DESIGN George E. Dieter | | a Linda C. Schmidt 4.00 y 3.00 | ee ae | mlENGINEERING DESIGN FIFTH EDITION George E. Dieter University of Maryland Linda C. Schmidt University of Maryland am \Connect Learn Succeed ~ENGINE! ING DESIGN, FIFTH EDITION Published by McGraw-Hill, a business unit of The McGraw-Hill Companies, Inc., 1221 Avenue of the Americas, New York, NY 10020. Copyright © 2013 by The McGraw-Hill Companies, Inc. All rights reserved, Previous editions © 2009, 2000, and 1991. Printed in the United States of America. No part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written consent of The McGraw-Hill Companies, Inc, including, ‘but not limited to, in any network or other electronic storage or transmission, or broadcast for distance learning. Some ancillaries, including electronic and print components, may not be available to customers outside the United States This book is printed on acid-free paper. 1234567890 DOCDOC 1098765432 ISBN 978-0-07.339814-3 MHI 0-07-339814-4 Vive President & Editor-in-Chief: Marty Lange Vice President of Specialized Publishing: Janice M. Roerig-Blong Editorial Director: Michael Lange Global Publisher: Raghorhaman Srinivasan Senior Sponsoring Editor: Bil Stenquist “Marketing Manager: Curt Reynolds Developmental Editor: Lorraine K. Buczek Project Manager: Melissa M. Leick Design Coordinator: Brenda A. Rolwes Cover Designer: Studio Montage, St. Louis, Missouri Cover Image: © Gerty Images RF Buyer: Laura Fuller ‘Media Project Manager: Balaji Sundararaman Compositor: Cenveo Publisher Services ‘Typelace: 10.5/12 Times Roman Printer: R. R. Donnelley Library of Congress Cataloging-in-Publication Data Dieter, George Ellwood. Engineering design, — Sth ed. / George E.. Dieter, Linda C . Schmidt pcm. ISBN 978-0-07.339814-3 (acid-free paper) 1. Engineering design. I. Schmidt, Linda C. IL Tile. TAI74.D495 2013, 620,0042—de23 2011048958 www.mbhe.comABOUT THE AUTHORS GEORGE E. DIETER is Glenn L, Martin Institute Professor of Engineering at the University of Maryland, The author received his B.S. Met.E. degree from Drexel University and his D.Sc. degree from Carnegie Mellon University. After a stint in industry with the DuPont Engineering Research Laboratory, he became head of the Metallurgical Engineering Department at Drexel University, where he later became Dean of Engineering. Professor Dieter later joined the faculty of Carnegie Mellon University as Professor of Engineering and Director of the Processing Research Insti- tute. He moved to the University of Maryland in 1977 as professor of Mechanical Engineering and Dean of Engineering, serving as dean until 1994 Professor Dieter is a fellow of ASM International, TMS, AAAS, and ASE. He has received the education award from ASM, TMS, and SME, as well as the Lamme Medal, the highest award of ASEE. He has been chair of the Engineering Deans Council, and president of ASEE. He is a member of the National Academy of Engi- neeting. He also is the author of Mechanical Metallurgy, published by McGraw-Hill, now in its third edition. LINDA C. SCHMIDT isan Associate Professor in the Department of Mechani- cal Engineering at the University of Maryland. Dr. Schmidt's general research inter- ests and publications are in the areas of mechanical design theory and methodology, design generation systems for use during conceptual design, design rationale capture, and effective student learning on engineering project design teams. Dr. Schmidt completed her doctorate in Mechanical Engineering at Carnegie Mellon University with research in grammar-based generative design, She holds B.S. and M.S. degrees from Iowa State University for work in Industrial Engineering, Dr. Schmidt is a recipient of the 1998 U.S, National Science Foundation Faculty Early Career Award for generative conceptual design. She co-founded RISE, a summer research experience that won the 2003 Exemplary Program Award from the American College Personnel Asso- ciation’s Commission for Academic Support in Higher Education. Dr. Schmidt wasiv ENGINEERING DESIGN awarded the American Society of Engineering Education's 2008 Merryfield Design Award. Dr. Schmidt is active in engineering design theory research and teaching engi- neering design to third- and fourth-year undergraduates and graduate students in mechanical engineering. She has coauthored a text on engineering decision-making, two editions of a text on product