S E M E S T E R I S E S S I O N 2 0 2 0 / 2 0 2 1

BDA 20402
ENGINEERING MATERIALS SELECTION
CHAPTER TWO:

THE DESIGN PROCESS

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THE DESIGN PROCESS
2.1 INTRODUCTION

2.2 DESIGN PROCESS

2.3 TYPES OF DESIGN

2.4 DESIGN TOOLS AND MATERIALS DATA

2.5 FUNCTION, MATERIAL, SHAPE AND PROCESS

2.6 FACTORS IN MATERIALS SELECTION

2.7 CASE STUDY

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THE DESIGN PROCESS:

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 THE DESIGN PROCESS:
2.2 Design Process…

• What is design…?
• An iterative process
(proses berulang).
• Based on:-
• market need
(keperluan pasaran),
and
• product specification
(spesifikasi keluaran)

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 THE DESIGN PROCESS:
2.2 Design Process…

MARKET
• THREE(3) stages in design • Define specification NEED
process:- • Determine function structure
1. CONCEPT (konsep) • Seek working principles
• Evaluate and select concepts
2. EMBODIMENT CONCEPT
(penyataan)
3. DETAIL (perincian) • Develop layout, scale, form
• Model and analyse assemblies
EMBODIMENT
• Optimize the functions
• Evaluate and select layout

DETAIL Iterate
• Analyse components in detail
• Select processing route
• Optimize performance and cost
• Prepare detailed drawings PRODUCT
S P E C I F I C AT I O N
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 THE DESIGN PROCESS:
2.2 Design Process…
• Product as SYSTEM TECHNICAL that consists of: Component 1.1

• A S S E M B L I E S (pemasangan) Assembly 1 Component 1.2

• S U B - A S S E M B L I E S (sub-pemasangan)
Component 1.3
• C O M P O N E N T S (komponen)
Component 2.1

Technical System Assembly 2 Component 2.2

Component 2.3

Component 3.1
Conventional
thinking of a Assembly 3 Component 3.2
technical system
design Component6 3.3
 THE DESIGN PROCESS:
2.2 Design Process…
TECHNICAL SYSTEM
INPUT OUTPUT
Energy Function 2 Function 3 Energy

Material Function 1 Function 6 Material

Function 4 Function 5
Information Information

SUB-SYSTEMS

• Besides that, there is an approach based on the
ideas of systems analysis which it thinks of the
inputs, flow, and outputs of information, energy
and materials.
• This design converts the inputs into the outputs
• In this approach, the system – divided into
subsystems – performs specific sub-functions.
• This arrangement is called the function structure
or function decomposition of the system.
• The design proceeds by developing concepts to fill
each of the sub-functions in the function
structure, each based on a working principle.
• This structure, when elaborated, helps structure
thinking about alternative design. 7
 THE DESIGN PROCESS:
2.2 Design Process…
Conventional thinking of a technical system design Alternative thinking of a technical system design

STORAGE

INPUT PROCESSING

OUTPUT

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 THE DESIGN PROCESS:
2.3 Types of Design
• Involves new idea or working
principle.
ORIGINAL
• New material suggests new product,
or new product demand the
development of new material. Smart Above & below
kitchen stove water level house
• Also called DEVELOPMENT Design.
• Develop / enhance the existing
ADAPTIVE To y o t a R U S H
concept from the material aspect
vs
Perodua ARUZ

• A change of scale, dimension, or

detailing without change of function Perodua BEZZA
VARIANT auto / manual / colour
or the method of achieving it.
• Change of scale or range of conditions / 1000 cc / 1300 cc
may require change of material. 9
 THE DESIGN PROCESS:
2.4 Design Tools and Materials Data
• Design tools are needed in
Market Need
Design Tools order to implement the steps in
Material Selection Figure.
Function modelling
ALL MATERIALS
Viability studies Concept (low precision data) • The tools enable the modeling
and optimization of a design,
Approximate analysis easing the routine aspects of
each phase.
Geometric modelling SUBSET OF MATERIALS
Embodiment (higher precision data)
• Material selection is very
Simulation
important and enters at every
Optimization methods stage of the design.
Detail ONE MATERIAL
Cost modelling (best available data • Complete and precise
precision)
information about materials are
Component modelling
required to enable the selection
Product
Finite element analysis process.
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 THE DESIGN PROCESS:
2.5 Function, Material, Shape & Process
• The selection of a material FUNCTION
Transmit loads,
and process cannot be
Contain pressure • Function – dictates the choice of
separated from the choice of Store energy, etc,
shape. both material and shape.
at minimum mass,
• ‘Shape’ – include the or at minimum cost,
external shape (macro- or with minimum
shape) and internal shape Environmental
impact
(micro-shape).
• The figure interaction
between function, material, Shape • Shape - restricts the choice
Material
shape and process. of material and process.
• The more sophisticated the
design, the tighter the
specifications and the greater Process • Process – influenced by material (by its
interactions. formability, machinability, etc.), and
obviously interact with shape. 11
 THE DESIGN PROCESS:
2.6 Factors in Materials Selection
Physical size, shape & weight of material

