Engineering design process

Engineering Design Process

Second Edition

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Engineering Design Process

Second Edition

Yousef Haik

University of North Carolina—Greensboro

Tamer Shahin

Kings College London, UK

Australia • Brazil • Japan • Korea • Mexico • Singapore • Spain • United Kingdom • United States

Engineering Design Process,

Second Edition

Yousef Haik and Tamer Shahin

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Christopher M. Shortt

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Library of Congress Control Number: 2010922617

ISBN-13: 978-0-495-66814-5

ISBN-10: 0-495-66814-1

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1 2 3 4 5 6 7 13 12 11 10

To our parents, wives, and children.

To future designers.

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Chapter 1 Introduction 2

Lab 1: Ethics 27

Lab 2: Ethics and Moral Frameworks 33

Chapter 2 Essential Transferrable Skills 42

Lab 3: Ice Breaking—Forming Teams 45

Lab 4: Team Dynamics 54

Lab 5: Project Management (Microsoft Project) 61

Lab 6: Presentation Style 90

Chapter 3 Identifying Needs and Gathering Information

(Market Research) 98

Chapter 4 Customer Requirements 114

Lab 7: Kano Model Customer Needs Assessment 126

Chapter 5 Establishing Functional Structure 132

Lab 8: Reverse Engineering 148

Chapter 6 Specifications 152

Chapter 7 Developing Concepts 172

Chapter 8 Concepts Evaluation 190

Chapter 9 Embodiment Design 212

Lab 9: Ergonomics 222

Chapter 10 Detailed Design 230

Lab 10: Material Selection Tutorial 239

Lab 11: Geometric Dimensioning and Tolerancing 243

Lab 12: Use of Pro/MECHANICA® for

Structural Analysis 243

Chapter 11 Selection of Design Projects 270

Brief Table of Contents

vii

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Preface xv

Chapter 1 Introduction 2

1.1 Objectives 3

1.2 Definition of Engineering Design 3

1.2.1 Design Levels 3

1.3 Importance and Challenges of Engineering Design 4

1.4 Introduction to Systematic Design 6

1.5 Design Process 8

1.5.1 Identifying Customer Needs (Requirements) 12

1.5.2 Market Analysis (Requirements) 14

1.5.3 Defining Goals (Requirements) 15

1.5.4 Establishing Functions (Product Concept) 16

1.5.5 Task Specifications (Product Concept) 18

1.5.6 Conceptualization (Solution Concept) 19

1.5.7 Evaluating Alternatives (Solution Concept) 20

1.5.8 Embodiment Design 20

1.5.9 Analysis and Optimization 20

1.5.10 Experiment 21

1.5.11 Marketing 21

1.6 Professionalism and Ethics 22

1.6.1 NSPE Code of Ethics 22

LAB 1: Ethics 27

LAB 2: Ethics and Moral Frameworks 33

1.7 Problems 38

1.7.1 Team Activities 38

1.7.2 Individual Activities 38

1.8 Selected Bibliography 40

Chapter 2 Essential Transferable Skills 42

2.1 Objectives 43

2.2 Working In Teams 43

2.2.1 Forming a Team 44

LAB 3: Ice Breaking—Forming Teams 45

2.2.2 Dynamics of a Team 51

LAB 4: Team Dynamics 54

2.3 Scheduling 55

2.3.1 Gantt Chart 56

2.3.2 CPM/PERT 57

Contents

ix

2.3.3 CPM/PERT Definitions 57

2.3.4 CPM/PERT Network Development 58

LAB 5: Project Management (Microsoft Project) 61

2.4 Research Skills 82

2.5 Technical Writing and Presentation 83

2.5.1 Steps in Writing a Report 84

2.5.2 Illustration Guidelines 85

2.5.3 Mechanics of Writing 86

2.6 Presentation Style 87

2.6.1 Objective 87

2.6.2 Oral Presentation Obstacles 88

2.6.3 Oral Presentation Dos and Don’ts 88

2.6.4 Oral Presentation Techniques 89

2.6.5 Question/Answer Session 89

LAB 6: Presentation Style 90

2.7 Problems 94

2.7.1 Team Activities 94

2.7.2 Individual Activities 94

2.8 Selected Bibliography 97

Chapter 3 Identifying Needs and Gathering

Information (Market Analysis) 98

3.1 Objectives 99

3.2 Problem Definition: Need Statement 99

3.3 Gathering Information: Clarifying the Need 101

3.4 How To Conduct a Market Analysis 102

3.4.1 Define the Problem 102

3.4.2 Develop a Strategy 104

3.4.3 Organize and Check the Information Gathered 105

3.5 Relevant Information Resources 106

3.5.1 Product Information 106

3.5.2 Industry Information 106

3.5.3 Company Information 108

3.5.4 Market Information 109

3.6 Web Tools 110

3.7 Case Study: Automatic Aluminum Can Crusher 110

3.7.1 Need Statement 110

3.7.2 Market Research 110

3.7.3 Market Information 111

3.7.4 Patents 112

3.8 Problems 112

3.8.1 Team Activities 112

3.8.2 Individual Activities 113

3.9 Selected Bibliography 113

Chapter 4 Customer Requirements 114

4.1 Objectives 115

x Contents

4.2 Identifying Customer Requirements 115

4.3 Prioritizing Customer Requirements 116

4.4 Case Study: Automatic Aluminum Can Crusher—Requirements 118

