ch 1 design methodology.pdf

MS5016 Design Methodology & Optimizationby I Wayan Suweca, KK-PM ITB

1-1

MS5016 Design Methodology and Optimization1

Hosted by: I Wayan Suweca

Innovative Design



1-2

Design Optimization


Rapid Prototyping



1-3

1.1 1.1 What is Design?What is Design?

Chapter 1DESIGN METHODOLOGY

Needs

123

MappingProducts

123


Design is defined as the mapping process from functional space tothe physical space to satisfy the designer-specified goals or objectives

Functionalspace

Physicalspace

Routine designAll possible solution types are enumerated (that is, all the tt ib t li bl f l th d d th t t i

1.2 1.2 Classes of DesignClasses of Design (Brown & Chandrasekaran, 1985)

attributes, applicable useful methods, and the strategies are known a priori).

Innovative designThe knowledge base is already known and available to designer. The solutions are novel, but no new knowledge is added.


Creative designNeither the attributes nor the strategies are known ahead of time. New variables and new knowledge bases are added to the system.


1-4

Design methodology is a prescribed sequence of action in design process.

It is important to know in what context a given

1.3 1.3 DesignDesign MethodologyMethodology

p gmethodology is applicable and for what problem types it is useful.

Some examples of design methodology are:

French method Ibrahim Zeid method


Ullman method VDI method Pahl & Beitz method Dieter method Hatamura method

Needs

Analysis of problem

Statement of problem

French Method

Conceptualdesign

Selected Scheme

s

: Process

: Result


Embodiment ofschemes

Detailing

Working drawing

: Result


1-5

Designneed

Designspecifications

Feasibility study with collecting design information

Design Process

Synthesis

Analysis

Ibrahim Zeid Method

Designdocumentation

Designevaluation

Designanalysis,

optimizationDesign Analysis model

Designconcept-

ualization

Process planning Production

Quality control Packaging Shipping

Production planning

Design and procurement of new tools

CAD + CAE


MarketingOrder materials

NC/CNC/DNC Pro-gramming

Manufacturing Process

CAM

TeamEstablishment

JobDevelopment

ProjectDefinition & Planning

SpecificationDefinition

CustomerIdentification

EstablishCustomer Needs

ProductDevelopment

ConceptualDesign

ProductSupport

CreateConcept

EvaluateConcept

ProduceProduct

Performance &Strength

C t

Start

SalesSupport

TechnicalModification

ct e

valu

atio

n

Cost & schedule estimation

MarketAnalysis

EstablishTechnical

Specification

CompetitorEvaluation

DetermineTarget

Documentation &Communication

Make Decisionfor the Concept

Changethe plan

Production

Cost

Documentation &Communication

Yes

Manufacturing &Assembling

Support

CustomerSupport

Yes

Pro

duc

Yes

Make Decision for the product

Yes


UllmanMethod

Project planapproved?

Spec.approved?

No

Conceptapproved?

Productionapproved?

Improve?

No

Stop

Yes

Improve?

Stop

No

No

Improve?

Stop

No

No

Yes

Yes

Improve?

Stop

No

No

Yes

End


1-6

Task

Clarify & definethe task1

Determine functionand their structure2

d fo

llow

ing

stag

es

Specification

Phase I

STAGES RESULTS PHASES

Develop layout ofkey modules5

Divide intorealizable modules4

Search for solution principlesand their combinations3

d ba

ckw

ards

bet

wee

n pr

evio

us a

nd Function structures

Principles solutions

Module structure

ulfil

l and

ada

pt r

equi

rem

ent Phase II

Phase III

MS5016 Design Methodology and Optimization11Further Realization

Prepare production andoperating instructions7

Complete overallmodules6

Iter

ate

forw

ards

and

Definitive layouts

Product documents

Preliminary layouts F

Phase IV

VDI Method

TaskMarket, company, economy

Plan and clarify the task

Develop the principles

Requirement list(Design specification)

men

ts li

st

Plan

ning

and

clar

ifyin

g th

e ta

skep

tual

si

gn

miz

atio

n of

the

pr

inci

ple

Develop the principles

Develop the construction structure

Define the construction structure

Concept(Principle solution)

Preliminary layout

Upg

rade

an

d im

prov

e

form

atio

n ad

apt

the

requ

irem

Conc de

sEm

bodi

men

t de

sign

n of

th

e io

n

tim

izat

ion

of t

he la

yout

, fo

rms

and

mat

eria

ls

Opt

im


Prepare production andoperating documents

Solution

Definitive layout

Product documentatation

UIn

Det

ail

desi

gn Opt

imiz

atio

npr

oduc

ti

Opt

f

Pahl & Beitz Method


1-7

Plan and clarify the task:Analyze the market & the company situationFind & select product ideasFormulate a product proposalClarify the taskElaborate a requirements list

