Chandigarh Engineering College-CGC

Landran, Mohali
Department of Mechanical Engineering

Solution of PTU Paper

Product Design and Development (BTME-614-18)
Date of Exam: 21.01.2022
Q.1. Differentiate between design by evolution and innovation. Write down the essential
factors of product design.
Answer:
Differentiate between design by evolution and design by innovation:
Design by evolution and design by innovation are two approaches to product design that differ
in their underlying principles and methodologies. Here's a comparison between the two:

Design by Evolution:
Design by evolution, also known as incremental design or iterative design, involves making
gradual improvements or modifications to an existing design. It is an evolutionary approach
that builds upon existing designs, making incremental changes based on user feedback, market
demands, or technological advancements. Key characteristics of design by evolution include:
Iterative Process: Design by evolution follows an iterative process, where multiple iterations
of the design are made over time. Each iteration aims to enhance specific aspects of the product
based on identified areas for improvement.
Incremental Changes: Design by evolution focuses on making small, incremental changes to
the existing design. These changes could include adding new features, improving performance,
addressing user feedback, or refining aesthetics.
Risk Mitigation: Design by evolution often prioritizes risk mitigation by minimizing radical
or disruptive changes. It aims to maintain compatibility with existing systems, reduce the
likelihood of errors or failures, and provide a smooth transition for users.
Continuous Improvement: Design by evolution emphasizes continuous improvement by
learning from user experiences, feedback, and market trends. It seeks to refine the design based
on real-world usage and user preferences.
Market Stability: Design by evolution is commonly employed when the market is relatively
stable and incremental improvements are sufficient to meet customer needs and expectations.

Design by Innovation:
Design by innovation, also referred to as radical design or disruptive design, involves a more
revolutionary approach to product design. It focuses on creating entirely new concepts,
technologies, or approaches that significantly depart from existing designs. Key characteristics
of design by innovation include:
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
Paradigm Shift: Design by innovation aims to challenge existing conventions, break through
boundaries, and introduce novel ideas or technologies. It often involves radical departures from
conventional thinking and existing design paradigms.
Blue-Sky Thinking: Design by innovation encourages exploration, experimentation, and
creative thinking to generate groundbreaking concepts. It embraces a mindset of challenging
assumptions and exploring uncharted territories.
Disruptive Changes: Design by innovation often involves disruptive changes that can reshape
entire industries or create new markets. It may introduce entirely new features, functionalities,
or business models that significantly differentiate the product from existing offerings.
Higher Risk: Design by innovation carries a higher level of risk compared to design by
evolution. It involves greater uncertainty and a higher likelihood of failure, as the design may
be unproven and may require new technologies or resources.
Market Instability: Design by innovation is commonly employed in dynamic and rapidly
evolving markets where existing solutions are inadequate or where disruptive technologies
have the potential to create new opportunities.
User Education: Design by innovation may require educating users about new concepts,
features, or ways of interacting with the product. It may take time for users to adapt to and
embrace the radical changes introduced by the design.
It's important to note that design by evolution and design by innovation are not mutually
exclusive and can coexist in the product design landscape. Depending on the specific
circumstances, market dynamics, and business goals, organizations may adopt a combination
of both approaches to achieve incremental improvements and radical innovations in their
product offerings

Essential factors of Product Design:

