Product Design and Development, MME2259a
Fall 2011
Prof. Paul M. Kurowski, Ph.D., P.Eng.
Department of Mechanical and Materials Engineering
The University of Western Ontario
1
WHAT IS A DESIGN?
•
Design is the quest for simplicity and order.
•
Explicit in the term design are the concepts of order and
organization.
•
Design is the process of inventing artifacts that display a
new physical order, organization, and form in response
to function.
•
Design is a conscious and intuitive effort directed
toward the ordering of the functional, material, and visual
requirements of the problem.
•
Design is a statement of order and organization. Its goal
is unity. It must hold together. It is an expression of the
human ubiquitous quest for order.
•
Design implies intention, meaning, and purpose.
•
The planning and patterning of any act toward a desired,
foreseeable end constitutes the design process.
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DESIGN IS COOL
The notion of bringing something into being that
did not exist before, whether from scratch or on the
foundation of an existing design, is fascinating.
Could there be a headier pursuit than participating
in creation itself?
Machine Design August 7, 2008
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OBJECTIVE MME2259a
Considering that designing is creative activity, the objective of MME2259a is
to introduce design methodology and design tools (applicable to Mechanical
Engineering) which are used to execute this creative design process with the
objective of creating products that satisfy customers’ needs.
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OBJECTIVE MME2259a
Please download from our web page and read (CDEN2006)
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PROCESS OF DESIGN
Products that
Meet Need
Design Need
Paths of the Design Process
Design Knowledge
Manufacturing
Material Science
Kinematics
Physics
Electronics
Economics
Thermodynamics
Mechanics
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TYPES OF ENGINEERING DESIGN
(i)
Selection Design – choose item(s) from a catalog
(ii)
Configuration Design – organize the packaging of components
(iii)
Parametric Design – finding variables or parameters.
(iv)
Redesign, alternative design – modifying an existing product.
(v)
Original Design – develop a totally new product.
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SELECTION DESIGN
Given:
Shaft diameter
Speed
Radial force
20 mm
2000 rpm
6675 N (or 1500 lb)
Housing
Bearing
20 mm
6675 N
Shaft
Require:
To select an appropriate bearing.
Possible Solutions:
[Ullman 1992]
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SELECTION DESIGN
“Fundamentals of Engineering Design” Barry Hyman, Prentice Hall
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CONFIGURATION DESIGN
Computer components:
Keyboard
Mother
board
Extension slots
Floppy
drive
Power
supply
Possible configurations for a computer (in each case, the bottom of the sketch
represents the front of the computer).
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CONFIGURATION DESIGN
“Fundamentals of Engineering Design” Barry Hyman, Prentice Hall
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CONFIGURATION DESIGN
Configuration design
Selection and arrangement of components on a product
Selection and arrangement of features on a part
Factors in configuration design
Spatial limitations
Product interactions with other physical objects and the user(s)
Maintenance
Wear
Desired customization by the user
Need to include standard parts and assemblies
Need to conform to industrial standards
Need to replace consumable materials
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CONFIGURATION DESIGN
Design for function check list
Configuration alternatives can be
analyzed according to
Design for function
Strong
Stiff or flexible
Buckle resistant
Thermal expansion
Design for assembly
Vibration
Design for manufacture
Noise
Heat transfer
Fluids transport/storage
Energy efficient
Stable
Reliable
Human factors/ergonomics
Safe
Easy to use
Maintainable
Repairable
Durable
Life cycle cost
Styling/aesthetics
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PARAMETRIC DESIGN
Example:
Design a cylindrical storage tank that
holds 4 m3 of liquid.
l
Volume: V = p x r2 x l
thus
4=pxr2xl
1.273 = r 2 x l
2r
Note: There are an infinite number of values for (r, l); therefore more information is necessary.
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PARAMETRIC DESIGN
“Fundamentals of Engineering Design” Barry Hyman, Prentice Hall
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REDESIGN
1890 Humber bicycle
1990 Trimble bicycle
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ORIGINAL DESIGN ?
Boeing 787
www.elmundo.es
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ANALYSIS VS. DESIGN
Analysis Problem – a well defined problem with one correct solution.
Design Problem – an ill-defined problem with numerous satisfactory solutions.
Example:
The problem of designing a simple lap joint.
Analysis Problem –
What size of SAE Grade 5 bolt should be
used to fasten together two pieces of 1045
sheet steel, each 4 mm thick and 60 mm
wide, which are lapped over each other
and loaded with 100N ?
Design Problem –
Design a joint to fasten together two
pieces of 1045 sheet steel, each 4 mm
thick and 6 cm wide, which are lapped
over each other and loaded with 100N.
