DESIGN AND MANUFACTURING Engineering Design

What is Designing The Process of Design The Purpose of Design

What is Designing
To Design is to innovate and to create.
A civil engineer designs skyscrappers, bridges or water distribution networks. A mechanical engineer designs new fuel efficient automobiles, cranes, robots etc. An architect designs low-cost housing for the urban poor, modern hospital, or domed-in sports stadia. A chemical engineer designs petroleum refineries, etc. An aerospace engineer designs comfortable aeroplanes to travel from one city to another, or long-range missiles to wipe out these cities.

Almost all human activity seems to revolving around design. The verb to design is used in such a wide range of contexts that one is no longer sure of what the word implies
Surely, the design of a supersonic fighter aircraft must be a precise, mathematically oriented and highly organised activity, while a movie-set design would hardly appear to be so.

Design is an activity directed towards a need; it is creative; and it is concerned with the best use of resources. The constraints on a design and its designer can be the constraints of resources, of tight deadlines, and could be legal in nature. Design is a process concerned with generating ideas and suggesting ways to turn these ideas onto reality to satisfy some needs optimally under the relevant constraints. The definition of designing given above includes not only the work of engineers and architects but also that of managers, planners, politicians, acedemicians and others who have specific goals and who work to achieve a design as optimally as possible within the constraints of available resources.

The Design Process

Early Man as a Designer Design by Evolution Inadequacy of Evolutionary Method in Modern Design Situation A Description of the Design Process The Structure of the Design Process The Morphology of Design The Design Process: Decision-making and Iteration

What Early Man as a Designer

To Design is to innovate and to create.
A civil engineer designs skyscrappers, bridges or water distribution networks. A mechanical engineer designs new fuel efficient automobiles, cranes, robots etc. An architect designs low-cost housing for the urban poor, modern hospital, or domed-in sports stadia. A chemical engineer designs petroleum refineries, etc. An aerospace engineer designs comfortable aeroplanes to travel from one city to another, or long-range missiles to wipe out these cities.

Almost all human

Identification and Analysis of Need

Realization of Need True Needs Preliminary Need Statement Analysis of Need Specifications Standards of Performance Enviromental Factors Resources

Origination of Design Concepts

Solving the Design Problem:Creativity The Creative Attitude The Creative Procees Mental Set or Fixity Creativity by Analogy with Prior Systems Use of Checklists Search for Design Concepts Morphological Analysis A Kerosene Stove An Example of Morphological Analysis Heat Dissipation from Coolant Water An Example of Two-dimensional Morphological Matrix Brainstorming Idea Hunting by a Group of Persons

The Design Decisions

The Place of Decision-making in Designing A Measure of Physical Realizability An Example: Protection in Automobile Head-on Crash Economic and Financial Feasibility The Quality of Design The Concept of Utility Using Utility for Design Selection

Development of Design
From Concept to Product Designing for Function Designing for Production Designing for Shipping, Handling and Installing Designing for Use Designing for Maintenance The Detailed Design

Manufacturing Processes
What is Manufacturing Role of Manufacturing in Design Manufacturing Processes

Metal Casting
The Casting Process
Pattern and Mould Melting and Pouring Solidification and Cooling Removal and Finishing

Metal-Casting Processes
Sand Casting Investment Casting Permenant Mould Casting

Comparision of Casting Processes Casting is oldest & perhaps the most popular mean of producing the desired shape. The process basically involves melting & superheating the raw material upto the desired temperature & pouring it into the mould cavity at an specified rate. The molten metal is then allowed to solidify in the mould cavity & on cooling, the product is taken out to get the casting. Several casting processes have been developed over the years, each having its own characteristics, applications, advantages & limitations. These processes can be classified on the basis of the type of mould & pattern used in the process as in figure.

Casting Process

Expendable Mould Casting

Permanent Mould Casting

Permanent Pattern Sand Casting

Expendable Pattern Investment Flask Casting

The basic features common to all cating processes are :1. Pattern & mould 2. Melting & pouring 3. Solidification & casting 4. Removal & finishing Metal-casting Processes 1. Sand Casting 2. Investment Casting

3.

Permanent Mould Casting a) Gravity Feed Permanent mould casting b) Low pressure permanent mould casting c) Die casting d) Centrifugal casting e) Continuous casting

Selection of castinf process depends on following factors 1. Size and shape of casting (overall dimension, weight & complexity of shape). 2. Surface finish and dimensional accuracy required. 3. Strength of casting (Material & grain structure) 4. Cast of pattern and mould (Initial cost) 5. Quantity required (Production volume & rate). 6. Overall quantity required (Finishing required). Comparision of casting process

Metal Forming
While casting exploits the fluidity of liquids to get the desired configuration, metal forming processes exploit the ability of metals to flow plastically in solid state. Friction at the tool-work interface is an important consideration in metal forming. Temperature & speed of deformation are two other important considerations. Cold & hot working Graph of Cold & hot working Advantages & disadvantages of cold & hot working process Metal Forming processes 1. Rolling. 2. Forging. 3. Extrusion. 4. Wire & Tube Drawing. 5. Deep Drawing. 6. Punching & Blanking. Comparision of Forming Processes

Machining Processes
Metal Cutting
Basic Metal-cutting Operations

Grinding Operations Finishing Operations Comparision of Machining Processes Unconventional Machining

Ultrasonic Machining (USM) Electrochemical Machining (ECM) Electro-discharge Machining (EDM) Laser Beam Machining (LBM) Comparision of Unconventional Machining Processes

Welding and Allied Processes

Classification of Welding and Allied Processes
Solid-state Welding Liquid-state Welding Solid/Liquid-state Welding

Comparision of Welding and Allied Processes

Selection of Manufacturing Processes

Manufacturing Cost

Production Volume Manufacturing Characteristics and Material Properties Shapes and Sizes Dimensional Accuracy and Surface Finish Functional Requirements

Design for Manufacturability

Designing for Economical Production Design Considerations for Manufacturing
Design Considerations in Sand Casting Design Considerations in Forging Design Considerations in Machining

Design Considerations in Grinding Design Considerations in Welding

Integrated Manufacturing
Why Integration? System Concept Manufacturing Information Technology and its Elements

Tools and Technology for Integration

Group Technology
Classification and Coding Production Flow Analysis (PFA) Group Layout Advantages and Disadvantages of GT

Simulation Database Data Communication Overview of Numerical Control Material Handling and Storage

Conveyor Systems Automated Guided Vehicles Industrial Robots

Process Planning Concurrent Engineering