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Welcome to Engineering Design, At UMD-MIE we say:

Student teams use design and analysis methods learned in previous courses to develop, design or improve an industrial system problem. These design problems are, generally, drawn from real-world system problems existing in industrial organization in the region. We consider that design is a customer-centric process that will lead to mutually beneficial outcomes It is truly a process so we start with a clear problem analysis and then propose and pursue a final design in hardware, software, and/or system improvement

Welcome to Engineering Design


Function to form Phases of design Product realization process Roles for engineers Concurrent engineering Teamwork Summary

Engineering Design

machines mechanisms motion energy conversion

sketch / draw predict behavior test / experiment materials manufacturing

customer desires company constraints synthesize alternatives analyze evaluate

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.

F o r m E v e r F o l l o w s F u n c t i o n .

How are Function and Form related


control hold move protect store decision making processes shape configuration size materials manufacturing processes

Function

Design

Form

Form Ever Follows Function Luis Sullivan

Design definition

Set of decision making processes and activities to determine the form of an object, given the customers desired function.

Making Decisions? Use the design process


Formulating Problem
Establish functional requirements Determine constraints Set performance targets Design specifications Create alternative forms (shape, configuration, size, materials, manufacturing processes)

Redesign iteration

Generating Alternatives

all alternatives

Analyzing Alternatives
feasible alternatives

Evaluating Alternatives
best alternative design candidate Manufacturing specifications

Are there phases of design?

How do design decisions change over time? Is there a logical grouping of decisions?

Example design problem - Stop a spinning shaft


(8 inch diameter, 1000 lbs, steel, 3000 rpm) Early in the design process, we decide upon the specifics of the function to be performed: 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

Decisions relating to concept?


Decide physical principles that will perform the function 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

Concept Design Phase

Decisions on configuring products and new components?


Decide upon product components & how they are arranged Decide upon part features & how they are arranged
Product configuration: disk/caliper, or drum, or band brake location 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

Values for Parameters?


Decide upon specific values for design variables 1. rotor diameter (outer) 2. rotor thickness 3. brake pad width 4. pad material 5. hydraulic pressure on piston

Parametric Design Phase

Completing the details

Decide upon the remaining manufacturing specifications machined rotor tolerances pad bonding resin assembly/testing procedure

Detail Design Phase

Final Form is the solution to a design problem


Function ---- stop a spinning shaft

Form rotor: 10 inch diameter, CG Cast Iron, 3/8-inch thick, cooling passages forged steel caliper/housing brake pads, 2 opposing, 4 sq. in., metal particles/epoxy matrix steel piston,1-inch diameter, with elastomeric seals 100 psi hydraulic piston pressure

Design Phases
Formulation

Concept

Preliminary Design

Configuration Embodiment Design Parametric

Detail

Design versus the Product Realization Process?


Realized Product

Production Design Service Disposal Engineering Design Distribution Industrial Design Manufacturing Sales / Marketing (Production)

Customer Need

Phases in the life of a product


Design establish function determine form fabricate assemble distribute set up operate maintain repair take down disassemble recycle dispose

Manufacture

Use

Retire

To satisfy the consumer We must consider all the phases in the life of a product

Product realization begins the Product Life Cycle

Income

Introduction Growth

Maturity Sales

Saturation Decline

Investment

Time Product Development

How do we, as engineers, fit into the PRP?

Where do engineers work?


Employer Manufacturing Engineering Services Government (Federal, State & Local) Self-employed Other Total (U.S. Department of Labor, 2000). Thousands 732 401 179 43 110 1465 % 50 27 12 3 8 100

Engineering Roles in Design & Manufacturing


Sales & Marketing Job Title Sales Engineer Description Meets customers, determines needs, 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 Industrial Designer Design Engineer Establishes essential product appearance, human factors Decides part or product form including: shape, size, configuration, materials, and manufacturing processes Investigates and develops improved materials Designs and conducts performance and safety tests

Research & Development

Materials Engineer Test Engineer

Engineering Roles in Design & Mfg


Manufacturing Industrial Engineer Designs fabrication, assembly and warehousing systems Develops manufacturing tools and fixtures Establishes and maintains raw materials and finished goods quality controls Designs and maintains processing plant facilities Coordinates project work tasks, budgets and schedules

Manufacturing Engineer Quality Control Engineer

Processing / Operations

Plant Engineer Project Engineer

Functional organization chart


Stockholders

Board of Directors

President

Purchasing

Manufacturing

Research & Development

Sales & Marketing

Finance

Purchasing Estimating Expediting

Production Operations Quality Control Industrial Engineering Manufacturing Engineering Production Planning Tooling

Design Engineering Industrial Design Prototyping Testing Materials Research

Sales Customer Service Marketing Advertising

Accounting Budgeting Planning

typical manufacturing company

Concurrent engineering design team

Product Manager No more over the wall

Sales Marketing

Industrial Design

Design Industrial Mfg. Engineering Engineering Engineering Purchasing

Production

Teamwork is a professional team sport!


Professional Team Competitors Team owners Coaches Referees, umpires Industry Companies Investors Managers Lawyers, judges

Communication Fumbles, injuries Individual skills Team skills

Coordination Mistakes, losses Specialized jobs People skills

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 team sport

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