output : constraints & functions : competitive products : establishing design specs generating design alternative : performance specification method morphological chart : brainstorming reverse engineering : conceptual design design specification

Methods In The Design Process

Preliminary Design
Input Sources Tasks Methods Means Output : conceptual design : heuritics & simple models : model, test evaluate conceptual design : weighted objectives tree pairwise comparision chart : metric definition simulation & computer analysis : a selected design

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Methods In The Design Process

Detailed design
Input Sources Tasks Methods Means Output : selected design : design codes & handbooks : refine optimize the chosen design : discipline specific CADD : formal design reviews beta testing : proposed fabrication specs final design review

Methods In The Design Process

Design Communication
Input Sources Tasks Methods Means Output : fabrication specs : feedback from clients : document the completed design : N/A : N/A : final report 1- fabrication specs 2- justification for fabrication specs

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The Design Process

Computer analysis involves the development of a computer based model, which may consist simply of the equations relevant to describing the design, and application of various analytic, disciplinediscipline-based techniques. These include finite element analysis (FEA), integrated circuit modeling, failure mode analysis, criticality analysis.

The Design Process

Computer based models are used widely in all engineering disciplines and they become even more important as a design project moves into detailed design. Refering to such tools as discipline disciplinespecific CADD systems.

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The Design Process

Problem identification
(market analyst-design brief)

Specifications Concepts Layouts Drawings Product

Conceptual design
(Product designer)

Embodiment design
(Design Analyst)

Detail design
(Development & Research Engineer)

Manufacture
(Process Planner and Production Engineer)

Morphology of Design - (Seven phases of design)

1. Conceptual design 2. Embodiment design 3. Detail design 4. Planning for manufacture 5. Planning for distribution 6. Planning for use 7. Planning for retirement of product

Design Process
Define Problem
Problem statement Bench marking PDS, QFD Project planning

Gather Information
Internet, Patents Trade Literature

Concept Generation
Brainstorming Functional decomposition Morphological chart

Evaluation of Concepts
Pugh concept Selection Decision matrices

Conceptual design
Product Architecture
Arrangement of physical elements to carry out function

Configuration Design
Prelim. Selection of matls. & mnfg. Modeling & sizing of parts

Parametric Design
Robust design Tolerances Final dims. DFM

Detail Design
Detailed drawings & Specifications

Preliminary / Embodiment design

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Detail Design
By the use of concurrent engineering methods (Design for X), aided and abetted by CAE, the boundary between embodiment and detail design has become blurred.

Therefore;
It is no longer correct to say that detail design is the phase of design where all of dimensions, tolerances and details are finalized.

Detail Design
However; Detail design as name implies, is the phase where;
- all the details are brought together - all decisions are finalized - and a decision is made by the management to release the design for production

Poor detail design can ruin a brilliant design concept and lead to manufacturing defects, high costs, and poor reliability in service A brilliant detail design will not rescue a poor conceptual design

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Design For X
DFA DFM DFD DFI DFM DFML DFP DFQ DFR DFR DFR DFS DFS DFS DFT DFE DFESD DFEMC Design For Assembly Design For Manufacturability Design For Disassembly Design For Install ability Design For Maintainability Design For Material Logistics Design For Portability (Software) Design For Quality Design For Redesign Design For Reliability Design For Reuse Design For Safety Design For Simplicity Design For Speed Design For Test Design For Environment Design For Electrostatic Discharge Design For Electro-Magnetic Compatibility

Design For Manufacture & Assembly (DFMA)

Processes or procedures for integration of design and manufacture, with the goals of reducing manufacturing costs and improving product quality are termed as DFM. Associated with this for assembly is DFA.
DFM Guidelines

Minimizing total number of parts

Standardize components

Use common parts across product lines

Design parts to be multifunctional

Design parts for ease of fabrication

Avoid too tight tolerances

Avoid secondary operations

Utilize the special characteristics of processes

Assembly process consist of two parts

Handling -Manual -Automated - Robotic Insertion
Minimizing total number of parts Minimizing assembly surfaces

