Mechanical Design Problems & Process

Outline

Definition of Design Need for Mechanical design Product function, behavior and performance Types of Mechanical Design Problems Languages of Mechanical Design Summary

Design definition

Set of decision making processes and activities to determine the form of an object,

given the customers desired function.

Need for Mechanical Design

Before 20th century discipline of mechanical design required knowledge of only mechanical parts and assemblies Presently, now most devices are mechatronic systems have mechanical, electronic and software. E.g, Cameras, office copiers, cars and just about everything No matter, how electronic or computer-centric devices become, nearly all products require mechanical functions and a mechanical interface with humans Additionally, all products require mechanical machinery for manufacture and assembly and mechanical components for housing Thus, no matter how smart products become, there will always be the need for mechanical design

Decomposition of a system

A system is generally considered a grouping of objects that perform a specific function During the design process: the function of the system and its decomposition are considered first After the function has been decomposed into the finest subsystems possible, assemblies and components are developed to provide these functions For mechanical devices, the general decomposition is: system subsystem assembly component During the early phases of the design process, when developing systems is the focus of the effort, it is often unclear whether the actual function will be met by mechanical assemblies, electrical circuits, software programs or a mix of these elements

A Kodak Zoom camera

Example of a Mechatronic system Function: Record images Can be decomposed into: photographic system, exposure system and the shutter system (system view) Many different physical forms can accomplish the function of each system variety of cameras

The shutter assembly

Subsystem whose function is to control light coming through the lens Part of the exposure system that includes the light meter, the controller and the auto focus system Assembly of components in terms of the physical components or form of the camera (Assembly view)

Decomposition of design disciplines

Steps in the design process: 1. The function of the system and its decomposition are considered first 2. After the function has been decomposed into the finest subsystems possible, assemblies and components are developed to provide these functions Feature refers to specific attributes of systems, assemblies or components that are important, such as dimensions, material properties, shapes or functional details

Product function, behavior and performance

In mechanical Engineering, the terms function, operation and purpose are used to describe what a device does Mechanical devices are classified by their function. E.g., Screw driver whose function is to insert or remove a screw In telling the function of the screw driver, no information is given on how this function is achieved for this we need some information on the form of the device Form relates to any aspect of physical shape, geometry, construction, material or size Behavior and performance are also related to the function Performance is the measure of function and behavior how well the device does what it is designed to do Eg., of a cycle handlebar support 50kg is a measureable desired performance (specification)

Function and behavior subtle difference

Behavior can be simulated or measured, whereas function is only a desire

Types of Mechanical Design Problems

1. 2. 3. 4. 5.

For example, we might be designing a new type of consumer product that will accept a whole raw egg, break it, fry it, and deliver it on a plate. Since this is a new product, there will be a lot of original design work to be done. As the design process proceeds, we will configure the various parts. To determine the thickness of the frying surface we will analyze the heat conduction of the frying component, which is parametric design. And we will select a heating element and various fasteners to hold the components together. Further, if we are clever, we may be able to redesign an existing product to meet some or all of the requirements. It is rare to find a problem that is purely one type. So the following are the different types of design problems: Selection design Configuration design Parametric design Original design Redesign

Selection Design selecting a bearing to support a shaft

Involves choosing one item or more from a list of similar items choosing an item form a catalog; E.g. of choosing a cutting tool from the supplier catalog To solve a selection problem, we must start with a clear need The catalog then effectively generates potential solutions for the problem The potential solutions are evaluated with respect to specific requirements to make the right choice

Table 02_03

Configuration Design a slightly more complex type of design packaging design

All the components have been designed and the problem is how to assemble them into the completed product playing with an Erector set or construction toy or arranging living-room furniture Configuration design answers the questions How do we fit all the assemblies in an envelop? Or Where do we put what? Randomly select one component from the list and position it so that all the constraints on that assembly are met; then second component is selected and place if a conflict arises, we back up and try again

Parametric Design
Finding values for the features that characterize the object being studied Example of designing a cylindrical storage tank that must hold 4 m3 of liquid. This tank is described by the parameters r, its radius, and l, its length and its volume is determined by

Original Design
Any time the design problem requires the development of a process, assembly, or component not previously in existence it calls for an original design. It can be said that if we have never seen a wheel and we design one, then we have an original design Though most selection, configuration, and parametric problems are represented by equations, rules, or some other logical scheme, original design problems usually cannot be reduced to any algorithm. Each one represents something new and unique.

