2019

ENME1EDH2
MECHANICAL ENGINEERING
DESIGN
Lecturer: Mr. C.I. Basson
Room: 238
Tel: 031 260 1180
E-mail: [email protected]
Consultation Times: Monday 12:20 – 13:05
Friday 12:20 – 13:05
 Mechanical Engineering Design:
OVERVIEW

■ Mechanical engineering design is

to either formulate a plan for the
satisfaction of a specified need or
to solve a specific problem.
■ If the plan results in the creation
of something having a physical
reality, then the product must be
functional, safe reliable,
competitive, usable,
manufacturable and marketable.
 Mechanical Engineering Design:
OVERVIEW
Design has the following characteristics:
■ Has an innovative and highly interactive process.
■ It is a decision making process.
– Decisions have to be made with the lack or abundance of information for
the specific problem.
■ It is a communication-intensive activity.
– An engineer has to communicate effectively.
■ A designer’s personal resources of creativeness, communicative ability and
problem solving skills are intertwined with the knowledge of technology and
first principles.
The traits of a design engineer
■ The skills and knowledge base of design engineers should be extensive.
■ Design engineers are associated with the production and processing of energy.
■ They provide the means of production, the tools of transportation, and the
techniques of automation.
■ Design engineers in the mechanical field should be knowledgeable of all the
disciplines in the mechanical engineering field.
– These may include fluid flow, heat transfer, friction, energy transport,
material selection, thermomechanical treatments, statistical descriptions,
strength of materials, turbo-machinery, machine-component design etc.
Phases of engineering design
The design process can be divided in to 6 main phases, namely:

■ Identification of need
■ Definition of problem
■ Synthesis
■ Analysis and optimization
■ Evaluation
■ Presentation
Identification of need

■ Design process starts with this phase.

■ Requires recognition and phrasing of the need
and often requires creativity.
■ Need may have a vague content and there is a
uneasy sense of something that is not in place.
■ Sometimes the need is not evident at all and
the recognition can be triggered by a particular
adverse circumstance or random
circumstances.
Definition of problem

■ More specific than the identification of need.

■ In this phase all specifications must be
defined for the problem or object.
■ The specifications are identified as inputs
and outputs quantities, characteristics and
dimensions of the product, and all the
limitations on these quantities.
■ Of ten the costs defined, the number of
units to be manufactured, the life cycle, the
range the operating temperature and the
reliability.
■ Specifics for example are: Speed rate, feed
rate, temperature limitations, maximum
range, expected variations, dimensional and
weight limitations ,etc.
Synthesis

■ Also called the invention of the concept or conceptual design.

■ Various schemes must be proposed, investigated and quantified in
terms of established metrics.
■ As the phase continues, analyses must be performed to asses whether
the system performance is satisfactory or better, and how well the
system performs.
■ Schemes that do not survive the analysis are revised, improved or
discarded.
■ Those with potential are optimized to determine the best performance.
■ Competing schemes are compared so that the path leading to most
competitive product is chosen.
Synthesis (Continued)
Some design considerations: ■ Friction
■ Functionality ■ Weight
■ Strength/stress ■ Life expectancy
■ Distortion/deflection/stiffness ■ Noise
■ Wear ■ Styling
■ Corrosion ■ Shape
■ Safety ■ Size
■ Reliability ■ Control
■ Utility ■ Thermal properties
■ Cost ■ ETC.
Analysis and optimization

■ Construction and devising of abstract models of the system will admit

some form of mathematical model.
■ In creating synthetic models we hope simulate real world models.
■ Analyse is a significant phase of the process.
Evaluation

■ Evaluation is the final proof of successful design and usually involves

testing of the prototype.
■ This phase reveals the discovery whether the product satisfies the
need.
■ Questions involved:
– Is it reliable?
– Will it compete successfully with similar products?
– Is it economical to manufacture?
– Is it easily maintained and adjusted?
– Can profit be made from it sale or use?
– ETC.
Presentation

