Product Design and Development, MME2259a Fall 2012

1. Product Design and Development, MME2259a Fall 2012 Prof. Paul M. Kurowski, Ph.D., P.Eng. Department of Mechanical and Materials EngineeringWestern University

2. Design is the quest for simplicity and order. Explicit in the term design are the concepts of order and organization. Design is the process of inventing artifacts that display a new physical order, organization, and form in response to function. Design is a conscious and intuitive effort directed toward the ordering of the functional, material, and visual requirements of the problem. Design is a statement of order and organization. Its goal is unity. It must hold together. It is an expression of the human ubiquitous quest for order. Design implies intention, meaning, and purpose. The planning and patterning of any act toward a desired, foreseeable end constitutes the design process. WHAT IS A DESIGN?

3. DESIGN IS COOL The notion of bringing something into being that did not exist before, whether from scratch or on the foundation of an existing design, is fascinating. Could there be a headier pursuit than participating in creation itself? Machine Design August 7, 2008

4. OBJECTIVE MME2259a Considering that designing is creative activity, the objective of MME2259a is to introduce design methodology and design tools (applicable to Mechanical Engineering) which are used to execute this creative design process with the objective of creating products that satisfy customers’ needs.

5. OBJECTIVE MME2259a Please download from our web page and read (CDEN2006)

6. PROCESS OF DESIGN Products that Meet Need Design Need Paths of the Design Process Design Knowledge Manufacturing Electronics Material Science Economics Kinematics Thermodynamics Physics Mechanics

7. Selection Design – choose item(s) from a catalog Configuration Design – organize the packaging of components Parametric Design – finding variables or parameters. Redesign, alternative design – modifying an existing product. Original Design – develop a totally new product. TYPES OF ENGINEERING DESIGN

8. Given: Shaft diameter 20 mm Speed 2000 rpm Radial force 6675 N (or 1500 lb) Require: To select an appropriate bearing. Possible Solutions: SELECTION DESIGN Housing Bearing 20 mm 6675 N Shaft [Ullman 1992]

9. SELECTION DESIGN “Fundamentals of Engineering Design” Barry Hyman, Prentice Hall

10. Computer components: Possible configurations for a computer (in each case, the bottom of the sketch represents the front of the computer). CONFIGURATION DESIGN Keyboard Mother board Floppy drive Power supply Extension slots

11. CONFIGURATION DESIGN “Fundamentals of Engineering Design” Barry Hyman, Prentice Hall

12. CONFIGURATION DESIGN • Configuration design • Selection and arrangement of components on a product • Selection and arrangement of features on a part • Factors in configuration design • Spatial limitations • Product interactions with other physical objects and the user(s) • Maintenance • Wear • Desired customization by the user • Need to include standard parts and assemblies • Need to conform to industrial standards • Need to replace consumable materials

13. CONFIGURATION DESIGN • Design for function check list • Strong • Stiff or flexible • Buckle resistant • Thermal expansion • Vibration • Noise • Heat transfer • Fluids transport/storage • Energy efficient • Stable • Reliable • Human factors/ergonomics • Safe • Easy to use • Maintainable • Repairable • Durable • Life cycle cost • Styling/aesthetics • Configuration alternatives can be analyzed according to • Design for function • Design for assembly • Design for manufacture

14. Example: Design a cylindrical storage tank that holds 4 m3 of liquid. Volume:V = p x r2 x l thus 4 = p x r 2 x l 1.273 = r 2 x l Note: There are an infinite number of values for (r, l); therefore more information is necessary. PARAMETRIC DESIGN l 2r

15. PARAMETRIC DESIGN “Fundamentals of Engineering Design” Barry Hyman, Prentice Hall

16. REDESIGN 1890 Humber bicycle 1990 Trimble bicycle

17. ORIGINAL DESIGN ? Boeing 787 www.elmundo.es

18. Analysis Problem – a well defined problem with one correct solution. Design Problem – an ill-defined problem with numerous satisfactory solutions. Example: The problem of designing a simple lap joint. ANALYSIS VS. DESIGN Analysis Problem – What size of SAE Grade 5 bolt should be used to fasten together two pieces of 1045 sheet steel, each 4 mm thick and 60 mm wide, which are lapped over each other and loaded with 100N ? Design Problem – Design a joint to fasten together two pieces of 1045 sheet steel, each 4 mm thick and 6 cm wide, which are lapped over each other and loaded with 100N.

