Dym, Little and Orwin's Engineering Design: A Project-Based Introduction, 4th Edition gets students actively involved with conceptual design methods and project management tools. The book helps students acquire design skills as they experience the activity of design by doing design projects. It is equally suitable for use in project-based first-year courses, formal engineering design courses, and capstone project courses.

Clive Dym was a professor emeritus of Engineering Design and also Director of the Center for Design Education at Harvey Mudd College. He served as the chair of the engineering department at Harvey Mudd College from 1999 through 2002.

Foreword

Preface

Acknowledgments

Part I: Introduction

Chapter 1 Engineering Design
What does it mean to “design” something? Is engineering design different from other kinds of design?

1.1 Where and when do engineers design?

1.2 A basic vocabulary for engineering design

Defining engineering design

Assumptions underlying our definition of engineering design

Measuring the success of an engineering design

Form and function

Design and systems

Communication and design

1.3 Learning and doing engineering design

Engineering design problems are challenging

Learning design by doing

1.4 Managing engineering design projects

1.5 Notes

Chapter 2 Defining a Design Process and a Case Study
How do I do engineering design? Can you show me an example?

2.1 The design process as a process of questioning

2.2 Describing and prescribing a design process

2.3 Informing a design process

Informing a design process by thinking strategically

Informing a design process with formal design methods

Acquiring design knowledge to inform a design process

Informing a design process with analysis and testing

Getting feedback to inform a design process

2.4 Case study: Design of a stabilizer for microlaryngeal surgery

2.5 Illustrative design examples

2.6 Notes

Part II: The Design Process and Design Tools

Chapter 3 Problem Definition: Detailing Customer Requirements
What does the client require of this design?

3.1Clarifying the initial problem statement

3.2 Framing customer requirements

Lists of desired attributes and of design objectives

3.3 Revised project statements: Public statements of the design project

3.4 Designing an arm support for a CP-afflicted student

3.5 Notes

Chapter 4 Problem Definition: Clarifying the Objectives
What is this design intended to achieve?

4.1 Clarifying a client’s objectives

Representing lists of objectives in objectives trees

Remarks on objectives trees

The objectives tree for the juice container design

4.2 Measurement issues in ordering and evaluating objectives

4.3 Rank ordering objectives with pairwise comparison charts

An individual’s rank orderings

Aggregating rank orderings for a group

Using pairwise comparisons properly

4.4 Developing metrics to measure the achievement of objectives

Establishing good metrics for objectives

Establishing metrics for the juice container

4.5 Objectives and metrics for the Danbury arm support

4.6 Notes

Chapter 5 Problem Definition: Identifying Constraints
What are the limits for this design problem?

5.1 Identifying and setting the client’s limits

5.2 Displaying and using constraints

5.3 Constraints for the Danbury arm support

5.4 Notes

Chapter 6 Problem Definition: Establishing Functions
How do I express a design’s functions in engineering terms?

6.1 Establishing functions

Functions: Input is transformed into output

Expressing functions

6.2 Functional analysis: Tools for establishing functions

Black boxes and glass boxes

Dissection, or reverse engineering

Enumeration

Function-means trees

Remarks on functions and objectives

6.3 Design specifications: Specifying functions, features and behavior

Attaching numbers to design specifications

Setting performance levels

Interface performance specifications

House of Quality: Accounting for the customers’ requirements

6.4 Functions for the Danbury arm support

6.5 Notes

Chapter 7 Conceptual Design: Generating Design Alternatives
How do I generate or create feasible designs?

7.1 Generating the “design space,” a space of engineering designs

Defining a design space by generating a morphological chart

Thinking metaphorically and strategically

The 6–3–5 method

The C-sketch method

The gallery method

Guiding thoughts on design generation

7.2 Navigating, expanding and contracting the design space

Navigating design spaces

Expanding a design space when it is too small

Contracting a design space when it is too large

7.3 Generating designs for the Danbury arm support

7.4 Notes

Chapter 8 Conceptual Design: Evaluating Design Alternatives and Choosing a Design
Which design should I choose? Which design is “best”?

8.1 Applying metrics to objectives: Selecting the preferred design

Numerical evaluation matrices

Priority checkmark method

Best of class chart

An important reminder about design evaluation

8.2 Evaluating designs for the Danbury arm support

8.3 Notes

Part III: Design Communication

Chapter 9 Communicating Designs Graphically
Here’s my design; can you make it?

9.1 Engineering sketches and drawings speak to many audiences

9.2 Sketching

9.3 Fabrication specifications: The several forms of engineering drawings

Design drawings

Detail drawings

Some Danbury arm support drawings

9.4 Fabrication specifications: The devil is in the details

9.5 Final notes on drawings

9.6 Notes

Chapter 10 Prototyping and Proofing the Design
Here’s my design; how well does it work?

10.1 Prototypes, models and proofs of concept

Prototypes and models are not the same thing

Testing prototypes and models, and proving concepts

When do we build a prototype?

