ENGINEERING DESIGN

1.1 INTRODUCTION
1.2 ENGINEERING DESIGN PROCESS
1.2.1 IMPORTANCE OF THE ENGNEERING DESIGN PROCESS
1.2.2 TYPES OF DESIGN
1.3 WAY 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
 ENGINEERING DESIGN
1.1 INTRODUCTION
a. What is design?

- Webster’s dictionary says that to design is “to fashion after a plan,”

To design is:
Synthesize together something new or to arrange existing things in
a new way to satisfy a recognized need of society.
- Good design requires both analysis and synthesis.
 ENGINEERING DESIGN
1.1 INTRODUCTION
a. What is 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.
 ENGINEERING DESIGN
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
 ENGINEERING DESIGN

- Compromise:
Requires balancing multiple and sometimes conlicting
requirements
 ENGINEERING DESIGN
1.2 ENGINEERING DESIGN PROCESS
1.2.1 IMPORTANCE OF THE ENGNEERING DESIGN PROCESS

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 .
You cannot compensate in manufacturing for defects introduced in
the design phase .
The design process should be conducted so as to develop quality,
cost-competitive products in the shortest time possible .
1.2.1 IMPORTANCE OF THE ENGNEERING DESIGN PROCESS
 ENGINEERING DESIGN
1.2.2 TYPES OF DESIGN

- Original design , also called innovative design

- Adaptive design
- Redesign
- Selection design
- Industrial design
 ENGINEERING DESIGN
1.3 WAY TO THINK ABOUT THE ENGINEERING DESIGN PROCESS
1.3.1 A SIMPLIFIED ITERATION MODEL
 ENGINEERING DESIGN
1.3.2 DESIGN METHOD VERSUS SCIENTIFIC METHOD
 ENGINEERING DESIGN

1.3.3 A PROBLEM- SOLVING METHODOLOGY

Definition of the problem

Gathering of information
Generation of alternative solutions
Evaluation of alternatives and decision making
Communication of the results
 1.4 CONSIDERATIONS OF A GOOD DESIGN

Achievement of Performance Requirements

1.4.1

Total Life Cycle

1.4.2

Regulatory and Social Issues

1.4.3
1.4.1 Achievement of Performance
Requirements

primary performance
requirements
Performance
Requirements
complementary
performance
requirements
1.4.1 Achievement of Performance
Requirements
Design may be required to grasp an object of a
certain mass and move it 50 feet in one minute

Functional/primary Complementary
performance performance
requirements requirements

Forces, strength, deflection, Reliability, ease, economy, and

or energy or power output or safety of maintenance, noise
consumption level
1.4.1 Achievement of Performance Requirements

TOOL
computer

Computer Aided
Finite Element Method
Engineering CAE

Calculations of stress, temperature,

and other field-dependent variables When these analytical methods
can be made rather handily for are coupled with interactive
complex geometry and loading computer graphics
conditions
 1.4.1 Achievement of Performance Requirements

Achievement Performance
Requirements

Manufacturing
technology
must be
Environmental Aesthetic closely human factors cost
requirements requirements integrated engineering
with product
design
1.4.1 Achievement of Performance Requirements

Environmental
requirements

service green
conditions design

extremes of temperature, humidity,

corrosive conditions, dirt, vibration, maintaining a safe and clean
and noise, must be predicted and environment
allowed for in the design
1.4.1 Achievement of Performance Requirements

Aesthetic Shape, Color, surface texture

factors as balance, unity, and interest
requirements

human muscle power and response times

human factors
engineering
restrictions on the manufacturing
Manufacturing processes
technology
product development cost, initial product
cost, life cycle product cost, tooling cost,
cost and return on investment
 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 trade-off
the total life cycle

first step is evaluation

of the service minimum cost
conditions

Next, the properties of

materials that relate
maximum
most directly to the
durability
service requirements
must be determined
 1.4.2 Total Life Cycle
Material selection : Fatigue, creep (nhão), toughness (dai), ductility (tính mềm, dễ
uốn), and corrosion resistance (khả năng chống ăn mòn) có thể phải được xem
xét.
Energy costs: 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.
 1.4.3 Regulatory and Social Issues

• ASTM
• ASME
• Occupational Safety and Health
Administration (OSHA)
• Consumer Product Safety Commission (CPSC)
• Environmental Protection Agency (EPA)
• Department of Homeland Security (DHS)
 1.5 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

 1.5 DESCRIPTION OF DESIGN PROCESS
Figure 1.7 shows the various activities that make up the first three phases
of design: conceptual design, embodiment design, and detail design
 1.5.1 Phase I. Conceptual Design

The process by which the design is initiated.

