aero sys eng intro

8/9/2019 Aero Sys Eng Intro

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School of Aerospace Engineering

Aerospace Systems Engineering

A Modern Approach

Dr. Daniel P. Schrage

Professor and Director,

Center of Excellence in Rotorcraft Technology(CERT)Center for Aerospace Systems Analysis (CASA)


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Course Materials

Primary Text, Dieter, !Engineering Design"

A #aterials and Processing Approach$, %rd

Edition, #c&ra' ill, ***

Secondary Text,$Systems Engineering

+ndamentals$ Defense Systems

#anagement College, -/


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The Prodct Design Process

(Chapter -, Dieter)

0ntrodction and 0mportance of Prodct Design

The Design Process 1 A Simplified Approach

Considerations of a &ood Design

Detailed Description of Design Process

#ar2eting

3rgani4ation for Design

Compter5Aided Engineering

Designing to Codes and Standards

Design Re6ie'

Technological 0nno6ation and the Design Process


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Some Important Concepts Design" ! to fashion after a plan$ (7e8ster Dictionary)

lea6es ot the essential fact that to design is to createsomething that has ne6er 8een

Synthesis" !plling together$

A8ility to design is 8oth a scienceand an art

The science!can 8e learned$ throgh techni9es : methodsThe artis 8est !learned 8y doing$ design

Discovery" !getting the first sight of, or the first 2no'ledge of

something$, as 'hen Colm8s disco6ered America

Invention" re9ires the design 8e a step 8eyond the limits ofexisting 2no'ledge (8eyond the state of the art). Some designs

are trly in6enti6e, 8t most are not


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Aerodynamics Economics

Propulsion

Safety

Aerodynamics

S&C

Propulsion

Performance

Manufacturing

Economics

Safety

Structures

Manufacturing

Structures Performance

Conceptual Design Tools(First-Order Methods)

Synthesis & Sizing

Preliminary Design Tools(Higher-Order Methods)

Geometry

Mission

IncreasingSophistication andComplexity

Approximating FunctionsDirect Coupling of Analyses

Integrated RoutinesTable Lookup

Integrated Synthesis and AnalysisVarying Fidelity of Synthesis, Sizing& Analysis

S&C


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Good Design requires both Synthesis & Analysis

Typically, 'e approach complex pro8lems li2e design 8ydecomposing the pro8lem into managea8le parts orcomponents1 ;ecase 'e need to nderstand ho' the part 'ill perform in ser6ice

'e mst 8e a8le to calclate as mch a8ot the part


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The our Challenges !C"s# of the

Design En$ironment Creati$ity1 Re9ires creation of something that has not existed 8efore

or not existed in the designer


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roduct Design rocess Engineering design process can 8e applied to se6eral

different ends

1 Design of roducts, 'hether they 8e consmer goods

and appliances or highly complex prodcts sch as

missile systems or >et planes

1 Another is a comple% engineered systemsch as anelectric po'er generating station or a petrochemical

plant

1 ?et another is the design of a building or bridge

The principles and methodology of design can 8e sefllyapplied in each of these sitations. o'e6er, the emphasis

in Dieter


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Dieter"s 'oo( Goal

Pro6ide insight into the crrent 8estpractices for doing prodct design

The design process shold 8e condcted soas to de6elop 9ality cost5competiti6e

prodcts in the shortest time possi8le 0s necessary, 8t insfficient for Aerospace

Systems Design


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)apanese Auto Industry and The *+S+ Auto Industry

90%

Total Japanese

Changes Complete

U.S. Company

Japanese

Company

20-24

M

onths

14-17

M

onths

1-3

M

onths

Job#

1

3

M

onths

Num

berofEngine

ering

Product

ChangesProcessed

Japanese/U.S. Engineering Change Comparison


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The ,uality Engineering rocess

pro$ides -ecomposition Methods & Tools

Customer

Quality

FunctionDeployment

Off-Line

Quality

FunctionDeployment

Off-Line

Seven

Managementand Planing

ToolsOff-Line

Seven

Management

and Planing

ToolsOff-Line

Statistical

ProcessControl

On-Line

Statistical

ProcessControl

On-Line

Roust

Design Met!ods"Taguc!i# Si$ -

Sigma# DO%&Off-Line

Roust

Design Met!ods

"Taguc!i# Si$ -

Sigma# DO%&Off-Line

'no(ledge Feedac)

*+eeds*,dentify

,mportant

,tems

*ariation

%$periments

*Ma)e

,mprovements

*.old /ains

*Continuous

,mprovement

!a"#ng hea$ the &"o#'e o( the ')stome$*+ ,- p$#o$#t#/es he$e#mp$o"ements a$e neee1 Tag)'h# p$o"#es the me'han#sm (o$#ent#(y#ng these #mp$o"ements


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Traditional Design & De$elopment *sing only a Top

Do.n DecompositionSystems Engineeringrocess


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IPPD Environment for System Level Design Trades andCycle Time Reduction

S/STEM

-0CESS

-EC0M0SITI01

S/STEM

*1CTI01A2

DEC0M0SITI01

C0M01E1T

*1CTI01A2

DEC0M0SITI01

C0M01E1T

-0CESS

-EC0M0SITI01

A-T

-0CESS

-EC0M0SITI01

A-T

*1CTI01A2

DEC0M0SITI01

roduct

Tradesrocess

Trades

roduct

Trades

rocess

Trades

-E2IMI1A-/

DESIG1

!A-AMETE-#

-E2IMI1A-/

DESIG1

!A-AMETE-#

DETAI2

DESIG1

!T02E-A1CE#

DETAI2

DESIG1

!T02E-A1CE#

MA1*ACT*-I1G

-0CESSES

C01CET*A2

DESIG1!S/STEM#

rocess

Trades

I1TEG-ATED

-0D*CT

-0CESS

DE3E20ME1T

roduct

Trades


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School of Aerospace EngineeringCC012314035ppt

Typical System @ife Cycle Cost

Cumulative

Percent

of LCC

Production# Deployment#

Operations and Support%6MDPD 6 RRCon %$p

*

**

***

7008

948

408

248

08

Life Cycle Cost

:ctually %$pended

Life Cycle Cost%ffectively Rendered

;nc!angeale fora /iven Design


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-amifications of the ,uality -e$olution

