DESIGN PROCESS AND MATERIAL SELECTION

Dr. Alexey Sverdlin Mechanical Engineering Department Marquette University

I dont design clothes, I design dreams

Ralph Lauren, NY Times, 19 April 1986.

The process of translating an idea or need for a device into the detailed information (drawings, bill of materials, etc.) from which the device or product can be made.

 Technical design Industrial design Product design

Technical design includes the aspects of design that bear on the proper technical functioning of the product. Industrial design includes the aspects of design that bear on the satisfaction afforded by the product. Product design means the synthesis of technical and industrial design to create successful products.

 Observation Perception

The design of a device or product for Carrying loads Transmitting power Conducting heat Resisting wear Etc.

The product itself is called a technical system:

Subassemblies Components

The design converts the inputs into the outputs.

The design proceeds by developing concepts to perform the functions in the function structure, each based on a working principle. The designer considers alternative concepts and the ways in which these might be separated or combined.

Original Design
Design of something totally new

Adaptive or Developmental Design

Design resulting in an incremental advance in a device

Variant Design
Scaling up or scaling down a design

Hubble Telescope

Mars Rover

New designs can spur the development of new materials to meet the need.
Example: Gas turbine design spurred the development of single crystal nickel based alloy turbine blade alloys.

New materials can spur new designs

Example: Carbon fiber composite spurred the design of stealth aircraft.

Tennis Rackets

Wood

Aluminum

Carbon Fiber

Briggs and Stratton Engines

3.5 HP

10 HP

Functional Design
Design from a systems (input/output) point of view. (Materials selection is usually not considered here.)

Assembly or Component Design

Design of individual components and assemblies of technical systems. (Materials selection is usually considered here.)

Internal Combustion Engine

Inputs
Fuel Air Control Signals Electrical Power Fuel Injection System Motor (Block, crank, pistons, etc.

Outputs
Rotational Mechanical Energy Control Signals Exhaust Gases Heat

Electrical System

Cooling System

Engine Block

Motor

Crank Shaft
Pistons

Internal Combustion Engine

Fuel Injection System Cooling System Electrical System

Fuel Injectors Intake Manifold Radiator Water Pump Alternator Spark Plugs

Note: Materials selection made at the component level

Original design involves a new idea or working principle:

The ballpoint pen The compact disc

Almost all design is adaptive or developmental. Adaptive design takes an existing concept and seeks an incremental advance performance, to reduce cost, or to adapt it to changing market conditions.

Variant design involves a change of scale or dimension or detailing without a change of function or the method of achieving it.
Boilers Boats Cars

Testing and Failure Analysis Prototype

Screening Increasing specificity in materials selection and material properties

Increasing sophistication in design tools and accuracy of calculations

Selection of specific materials

Ashby, p.17

Main basis for selecting a material for a function is its properties. Available shape of a material affects selection. Ability to process Function, material, shape and process must material affects all be taken into account in selection. selection.