MECHANICAL ENGINEERING DEPARTMENT

DJJ5133 ENGINEERING DESIGN

NAME: KUBHERAN A/L SELVATHURAI

MATRIKS NO: 23DKM18F2033

LECTURER’S NAME: ENCIK MOHD FUAAD BIN FESUL

CASE STUDY
1. CONCEPT GENERTION AND DESIGN CONSIDERATION
1.0 DECISION MAKING AND CONCEPT SELECTION
  series of decision-making techniques are considered. During a design
process several of these techniques might be used. To move quickly when the
stakes are low, simple decision-making techniques are appropriate.

 for example, Is the decision whether or not to choose a single course of

action? In other words, is the decision between "yes" and "no"? If so, simple
majority voting or consensus may be appropriate.

 Is the decision to pick one of a small number (say 3 or less) items? If so,
then simple majority voting, instant run-off voting or multibooting can be helpful.

 If the decision to is choose one (or a few) from a list of many options, then
a method using decision matrices maybe helpful. Perhaps multiple rounds of
decision-making will be necessary.

1.1CONCEPT GENERATION IN THE PRODUCT DEVELOPMENT

PROCESS
(a). FUNTIONAL DECOMPOSITION AND SYNTHESIS
Design Synthesis is the process of taken the functional architecture developed in
the Functional Analysis and Allocation step and decomposing those functions into
a Physical Architecture (a set of product, system, and/or software elements) that
satisfy system required functions. Synthesis is the process whereby the Functional
Architectures and their associated requirements are translated into physical
architectures and one or more physical sets of hardware, software and personnel
solutions. It is the output end of the Design Loop. As the designs are formulated, their
characteristics are compared to the original requirements, developed at the beginning
of the process, to verify the fit. The output of this activity is a set of analysis-verified
specifications which describe a balanced, integrated system meeting the requirements,
and a database which documents the process and rationale used to establish these
specifications.
(b) MORPHOLOGICAL ANALYSIS

In order to apply morphological analysis to product design, we simply identify

the critical functions in our function structure diagram and then identify many
different solutions for each function. The results of this research are compiled
and presented in morphological chart. A morphological chart has the critical sub
functions listed across the 1st row and then each column contains the different
solutions for each critical function. Morphological analysis is the analysis of
morphology in various fields. Morphological analysis (problem-solving) or
general morphological analysis, a method for exploring all possible solutions to
a multi-dimensional, non-quantified problem. Analysis of morphology
(linguistics), the internal structure of words. Analysis of morphology (biology),
the form and structure of organisms and their specific features. Mathematical
morphology, a theory and technique for analysis and processing of images and
geometrical structures. Morphological dictionary, in computational linguistics, a
linguistic resource that contains correspondences between surface form and
lexical forms of words.

(c) PUGH CONCEPT SELECTION PROTECTION

The Pugh concept selection method does not aim to select the best concept, but to develop
the best concept. Most of the time, there is not one superior concept, but each with
strengths and weaknesses. Thus, the Pugh concept selection combines and improves
concepts by removing bad features and combining only the best ones. The Pugh concept
selection method aims to go from specification to concept. It emphasizes both convergent
thinking and divergent thinking. Convergent by selecting among options and divergent by
synthesizing new options.
This section outlines how to execute the Pugh Concept Selection. Firstly, prepare the
selection matrix with design concepts on the top row

 Prepare selection matrix with design concepts (top row) and criteria (leftmost
column)
 Select the datum, the “best” concept, the concept to beat. Could be a
competitors’
 Rate each concept against the selection criteria relative to the neutral
 Use the key
○ 0 = Same
○ + = Better
○ - = Worse
○ Seach for info from external source (spec sheets), ask an expert
○ Build a prototype and test!