■ This phase shows the effective

communication to the
stakeholders involved.
■ Engineer may present his
solution or work to
administrative, management or
supervisory persons.
■ If the presentation and
communication of the solution
or product is not done
effectively then the time and
effort spent on obtaining the
solution have been largely
wasted.
Concurrent Engineering
What is concurrent engineering?
■ Concurrent engineering is a systematic approach to the
integrated, concurrent design of products and their related
processes, including manufacture and support. This
approach is intended to cause the developers from the
outset, to consider all elements of the product life cycle
from conception to disposal, including quality, cost,
schedule, and user requirements.
 Practicability of Concurrent
Engineering
■ Market share and profitability are the major determinants of
the success of any organization.
■ The factors that influence and improve the competitive edge
of a company are unit cost of products, quality, and lead time.
■ Concurrent engineering has emerged as discipline to help
achieve the objectives of reduced cost, better quality, and
improved delivery performance. Concurrent engineering is
perceived as a vehicle for change in the way the products and
processes are designed, manufactured, and distributed.
■ Concurrent engineering is a management and engineering
philosophy for improving quality and reducing costs and lead
time from product conception to product development for new
products and product modifications.
Practicability of Concurrent
Engineering (Continued)
■ CE means that the design and development of the product,
the associated manufacturing equipment and processes,
and the repair tools and processes are handled
concurrently.
■ The concurrent engineering idea contrasts sharply with
current industry sequential practices, where the product is
first designed and developed, the manufacturing approach
is then established.
■ And finally the approach to repair is determined.
Types of engineering design processes

Serial or Sequential
Engineering
■ Sequential engineering
is the term used to
describe the method of
production in a linear
format. The different
steps are done one after
another, with all
attention and resources
focused on that one
task. After it is
completed it is left alone
and everything is
Traditional product development
process
 Concurrent Engineering

