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The Engineering Design Primer
The Engineering Design Primer
Keith L. Richards
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have
been made to publish reliable data and information, but the author and publisher cannot assume responsibility
for the validity of all materials or the consequences of their use. The authors and publishers have attempted to
trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if
permission to publish in this form has not been obtained. If any copyright material has not been acknowledged,
please write and let us know so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted,
or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, includ-
ing photocopying, microfilming, and recording, or in any information storage or retrieval system, without writ-
ten permission from the publishers.
For permission to photocopy or use material electronically from this work, please access www.copyright.com
(http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive,
Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration
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Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only
for identification and explanation without intent to infringe.
Preface............................................................................................................................................ xix
About the Author......................................................................................................................... xxi
5. Conceptual Design................................................................................................................ 89
5.1 Creativity Methods...................................................................................................... 89
5.2 Breaking the Mindset.................................................................................................. 89
5.2.1 Inversion........................................................................................................ 89
5.2.2 Analogy.........................................................................................................90
5.2.3 Empathy......................................................................................................... 90
5.2.4 Fantasy........................................................................................................... 90
5.2.5 Brainstorming...............................................................................................90
x Contents
8. Decision-Making................................................................................................................. 145
8.1 What Is Decision-Making......................................................................................... 145
8.1.1 Intuition....................................................................................................... 145
8.1.2 Reasoning.................................................................................................... 145
8.1.3 Applying Both Intuition and Reasoning................................................ 145
8.1.4 What Can Prevent Effective Decision-Making?..................................... 145
Contents xiii
The philosophy behind the engineering design primer is to introduce student engineers
to the world of engineering design. Most student engineers start in the drawing office as
draughtsmen and the majority stay there for the duration of their working lives with little
thought of progressing into design engineering. From the author’s experience, the draw-
ing office lays a very good foundation for a career in design and allows the student to
explore the many facets of design.
The first part of the book introduces the student to the workings of the drawing office
together with the working principles of producing a drawing having sufficient detail to
enable the part to be manufactured. Chapter 3 covers the principles of the design process
followed by the design specification or PDS. This is the singular most important document
in the design process as it lays down the definition of the design in so far as what the com-
pany will produce and most importantly what the customer is expecting.
Chapter 6 covers ‘Design for “X”’ discussing such items as manufacture, reliability,
robustness, maintainability and serviceability. Life cycle costing is also discussed in this
chapter.
Quality is discussed in Chapters 6 and 11. It is important for the producer that the cus-
tomer has the utmost confidence that the product they buy will meet all their expectation.
I make no apology for discussing probabilities and engineering statistics as these items
are important when discussing reliability.
The book is rounded off with chapters on material selection, mathematical modelling
and configuration management, the later covering change controls. Communication is an
important attribute for the budding designer to stand up and confidently and clearly to put
his case across for the adaptation of his/her design.
The author wishes the readers every success in their respective design careers and hopes
it will provide them many years of employment as, it has for him.
xix
About the Author
xxi
1
Organisation and Structure of the Drawing Office
1.1 Introduction
Over the last few years the ‘drawing office’ has seen a massive revolution. Digital draught-
ing has replaced the original method of paper and manual drawing, and alongside this
major change there has been a technological revolution in the way drawing prints are now
processed and the way data is now transferred to the multi-axis machining centres on the
shop floor.
Drawing offices used to be quite noisy with general chatter and heated discussions,
now all this has been replaced by a quiet environment with only the clatter of key-
boards to be heard. Any major discussions are carried out in side offices to the main
drawing area.
Figures 1.1 to 1.5 show typical drawing offices from 1900 to the present day, and the
changes that have taken place can be seen. This has been reflected across the engineering
industry in the United Kingdom.
1
2 The Engineering Design Primer
FIGURE 1.1
A drawing office in early 1900s.
FIGURE 1.2
1923 drawing office.
FIGURE 1.3
1963 drawing office.
FIGURE 1.4
A typical computer-aided design (CAD)/computer-aided manufacturing (CAM) drawing office in 1986.
FIGURE 1.5
A computer-aided design (CAD)/computer-aided manufacturing (CAM) drawing office in 1991.
4 The Engineering Design Primer
FIGURE 1.6
Relationship between the drawing office and other departments.
The earliest British Standard relating to engineering appeared in 1903 and covered
a range of sizes for metal bars, sheet, nuts and bolts and flanges, etc. The first British
Standard relating to drawing office practice was published in 1927 and covered the fol-
lowing factors:
• Methods of projection
• Types of lines
• Views and sections
• Screw threads
• Tapers
First angle projection was the preferred method for the illustrations, and the publication
was printed on A5 sheets of paper.
