ME 362

MECHANICAL
ENGINEERING DESIGN
Part 1.1

Muhammad Ilyas
 INTRODUCTION
Instructor
Muhammad Ilyas
PhD (ISAE-SUPAERO)
Assistant Professor
Office: G15 at FME
Ext. 2228
ilyas@giki.edu.pk

Availability:
Monday to Thursday: 1500-1700 Hrs.

Experience: Design for Manufacturing

Research: Rapid Dynamics, Material Characterization,
Predictive Simulations (FEA)
 COURSE CONTENTS

Philosophy and concept of engineering design

Engineering creativity
Phases and procedures in design
Management of engineering projects
Computer aided design (CAD)
Case studies in design with emphasis on
System modelling,
Optimization and
Reliability
Application of industrial design codes
COURSE OUTLINE

Philosophy and concept of engineering design se

ur
Engineering creativity c o
he
Phases and procedures in design
g t
r in
Management of engineering projects
d u
e d
Computer aided design (CAD)
er
Case studies in design with cov emphasis on
b e
System modelling, ill
s w
Optimisation
p ic and
t o
e
Reliability
h
llt
Application of industrial design codes
A
 COURSE/REFERENCE BOOKS

Mechanical Engineering Design by G E Dieter and L C

Schmidt, 4th Edition, Published by McGraw Hill, (ISBN
978-0-07-339814-3)
Product Design for Manufacture and Assembly, Second
Edition revised and expanded. By Geoffrey Boothroyd,
Peter Dewhurst and Winston Knight Published by Marcel
and Dekker, Inc (ISBN 0-8247-0584-X)
Any Engineering Design related book (e.g., Mechanical
Engineering Design (Shigleys MED) by BudynasNisbett)
www
ME362 ...
CLO_1
Understand the methods for problem identification,
need analysis, information gathering to provide a
viable economical solution.
CLO_2
Identifyvarious steps of the design process and
methods used for material selection, risks and costs
evaluation.
CLO_3
To communicate and implement effectively the design
process
ME362 ...
Monday - Friday
Timings-time table

Final class grade will be based on:

4 ~ 8 Quizzes 10%
01 Mid Exams 25%
Case Studies & Course Project 25%
01 Final 40%

Total 100%
CASE STUDIES & COURSE PROJECT
Case Studies / Design Projects have a major role
in this subject for practical problem solving
Discussion can be arranged with the instructor as per
request from students
Project may include
Theory / Analysis
Experimental work
Both
Assessment
Report
Presentation
Viva
 CASE STUDIES & COURSE PROJECT
Proposed Projects
SplitHopkinsons Pressure Bar Apparatus
Drop Tower Test Apparatus
Bring your ideas / project
Title Submission : Next week!
Projects should have two phases:

Before mid term phase

Until final term
The 1st phase of project should include all steps / design
studies, covered before mid term
The 2nd phase of project should cover methodologies
covered till final term
COURSE TOPICS
The Product Design Process
Need Identification and Problem Definition
Gather Information (as assignment)
Concept Generation and Evaluation
Embodiment Design
Modeling and Simulation
Materials Selection and Materials in Design
Materials Processing and Design
Risk, Reliability and Safety
Robust and Quality Design
Cost Evaluation
Detailed Design
Communicating the Design (as assignment)
COURSE TOPICS
Chapter 1 to 6 are related to general steps
involved in design process planning
Chapter 7 to 14 are related to the application of
knowledge already gained above
Chapter 16 is concerned with filling in the
details to ensure that a proven and tested
design can be manufactured
Chapter 17 is most important because as a
Design Engineer you must be able to
communicate your peers, your subordinates,
and your superiors as a successful Project
manager
COURSE TOPICS
Mechanical Engineering Design by G E Dieter
and L C Schmidt

ot
y n
ma
k
b oo
his !
f t r s e
s o u
p ic is co
t o t h
e
th d in
f
o ere
l l
A cov
be
TODAYS LECTURE

This lecture will mainly cover the following topics

Engineering Design Introduction

Design (Definition) / Product / Good Design
Design Process
Importance of design process
Types of design
Static vs Dynamic product
Problem solving methodology in design process
Description of Design Process
 INTRODUCTION
Design is a practice used not only by engineers but also
by other creative members of the society

artist, a sculptor, a composer, a playwright etc.

Everyday we see so many examples of designing same

part in different ways

Design examples of general and engineering applications?

DESIGNS OF A DUSTBIN IN PUBLIC PLACES
MORE.
http://www.3dlabz.com/3d-product-animation-
company.htm
INTRODUCTION
As practiced by many professionals, design has many
definitions
To fashion after a plan
To decide upon the look and functioning of a part / object
Realization of a concept
To create something that has never been

Then what is the Formal Definition of Design..?