● Rank concepts

● Combine and improve concepts

● Select one or more

● Reflect on results and process

1.2 EXPLAIN CREATIVE THINKING METHOD
Brainstorming

This technique can be very useful in small or large-scale problems that

require a creative solution. The main goal is to form a group of people and
throw around ideas without interference.
The general idea of brainstorming is that, by having an excess of potential
solutions, it gets easier to reach one with the highest level of quality.
Brainstorming has several advantages that can help you exercise your
creative thinking skills. For starters, it does not require a rigid structure to
function, being very informal. However, it can be facilitated by professional
guidance. Also, the people involved do not even need to be together at the
same time, as you can use a virtual setting or put ideas into a shared
document. For it to work well, all participants must be aware of the problem
that requires a creative solution and are familiar with how brainstorming
works. In the end, do not forget to register all the ideas through proper
documentation.
Lateral thinking

Sometimes, the answer to a problem is not in front of it, but besides it. That
is the general idea of lateral thinking, which is a great way to exercise your
creative skills and come up with innovative plans.
Lateral thinking involves looking in less obvious areas and lines of
reasoning. It can work well if you and your partners try to put yourselves
under different perspectives or reverse the problem to look at it differently.
For instance, the direct solution to a loss of sales online would be to put up
more ads and promotions. However, lateral thinking might reach alternative
paths, like using e-mail marketing to reach customers that have not bought
from you in a while.
This can be extrapolated further, even using absurd lines of thinking to get
your creative juices flowing. The most important aspect of this process is
to go where you would not usually choose to go.
Mind mapping
The process of mind mapping helps you connect ideas you never imagined
could be combined. Because of that, it might help you reach appropriate
solutions while using creative thinking skills.
A mind map is a chart where you input ideas and connect them. It can have
possible solutions to a problem, its immediate consequences, and be the best
course of action to deal with them. Alternatively, your mind map can serve
as a way to see a bigger picture regarding what you are trying to do.
 Mind mapping can even be done individually. Sometimes, you may already
have all the ideas you need but it is required to put them to paper. Creating a
mind map helps to organize them and naturally reach conclusions.
Also, since a mind map is essentially an infographic, those who were not
part of the process can easily understand it. Therefore, it serves as a valid
piece of documentation.

1.3Explain this following below:

(a)ANALYTIC HIERARCHY PROCESS

The multi-criteria programming made through the use of the analytic hierarchy
process is a technique for decision making in complex environments in which
many variables or criteria are considered in the prioritization and selection of
alternatives or projects.

(b)PRODUCT ARCHITECTURE

Product architecture is the organization (or chunking) of a product’s functional

elements. It’s the ways these elements, or chunks, interact. It plays a significant
role in how to design, make, sell, use, and repair a new product offering.
Linking to system-level design and the principles of system engineering.

(c) CONFIGURATION DESIGN

Configuration design is a kind of design where a fixed set of predefined

components that can be interfaced (connected) in predefined ways is given, and
an assembly of components selected from this fixed set is sought that satisfies a
set of requirements and obeys a set of constraints.

(d) PARAMETRIC DESIGN

Parametric design is a process based on algorithmic thinking that enables the

expression of parameters and rules that, together, define, encode and clarify the
relationship between design intent and design response.

Parametric design is a paradigm in design where the relationship between

elements is used to manipulate and inform the design of complex geometries
and structures.
1.4Explain the Design for Manufacture (DFM) and Design For Assembly
(DFA)

Design for Manufacture (DFM)

DFM describes the process of designing or engineering a product in
order to facilitate the manufacturing process in order to reduce
its manufacturing costs. DFM will allow potential problems to be
fixed in the design phase which is the least expensive place to
address them.

Design For Assembly (DFA)

Design for assembly (DFA) is a process by which products are
designed with ease of assembly in mind. If a product contains fewer
parts it will take less time to assemble, thereby
reducing assembly costs.
1.5DIMENSIONS AND TOLERANCES

Geometric Dimensioning and Tolerancing (GD&T) is a system for

defining and communicating engineering tolerances. It uses a symbolic
language on engineering drawings and computer-generated three-
dimensional solid models that explicitly describe nominal geometry and
its allowable variation. It tells the manufacturing staff and machines what
degree of accuracy and precision is needed on each controlled feature of
the part. GD&T is used to define the nominal (theoretically perfect)
geometry of parts and assemblies, to define the allowable variation in
form and possible size of individual features, and to define the allowable
variation between features.