4.5 Organizing Customer Requirements—Objective Tree 120

4.6 Case Study: Automatic Aluminum Can Crusher—Objective Tree 123

LAB 7: Kano Model Customer Needs Assessment 126

4.7 Problems 129

4.7.1 Team Activities 129

4.8 Selected Bibliography 131

Chapter 5 Establishing Functional Structure 132

5.1 Objectives 133

5.2 Functions 134

5.3 Function Decomposition and Structure 134

5.3.1 Bounding Box and Overall Function Diagram 134

5.3.2 Function Tree 136

5.3.3 Function Structure 137

5.4 Detailed Procedure to Establish Functional Structures 139

5.5 Function Structure Examples 140

5.6 Reverse Engineering 144

5.6.1 Reverse Engineering Example—Dishwasher 145

5.7 Reverse Engineering Example—Paper Stapler 147

LAB 8: Reverse Engineering 148

5.8 Problems 149

5.8.1 Team Activities 149

5.9 Selected Bibliography 150

Chapter 6 Specifications 152

6.1 Objectives 153

6.2 Performance-Specification Method 156

6.3 Case Study Specification Table: Automatic Can Crusher 158

6.4 Quality-Function-Deployment Method 159

6.5 House of Quality: Automatic Can Crusher 165

6.6 Problems 169

6.6.1 Team Activities 169

6.6.2 Individual Activities 170

6.7 Selected Bibliography 171

Chapter 7 Developing Concepts 172

7.1 Objectives 173

7.2 Developing Working Structures 174

7.3 Steps to Develop Concepts From Functions 176

7.4 Brainstorming 177

7.4.1 Mechanism of Brainstorming Session 177

7.4.2 Ideation 178

7.5 Creativity 179

7.5.1 How to Increase Your Level of Creativity 180

Contents xi

7.6 Developing Concepts—Samples 182

7.6.1 Mechanical Vent 182

7.6.2 Wheelchair Retrieval Unit 182

7.6.3 Automatic Can Crusher 185

7.7 Problems 185

7.7.1 Team Activities 185

7.7.2 Individual Activities 188

7.8 Selected Bibliography 188

Chapter 8 Concepts Evaluation 190

8.1 Objectives 191

8.2 Sketch Assembly of Alternatives 192

8.3 Evaluating Conceptual Alternatives 192

8.3.1 Pugh’s Evaluation Matrix 194

8.3.2 Decision Matrix 195

8.4 Concepts Evaluation: Machine Shop Kit 197

8.5 Concepts Evaluation: Automatic Can Crusher 202

8.6 Problems 210

8.6.1 Team Activities 210

8.6.2 Individual Activities 210

8.7 Selected Bibliography 210

Chapter 9 Embodiment Design 212

9.1 Objectives 213

9.2 Product Drawings 214

9.3 Prototype 216

9.4 Design for “X” 217

9.4.1 Design for Manufacturing 217

9.4.2 Design for Assembly 218

9.4.3 Design for Environment 218

9.5 Safety Considerations 218

9.5.1 Safety Analysis Techniques 218

9.6 Human Factors 219

9.6.1 Human Sensory Capabilities 220

9.6.2 Anthropometric Data 221

LAB 9: Ergonomics 222

9.7 Problems 228

9.7.1 Team Activities 228

9.8 Selected Bibliography 229

Chapter 10 Detailed Design 230

10.1 Objectives 231

10.2 Analysis 232

10.3 Material Selection 232

10.3.1 Material Classifications and Properties 233

10.3.2 Material Selection Process 233

10.3.3 Primary Manufacturing Methods 235

xii Contents

10.4 Material Selection Theory–An Introduction 235

10.4.1 Density 235

10.4.2 Melting Point 236

10.4.3 Coefficient of Linear Thermal Expansion 236

10.4.4 Thermal Conductivity 236

10.4.5 Strength of Material 236

10.4.6 Ductility 237

10.4.7 Fatigue Properties 237

10.4.8 Impact Properties 237

10.4.9 Hardness 238

10.5 Bill of Material 238

LAB 10: Material Selection Tutorial 239

10.6 Geometric Dimensioning and Tolerancing 241

LAB 11: Geometric Dimensioning and Tolerancing 243

LAB 12: Use of Pro/MECHANICA® for Structural Analysis 243

10.7 Analysis Example: Mechanical Vegetable Harvesting Machine 250

10.8 Cost Analysis 257

10.9 Costs Classifications 258

10.10 Cost Estimate Methods 259

10.11 Labor Costs 261

10.12 Product Pricing 261

10.12.1 Break-Even Chart 261

10.12.2 Linear Programming 263

10.13 Problems 265

10.13.1 Team Activities 265

10.13.2 Individual Activities 266

10.14 Selected Bibliography 269

Chapter 11 Selection of Design Projects 270

11.1 Design Project Rules 271

11.2 Aluminum Can Crusher 273

11.2.1 Objective 273

11.2.2 Specifications 273

11.3 Coin Sorting Contest 273

11.3.1 Objective 273

11.3.2 Constraints 274

11.4 Model (Toy) Solar Car 274

11.4.1 Objective 274

11.4.2 Specifications 274

11.5 Workshop Training Kit 275

11.5.1 Specifications 275

11.6 Shopping Carts 275

11.6.1 Specifications 275

11.7 Mechanical Vents 276

11.7.1 Specifications 276

11.8 All Terrain Vehicle 276

11.9 Pocket-Sized Umbrella 277

Contents xiii

11.10 Model of Therapeutic Wheelchair 277

11.11 Disposable Blood Pump 277

11.12 Newspaper Vending Machine 278

11.13 Peace Corps Group Projects 278

11.13.1 Projects 278

11.13.2 Materials 279

11.13.3 Machining 279

11.13.4 Deliverables 279

Index 280

xiv Contents