Design establishes and defines solutions to, and
pertinent structures, for problems not solved before, or
new solutions to problems which have previously been
solved in a different way.
Conclusion Essence of Engineering is DESIGN
 DESIGN

Generally we design to;

Meet specified requirements and solve problems

But sometimes;
It is possible to create a need!!
I like it, I want it now, what is it?
seymour powell

????
????
 DESIGN AND SOCIETY

Design is something we do in social,

economic and cultural realms

DESIGN

NOT JUST
something we do to things!!
Christopher Frayling,
Chairman of the Design Council
 DESIGN AND SOCIETY

Design is something we do in social,

economic and cultural realms

DESIGN
To design is to pull together
something
new or to arrange existing things
in a new way to satisfy a
recognized need of society

NOT JUST
something we do to things!!
 DESIGN

Engineering Design is a purposeful activity directed

purposeful activity
towards the goal
goal of fulfilling human needs, particularly
those which can be met by technological factors of our
technological factors
civilisation

The process
process of seeking a match between a set of customer
derivedproduct
derived product requirements and a way of meeting those
requirements
requirements or finding an acceptable compromise

Total Design the systematic activity necessary from the

systematic activity
identification of the market/user need to the selling of the
market user need
successful product to satisfy
satisfy that need an activity that
that need
encompasses product,product,process, peopleand
process, people and organisation
organisations
 DESIGN SPECIALISM
Design specialties have a wide range of applications
building product industrial

graphic engineering
DESIGN

packaging defence manufacturing

 WHAT IS A PRODUCT
Something created by physical labour
and/or intellectual effort

Design Product could be

Consumer goods, Appliances,

Missiles, Jets, Planes

It may be complex engineering

system
Electric power generating system
Petrochemical plants
Building/bridge design
 DESIGN PRODUCT GROWTH
A design product grows based on the requirements of

Society, Culture
Environment,
Economy
It also pays attention to
the

Problems,
Requirements,
Needs, Desires

Strive to Improve
~ Quality of Life ~
Innovation ~ Performance ~
Evolution

Variant

Redesign

Original Adaptive
ENGINEERING DESIGN

Is Design a Science or Art?

Is it a Discovery or Invention?

Examples
ENGINEERING DESIGN

Ability to Design is both a Science and an Art

Science : can be learned by techniques and methods
(covered in textbook)
Art : is best learned by performing the activities
(design)
Discovery : is getting the first sight of, or first
knowledge of
something (e.g. North America, Graphene)
We can discover what has already existed but has not been
known before
Design should not be confused with Discovery
Design is the product of Planning and Work
Invention:
Design may or may not involve invention
ENGINEERING DESIGN

Conclusion
Engineering Design extends beyond the boundaries of
Science
Why??
Because
As a Design Engineer during professional career, you may
have the opportunity
To create dozens of designs
Have satisfaction of seeing them become working reality
As a Scientist during professional career, you may have the
opportunity:
To make one creative addition to human knowledge in your
whole life and many never do so
Can discover a new star but can not make one
Have to ask an Engineer to do it (e.g CERN)
ENGINEERING DESIGN

What is a Good Design ?

Good design requires both Analysis and Synthesis
Analysis
Decomposing problem into manageable parts
To understand performance/behavior of parts in service
using appropriate discipline of science/engineering and
computational tools
Usually involves simplification of real world problems
through models
Synthesis
Identification of Design Elements that will comprise
Product
Sometimes, its decomposition into parts
Combination of part solutions into a total workable system
 ENGINEERING DESIGN

Analysis offers a science of parts you take portions of

a part and study / work on it

Synthesis a science of the integration of parts you

combine parts and study / work on it
 Electronic
ENGINEERING DESIGN Design

Industrial

What is a Real World Problem that you Design

Civil
intend to design? Design

Partial Design Vs Total Design

Rarely neat and defined
Electronic
May need many engineering (fluid, Hydraulic
Mechanical
Electrical
solid mechanics etc) and non- Biochem Civil

engineering discipline (economics, Technical Facto

finance, law etc)
Input data may be best but out of the
scope of the individual Non-Technical Fac
Constraints may be time, money,
societal, environmental or energy That impinge o
regulations etc.
Product Design
 ENGINEERING DESIGN
How the Final Design will fare ?
Is it the best, most efficient?
The correct answer -- rarely known (a priori)
Only time will tell.!!!!!
One is hopeful that His Design will Work
 DESIGN PROCESS

The process through which a product is designed from

scratch to the product realization : Engineering Design
Process
Engineering design process can be used to achieve
several different outcomes:
Design of products
consumer goods (e.g. refrigerators, power tools, DVD
players etc) or
complex products (e.g. a missile system, jet transport plane)
Design of complex engineered systems
such as an electrical power generating station or a
petrochemical plant, a building or a bridge
THE DESIGN PROCESS

