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Design

Design Interaction
Interaction
Function

Manufacturing
Manufacturing Materials
Materials &
&
Processes
Processes

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Design
Design Interaction
Interaction

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Materials
Materials in
in an
an engine
engine

Function

Material

Figure I.1 Section of an automotive engine - the Duratec V-6 - showing various
components and the materials used in making them. Source: Courtesy of Ford
Motor Company. Illustration by David Kimball.
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Design
Design Interaction
Interaction

Design
Design Interaction
Interaction

Function

Material

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Function

Material

Shape

Shape

Process

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1

History
History of
of Mfg.(until
Mfg.(until 1700)
1700)

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History
History of
of Mfg.(1700-1960)
Mfg.(1700-1960)

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History
History of
of Mfg.
Mfg. (1960-2000s)
(1960-2000s)

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Manufacturing
Manufacturing
Manufacturing
Raw material to finished goods
Conversion process
z Add value
z Discrete part manufacture
z
z

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Product
Product Design
Design Process
Process

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Production
Production System
System

Figure I.4 (a) Chart showing the


various steps involved in design
and manufacturing a product.
Depending on the complexity of
the product and the type of
materials used, the time span
between the original concept and
the marketing of the product may
range from a few months to many
years.
(b) Chart showing general
product flow in concurrent
engineering, from market analysis
to selling the product. Source:
After S. Pugh, Total Design.
Addison-Wesley, 1991.

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Redesign
Redesign of
of Parts
Parts

Engineering
Engineering
Engineering
z

Product Design
Product Manufacturing

Redesign

Figure I.5 Redesign of parts to facilitate assembly. Source: Reprinted


from G. Boothroyd and P. Dewhurst, Product Design for Assembly, 1989.
Courtesy of Marcel Dekker, Inc.
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Factors
Factors (terms)
(terms)
z
z
z
z
z
z
z
z

Tool
Tool Material
Material Changes
Changes

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Manufacturing
Manufacturing Processes:
Processes: Casting
Casting

Processes
Processes
Processes
4 basic process

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Materials (environment)
Cost (economy of scale)
Time (concurrency, rapid prototype)
Quality (tolerances, liability)
Technology (CAD/CAM/CAE, GT, AI)
Inspection
System (people, teamwork)
Dynamic (next slide)

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Casting
Forming
Material Removal
Joining

Other processes
Finishing
Painting
Figure I.7a Schematic illustration of various casting processes

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Machining
Machining

Forming
Forming and
and Shaping
Shaping

Figure 1.7e Schematic illustrations of various


machining and finishing processes.

Figure I.7b Schematic illustration of various bulk deformation processes


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Joining
Joining

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Application
Application of
of CAD/CAM
CAD/CAM
Figure I.14 Machining a mold
cavity for making sunglasses.
(a) Computer model of the sunglass
as designed and viewed on the
monitor.
(b) Machine the die cavity using a
computer numerical-control milling
machine
(c) Final product. Source: Courtesy of
Mastercam/CNC Software, Inc.

Figure I.7f Schematic illustration of various joining processes


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Engineering
Engineering Mentality
Mentality
How do we do that?
z How do we do that better?
z

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