Download - Ch 1 Design Methodology.pdf
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MS5016 Design Methodology & Optimizationby I Wayan Suweca, KK-PM ITB
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MS5016 Design Methodology and Optimization1
Hosted by: I Wayan Suweca
Innovative Design
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Design Optimization
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Rapid Prototyping
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MS5016 Design Methodology & Optimizationby I Wayan Suweca, KK-PM ITB
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1.1 1.1 What is Design?What is Design?
Chapter 1DESIGN METHODOLOGY
Needs
123
MappingProducts
123
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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.
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Creative designNeither the attributes nor the strategies are known ahead of time. New variables and new knowledge bases are added to the system.
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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
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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
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Embodiment ofschemes
Detailing
Working drawing
: Result
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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
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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
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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
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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
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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
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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
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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:
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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
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Automated Manufacturing Equipment
Manufacturing Product
Test Finished Product
Ship Product
Monitor Field Performance
CAM
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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
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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
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Incr
easIn
CONCEPTUAL LEVEL
COMPONENT LEVEL
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Lowering level of abstraction
Functional LevelDomain independent nil Domain-independent representation
Conceptual LevelExisting solution information
sing
Abs
trac
tion
ncre
asin
g D
etai
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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 .
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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.
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1.5FunctionalbasedDesignNeedidentification
EstablishProductSpecificationSpecification
DefineProductFunction
SelectMechanism/StructuretoSatisfy
Function
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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
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, ,, ,into identifiable subinto identifiable sub--functions corresponding to functions corresponding to subtasks.subtasks.
Product FunctionInputs Outputs
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CUT Finger ForceFinger Nail
Clipped Nail, Clean Finger
Kinetic Energy in nail, sounds
Product Function and Function Structure
NAILHands Kinetic EnergyHands
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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
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Edition, 2001.