Lecture 01

Introduction to Engineering Design,

Manufacturing, and Assembly
Introduction
Corrado Poli
Mechanical and Industrial Engineering
UMass Amherst
Fall 2001

Present Situation

Conception of an idea
Design
Engineer
Analyze
Detail
Material specification
Tool/Process Design
Production
Conception of an Idea
- Most Common Sources -
Feedback from customers - who buy, sell,
repair, or use the companys products.
Factory, shop, and office employees.
New technology.
From this go to
Industrial (Product) Design - with artistic
renderings and non-functional models
Design, Engineer, Analyze, Detail
All overlap
Engineering design (overlaps product
design) subdivided into
- conceptual design
- configuration design of parts,
- parametric design,
- detail design
Engineered
Configuration Design
Standard parts
- type of pump (reciprocating, centrifugal,etc.)
- type of spring (helical, leaf, beam, etc.)
- Gear, chain, or belt, etc
Special purpose parts
- geometric configuration (box shaped, flat, I-
beam, channel section, etc.)
- presence and location of features (holes,
ribs, bosses, etc.)
Parametric Design
Add dimensions and tolerances to features
Specify material (maybe)

Detailed Stage
Rest of dimensions and tolerances needed
for manufacturing
Production Design
Overlaps with detail design
Design of tooling
Planning manufacturing process
Planning for QC
Ramping up for production
Problems with Sequential Mode
Old habits are hard to break.
Sequential mode of operation indicated here
still the predominant mode.
Decisions made early have great effect on
subsequent stages.
No single person in charge.
Each group blames the other => process
goes out of control.
One Possible Solution




Involve Everyone (Team Approach)- from
beginning to end.
Team in charge of product from cradle to grave.
Product and process design done simultaneously.
Team
Product Design
Process Design
Production Control
Marketing
Production
Shipping
Make Designers Manufacturing
Literate
Goal 1- Learn how parts are manufactured!


Goal 2 - Recognize costly to produce
features (cost drivers) so they can be
avoided!

Turning
Facing
Boring
Planning
Milling
Drilling
EDM
etc
Machining
Sand
Shell Mold
Plaster Mold
Ceramic Mold
Investment
Die
etc
Casting
Rolling
Drawing
Extrusion
Forging
etc
Bulk Deformation
Stamping
Drawing
Spinning
Stretching
Bending
etc
Local Deformation
Extrusion
Injection Molding
Compression Molding
Transfer Molding
Blow Molding
etc
Polymer Processing
Powder Metallurgy
Ceramic Processing
etc
Others
Welding
Brazing
Soldering
etc
Assembly
Manufacturing Processes
Which Process to Emphasize?
Lets look at some assembly drawings
created by various students as part of a
course project.

Parts
Most of these assemblies consist of
- Standard Parts
- Special Purpose Parts
Most special purpose parts are
Thin walled
Produced by
Die Casting Stamping Injection Molding
Other Important Processes
Machining (molds need to be machined)
Drawing (wire, rods, etc.)
Extrusion (long parts with constant cross-
section)
Rolling
Forging
Other casting processes (investment, sand,
etc.)