Decisions made in the design process cost 6ery

little in terms of the o6erall prodct cost 8t ha6e

a ma>or effect on the cost of the prodct ality cannot 8e 8ilt into a prodct nless it is

designed into it

The design process shold 8e condcted so as to

de6elop 9ality cost5competiti6e prodcts in the

shortest time possi8le


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Design rocess aradigm Shift(Research Opportunities in Engineering Design, NSF Strategic lanning !or"shop Final

Report, April #$$%)

100%

50%

0%

Todays Design ProcessFuture Design Process

KnowledgeAboutDesign

DesignFree

dom

CostComm

itted

Concept

Preliminary

Design

Analysisand DetailDesign

PrototypeDevelopment

Redesign ProductRelease

Aparadigm shiftis nder'ay thatattempts to change the 'ay complexsystems are 8eing designed

Emphasis has shifted from design forperformanceto design foraffordability, 'here afforda8ility is

defined as the ratio of systemeffectiveness to system cost +profit

System Cost - Performance Tradeoffsmst 8e accommodated early

Donstream !noledgemst 8e8roght 8ac2 to the early phases ofdesign for system level tradeoffs

The design +reedom cr6e mst 8e"ept openntil !noledgeabletradeoffscan 8e made


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Static $s Dynamic roducts

Some prodcts are static, in that the changes intheir design concept ta2e place o6er a long time

periodB rather, incremental changes occr at thes8system and component le6els (most air6ehicles are static)

3ther prodcts are dynamic, li2e

telecommnications systems and soft'are, thatchange the 8asic design concept fairly fre9entlyas the nderlying technology changes (a6ionicsand mission e9ipment : soft'are are dynamic)


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Simplified Design Process

Definition of the Pro8lem

&athering 0nformation

&eneration of Alternati6e Soltions

E6alation of Alternati6es

Commnication of the Reslts

G i


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Georgia Tech Generic ID Methodology

COMPUTER-INTEGRATED ENVIRONMENT

P

R

O

D

U

C

T

D

E

S

IG

N

D

R

IV

E

N

P

R

O

C

E

S

S

D

E

S

IG

N

DR

IV

E

N

REQUIREMENTS& FUNCTIONALANALYSIS

SYSTEM DECOMPOSITION&FUNCTIONAL ALLOCATION

SYSTEM SYNTHESISTHROUGH MDO

SYSTEM ANALYSIS&

CONTROL

ESTABLISHTHE NEED

DEFINE THE PROBLEM

ESTABLISHVALUE

GENERATE FEASIBLEALTERNATIVES

EVALUATEALTERNATIVE

7 M&P TOOLS ANDQUALITY FUNCTIONDEPLOYMENT (QFD)

ROBUST DESIGNASSESSMENT &OPTIMIZATION

ON-LINE QUALITYENGINEERING &STATISTICALPROCESS

MAKE DECISION

SYSTEMSENGINEERING METHODS

QUALITYENGINEERING METHODS

TOP-DOWN DESIGNDECISION SUPPORT PROCESS

G i T h


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Detailed Description of Design roblems!Morris Asimo."s Morphology of design#

Phase 0. Conceptal Design

Phase 00. Em8odiment Design (Preliminary Design)

Phase 000. Detail Design Phase 0. Planning for #anfactre

Phase . Planning for Distri8tion

Phase 0. Planning for se

Phase 00. Planning for Retirement of the Prodct

G i T h


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Discrete Steps in Engineering Design rocess

G i T h


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Design Depends on Indi$idual 4ho Defines roblem

G i T h


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Classification of roducts 'ased on Mar(et

latform roduct

1 0s 8ilt arond a preexisting technological s8systems, e.g. Apple

#acintosh operating systems

1 0s similar to a technology5psh prodct

Process50ntensi6e Prodcts

1 #anfactring process places strict constraints on the properties of

the prodct

1 Examples are atomoti6e sheet, steel, food prodcts,semicondctors chemicals and paper

Cstomi4ed Prodcts

1 ariations in configration and content created in response to a s

G i T h


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The Total Materials Cycle

G i T h


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The Systems Engineering rocess

Process Input

*Customer +eedsuirements

- Missions - Measures of %ffectiveness

- %nvironments

- Constraints*Tec!nology ?ase*Output Re>uirements from Prior

Development %ffort*Program Decision Re>uirements*Re>uirements :pplied T!roug!

Specifications and Standards

Requirements Analysis*:naly@e Missions 6 %nvironments*,dentify Functional Re>uirements*Defineuirement

Functional Analysis/Allocation*Decompose to Lo(er-Level Functions*:llocate Performance 6 Ot!er Limiting Re>uirements to

:ll Functional Levels*Define


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School of Aerospace EngineeringCC01231B315ppt

Systems Engineering, 0ts Prpose

To satisfy a mission need 'ith a system

that is cost effecti6e, operationallysita8le, and operationally effecti6e.

Georgia Tech


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Systems Engineering 38>ecti6es Translate cstomer needs into 8alanced systems8system

design re9irements and prodct

0ntegrate technical inpts of the entire de6elopmentcommnity and all technical disciplines into a coordinated

program effort Transition ne' technologies into prodct and a8atement

program

Ensre the compati8ility of all fnctional and physical

interfaces erify that the prodct meets the esta8lished re9irements

Condct a formal ris2 management and

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7hat 0s a System= A system is a collection of components

(s8systems) that

10nteract 'ith one another

1a6e emergent capa8ilities 5 capa8ilities a8o6e

and 8eyond 'hat the same collection of

components 'old if they did not interact

10nteracting components implies architectre


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School of Aerospace EngineeringCC01231B3B5ppt

System Element Constitents E9ipment ard'are1 #ission hard'are

1 &rond e9ipment

1 #aintenance e9ipment

1 Training e9ipment

1 Test e9ipment

1Special e9ipment

1 Real Property

1 Spares


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Systems Engineering rinciples Apply to All Acquisition

hases at All 2e$els of the Engineering 5ierarchy

Levels in t!e

System .ierarc!y

C%D - Concept %$ploration


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Systems

Engineering

Process

Systems Engineering 0n 0PD

ProductTeamsProductTeams

,PD

ConcurrentDevelopmentConcurrentDevelopment

Systems

%ngineering

Process


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System Element Constitents (cont.)