Product design involves considering multiple factors to create a successful and effective
product. These essential factors encompass various aspects, including functionality, aesthetics,
usability, manufacturability, and sustainability. Here are some of the key factors to consider in
product design:
Functionality: The product must perform its intended function efficiently and effectively. It
should meet the needs and requirements of the users, addressing their problems and providing
the desired features and functionalities.
User-Centered Design: Designing with the end-user in mind is crucial. Understanding the
target audience, their preferences, behaviors, and usability requirements helps create a user-
centered design. User research, user testing, and feedback gathering aid in designing products
that are intuitive, user-friendly, and deliver a positive user experience.
Aesthetics: Aesthetics plays a significant role in product design, influencing its visual appeal,
form, and emotional connection with users. A well-designed product should have an attractive
and visually pleasing appearance, considering factors such as shape, color, texture, and overall
design composition.
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
Usability and Ergonomics: Usability focuses on designing products that are easy to use,
navigate, and understand. It involves considerations such as intuitive controls, clear
instructions, appropriate feedback, and ergonomic design that ensures comfort and ease of use
for the end-users.
Material Selection: The choice of materials impacts the functionality, durability, aesthetics,
and sustainability of the product. Material selection should take into account factors such as
strength, weight, cost, environmental impact, and desired product performance.
Manufacturability: Design for manufacturability (DFM) ensures that the product can be
efficiently and cost-effectively manufactured. Considering manufacturing processes, tooling
requirements, and assembly methods during the design phase helps streamline production,
reduce costs, and improve overall efficiency.
Sustainability: Incorporating sustainable design principles helps minimize the environmental
impact of the product throughout its lifecycle. This includes considerations such as using eco-
friendly materials, reducing waste, optimizing energy efficiency, and promoting recyclability
or reusability.
Safety and Regulations: Designing products that meet safety standards and regulations is
essential to protect users from potential hazards or risks. Compliance with relevant safety
guidelines ensures the product's safety during use, handling, and maintenance.
Branding and Identity: Aligning the product design with the brand identity and values of the
organization helps create a consistent and recognizable brand experience. The design should
incorporate brand elements such as logos, colors, typography, and visual styles to reinforce the
brand image.
Cost-Effectiveness: Balancing the desired product features and quality with cost
considerations is important. Design decisions should consider the manufacturing costs,
materials, production efficiency, and overall value proposition to ensure the product is cost-
effective and meets the target price point.
By addressing these essential factors in product design, businesses can create products that are
functional, aesthetically pleasing, user-friendly, sustainable, and aligned with customer needs
and expectations. It's important to strike a balance between these factors based on the specific
product, target market, and business objectives.

Q. 2. Elaborate the generic product development process with example of making new
mobile phone.
Answer: The generic product development process consists of a series of stages that guide the
development of a new product from concept to commercialization. While the specifics may
vary depending on the industry and company, the following is an example of the generic
product development process applied to the creation of a new mobile phone:
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
Idea Generation: The process begins with generating ideas for the new mobile phone. This
can be done through various methods, such as market research, customer feedback,
brainstorming sessions, or technological advancements. For example, the company may
identify the need for a high-performance, affordable smartphone with advanced camera
features based on market trends and consumer demands.
Concept Development: Once the idea is generated, the next step is to develop the concept for
the mobile phone. This involves outlining the key features, specifications, design elements, and
target market. Concept development may include creating initial sketches, conducting
feasibility studies, and analyzing the technical and financial viability of the idea.
Feasibility Assessment: The feasibility assessment evaluates the technical, economic, and
market feasibility of the new mobile phone concept. This involves analyzing factors such as
manufacturing capabilities, component sourcing, cost estimation, regulatory requirements,
intellectual property considerations, and competitive analysis. The feasibility assessment helps
determine the potential success and viability of the concept.
Design and Development: In this stage, the mobile phone concept is translated into detailed
designs. The design team creates 2D and 3D renderings, considering factors like aesthetics,
user experience, ergonomics, and functionality. Engineering teams work on developing the
hardware, software, and electronics components of the phone. Prototyping and testing are
carried out to validate the design and make necessary refinements.
Testing and Validation: The newly designed mobile phone undergoes rigorous testing to
ensure its performance, functionality, and reliability. Various types of tests are conducted,
including performance testing, durability testing, usability testing, and compliance testing to
meet industry standards and regulations. Feedback from beta testing or user trials may also be
collected to further refine the product.
Production and Manufacturing: Once the design is finalized and validated, the
manufacturing process begins. This involves sourcing materials, establishing supply chains,
and setting up production facilities. The mobile phone components are manufactured,
assembled, and undergo quality control measures to ensure consistency and reliability. The
production process is optimized for efficiency, scalability, and cost-effectiveness.
Marketing and Launch: In this stage, the marketing strategy for the new mobile phone is
developed. This includes defining the target market, positioning the product, creating
promotional materials, and planning the product launch. Marketing activities may involve
digital and traditional advertising, public relations, influencer collaborations, and social media
campaigns. The mobile phone is officially launched into the market, generating awareness and
creating demand.
Commercialization and Sales: The mobile phone is made available for sale through various
channels such as online platforms, retail stores, or authorized distributors. Sales teams work on
promoting the product, engaging with customers, and closing deals. Customer support and
after-sales services are provided to ensure customer satisfaction and loyalty.
Post-Launch Evaluation: After the mobile phone is introduced to the market, post-launch
evaluations are conducted to assess its performance, customer feedback, sales performance,
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
and market acceptance. This information is used to gather insights for future product
improvements, updates, or the development of new models.
The generic product development process provides a systematic framework to guide the
creation of a new mobile phone, ensuring that all crucial stages are addressed and necessary
considerations are taken into account. It allows companies to efficiently bring innovative and
competitive products to the market while minimizing risks and maximizing success.

