Engineering Design MECH 3111

Lecture 1
1.1 Module Information Sheet

1.2 The Design Process (Pahl and Beitz)*

1.3 Stages in the Design Process*

1.4 Design/Re-design Projects

Specifications
>Select Design Application (mass produced)
>Produce Assembly Drawing (exploded view with minimum of 10 components)
>Estimate time for manually assembling the product
>Work out assembly time (cost)
>Create detailed part drawing of each component
>Estimate approximate relative cost to manufacture each of the part
>Work on costing for the design/re-design
>Produce final design with exploded view and detailed part drawings
>Reports should not be more than 10 pages (to be submitted in week 12)

Prepared by: Dr.D.K.Hurreeram

 Engineering Design MECH 3111
Lecture 2

2.1 Definitions
Designed Objects (Functional Design)
•Any material or object that has been or is to be manufactured from information prepared for
that purpose. Design is information (words, graphics, electronic data etc)
•size, shape, function, materials, marketing, simulated performance, manufacturing processes,
tolerances…
Parts
•a designed object with no assembly operations in its manufacture.
Assemblies and sub assemblies
•a collection of two or more parts
Components
•includes special purpose parts, standard parts, standard assemblies or modules
Products and machines
•a functional designed object that is made to be sold and/or used as a unit
•a machine is a product whose function is to contribute to the manufacture of products and
other m/cs
Manufacturing, Design and Design for Manufacturing
•Big M and little m Manufacturing
•Design is the process that modifies information we have about an artifact or designed object
whereas manufacturing modifies its physical state (production)
Prepared by: Dr.D.K.Hurreeram
 Engineering Design MECH 3111
Lecture 2
Engineering Design Considerations
2.2 Engineering Design
Engineering Conceptual Design
>a new product, a sub-assembly, a part within a product or sub-assembly
>understand physical principle by which the object will function (physical concept)
>preparation of the engineering design specifications
>generate alternatives (decomposition)
>evaluate the alternatives
>number of components (standard modules, parts , special purpose parts) created as
concepts
Configuration Design of parts and components
>involves deciding the type or class of components to be used (type of pump, spring etc)
>determine geometric features and how these features are connected or related physically
>information about the material classes, manufacturing processes
Parametric Design
>Design Analysis, Codes and Standards
>finding exact dimensions and tolerances
>exact material choice
>information about the dimensions, functionality and manufacturability
Detail Design
>Describe the design object fully and accurately in preparation for manufacturing
Prepared by: Dr.D.K.Hurreeram
 Engineering Design MECH 3111
Lecture 2
Engineering Design Considerations

2.3 Other Considerations for Engineering Designers

Firm’s Strategy, Customer Requirement
Quality, Cost, Speed, Flexibility
Continuous improvement, Cross Functionality, Team work

2.4 Concurrent Engineering, Design for ‘X’

>Customer (Use of QFD, House of Quality)
>Manufacturing (for ease and cost of manufacturing)
>Assembly (evaluating qualitatively and quantitatively the time and cost of handling and
inserting parts in a product or machine, easily assembled parts etc)
>Robustness (how well a product performs for its customers in the presence of variations in the
environmental conditions in which it is used, Taguchi Method)

2.5 Getting involved in Design

>Materials and Manufacturing processes
>Design Methods and Tools
>Engineering Analysis Methods and Tools
>Management Methods and Tools
>Key Company Specific Core Technologies
Prepared by: Dr.D.K.Hurreeram
 Engineering Design MECH 3111
Lecture 3
Manufacturing Considerations
3.1 Design for Customer v/s manufacturability
Take advantage of economies of scale
>minimise number of parts in the product (fewer parts, the better principle)
>minimise product variation and part variety
>use assembly oriented construction principles
>use sub-assemblies
>design for ease of insertion
>design for ease of fastening and joining
>design for ease of handling
>design for ease of labelling
>design for ease of testing
>use a base component
Aim to standardise as much as possible
>use part of known capability and from known suppliers
>use parts that are a variation on a standard; try to develop part families
use simple low cost operations
>use established technologies as far as possible
>avoid high cost technologies unless technically essential
>choose simple, regular shapes and part assemblies