Concurrent engineering,
also known as
simultaneous engineering,
is a method of designing
and developing products,
in which the different
stages run simultaneously,
rather than consecutively.
It decreases product
development time and also
the time to market, leading
to improved productivity
and reduced costs.
New model for product design
Why concurrent engineering ?
■ Increasing product variety and technical complexity that
prolong the product development process and make it more
difficult to predict the impact of design decisions on the
functionality and performance of the final product.
■ Increasing global competitive pressure that results from the
emerging concept of reengineering.
■ The need for rapid response to fast-changing consumer
demand.
■ The need for shorter product life cycle.
■ Large organizations with several departments working on
developing numerous products at the same time.
■ New and innovative technologies emerging at a very high
rate, thus causing the new product to be technological
obsolete within a short period.
Concurrent engineering in the product
life cycle
■ 1. Development and production lead time reduction
■ 2. Measurable quality improvements
■ 3. Engineering process improvements
■ 4. Cost reduction
 Process life cycle in
engineering process phases
System lifecycle consists of the following:
■ Conceptual design
■ Preliminary system design
■ Detail design and development
■ Production and construction
■ Utilization and support
■ Phase-out and disposal
Process life cycle in
engineering process phases
(continued)
CONCEPTUAL DESIGN
The conceptual design stage is the stage
where an identified need is examined,
requirements for potential solutions are
defined, potential solutions are evaluated
and a system specification is developed.
The system specification represents the Key steps within the conceptual design
technical requirements that will provide stage include:
overall guidance for system design. ■ Need identification
Because this document determines all
future development, the stage cannot be ■ Feasibility analysis
completed until a conceptual design ■ System requirements analysis
review has determined that the system
specification properly addresses the ■ System specification
motivating need. ■ Conceptual design review
 Process life cycle in
engineering process phases
(continued)
PRELIMINARY SYSTEM DESIGN
During this stage of the system
lifecycle, subsystems that perform
Key steps within the preliminary
the desired system functions are
design stage include:
designed and specified in
compliance with the system ■ Functional analysis
specification. Interfaces between
subsystems are defined, as well as ■ Requirements allocation
overall test and evaluation ■ Detailed trade-off studies
requirements. At the completion of
this stage, a development ■ Synthesis of system options
specification is produced that is ■ Preliminary design of engineering
sufficient to perform detailed design models
and development.
■ Development specification
■ Preliminary design review
 Process life cycle in
engineering process phases
(continued)
DETAIL DESIGN AND DEVLOPMENT
This stage includes the development of Key steps within the detail design and
detailed designs that brings initial design development stage include:
work into a completed with form of
■ Detailed design
specifications. This work includes the
specification of interfaces between the ■ Detailed synthesis
system and its intended environment and
a comprehensive evaluation of the ■ Development of engineering and
systems logistical, maintenance and prototype models
support Requirements. The detail design ■ Revision of development specification
and development is responsible for
producing the product, process and ■ Product, process and material
material specifications and may result in specification
substantial changes to the development ■ Critical design review
specification.
 Process life cycle in
engineering process phases
(continued)
PRODUCTION AND CONSTRUCTION
During the production and/or
construction stage the product is built or
Key steps within the product construction
assembled in accordance with the
stage include:
requirements specified in the product,
process and material specifications and is■ Production and/or construction of
deployed and tested within the system components
operational target environment. System
assessments are conducted in order to ■ Acceptance testing
correct deficiencies and adapt the ■ System distribution and operation
system for continued improvement.
■ Operational testing and evaluation
■ System assessment
 Process life cycle in
engineering process phases
(continued)
UTILIZATION AND SUPPORT
Once fully deployed, the system is used
for its intended operational role and
PHASE-OUT AND DISPOSAL
maintained within its operational
environment. Effectiveness and efficiency of the
system must be continuously evaluated
Key steps within the utilization and
to determine when the product has met
support stage include:
its maximum effective lifecycle.
■ System operation in the user Considerations include: Continued
environment existence of operational need, matching
between operational requirements and
■ Change management
system performance, feasibility of
■ System modifications for system phase-out versus maintenance,
improvement and availability of alternative systems.
■ System assessment
 Product life cycle
• A new product progresses through a sequence
of stages from introduction to growth, maturity,
and decline. This sequence is known as
the product life cycle and is associated with
changes in the marketing situation, thus
impacting the marketing strategy and the
marketing mix.

Product Life Cycle consist of 4 main

stages:

 Introduction stage
 Growth stage
 Maturity stage
 Declining stage
Product life cycle (continued)
1. Introduction Stage
– This stage of the cycle could be the most expensive for a company launching a new product.
The size of the market for the product is small, which means sales are low, although they will be
increasing. On the other hand, the cost of things like research and development, consumer
testing, and the marketing needed to launch the product can be very high, especially if it’s a
competitive sector.
Product life cycle (continued)
2. Growth Stage
– The growth stage is typically characterized by a strong growth in sales and profits, and
because the company can start to benefit from economies of scale in production, the profit
margins, as well as the overall amount of profit, will increase. This makes it possible for
businesses to invest more money in the promotional activity to maximize the potential of this
growth stage.
Product life cycle (continued)
3. Maturity Stage
– During the maturity stage, the product is established and the aim for the manufacturer is now to
maintain the market share they have built up. This is probably the most competitive time for most
products and businesses need to invest wisely in any marketing they undertake. They also need to
consider any product modifications or improvements to the production process which might give them a
competitive advantage.
Product life cycle (continued)
4.Decline Stage – Eventually, the market for a product will start to shrink, and this is what’s known as
the decline stage. This shrinkage could be due to the market becoming saturated (i.e. all the customers
who will buy the product have already purchased it), or because the consumers are switching to a
different type of product. While this decline may be inevitable, it may still be possible for companies to
make some profit by switching to less-expensive production methods and cheaper markets.