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Prof. Paul M. Kurowski, Ph.D., P.Eng.

Department of Mechanical and Materials EngineeringThe University of Western Ontario

Product Design and Development, MME2259a

Fall 2011

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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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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

DESIGN IS COOL

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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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Please download from our web page and read (CDEN2006)

OBJECTIVE MME2259a

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PROCESS OF DESIGN

Design Need Products that Meet Need

Paths of the Design Process

Design Knowledge

Manufacturing

Material ScienceEconomics

KinematicsThermodynamicsPhysics

Electronics

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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Given:

Shaft diameter 20 mm

Speed 2000 rpm

Radial force 6675 N (or 1500 lb)

Require:

To select an appropriate bearing.

Possible Solutions:

Bearing

Shaft

Housing

6675 N20 mm

[Ullman 1992]

SELECTION DESIGN

9“Fundamentals of Engineering Design” Barry Hyman, Prentice Hall

SELECTION DESIGN

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Computer components:

Possible configurations for a computer (in each case, the bottom of the sketch represents the front of the computer).

Keyboard Mother board

Extension slots Floppy drive

Power supply

CONFIGURATION DESIGN

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CONFIGURATION DESIGN

“Fundamentals of Engineering Design” Barry Hyman, Prentice Hall

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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

CONFIGURATION DESIGN

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Configuration alternatives can be

analyzed according to

Design for function

Design for assembly

Design for manufacture

CONFIGURATION DESIGN

Design for function check list

Strong

Stiff or flexible

Buckle resistant

Thermal expansion

Vibration

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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Example:

Design a cylindrical storage tank that

holds 4 m3 of liquid.

Volume: V = x r2 x l

thus 4 = x r 2 x l

1.273 = r 2 x l

Note: There are an infinite number of values for (r, l); therefore more information is necessary.

2r

l

PARAMETRIC DESIGN

15“Fundamentals of Engineering Design” Barry Hyman, Prentice Hall

PARAMETRIC DESIGN

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1890 Humber bicycle

1990 Trimble bicycle

REDESIGN

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Boeing 787

www.elmundo.es

ORIGINAL DESIGN ?

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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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SAE Specifications for Steel Bolts

http://www.americanfastener.com/technical/grade_markings_steel.asp

ANALYSIS VS. DESIGN

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http://www.eng.uwo.ca/MME2259a/2011

http://www.eng.uwo.ca/designcentre

http://www.eng.uwo.ca/mechanical/undergrad/current/course_outlines.htm

MME2259a WEBPAGES

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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

DESIGN PROJECT

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LAB SCHEDULE

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MARKING

Individual marks

Two individual assignments (7.5% each) 15%

Final examination (closed book) 40%

Team marks

Individual Design Notebook 9%

Product Development File (PDF) 14%

Final report 14%

Design presentations (1% each) 3%

Final presentation 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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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%.

TEAM WORK

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DESIGN PROCESS AND THE PRODUCT LIFE-CYCLE

QFD Process FMEATaguchiDFMValidation TestingPoke YokeSimulation

Requirements Definition

Concept Development

Manufacturing

Detailed Product Design

Prototype

Service & Support

Manufacturing System Concept Development

Detailed Process Design

QFD Process FMEASimulation

Product Design Manufacturing Process Design

The extend of our design project

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(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.

In our design project focus will be on selection design

TYPES OF ENGINEERING DESIGN - AGAIN

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MME2259a vs ES1050

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Lectures

Labs

SolidWorks

COURSE PROGRESS

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https://www.virtualtester.com/solidworks/branding/user-portal/user-portal.html

CSWA EXAM - BONUS

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http://blogs.solidworks.com/teacher/2011/09/linking-undergraduate-engineering-curriculum-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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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

DESIGN PROJECT

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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