development, and a team-training curriculum for faculty using engineering student project teams. Dr. Schmidt was the guest editor of the Journal of Engineering Valuation & Cost Analysis and has served as an Associ- ate Editor of the ASME Journal of Mechanical Design. Dr. Schmidt is a member of ASME, SME, and ASE.BRIEF CONTENTS Chapter Chapter Chapter Chapter Chapter Chapter Chapter Chapter Chapter Chapter 10 Chapter 11 Chapter 12 Chapter 13 Chapter 14 Chapter 15 Chapter 16 Chapter 17 Chapter 18 Cau aneune Engineering Design 1 Product Development Process 36 Problem Definition and Need Identification 70 ‘Team Behavior and Tools 18 Gathering Information 158 Concept Generation 191 Decision Making and Concept Selection 244 Embodiment Design 299 Detail Design 386 Design for Sustainability and the Environment all Materials Selection 437 Design with Materials 487 Design for Manufacturing 526 Risk, Reliability, and Safety 628 Quality, Robust Design, and Optimization 680 Economic Decision Making B4 Cost Evaluation 716 Legal and Ethical Issues in Engineering Design www.mbhe.com/dieter Appendices Al Author & Subject Indexes LlDETAILED CONTENTS Preface Chapter 1 Engineering Design LL 12 13 14 Ls 16 17 18 1 Tntroduction Engineering Design Process ‘Ways to Think about the Enginecring Design Process Description of Design Process Considerations of a Good Design Computer-Aided Engineering Designing to Codes and Standards Design Review Societal Considerations in Engineering Design 1.10 Summary Chapter 2 Pro 24 22 23 24 25 2.6 27 New Terms and Concepts Bibliography Problems and Exercises duct Development Process Introduction Product Development Process Product and Process Cycles Organization for Design and Product Development Markets and Marketing Technological Innovation Summary Now Terms and Concepts Bibliography Problems and Exercises xiii 14 0 22 24 26 28 32 3 33 33 36 36 36 44 48 35 6 66 67 67 67DETAILED CONTENTS vii Chapter 3 Problem Definition and Need Identification 70 3.1 Introduction 70 3.2 Identifying Customer Needs n 3.3. Customer Requirements 80 3.4 Gathering Information on Existing Products 86 3.5 Establishing the Engineering Characteristics 94 3.6 Quality Function Deployment 99 3.7 Product Design Specification 11 3.8 Summary 113 New Terms and Concepts us Bibliography us Problems and Exercises 116 Chapter 4 Team Behavior and Tools 118 4.1 Introduction us 4.2 What It Means to be an Effective Team Member 119 4.3. Team Leadership Roles 120 44° Team Dynamics 121 4.5 Effective Team Meetings 123, 4.6 Problem-Solving Tools 12s 4.7 Time Management 144 4.8 Planning and Scheduling 146 49° Summary 154 New Terms and Concepts 154 Bibliography 155 Problems and Exercises 155 Chapter 5 Gathering Information 158 5.1 The Information Challenge 158 5.2 Types of Design Information 160 5.3 Sources of Design Information 161 5.4 Library Sources of Information 164 5.8 Government Sources of Information 168 $.6 Information From the Internet 169 5.7 Professional Societies and Trade Associations m4 8.8 Codes and Standards 176 5.9 Patents and Other Intellectual Property 178, 5.10 Company-Centered Information 187 S.11 Summary 188, New Terms and Concepts 189 Bibliography 189 Problems and Exercises 189 Chapter 6 Concept Generation 191 6.1 Introduction to Creative Thinking 192 6.2 Creativity and Problem Solving 19663 64 65 66 67 68 ENGINEERING DESIGN Creative Thinking Methods Creative Methods for Design Functional Decomposition and Synthesis Morphological Methods TRIZ: The Theory of Inventive Problem Solving Summary New Terms and Concepts Bibliography Problems and Exercises Chapter 7 Decision Making and Concept Selection at 72 13 14 18 16 17 18 Introduction Decision Making Evaluation Processes Using Models in Evaluation Pugh Chart Weighted Decision Matrix Analytic Hierarchy Process (AHP) Summary New Terms and Concepts Bibliography Problems and Exercises Chapter 8 Embodiment Design 81 8.2 83 8.4 85 8.6 87 88 89 8.10 8.1L 8.12 8.13 Introduction Product Architecture Steps in Developing Product Architecture Configuration Design Best Practices for Configuration Design Parametric Design Dimensions and Tolerances Industrial Design Human Factors Design Life-Cycle Design Prototyping and Testing Design for X (DFX) Summary New Terms and Concepts Bibliography Problems and Exercises Chapter 9 Detail Design 91 9.2 9.3 Introduction Activities and Decisions in Detail Design Communicating Design and Manufacturing Information. 