Redesign
Most design problems solved in industry are for the redesign of an existing product Modification of an existing product to meet new requirements. Example of hydraulic cylinder from 0.25m to 0.3m long Many redesign problems are routine and the design domain is so well understood that the method used can be put in a handbook as a series of formulas or rules.

1890 Humber bicycle

Recumbent bike (FantasE)

The Martin Mount Vision mountain bike

Mature design and its evolution

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Mature design - remained virtually unchanged over many years. There are many examples of mature designs in our everyday lives: pencil sharpeners, hole punches, and staplers are a few found on the average desk. For these products, knowledge about the design problem is high. There is little more to learn. Why did a mature design like a bicycle begin evolving again? Customers are always looking for improved performance. Mountain bicycles of the style shown in Figure are better able to handle rough terrain than traditional bikes. There is improved understanding of human comfort, ergonomics, and suspensions. Customers are always looking for something new and exciting even if performance is not greatly improved. Materials and components have improved. So, even mature designs change to meet new needs, to attract new customers, or to take advantage of new materials. Part of the design of a new bicycle like the Recumbent bike (FantasE) is routine, and part is

original

Many subproblems were parametric problems, selection problems, and configuration problems. Thus, the redesign of a product, even a mature one, may require a wide range of design activity.

Variant Design
Sometimes companies will produce a large number of variants of their products. A variant is a customized product designed to meet the needs of the customer. For example, when you order a new computer from companies such as Dell, you can specify one of three graphics cards, two battery configurations, three communication options, and two levels of memory. Any combination of these is a variant that is specifically tuned to your needs.

Conceptual Design and Product Design

Two other terms that will be used throughout this course are conceptual design and product design. These are general terms for two parts of the product development process. First, you must develop a concept and then refine the concept into a product. The activities during the conceptual and product development phases may make use of original, parametric, configuration, selection design and redesign as needed.

Languages of Mechanical Design

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Many languages or representations can be used to describe a mechanical object Difference between detailed drawing of a component and the actual hardware (component) both drawing and the hardware represent the same object however, they each represent it in a different language Example of a bolt Word bolt is a textual (semantic or word) description of the component Can also be represented through equations that describe its functionality and possibly its form Ability of a bolt to carry shear stress (function) is described by the equation = F / A

Different representations (languages) to describe the bolt

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Semantic: verbal or textual representation of the object bolt Graphical: drawing of the object orthogonal drawings, sketches or artistic renderings Analytical: Equations, rules or procedures representing the form or function of the object - = F / A Physical: the hardware or a physical model of the object In most mechanical design problems, initial need is expressed in a semantic language written specification or a verbal request by a customer or supervisor Final result of the design process is a physical product In between, the Designer produces a graphical representation of the product All the languages will be used as the product is refined from its initial, abstract semantic representation to its final form

Abstract sketch and final drawing of a component

Table 02_01

Table 02_02

Summary

A product can be divided into functionally oriented operating systems. These are made-up of mechanical assemblies, electronic circuits, and computer programs. The important form and function aspects of mechanical devices are called features. Function and behavior tell what a device does; form describes how it is accomplished. Mechanical design moves from function to form. One component may play a role in many functions, and a single function may require many different components. There are many different types of mechanical design problems: selection, configuration, parametric, original, redesign, routine, and mature. Mechanical objects can be described semantically, graphically, analytically, or physically. Mechanical design is the refinement from abstract representations to a final physical artifact.

References
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Ullman DG, The Mechanical Design Process, 3rd and 4th edition, McGraw Hill International, 2011. William Singhose and Jeff Donnell, Introductory Mechanical Design Tools, 2011.