1.6Explain the following below:

(a) Intellectual Property
Intellectual property is a category of property that includes intangible
creations of the human intellect. There are many types of intellectual
property, and some countries recognize more than others. The most well-
known types are copyrights, patents, trademarks, and trade secrets
(b) PATENTS

A patent is a form of intellectual property that gives its owner the legal right to
exclude others from making, using, or selling an invention for a limited period
of years in exchange for publishing an enabling public disclosure of the
invention. In most countries, patent rights fall under private law and the patent
holder must sue someone infringing the patent in order to enforce his or her
rights. In some industries patents are an essential form of competitive
advantage; in others they are irrelevant.

(c) COPYRIGHTS

Copyright is a type of intellectual property that gives its owner the exclusive
right to make copies of a creative work, usually for a limited time. The creative
work may be in a literary, artistic, educational, or musical form. Copyright is
intended to protect the original expression of an idea in the form of a creative
work, but not the idea itself.

(d) TRADEMARKS

A trademark is a type of intellectual property consisting of a recognizable sign,

design, or expression which identifies products or services of a particular source
from those of others, although trademarks used to identify services are usually
called service marks. The trademark owner can be an individual, business
organization, or any legal entity. A trademark may be located on a package, a
label, a voucher, or on the product itself. For the sake of corporate identity,
trademarks are often displayed on company buildings. It is legally recognized as
a type of intellectual property.
1.7Explain the life cycle design

Life-cycle engineering seeks to incorporate various product life-cycle

values into the early stages of design. These values include functional
performance, manufacturability, serviceability, and environmental
impact. We start with a survey of life-cycle engineering research
focusing on methodologies and tools. Further, the paper addresses
critical research issues in life-cycle design tools: design representation
and measures for life-cycle evaluation. The paper describes our design
representation scheme based on a semantic network that is effective for
evaluating the structural layout. Evaluation measures for serviceability
and recyclability illustrate the practical use of these representation
schemes.

1.8Determine and explain design for sustainability and the environment

Environmental sustainability as a topic in international studies is most
often considered in the context of “sustainable development,” a goal-
oriented, normative concept that suggests the need to reconcile the often
conflicting goals of economic development, environmental protection,
and social progress. The environmental pillar refers to the laws,
regulations, and other policy mechanisms
concerning environmental issues. These issues include air and water
pollution, solid waste management, ecosystem management,
maintenance of biodiversity, and the protection of natural resources,
wildlife and endangered species.
1.9Explain the material selection in design process

Material selection is a step in the process of designing any physical

object. In the context of product design, the main goal of material
selection is to minimize cost while meeting product performance goals.
Process Selection refers to the way an organization chooses to produce
its good or services. It takes into account selection of technology,
capacity planning, layout of facilities, and design of work systems.
Process selection is a natural extension after selection of new products
and service.
1.10 Explain the Cost requirement and Bill of Material (BOM) in process

It used to be that costs were a fact, which one encountered after finishing
a product. These days the emphasis has shifted from performance driven
to cost reduction. In order to produce efficient in all phases of the product
life cycle, the design phase is critical. It’s said that 70% of the life cycle
is determined during design.
In order to reduce the costs there are several product design measures
such as Quality Function Deployment, Design For Manufacturing and
Assembly, Value Analysis/Function Analysis, Early Supplier
Involvement, Activity Based Costing, Target Costing and several
guidelines. The last two methods and the guidelines will be described
here.
A bill of materials (BOM) is an extensive list of raw materials,
components, and instructions required to construct, manufacture, or repair
a product or service. A bill of materials usually appears in a hierarchical
format, with the highest level displaying the finished product and the
bottom level showing individual components and materials.
2 STRESS ANALYSIS

2.1What is the definition of stress analysis?

Stress analysis is an engineering discipline that uses many methods to
determine the stresses and strains in materials and structures subjected
to forces. In continuum mechanics, stress is a physical quantity that
expresses the internal forces that neighbouring particles of a continuous
material exert on each other, while strain is the measure of the deformation
of the material.

In simple terms we can define stress as the force of resistance per unit per
unit area, offered by a body against deformation. Stress is the ratio of force
over area (S =F/A, where S is stress, F is the external force or load and A is
the cross-sectional area). Strain is the ratio of change in length to the original
length, when a given body is subjected to some external force (Strain=
change in length÷the original length).

