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Foreword x
Preface xi
Acknowledgments xvi
Part I Introduction 1
Chapter 1 Engineering Design 3
What does it mean to design something? Is engineering design different from other kinds of design?
1.1 Where and when do engineers design? 3
1.2 A basic vocabulary for engineering design 7
1.2.1 Defining engineering design 7
1.2.2 Assumptions underlying our definition of engineering design 8
1.2.3 Measuring the success of an engineered design 9
1.2.4 Form and function 9
1.2.5 Design and systems 10
1.2.6 Communication and design 10
1.3 Learning and doing engineering design 12
1.3.1 Engineering design problems are challenging 12
1.3.2 Learning design by doing 13
1.4 Managing engineering design projects 14
1.5 Notes 15
Chapter 2 Defining a Design Process and a Case Study 16
How do I do engineering design? Can you show me an example?
2.1 The design process as a process of questioning 16
2.2 Describing and prescribing a design process 19
2.3 Informing a design process 24
2.3.1 Informing a design process by thinking strategically 24
2.3.2 Informing a design process with formal design methods 24
2.3.3 Acquiring design knowledge to inform a design process 25
2.3.4 Informing a design process with analysis and testing 26
2.3.5 Getting feedback to inform a design process 27
2.4 Case study: Design of a stabilizer for microlaryngeal surgery 27
2.5 Illustrative design examples 34
2.6 Notes 35
Part II The Design Process and Design Tools 37
Chapter 3 Problem Definition: Detailing Customer Requirements 39
What does the client require of this design?
3.1 Clarifying the initial problem statement 40
3.2 Framing customer requirements 41
3.2.1 Lists of design attributes and of design objectives 41
3.3 Revised problem statements: Public statements of the design project 43
3.4 Designing an arm support for a CP-afflicted student 44
3.5 Notes 46
Chapter 4 Problem Definition: Clarifying the Objectives 47
What is this design intended to achieve?
4.1 Clarifying a client’s objectives 47
4.1.1 Representing lists of objectives in objectives trees 49
4.1.2 Remarks on objectives trees 50
4.1.3 The objectives tree for the juice container design 51
4.2 Measurement issues in ordering and evaluating objectives 53
4.3 Rank ordering objectives with pairwise comparison charts 54
4.3.1 An individual’s rank orderings 54
4.3.2 Aggregating rank orderings for a group 55
4.3.3 Using pairwise comparisons properly 56
4.4 Developing metrics to measure the achievement of objectives 57
4.4.1 Establishing good metrics for objectives 58
4.4.2 Establishing metrics for the juice container 61
4.5 Objectives and metrics for the Danbury arm support 62
4.6 Notes 66
Chapter 5 Problem Definition: Identifying Constraints 67
What are the limits for this design problem?
5.1 Identifying and setting the client’s limits 67
5.2 Displaying and using constraints 68
5.3 Constraints for the Danbury arm support 69
5.4 Notes 70
Chapter 6 Problem Definition: Establishing Functions 71
How do I express a design’s functions in engineering terms?
6.1 Establishing functions 71
6.1.1 Functions: Input is transformed into output 72
6.1.2 Expressing functions 72
6.2 Functional analysis: Tools for establishing functions 73
6.2.1 Black boxes and glass boxes 73
6.2.2 Dissection or reverse engineering 75
6.2.3 Enumeration 76
6.2.4 Function–means trees 79
6.2.5 Remarks on functions and objectives 80
6.3 Design specifications: Specifying functions, features, and behavior 81
6.3.1 Attaching numbers to design specifications 81
6.3.2 Setting performance levels 84
6.3.3 Interface performance specifications 85
6.3.4 House of quality: Accounting for the customers’ requirements 86
6.4 Functions for the Danbury arm support 88
6.5 Notes 91
Chapter 7 Conceptual Design: Generating Design Alternatives 92
How do I generate or create feasible designs?