DFA Guidelines

Avoid separate fasteners

Minimize assembly direction

Maximize compliance in assembly

Minimize handling in assembly

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Design Process
Product Design
Consumer goods Appliances, missiles, jets, planes

Complex Engineering System

Electric power generating system Petrochemical plants Building/bridge design

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Importance of design process

Market development Conceptual design Product cost commitment during phases of design process Product use 70~80% = for Design commitment 25% = for manufacture 5% = for design 95% = for material, manufacture, labor, capital

Percentage of product cost commited

Functional design

Manufacturing
Cost incurred

Time (nonlinear)

Allocation of Resources

Traditional Traditional World World Class Class

Concept

Design

Manufacturing

Support

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Distribution Of Design Changes

Number of Design Changes Company 1 Company 2

90% of Total changes complete

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12 Months

Production begins

Design to Codes & Standards

Chief Aspects

Much designs are not very different from what has been done in the past

Makes the best practice available to everyone, ensuring efficiency and safety Promotes interchangeability and compatibility

CODE
Collection of laws and rules that assists a Government agency in meeting its obligation to protect the general welfare by preventing damage to property or injury or loss of life to persons
Tell the engineer what to do and when under what circumstances to do it Usually are legal requirements, e.g. building code, fire code etc. Often incorporate national standards into them by reference

STANDARD
A general agreed upon set of procedures, criteria, dimensions, materials and parts
Tell engineer how to do it Usually regarded as recommendations, that do not have force of law This way standards become legally enforceable

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Design to Codes & Standards

TYPES OF DESIGN STANDARDS
Performance Standards Published for many products - (For seat belts, auto crash safety etc.) Test Method Standards For measurement of properties - (Yield strength, thermal conductivity, sensitivity) Code Practice Provides detailed design methods for a repetitive technical problem (Design of piping, heat exchanger Pressure vessel etc. ASME, BS (PD))

STANDARDS PREPARATION
1. Individual companies for their own proprietary use 2. By group of companies of the same industrial sector 3. Government Specification Standards, as Govt. is the purchaser of large number of goods and services 4. Defense Product Standards

Design For X
A growing emphasis on Concurrent Engineering, as it involves cross-functional teams, parallel design and vendor partnering etc. A successful design must satisfy requirements functionality, appearance, and cost durability and reliability

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Product Design & Development

Product Design Specification (PDS)

A detailed document that describes what design must be in terms of performance requirements, environment in which it must operate, product life, cost, reliability and host of other design requirements Essence of Technical Review of design is to compare the finding against detailed PDS Basic reference document for both product design and design review

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ReRe-design
A common situation in Design Process As a result of Design Review, Details of design are changed many times as prototypes are developed and tested

(Old Design of railcar wheel Vs. improved deign)

Trends in Product Development

Increased variety, mass customization Increased focus on customer requirements Decreased product lifecycles Increased product complexity Decreased time to market More design by suppliers
Shrinking Product Lifetimes 1970s

1980s

1990s

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Role Of Design Engineer

No longer totally responsible for product design Responsible for more than what was traditionally considered design Merging of design engineer and manufacturing engineer

In this regard Design for Manufacture and Analysis (DFMA) is becoming increasingly important and will be discussed in later discussion

The Traditional Product Development Process

Customer requirements (sales and marketing) Conceptual design (Industrial designers) Detailed design and analysis (engineering)

Manufacturing

Distribution and Sales

Disposal (not our problem)

Support and Service

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The Design Process

Questions : 1. When would you be likely to use a descriptive model of the design process? When would you use a prescriptive model ? 2. Explain the differences between tasks, methods, and means? 3. Explain how a computer will help an engineering company in the design and manufacturing process ?

The Design Process

References : D.G. ULLMAN, The The Mechanical Design Process, Process, McGraw McGraw-Hill, 1997. C.L. DYM and P. LITTLE, Engineering Engineering Design: A Project Project-based Introduction Introduction, , John Wiley, 2000.

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