Product Design and Development, MME2259a Fall 2011 Prof. Paul M. Kurowski, Ph.D., P.Eng. Department of Mechanical and Materials Engineering The University of Western Ontario

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.

DESIGN IS COOL 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

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.

Please download from our web page and read (CDEN2006) OBJECTIVE MME2259a Please download from our web page and read (CDEN2006)

Paths of the Design Process PROCESS OF DESIGN Products that Meet Need Design Need Paths of the Design Process Design Knowledge Manufacturing Material Science Electronics Economics Kinematics Thermodynamics Physics Mechanics

TYPES OF ENGINEERING DESIGN Selection Design – choose item(s) from a catalog Configuration Design – organize the packaging of components Parametric Design – finding variables or parameters. Redesign, alternative design – modifying an existing product. Original Design – develop a totally new product.

SELECTION DESIGN Given: Shaft diameter 20 mm Speed 2000 rpm Radial force 6675 N (or 1500 lb) Require: To select an appropriate bearing. Possible Solutions: Housing Bearing 20 mm 6675 N Shaft [Ullman 1992]

“Fundamentals of Engineering Design” Barry Hyman, Prentice Hall SELECTION DESIGN “Fundamentals of Engineering Design” Barry Hyman, Prentice Hall

CONFIGURATION DESIGN 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

“Fundamentals of Engineering Design” Barry Hyman, Prentice Hall CONFIGURATION DESIGN “Fundamentals of Engineering Design” Barry Hyman, Prentice Hall

CONFIGURATION DESIGN 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 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 Configuration alternatives can be analyzed according to Design for function Design for assembly Design for manufacture

PARAMETRIC DESIGN Example: Design a cylindrical storage tank that l holds 4 m3 of liquid. Volume: V = p x r2 x l thus 4 = p 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. l 2r

“Fundamentals of Engineering Design” Barry Hyman, Prentice Hall PARAMETRIC DESIGN “Fundamentals of Engineering Design” Barry Hyman, Prentice Hall

REDESIGN 1890 Humber bicycle 1990 Trimble bicycle

ORIGINAL DESIGN ? Boeing 787 www.elmundo.es

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.

SAE Specifications for Steel Bolts ANALYSIS VS. DESIGN SAE Specifications for Steel Bolts http://www.americanfastener.com/technical/grade_markings_steel.asp

MME2259a WEBPAGES http://www.eng.uwo.ca/MME2259a/2011 http://www.eng.uwo.ca/designcentre http://www.eng.uwo.ca/mechanical/undergrad/current/course_outlines.htm

DESIGN PROJECT 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

LAB SCHEDULE

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

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%.

TEAM WORK 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%.

DESIGN PROCESS AND THE PRODUCT LIFE-CYCLE Product Design Manufacturing Process Design Requirements Definition Manufacturing System Concept Development QFD Process FMEA Simulation Concept Development Detailed Process Design QFD Process FMEA Taguchi DFM Validation Testing Poke Yoke Simulation Detailed Product Design Prototype The extend of our design project Manufacturing Service & Support

TYPES OF ENGINEERING DESIGN - AGAIN In our design project focus will be on selection design Selection Design – choose item(s) from a catalog Configuration Design – organize the packaging of components Parametric Design – finding variables or parameters. Redesign, alternative design – modifying an existing product. Original Design – develop a totally new product.

MME2259a vs ES1050

COURSE PROGRESS Lectures Labs SolidWorks

CSWA EXAM - BONUS https://www.virtualtester.com/solidworks/branding/user-portal/user-portal.html

http://blogs. solidworks http://blogs.solidworks.com/teacher/2011/09/linking-undergraduate-engineering-curriculum-around-solidworks.html

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

DESIGN PROJECT 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

truss.SLDPRT

sheet.SLDPRT

NEW COMPUTER LABS

NEW COMPUTER LABS

NEW COMPUTER LABS