Develop the principle solution:Identify essential problemsEstablish function structuresSearch for working principles and working structuresSearch for working principles and working structuresCombine and firm up into concept variantsEvaluate against technical and economic criteria

Develop the construction structure:Preliminary form design, material selection and calculationSelect best preliminary layoutsRefine and improve layoutsEvaluate against technical and economic criteria

Develop the construction structure:


Develop the construction structure:Eliminate weak spotsCheck for errors, disturbing influences and minimum costsPrepare the preliminary parts list and production and assembly documents

Prepare production and operating documents:Elaborate detail drawing and parts listsComplete production, assembly, transport and operating instructionsCheck all documents

Product Specification

Develop Design Concept

Analysis Critical Design Features

Create Detail Design

Historical andCurrent Test Data

Modify Design

D

Dieter Method

Analysis Detail Design

Generate Detailed Drawings

Build Prototype

Test Prototype

Program N/C Machine Tools andA tomated Man fact ing Eq ipment

Design Database

CAD


Automated Manufacturing Equipment

Manufacturing Product

Test Finished Product

Ship Product

Monitor Field Performance

CAM


1-8

Total project planning

Design planning

Sketch drawing

< Task stage > < Outcomes >

Project proposal document

Design planning documentDesign specification document

nse

Scheme drawing

Final scheme drawing

Parts drawing

Scheme drawing

Parts drawingPart list

Final scheme drawingDesign document (including design calculation)

Assembly drawing Fabrication specification document

Des

ign

in a

nar

row

sen

Des

ign

in a

bro

ad se

nse


Assembly drawing

Parts fabrication

Assembly

Inspection

Fabrication specification document Operation instruction document Inspection specification document

Hatamura Method

1.4 Functional Based Approach

nil

NEEDS

sing

Abs

trac

tion

ncre

asin

g D

etai SPECIFICATION

FUNCTIONAL LEVEL


Incr

easIn

CONCEPTUAL LEVEL

COMPONENT LEVEL


1-9

Lowering level of abstraction

Functional LevelDomain independent nil Domain-independent representation

Conceptual LevelExisting solution information

sing

Abs

trac

tion

ncre

asin

g D

etai


Component LevelDetail information

Incr

easIn

Lowering level of abstraction

Functional level of abstractionThe level at which design requirements and systems are represented generically with no mention of conceptual p g y por physical realization.

Conceptual level of abstractionThe level at which systems are modeled in terms of possible solution principles for fulfillment of the design requirements or specifications .


Component level of abstractionThe level at which systems are modeled in terms of specific, physical entities that may realize the chosen concepts and/or fulfill the design requirements.


1-10

1.5FunctionalbasedDesignNeedidentification

EstablishProductSpecificationSpecification

DefineProductFunction

SelectMechanism/StructuretoSatisfy

Function


DetailingMechanism/Structure

ProduceDetailDrawing

Function:Function:A function of a product is a statement of a clear, A function of a product is a statement of a clear, reproducible relationship between the available reproducible relationship between the available input and the desired output of a product, input and the desired output of a product, independent of any particular form.independent of any particular form.

Product function:Product function:Product function is the overall intended function of Product function is the overall intended function of the product the product what it is to do.what it is to do.

SubSub--function:function:SubSub--function is a component of a product function. function is a component of a product function. An overall function can, and often must, be divided An overall function can, and often must, be divided


, ,, ,into identifiable subinto identifiable sub--functions corresponding to functions corresponding to subtasks.subtasks.

Product FunctionInputs Outputs


1-11


CUT Finger ForceFinger Nail

Clipped Nail, Clean Finger

Kinetic Energy in nail, sounds

Product Function and Function Structure

NAILHands Kinetic EnergyHands



1-12


References:

Nam P. Suh, The Principal of Design, Oxford University Press, 1990. Yotaro Hatamura, The Practice of Machine Design, Clarendon Press-

Oxford, 1st Edition, 1999.

Ibrahim Zeid, CAD/CAM Theory and Practice, McGraw-Hill, Int. Edition, 1991.

Chris McMahon and Jimmie Browne, CAD/CAM Principles, Practice and Manufacturing Management, Addison-Wesley, 2nd Edition, 1998.

Kevin N. Otto and Kristin L. Wood, Product Design Techniques in Reverse Engineering and New Product Development, Prentice Hall, 1st


Edition, 2001.

ch 1 design methodology.pdf

Documents