Personnel

1 Training

1 Tas2s

1Fm8er

1 Types and s2ills

Data

1 Parts #anals1 #aintenance #anals

1 3perating #anals

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Systems Thin2ing

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Roles of Systems EngineersG Re9irements 3'ner System Designer

System Analyst

alidationerification Engr

@ogistics3ps Engineer

&le Among S8systems

* Customer ,nterface* Tec!nical Manager

* ,nformation Manager

* Process %ngineer

* Coordinator

* Classified :ds S%

SourceE T(elve Roles of Systems

%ngineers# Sara! S!eard;RLE (((5soft(are5org


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7hat 0s a System= A system is a collection of components

(s8systems) that

10nteract 'ith one another

1a6e emergent capa8ilities 5 capa8ilities a8o6e

and 8eyond 'hat the same collection of

components 'old if they did not interact

10nteracting components implies architectre

Georgia Tech


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Examples of Systems Aircraft engine 6s a collection of parts Aircraft 'ith engines and a6ionics

Air traffic control 'ith aircraft, airfields,radars, controllers, CCS

Air transportation 'ith air traffic control,

airlines, passengers, cargo, maintenance,pic2p and deli6ery

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#ore Complex Systems

Systems of SystemsG 0ndi6idal systems can operate on their o'n

Systems of systems not o'ned andcontrolled as a 'hole 8y single entity

G#ar2 #aier, !Architecting Principles for Systems5of5

Systems$, Hornal of the 0nternational Concil onSystems Engineering, ol 0, -/


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Technical Director 0s the Systems

Thin2er 0f not, o8>ecti6es, approaches, and

decisions 'ill not reflect systems

thin2ing Technical Directors 'ho donect

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g


7hy 0s Systems Thin2ing

&ood= 0ntracta8le pro8lems often ha6e soltions in

the design space of the larger system

Soltions in the larger systems space are oftenless costly or less ris2y

0ntegration 'ith external systems areaddressed

early in the de6elopment


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g


A Dose of Reality Separate trash collections for recyclea8le'old do8le the cost

#ar2et for recycled ne'spaper andalminm

cans 'as satrated

nsold recyclea8les 'old ha6e to 8estored 55 at additional cost

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g


Starting to Thin2 Systems 7ho crrently collects trash=

+rom 'hom=

7hat is done 'ith the trash=


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g


The @and +ills as Part of the

System I-JG per ton to dmp trash in the land fill

Expected to reach I%* per ton in -K years

@and fills charge I-K* per ton in Fe'

?or2

Gee, maybe we should think aboutconserving the land fills?

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g


A Systems Soltion T'o collections per 'ee213ne for recyclea8les

13ne for non5cyclea8le trash

Slight increase in fees for storingrecyclea8les

Market demand of recycled paperand aluminum increase soared in 5years

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Conse9ences of Systems

Thin2ing The original o8>ecti6e (sa6ing

resorces)

'as satisfied Crrent costs 'ere contained

+tre cost containment made theslightincrease salea8le to the p8lic

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Dieter Chapter 67

"eed Identification and Problem Definition

3f all the steps in the engineering design process, pro8lemdefinition is the most important

;efore the Pro8lem5Definition Step" Design pro>ects

commonly fall into one of fi6e types"1 ariation of an existing prodct

1 0mpro6ement of an existing prodct

1 De6elopment of a ne' prodct for lo'56olme prodction rn

1 De6elopment of a ne' prodct for mass prodction

1 3ne5of5a52ind5 design

0dentifying Cstomer Feeds

&athering 0nformation from Cstomers

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Dieter Chapter 67

"eed Identification and Problem Definition

Constrcting a Sr6ey 0nstrment

;enchmar2ing

Cstomer Re9irements

ality +nction Deployment

Prodct Design Specification1 The 8asic control and reference docment for the design and

manfactre of the prodct

1 0n5se Prposes and #ar2et1 +nctional Re9irments

1 Corporate Constraints

1 Social, Political and @egal Re9irements

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resentation 0utline

Synthesis and Si4ing of Aerospace ehicles

#ane6era8ility and Agility Considerations

for Aerial ehicles

Atonomos ehicle Considerations

Smmary and Conclsions

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Synthesis and Si8ing of Aerial 3ehicles

+or Aerial ehicles Synthesis and Si4ing pro6ides the Closre

8et'een #ission Re9irements and &eometric Configration

Soltions

A +el and ThrstPo'er ;alance Approach is sed 'hich

allo's for analytical design optimi4ation (min. &7, etc.)throgh the copling of a fe' critical design parameters

(+7Laspect ratio, 'ing loadingB R7Ldis2 loading)

#ane6era8ility and Agility can 8e related to Energy

Principles (differences 8et'een ThrstPo'er A6aila8le and

ThrstPo'er Re9ired), andling alities and the design of

the +lightControl System

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Maneu$erability and Agility

Considerations for Aerial 3ehicles

Fied !ing Fighter Aircraftnormally ha6e a good high speed

capa8ility, good mane6era8ility at normal com8at speeds (medim to

high s8sonic and transonic speeds), high specific excess po'er, good

to excellent a6ionics, and the a8ility to employ gns and a 'ide range

of air5to5air missiles. To achie6e these capa8ilities, their optimm

mane6ering speeds are sally rather high, impacting on lo' speed

mane6era8ility

Rotary 7ing Aircraft ha6e excellent lo' speed capa8ility de to the

rotor h8 control moments 'hich pro6ides excellent control po'er in

any axix. This allo's rotary 'ing aircraft to fly Fap5of5the5Earth andstress aggressi6e concealed mo6ement to ta2e fll ad6antage of

mas2ing pro6ided 8y trees and terrain and attac2ing from a position of

ad6antage at maximm standoff range

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Summary and Conclusions Aerial ehicle Design and Performance is highly

dependent on the #ission identified and se of a +el and

ThrstPo'er Synthesis Approach

+or high speed, high altitde, high mane6ering attac2

missions, sch as Sppression of Enemy Air Defense(SEAD), +ixed 7ing Aerial ehicle are the Choice

