CHAPTER 1

INTRODUCTION TO MECHANICAL DESIGN PROCESS

MEC531 MECHANICAL ENGINEERING DESIGN 1

Phase 2: Embodiment Design

a.k.a Preliminary Design. Decisions are made in this design phase strength, material selection, size, shape, and spatial compatibility. Any major changes beyond this design phase become very expensive. Have 3 major task:
1. Product architecture Dividing the overall system into subsystems or module. How the physical components of the design are to be arranged and combined? Configuration design What features (e.g. holes, ribs, splines and curves) will be present and how those features are to be arranged in space relative to each other? Producing a physical prototype model may be appropriate.

2.

3.

Parametric design Involves the information on the part configuration and aims to establish its exact dimensions and tolerances. Important aspect of parametric design is to examine the part, assembly and system for design robustness.

Product Architecture

Arrangement of the physical elements to carry out its required function Relationship among the component in the product and the function the product performs. i.e. defining the building blocks of the product in terms of what they do and their interfaces 2 types: 1. Integral architecture 2. Modular architecture

Integral architecture The implementation of function uses only one or few chunks. Component perform multiple function: so called function sharing. E.g.: wrench, screwdriver Note: (1 physical element serve large number of function) Changes made to any component tent to propagate to other (or many) physical elements Often adopted when there is a constraint of weight, space or cost.

Modular Architecture The chunks implement only one or a few function Accomplish overall function through combination of building block/ modules Interaction between chunk are well defined E.g.: computers Advantage:

Component can be manufacture in higher quantity- save cost Shortening product development Cycles- modules dev independently Easier to evolve overtime To adapt to needs of different customers To replaced component as they wear out or used up

Design for Human Factor Designing something and considered the interaction between human and product. Deals with the characteristics, abilities and needs of human and the interfaces between human and technical products. Related with ergonomic and anthropometric data. 4 ways human interacts with a product:

1. 2. 3. 4.

As an occupant of workspace. As a power source (muscle power). As a sensor (looking for a warning light). As a controller (control pedal).

Creating user-friendly Design Fit the product to the users physical attributes and knowledgefrom ergonomics and anthropometric data. Simplify tasks- straightforward. Make the controls and their functions obvious- place the controls for function adjacent to the device. Provide feedback- sound or flashing dashboard light. Good displays- digital, analog. Make controls easy to handle. Standardize- arrangement of brake and clutch. Anticipate human errors- provide warning or emergency button.

Configuration Design

Establishing the shape and general dimensions of the components. Components include special purpose parts, standard parts, standard assemblies or modules. Develop from function. Configuration depending on: 1. Available materials and production methods
2. 3. Spatial constraints Product architecture

Modeling Represent in physical appearance of the design ideas. Engineers use models for thinking, communicating, predicting, controlling and training. Various type of model, (i.e. scale models, prototype, equations, CAD/CAE modeling).

Simulation Model subject to various input or environmental condition. To observe how they behave. Explore the results that might be obtained from the real-world system. Manipulation of the model. Usually involves computer performance or laborious computational. E.g.: using prototype model, simulator.

Analysis Involve calculation from understanding of mathematical and engineering fundamental. Ensuring the design concept are able and reliable to be perform or manufacture. It will support the dimension, shape, size, component and material selected have the suitability in the design. Finite-element analysis solve wide range of engineering problems area such as stress analysis, thermal analysis and fluid flow, diffusion, and magnetic field interaction. However, understanding the fundamentals are important! Several types of software (i.e. Nastran, Abaqus, Lusas, Ansys).

Materials selection An important aspect of design for mechanical, electrical, thermal, chemical or other application is selection of the best material or materials. Systematic selection of the best material for a given application begins with properties and costs of candidate materials. For example, a rod which should be stiff and light requires a material with high Young modulus and low density. If the rod will be pulled in tension, the specific modulus, or modulus divided by density E / , will determine the best material. But because a plate' s bending stiffness scales as its thickness cubed, the best material for a stiff and light plate is determined by the cube root of stiffness divided density . Refer Ashby Plot.

Parametric Design

Set the dimensions and tolerances in order to maximize quality and performance and minimize cost. Objective : to set values for the design variables that will produce the best possible design considering both performance and manufacturability. Design variables:
1. 2. Attribute of a part The value is under designer control.

Attributes identified in configuration design become design variables for parametric design.

A few established method in designing to maximise performance and quality : FMEA

Ratings for Severity, Occurrence and Detection of failure S x O x D = Risk priority Number (RPN) Performed to every failure mode

Design for reliability Robust design Design for Assembly (DFA) Design for Manufacture (DFM)

Failure Mode and Effect Analysis (FMEA) FMEA is designed to assist the engineer improve the quality and reliability of design. Properly used the FMEA provides the engineer several benefits. Among others, these benefits include:

Improve product/process reliability and quality. Increase customer satisfaction. Early identification and elimination of potential product/process failure modes. Prioritize product/process deficiencies. Capture engineering/organization knowledge. Emphasizes problem prevention. Documents risk and actions taken to reduce risk. Provide focus for improved testing and development. Minimizes late changes and associated cost. Catalyst for teamwork and idea exchange between functions.

Crow, 2002

Crow, 2002