Prepared by: Dr.D.K.Hurreeram

 Engineering Design MECH 3111
Lecture 3
Manufacturing Considerations
3.2 Manufacturing Processes
Machining Processes
Turning, Facing, Boring, Planing, Milling , Drilling, Grinding, Sawing, EDM, Wire EDM,
Chemical Milling, ECM, Laser Cutting, Ultra Sonic Machining...
Casting Processes
Sand, Shell Mold, Plaster Mold, Ceramic Mold, Die, Permanent Mold, Centrifugal, Investment…
Deformation Processes
Forging, Rolling,Wire Drawing, Tube Drawing, Extrusion, Coining, Roll Forming…
Sheet Metal Working Processes
Blanking, Punching, Bending, Drawing, Deep Drawing, ironing, Spinning, Stretching …
Polymer Processing
Extrusion, Injection Molding, Compression Molding, Blow Molding, Transfer Molding, Casting,
Thermoforming…
Powder Metallurgy
Assembly Processes
Welding, Brazing, Soldering, Resistance Welding, Adhesive Bonding, Press/Snap Fits, Manual
Assembly, Automatic Assembly…

3.3 Assignment (for processes in italics or for all, if you wish)

What is involved, when used, for which material, design attributes to be borne in mind while
using each of the above processes
Prepared by: Dr.D.K.Hurreeram
 Engineering Design MECH 3111
Lecture 3
Manufacturing Considerations
3.4 Example
Injection Molding
What is involved
Thermoplastic pellets melted and melt injected under high pressure (70 MPa) into a mold. Molten
plastic takes the shape of the mold, cools, solidifies, shrinks and is ejected. Molds usually made
in two parts (internal and external part). Use of injection molding machine. Mainly used for
thermoplastics (gears, cams, pistons, rollers, valves, fan blades, rotors, washing machine
agitators, knobs, handles, camera cases, battery cases, sports helmets etc…)

Design attributes
>ejector system needed (pins to eject the cooled part off the mold)
>consideration for shrinkage
>elements called runners, sprues, and gates used to transfer the melt into the mold.
>Provision for internal and external undercuts
>70% of total cycle time is for part solidification

Prepared by: Dr.D.K.Hurreeram

 Engineering Design MECH 3111
Lecture 3
Manufacturing Considerations
3.5 General DFM Guidelines (Injection Molding, Compression Molding, Transfer
Molding, Die Casting Processes)
>flow is smooth and fills the cavity evenly; cooling and hence solidification can be rapid to
shorten cycle time and uniform to reduce warpage; ejection is achieved with minimum tooling
>location of the parting surface, direction of closure and the design of the part must be considered
simultaneously to provide for ejection of the part after solidification (seek advice from
manufacturing expert)
>sharp corners and sudden changes or large differences in wall thickness should be avoided
because they create flow problems and also make uniform cooling difficult
>as far a possible avoid thick walls or heavy sections; every effort should be made to design parts
of uniform wall thickness
>consider appropriate number of gates at the right location to allow for easy flow
3.6 General DFM Guidelines (Stamping)
>keep the number of distinct features in a part to the minimum
>avoid closely space features when possible
>Avoid narrow cutouts and narrow projections
>the number of bend stages to be kept to a minimum
>bend angles greater than 90 should be avoided whenever possible
>side action features to be avoided or kept to a minimum

Prepared by: Dr.D.K.Hurreeram

 Engineering Design MECH 3111
Lecture 3
Manufacturing Considerations
3.4 General DFM Guidelines (Forging)
>if possible avoid the use of forging (expensive operation)
>select materials that are relatively easy to deform
>part shapes that provide smooth and easy external flow paths are desirable
>ribs if any, should be widely spaced
>internal and external undercuts caused by projections much be avoided

3.5 General DFM Guidelines (Machining)

>if possible avoid machining
>specify the most liberal tolerances and surface finishes
>for turning operations on a lathe, avoid designs that require sharp internal corners
>for planing and milling operations, avoid sharp corners and slot widths and shapes other than
those available using standard off the shelf cutters.

3.6 General DFM Guidelines (Assembly

>use minimum number of parts
>parts should be designed so that they are easy to grasp and manipulate with one hand
>parts are end to end and rotationally symmetric as much as possible
>parts are designed so that they are easy to align and to insert
>for manual assembly both access and vision are not restricted, for automatic assembly insertion
is in a straight line Prepared by: Dr.D.K.Hurreeram