INTRODUCTION TO MECHANICAL ENGINEERING DESIGN (Extracted from ZAR)

Simply, design may be defined as to create something useful according to plan in structured steps leading to the desired result. The
something useful can be a process of devising a system, component, or process. It is an iterative decision making process in which basics
in science, mathematics and engineering are optimally applied.

Design tools, design criteria and design process

Students will be exposed to the design activity and process for understanding, creativity, innovativeness, decision making and utilization
of effective technological aids.
The design process steps is depicted in Figure 1.
Design Process:
1.

2.
3.

4.

5.
6.

7.

Identification of a need Problem recognition and definition

Market survey/analysis: Profit and economics:

Consumers needs
Information Search Data gathering

Past work
Criteria and Constraints Design requirements

Specified functions and Function structure

technical requirements geometry, kinematics,

forces, materials, assembly, maintainability,
ergonomics, recycling, etc

Economic factors, safety, reliability, aesthetics,

ethics, and social impacts
Concept generation Synthesis of configurations

Systematic techniques preliminary layouts

Creative ingenuity/ability form designs

Feasibility calculations
Alternative Solutions Evaluation of alternatives

Selection of optimum configuration

Manufacturing specifications

Selection of materials and dimensions

Optimization techniques

Complete form designs

Design Analysis and Experiment Comparison

8.

From A R Eide, R D Jenison, L H Mashaw, J L Northop,

Introduction to Enginering Design, MCGraw-Hill, International
Edition, Singapore, 1998

1. Identification of a need-start with broad or general leading to specific or start direct

to desired product [PO3]

2. Problem definition[PO1]

3. Search [PO10]
4. Constrains [PO1]
5. Criteria [PO1]

6. Alternative solutions-creativity, innovation[PO3]

7. Analysis-use of mathematics and science for performance of solution.[PO1]

Theoretical mathematical modeling

8. Decision [PO3]

Experimental mock-up, model, and prototype

Production

9. Specification

9.

Production drawings and production documents

10. Communication [PO7]

Detailed manufacturing instructions

Communication
Oral/Written-Graphics-internal & external: Format of written report-Cover page, Abstract, Table of contents, Body, and Conclusions
and Recommendations. Include Appendixes for further detail information so as not to
interrupt
write-up.
Figure
1 of
Steps
in design process
Oral presentation-Clarity, appropriate graphic displays etc. [Evaluation-content and subject knowledge, use of aids,

Summarize in 5 steps
1. Problem definition
2. Invention
3. Analysis
4. Decision
5. Implementation

Conceptual design-a product

Idea or concept is the initial or origin of the product. Airplane may come from observation of birds flying or a sailboat from a floating log.
The steps in conceptual design are given in Table 1.
Table1: Steps in Conceptual Design Phase
Step 1
Identify Problems
Problem Statement
Benchmarking
QFD
PDS

Step 2
Gather Information
References
Electronic Media
Internet

Step 3

Step 4

Generating concepts
Brainstorming
Functional decomposition
Morphological chart

Concept Evaluation
Pugh concept
Decision Matrix
Taguchi Method

Preliminary Design Phase: Table 2 depicts the preliminary design steps.

Table2 Preliminary design Steps
Step 1
Product architecture
Arrangement of physical elements to carry out function
Design for human factor

Step 2
Configuration design
Modeling
Simulation
Materials selection
DFM, DFA

Step 3
Parametric design
Robust design
FMEA
Final dimension

Detail Design

Final Phase- Detail design

Process after Embodiment design
85% of product process completed
Waiting for final decision to be manufactured

Stages in Detail Design

Detail design phase consist of several stages:
Detail drawings
Qualification prototype testing
Bill of Materials (BOM)
Decision on make/buy
Detailed the product specification
Detailed cost estimate
Final Design review
Release to manufacturing/ production
Example of process of design: Identification of needs.
The example cited here is how selection of concept from various alternatives of
heating of a kiln for curing timber based on a broad idea on energy.
The followings maybe some recorded statements related the kiln operation:
Firewood is not as commercially available as it used to be.
The price of firewood has risen significantly.
People are now more willing to cut and split their own firewood than they were previously.
The small, inexpensive chain saw has made the cutting portion of the task
more acceptable, but splitting the wood is still a major problem.
So there is need inexpensive supply of firewood.
The followings are alternatives of obtaining firewood supply:
Purchase firewood from supplier.
Purchase standing timber to be cut for firewood.
Purchase trees that have been cut or that have fallen.
Hire a portion of the work done.
Design improved equipment to facilitate portion of the process.

L
C

PRESSURE WEDGE
IDEA SKETCH #3
(c)

Figure 2 Different sketches of pressure wedge

Some sketches of pressure wedges are shown in Figure 2. The equipment

is to split the log. Notice the different concepts and methods used in the process.
However if one looks at the overall broad area of need, then, the supply
of energy will be the main focus.
A broad spectrum of means to obtain energy is depicts in Figure 3. As indicated
the main sources are from fossil fuel, wind, geothermal, solar, nuclear and organic.
The sub-sources are also displayed. Figure 3 provides plentiful of alternatives of obtaining
heat. It opens up avenues for development in specialist areas and invention of new devices.
It provides comprehensive information of energy procurement methods, that is, a decision
tree pertaining to energy.
To further illustrate decision making in design, alternatives to convert rotational motion
to linear motion are shown in Figure 4.
The idea on concept design and decision making illustrated in Figures 2, 3 and 4 will be briefly
discussed in the classroom.

Figure 3 Energy decision tree

Figure 4 Several means of converting rotational to linear motion

Program Outcomes (PO):

PO1

Ability to acquire and apply knowledge of science and engineering fundamentals

PO2

Ability to acquire in-depth technical competencies in a specific engineering discipline

PO3

Ability to undertake problem identification, formulation and solution.

PO4

Ability to utilize systems approach to design and evaluate operational performance.

PO5

Ability to undertake the principles of design for sustainable development.

PO6

Ability to practice professional and ethical responsibilities and commitment to them

PO7

Ability to communicate effectively with engineers and the community at large.

PO8

Ability to function effectively individually and in a group

PO9

Ability to undertake social, cultural, global and environmental responsibilities of a professional engineer.

PO10

Ability to recognize the need to undertake life-long learning, and possessing or acquiring the capacity to do so.

PO11

Ability to demonstrate managerial and entrepreneurial skills.

PO12

Ability to demonstrate leadership skills.