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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