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ANALYSIS VS. DESIGN
SAE Specifications for Steel Bolts
http://www.americanfastener.com/technical/grade_markings_steel.asp
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MME2259a WEBPAGES
http://www.eng.uwo.ca/MME2259a/2011
http://www.eng.uwo.ca/designcentre
http://www.eng.uwo.ca/mechanical/undergrad/curre
nt/course_outlines.htm
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DESIGN PROJECT
The goal of the term project is to design a consumer product such as: log
splitter, wheelbarrow, utility trailer, boat trailer, towing hitch, bicycle hitch carrier,
car turntable etc. The selected project must allow the design team to use CAD
design techniques such as assemblies, weldments and sheet metal.
It also must allow the use of Motion Simulation. The choice of product will be
made by design team and will be approved by course instructor.
Each design team will:
 identify the need
 establish relevant design specifications
 generate and evaluate several concepts
 develop detailed design including engineering drawings
 develop design documentation
 use design simulation (limited to Motion Simulation) to investigate product
performance
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LAB SCHEDULE
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MARKING
Individual marks
Two individual assignments (7.5% each)
Final examination (closed book)
Team marks
Individual Design Notebook
Product Development File (PDF)
Final report
Design presentations (1% each)
Final presentation
15%
40%
9%
14%
14%
3%
5%
* Adjusted by team participation
5% bonus will be assigned to the final mark upon successful completion of
Certified SolidWorks Associate (CSWA) Exam
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TEAM WORK
MARK DISTRIBUTION
To make the grading process fair, each member of the design team will evaluate every member of the
group (including themselves) for the percent of his/her contribution to the project. These confidential
evaluations must be justified and supported by written commentary. The resultant evaluations will be
averaged to find each student's contribution and to determine the student’s individual grade.
For example, if there are four students in a group and each student makes an equal (25%)
contribution then all members will receive the same grade for the project. However, if the individual
contributions vary then the grades will be corrected by the difference from 25%. For example, if the
group mark for the project was 80% and student A makes a 40% contribution to the project then
his/her mark will be 95% (i.e. 80+(40 - 25)). Furthermore, if student B in the same group makes a
30% contribution then that student will be assigned a mark of 85%
(i.e. 80 + (30 - 25)). Finally, if students C and D make contributions of 20% and 10% then their
individual marks will be 75% and 65%, respectively. Note that the maximum possible mark for the
project is 100%.
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TEAM WORK
For example, if there are four students in a group and each student makes an equal (25%) contribution then all members will receive the same grade for the project.
However, if the individual contributions vary then the grades will be corrected by the difference from 25%. For example, if the group mark for the project was
80% and student A makes a 40% contribution to the project then his/her mark will be 95% (i.e. 80+(40 - 25)). Furthermore, if student B in the same group makes a
30% contribution then that student will be assigned a mark of 85% (i.e. 80+(30 - 25)). Finally, if students C and D make contributions of 20% and 10% then their
individual marks will be 75% and 65%, respectively. Note that the maximum possible mark for the project is 100%.
25
DESIGN PROCESS AND THE PRODUCT LIFE-CYCLE
Product Design
Manufacturing Process Design
Requirements Definition
Manufacturing System
Concept Development
Concept Development
Detailed Process
Design
Detailed
Product
Design
Prototype
QFD
Process FMEA
Simulation
QFD
Process FMEA
Taguchi
DFM
Validation Testing
Poke Yoke
Simulation
The extend of our
design project
Manufacturing
Service & Support
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TYPES OF ENGINEERING DESIGN - AGAIN
In our design project
focus will be on
selection design
(i)
Selection Design – choose item(s) from a catalog
(ii)
Configuration Design – organize the packaging of components
(iii)
Parametric Design – finding variables or parameters.
(iv)
Redesign, alternative design – modifying an existing product.
(v)
Original Design – develop a totally new product.
27
MME2259a vs ES1050
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COURSE PROGRESS
Lectures
Labs
SolidWorks
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CSWA EXAM - BONUS
https://www.virtualtester.com/solidworks/branding/user-portal/user-portal.html
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http://blogs.solidworks.com/teacher/2011/09/linking-undergraduate-engineeringcurriculum-around-solidworks.html
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HOMEWORK
•
Form design teams - 4 people
•
Buy design notebook and bring it to the lab next week
•
Think about your design project, we’ll decide next week in the lab
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DESIGN PROJECT
The goal of the term project is to design a consumer product such as: log
splitter, wheelbarrow, utility trailer, boat trailer, towing hitch, bicycle hitch carrier,
car turntable etc. The selected project must allow the design team to use CAD
design techniques such as assemblies, weldments and sheet metal.
It also must allow the use of Motion Simulation. The choice of product will be
made by design team and will be approved by course instructor.
Each design team will:
 identify the need
 establish relevant design specifications
 generate and evaluate several concepts
 develop detailed design including engineering drawings
 develop design documentation
 use design simulation (limited to Motion Simulation) to investigate product
performance
33
truss.SLDPRT
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sheet.SLDPRT
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NEW COMPUTER LABS
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NEW COMPUTER LABS
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NEW COMPUTER LABS
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