+or lo' speed, lo' altitde, high agility(along 'ith

6ertical ta2eoff and landing (T3@)capa8ility)

reconnaissance and attac2 missions, sch as r8an7arfare, Rotary 7ing Aerial ehicles are the Choice

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Technological Inno$ation and The Design rocess

The ad6ancement of technology has three phases"

1 'nention" The creati6e act 'here8y an idea is concei6ed

1 'nnoation" The process 8y 'hich an in6ention or idea is 8roght

into sccessfl practice and is tili4ed 8y the economy1 Diffusion" The sccessi6e and 'idespread initiation of sccessfl

inno6ation

The technological inno6ation acti6ity can considered to 8e"

0dent. 3f

#2t Feed

Prodct

idea

Pilot

lot

Trial

sales

Commerc

ExploitationDe6elop

ment


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Societal Considerations in Engineering

Characteristics of an En6ironmentally

Responsi8le Design

+i6e roles of go6ernment in interacting 'ithtechnology

Technology 0dentification, E6alation and

Selection (T0ES)

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Dieter7 Chapter :

Team 'eha$ior and Tools A team is a small nm8er of people 'ith complementary s2ills 'ho are

committed to a common prpose, performance goals, and approach for 'hichthey hold themsel6es mtally acconta8le

Differences 8et'een a 'or2ing grop and a team

7or2ing &rop Team

5Strong, clearly focsed leader 50ndi6idal : mtal acconta8ility

5The grop,s prpose is the 5 Specific team prpose that the team

Same as the 8roader org.msn. 0tself de6elops

5 0ndi6idal 'or2 prodcts 5 Collecti6e 'or2 prodcts

5 Rns efficient meetings 5 Encorages open5ended discssion

and acti6e pro8lem5sol6ing meetings

5 #easres its effecti6eness 5 #easres performance directly 8y

indirectly 8y its inflence assessing collecti6e 'or2 prodcts

5Discsses,decides and delegates 5 Discsses, decides and does real 'or2

together

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Dieter7 Chapter :

Team 'eha$ior and Tools 7hat 0t #eans to 8e an Effecti6e Team #em8er

1 Ta2e responsi8ility for the sccess of the team

1 ;e a person 'ho deli6ers on commitments

1 ;e a contri8tor to discssions

1 &i6e yor fll attention to 'home6er is spea2ing and demonstrate this 8y as2ing helpfl9estions

1 De6elop techni9es for getting yor message across to the team1 @earn to gi6e and recei6e sefl feed8ac2

The follo'ing are characteristics of an effecti6e team"1 Team goals are as important as indi6idal goals

1 The team nderstands the goals and is committed to achie6ing them

1 Trst replaces fear and people feel comforta8le ta2ing ris2s

1 Respect, colla8oration and open5mindedness are pre6alent

1 Team mem8ers commnicate readilyB di6ersity of opinions are encoraged

1 Decisions are made 8y consenss and ha6e the acceptance and spport of the mem8ers ofthe team

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Dieter7 Chapter :

Team 'eha$ior and Tools

TEA# R3@ES" 7ithin a team mem8ers assme differentroles in addition to 8eing an acti6e team mem8er

TEA# D?FA#0CS"Stdents of team 8eha6ior ha6eo8ser6ed that most teams go throgh fi6e stages of

de6elopment E++ECT0E TEA# #EET0F&S" Stdents 'ho complain

a8ot design pro>ects ta2ing too mch time often are reallyexpressing their ina8ility to organi4e their meetings andmanage their time effecti6ely

PR3;@E#S 70T TEA#S" A 'ell5fnctioning teamachie6es its o8>ecti6es 9ic2ly and efficiently in anen6ironment that indces energy and enthsiam

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Dieter7 Chapter :

Team 'eha$ior and Tools

PR3;@E# S3@0F& T33@S

T0#E #AFA&E#EFT

P@AFF0F& AFD SCED@0F&

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Dieter7 Chapter ect them toan e6alation scheme to determine the 8est concept or

small s8set of 8est concepts +inally, a decision process 'ill 8e sed to decide on the

8est concept to de6elop into the final design

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Dieter7 Chapter


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Dieter7 Chapter


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Dieter7 Chapter


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Dieter7 Chapter @

Embodiment !reliminary# Design #any .S. 'riters di6ide the design process into % phases"

1 Conceptal Design

1 Preliminary (Em8odiment) Design

1 Detail Design

3thers call em8odiment design !analytical design$ 8ecase it is the

design phase 'here most of the detailed analysis and calclation occrs Dieter adopts the terminology conceptal design, em8odiment design,

and detail design 8ecase they seem to 8e more descripti6e of 'hatta2es place in each of these design phases

#o6ing the setting of dimensions and tolerances into em8odiment

design (from detail design) is in 2eeping 'ith the crrent trend fortili4ing CAE so as to mo6e the decision ma2ing as early as possi8le inthe desing process to compress the prodct de6elopment cycle

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Dieter7 Chapter @

Three different forms of design"1 Rotine design" the attri8tes that define the design and the

strategies and methods for attaining them are 'ell 2no'n

1 0nno6ati6e design" not all attri8tes of the design may 8e 2no'n8eforehand, 8t the 2no'ledge 8ase for creating the design is2no'n

1 Creati6e design" neither the attri8tes of the design nor thestrategies for achie6ing them are 2no'n ahead of time

The Conceptal design phase is most central to inno6ati6edesign

At the opposite pole is selection design or catalog design,'hich is more central to rotine design

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Dieter7 Chapter @roduct Architecture

Prodct architectre is the arrangement of the physical elements of a prodct to

carry ot its re9ired fnctions 0t is in the Em8odiment design phase that the layot and architectre of the

prodct mst 8e esta8lished 8y defining 'hat the 8asic 8ilding 8loc2s of theprodct shold 8e in terms of 'hat they do and 'hat their interfaces 'ill 8e8et'een each other. Some organi4ations refer to this assyste)*leel design

