MECHANICAL ENGINEERING DESIGN 1

MEC 531

PART A
MECHANICAL DESIGN PROCESS

By:
NURZAKI IKHSAN
CHAPTER 1
INTRODUCTION TO MECHANICAL
DESIGN PROCESS

Chapter Outline

1. The Phases of Design

2. Problem identification and definition
3. Product design specifications
4. Concept development, evaluation and selection
 The Phase Of Design

What is Design?
Design is an innovative and highly iterative process. It is also a decision-making
process.

Why do we design ?
To survive!

As an engineer as technical provider, we provide solutions to particular problems

However -if clients are not completely satisfied with provider then they will dismiss

They will go somewhere else and tell everyone about the unsatisfactory
 The Phase Of Design

7 Phases Design Process

Define Gather Concept Evaluation of Product Configuration Parametric

Problem Information Generation Concepts Architecture Design Design

Phase I. Phase II.

Conceptual Embodiment
Design Design

Phase III.
Detail Design

Phase VII. Phase VI. Phase V. Phase IV.

Planning for Planning for Planning for Planning for
Retirement Use Distribution Manufacture
 The Phase Of Design

7 Phases Design Process

Define Gather Concept Evaluation of

Problem Information Generation Concepts

Phase I. Feasibility Study.

Conceptual
Design Requires greatest creativity, involves the most
uncertainty and requires coordination among many
functions in the business organization.

Discrete activities to be considered:

Identification of customer needs
Problem definition
Gathering information
Conceptualization
Concept selection
Design review
 The Phase Of Design

7 Phases Design Process

Define Gather Concept Evaluation of

Problem Information Generation Concepts

Phase I. Most important steps in the engineering design

Conceptual process is identifying customer needs.
Design
The customer needs can be gained from:
Interviewing customers
Focus group
Customer survey
Customer complaints

Tools to achieve this:

Benchmarking
QFD
PDS
 The Phase Of Design

7 Phases Design Process

Define Gather Concept Evaluation of

Problem Information Generation Concepts

Phase I. Information from Internet

Conceptual Engineering URLs
Design
Patent Literature
Intellectual Property
Patents

Handbook
 The Phase Of Design

7 Phases Design Process

Define Gather Concept Evaluation of

Problem Information Generation Concepts

Phase I. Brainstorming
Conceptual
Design Functional decomposition

Morphological chart
 The Phase Of Design

7 Phases Design Process

Define Gather Concept Evaluation of

Problem Information Generation Concepts

Phase I. Comparison Based on Absolute Criteria

Conceptual
Design Pughs Concept Selection Method

Weighted Decision Matrix

 The Phase Of Design

7 Phases Design Process

Preliminary Design.
Product Configuration Parametric
Decisions are made in this design phase: strength, Architecture Design Design
material selection, size, shape, and spatial compatibility.

Any major changes beyond this design phase become Phase II.
very expensive. Embodiment
Design
 The Phase Of Design

7 Phases Design Process

Arrangement of the physical elements to carry out its

required function. Product Configuration Parametric
Architecture Design Design
i.e. defining the building blocks of the product in terms of
what they do and their interfaces
Phase II.
Design for Human Factor Embodiment
Design
Creating user-friendly Design
 The Phase Of Design

7 Phases Design Process

Establishing the shape and general dimensions of the

components. Product Configuration Parametric
Architecture Design Design
Components include special purpose parts, standard
parts, standard assemblies or modules.
Phase II.
Develop from function. Embodiment
Design
Configuration depending on:
1. Available materials and production methods
2. Spatial constraints
3. Product architecture
 The Phase Of Design

7 Phases Design Process

Set the dimensions and tolerances in order to maximize

quality and performance and minimize cost. Product Configuration Parametric
Architecture Design Design
Objective : to set values for the design variables that
will produce the best possible design considering both
performance and manufacturability. Phase II.
Embodiment
A few established method in designing to maximise Design
performance and quality :

FMEA
Design for reliability
Robust design
Design for Assembly (DFA)
Design for Manufacture (DFM)
 The Phase Of Design

7 Phases Design Process

Any missing or incomplete information are added
arrangement, form, dimensions, tolerances,
surface properties, materials and manufacturing of
each part
Activities to be completed in the detail design
phase (documentation):
Final Phase- Detail design
Waiting for final decision to be manufacture
The design is brought to the stage of a
complete engineering description of a tested
and producible product.

Detail engineering drawing.