Stress analysis is a primary task for civil, mechanical and aerospace

engineers involved in the design of structures of all sizes, such
as tunnels, bridges and dams, aircraft and rocket bodies, mechanical parts,
and even plastic cutlery and staples. Stress analysis is also used in the
maintenance of such structures, and to investigate the causes of structural
failures.
2.1 Explain differentiate between direct tension and direct compression of
stresses

BASIS OF
TENSION COMPRESSION
COMPARISON

Tension is the force that Compression is the force that

Description tries to elongate a body or tries to shorten the body or an
an object.   object.  

If a body is in tension, the If a body is in compression, the

Effect Of Force overall forces are pulling forces acting upon it are directed
away from the object.   towards the body.  

Tension can be related to Compression can be associated

Relation pulling on the ends of a with pushing on the ends of a
rod.   road toward the middle.  

Compression can be used to the

Tension is a force
Nature transference of force in the
promulgation method.  
hydraulic system as pressure.  

Tension is only
Compression is applicable to any
Applicability applicable in solid
material.  
strings.  

The direction of force in In compression, the direction of

Direction Of
tension is outward from force acting on the object is
Applied Force
the object.   always inward to the object.  

Tension is considered as Compression is considered as a

Consideration
a force.   phenomenon.  

Examples of tension are

An example of compression is
Example ropes, the cable of crane,
concrete pillars.  
nails, threads etc.  
 2.2Draw and explain the graph stress-strain diagram for mild stell material
and the characteristic points which determine the main mechanical
properties

 Stress: If an applied force causes a change in the dimension of the

material, then the material is in the state of stress. If we divide the applied
force (F) by the cross-sectional area (A), we get the stress.

 Strain: Strain is the change in the dimension (L-L0) with respect to the

original. It is denoted by the symbol epsilon (ε). The formula is ε = (L-L0)
/ L0. For a shear force, strain is expressed by γ (gamma)

CHARACTERISTICS POINTS

If tensile force is applied to a steel bar, it will have some elongation. If the force
is small enough, the ratio of the stress and strain will remain proportional. This
can be seen in the graph as a straight line between zero and point A – also called
the limit of proportionality. The characteristic point of a one-parameter family
of surfaces corresponding to the value u0 of the parameter is the limit of
the point of intersection of the surfaces corresponding to the values u0, u1, and
u2 of the parameter as u1 and u2 approach u0 independently.
 2.3Analyse and illustrate the fundamentals of mechanical stress testing
induced by a certain static load as below:

2.3.1 Tension or tensile testing

A tensile test, also known as a tension test, is one of the most fundamental and
common types of mechanical testing. A tensile test applies tensile (pulling)
force to a material and measures the specimen's response to the stress.

2.3.2 COMPRESSION

In compression test the material experiences opposing forces that push inward
upon the specimen from opposite sides or is otherwise compressed, squashed,
crushed, or flattened. The test sample is generally placed in between two hard
metal bearing blocks that distribute the applied load across the entire surface
area of two opposite faces of the test sample and then the plates are pushed
together by a universal testing machine causing the sample to flatten. A sample
will get shortened in the direction of the applied forces and expands in the
direction perpendicular to the force.

2.3.3 SHEAR

The Direct Shear Test is an experimental procedure conducted in geotechnical

engineering practice and research that aims to determine the shear strength of
soil materials. Shear strength is defined as the maximum resistance that a
material can withstand when subjected to shearing.

Generally, the Direct Shear Test is considered one of the most common and
simple tests to derive the strength of a soil and can be performed on undisturbed
or remoulded samples.

2.3.4 TORSION

In the field of solid mechanics, torsion is the twisting of an object due to an

applied torque. Torsion is expressed in either the Pascal, an SI unit for newtons
per square metre, or in pounds per square inch while torque is expressed in
newton metres or foot-pound force. orsion is the application of a twisting or
turning force to an object. This twisting force most often involves movement in
one direction at one end of an object and stability or movement in the opposite
direction at the other end.