Q.3. How does the ease of tool locating and clamping affects the design efficiency? Give
some examples of design of powder metallurgical parts.
Answer:

Tool locating and clamping affects the design efficiency:

Tool locating and clamping play a crucial role in the design efficiency of manufacturing
processes. Proper tool locating and clamping techniques can significantly impact the
productivity, accuracy, and overall efficiency of the production process. Here are some ways
in which tool locating and clamping affect design efficiency:
Precision and Accuracy: Accurate and precise tool locating and clamping are essential for
achieving precise and accurate machining or manufacturing. Proper alignment and positioning
of tools ensure that the intended operations are performed with the desired level of precision.
Any misalignment or improper clamping can lead to dimensional inaccuracies, poor surface
finish, and increased scrap or rework, which negatively impact design efficiency.
Repeatability and Consistency: Consistency and repeatability are vital in manufacturing
processes, especially in high-volume production. Effective tool locating and clamping
techniques ensure that tools are positioned consistently and securely for repeated operations.
This helps maintain consistent quality, reduce variations, and increase production efficiency.
Setup Time Reduction: Efficient tool locating and clamping methods can significantly reduce
setup time between different production runs or job changes. Quick-change tooling systems,
modular fixturing, or dedicated tooling setups facilitate faster and more efficient tool changes,
reducing downtime and improving overall productivity.
Ergonomics and Safety: Considerations for ergonomics and operator safety are important in
tool locating and clamping design. Easy access to tooling, ergonomic handles or levers for
clamping, and proper tool balance contribute to operator comfort and safety. Well-designed
clamping systems minimize the risk of accidents or injuries during tool changes or adjustments,
improving both efficiency and workplace safety.
Flexibility and Adaptability: Tool locating and clamping designs that allow for flexibility
and adaptability are beneficial when dealing with diverse product requirements or design
changes. Modular fixturing or adjustable tooling systems enable quick adaptation to
accommodate different part sizes, geometries, or machining operations. This flexibility reduces
the need for extensive redesign or tooling changes, enhancing overall design efficiency.
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
Manufacturing Efficiency: Effective tool locating and clamping methods optimize the
manufacturing process by reducing non-productive time, minimizing rework, and improving
throughput. When tools are securely located and properly clamped, there is less vibration,
reduced tool wear, and improved cutting performance, leading to higher machining speeds,
improved material removal rates, and overall production efficiency.
Design for Manufacturing (DFM): Considering tool locating and clamping during the design
phase of a product can contribute to improved manufacturability and design efficiency.
Designing parts with features that facilitate easy access for tooling, efficient clamping
mechanisms, or standardized tooling setups can streamline the production process and reduce
costs associated with complex tooling or setups.
Efficient and effective tool locating and clamping methods are crucial for achieving optimal
design efficiency in manufacturing processes. By considering these factors during the design
phase, manufacturers can enhance productivity, improve product quality, reduce setup time,
ensure operator safety, and increase overall manufacturing efficiency.
Examples of design of powder metallurgical parts
Powder metallurgy is a manufacturing process that involves the production of parts and
components using powdered metal materials. The design of powder metallurgical parts is
driven by the unique characteristics and capabilities of the powder metallurgy process. Here
are a few examples of the design considerations for powder metallurgical parts:
Complex Geometries: Powder metallurgy allows for the production of parts with intricate and
complex geometries that are difficult to achieve using traditional manufacturing methods.
Examples include gears with intricate tooth profiles, sprockets with complex shapes, or
components with internal features such as holes, slots, or channels.
Porosity Control: Powder metallurgy enables control over the porosity of the final part. The
design can incorporate specific porosity requirements based on the desired properties, such as
for lubricant retention, acoustic damping, or filtration applications. The design considerations
include the size, shape, and distribution of the pores within the part.
Self-Lubricating Features: Powder metallurgy allows for the incorporation of self-lubricating
properties into the part design. For example, oil-impregnated bearings can be produced with
designed-in oil reservoirs or pockets that provide continuous lubrication during operation. This
eliminates the need for external lubrication and enhances the performance and durability of the
part.
Complex Blends and Alloys: Powder metallurgy facilitates the production of parts using
blended or alloyed metal powders. The design can involve the selection of specific powder
blends or alloy compositions to achieve desired material properties, such as improved strength,
wear resistance, or corrosion resistance.
Net Shape Design: Powder metallurgy often enables the production of near-net-shape or fully
net-shape parts, reducing the need for additional machining operations. The design can be
optimized to minimize material waste, reduce machining costs, and achieve dimensional
accuracy and surface finish requirements.
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
Structural Reinforcements: Powder metallurgy allows for the incorporation of structural
reinforcements within the part design. Examples include the addition of inserts, filaments, or
fibers to enhance the strength, stiffness, or impact resistance of the final component.
Part Consolidation: Powder metallurgy offers the opportunity to consolidate multiple parts
into a single complex part. This can simplify assembly processes, reduce the number of
components, and improve overall part performance. Examples include multi-level complex
components or assemblies with integrated features.
Design for Sintering: Sintering is a key step in the powder metallurgy process. The design of
powder metallurgical parts should consider factors such as shrinkage, distortion, and part
density during sintering. Design features can be incorporated to account for these factors and
ensure dimensional stability and desired material properties in the final part.
These examples illustrate some of the design possibilities and considerations specific to powder
metallurgical parts. Each design should be tailored to the unique requirements of the
application, material properties, and manufacturing process parameters. Collaborating with
experienced powder metallurgy engineers and manufacturers can help ensure the successful
design and production of high-quality powder metallurgical parts.