Verification testing of prototype.
Assembly drawings and instruction, BOM. Phase III.
A detailed product specification. Detail Design
Decisions either to fabricate each part or to buy it
A detailed cost estimation.
A design review as a conclusion of the detail
design phase before beingpassed to manufacturing.
The Phase Of Design
 Product Design Specifications (PDS)

A document that contains all of the facts related to the outcome of

the product development (document listing the problem in detail).
It should avoid forcing the design direction toward a particular
concept and predicting the outcome.
Should be understood that the PDS is evolutionary and will change
as the design process proceeds.
It is important to work with the customer and analyse the
marketplace to produce a list of requirements necessary to
produce a successful product.
The designer should constantly refer back to this document to
ensure designs are appropriate.
 Product Design Specifications (PDS)
Example: PDS

1. What is the product going to be?

2. What are the dimensions of the product?
3. What materials does the product require?
4. What is the estimate cost of the materials?
5. What tools/technology will be used to work on the project?
6. Are the tools/technology accessible, or will special arrangements need to be made?
7. What is the time estimate for completing the project?
8. Where will the product be worked on primarily?
9. Will an outside company be used to complete the project?
10. Will materials need to be ordered? If so, how much time should be allotted for
shipping, ordering, etc?
11. Will an expert in the field need to assist with the creation of the product? If so,
when will this person be contacted to set up a mutually convenient time to meet?
12. Who will benefit from the benefit from the creation of the product?
13. Why is it necessary to create this product?
14. How will the product demonstrate technical knowledge?
 Product Design Specifications (PDS)

PRODUCT DESIGN SPECIFICATION

Product: Lightweight wheel for Formula Student car.

Weight :Maximum 3kg

Size :13 diameter;
15-25mm centre thickness
Timescale :18 weeks from initial phase to manufacture.
Cost :Maximum RM300 per wheel
Quantity :4 on initial design run
Safety :-Design for fatigue life of 250000 cycles at approximately
1.4g loading
-Interface between centre and rims must be airtight
-Smooth surface finish
-Secure fittings
 Product Design Specifications (PDS)

Competition :There are few competitors in niche market, but

various racing wheel manufacturers.
Maintenance :Seals and bolts must be checked occasionally.
Customer :Lightweight motorsport / weekend racer.
Manufacturing Facilities :Dependent upon material
CNC and Casting in-house.
Other manufacturing must be out-sourced.
Installation :4 inch PCD 4 stud formation.
Materials :Range of materials to be modelled:
Aluminium 2024 T6
Steel
Plastics
 Concept Development, Evaluation and Selection

Generating Design Concepts

Brainstorming
Most common method used by design teams for generating ideas for design
concepts in conceptual design.
Think of all the possible limitations or shortcomings of the product.

Functional decomposition (breakdown)

A logical approach for describing the transformation between the initial and final
states of a system or device.
Physical decomposition separating the product or subassembly directly into its
subsidiary subassemblies and components (output = physical decomposition block
diagram).
Functional decomposition a general description of a device is refined into more
specific arrangements of functions and subfunctions.
 Concept Development, Evaluation and Selection
Physical decomposition

Urban Car

Suspension Steering Braking

Chassis Power train
system system system

Functional decomposition

Power train

Variable valve
Direct injection 3.5 cc
timing

The controller are use to The gasoline is highly pressurized, and

The engine consist of 6
varies the operational of the injected via a common rail fuel line
pistons
open-closed valve directly into the combustion chamber
 Concept Development, Evaluation and Selection

Morphological chart
Representing and exploring all the relationships in multidimensional problems
regarding shape and form
 Concept Development, Evaluation and Selection

Concept Evaluation & Selection

Evaluation methods:
1. Pugh concept selection method.
2. Weighted decision matrix.
 Concept Development, Evaluation and Selection

Pugh Concept Selection Method

This method compares each concept relative to a reference or datum concept.
Each criterion determines whether the concept is better than, poorer than or about
the same as the reference concept.

Steps in this Pugh concept selection method:

1. Choose the criteria by which the concepts will be evaluated
- Can refer to QFD (House of Quality).
2. Formulate the decision matrix
- Concepts on the row headings and criteria on the column headings.
3. Clarify the design concepts
- Make sure every team member understand every concept developed.
 Concept Development, Evaluation and Selection

4. Choose the datum concept

- Reference concept with which all other concepts are compared.
5. Run the matrix
- Use a three-level scale, better (+), worse (-) or same (S).
6. Evaluate the ratings
- Sum up the +, - and S ratings.
7. Establish a new datum and rerun the matrix
- To gain added insight regarding the highest rated concept.
8. Examine the selected concept for improvement opportunities
- Is there any improvement that can be done considering the worse ratings gained for
the selected concept.
Concept Development, Evaluation and Selection
 Concept Development, Evaluation and Selection

Weighted Decision Matrix

Evaluating competing concepts by ranking the design criteria with weighting factors
and scoring the degree to which each design concept meets the criterion.
Weighting factors:
- A 5-point scale (0-4) knowledge of the criteria is not very detailed.
- An 11-point scale (0-10) the information is more detail.
The evaluation steps are quite similar to Pugh concept selection method but without
any datum.
Concept Development, Evaluation and Selection