CHAPTER 3 (a)

The Design Process & The Role of CAD

MEC435 COMPUTER-AIDED DESIGN
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3.1 DESIGN PROCESS

Any product begins with a need based on customers and markets demand before being translated into a finished product. Main processes involve:
Design process. Manufacturing process.

Types of Design
Original Design
Also called innovative design. A truly original design involves invention. Successful original design rarely occur, but when they do occur they will give a big impact to the market. E.g. Microprocessor.

Adaptive Design
Adapts a design from a known solution to fulfill a different need to produce a novel application. Involves synthesis and are relatively common in design. E.g. Adapting the ink-jet printing concept to spray binder to hold particles in place in a RP machine.

Redesign
Mostly practiced to improve an existing design. Usually does not involve the change in the working principle or concept if the original design. Maybe changing some of the design parameters (e.g. materials, shape, etc.) variant design.

Selection Design
Most design uses standards components supplied by vendors. Implemented by selecting certain components base on the needed performance, quality and cost from catalogs of potential vendors.

Industrial Design
Deals with improving the appeal of a product to the human senses especially its visual appeal (aesthetic). More artistic than engineering but still an important aspect of kinds of design. Consideration on how the human user can best interface with the product.
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Closed-loop Product Cycle

Product Cycle in Conventional Manufacturing Environment

Product Cycle in Computerized Manufacturing Environment

Morphology of Design

Phase 1: Conceptual Design Phase 2: Embodiment Design Phase 3: Detail Design Phase 4: Planning for Manufacture Phase 5: Planning for Distribution Phase 6: Planning for Use Phase 7: Planning for Retirement of product
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Engineering Design Process 1st Three Phases

Concept generation Creativity methods Brainstorming Functional models Decomposition Systematic design methods

Define problem Problem statement Benchmarking QFD PDS Project planning

Gather information Internet Patent Technical articles Trade journal Consultants

Evaluate & select concept Decision making Selection criteria Pugh chart Decision matrix AHP

Phase 1- conceptual design

Product architecture Arrangement of physical elements Modularity

Configuration design Preliminary selection of materials and manufacturing process Modeling Sizing of parts
Phase 2- embodiment design

Parametric design Robust design Set tolerance DFM,DFA,DFE Tolerances

Detail design Engineering drawings Finalize PDS

Phase 3- detail design

PRINCIPLES OF DFMA
Minimize total number of parts Use modular design Minimize part variations Use a multifunctional design Design parts for multiuse Design to simplify fabrication Use of fastener Minimize assembly direction Maximize compliance Minimize handling Eliminate or simplify adjustment Avoid flexible component
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Design For Manufacture (DFM)

Design for ease of manufacture of the collection of parts or product More as a philosophy It is a way of thinking that can be applied to component or product DFM 3 key element:
1. Process selection 2. Reducing the number of process stages 3. Designing of the process

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1. Process Selection
Analysis of material and processing methods for individual component based on: - Tolerance requirement - Production volume - Component complexity requirement - Critical performance criteria

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2. Reducing Process Stages

Eliminate unnecessary process stages through: - Component minimization - Elimination of finishing process - Combining processes

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3. Design of the Process

To ensure design of component will satisfy the specific production process Exploit the benefits and limitation of the process - Design for machining - Design for casting - Design for injection moulding - Design for Powder Metallurgy

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Design for Assembly (DFA)

Simplicity minimize part number, part variety, simplify assembly sequences and component handling and insertion Standardize on material usage Use the widest possible tolerance Choose material that suit function and production process Minimize non value added operations Team work Reduce number of parts Ensure that the remaining parts are easy to assemble
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Design for Assembly Outcomes

Shorten product design time Reduce assembly time Simplify assembly process Reduce total material cost Improves quality and reduce defects Reduce labour content

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OTHER DESIGN CONSIDERATIONS

1. Product Use 2. Design Life 3. Human Factor Consideration

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1. Product Use
Customer is always right U.S. consumer products are developed under a philosophy that the customer will buy the cheapest product available. But it is hopefully not as true for engineering design products where the customer is more sophisticated and will normally demand performance, reliability, serviceability, reasonable cost, safe operation, and good human engineering (ergonomics). Customer expectations are compared with the various product design characteristics to identify those that are not addressed and to develop an optimized product plan incorporating design modifications accommodating the dominant expectations. Product liability in the United States is a design consideration that is growing in importance. Users of products are increasingly aware of their opportunities to sue manufacturers, and court sentiment often leans toward the 18 consumer even when product misuse is involved.

2. Design Life
Many engineering design products are designed for a specific installation or assembly, and it is normally assumed that they will remain in this application for their useful life. Design life is in terms of cycles or hours of operation, and it is a fairly straightforward task to design and test the product to meet these requirements. Some thought needs to be given to retirement of the product after completion of its design life. If the environment is to be treated as surroundings (in a thermodynamic context), the product must be capable of being refurbished and reused or the materials of construction must be recyclable or biodegradable.

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3. Human Factor Consideration

All designers should consider the operator of the device, component, or system under development and strive to produce user-friendly products. The term operator must include the person(s) that maintains and repairs the product as well as the person that uses it. A significant amount of anthropomorphic information is available that can be used to determine the size and location of manually actuated devices on the product as well as the optimum location of visual elements. An individual's capacity for doing work should be considered in the design and, for repetitious tasks, a system layout should be selected that minimizes boredom but does not overload the individual's capacity to comprehend. The product must be aesthetically appealing because many products are purchased primarily due to their look and may be the 20 feature that initially interests the potential buyer.

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3.2 COMPUTER APPLICATIONS

Three (3) major computer applications in engineering environment.
1. Design 2. Analysis 3. Manufacturing

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Computer Application in Design

Conceptual and also geometrical modeling design stage uses a lot of computer application. Both hardware and software. Visualizing and styling of products for concept generation 1st idea of product. Widely usage of CAD tools graphics and 3D modeling. E.g. Hardware: 3D Scanner, digitizer, pointing device etc. E.g. Software: AutoCAD, Pro-Engineer, Solidworks, UniGraphics, CATIA etc.

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Computer Application in Analysis

Engineering analysis and optimization design stage uses computer application. Mainly for design analysis structure, strength, heat transfer, fluid flow etc. Analysis may be used as a source of design verifications for design calculations and predictions. Involves CAE tools FEA, CFD, Ergonomics etc. E.g. ABAQUS, ANSYS, Mannequin-Pro, CFX etc.

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Computer Application in Manufacturing

Mainly used for planning, monitoring, control and executing manufacturing processes. Use of CAM tools CNC machines, software etc. Involves wide areas from process planning to marketing. E.g. Software: MasterCAM

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