utf8''2-the design process
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DESIGN PROCESS AND
MATERIAL SELECTIONDr. Alexey Sverdlin
Mechanical Engineering DepartmentMarquette University
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I dont design clothes,I design dreamsRalph Lauren, NY Times, 19 April 1986.
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The process of translating an idea or need
for a device into the detailed information(drawings, bill of materials, etc.) from
which the device or product can be made.
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Technical design Industrial design
Product design
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Technical design includes the aspects ofdesign that bear on the proper technical
functioning of the product. Industrial design includes the aspects of
design that bear on the satisfaction affordedby the product.
Product design means the synthesis oftechnical and industrial design to createsuccessful products.
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ObservationPerception
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The design of a device or product for Carrying loads
Transmitting power Conducting heat Resisting wear Etc.
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The product itself is called a technical system:
Subassemblies
Components
The design converts the inputs into the
outputs.
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The design proceeds by developing conceptsto perform the functions in the function
structure, each based on a working principle. The designer considers alternative concepts
and the ways in which these might beseparatedor combined.
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Original Design
Design of something totally new
Adaptive or Developmental DesignDesign resulting in an incremental advance in a
device
Variant Design
Scaling up or scaling down a design
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Hubble Telescope Mars Rover
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New designs can spur the development ofnew materials to meet the need.
Example: Gas turbine design spurred thedevelopment of single crystal nickel based alloy
turbine blade alloys.
New materials can spur new designs
Example: Carbon fiber composite spurred thedesign of stealth aircraft.
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Wood Aluminum Carbon Fiber
Tennis Rackets
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3.5 HP
Briggs and Stratton Engines
10 HP
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Functional Design
Design from a systems (input/output) point of view.
(Materials selection is usually not considered here.)
Assembly or Component Design
Design of individual components and assemblies of
technical systems. (Materials selection is usually
considered here.)
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Fuel
Air
Control
Signals
Electrical
Power
Internal Combustion Engine
Fuel
InjectionSystem
Electrical
System
Motor
(Block, crank,
pistons, etc.
Cooling
System
Inputs
Rotational
Mechanical
Energy
Control
Signals
Exhaust
Gases
Heat
Outputs
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InternalCombustion
Engine
Motor
FuelInjection
System
Cooling
System
Electrical
System
Engine Block
Crank Shaft
Pistons
Fuel Injectors
Intake Manifold
Radiator
Water Pump
Alternator
Spark Plugs
Note: Materials selection made at the component level
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Originaldesign involves a new idea orworking principle:
The ballpoint pen The compact disc
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Almost all design is adaptiveor developmental. Adaptive design takes an existing concept and
seeks an incremental advance performance, toreduce cost, or to adapt it to changing marketconditions.
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Variant design involves a change of scale ordimension or detailing without a change of
function or the method of achieving it. Boilers
Boats
Cars
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Prototype
Testing
and
Failure
Analysis
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Ashby, p.17
Increasing
sophistication
in design toolsand accuracy
of calculations
Increasing
specificity in
materialsselection and
material
properties
Screening
Selection of
specific
materials
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Main basis for selectinga material for a
function is its
properties.
Available shape of a
material affects
selection. Ability to process
material affects
selection.
Function, material, shape and process must
all be taken into account in selection.
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