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Welcome to Engineering Design, At UMD-MIEwe say:
Student teams use design and analysis methodslearned in previous courses to develop, design orimprove an industrial system problem. These designproblems are, generally, drawn from real-worldsystem problems existing in industrial organization inthe region.
We consider that design is a customer-centricprocess that will lead to mutually beneficial outcomes
It is truly a process so we start with a clear problemanalysis and then propose and pursue a final designin hardware, software, and/or system improvement
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Welcome to Engineering Design
Function to form
Phases of design
Product realization process
Roles for engineers
Concurrent engineering
Teamwork
Summary
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Engineering Design
machines sketch / draw customer desiresmechanisms predict behavior company constraintsmotion test / experiment synthesize alternatives
energy conversion materials analyze
manufacturing evaluate
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What is Design, really?
Which of the following is design and which is analysis?
A. Given that the customer wishes to fasten together two steel
plates, select appropriate sizes for the bolt, nut and washer.
B. Given the cross-section geometry of a new airplane wing
we determine the lift it produces by conducting wind tunnel
experiments.
Design Analysis
Form is the solution to a design problem.
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How are Function and Form related
Design
controlhold
move
protect
store
decision making processes
shape
configuration
size
materialsmanufacturing
processes
Function
Form
Form Ever Follows Function
Luis Sullivan
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Designdefinition
Set of decision making processesand activities
to determine the formof an object,
given the customers desired function.
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Making Decisions? Use the design process
Establish functional requirementsDetermine constraints
Set performance targets
Generating
Alternatives
Formulating
Problem
Analyzing
Alternatives
Evaluating
Alternatives
Create alternative forms
(shape, configuration, size, materials,
manufacturing processes)
all alternatives
feasible alternatives
Redesign
iteration
Design specifications
best alternative design candidate
Manufacturing specifications
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Are there phases of design?
How do design decisions change over time?
Is there a logical grouping of decisions?
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Example design problem - Stop a spinning shaft
(8 inch diameter, 1000 lbs, steel, 3000 rpm)
Decide upon a satisfactory rate of deceleration Determine the length of the shaft
Determine where it is supported
Determine what actuating energy is available
Decide to reverse engineer an existing product
Choose to research brakes in the library
Formulation Phase
Early in the design process, we decide upon the specifics
of the function to be performed:
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Decisions relating to concept?
1. surface friction (e.g. drum brake, disk/caliper)
2. opposing magnetic fields (e.g. inverse motor) 3. air friction (e.g. fan blades)
Assume we decide on surface friction
Decidephysical principlesthat will perform the function
Concept Design Phase
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Decisions on configuring productsand new components?
Product configuration:
disk/caliper, or drum, or band brakelocation on shaft (right. left, middle)
(Assume we decide on a disk/caliper brake)
Part configuration:
relative size of hub to disk
relative size of rotor thickness to diameter
Configuration Design Phase
Decide upon product components& how they are arranged
Decide upon partfeatures& how they are arranged
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1. rotor diameter (outer)
2. rotor thickness3. brake pad width
4. pad material
5. hydraulic pressure on piston
Values for Parameters?
Decide upon specific values for design variables
Parametric Design Phase
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machined rotor tolerances
pad bonding resin
assembly/testing procedure
Completing the details
Detail Design Phase
Decide upon the remaining manufacturing specifications
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Function---- stop a spinning shaft
Final Form is the solution to a design problem
Form
rotor: 10 inch diameter, CG Cast Iron, 3/8-inch thick, cooling
passages
forged steel caliper/housingbrake pads, 2 opposing, 4 sq. in., metal particles/epoxy matrix
steel piston,1-inch diameter, with elastomeric seals
100 psi hydraulic piston pressure
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Design Phases
Formulation
Detail
Parametric
Configuration
Concept
Embodiment
Design
Preliminary
Design
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Design versus the Product Realization Process?
Industrial Design
Engineering Design
Production Design
Manufacturing
(Production)
Distribution
ServiceDisposal
Customer
Need
Realized
Product
Sales / Marketing
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Phases in the life of a product
Manufacture
Retire
Design
Use
establish functiondetermine form
fabricate
assemble
distribute
set up
operate
maintain
repair
take downdisassemble
recycle
dispose
To satisfy the consumer
We must consider allthe phases in the life of a product
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Inco
me
Investm
ent
Introduction Growth Maturity Saturation Decline
Sales
Time
ProductDevelopment
Product realization begins the ProductLife Cycle
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How do we, as engineers, fit into the PRP?
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(U.S. Department of Labor, 2000).
Manufacturing 732 50
Engineering Services 401 27
Government (Federal, State & Local) 179 12
Self-employed 43 3
Other 110 8
Total 1465 100
Employer Thousands %
Where do engineers work?
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Engineering Roles in Design & Manufacturing
Job Title Description
Sales &Marketing
Sales Engineer Meets customers, determinesneeds, presents product offerings
Applications Engineer Assists sales & marketing solving
technical issues with respect to the
use of product
Field Service Engineer Installs, maintains and repairs
equipment at customers sites
Research &
Development
Industrial Designer Establishes essential product
appearance, human factors
Design Engineer Decides part or product form
including: shape, size,
configuration, materials, and
manufacturing processes
Materials Engineer Investigates and develops improved
materials
Test Engineer Designs and conducts performance
and safety tests
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Engineering Roles in Design & Mfg
Manufacturing Industrial Engineer Designs fabrication,
assembly and warehousing
systems
Manufacturing
Engineer
Develops manufacturing
tools and fixtures
Quality ControlEngineer
Establishes and maintainsraw materials and finished
goods quality controls
Processing /
Operations
Plant Engineer Designs and maintains
processing plant facilitiesProject Engineer Coordinates project work
tasks, budgets and
schedules
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typical manufacturing company
Functional organization chart
PurchasingEstimating
Expediting
Purchasing
Production OperationsQuality Control
Industrial Engineering
Manufacturing Engineering
Production Planning
Tooling
Manufacturing
Design EngineeringIndustrial Design
Prototyping
Testing
Materials Research
Research & Development
SalesCustomer Service
Marketing
Advertising
Sales & Marketing
AccountingBudgeting
Planning
Finance
President
Board of Directors
Stockholders
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Design
Engineering
Mfg.
Engineering ProductionSales
Marketing
Product
Manager
Industrial
Design
Industrial
Engineering Purchasing
Concurrentengineering design team
No moreover the wall
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Teamwork is a professional teamsport!
Professional Team Industry
Competitors Companies
Team owners Investors
Coaches Managers
Referees, umpires Lawyers, judges
Communication Coordination
Fumbles, injuries Mistakes, losses
Individual skills Specialized jobs
Team skills People skills
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Summary
Design is decision making
Product realization process includes engineering design
Design process requires formulating, generating,
analyzing, evaluating, refining Form follows function
Product realization is a professional teamsport