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DESIGN PROCESS
2
Need analysis
System/Technical/
Functional Analysis and Design & analysis of
Design of the Product/system Dimensions/Size
Description/Theory of
Dimensioning
Manufacturing and
construction
Design & analysis of
mechanisms for strength,
Usage/exploitation forces, moments &
movements
Salvation
Need Analysis of
Initial Analysis forces
design
analysis System Analysis of
Analysis strength,
vibrations, &
Functional other aspects
Evolving
concept
Analysis
Analysis of
Dimensions
Evolve
Shape Product
design Concept Detailed Design
Detailed
design General Component/p
Assembly arts
Concept options
Manufac
turing
Total structure Pre- Physical
systems
design production Performance
design
prototype Testing
Individual form
design
Proto-type Technical breakthrough
developme working prototype
nt developed!!!
As can be seen from the above life cycle (fig 2.1)the creation of a
new product or systems takes in many levels of activity and many
skills as shown in the block diagram (fig 2.1 contd.)above.
The main aim of this text book is to analyze closely some of these
design aspects like creation of a product, form design, form
factors and appearance of the product. Apart form the above topic,
this text book will also discuss topics such as Need Analysis,
System Analysis, Technical Analysis, and Functional Analysis.
Hence, the contents of this text book should be seen only as apart
of design technique.
2.2NEED ANALYSIS AND SPECIFYING THE NEEDS:
2.2.1 DEFINITION OF TERMS
1.1.1 Design
The word” design” has many meanings including the following.
To plan, conceive, invent and to designate so as to transmit the
plan to others. Design means creation of the purest sense. It is the
initial process in the construction, manufacturing etc. of products.
2.2.1.2 Construction
It is the process of materialization of the design layout.
Construction could be experimental (prototypes and models) for
testing or manufacturing purposes, or final as in the case building
and road constructions.
1.1.3 Manufacturing
It is the process of industrialization of a product for consumer
applications. Manufacturing could be unit/job/batch/mass
production using machine tools.
1.1.4 Mechanical design and construction
Unlike what is commonly called building construction
(construction of buildings, roads, bridges etc.) mechanical design
and construction deals with the creation and construction of
mechanically or electro- mechanically operated mechanisms such
as machine tools, devices, equipments or systems.
Design
Construction
Manufacturing
money that been placed on the problem, and your own position in
the organization.
Hook
External Environment
Internal Environment
Resources:
Man Power Process
Material Input Transfo Output Products
Machine rmation and
Information Services
Money
SYSTEM
Fig 2.9 Systems Approach
First of all a designer should establish whether he has got the
required resources (shown in Fig 2.9) to construct a designed
product. Without the possible availability of the minimum
required resources to manufacture a product there is no point in
making a design.
Hence using the systems approach towards need specification and
satisfaction the designer should make sure that all resources are
available at the disposal of the organization/Agency for which the
design is made and then he can proceed with the design process.
Before proceeding further on the system analysis first let us
discuss the various levels of systems (viz.,) manual systems,
mechanical systems, automated systems etc.
2.3.4 SYSTEM LEVELS
Systems may be classified in terms of processing power and the
degree of automation involved. They are
• Manual systems: in a manual system the earliest and still
most prevalent type of system is a system where the human
being is the data and the process processor. Remark:
Animals can also be integrated as process processors in this
system.
Technical
Command Object Physical
Environment
Energy Human
Environment Environment
HUMAN
ENERGY
ENVIRONMENT ENVIRONMENT
User and Crane (Possible accidents to
(Hand And Muscular human being due to
Energy, Lifting Energy) failure)
Problem
Analysis
Main
C Functions
R
I Sub-
T Functions
E and Means
R
I
A Basic
Structure
Quantified
Structure
Pass thro’ Water Tea Tea Water Remove tea Remove leaves
heating surface
Water Tea
element element
energy to water to
Bring Bring Measure Time Measure Tea Measure time
Concentration dependent status
Figure 2.21 A vice. The starting point for figures 2.22 to 2.24
Figure 2.24 Suggested form designs for the sliding jaw, based
on two different groups of the functional surfaces.
Refer Figure 2.27, when designing the frame there are three
banned areas:
1. There must be room for the piston in all its positions.
2. There must be room for an object of a closely defined
maximum size
3. There must be room for the object to be put into and taken
out of the press.
In other words the frame must be designed so that the two
functional surfaces are connected in a way which takes account of
the banned areas, and which allows it to fulfill its function- to
transmit the necessary forces.
300
p
2
P=150 tons
Fig 2.40 Ladle
C C
B B
A A
thickness of the hook. Section ‘B’ will establish the shank width
and Section ‘C’ will establish eye details.
a c c
Y Y
A A’
380 C C
t
v
R
R Centroid Axis
Centroid
r Neutral Axis
P/2 Axis
SECTION AA’
I) Stresses at section A-A:
Fig stresses
Three different 2.42 Thecan
ladle
act hook
at the as curved
bight beam.
section of the hook. Of
the three, the bending stress in the curved section of the hook that
is due to the weight of the ladle is the most significant. Because of
geometry, the hook at section A is classified as a curved beam. A
characteristic of the curved beam is that the neutral axis does not
coincide with the centroid axis (Fig 2.42).
My
σ=
Ay ( r − y )
where r = v+y (refer Fig 2.15) A = 2ct
P 150 x104
The bending moment is R=M= (190 + c )
2 2
75 x104 (190 + c )
∴Maximum Tensile Stress σmax = y
Ay ( r − y )
Since minimum value of (r-y) is ‘a’ and the maximum value of y
is (c - y )
75 x104 (190 + c )
σ max =
Ay a
c− y ( )
By definition;
A 2ct
y =R- = (190 + c ) −
dA dA
∫V ∫v
a+2 c
dA tdv
∫v = ∫
+2 c
= t ln v 190
190
a
v
190 + 2c
= t ln
190
2ct
∴ y = (190 + c ) −
190 + 2c
t ln
190
if we let 2c = 600mm
then y = 69mm
10792
and σ max =
t
2. The direct (axial) stress in section ‘A-A’ is,
75 x104 1250
σd = =
600t t
3. The lateral (sidewise) bending stress in section ‘A-A’ is,
25 mm
l
t
2c
12
293.88 175
= − 25
w 2
18367.5
=
w
These two stresses act simultaneously at the location of B:
∴ σ total = σ d + σ lb
4285.7 18367.5
∴86 = +
w w
∴w =263.43 ≈ 264 mm
j 200 j 175
175
182 200 182
264
B
3000
380 600