DESIGN METHODS &

APPLICATIONS

WEEK 1
INTRODUCTION TO
DESIGN
PowerPoint Slides
Lecturer
Nur Hasalli Binti Hj Ibrahim

Last Updated:May 6, 2017 1

 Chapter Overview

Chapter 1 introduced you to the original concept

or idea that involves in engineering design.
You will learn the design process and understand
the importance of every parts of the design
methodology.
You will understand the major role of CAD system
that offer the user many different solutions in
creating or improving product design.

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 Learning Objectives

Describe why the use of graphics is an effective

means of communicating when designing.
Recognize the interactive steps associated with
the design process.
Understand the process involved in developing a
product design specification from a market brief.
Identify different types of computer application in
the design process and its importance in industry
now.

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 Learning Outcomes

Students are required to understand the definition

of engineering design.
To gain good understanding of design process.
Students are able to recognize different type of
computer application in industry now.
Students will understand the importance of
learning CAD system to create or improve their
product design.

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 Engineering Design

Engineering design is an iterative decision-

making process that has the objective of creating
and optimizing a new or improved engineering
system for the fulfillment of a human need or
desire that:
i) apply scientific and engineering knowledge to the solution of
technical problems.
ii) optimize the solution within the requirements and constraints set by
material, technological, economic, legal and environmental
consideration.
iii) affect almost all areas of human life, use the laws and insights of
science, build upon special experience and require professional
integrity and responsibility.

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 Relationship in Industry Now

Sales
Related

Business
Product
Function

Product Design
Production
& Product
cost

Production

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 Relationship in Industry Now
Target Product
market promotion

Sales
Product
Related
form
Price
Product Business
Product Distribution
Design
Function Coverage
Cost/Risk

Manufacturing Production
Materials Process & Product
cost

Production Planning/
Facilities Scheduling
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 Engineers Professional Responsibilities

The modern engineers have professional

obligation to clients and to society. To satisfy their
obligations to society, engineers must be able to:
i) exercise judgment and take responsibility for every
design process.
ii) anticipate a variety of viewpoints and requirements and
to incorporate these into decision-making activities in
every design process.
iii) perceive problem in their full environmental context
and seek the solution that best satisfies the goals and
objectives of clients and society.

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 Basic Design Process

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 Design Process in Details
DESIRE / NEED

DEFINITION OF
PROBLEM

SPECIFICATION

PROJECT PLANNING

INITIAL CONCEPTUAL
DESIGN

ANALYSIS /
CHANGE THE DESIGN
OPTIMIZATION
Product Development Yes
No CAN THE DESIGN BE
EVALUATION
IMPROVED?
Yes No
DESIGN IMPOSSIBLE
MARKET FOR THE GIVEN
SPECIFICATION

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 Product Development

Generating the product

Form generation from function Generate product
Material and process selection
Evaluating the product Performance and robustness

Evaluating functional changes Cost

Evaluating performance
Sensitivity analysis Production
Tolerance analysis
Make product decisions
Robustness of design
Design for cost value engineering Document & Communicate
Design for manufacture, assembly,
reliability and environment Release Product for Market

Applying for patents

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 Generating the Product

Today, a number of product development can be

performed with the assistance of a computer.
These tasks include:
i) Computer-aided design
ii) Computer-aided engineering
iii) Computer-aided manufacturing

Benefits of employing the computer to aid the

design and manufacturing process:
i) improve accuracy of design and engineering productivity
ii) shorter lead time and reduced labour
iii) saving in materials and machining time
iv) faster response to market needs
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 Computer Application in Design

Computer-Aided Design (CAD)

After several evaluations, CAD system will be used to
generate actual and precise drawing for every new
product in two-dimension (2D) or three dimension (3D)
that:
i) complete with dimension and tolerance.
ii) attached with part list / bill of material.
iii) includes scaling of drawings, sectional and detail views.
iv) increases drawing productivity by approximately four
times over conventional manual drawing.
v) provides a higher degree of understanding of the new
product especially for those who cannot imagine in 3D.

