The Mechanical Design Process

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  • Edition: 4th
  • Format: Hardcover
  • Copyright: 2009-02-02
  • Publisher: McGraw-Hill Education
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The fourth edition ofThe Mechanical Design Processcombines a practical overview of the design process with case material and real-life engineering insights. Ullman's work as an innovative designer comes through consistently, and has made this book a favorite with readers...This book conveys the "flavor" of design, addressing both traditional engineering topics as well as real-world issues like creative thinking, synthesis of ideas, visualization, teamwork, sense of customer needs and product success factors, and the financial aspects of design alternatives, in a practical and motivating manner. The Industrial Clamp brings the design stages and concepts to life, and shows the actual steps taken to generate design ideas and bring them to fruition. Approaches to concept generation, including TRIZ and axiomatic design, are given strong coverage...This text is appropriate primarily for the Senior Design course taken by mechanical engineering students, though it can also be used in design courses offered earlier in the curriculum. Working engineers also find it to be a readable, practical overview of the modern design process..

Table of Contents

Prefacep. xi
Why Study the Design Process?p. 1
Introductionp. 1
Measuring the Design Process with Product Cost, Quality, and Time to Marketp. 3
The History of the Design Processp. 8
The Life of a Productp. 10
The Many Solutions for Design Problemsp. 15
The Basic Actions of Problem Solvingp. 17
Knowledge and Learning During Designp. 19
Design for Sustainabilityp. 20
Summaryp. 21
Sourcesp. 22
Exercisesp. 22
Understanding Mechanical Designp. 25
Introductionp. 25
Importance of Product Function, Behavior, and Performancep. 28
Mechanical Design Languages and Abstractionp. 30
Different Types of Mechanical Design Problemsp. 33
Constraints, Goals, and Design Decisionsp. 40
Product Decompositionp. 41
Summaryp. 44
Sourcesp. 44
Exercisesp. 45
On the Webp. 45
Designers and Design Teamsp. 47
Introductionp. 47
The Individual Designer: A Model of Human Information Processingp. 48
Mental Processes That Occur During Designp. 56
Characteristics of Creatorsp. 64
The Structure of Design Teamsp. 66
Building Design Team Performancep. 72
Summaryp. 78
Sourcesp. 78
Exercisesp. 79
On the Webp. 80
The Design Process and Product Discoveryp. 81
Introductionp. 81
Overview of the Design Processp. 81
Designing Quality into Productsp. 92
Product Discoveryp. 95
Choosing a Projectp. 101
Summaryp. 109
Sourcesp. 110
Exercisesp. 110
On the Webp. 110
Planning for Designp. 111
Introductionp. 111
Types of Project Plansp. 113
Planning for Deliverables The Development of Informationp. 117
Building a Planp. 126
Design Plan Examplesp. 134
Communication During the Design Processp. 137
Summaryp. 141
Sourcesp. 141
Exercisesp. 142
On the Webp. 142
Understanding the Problem and the Development of Engineering Specificationsp. 143
Introductionp. 143
Step 1: Identify the Customers: WhoAreThey?p. 151
Step 1: Determine the Customers' Requirements: What Do the Customers Want?p. 151
Step 3: Determine Relative Importance of the Requirements: Who Versus Whatp. 155
Step 4: Identify and Evaluate the Competition: How Satisfied Are the Customers Now 7p. 157
Step 5: Generate Engineering Specifications: How Will the Customers' Requirement Be Met?p. 158
Step 6: Relate Customers' Requirements to Engineering Specifications: How to Measure What?p. 163
Step 7: Set Engineering Specification Targets and Importance: How Much Is Good Enough?p. 164
Step 8: Identify Relationships Between Engineering Specifications: How Are the Hows Dependent on Each Other?p. 166
Further Comments on QFDp. 168
Summaryp. 169
Sourcesp. 169
Exercisesp. 169
On the Webp. 170
Concept Generationp. 171
Introductionp. 171
Understanding the Function of Existing Devicesp. 176
A Technique for Designing with Functionp. 181
Basic Methods of Generating Conceptsp. 189
Patents as a Source of Ideasp. 194
Using Contradictions to Generate Ideasp. 197
The Theory of Inventive Machines, TRIZp. 201
Building a Morphologyp. 204
Other Important Concerns During Concept Generationp. 208
Summaryp. 209
Sourcesp. 209
Exercisesp. 211
On the Webp. 211
Concept Evaluation and Selectionp. 213
Introductionp. 213
Concept Evaluation Informationp. 215
Feasibility Evaluationsp. 218
Technology Readinessp. 219
The Decision Matrix-Pugh's Methodp. 221
Product, Project, and Decision Riskp. 226
Robust Decision Makingp. 233
Summaryp. 239
Sourcesp. 239
Exercisesp. 240
On the Webp. 240
Product Generationp. 241
Introductionp. 241
BOMsp. 245
Form Generationp. 246
Materials and Process Selectionp. 264
Vendor Developmentp. 266
Generating a Suspension Design for the Marin 2008 Mount Vision Pro Bicyclep. 269
Summaryp. 276
Sourcesp. 276
Exercisesp. 277
On the Webp. 278
Product Evaluation for Performance and the Effects of Variationp. 279
Introductionp. 279
Monitoring Functional Changep. 280
The Goals of Performance Evaluationp. 281
Trade-Off Managementp. 284
Accuracy, Variation, and Noisep. 286
Modeling for Performance Evaluationp. 292
Tolerance Analysisp. 296
Sensitivity Analysisp. 302
Robust Design by Analysisp. 305
Robust Design Through Testingp. 308
Summaryp. 313
Sourcesp. 313
Exercisesp. 314
Product Evaluation: Design For Cost, Manufacture, Assembly, and Other Measuresp. 315
Introductionp. 315
DFC-Design For Costp. 315
DFV-Design For Valuep. 325
DFM-Design For Manufacturep. 328
DFA-Design-For-Assembly Evaluationp. 329
DFR-Design For Reliabilityp. 350
DFT and DFM-Design For Test and Maintenancep. 357
DFE-Design For the Environmentp. 358
Summaryp. 360
Sourcesp. 361
Exercisesp. 361
On the Webp. 362
Wrapping Up the Design Process and Supporting the Productp. 363
Introductionp. 363
Design Documentation and Communicationp. 366
Supportp. 368
Engineering Changesp. 370
Patent Applicationsp. 371
Design for End of Lifep. 375
Sourcesp. 378
On the Webp. 378
Properties of 25 Materials Most Commonly Used in Mechanical Designp. 379
Introductionp. 379
Properties of the Most Commonly used Materialsp. 380
Materials Used in Common Itemsp. 393
Sourcesp. 394
Normal Probabilityp. 397
Introductionp. 397
Other Measuresp. 401
The Factor of Safety as a Design Variablep. 403
Introductionp. 403
The Classical RuIe-of-Thumb Factor of Safetyp. 405
The Statistical, Reliability-Based, Factor of Safetyp. 406
Sourcesp. 414
Human Factors in Designp. 415
Introductionp. 415
The Human in the Workspacep. 416
The Human as Source of Powerp. 419
The Human as Sensor and Controllerp. 419
Sourcesp. 426
Indexp. 427
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