1. 1 Prof. Paul M. Kurowski, Ph.D., P.Eng. Department of Mechanical and Materials Engineering Western University Product Design and Development, MME2259a Fall 2012

2. 2 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.

3. 3 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

4. 4 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.

5. 5 Please download from our web page and read (CDEN2006) OBJECTIVE MME2259a

6. 6 PROCESS OF DESIGN Design Need Products that Meet Need Paths of the Design Process Design Knowledge Manufacturing Material Science Economics Kinematics Thermodynamics Physics Electronics Mechanics

7. 7 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.

8. 8 Given: Shaft diameter20 mm Speed2000 rpm Radial force6675 N (or 1500 lb) Require: To select an appropriate bearing. Possible Solutions: Bearing Shaft Housing 6675 N20 mm [Ullman 1992] SELECTION DESIGN

9. 9 “Fundamentals of Engineering Design” Barry Hyman, Prentice Hall SELECTION DESIGN

10. 10 Computer components: Possible configurations for a computer (in each case, the bottom of the sketch represents the front of the computer). KeyboardMother board Extension slots Floppy drive Power supply CONFIGURATION DESIGN

11. 11 CONFIGURATION DESIGN “Fundamentals of Engineering Design” Barry Hyman, Prentice Hall

12. 12 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

13. 13 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

14. 14 Example: Design a cylindrical storage tank that holds 4 m 3 of liquid. Volume: V =  x r 2 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. 2r2r l PARAMETRIC DESIGN

15. 15 “Fundamentals of Engineering Design” Barry Hyman, Prentice Hall PARAMETRIC DESIGN

16. 16 1890 Humber bicycle 1990 Trimble bicycle REDESIGN

17. 17 Boeing 787 www.elmundo.es ORIGINAL DESIGN ?

18. 18 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.

19. 19 SAE Specifications for Steel Bolts http://www.americanfastener.com/technical/grade_markings_steel.asp ANALYSIS VS. DESIGN

20. 20 http://www.eng.uwo.ca/MME2259a/2012 http://www.eng.uwo.ca/designcentre http://www.eng.uwo.ca/mechanical/undergrad/curre nt/course_outlines.htm MME2259a WEBPAGES

21. 21 LAB SCHEDULE Sep. 11, Sep.13Laboratory:Problem Statement Lab. Homework:QFD; Design Specifications Sep. 18, Sep. 20Laboratory:Product Design Specifications, Program Plan Lab. Homework:Planning and Scheduling the Project Sep. 25, Sep. 27Laboratory:Design Review Meeting # 1 Lab. Homework:Concept Generation and Evaluation Oct. 2, Oct. 4Laboratory: Concept Generation and Evaluation Lab. Homework:Concept Generation and Evaluation Oct. 9, Oct. 11Laboratory:none (Thanksgiving Holiday) Lab. Homework:Preparation for Design Review # 2 Oct. 16, Oct. 18LaboratoryDesign Review Meeting # 2 Lab. HomeworkDetailed Design Oct. 23, Oct. 25Laboratory:Detail Design Lab. Homework:Detail Design Oct. 30, Nov. 1Laboratory:Detail Design Lab. Homework:Detail Design Nov. 6 Nov. 8Laboratory:Detail Design Lab. Homework:Detail Design Nov. 13, Nov. 15Laboratory:Design Review Meeting # 3 Lab. Homework:Detail Design Nov. 20, Nov. 22Laboratory:Detail Design, Design Simulation Lab. Homework:Detail Design, Design Simulation Nov. 27, Dec. 29Laboratory:Detail Design, Design Simulation Lab. Homework:Detail Design, Design Simulation Dec. 4, Dec. 6Laboratory:Final presentations Lab. Homeworknone Notes The final design report, Product Development File (PDF) binder and the individual design notebooks are due on the last day of classes. The above schedule and topics are subject to adjustments and changes as needed.

22. 22 MARKING Individual marks Two individual assignments (5% each)10% Oct 1st, 2012, Nov. 19th, 2012 Midterm examination 20% Nov. 6th, 2012 Final examination (limited open book)50% Fall examination session Team marks Individual Design Notebook 5% Final report and Product Data File 12% Design presentations (1% each) 3% Successful completion of the Certified SolidWorks Associate (CSWA) exam will count as a bonus assignment worth 5%.

23. 23 DESIGN PROCESS AND THE PRODUCT LIFE-CYCLE QFD Process FMEA Taguchi DFM Validation Testing Poke Yoke Simulation Requirements Definition Concept Development Manufacturing Detailed Product Design Prototype Service & Support Manufacturing System Concept Development Detailed Process Design QFD Process FMEA Simulation Product DesignManufacturing Process Design The extend of our design project

24. 24 (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

25. 25 MME2259a vs ES1050

26. 26 Lectures Labs SolidWorks COURSE PROGRESS

27. 27 https://www.virtualtester.com/solidworks/branding/user-portal/user-portal.html CSWA EXAM - BONUS

28. 28 http://www.sdcpublications.com/Textbooks/Official-Certified-SolidWorks-Associate-Examination/ISBN/978-1-58503-656-1/ CSWA

29. 29 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

30. 30 truss.SLDPRT

31. 31 sheet.SLDPRT

32. 32 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 Install SolidWorks 2012

33. 33 To install SolidWorks go to: www.solidworks.com/SEK Use SEK-ID = XSEK12 Ask Maryam Refan (mrefan@uwo.ca) for serial number for activationmrefan@uwo.ca SOLIDWORKS INSTALLATION

34. 34 Sample projects

35. 35 Boat cargo crane

36. 36 Davit holding a rescue boat A davit (dāv'ĭt, dā'vĭt) is a structure, usually made of steel, which is used to lower things over an edge of a long drop off such as lowering a maintenance trapeze down a building or launching a lifeboat over the side of a ship.

37. 37 Railway tricycle

38. 38 Hand cart

39. 39 Hand cart

40. 40 Wheelbarrow

41. 41 Boat trailer

42. 42 Pedal kart – 4 wheeler

43. 43 Pedal kart – 3 wheeler

44. 44 Car turntable

45. 45 Log splitter

46. 46 Utility trailer

47. 47 Engine hoist

48. 48 Engine stand

49. 49 Transmission jack

50. 50 Mechanics creeper

51. 51 Bicycle rack

52. 52 Towing attachment

53. 53 Where to look for project ideas?