2.3.5 BENDING

Bending is a process by which metal can be deformed by plastically deforming

the material and changing its shape. The material is stressed beyond the yield
strength but below the ultimate tensile strength. The surface area of the material
does not change much. Bending usually refers to deformation about one axis.
Bending is a manufacturing process that produces a V-shape, U-shape, or
channel shape along a straight axis in ductile materials, most commonly sheet
metal. Commonly used equipment include box and pan brakes, brake presses,
and other specialized machine presses.

2.4 STRAIN DUE TO A DIRECT AXIAL TENSILE LOAD AND DIRECT

AXIAL COMPRESSIVE LOAD
DIRECT AXIAL TENSILE LOAD

An axial tensile load, for example, will cause a structural member to increase in
length, whereas a compressive load would cause it to shorten.

Suppose that δ is the change in length produced by either a tensile or

compressive axial load. We now define the direct strain, ɛ, in the member in
non-dimensional form as the change in length per unit length of the member.

DIRECT AXIAL COMPRESSION LOAD

The loads applied to a column are only axial loads. Loads on columns are
typically applied at the ends of the member, producing axial compressive
stresses. However, on occasion the loads acting on a column can include axial
forces, transverse forces, and bending moments.

2.5 THE TORSIONAL SHEAR STRESS FORMULA ON A SHAFT

 When a shaft is subjected to a torque or twisting a shearing stress is
produced in the shaft. The shear stress varies from zero in the axis to a
maximum at the outside surface of the shaft. The shear stress in a solid
circular shaft in a given position can be expressed as: τ = T r / J (1)

2.6 RELATIONSHIP AMONG TORQUE, POWER AND ROTATIONAL

SPEED

With ω as rotational velocity in radians/sec, T is torque in N.m, and n

is rotational speed in rpm. Thus, as rotational speed decreases through the
gearbox, torque increases, and vice versa. The torque change through the
gearbox is equal to the multiple of the gearbox ratio. Torque is the rotational
equivalence of linear force. Speed measures the distance covered in unit time.
The relation between torque and speed are inversely proportional to each
other. The torque of a rotating object can be mathematically written as the ratio
of power and angular velocity.

2.7 A flat bar with cross section of 3mm x 50.8mm is exerted upon tensile
load of 500N and shear load of 300N. Find its tensile stress and shear
stress.

- given:
σ :3.281 x 106 N /m2

ii) Shear stress, τ

v
τ:
A
Cross sectional area = 3mm x 50.8mm

= 152.4mm2

= 1.524×10-4 m2

Tensile load = 500N

Shear load = 300N

i) Tensile stress, σ
F
σ:
A

500
σ:
1.524 ×10−4

2.8 A flat bar with cross section of 5mm x 76.2mm has 70MPa tensile stress
and 35Mpa shear stress. Find the tensile and shear load could be supported
by the bar.

Given:

Cross section area : 5mm x 76.2mm

: 381 mm2

: 3.81×10-4 m2

Tensile stress, σ :70 Mpa

: 70 x 106 Pa

Shear stress, τ :35 Mpa

: 35 x 106 Pa

i) Tensile load, F
F F
σ: 70 x 106 :
A 3.81 x 10−4
F :70 x 106 x 3.81 ×10−4 F :26.67
×103N
ii) Shear load ,V
V V
τ: 35 x 106 :
A 3.81 x 10−4
-4
V :35 x 106 x3.81×10

V :13.335×103N

2.9 A solid round section of 30mm diameter shaft has allowable of 40Mpa
shear stress. Find the power delivered by shaft if the rotational speed is 800
rev/min.

Given :
P : Tω
d : 30 mm
: 212.052 x 83.776
: 0.03 m
:17764.952 Watt
r : 0.03 ÷ 2
: 17.765 Kw
: 0.015 m
6
τ : 40 x 10