Q.4. How the process capability of machine can be established? What are the
consequences faced by the organization for not considering the aesthetic principles
during product design.
Answer:

Establishment of machine process capability:

Process capability is a measure of a machine's ability to consistently produce parts or
components within specified tolerances. Establishing the process capability of a machine
involves a series of steps to assess its performance and determine its ability to meet the desired
requirements. Here's an outline of how the process capability of a machine can be established:
Define Specifications: Start by clearly defining the specifications and tolerances that the
machine must meet. This includes identifying the critical dimensions, features, and quality
requirements for the parts or components being produced.
Select Measurement Methods: Determine the appropriate measurement methods and
instruments to accurately assess the produced parts. This may involve using coordinate
measuring machines (CMMs), gauges, calipers, or other measurement tools suitable for the
specific features being evaluated.
Collect Data: Begin collecting data by measuring a representative sample of parts produced
by the machine. Ensure that the sample size is statistically significant for accurate analysis. The
measurements should cover the critical dimensions and features identified in the specifications.
Calculate Process Capability Indices: Calculate process capability indices, such as Cp, Cpk,
or Ppk, using the collected data. These indices quantify the machine's ability to meet
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
specifications. Cp assesses the potential capability, while Cpk or Ppk evaluates the actual
capability considering process centering and variation.
Assess Capability Indices: Analyze the calculated process capability indices to determine the
machine's performance. Typically, a Cp or Cpk value greater than 1 indicates that the machine
is capable of meeting the specifications. However, the specific requirements may vary
depending on industry standards and customer expectations.
Interpret Results: Interpret the results of the process capability analysis. If the machine's
capability indices meet or exceed the specified requirements, it indicates that the machine is
capable of consistently producing parts within the specified tolerances. If the indices fall below
the desired thresholds, further investigation and improvements may be necessary.
Identify Causes of Variation: If the process capability indices are below the desired levels,
identify the sources of variation that contribute to the deviation from specifications. This may
involve analyzing factors such as machine settings, tooling, material variations, operator
influence, or environmental conditions.
Implement Improvements: Based on the identified causes of variation, implement
appropriate improvements to enhance the machine's capability. This may involve adjustments
to machine settings, optimizing tooling, refining processes, or providing training to operators.
Validate Improved Capability: After implementing improvements, repeat the data collection
and process capability analysis to validate the enhanced capability of the machine. Compare
the new capability indices with the previous results to assess the effectiveness of the
improvements.
Monitor and Continuously Improve: Establish a system for monitoring the machine's
capability on an ongoing basis. Regularly collect data and perform process capability analysis
to ensure that the machine maintains its capability and identify opportunities for further
improvements.
By following these steps, manufacturers can establish the process capability of a machine,
assess its performance, and take appropriate actions to enhance its capability. This ensures
consistent production of parts within specified tolerances, leading to improved quality,
customer satisfaction, and overall manufacturing efficiency.