Mechanical the ability of the materials to withstand the type of stresses

(tensile, compression, bending and cyclic) imposed on it.
INTERRELATED CONSTRAINTS

the ability to form or shape the material (different

Processing & Fabricability material – different method of processing).

the length of time the materials perform their intended

Life of Component
function in the environment to which they are exposed.

Cost & Availability market-driven economy, quantity and standardization.

technical requirements imposed on materials or components

Code
(usually set by the customer), eg. ASTM, ASME, SAE etc.

Statutory & Others relate to local, state and federal regulations about materials and
processes used or material disposal, eg. OSHA, JAS etc. 12
 THE DESIGN PROCESS:
2.6 Factors in Materials Selection
Criteria and tools for materials selection

 Current engineering designers choose materials to meet three general criteria –

property profile, processing profile and environmental profile.

 As for the environmental profile, the most popular approach is the life-cycle analysis.
The factor includes:
o the process used to extract the materials from its ore and then to bring it to its
usable form
o the total energy spent during use of component (in transport industry)
o the recoverable energy after its use.
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 THE DESIGN PROCESS:
2.6 Factors in Materials Selection

Sustainable Design:
• Reduce carbon footprint
• Reduce total energy consumed
• Reduce impact to air
• Reduce impact to water

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 THE DESIGN PROCESS:
2.7 Case Study: Devices to open corked bottles

cork
• The market need : ‘A device is
required to allow access to water in a
corked container’.

• Additional requirements :
o with convenience
o at modest cost
o without contaminating the water

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 THE DESIGN PROCESS:
2.7 Case Study: Devices to open corked bottles
Five concepts for doing this are :
a) Axial traction / pulling
b) Shear tractions
c) Push it out from below
d) Pulverize
e) Bypass – eg. knocking the neck of the
bottle
Concepts (d) and (e) shall be eliminated
because they might contaminate the
water. Therefore, concepts (a), (b) & (c)
are taken into consideration.
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 THE DESIGN PROCESS:
2.7 Case Study: Devices to open corked bottles

The figure shows one for each of the

first three concepts :
a) A screw is threaded into the cork to
which an axial pull is applied.
b) Slender plastic blades inserted
down the sides of the cork apply
shear tractions when pulled.
c) The cork is pierced by a hollow
needle through which a gas is
pumped to push it out.

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 THE DESIGN PROCESS:
2.7 Case Study: Devices to open corked bottles

 The function structures of those

cork removers are the same
(generate force, transmit force
and apply force to cork).

 However, they differ in the

working principle by which these
functions are achieved.

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 THE DESIGN PROCESS:
2.7 Case Study: Devices to open corked bottles

(a) (b) (c) (d)

 The embodiment sketches for devices based on just one concept that of axial traction is
shown in the figure.
 Each system is made up of components perform a sub-function.
 The requirements of these sub-functions are the inputs to the material selection method.
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 THE DESIGN PROCESS:
2.7 Case Study: Devices to open corked bottles
examples of actual cork removers using these working principles.

(d) shear blade systems

(b) gear lever,

screw-assisted (c) spring-assisted pull
pull (e) pressure-
(a spring in the body is induced removal
compressed as the systems.
(a) direct pull screw is driven into the
cork)
 THE DESIGN PROCESS:
2.7 Case Study: Devices to open corked bottles

1802 1930 2011 21

 [And] who created seven heavens in layers. You do not see in the creation
of the Most Merciful any inconsistency. So return [your] vision [to the sky];
do you see any breaks?
Dialah yang telah mengaturkan kejadian tujuh petala langit yang berlapis-
lapis; engkau tidak dapat melihat pada ciptaan Allah Yang Maha Pemurah
itu sebarang keadaan yang tidak seimbang dan tidak munasabah; (jika
engkau ragu-ragu) maka ulangilah pandangan mu - dapatkah engkau
melihat sebarang kecacatan?

Then return [your] vision twice again. [Your] vision will return to you
humbled while it is fatigued.
Kemudian ulangilah pandanganmu berkali-kali, nescaya pandanganmu itu
akan berbalik kepadamu dengan hampa (daripada melihat sebarang
kecacatan), sedang ia pula berkeadaan lemah lesu (kerana habis tenaga
dengan sia-sia).

END OF CHAPTER TWO…

Al Mulk 67:3-4
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