There are t'o entirely opposite styles of prodct architectre, modlar and

integral"1 #odlar" components (chn2s) implement only one or a fe' fnctions and theinteractions are 'ell defined

1 0ntegral" implementation of fnctions ses only one or a fe' components (chn2s)leading to poorly defined interactions 8et'een components (chn2s)

0n integral prodct achitectres components perform mltiple fnctions

Prodcts designed 'ith high performance as a paramont attri8te often ha6ean integral architectre


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Dieter7 Chapter @roduct Architecture

+or step process for esta8lishing the prodct architectre

1 Create a schematic diagram of the prodct (++;D, Schematic

;loc2 Diagram)

1 Clster the elements of the schematic (DS#, De#A0D)1 Create a rogh geometric layot (%56ie' dra'ing)

1 0dentify the fndamental and incidental interactions

(0nterrelationship Diagraph, Compati8ility #atrix)

SEE EQA#P@ES +R3# TEQT


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Dieter7 Chapter @Configuration Design

Steps in starting Configration design"1 Re6ie' the PDS

1 Esta8lish the spatial constraints that pertain to th prodct or thes8assem8ly 8eing designed. #ost ha6e 8een set 8y the prodctarchitectre

1 Create and refine the interfaces or connections 8et'een components1 #aintain fnctional independence in the design of an assem8ly or

component

1 Ans'er the follo'ing 9estions"

Can the part 8e eliminated or com8ine 'ith another part=

Can a standard part or modle 8e sed &enerally, the 8est 'ay to get started 'ith configration design is to >st

start s2etching alternati6e configrations of a part

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Dieter7 Chapter @arametric Design

0n configration design the emphasis 'as on starting 'ith

the prodct architectre and then 'or2ing ot the 8est

form for each component

0n parametric design the attri8tes of parts identified in

configration design 8ecome the design 6aria8les forparametric design

A design 6aria8le is an attri8te of a part 'hose 6ale is

nder the control of the designer

Ro8stness means achie6ing excellent performance nder

the 'ide range of conditions that 'ill 8e fond in ser6ice


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Dieter7 Chapter Modeling and Simulation

The Role of #odels in Engineering Design

1 Descripti6e model

1 Predicti6e model

1 Static or dynamic1 Deterministic or pro8a8ilistic

1 0conic5analog5sym8olic

1 Simlation

1The Prototype


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Dimensional Analysis

1 ;c2ingham Pi Theorem

Similitde and Scale #odels1 Scale models

1 &eometric similarity

#odel dimension scale factor x prototype dimension

1 Static similarity5same portion as geometric dim nder cons. stress1 inematic similarity5 ratio of time proportionality

1 Dynamic similarity5 fixed ratio of forces

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Simlation1 +inite5Difference #ethod

A method of approximate soltion of partial differential e9ations

1 #onte Carlo #ethod A 'ay of generating information for a simlation 'hen e6ents occr in a

random 'ay

1 &eometric #odeling on the Compter +rom it initiation,CAD has promised K important 8enefits to the

engineering design process

1 Atomation of rotine design tas2s

1 A8ility to design in %D

1 Design 8y Solid #odeling1 Electronic transfer of the design d8 to manf (CADCA#)

1 A paperless design process

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Srface #odeling

#ethods of &enerating Solids

Constraint5;ased #odeler and +eatres

+inite5Element Analysis

1 Types of Elements

1 Steps in the +EA Process

Preprocessing" &eometry, #atl constit reln, +E mesh, ;ndy Conds

Postprocessing" Data interpret., Error estim., Design optim

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Compter isali4ation

1 Dynamic Analysis

1 0nteracti6e Prodct Simlation

Rapid Prototyping


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Dieter7 Chapter BMaterials Selection and Materials in Design

Relation of #aterials Selection to Design1 An incorrectly chosen material can lead not only to failre of the part

8t also to nnecessary life5cycle cost

1 Selecting the 8est material for a part in6ol6es more than selecting amaterial that has the properties to pro6ide the necessary performance in

ser6iceB it is also intimately connected 'ith the processing of thematerial into the finished part (+ig. /.-)

1 As design proceeds from concept design, the material and processselection 8ecomes more detailed

1 +igre /. compares the design methods and tools sed at each designstage 'ith the materials and processes selection

1 Ths, material and process selection is a progressi6e process ofnarro'ing from a large ni6erse of possi8ilities to a specific materialand process selection


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Performance Characteristics of #aterials1 The performance or fnctional re9irements of material sally is

expressed in terms of physical, mechanical, thermal, electrical, orchemical properties

1 #aterial properties are the lin2 8et'een the 8asic strctre and

composition of the material and the ser6ice performance of the part(+igre /.%)

1 7e can di6ide strctral engineering materials into metals, ceramics,and polymersB +rther di6ision leads to the categories of elastomers,glasses, and compositesB +inally, there is the technology dri6ingclass of electronic, magnetic, and semicondctor materials

1 The chief characteristics of metals, ceramics, and polymers are gi6enin Ta8le /.-

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Materials Selection and Materials in Design Performance Characteristics of #aterials

1 The ltimate goal of materials science is to predict ho' to impro6e the properties

of engineering materials 8y nderstanding ho' to control the 6arios aspects ofstrctre

1 +igre /.M relates 6arios dimensions of strctre 'ith typical strctral elements

1 The first tas2 in materials selection is to determine 'hich material properties arerele6ant to the sitation

1 +igre /.K sho's the relations 8et'een some common failre modes and themechanical properties most closely related to the failres

1 The material properties sally are formali4ed throgh specifications"Performance and Prodct specifications

1 Ta8le /. pro6ides a fairly complete listing of material performancecharacteristics

1 +igre /.N illstrates the generic tree that is de6eloped 8y expanding the categoryof fatige properties

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The #aterials Selection Process1 The pro8lem is not only often made difficlt 8y insfficient or

inaccrate property data 8t is typically one of decision ma2ing in theface of mltiple constraints 'ithot a clear5ct o8>ecti6e fnction

1 A pro8lem of materials selection sally in6ol6es one of t'o differentsitations

Selection of the materials for a ne' prodct or design

Ree6alation of an existing prodct or design to redce cost,increase relia8ility, impro6e performance, etc.