Consequences faced by the organization for not considering the aesthetic principles during
product design:
Failing to consider aesthetic principles during product design can have several consequences
for an organization. These consequences may impact the product's market acceptance,
customer satisfaction, brand image, and overall business success. Here are some potential
consequences of not considering aesthetic principles:
Reduced Market Appeal: Aesthetics play a significant role in attracting customers and
capturing their attention. If a product lacks visual appeal or has an unattractive design, it may
struggle to stand out in a competitive market. This can lead to reduced market appeal and lower
customer interest, resulting in decreased sales and market share.
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
Poor Customer Perception: Aesthetics influence how customers perceive and evaluate a
product. If the design is unappealing or does not align with customer expectations, it may create
a negative perception of the product's quality, value, and overall desirability. This can deter
potential customers from purchasing the product and harm the organization's reputation.
Limited Differentiation: Aesthetics can be a key factor in differentiating a product from
competitors. A well-designed and visually appealing product can set itself apart in the market,
attracting customers who value aesthetics as part of their purchase decision. Neglecting
aesthetic principles can result in a lack of differentiation, making it challenging to establish a
unique selling proposition and competitive advantage.
Negative User Experience: Aesthetics not only involve the visual aspect but also contribute
to the overall user experience. Poorly designed products may have usability issues, lack
ergonomics, or fail to consider user preferences and needs. This can lead to frustration,
discomfort, or difficulty in using the product, resulting in a negative user experience and
potential customer dissatisfaction.
Brand Perception and Image: The design of a product reflects the organization's brand
identity and image. Neglecting aesthetic principles can undermine the brand perception,
suggesting a lack of attention to detail, quality, or innovation. This can negatively impact the
overall brand image and erode customer trust and loyalty.
Missed Business Opportunities: Aesthetics can create opportunities for new market
segments, collaborations, or partnerships. Organizations that prioritize aesthetic design may
attract potential business partners or engage with customers who value aesthetics as a
significant factor in their purchasing decisions. Failing to consider aesthetics may limit these
opportunities and hinder potential business growth.
Increased Redesign and Rework Costs: Neglecting aesthetic principles during product
design may result in poor initial designs or product concepts that require significant redesign
or rework. This can lead to increased costs in terms of time, resources, and materials. Iterative
design processes to address aesthetic shortcomings may delay product launch timelines and
increase overall development expenses.
Considering aesthetic principles during product design is crucial to create visually appealing,
marketable, and desirable products. It helps organizations differentiate themselves, attract
customers, enhance brand perception, and drive business success. By valuing aesthetics as an
integral part of the design process, organizations can create products that resonate with
customers and deliver memorable user experiences.

Q.5. Explain the strategies and principles considering while designing a product for safety
and ease.
Answer: When designing a product for safety and ease of use, several strategies and principles
should be considered to ensure that the product is user-friendly, minimizes risks, and provides
a positive user experience. Here are some key strategies and principles to keep in mind:
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
User-Centered Design: Adopt a user-centered design approach by understanding the needs,
abilities, and limitations of the target users. Conduct user research, usability testing, and gather
feedback throughout the design process to ensure the product is tailored to user preferences
and capabilities.
Compliance with Safety Standards: Familiarize yourself with applicable safety standards
and regulations relevant to the product. Design the product to meet or exceed these
requirements to ensure user safety and reduce liability risks.
Hazard Identification and Mitigation: Identify potential hazards associated with the product
and implement appropriate design measures to mitigate those risks. Consider both obvious and
hidden hazards, such as sharp edges, pinch points, electrical safety, choking hazards, or
chemical exposure. Use safety features like guards, interlocks, warnings, and clear instructions
to mitigate risks.
Intuitive User Interface: Design the product with an intuitive and user-friendly interface.
Minimize complexity, ensure clear labeling, use standardized symbols or icons, and provide
concise instructions to guide users in the safe and proper use of the product.
Ergonomics and Human Factors: Consider ergonomic principles to ensure the product is
comfortable, easy to handle, and suitable for a wide range of users. Design features like
appropriate handle grip, adjustable components, and accessible controls to accommodate
different body sizes, strengths, and abilities.
Error-Proofing Design: Implement design features that prevent or minimize user errors. Use
mechanisms like color-coding, shape differentiation, or asymmetry to aid users in proper
product operation. Incorporate fail-safe mechanisms that prevent dangerous situations or
provide clear indications when errors occur.
Clear and Effective Documentation: Provide clear, concise, and accessible user manuals,
guides, or instructional materials. Use plain language, visual aids, and step-by-step instructions
to help users understand the product's safe operation, maintenance procedures, and
troubleshooting.
Durability and Reliability: Design the product with durable materials, robust construction,
and reliable components. This ensures the product can withstand expected use conditions,
reducing the risk of malfunctions, failures, or safety hazards.
Accessibility and Universal Design: Consider the needs of users with disabilities or
impairments when designing the product. Incorporate universal design principles to make the
product accessible to a broader range of users, including those with physical, sensory, or
cognitive limitations.
Continuous Improvement and Feedback: Establish mechanisms to collect user feedback,
monitor product performance, and address safety concerns. Implement processes to
continuously improve the product's safety features, ease of use, and user satisfaction based on
user feedback and real-world usage data.
By incorporating these strategies and principles into the product design process, organizations
can create products that prioritize safety, ease of use, and user satisfaction. This not only
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
reduces the risk of accidents or injuries but also enhances the overall user experience, leading
to customer loyalty and positive brand reputation.