19. ANALYSIS VS. DESIGN SAE Specifications for Steel Bolts http://www.americanfastener.com/technical/grade_markings_steel.asp

20. MME2259a WEBPAGES http://www.eng.uwo.ca/MME2259a/2012 http://www.eng.uwo.ca/designcentre http://www.eng.uwo.ca/mechanical/undergrad/current/course_outlines.htm

21. LAB SCHEDULE Sep. 11, Sep.13 Laboratory: Problem Statement Lab. Homework: QFD; Design Specifications Sep. 18, Sep. 20 Laboratory: Product Design Specifications, Program Plan Lab. Homework: Planning and Scheduling the Project Sep. 25, Sep. 27 Laboratory: Design Review Meeting # 1 Lab. Homework: Concept Generation and Evaluation Oct. 2, Oct. 4 Laboratory: Concept Generation and Evaluation Lab. Homework: Concept Generation and Evaluation Oct. 9, Oct. 11 Laboratory: none (Thanksgiving Holiday) Lab. Homework: Preparation for Design Review # 2 Oct. 16, Oct. 18 Laboratory Design Review Meeting # 2 Lab. Homework Detailed Design Oct. 23, Oct. 25 Laboratory: Detail Design Lab. Homework: Detail Design Oct. 30, Nov. 1 Laboratory: Detail Design Lab. Homework: Detail Design Nov. 6 Nov. 8 Laboratory: Detail Design Lab. Homework: Detail Design Nov. 13, Nov. 15 Laboratory: Design Review Meeting # 3 Lab. Homework: Detail Design Nov. 20, Nov. 22 Laboratory: Detail Design, Design Simulation Lab. Homework: Detail Design, Design Simulation Nov. 27, Dec. 29 Laboratory: Detail Design, Design Simulation Lab. Homework: Detail Design, Design Simulation Dec. 4, Dec. 6 Laboratory: Final presentations Lab. Homework none Notes The final design report, Product Development File (PDF) binder and the individual design notebooks are due on the last day of classes. The above schedule and topics are subject to adjustments and changes as needed.

22. MARKING Individual marks Two individual assignments (5% each) 10% Oct 1st, 2012, Nov. 19th, 2012 Midterm examination 20% Nov. 6th, 2012 Final examination (limited open book) 50% Fall examination session Team marks Individual Design Notebook 5% Final report and Product Data File 12% Design presentations (1% each) 3% Successful completion of the Certified SolidWorks Associate (CSWA) exam will count as a bonus assignment worth 5%.

23. DESIGN PROCESS AND THE PRODUCT LIFE-CYCLE Product Design Manufacturing Process Design Requirements Definition Manufacturing System Concept Development QFD Process FMEA Simulation Concept Development QFD Process FMEA Taguchi DFM Validation Testing Poke Yoke Simulation Detailed Process Design Detailed Product Design Prototype The extend of our design project Manufacturing Service & Support

24. Selection Design – choose item(s) from a catalog Configuration Design – organize the packaging of components Parametric Design – finding variables or parameters. Redesign, alternative design – modifying an existing product. Original Design – develop a totally new product. TYPES OF ENGINEERING DESIGN - AGAIN In our design project focus will be on selection design

25. MME2259a vs ES1050

26. COURSE PROGRESS Lectures Labs SolidWorks

27. CSWA EXAM - BONUS https://www.virtualtester.com/solidworks/branding/user-portal/user-portal.html

28. CSWA http://www.sdcpublications.com/Textbooks/Official-Certified-SolidWorks-Associate-Examination/ISBN/978-1-58503-656-1/

29. DESIGN PROJECT • The goal of the term project is to design a consumer product such as: log splitter, wheelbarrow, utility trailer, boat trailer, towing hitch, bicycle hitch carrier, car turntable etc. The selected project must allow the design team to use CAD design techniques such as assemblies, weldments and sheet metal. • It also must allow the use of Motion Simulation. The choice of product will be made by design team and will be approved by course instructor. • Each design team will: • identify the need • establish relevant design specifications • generate and evaluate several concepts • develop detailed design including engineering drawings • develop design documentation • use design simulation (limited to Motion Simulation) to investigate product performance

30. truss.SLDPRT

31. sheet.SLDPRT

32. HOMEWORK • Form design teams - 4 people • Buy design notebook and bring it to the lab next week • Think about your design project, we’ll decide next week in the lab • Install SolidWorks 2012

33. SOLIDWORKS INSTALLATION To install SolidWorks go to: www.solidworks.com/SEK   Use SEK-ID = XSEK12 Ask Maryam Refan (mrefan@uwo.ca) for serial number for activation

34. Sample projects

35. Boat cargo crane

36. A davit (dāv'ĭt, dā'vĭt) is a structure, usually made of steel, which is used to lower things over an edge of a long drop off such as lowering a maintenance trapeze down a building or launching a lifeboat over the side of a ship. Davit holding a rescue boat

37. Railway tricycle

38. Hand cart

39. Hand cart

40. Wheelbarrow

41. Boat trailer

42. Pedal kart – 4 wheeler

43. Pedal kart – 3 wheeler

44. Car turntable

45. Log splitter

46. Utility trailer

47. Engine hoist

48. Engine stand

49. Transmission jack

50. Mechanics creeper