1 0t generally is not possi8le to reali4e the fll potential of a ne' materialnless the prodct is redesigned to exploit 8oth the properties and the

manfactring characteristics of the material1 0n other 'ords, a simple s8stittion of a ne' material 'ithot changing

the design rarely pro6ides optimm tili4ation of the material

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#aterials selection for a ne' prodct or ne' design" The steps that mst 8e

follo'ed are"1 Define the fnctions that the design mst perform

1 Define the manfactring parameters

1 Compare the needed properties and parameters 'ith large data8ase

1 0n6estigate the candidate materials in more detail

1 De6elop design data andor a design specification

#aterials s8stittion in an existing design1 Characteri4e the crrently sed material in terms of performance, manfactring

re9irements, and cost

1 Determine 'hich characteristics mst 8e impro6ed for enhanced prodct fnction

1 Search for alternati6e matls : processing rotes

1 Compile a short list of matls : processing rotes and se these to estimate the costs

of manfactred parts1 E6alate the reslts of Step M : ma2e a recommendation for a replacement material


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Sorces of 0nformation on #aterials Properties1 Conceptal Design

Typical material selection references, sch as Ash8y scheme

1 Em8odiment (Preliminary) Design Design decisions are 8eing made on the layot and si4e of parts and components

Design calclations re9ire materials properties for a narro'er class of materials 8t

specific to a particlar heat treatment or manfactring process These data are typically fond in hand8oo2s and compter d8s.

1 Detail Design ery precise data is re9ired

This goes 8eyond >st material properties to inclde information on manfactra8ility,cost, the experience in other applns, a6ail in the si4es and forms needed, and isses ofrepeat. of properties : A

T'o often o6erloo2ed factors are 'hether the manfactring process 'ill prodcedifferent properties in different directions in the part, and 'hether the part 'ill containa detrimental state of residal stress after manfactre

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pMaterials Selection and Materials in Design

Economics of #aterials

1 ltimately the decision on a particlar design 'ill come do'n to a trade5off8et'een performance and cost

1 7here performance doesn


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pMaterials Selection and Materials in Design

#ethods of #aterials Selection1 There is no method or small nm8er of methods of materials selection that has

e6ol6ed to a position of prominence

1 Since the final choice is a trade5off 8et'een cost and performance (properties),it is logical to attempt to express that relation as careflly as possi8le

1 +igre /.-* sho's the costs of s8stitting light'eight magterials to achie6e'eight sa6ing (fel economy) in atomo8iles

1 0t is important to reali4e that the cost of a material expressed in dollars per

pond may not al'ays 8e the most 6alid criterion

1 Total @@C is the most appropriate cost to consider

1 Consideration of factors 8eyond >st the initial materials cost leads to relationsli2e the relation sho'n in +igre /.--

1 A classic sitation regarding cost is the choice 8et'een t'o or more materials'ith different initial costs and different expected li6es. This is a standard

pro8lem in the field of engineering economy (See Chap. -%)

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Selection 'ith Compter5Aided Data8ases

1 se of a #erit +actor approach similar to an 3EC

#aterial Performance 0ndices

1 A materials performance index is a grop of material properties'hich go6erns some aspect of the performance of a component

Decision #atrices

1 Pgh Selection #ethod

1 7eighted Property 0ndex #aterials Selection 8y Expert Systems

ale Analysis


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Dieter7 Chapter

Materials rocessing and Design

Role of Processing in Design1 Prodcing the design is a critical lin2 in the chain of e6ents that starts

'ith a creati6e idea and ends 'ith a sccessfl prodct in themar2etplace

1 A serios pro8lem has 8een the tendency to separate the design andmanfactring fnctions into separate organi4ational nits

1 #ore con6entional manfactring is di6ided into (-) processengineering, () tool engineering, (%) 'or2 standards, (M) plantengineering, and (K) administration and control

1 7e ordinary thin2 of modern engineering in terms of the atomoti6eassem8le line, 8t mass prodction manfactring systems accont for

less than K percent of metal pars manfactred1 The ma>or opportnity for greatly increasing manfactring

prodcti6ity in small5lot manfactre

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p

Materials rocessing and Design Classification of Manufacturing rocesses

1 Solidification (casting) processes

1 Deformation processes

1 #aterial remo6al or ctting (machining) processes

1 Polymer processing

1 Po'der processing

1 Hoining processing

1 eat treatment and srface treatment

1 Assem8ly processes

Types of rocess Systems

1 Ho8 shop 5 Assem8ly line1 ;atch 5 Continos flo'

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p

Materials rocessing and Design actors Determining rocess Selection

1 Cost of manfactre and life cycle cost1 antity of parts re9ired

1 Complexity 1 shape, form, si4e

1 #aterial

1 ality of part

1 A6aila8ility, lead time, and deli6ery schedle

Design for Manufacturability !DM#

1 D+# &idelines (#in tot of partsB Standardi4e compsB secommon parts across prodct linesB Design parts to 8e mltifcnlBDesign parts for ease of fa8.B A6oid too tight tolerancesB A6oidsecondary opnsB tili4e the special characteristics of processes)

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Dieter7 Chapter


Design for Assem8ly (D+A)1 The assem8ly process consists of t'o operations, handling

follo'ed 8y insertion

1 There are three types of assem8ly, classified 8y the le6el ofatomation

1 A list of D+A gidelines are" #in. the tot. no. of parts

#in. the assem8ly srfaces

A6oid separate fasteners

#in. assem8ly direction

#ax. compliance in assem8ly

#in handling in assem8ly

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Early Estimation of #anfactring Cost

1 The decisions a8ot materials, shape, featres and tolerances that

are made in the em8odiment phase of design determine the

manfactring cost of the prodct

1 0t is not often possi8le to get large cost redctions once prodction

has 8egn 8ecase of the high cost of change at this stage of the

prodct life cycle

1 Therefore, 'e need a 'ay of identifying costly designs as early as

possi8le in the design process1 3ne 'ay is to inclde 2no'ledgea8le manf psnl on 0PT