Problem identification Specifications

(Market analyst)

Conceptual design Concepts

(Product designer)

Embodiment design Layouts

(Design Analyst)

Detail design Drawings

(Development & Research Engineer)

Manufacture Product
(Process Planner and Production Engineer)
 IMPORTANCE OF DESIGN PROCESS
Any product development involves
Planning
Design
Manufacturing & QC
Marketing
It is important to devote due time to all of the above
The quality of a product is dependent on all of the phases
involved in the development
Design process is one of the major contributors towards
achieving the quality products!
Although, the cost of design may be smaller compared to
manufacturing costs the decisions made during design
stage affects 70 to 80% of manufacturing cost of the product
 IMPORTANCE OF DESIGN PROCESS
In the early 80s,
US companies start to feel pressure of quality products from
overseas
Response: emphasis is placed on reducing the manufacturing
costs
US NRC study (1991)
Companies realize: the key to world-competitive products lies
in high-quality product design
The competitiveness of product based on design can be
seen through the following three parameters:
Cost
Quality
Product cycle time
IMPORTANCE OF DESIGN PROCESSDESIGN COST
Product cost commitment during phases of design process
manufacturing
70~80% = for Design commitment decisions are
25% = for manufacture responsible for about
~ 25% cost of the
product

~ 95% of cost incurred

Design decisions are
responsible for about
~ 70% cost of the
product
5% = for design
95% = for material,
manufacture, labor,
capital
~ 5% of cost incurred
 IMPORTANCE OF DESIGN
PROCESS
Product cost commitment during phases of design process
 IMPACT OF DESIGN DESIGN
COST
Decision made in the design process are very important and it
will affect the cost of the product

Although design costs are very little in terms of the overall

product cost but have a major effect on the cost of the
product
If the design proves to be faulty just before the product
goes to market, it will cost a great deal of money to
correct the problem
IMPACT OF DESIGN PRODUCT QUALITY

The conventional concept of product quality : inspect the

product as it comes off the production line
However, today quality of the product means that quality
should be built into the design
One cannot compensate for the defects introduced in
the design phase in the manufacturing of the product
To incorporate quality within the product the
performance and features that are truly desired by the
customer who purchases the product are to be
incorporated in the product
IMPACT OF DESIGN PRODUCT CYCLE TIME

Cycle time : the development time required to bring a new

product to market
The use of new organizational methods, the widespread use
of computer-aided engineering, and rapid prototyping
methods are contributing to reducing product cycle time
Not only does reduced cycle time in-crease the
marketability of a product, but it reduces the cost of
product development
The design process should be conducted so as to develop
quality, cost-competitive products in the shortest time
possible
 STATIC PRODUCT VS DYNAMIC PRODUCT
Static Product
Products for which change in design
concept takes long time period e.g.,
refrigerators, automobiles etc
Exists in market where customer is not
eager to change and does not demand
significant improvement
Market characterized by stable number
of large producers
High price competition and little
research
Products are similar to each other
Technology is stable and mature
Users dont demand significant
improvement Industries standards may
even restrict change
Dynamic Product
Basic design concept varies frequently
as the original technology changes e.g.,
telecom systems, software etc
Customers may even drive change.
Customer seeks to reduce product cycle
time
Market is characterized by many small
producers
Involves active market research
Companies seek new product
Technology is rapidly advancing
There is a high product differentiation
and low industry standardization
TYPES OF DESIGN
 TYPES OF DESIGN
Original design: Original and Innovative concept to achieve a
need e.g. the design of the microprocessor was an original
design
Adaptive design: The design team adapts a known solution to
satisfy a different need, aim: to produce a novel application.
e.g. adapting the ink-jet printing concept to spray binder/glue to
hold particles in place in a rapid prototyping machine
Redesign: Improve an existing design. The task may be to redesign
a component in a product that is failing in service, or redesign
a component to reduce its cost of manufacture e.g. the change
in the shape of a part to reduce a stress concentration, or a new
material substituted to reduce weight or cost
TYPES OF DESIGN

Selection design: In this case, the design task consists of

selecting the components with the desired performance,
quality, and cost from the catalogs of potential vendors e.g. to
select nuts and bolts of available sizes prescribed in the from
the fortress-fasteners catalogue
Industrial design: This form of design deals with improving
the appeal of a product to the human senses, especially
its visual appeal. While this type of design is more
artistic than engineering, it is a vital aspect of many kinds
of design. e.g., design of office wares
TODAYS LECTURE

This lecture will mainly cover the following topics

Engineering Design Introduction
Design Definition/ Product/ Good Design/
Design Process
Importance of design process
Types of design
Static vs Dynamic product
Problem solving methodology in design process

Description of Design Process