Creating a number of possible solutions.
Sometimes called the feasibility study.
There are 7 types of discrete activities that we consider under conceptual
design:
+ Identification of customer needs
+ Problem definition
+ Gathering information
+ Conceptualization
+ Concept selection
+ Refinement of the PDS
+ Design review
 1.5.2 Phase II. Embodiment Design

This design phase that decisions are made on strength, material

selection, size, shape, and spatial compatibility
This design phase is sometimes called preliminary design
Embodiment design is concerned with three major tasks:
+ Product architecture
+ Configuration design of parts and components
+ Parametric design of parts
 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.
-In the detail design phase the following activities are completed and
documents are prepared:
+ Detailed engineering drawings.
+ Verification testing of prototypes.
+ Assembly drawings and assembly instructions.
+ A detailed product specification.
+ Decisions
+ Preceding information
+ Design review
 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.
-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
+ 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.
 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.
- A system of warehouses for distributing the product may have to be
designed
- The economic success of the design often depends on the skill exercised in
marketing the product. (*)
 1.5.6 Phase VI. Planning for Use
- The use of the product by the consumer is all-important, The following
specific topics can be identified as being important user-oriented concerns
in the design process: ease of maintenance, durability, reliability, product
safety, con-venience in use (human factors engineering), aesthetic appeal,
and economy of op-eration.
- Phase VI of design is becoming increasingly important with the growing
concerns for consumer protection and product safety.
- 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 (*). 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
- formal area of study called industrial ecology. Design for the environment,
also called green design, has become an important consideration in design.
As a result, the design of a product should include a plan for either its
disposal in an environmentally safe way or, better, the recycling of its
materials or the remanufacture or reuse of its components.
 1.6. COMPUTER AIDED ENGINEERING

 Producing a major change in the way engineering design

is practed
 Greatest impact of CAE is in engineering drawing
 Making change and using part of old design in new
drawing
 Three-dimensional modeling has become prevalent
 Analysis, design optimization, simulation,
manufacturing
 The Ultimate computer simulation is vertual reality
 1.6. COMPUTER AIDED ENGINEERING

 The computer extends the designer’s capabilities in

several way.
 Make more complex task
 Analyze complex problems faster and more completely
 Share information sooner with the others
 The link between CAD and CAM is very important. By
using internet, these persons can be on different
continents ten time zones away
1.6. COMPUTER AIDED ENGINEERING
 1.6. COMPUTER AIDED ENGINEERING

 Spreadsheet application
 Quickly make multiple calculation
 Ability to automatically recaculate results
 Numerical analysis
EX: TK Solver, MathCAD, Eureka, Mathematica, Maple,
Malab.
 Matlab: user-friendly interface, propramable, excellent
graphics features, solving differential equations.
 1.7. DESIGNING TO CODES AND STANDARDS
 Making the best practice available to everyone, thereby
ensuring efficiency and safety.
 Promoting interchangeability and compatibility
 A code is a collection of laws and rules.
 A standard is a gererally agreed-upon set of procedure,
criteria, dimension, materials, or parts
 Standards refer to generalized situations
 Code tell engineering what to do and when and under
what circumstances to do it
 Standard tell engineering how to do.
 1.7. DESIGNING TO CODES AND STANDARDS

 Two broad form of codes: performance codes and

prescriptive codes.
• Performance codes: Terms of the specific requirement
that is expected to be achieved.
• Prescriptive codes: Terms of specific details and leave no
discretion to the designer. A form of code is government
regulations.
 1.7. DESIGNING TO CODES AND STANDARDS
 Three categories of standard: performance, test methods
and codes of practice.
• Test method standards set forth methods for mesuring
properties such as yield strength, thermal
conductivity…,published by the American Society for
Testing and Material (ASTM)
• Codes of practice: design of piping, heat exchanger,
pressure vessels, developed by the American Society of
Mechanical Engineers, American Nuclear Society
 Another important set of standards are government
(federal, state, and local) specification standards.
 1.7. DESIGNING TO CODES AND STANDARDS
 Three categories of standard: performance, test methods
and codes of practice.
• Test method standards set forth methods for mesuring
properties such as yield strength, thermal
conductivity…,published by the American Society for
Testing and Material (ASTM)
• Codes of practice: design of piping, heat exchanger,
pressure vessels, developed by the American Society of
Mechanical Engineers, American Nuclear Society
 Another important set of standards are government
(federal, state, and local) specification standards.
 1.7. DESIGNING TO CODES AND STANDARDS

 Engineering design process is concerned with balancing

four goals: Proper function, optimum performance,
adequate reliability and low cost.
 Group technology (GT): based on similarities in design in
geometrical shape or manufacturing process
 1.8. DESIGN REVIEW

 Vital aspect of design process.

• Provide an opportunity to ask critical questions and
exchange vital information
• Identifying problems with the design, determining future
courses of action, initiating action to correct any problem
areas
• Design, manufacturing, marketing, purchasing, quality
control, field service presentation.
 Shedule: conceptual, interim and final reviews.
 1.8. DESIGN REVIEW

 Two main aspects:

• Technical elements of the design
- Performance requirements, environment, product life,
quality, reliability, cost.
• Business aspects of the product
- Marketing and sales of product, maintaining time shedule
 1.8. DESIGN REVIEW

 REDESIGN

• Two categories: Fixes and updates

• Modification of an existing product to meet new
requirements.
 1.8. DESIGN REVIEW
 REDESIGN