Product Design and Development, MME2259a
Fall 2012
Prof. Paul M. Kurowski, Ph.D., P.Eng.
Department of Mechanical and Materials Engineering
Western University
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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/2012
http://www.eng.uwo.ca/designcentre
http://www.eng.uwo.ca/mechanical/undergrad/curre
nt/course_outlines.htm
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LAB SCHEDULE
Sep. 11, Sep.13
Laboratory:
Lab. Homework:
Problem Statement
QFD; Design Specifications
Sep. 18, Sep. 20
Laboratory:
Lab. Homework:
Product Design Specifications, Program Plan
Planning and Scheduling the Project
Sep. 25, Sep. 27
Laboratory:
Lab. Homework:
Design Review Meeting # 1
Concept Generation and Evaluation
Oct. 2, Oct. 4
Laboratory:
Lab. Homework:
Concept Generation and Evaluation
Concept Generation and Evaluation
Oct. 9, Oct. 11
Laboratory:
none (Thanksgiving Holiday)
Lab. Homework:
Preparation for Design Review # 2
Oct. 16, Oct. 18
Laboratory
Lab. Homework
Design Review Meeting # 2
Detailed Design
Oct. 23, Oct. 25
Laboratory:
Lab. Homework:
Detail Design
Detail Design
Oct. 30, Nov. 1
Laboratory:
Lab. Homework:
Detail Design
Detail Design
Nov. 6 Nov. 8
Laboratory:
Lab. Homework:
Detail Design
Detail Design
Nov. 13, Nov. 15
Laboratory:
Lab. Homework:
Design Review Meeting # 3
Detail Design
Nov. 20, Nov. 22
Laboratory:
Lab. Homework:
Detail Design, Design Simulation
Detail Design, Design Simulation
Nov. 27, Dec. 29
Laboratory:
Lab. Homework:
Detail Design, Design Simulation
Detail Design, Design Simulation
Dec. 4, Dec. 6
Laboratory:
Lab. Homework
Final presentations
none
Notes
The final design report, Product Development File (PDF) binder and the individual design notebooks are due on the last day of classes.
The above schedule and topics are subject to adjustments and changes as needed.
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MARKING
Individual marks
Two individual assignments (5% each)
10%
Oct 1st, 2012, Nov. 19th, 2012
Midterm examination
20% Nov. 6th, 2012
Final examination (limited open book)
50%
Fall examination session
Team marks
Individual Design Notebook
Final report and Product Data File
Design presentations (1% each)
5%
12%
3%
Successful completion of the Certified SolidWorks Associate (CSWA) exam will count as a bonus
assignment worth 5%.
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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.
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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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CSWA
http://www.sdcpublications.com/Textbooks/Official-Certified-SolidWorks-Associate-Examination/ISBN/978-1-58503-656-1/
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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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truss.SLDPRT
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sheet.SLDPRT
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HOMEWORK
•
Form design teams - 4 people
•
Buy design notebook and bring it to the lab next week
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Think about your design project, we’ll decide next week in the lab
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Install SolidWorks 2012
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SOLIDWORKS INSTALLATION
To install SolidWorks go to: www.solidworks.com/SEK
Use SEK-ID = XSEK12
Ask Maryam Refan (mrefan@uwo.ca) for serial number for
activation
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Sample projects
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Boat cargo crane
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A davit (dāv'ĭt, dā'vĭt) is a
structure, usually made of steel,
which is used to lower things over
an edge of a long drop off such as
lowering a maintenance trapeze
down a building or launching a
lifeboat over the side of a ship.
Davit holding a rescue boat
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Railway tricycle
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Hand cart
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Hand cart
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Wheelbarrow
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Boat trailer
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Pedal kart – 4 wheeler
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Pedal kart – 3 wheeler
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Car turntable
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Log splitter
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Utility trailer
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Engine hoist
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Engine stand
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Transmission jack
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Mechanics creeper
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Bicycle rack
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Towing attachment
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Where to look for project ideas?
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