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SEMM 1921

Chapter 10

Mechanical Engineering Design Process

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Objectives

  • To introduce engineering design process flow.
  • To give exposure on what need to be done during design process.
  • To acknowledge what are other mechanical subjects related in design process.
  • To address the importance of engineering design analysis in innovation

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DESIGN PROCESS

  1. PROBLEM DEFINITION & DESIGN NEEDS
  2. LITERATURE & MARKET REVIEW (DESIGN RESEARCH)
  3. DESIGN SPECIFICATION (PDS)
  4. CONCEPTS GENERATION
  5. CONCEPT SELECTION EVALUATION
  6. REFINE FINAL CONCEPT
  7. ENGINEERING ANALYSIS
  8. FINAL DESIGN
  9. DRAWING & FABRICATION
  10. MODELING, PROTOTYPING & TESTING

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Problem

Definition

Design

Research

Concept

Generation

Concept

Selection

Engineering

Analysis

Final

Design

DETAILED ANALYSIS (DESIGN ENGINEERING)

PRODUCT

CONCEPTUAL DESIGN

NEEDS

INTRODUCTION TO DESIGN

COMPONENT DESIGN / MATERIAL SCIENCE

SOLID MECHANICS II / MECHANICS OF MACHINES / ADVANCED ACADEMIC ENGLISH / MECHANICS OF FLUIDS II / APPLIED THERMODYNAMICS / MANUFACTURING PROCESSES / CONTROL ENGINEERING / INDUSTRIAL ENGINEERING / FINITE ELEMENT METHODS

ENGINEERING DRAWING / INTRODUCTION TO MECHANICAL ENGINEERING

THE PRODUCT DESIGN PROCESS�

PDS

Refine Concept

Drawing, Prototyping, Testing

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PROBLEM DEFINITION & DESIGN NEEDS

  • BRAINSTORMING SESSION – LISTING OF QUESTION AND REQUIREMENT.
  • WHY NEED NEW DESIGN ?
  • WHAT IS THE PROBLEM OF CURRENT EXISTING PRODUCT ?
  • HOW THE NEW DESIGN WILL PROVIDES SOLUTION ?
  • NEW REGULATION OR TREND ?

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Design needs

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LITERATURE REVIEW & MARKET SURVEY

  • DO MIND MAPPING
  • ORGANISE SPIDER DIAGRAM
  • ASSIGN RESEARCH AREA
  • PREPARE BRIEF NOTES
  • DATA, TABLES AND CHARTS
  • DEFINE LIMITATION
  • DEFINE WORKING AREA/ DOMAIN
  • DEFINE PARAMETRIC VARIANCES

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Needs into Specifications

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DESIGN SPECIFICATION

  • SET CLEAR LIMITATION – DIMENSION COST WEIGHT CAPACITY
  • PROVIDES WORKING DOMAIN FOR DESIGNERS
  • SET AS A GUIDE TO GENERATE CONCEPT DESIGN
  • TO PROVIDE DESIGN CONCEPT THAT WILL NOT EXCEED OR PERFORM UNDER REQUIREMENT.

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Specification

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CONCEPT GENERATION

  • CONCEPT IS AN INITIAL PROPOSE DESIGN SOLUTION
  • NORMALLY MORE THAN ONE CONCEPT GENERATED (USE MORPHOLOGY CHART )
  • PREPARE SKETCHING, NO DIMENSION REQUIRED
  • CONCEPT MUST BE WORKABLE TOWARDS SOLVING PROBLEM
  • FOLLOW ALL DESIGN SPECIFICATION AND FULLFILL DESIGN NEEDS

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MORPHOLOGY CHART

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Concepts sketching

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CONCEPT SELECTION

  • SELECTING THE BEST CONCEPT
  • CREATING SELECTION CRITERIA BASE ON ERGONOMIC, MAINTENANCE, OPERATION, PERFOMANCE
  • CRITERIA WEIGHTAGE
  • MATRIX EVALUATION TECHNIQUE

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Design criteria matrix

EVALUATION MATRIX

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ENGINEERING ANALYSIS

  • STRESS DISTRIBUTION
  • SAFETY FACTOR
  • FATIGUE ANALYSIS
  • DURABILTY
  • COMPONENT SELECTION
  • MATERIAL SELECTION

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Bending Stress Analysis

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Human walking analysis

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Vibration analysis

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FINAL DESIGN

  • FULLY SATISFY DESIGN SPEC AND NEEDS
  • CLEAR SCHEMATIC AND DRAWING
  • FOR SYSTEM OR PROCESS - ALGORITHM AND FLOWCHART MUST BE WELL DEFINE
  • VIRTUAL 3D MODEL

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3D Model

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DRAWING & FABRICATION

  • 2D OR 3D MODEL
  • ORTHOGRAPHIC AND ISOMETRIC
  • EXPLODED AND SECTIONAL DWG
  • ASSEMBLY DWG
  • PRODUCTION DWG
  • PARTS MACHINING AND FABRICATING

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Sectional dwg

Exploded dwg

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Fabrication

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PROTOTYPE AND TESTING

  • COMPLETE DESIGN ASSEMBLY
  • SETTING AND FINE TUNING
  • SERIES OF TESTING AND EVALUATION AND IMPROVEMENT
  • FINAL PRODUCT REFINING BEFORE PRODUCTION

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Prototype testing