1

PDB 41103

Advanced Product Design

(PDE7)

2

Course Objectives

• To study how Computer Aided Engineering is used as a tool for engineering design and analysis.

• To study the business and social/ethics context for developing products

3

Assessment

Test 20%

Assignments 20%

Project 30%

Final Exam (Theory) 30%

100%

4

Apply your Final Year project in this course

Consider Manufacturability and Value Engineering early in the design phase.

The Project is assessed for economy of costs, simplicity of manufacture and reliability.

Project

5

Review of Design Process

6

The Design Process

Problem Definition

“If we know the problem, we can (may) find a solution”

Clarification of the task, which involves collecting information about the design requirements and the constraints on the design, and describing these in a specification or criteria

7

Gathering Customer Needs

• Interview• Focus groups• Surveys• Observation

• Library/Online• Existing Products• Experts

• Prior Experience

From the Custome

r

Through Research

From the Design Team

The Design ProcessRecognition of a needDefinition of the problemGathering Information

8

Conceptualization

- Creativity

-Intuition-Brainstorm-Lateral thinking

using ingenuity, experience, and knowledge to work out a preliminary concept of what the design should look like, which involves establishment of the functions to be included in the design, and identification and development of suitable solutions.

The Design Process

9

Feasibility Assessment

To ensure that the project proceeds into the design phase on a basis of a concept that is achievable, both technically and within cost constrains, and that new technology is required only in those areas that have been thoroughly examined and agreed to.

Feasibility assessment period is the time for defining the concept enough that design can proceed with confidence that the end product will accomplish the intended purpose with available resources.

The Design Process

10

Establishing the PDSThis is the most important elements in the design process because it will set up the Principle Guidelines for the overall design, including: -parameters to define product functionality and performance - product reliability- manufacturability- maintainability- availability- testability- etc“If we know the problem, if we can define the problem, we can (may) find a solution”

The Design Process

11

Establishing the PDSThe design requirements need to be specific. Although requirements are established to be permanent and inviolate, they should nevertheless be continuously reviewed and revalidated during the design process, at least until the design is frozen, to ensure that they continue to reflect the goals and objects of the project.

Sample of PDS:Geometry: size, dimension, tolerance for system and each partsFunction: material, structural stiffness, strength, and deformationManufacturing: process, quality, metrologyCost: manufacturing, assembly, total product development, etc.

The Design Process

12

- Preliminary designOverall system configuration is defined, a schematic, diagram, layout, definition drawing, or other engineering documentation will be developed to provide early project configuration control and to assist in ensuring interdisciplinary and intra-disciplinary integration and coordination during the detail design phase.

The Design Process

13

Detailed designDevelopment of a system and specifications that completely describes a proven and tested design so that it can be manufactured. It is during the detailed design phase that the project gets fully underway

The Design Process

14

Synthesis- a search for solutions. At this stage, the information required for the proposed conceptualization is organized and plan is devised for achieving that particular design. To achieve a profitable synthesis decision, all the elements affecting the design, including product design, cost, and labor, must be considered.

The Design Process

15

-Analysis/optimization- mathematical and experimental testing of the design to make sure it meets the criteria set forth in the problem definition. The design problem is broken into categories, such as stress analysis, vibration, fluid mechanics, and mechanism .In each category, the design as a whole or parts are tested for the ability to serve their particular function.

The Design Process

16

Questions in Synthesis and Analysis How do you make the design decision

-Is this a good design?-Why this design is better

than others?-Is my decision rational?-Can it be made?-How many design

parameters do I need to satisfy the function requirements?

The Design Process

17

Manufacturing

- detail design are defined in which the dimensions, tolerances, materials and form of individual components of the design are specified in detail and pass to manufacture department to make the product.

The Design Process

The Mechanical Design Process; D.G. Ullman

Factors influencing Success or Failure of a Product

Product Function

Sales Related

Production & Product

cost

Product Design

Business

Production

The Mechanical Design Process; D.G. Ullman

Factors influencing Success or Failure of a Product

Product Function

Sales Related

Production & Product

cost

Product Design

Business

Production

MaterialsManufacturing

Process

Facilities

Product form

Target market

Product promotion

Price

Cost/Risk

Planning/ Scheduling

Distribution Coverage

PROCESS BY WHICH DESIGN IS ACCOMPLISHED

1. ESTABLISH ALL CONSTRAINTS.– Safety

– Quality

– Environmental

– Economic– Market Requirements– Etc.

2. ESTABLISH A SET OF SPECIFICATIONS.

3. DEVELOP A DESIGN CONCEPT.

4. USE MATHEMATICAL AND PHYSICAL MODELS TO TEST THE DESIGN CONCEPT.

5. PHYSICAL MODELS DESIGNED AND EVALUATED.

6. COMPARISONS ARE MADE TO DETERMINE THE "DEGREE OF ACCEPTABILITY" OF EACH DESIGN.

7. PRODUCT OPTIMIZED.

8. DRAW CONCLUSIONS AS TO THE DEGREE TO WHICH THE DESIGN SATISFIES THE SPECIFICATIONS.

PROCESS BY WHICH DESIGN IS ACCOMPLISHED