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Dieter7 Chapter 9

Engineering Statistics = robability

A 8asic nderlying assmption of pro8a8ility theory is that itdeals 'ith random e6ents

A random e6ent is one in 'hich the conditions are sch thateach mem8er of the poplation F has an e9al chance of 8eingchosen

A special and precise system of langage and notation is sedin pro8a8ility theory

T'o e6ents A and ; are said to 8e independent if theoccrrence of either one has no effect on the occrrence of theother

T'o e6ents that ha6e no elements in common are said to 8emtally exclsi6e e6ents

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Dieter7 Chapter 9Engineering Statistics > Errors and Samples & requency

Distribution

The act of ma2ing any type of experimental o8ser6ation

in6ol6es t'o types of errors"

1 Systematic errors ('hich exert a nonrandom 8asis)

1 Experimental,or random, errors 7hen a large nm8er of o8ser6ations are made from a

random sample, a method is needed to characteri4e the

data

1 istograms,1 +re9ency Distri8tion

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Dieter7 Chapter 9Engineering Statistics > Measures of Central Tendency &

Dispersion

A fre9ency distri8tion can 8e descri8ed 'ith nm8ers

that indicate the central location of the distri8tion and

ho' the o8ser6ations are spread ot from the central

location (dispersion)1 Arithmetic mean, or a6erage

1 #ode and #edian

1 Standard De6iation

1 Range

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Dieter7 Chapter 9Engineering Statistics > Types of Distributions

Formal and @ognormal Distri8tions

1 #any physical measrements follo' the symmetrical, 8ell5shaped cr6e of thenormal, or &assian, fre9ency distri8tion

7ei8ll Distri8tion

1 7idely sed for many engineering pro8lems 8ecase of its 6ersatility, sincemany random 6aria8les follo' a 8onded, nonsymmetrical distri8tion, sch asfatige life of components

&amma Distri8tion1 sed to descri8e random 6aria8les that are 8onded at one end

Exponential Distri8tion

1 Special case of the gamma distri8tion for U -

Distri8tions for Discrete aria8les

1 The normal and other distri8tions discssed deal 'ith continos random

6aria8lesBho'e6er, there are important engineering pro8lems in 'hich therandom 6aria8le ta2es on only discrete 6ales

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Dieter7 Chapter 9Engineering Statistics > Sampling Distributions

The central pro8lem in statistics is relating the poplation

and the samples that are dra'n from it

This pro8lem is 6ie'ed from t'o perspecti6es"

1 7hat does the poplation tell s a8ot the 8eha6ior of the samples1 7hat does a sample or series of samples tell s a8ot the

poplation form 'hich the sample came

Distri8tion of Sample #eans

t Distri8tion Distri8tion of Sample ariances

+ Distri8tion


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Dieter7 Chapter 9Engineering Statistics > Analysis of 3ariance

7hen 'e ha6e three or more samples treatments 'e can

se a statistical procedre call the Analysis of ariance

(AF3A) 'hich is important in design of experiments

7ith AF3A 'e determine"1 The total spread of reslts 8et'een the different treatments

1 The spread of reslts 'ithin each treatment

3ne57ay Classification

T'o57ay Classification

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Engineering Statistics > Statistical Design of E%periments The greatest 8enefit can 8e gained from statistical analysis 'hen the experiments are

planned in ad6ance so that data are ta2en in a 'ay that 'ill pro6ide the most

n8iased and precise reslts commensrate 'ith the desired expenditre of time andmoney

This can 8est 8e done throgh the com8ined efforts of a statistician and the engineerdring the planning stage of the pro>ect

Pro8a8ly the most important 8enefit from statistically designed experiments is thatmore information per experiment 'ill 8e o8tained than 'ith an nplannedexperimentation

A second 8enefit is that statistical design reslts in an organi4ed approach to thecollection and analysis of information

Still another ad6antage of statistical planning is the credi8ility that is gi6en to theconclsions of an experimental program 'hen the 6aria8ility and sorces ofexperimental error are made clear 8y statistical analysis

+inally, an important 8enefit of statistical design is the a8ility to disco6er

interactions 8et'een experimental 6aria8les

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Dieter7 Chapter 9Engineering Statistics > Statistical Design of E%periments

0n general, there are three classes of statistically designedexperiments1 ;loc2ing designs se 8loc2ing techni9es to remo6e the effect of

8ac2grond 6aria8les from experimental error

1 +actorial designs are experiments in 'hich all le6els of each factorin an experiment are com8ined 'ith all le6els of e6ery other factor

1 Response srface designs are sed to determine the empiricalfnctional relation 8et'een factors (independent 6aria8les) and theresponse (performance 6aria8le). The central composite design and

rotata8le designs are fre9ently sed for this prpose +actorial Design

+ractional +actorial Designs

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Dieter7 Chapter 9Engineering Statistics > -egressional Analysis

Regression analysis is the statistical techni9e for

esta8lishing sch relationships 8et'een t'o or more

6aria8les

1 +nctional relation" emphasis is on prediction1 Association" correlation 8et'een 6aria8les, 'hich 6ary >ointly

#ethod of @east S9ares

@inear #ltiple Regression Analysis

Fonlinear Regression Analysis @ineari4ation Transformation


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-is( -eliability and Safety

A hazard(nsafe condition) is the potential for hman,property, or en6ironmental damage

A ris" is the li2elihood, expressed either as a pro8a8ility or as afre9ency, of a ha4ard


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-is( -eliability and Safety7 robabilistic Approach to

Design

There are three typical approaches for incorporating

pro8a8ilistic effects in design

1 The se of a factor of safety

1 The se of the a8solte 'orst case design1 The se of pro8a8ility in design

The se of pro8a8ility in design

Pf P(W X Sy)