202 212 216 226 229 240 241 242, 242 244 244 245 257 262 279 283 286 294 295 295 295 299 299 302 306 31 318 328 340 358 361 368 369 379 381 382 382 383, 386 386 387 391DETAILED CONTENTS ix 9.4 Final Design Review 402 9.5 Design and Business Activities Beyond Detail Design 403 9.6 Facilitating Design and Manufacturing with Computer-Based Methods 406 97 Summary 408 New Terms and Concepts 408 Bibliography 409 Problems and Exercises 409 Chapter 10 Design for Sustainability and the Environment 41 10.1 The Environmental Movement aul 10.2 Sustainabilty 416 10.3 Challenges of Sustainability for Business 420 10.4 End-Of Life Product Transformations 422 10.5 Role of Material Selection in Design for Environment 427 10.6 Tools to Aid Design for the Environment and Sustainability 431 10.7 Summary 436 New Terms and Concepts 435 Bibliography 436 Problems and Exercises 436 Chapter 11 Materials Selection 437 ILL Introduction 437 11.2 _ Performance Requirements of Materials 440 11.3 The Materials Selection Process 451 11.4 Sources of Information on Material Properties 455 ILS Cost of Materials 460 11.6 Overview of Methods of Materials Selection 462 117 Material Performance Indices 463 1L8 Materials Selection with Decision Matrices 4m 19 Selection with Computer-Aided Databases 476 11.10 Design Examples 47 11.11 Summary 481 New Terms and Concepts 482 Bibliography 483 Problems and Exercises 483 Chapter 12 Design with Materials 487 12.1 Introduction 487 12.2 Design for Brittle Fracture 488 12.3 Design for Fatigue Failure 494 12.4 Design for Corrosion Resistance 506 12.5 Design Against Wear su 12.6 Design with Plastics 516 12.7 Summary 523Chapter 13 Chapter 14 Chapter 15 ENGINEERING DESIGN New Terms and Concepts Bibliography Problems and Exercises Design for Manufacturing 1B. 13.2 13.3 B4 13.5 13.6 137 1B8 13.9 13.10 13.11 13.12 13.13 13.14 13.15 13.16 13.17 13.18 123.19 Risk, 141 14.2 143 4 5 146 147 148 9 Role of Manufacturing in Design Manufacturing Functions Classification of Manufacturing Processes Manufacturing Process Selection Design for Manufacture (DFM) Design for Assembly (DFA) Role of Standardization in DEMA Mistake-Proofing Early Estimation of Manufacturing Cost Process Specific DFMA Guidelines Design of Castings Design of Forgings Design for Sheet-Metal Forming Design for Machining Design of Welding Residual Stresses in Design Design for Heat Treatment Design for Plastics Processing Summary New Terms and Concepts Bibliography Problems and Exercises Reliability, and Safety Introduction Probabilistic Approach to Design Reliability Theory Design for Relisbility Failure Mode and Effects Analysis (FMEA) Fault Tree Analysis Defects and Failure Modes Design for Safety Summary New Terms and Concepts Bibliography Problems and Exercises Quality, Robust Design, and Optimization 151 15.2 The Concept of Total Quality Quality Control and Assurance 523 523 524 526 526 527 529 536 561 365 S72 S77 581 585 586 590 593 597 602 609 6s ols 3 625 625 626 628 628 634, 642, 657 662 667 670 62 615 676 676 61 680 680 683,Chapter 16 Chapter 17 15.3 15.4 15.5 15.6 18.7 15.8 15.9 15.10 DETAILED CONTENTS Statistical Process Control, Quality Improvement Process Capability Taguchi Method Robust Design Optimization Methods Design Optimization Summary New Terms and Concepts Bibliography Problems and Exercises Economic Decision Making 16.1 16.2 16.3 164 16.5 16.6 16.7 16.8 16.9 16.10 16.11 16.12 Introduction Mathematics of Time Value of Money Cost Comparison Depreciation Taxes Profitability of Investments Other Aspects of Profitability Inflation Sensitivity and Break-Even Analysis Uncertainty in Economic Analysis Benefit-Cost Analysis Summary New Terms and Concepts Bibliography Problems and Exercises Cost Evaluation a1 1712 173 a4 1715 116 a7 178 179 17.10 q7AL q7a2 1743 1744 1745 Introduction Categories of Costs The Cost of Ownership Manufacturing Cost Overhead Cost Activity-Based Costing Methods of Developing Cost Estimates Make-Buy Decision Product Profit Model Refinements to Cost Analysis Methods Cost of Quality Design to Cost Value Analysis in Costing Manufacturing Cost Models Life Cycle Costing 687 692 695 700 706 m2 8 9 730 730 ma 734 34 735 142 147 749 753 761 762 765 167 168 710 ™m m2 ™m 7716 716 11 780 781 782 784 787 792 793 798 803, 805, 808 sil 816Chapter 18 ENGINEERING DESIGN 17.16 Summary New Terms and Concepts Bibliography