10.2 Building models and prototypes

Who is going to make it?

Can we buy parts or components?

How, and from what, will the model/prototype be made?

How much will it cost?

10.3 Notes

Chapter 11 Communicating Designs Orally and in Writing
How do we let our client know about our solutions?

11.1 General guidelines for technical communication

11.2 Oral presentations: Telling a crowd what’s been done

Knowing the audience: Who’s listening?

The presentation outline

Presentations are visual events

Practice makes perfect, maybe . . .

Design reviews

11.3 The project report: Writing for the client, not for history

The purpose of and the audience for the final report

The rough outline: Structuring the final report

The topic sentence outline: Every entry represents a paragraph

The first draft: Turning several voices into one

The final, final report: Ready for prime time

11.4 Final report elements for the Danbury arm support

Rough outlines of two project reports

One TSO for the Danbury arm support

The final outcome: The Danbury arm support

11.5 Notes

Part IV: Design Modeling, Engineering Economics and Design Use

Chapter 12 Mathematical Modeling in Design
Math and physics are very much part of the design process!

12.1 Some mathematical habits of thought for design modeling

Basic principles of mathematical modeling

Abstraction, scaling and lumped elements

12.2 Some mathematical tools for design modeling

Physical dimensions in design (I): Dimensions and units

Physical dimensions in design (II): Significant figures

Physical dimensions in design (III): Dimensional analysis

Physical idealizations, mathematical approximations and linearity

Conservation and balance laws

Series and parallel connections

Mechanical-electrical analogies

12.3 Modeling a battery-powered payload cart

Modeling the mechanics of moving a payload cart up a ramp

Selecting a battery and battery operating characteristics

Selecting a motor and motor operating characteristics

12.4 Design modeling of a ladder rung

Modeling a ladder rung as an elementary beam

Design criteria

12.5 Preliminary design of a ladder rung

Preliminary design considerations for a ladder rung:

Preliminary design of a ladder rung for stiffness

Preliminary design of a ladder rung for strength

12.6 Closing remarks on mathematics, physics and design

12.7 Notes

Chapter 13 Engineering Economics in Design
How much is this going to cost?

13.1 Cost estimation: How much does this particular design cost?

Labor, materials and overhead costs

Economies of scale: Do we make it or buy it?

The cost of design and the cost of the designed device

13.2 The time value of money

13.3 Closing considerations on engineering and economics

13.4 Notes

Chapter 14 Design for Production, Use and Sustainability
What other factors influence the design process?

14.1 Design for production: Can this design be made?

Design for manufacturing (DFM)

Design for assembly (DFA)

The bill of materials and production

14.2 Design for use: How long will this design work?

Reliability

Maintainability

14.3 Designing for sustainability: What about the environment?

Environmental issues and design

Global climate change

Environmental life cycle assessments

14.4 Notes

Part V: Design Teams, Team Management and Ethics in Design

Chapter 15 Design Team Dynamics
We can do this together, as a team!

15.1 Forming design teams

Stages of group formation

Team dynamics and design process activities

15.2 Constructive conflict: Enjoying a good fight

15.3 Leading design teams

Leadership and membership in teams

Personal behavior and roles in team settings

15.4 Notes

Chapter 16 Managing a Design Project
What do you want? When do you want it? How much are we going to spend?

16.1 Getting started: Establishing the managerial needs of a project

16.2 Tools for managing a project’s scope

Team charters

Work breakdown structures

16.3 The team calendar: A tool for managing a project’s schedule

16.4 The budget: A tool for managing a project’s spending

16.5 Monitoring and controlling projects: Measuring a project’s progress

16.6 Managing the end of a project

16.7 Notes

Chapter 17 Ethics in Design
Design is not just a technical matter.

17.1 Ethics: Understanding obligations

17.2 Codes of ethics: What are our professional obligations?

17.3 Obligations may start with the client . . .

17.4 . . . but what about the public and the profession?

17.5 On engineering practice and the welfare of the public

17.6 Ethics: Always a part of engineering practice

17.7 Notes

Appendices

Appendix I: Practical Aspects of Prototyping

AI.1 Working safely in a shop

AI.2 Selecting materials

AI.3 Building techniques

AI.4 Selecting a fastener

Fastening wood

Fastening polymers

Fastening metals

What size temporary fastener should I choose?

AI.5 Notes

Appendix II: Practical Aspects of Engineering Drawing

AII.1 Dimensioning

Orthographic views

Metric vs. Inch

Line types

Orienting, spacing and placing dimensions

Types of dimensions

AII.2 Geometric tolerancing

The 14 geometric tolerances

Feature control frames

Material condition modifiers

Datums

Position tolerance

Fasteners

AII.3 How do I know my part meets the specifications in my drawing?

AII.4 Notes

Appendix III: Exercises

References and Bibliography

Index

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Summary

Author Biography

Table of Contents

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