In the early days prior to World War I, manufacturers simply fitted components together
without due regard to future replacement when any wear took place. The dimensions used
were those as used in the prototype part. When manufacturing industry was faced with
the introduction of quantity production as led by the gun trade where components had
to be manufactured at various manufacturing sites, measurements had to be more pre-
cise and methods devised to measuring the parts more easy. As each factory had devel-
oped its own standard methods, it became clear and imperative that a National Standard
was essential. British Standards published a comprehensive Limits and Fits standard. The
National Physical Laboratory was first founded in 1900 and it was obvious that this should
be the custodian of the measuring standards. All companies were required to have their
measuring equipment certified and calibrated by the laboratory to ensure a consistent
measuring system is applied across the industry.
There are two clear aspects that need to be considered for the specification of a compo-
nent drawing:
1. The drawing is required to show all relevant dimensions for the part in three
planes projections.
2. The metrologist produces an evaluation of the part with regard to limits and fits.
1. Development
2. Research
3. Manufacturing investigations, including metallurgy, heat treatments, etc.
4. Project planning
5. Field testing of products
Service:
The service department provides a prompt and efficient response to any service calls.
Any work the drawing office receives from this department is associated with:
Manufacturing:
This department is the recipient of all the drawing office manufacturing drawings that
have been approved for manufacture. The drawing office supplies all working drawings,
schedules and purchase requests for all proprietary items.
G. W. Wingate,
What the Beef Scandal Teaches
(Independent, April 6, 1899).
See:
UNITED STATES OF AMERICA: A. D. 1898-1899.
{635}
On the 4th of January the Senate received the treaty from the
President. On the 7th, Senator Mason, of Illinois, introduced
the following resolution, and, subsequently, spoke with
earnestness in its support:
"I am to speak for my country, for its whole past and for its
whole future. I am to speak to a people whose fate is bound up
in the preservation of our great doctrine of constitutional
liberty. I am to speak for the dead soldier who gave his life
for liberty that his death might set a seal upon his country's
historic glory. I am to speak for the Republican party, all of
whose great traditions are at stake, and all of whose great
achievements are in peril. …
"To that extent and to that alone we claimed and avowed the
reason for the declaration of war. So it follows that the mere
declaration of war did not affect in any manner our relations
with the Philippine Islands except to put us in a state of war
with them as a part of the Spanish domain, and in no manner
laid any obligations upon us as to those islands. We were not
charged with the duty of preserving order in Asia. We were not
charged with the obligations of seeing that they had a stable
and orderly government in any part of that hemisphere. No such
duty rested upon us. None such was assumed by us. Therefore
the simple declaration of war did not lay any obligation upon
us as to the Philippine Islands, and I desire that any Senator
will put his finger upon the act which laid us under any
obligations to the Philippine Islands outside of the fact that
in the war which ensued we took those who were the insurgents
in those islands to be our allies and made a common cause with
them.
"Now, Mr. President, all that grows out of that—all that grows
out of the fact of that cooperation and that alliance—is to
impose upon us a single obligation which we must not ignore.
How far does that obligation go? Does it require that we shall
for all time undertake to be the guardians of the Philippine
Islands? Does that particular obligation lay upon us the duty
hereafter, not only now but for years to come, to maintain an
expensive military establishment, to burden our people with
debt, to run the risk of becoming involved in wars in order
that we may keep our hands upon the Philippine Islands and
keep them in proper condition hereafter? I am unable to see
how the obligation growing out of the fact that they were our
allies can possibly be extended to that degree. No Senator has
yet shown any reason why such an obligation rests upon us, and
I venture to say that none which is logical will or can be
shown."
{638}
"Section 2.
That it is against the policy, traditions, and interests of
the American people to admit states erected out of other than
North American territory into our union of American States.
"Section 3.
That the United States accept from Spain the cession of the
Philippine Islands with the hope that the people of those
islands will demonstrate their capacity to establish and
maintain a stable government, capable of enforcing law and
order at home and of discharging the international obligations
resting on separate and independent States, and with no
expectation of permanently holding those islands as colonies
or provinces after they shall demonstrate their capacity for
self-government, the United States to be the judge of such
capacity."
Congressional Record,
December 6, 1898—February 6, 1899.
{639}
The Dingley Tariff Act, which became law on the 24th of July,
1897, authorized the making of tariff concessions to other
countries on terms of reciprocity, if negotiated within two
years from the above date. At the expiration of two years,
such conventions of reciprocity had been arranged with France
and Portugal, and with Great Britain for her West Indian
colonies of Jamaica, Barbadoes, Trinidad, Bermuda, and British
Guiana. With France, a preliminary treaty signed in May, 1898,
was superseded in July, 1899, by one of broader scope, which
opens the French markets to an extensive list of American
commodities at the minimum rates of the French tariff, and
cuts the American tariff from 5 to 20 per cent. on many French
products, not inclusive of sparkling wines. In the treaty with
Portugal, the reduction of American duties on wines is more
general. The reciprocal reduction on American products extends
to many agricultural and mineral products. The reciprocal
agreement with the British West Indies covers sugar, fruits,
garden products, coffee and asphalt, on one side, and flour,
meat, cotton goods, agricultural machinery, oils, etc., on the
other.