7.1 Generating the “design space,” a space of engineering designs 92
7.1.1 Defining a design space by generating a morphological chart 93
7.1.2 Thinking metaphorically and strategically 95
7.1.3 The 6–3–5 method 97
7.1.4 The C-sketch method 98
7.1.5 The gallery method 98
7.1.6 Guiding thoughts on design generation 99
7.2 Navigating, expanding, and contracting design spaces 99
7.2.1 Navigating design spaces 99
7.2.2 Expanding a design space when it is too small 100
7.2.3 Contracting a design space when it is too large 101
7.3 Generating designs for the Danbury arm support 101
7.4 Notes 105
Chapter 8 Conceptual Design: Evaluating Design Alternatives and Choosing a Design 106
Which design should I choose? Which design is “best”?
8.1 Applying metrics to objectives: Selecting the preferred design 106
8.1.1 Numerical evaluation matrices 107
8.1.2 Priority checkmark method 109
8.1.3 The best-of-class chart 110
8.1.4 An important reminder about design evaluation 111
8.2 Evaluating designs for the Danbury arm support 111
8.3 Notes 113
Part III Design Communication 115
Chapter 9 Communicating Designs Graphically 117
Here’s my design; can you make it?
9.1 Engineering sketches and drawings speak to many audiences 117
9.2 Sketching 119
9.3 Fabrication specifications: The several forms of engineering drawings 122
9.3.1 Design drawings 122
9.3.2 Detail drawings 125
9.3.3 Some Danbury arm support drawings 126
9.4 Fabrication specifications: The devil is in the details 127
9.5 Final notes on drawings 129
9.6 Notes 130
Chapter 10 Prototyping and Proofing the Design 131
Here’s my design; how well does it work?
10.1 Prototypes, models, and proofs of concept 132
10.1.1 Prototypes and models are not the same thing 132
10.1.2 Testing prototypes and models, and proving concepts 133
10.1.3 When do we build a prototype? 134
10.2 Building models and prototypes 135
10.2.1 Who is going to make it? 136
10.2.2 Can we buy parts or components? 136
10.2.3 How, and from what, will the model/prototype be made? 137
10.2.4 How much will it cost? 141
10.3 Notes 141
Chapter 11 Communicating Designs Orally and in Writing 142
How do we let our client know about our solutions?
11.1 General guidelines for technical communication 143
11.2 Oral presentations: Telling a crowd what’s been done 145
11.2.1 Knowing the audience: Who’s listening? 145
11.2.2 The presentation outline 146
11.2.3 Presentations are visual events 147
11.2.4 Practice makes perfect, maybe . . . 148
11.2.5 Design reviews 149
11.3 The project report: Writing for the client, not for history 150
11.3.1 The purpose of and audience for the final report 151
11.3.2 The rough outline: Structuring the final report 151
11.3.3 The topic sentence outline: Every entry represents a paragraph 152
11.3.4 The first draft: Turning several voices into one 153
11.3.5 The final, final report: Ready for prime time 154
11.4 Final report elements for the Danbury arm support 155
11.4.1 Rough outlines of two project reports 155
11.4.2 ATSO for the Danbury arm support 157
11.4.3 The final outcome: The Danbury arm support 158
11.5 Notes 158
Part IV Design Modeling, Engineering Economics, and Design Use 159
Chapter 12 Mathematical Modeling in Design 161
Math and physics are very much part of the design process!