The relia8ility R is defined asR -5Pf

See Example in Text

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Design

aria8ility in #aterial Properties

1 The mechanical properties of engineering materials exhi8it

6aria8ility

1 +ractre and fatige properties sho' greater 6aria8ility than do the

static tensile properties of yield strength and tensile strength

1 Conser6ati6e design 6ales for material properties are re9ired in

the design of minimm 'eight

Pro8a8ilistic Design

1 Re6ie' the illstrated example of a cran2 that mst spport asingle static load

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Design

Safety +actor

1 The se of a safety factor is far simpler 8t 'ith mch less

information content

1 sing a safety factor is a form of !derating$ 8t the extent of

redction from the tre capacity is not 2no'n

A8solte 7orse Case Design

1 0n a8solte 'orse case (A7C) design the 6aria8les are set at either

the lo'est or largest expected 6ales

1 A7C design, li2e the se of safety factor, is an approach thatacconts for the statistical natre of the design en6ironment in a

deterministic 'ay

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Dieter7 Chapter 99-is( -eliability and Safety7 -eliability Theory

Relia+ilityis the pro8a8ility that a system, component, orde6ice 'ill perform 'ithot failre for a specified period oftime nder specified operating conditions

The discipline of relia8ility engineering 8asically is a stdy ofthe cases, distri8tion, and prediction of failre

Definitions1 ean life" The a6erage life of the nm8er of components pt on test or

in ser6ice, measred o6er the entire life cr6e ot to 'earot

1 ean ti)e +et-een failures (..F/0The sm of sr6i6al time (p time)for all of the components di6ided 8y the nm8er of failres

1 ean ti)e +et-een failures (.1F/0The mean time 8et'een t'osccessi6e component failres. #T;+ is similar to #TT+, 8t it isapplied for components or systems that are repaired


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System Relia8ility

1 #ost mechanical and electronic systems comprise a collection of

components

1 The o6erall relia8ility of the system depends on ho' the indi6idal

components 'ith their indi6idal failre rates are arranged1 0t is o86ios that if there are many components exhi8iting series

relia8ility, the system relia8ility 9ic2ly 8ecomes 6ery lo'

1 A system in 'hich the components are arranged to gi6e parallel

relia8ility is said to 8e redndantB there is more than one

mechanism for the system fnctions to 8e carried ot1 0n a system 'ith fll acti6e redndancy all 8t one component may

fail 8efore the system failsB See Aircraft Example for partial redn.

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#aintenance and Repair1 0f a failed component can 8e repaired 'hile a redndant component

has replaced it in ser6ice, then the o6erall relia8ility of the systemis impro6ed

1 0f components s8>ect to 'ear can 8e replaced 8efore they ha6efailed, then the system relia8ility 'ill 8e impro6ed

1 Pre6enti6e maintenance is aimed at minimi4ing system failre

1 Repairing a failed component in a series system 'ill not impro6ethe relia8ility, since the system is not operating

1 o'e6er, decreasing the repair time 'ill shorten the period dring'hich the system is ot of ser6ice

1 aintaina+ilityis the pro8a8ility that a component or system thathas failed 'ill 8e restored to ser6ice 'ithin a gi6en time

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Dieter7 Chapter 99-is( -eliability and Safety7 Design for -eliability

The design strategy sed to ensre relia8ility can fall8et'een t'o 8road extremes

1 +ail5safe approach

1 !the one5horse shay$ approach

1 A8solte 'orse5case approach T'o ma>or areas of engineering acti6ity determine the

relia8ility of an engineering system1 Pro6ision for relia8ility mst 8e esta8lished dring the earliest

design concept stage, carried throgh the detailed design

de6elopment, and many steps in manfactre1 3nce the system 8ecomes operational, it is imperati6e that

pro6ision 8e made for its contined maintenance dring its ser6ice

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Dieter7 Chapter 99-is( -eliability and Safety7 Methods and Techniques

+ailre #ode and Effects Analysis (+#EA)1 Team58ased methodology for identifying potential pro8lems 'ith

ne' or existing designs

+alt Tree Analysis (+TA)

1 A techni9e that pro6ides a systematic description of thecom8inations of possi8le occrrences in a system that can reslt infailre or se6ere accidents

Defects and +ailre #odes1 ard'are failre

1 Soft'are failre1 man failre

1 3rgani4ation failre

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Dieter7 Chapter 99-is( -eliability and Safety7 Design for Safety

Safety may 'ell 8e the paramont isse in prodct design

There are three aspects to design for safety

1 #a2e the prodct safe, i.e. design all ha4ards ot of the prodct

1 0f a8o6e not possi8le, then design in protecti6e de6ices1 0f Step cannot remo6e all ha4ards, then 'arn the ser of the

prodct 'ith appropriate 'arnings li2e la8els, flashing lights, and

lod sonds

&idelines for Design for Safety

1 ;e familiar 'ith these

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Economic Decision Ma(ing


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g The ma>or engineering infrastrctre that 8ilt this nation 1 the railroads,

ma>or dams, 'ater'ays, and air transportation 1 re9ired a methodology

for predicting costs and 8alancing them against alternati6e corses ofaction

#athematics of Time ale of #oney

Depreciation

Taxes

Profita8ility of 0n6estments 3ther Aspects of Pro8a8ility

0nflation

Sensiti6ity and ;rea25E6en Analysis

ncertainty in Economic Analysis

;enefit5Cost Analysis

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Cost E$aluation


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An engineering design is not complete ntil 'e ha6e a good idea of the cost re9ired to 8ildthe design or manfactre the prodct

Categories of Costs #ethods of De6eloping Cost Estimates

Cost 0ndexes

Cost5Capacity +actors

Estimating Plant Cost

Design To Cost

#anfactring Costs

ale Analysis in Costing

36erhead Costs

Acti6ity5;ased Costing

Prodct Profit #odel

@earning Cr6e

Cost #odels

@ife Cycle Costing

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y g

Considerations Primary Text Chapters

1 Chap N" Em8odiment Design

1 Chap J" #odeling and Simlation

1 Chap /" #aterials Selection : #aterials in Design

1 Chap " #aterials Processing : Design1 Chap -*" Engineering Statistics

1 Chap --" Ris2, Relia8ility, and Safety

1 Chap -%" Economic Decision #a2ing

1 Chap -M" Cost E6alation

Secondary Text Chapter

1 Chap -%" #odeling and Simlation

aero sys eng intro

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