Rpm : 800 rev/min

2 πN
ω:
60
2 π (800)
ω:
60
ω :83.776 rad /s

π D4
Js :
32
 π (0.0 34 )
:
32

: 7.952 x 10−8 m 4

i) power
τ Gθ T
= =
R L J

τ T
=
R J
40 x 106 T
=
0.015 7.952 x 10−8
40 x 10 6 x 7.952 x 10−8
T:
0.015

T :212.053 Nm

REFERENCES

1. https://www.google.com/search?
q=FUNTIONAL+DECOMPOSITION+AND+SYNTHESIS&oq=FUNTI
ONAL+DECOMPOSITION+AND+SYNTHESIS&aqs=chrome..69i57j0
.1415j0j7&sourceid=chrome&ie=UTF-8
2. https://www.google.com/search?
sxsrf=ALeKk01HA3Qr8IEliT0N21Cxxn4QQIRJJg
%3A1599771265861&ei=gZJaX9mTNIOc4-
EPsdyU4AI&q=morphological+analysis+in+engineering+design&oq=m
orphological+analysis+engineering+&gs_lcp=CgZwc3ktYWIQARgBMg
YIABAWEB4yBggAEBYQHjoECAAQRzoECAAQQzoCCABQ-
54BWPPoAWCe8wFoAHACeACAAeIBiAG3BZIBBTEuMy4xmAEAo
AEBqgEHZ3dzLXdpesABAQ&sclient=psy-ab
3. https://www.google.com/search?
q=PUGH+CONCEPT+SELECTION+PROTECTION&sxsrf=ALeKk013
lesJAtyN-
_CU2bwVDN0F6RfTBg:1599771766142&source=lnms&tbm=isch&sa=
X&ved=2ahUKEwjqod6evt_rAhUMwjgGHQnDBzUQ_AUoAXoECA4
QAw&biw=1366&bih=646#imgrc=7wf33UCpRTccRM
4. https://www.google.com/search?
sxsrf=ALeKk02GIUtsqizEwmtmwwvDP6tjxfKshw
%3A1599774069850&ei=dZ1aX5-
4M9HJpgf1nbuYBQ&q=+Design+for+Manufacture+%28DFM
%29+&oq=+Design+for+Manufacture+%28DFM
%29+&gs_lcp=CgZwc3ktYWIQAzIECAAQHjoECCMQJzoGCAAQFh
AeUNfMA1j48ANg7fIDaABwAXgAgAGRAYgB3wGSAQMxLjGYA
QCgAQGqAQdnd3Mtd2l6wAEB&sclient=psy-
ab&ved=0ahUKEwjfxp3pxt_rAhXRpOkKHfXODlMQ4dUDCA0&uact
=5
5. https://asmedigitalcollection.asme.org/mechanicaldesign/article-
abstract/117/B/42/432232/Life-Cycle-Engineering-Design?
redirectedFrom=fulltext
6. https://www.google.com/search?sxsrf=ALeKk02sDLrzVn-
Le_Km8PTCnw8cTR_Idw
%3A1599776257488&ei=AaZaX4W5Hda9rQHg3pTICA&q=sustainabil
ity+and+the+environment&oq=sustainability+and+the+environment&gs
_lcp=CgZwc3ktYWIQAzIGCAAQBxAeMgYIABAHEB4yBggAEAcQ
HjIGCAAQBxAeMgYIABAHEB4yBggAEAcQHjIGCAAQBxAeMgYI
ABAHEB4yBggAEAcQHjIGCAAQBxAeUI0ZWI0ZYPIaaABwAXgAg
AFiiAFikgEBMZgBAKABAaoBB2d3cy13aXrAAQE&sclient=psy-
ab&ved=0ahUKEwjFvbD8zt_rAhXWXisKHWAvBYkQ4dUDCA0&uac
t=5
7. https://www.google.com/search?sxsrf=ALeKk02t82EQ-
Z99jh9xasVLcnB56Wo_GA%3A1599781338923&ei=2rlaX7P_N6yV4-
EPrMGeuAo&q=torque+speed+relation+formula&oq=RELATIONSHIP
+AMONG+TORQUE
%2C+POWER+AND+ROTATIONAL+SPEED&gs_lcp=CgZwc3ktYWI
QARgAMgQIABBHMgQIABBHMgQIABBHMgQIABBHMgQIABBH
MgQIABBHMgQIABBHMgQIABBHUABYAGDmG2gAcAJ4AIABAI
gBAJIBAJgBAKoBB2d3cy13aXrAAQE&sclient=psy-ab