12.1 Some mathematical habits of thought for design modeling 162
12.1.1 Basic principles of mathematical modeling 162
12.1.2 Abstractions, scaling, and lumped elements 162
12.2 Some mathematical tools for design modeling 163
12.2.1 Physical dimensions in design (i): Dimensions and units 164
12.2.2 Physical dimensions in design (ii): Significant figures 166
12.2.3 Physical dimensions in design (iii): Dimensional analysis 167
12.2.4 Physical idealizations, mathematical approximations, and linearity 169
12.2.5 Conservation and balance laws 171
12.2.6 Series and parallel connections 173
12.2.7 Mechanical–electrical analogies 176
12.3 Modeling a battery-powered payload cart 177
12.3.1 Modeling the mechanics of moving a payload cart up a ramp 177
12.3.2 Selecting a battery and battery operating characteristics 181
12.3.3 Selecting a motor and motor operating characteristics 184
12.4 Design modeling of a ladder rung 186
12.4.1 Modeling a ladder rung as an elementary beam 188
12.4.2 Design criteria 190
12.5 Preliminary design of a ladder rung 193
12.5.1 Preliminary design considerations for a ladder rung 193
12.5.2 Preliminary design of a ladder rung for stiffness 194
12.5.3 Preliminary design of a ladder rung for strength 195
12.6 Closing remarks on mathematics, physics, and design 196
12.7 Notes 196
Chapter 13 Engineering Economics in Design 197
How much is this going to cost?
13.1 Cost estimation: How much does this particular design cost? 197
13.1.1 Labor, materials, and overhead costs 198
13.1.2 Economies of scale: Do we make it or buy it? 200
13.1.3 The cost of design and the cost of the designed device 200
13.2 The time value of money 201
13.3 Closing considerations on engineering and economics 204
13.4 Notes 204
Chapter 14 Design for Production, Use, and Sustainability 205
What other factors influence the design process?
14.1 Design for production: Can this design be made? 206
14.1.1 Design for manufacturing (DFM) 206
14.1.2 Design for assembly (DFA) 207
14.1.3 The bill of materials and production 209
14.2 Design for use: How long will this design work? 209
14.2.1 Reliability 210
14.2.2 Maintainability 214
14.3 Design for sustainability: What about the environment? 215
14.3.1 Environmental issues and design 215
14.3.2 Global climate change 217
14.3.3 Environmental life-cycle assessments 218
14.4 Notes 218
Part V Design Teams, Team Management, and Ethics in Design 221
Chapter 15 Design Team Dynamics 223
We can do this together, as a team!
15.1 Forming design teams 223
15.1.1 Stages of group formation 224
15.1.2 Team dynamics and design process activities 226
15.2 Constructive conflict: Enjoying a good fight 227
15.3 Leading design teams 229
15.3.1 Leadership and membership in teams 229
15.3.2 Personal behavior and roles in team settings 230
15.4 Notes 231
Chapter 16 Managing a Design Project 232
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 232
16.2 Tools for managing a project’s scope 234
16.2.1 Team charters 234
16.2.2 Work breakdown structures 237
16.3 The team calendar: A tool for managing a project’s schedule 241
16.4 The budget: A tool for managing a project’s spending 243
16.5 Monitoring and controlling projects: Measuring a project’s progress 245
16.6 Managing the end of a project 248
16.7 Notes 249
Chapter 17 Ethics in Design 250
Design is not just a technical matter
17.1 Ethics: Understanding obligations 250
17.2 Codes of ethics: What are our professional obligations? 252
17.3 Obligations may start with the client . . . 255
17.4 . . . But what about the public and the profession? 256
17.5 On engineering practice and the welfare of the public 261
17.6 Ethics: Always a part of engineering practice 263
17.7 Notes 263
Appendices 264
Appendix A Practical Aspects of Prototyping 264
A.1 Working safely in a shop 264
A.2 Selecting materials 265
A.3 Building techniques 267
A.4 Selecting a fastener 269
Fastening wood 270
Fastening polymers 273
Fastening metals 274
What size temporary fastener should I choose? 278
A.5 Notes 278
Appendix B Practical Aspects of Engineering Drawing 279
B.1 Dimensioning 279
Orthographic views 279
Metric versus inch dimensioning 282
Line types 283
Orienting, spacing, and placing dimensions 284
Types of dimensions 284
Some best practices of dimensioning 285
B.2 Geometric tolerancing 286
The 14 geometric tolerances 287
Feature control frames 287
Material condition modifiers 290
Datums 292
Position tolerance 295
Fasteners 296
B.3 How do I know my part meets the specifications in my drawing? 298
B.4 Notes 299
Appendix C Exercises 300
References and Bibliography 309
Index 315
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