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 Compute-Aided Design (CAD)

AutoCAD
i. Generate all parts & assemblies in one file (Model platform).
ii. Edit basic features of parts & assemblies (Model platform).
iii. Manually change visual style from 2D wireframe into conceptual,
realistic or shaded (Model platform).
iv. Manually create multi-view with viewports in Layout platform.
v. Manually create sheet size (preferable A3 size) in Layout platform.
vi. Manually create bill of material (BOM) and balloon numbering in Layout
platform.
vii. Manually create exploded drawing from assemblies (Model platform).
Autodesk Inventor
i. Generate all parts & assemblies one file by one file with small size.
ii. Edit all features of parts & assemblies.
iii. Manually change visual style from shaded into 2D wireframe or
conceptual.
iv. Automatically create tasks from iv vii.

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 Introduction to Autodesk Inventor
Getting Started with User Interface

Application Menu

Ribbon (Command tabs &

panels)

Features history Browser

Parts & Assemblies

Environment

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 Evaluate the Product

Stress: a state property at a specific point within a body

(load, geometry, temperature, and manufacturing
processing).
Strength: an inherent property of a part (use of particular
material and process).
Engineers must accommodate uncertainty (change):
i. Composition of material and effect of variation on properties.
ii. Effect of thermo-mechanical treatment on properties.
iii. Effect of processing locally or nearby on properties.
iv. Effect of weldments and shrink fits on stress conditions.
v. Intensiy and distribution of loading or stress concentraton.
vi. Influence of time on geometry and strength.
vii. Effect of corrosion and wear.

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 Design Factor & Max. Allowable Stress
Design factor
loss of function parameter
nd
max . allowable parameter
Eg. Consider that the maximum load on a structure is known with an
uncertainty of 20% and the load causing failure is known within
15%. If the load causing failure is nominally 2000N, determine the
design factor and the maximum allowable load that will offset the
absolute uncertainties.
Ans. Loss-of-function load = 1/0.85
Max. load on the structure = 1/1.2
Design factor, 1 0.85
n d 1.4
1 1.2

Max, allowable load = 2000/1.4 = 1400 N

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 Design Factor & Max. Allowable Stress
Eg. A rod with a cross-sectional area of A and loaded in tension with
an axial force of P = 200 kN undergoes a stress, . Using a material
strength of 24000 kPa and a design factor of 3, determine the
minimum diameter of a solid circular rod.
Ans. loss of function strength
nd
max . allowable stress
24000
8000 MPa
3
P 200000
8000 MPa
A d 4 2

4(200000)3
d 56.4mm
(24000)

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 Design Factor, Safety Factor & Max.
Allowable Stress
From Table A-17, the next higher preferred size is 60 mm. Thus, the
safety factor, ns is:
(24000)60 2
ns 3.68
4(200000)

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 Design Factor, Safety Factor & Max.
Allowable Stress

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 Safety Factor & Max. Allowable Stress
Safety factor
ultimate stress
ns
max . allowable stress
A safety factor of 1.5 - 2 is generally applied for structures (static
load) and 4 - 8 for various dynamic loads.

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 Ultimate Stress & Material Properties
Ultimate stresses for different material properties:
Eg. Click New button > Select Metric tab > Standard (mm).ipt >
Choose Manage tab > Click Styles Editor button > Expand Material

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 Safety Factor & Max. Allowable Stress
A strut of diameter 25 mm and length 2 m carries an axial load of 20
kN. The ultimate compressive stress of the material is 350 MPa and
its modulus of elasticity is 150 GPa. Find the compressive stress in
the material, the safety factor in operation, and the change in length
of the strut.
Ans. Compressive stress in material
d 2 (0.025) 2
A 491 10 6 m 2
4 4
P 20 103
40.7 MPa
A 491 10 6

Safety factor in operation

ultimate stress 350 10 6
ns 8.6
max . allowable stress 40.7 10 6

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 Safety Factor & Max. Allowable Stress
The change in length
40.7 106
271 10 6

E 150 109
x l 270 10 6 2 0.543 mm

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 References

Joseph E. Shigley & Charles R. Mischke,

Mechanical Engineering Design, 8th Edition,
McGraw-Hill, 2006
Swift K. G. & Booker J. D., Process selection:
from design to manufacture, Arnold, London,
1997.
Corbett J., Dooner M. & Meleka J., Design for
manufacture: strategies principles and
techniques, Addison Wesley, 1991.
James M. Kirkpartick., AutoCAD; Drawing,
Modelling and Applications, Pearson, 2007

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