Q. 6. How efficient casting design shapes can be achieved? Give examples of designing for
machining ease.
Answer:

Casting design shapes:

Efficient casting design shapes can be achieved by considering several factors that optimize
the casting process and ensure high-quality castings. Here are some key considerations for
achieving efficient casting design shapes:
Draft Angles: Incorporating draft angles into the design helps facilitate the removal of the
pattern or the casting from the mold. Draft angles allow for smooth ejection, reduce the risk of
damage to the casting, and minimize the occurrence of defects such as undercuts or sticking.
Fillets and Radii: Adding fillets and radii to sharp corners or edges reduces stress
concentrations, promotes better material flow during the casting process, and minimizes the
risk of cracking or defects. Rounded features also make it easier to remove the casting from
the mold and improve the overall aesthetics of the final product.
Wall Thickness: Maintaining consistent and appropriate wall thickness throughout the casting
design is crucial for achieving uniform solidification and minimizing the risk of defects like
shrinkage or porosity. Avoiding abrupt changes in wall thickness helps ensure a smooth flow
of molten metal during casting.
Parting Lines and Gates: Carefully selecting the location of parting lines and gates in the
casting design can enhance the efficiency of the casting process. Optimizing the placement of
parting lines and gates improves mold filling, reduces turbulence, and facilitates the removal
of excess material or sprues.
Undercuts and Cores: Minimizing undercuts and complex core shapes simplifies the casting
process and reduces the need for additional operations like core removal or post-casting
machining. Designing for simpler core shapes or incorporating core slides can enhance the
efficiency of the casting process.
Consideration of Shrinkage: Anticipating and accommodating for the shrinkage that occurs
during solidification is crucial. Designing the casting with appropriate allowances for shrinkage
helps prevent distortions, dimensional inaccuracies, and residual stresses in the final product.
Examples of designing for machining ease:
Standardized Hole Sizes: Designing the product with standard hole sizes, such as following
standard drill bit sizes or metric/imperial measurements, facilitates easier and cost-effective
machining. This eliminates the need for custom tooling or special setups, streamlines the
machining process, and reduces machining time and costs.
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
Symmetrical Features: Incorporating symmetrical features in the design simplifies machining
operations. Symmetry allows for easier setup, reduces the number of required tool changes,
and improves machining accuracy by maintaining balance and reducing vibration during
machining.
Tolerances and Fits: Designing the product with appropriate tolerances and fits reduces the
complexity and difficulty of machining. Looser tolerances or more forgiving fits allow for
easier alignment and assembly, reducing the need for precise machining or secondary
operations.
Avoiding Internal Threads: Designing the product to avoid internal threads whenever
possible reduces the need for complex threading operations. Instead, utilizing external threads
or alternative fastening methods like inserts or clips simplifies machining and reduces the risk
of thread-related issues.
Minimizing Overhangs: Designing for minimal overhangs or extended features reduces the
risk of tool deflection, improves machining stability, and enhances surface finish. Minimizing
overhangs helps maintain rigidity during machining and avoids vibration or chatter, leading to
better machining efficiency and accuracy.
By implementing these design considerations, manufacturers can achieve efficient casting
design shapes that optimize the casting process and ensure high-quality castings. Additionally,
designing for machining ease reduces machining complexity, improves productivity, and
enhances the overall efficiency of the manufacturing process.