Problems and Exercises Legal and Ethical Issues in Engineering Design (Gee www.mbhe.com/aictet) 18.1 Introduction 18.2 The Origin of Laws 18.3 Contracts 18.4 Liability 18.5 Tort Law 18.6 Product Liability 187 Protecting Intellectual Property 18.8 ‘The Legal and Ethical Domains 18.9 Codes of Ethies 18.10 Solving Ethical Conflicts 18.11 Summary New Terms and Concepts Bibliography Problems and Exercises Appendices Author & Subject Indexes 820 821 821 821 826 826 827 828 831 832 833, 838, 839 841 846 851 853, 853, 854 AlPREFACE TO FIFTH EDITION THE FIFTH EDITION of Engineering Design continues the reorganization and expansion of topics introduced in the fourth edition. Major reorganization of topics to improve flow of information and increase learning have been made in Chapter 3, Problem and Need Identification; Chapter 6, Concept Generation; and Chapter 7, Decision Making and Concept Selection. A new, progressive example has been intro- duced and is continued through these thtee chapters. A new Chapter 10, Design for Sustainability and the Environment, has been added. The book continues its tradition of being more oriented to material selection, design for manufacturing, and design for quality than other broad-based design texts, ‘The text is intended to be used in either a junior or senior engineering design course with an integrated hands-on design project. At the University of Maryland we present the design process material, Chapters 1 through 9, to junior students in a course introducing the design process. The whole text is used in the senior capstone design course that includes a complete design project, starting from selecting a market to creating a working prototype. Students move quickly through the first nine chapters and emphasize Chapters 10 through 17 in making embodiment design decisions. ‘The authors hope that students will consider this book to be a valuable part of their professional library. Toward this end we have continued and expanded the practice of giving key literature references and referrals to useful websites. Many new references have been added and all websites have been verified as of June 2011. References to many of the design handbooks and design monographs available at knovel.com have been added to this edition. We have also used the extensive series of ASM Handbooks to extend topics in Chapters 11, 12, 13, 14, and 15. These are also available at knovel.com. New to This Edition + Reorganization and new material in Chapters 3, 6, and 7, including a progressive example throughout these chapters + New Chapter 10, Design for Sustainability and the Environmentxiv ENGINEERING DESIGN + Chapter 16, Economic Decision Making, brought into the book from text website + Section on Cost of Quality added to Chapter 17, Cost Evaluation + Many additional connections to useful design information on the Internet + Updated and new references including links to handbooks available through knovel.com + PowerPoint lecture slides available to instructors through McGraw-Hill Higher Education ‘We want to acknowledge the willingness of students from our senior design course for permission to use material from their report in some of our examples. The JSR Design Team members are: Josiah Davis, Jamil Decker, James Maresco, Seth McBee, Stephen Phillips, and Ryan Quinn. Special thanks to Peter Sandborn, Chandra Thamire, and Guangming Zhang, our colleagues in the Mechanical Engineering Department, University of Maryland, for their willingness to share their knowledge with us. Thanks also to Greg Moores of the DeWalt Division of Stanley Black and Decker, Inc. for his willingness to share his industrial viewpoint on several topics. We also thank the following reviewers for their helpful comments and suggestions: Bruce Floersheim, United States Military Acad- emy; Mark A. Johnson, Michigan Tech University; Jesa Kreiner, California State Uni- versity at Fullerton; David N. Kunz, University of Wisconsin, Platteville; Marybeth Lima, Louisiana State University; Bahram Nassersharif, University of Rhode Island; Ibrahim Nisanci, University of Arkansas at Little Rock; Keith E. Rouch, University of Kentucky; Paul Steranka, West Virginia University Institute of Technology; M. A. Wahab, Louisiana State University, John-David Yoder, Ohio Northern University; D. A. Zumbrunnen, Clemson University. George E. Dieter and Linda C, Schmidt College Park, MD 2012