Q. 7. Discuss the steps involved in implementing the Quality Function Deployment (QFD).
Answer: Implementing Quality Function Deployment (QFD) involves several steps to ensure
that customer requirements are effectively translated into product design and development.
Here are the typical steps involved in implementing QFD:
Identify Customer Requirements: Begin by gathering and identifying customer requirements
through various methods such as surveys, interviews, market research, or feedback analysis.
This includes understanding customer needs, expectations, preferences, and desired product
features.
Determine Technical Requirements: Translate customer requirements into specific technical
requirements that are measurable and actionable. These technical requirements represent the
design and engineering parameters that must be fulfilled to meet customer expectations.
Develop the House of Quality (HOQ): The House of Quality is a matrix that serves as a
central tool in QFD. It links customer requirements with technical requirements, highlighting
the relationships between them. In the HOQ, customer requirements are listed on one side,
while technical requirements, competitive assessment, and interrelationships between
requirements are mapped out in other sections of the matrix.
Prioritize Customer Requirements: Assign importance ratings or weights to each customer
requirement in the HOQ. These weights reflect the relative significance of each requirement
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Landran, Mohali
Department of Mechanical Engineering
based on customer feedback and market research. The prioritization helps focus design efforts
on meeting the most critical customer needs.
Define Design Characteristics: Design characteristics are specific measurable attributes or
features of the product that contribute to meeting the technical requirements. Identify and
define design characteristics that align with the technical requirements listed in the HOQ. These
characteristics serve as design targets to ensure that the product meets customer expectations.
Establish Relationships and Targets: Establish relationships between the customer
requirements, technical requirements, and design characteristics in the HOQ. Determine the
target values or ranges for each design characteristic based on engineering analysis, industry
standards, or benchmarks. This step helps ensure that the product design aligns with customer
requirements.
Design Verification: Verify and validate the design against the defined targets and
requirements. This may involve conducting simulations, prototypes, testing, or other evaluation
methods to assess whether the design characteristics meet the technical requirements and
ultimately fulfill the customer requirements.
Implement Continuous Improvement: QFD is an iterative process that encourages
continuous improvement. Analyze the results of design verification and customer feedback to
identify areas for improvement and incorporate changes into subsequent design iterations. This
continuous improvement process ensures that the product design evolves to meet changing
customer needs and market demands.
Cross-Functional Collaboration: Successful implementation of QFD requires cross-
functional collaboration and involvement of different teams, including marketing, engineering,
design, manufacturing, and quality assurance. Facilitate effective communication and
collaboration among these teams to ensure alignment and synergy in meeting customer
requirements.
Monitor Customer Satisfaction: Continuously monitor customer satisfaction and gather
feedback on the product's performance and features. This feedback serves as input for future
product development cycles and helps in refining customer requirements, technical
requirements, and design characteristics.
By following these steps, organizations can effectively implement QFD to align customer
requirements with product design and development, leading to customer satisfaction, improved
product quality, and enhanced market competitiveness.

Q. 8. How rapid prototyping is different from conventional machining? Write down the
impletion of rapid prototyping techniques.
Answer:

How rapid prototyping is different from conventional machining

Rapid prototyping and conventional machining are two different approaches to creating
prototypes or producing parts. Here are the key differences between the two:
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
Process: Conventional machining involves the removal of material from a block or stock
material using cutting tools, such as milling machines, lathes, or drills. It involves subtractive
manufacturing, where the desired shape is achieved by removing excess material. Rapid
prototyping, on the other hand, uses additive manufacturing techniques to build a part layer by
layer. It involves the deposition or solidification of material to create the desired shape.
Speed: Rapid prototyping lives up to its name by offering faster turnaround times compared to
conventional machining. With rapid prototyping techniques like 3D printing, parts can be
produced in hours or days, depending on the complexity and size. Conventional machining
processes often require more time, especially for complex or large-scale parts, due to the need
for setup, tool changes, and longer machining times.
Design Complexity: Rapid prototyping allows for greater design complexity and flexibility
compared to conventional machining. Additive manufacturing techniques can create intricate
geometries, complex internal structures, and customized designs that may be challenging or
costly to produce using conventional machining. Rapid prototyping enables the production of
parts with complex features in a single build, eliminating the need for multiple machining
operations.
Material Options: Conventional machining provides a wide range of material options,
including metals, plastics, composites, and more. Rapid prototyping techniques offer a growing
selection of materials, but the range may be more limited compared to conventional machining.
However, advancements in rapid prototyping have expanded the range of available materials,
including various plastics, metals, ceramics, and even biocompatible materials.
Cost: The cost structure for rapid prototyping and conventional machining can vary. Rapid
prototyping can be cost-effective for low-volume production or for producing prototypes and
small quantities of parts with complex geometries. Conventional machining is often more cost-
effective for large-scale production runs or when working with materials or part geometries
that are not suitable for rapid prototyping techniques.
Iterative Design: Rapid prototyping supports rapid iterations and design changes. Design
modifications can be easily incorporated by simply modifying the digital design file and
reprinting the part. Conventional machining may involve more time and cost to implement
design changes since it requires adjusting the machining setup, reprogramming toolpaths, or
creating new fixtures.
Surface Finish and Tolerance: Conventional machining can achieve precise tolerances and
high-quality surface finishes, especially with advanced machining techniques and post-
processing. Rapid prototyping may have limitations in achieving tight tolerances and smooth
surface finishes, although the quality has significantly improved in recent years. Additional
post-processing steps may be required for rapid prototyping parts to meet specific tolerance
and surface finish requirements.
Both rapid prototyping and conventional machining have their strengths and applications. The
choice between the two depends on factors such as design complexity, production volume, time
constraints, material options, and cost considerations. Organizations often use a combination
of these techniques, leveraging rapid prototyping for initial design validation and iteration, and
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
employing conventional machining for large-scale production or parts that require specific
tolerances and surface finishes.

Different steps of the impletion of rapid prototyping techniques:

The implementation of rapid prototyping techniques typically involves several steps to
transform a design concept into a physical prototype efficiently and effectively. Here are the
different steps involved in the implementation of rapid prototyping techniques:
Conceptualization: Begin by conceptualizing the design idea or concept for the product. This
may involve sketching, 3D modeling, or using CAD (Computer-Aided Design) software to
create a virtual representation of the product.
Design Preparation: Prepare the design file in a suitable format for rapid prototyping. This
may involve converting the design into STL (Standard Tessellation Language) format, which
is commonly used in additive manufacturing processes.
Material Selection: Determine the most appropriate material for the prototype based on the
intended purpose, functional requirements, and desired characteristics. Consider factors such
as strength, flexibility, temperature resistance, and aesthetics when selecting the material for
the rapid prototyping process.
Rapid Prototyping Technique Selection: Choose the specific rapid prototyping technique
that best suits the requirements of the design. Common techniques include 3D printing (using
various technologies like FDM, SLA, SLS), CNC machining, laser cutting, or vacuum casting.
Selecting the right technique depends on factors such as resolution, accuracy, material
compatibility, cost, and turnaround time.
Pre-Processing: Prepare the design file for the specific rapid prototyping technique. This may
involve slicing the 3D model into thin layers for 3D printing, generating toolpaths for CNC
machining, or setting parameters for laser cutting. Pre-processing ensures that the machine
understands the design and instructions for creating the physical prototype.
Prototype Production: Start the rapid prototyping process by operating the chosen machine
or technology. Follow the instructions specific to the selected technique, such as loading the
material, setting up the machine, initiating the build or machining process, and monitoring the
progress.
Post-Processing: Once the rapid prototyping process is completed, perform any necessary
post-processing steps to refine the prototype. This may include removing support structures,
sanding or smoothing surfaces, applying finishes or coatings, or assembling multiple prototype
parts. Post-processing aims to enhance the aesthetics and functionality of the prototype.
Evaluation and Testing: Evaluate the physical prototype to assess its functionality, form, and
fit. Conduct tests, measurements, and inspections to verify that the prototype meets the
intended requirements and design objectives. Identify any design flaws, weaknesses, or areas
for improvement.
Iterative Design and Modification: Based on the evaluation and testing results, iterate and
modify the design as necessary. Incorporate design changes or improvements identified during
the evaluation phase into the digital design file.
 Chandigarh Engineering College-CGC
Landran, Mohali
Department of Mechanical Engineering
Repeat Prototyping Cycle: Repeat the rapid prototyping cycle by adjusting the design,
selecting the appropriate technique, and producing subsequent prototypes until the desired final
prototype is achieved. The iterative process allows for continuous refinement and optimization
of the design based on feedback and testing results.
By following these steps, organizations can effectively implement rapid prototyping techniques
to develop functional prototypes quickly, validate design concepts, identify design flaws early,
and accelerate the product development cycle.