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Chapter 1 Engineering Design1

1.1 Introduction1

1.2 Engineering Design Process3

1.2.1 Importance of the Engineering Design Process4

1.2.2 Types of Designs5

1.3 Ways to Think About the Engineering Design Process6

1.3.1 A Simplified Iteration Model6

1.3.2 Design Method Versus Scientific Method8

1.3.3 A Problem-Solving Methodology10

1.4 Considerations of a Good Design14

1.4.1 Achievement of Performance Requirements14

1.4.2 Total Life Cycle17

1.4.3 Regulatory and Social Issues18

1.5 Description of Design Process19

1.5.1 Phase Ⅰ.Conceptual Design19

1.5.2 Phase Ⅱ.Embodiment Design20

1.5.3 Phase Ⅲ.Detail Design21

1.5.4 Phase Ⅳ.Planning for Manufacture22

1.5.5 Phase Ⅴ.Planning for Distribution23

1.5.6 Phase Ⅵ.Planning for Use23

1.5.7 Phase Ⅶ.Planning for Retirement of the Product23

1.6 Computer-Aided Engineering24

1.7 Designing to Codes and Standards26

1.8 Design Review29

1.8.1 Redesign30

1.9 Societal Considerations in Engineering Design31

1.10 Summary35

New Terms and Concepts36

Bibliography37

Problems and Exercises37

Chapter 2 Product Development Process39

2.1 Introduction39

2.2 Product Development Process39

2.2.1 Factors for Success43

2.2.2 Static Versus Dynamic Products46

2.2.3 Variations on the Generic Product Development Process46

2.3 Product and Process Cycles47

2.3.1 Stages of Development of a Product47

2.3.2 Technology Development and Insertion Cycle48

2.3.3 Process Development Cycle50

2.4 Organization for Design and Product Development51

2.4.1 A Typical Organization by Functions53

2.4.2 Organization by Projects54

2.4.3 Hybrid Organizations55

2.4.4 Concurrent Engineering Teams57

2.5 Markets and Marketing58

2.5.1 Markets59

2.5.2 Market Segmentation60

2.5.3 Functions of a Marketing Department63

2.5.4 Elements of a Marketing Plan63

2.6 Technological Innovation64

2.6.1 Invention，Innovation，and Diffusion64

2.6.2 Business Strategies Related to Innovation and Product Development67

2.6.3 Characteristics of Innovative People68

2.6.4 Types of Technology Innovation69

2.7 Summary71

New Terms and Concepts72

Bibliography72

Problems and Exercises73

Chapter 3 Problem Definition and Need Identification75

3.1 Introduction75

3.2 Identifying Customer Needs77

3.2.1 Preliminary Research on Customers Needs79

3.2.2 Gathering Information from Customers80

3.3 Customer Requirements86

3.3.1 Differing Views of Customer Requirements87

3.3.2 Classifying Customer Requirements89

3.4 Establishing the Engineering Characteristics91

3.4.1 Benchmarking in General93

3.4.2 Competitive Performance Benchmarking95

3.4.3 Reverse Engineering or Product Dissection96

3.4.4 Determining Engineering Characteristics97

3.5 Quality Function Deployment98

3.5.1 The House of Quality Configurations100

3.5.2 Steps for Building a House of Quality102

3.5.3 Interpreting Results of HOQ107

3.6 Product Design Specification109

3.7 Summary111

Bibliography113

New Terms and Concepts114

Problems and Exercises114

Chapter 4 Team Behavior and Tools116

4.1 Introduction116

4.2 What It Means to be an Effective Team Member117

4.3 Team Roles118

4.4 Team Dynamics119

4.5 Effective Team Meetings122

4.5.1 Helpful Rules for Meeting Success123

4.6 Problems with Teams124

4.7 Problem-Solving Tools126

4.7.1 Applying the Problem-Solving Tools in Design140

4.8 Time Management145

4.9 Planning and Scheduling146

4.9.1 Work Breakdown Structure147

4.9.2 Gantt Chart147

4.9.3 Critical Path Method149

4.10 Summary154

New Terms and Concepts155

Bibliography155

Problems and Exercises156

Chapter 5 Gathering Information158

5.1 The Information Challenge158

5.1.1 Your Information Plan159

5.1.2 Data，Information，and Knowledge160

5.2 Types of Design Information162

5.3 Sources of Design Information162

5.4 Library Sources of Information166

5.4.1 Dictionaries and Encyclopedias167

5.4.2 Handbooks169

5.4.3 Textbooks and Monographs169

5.4.4 Finding Periodicals169

5.4.5 Catalogs，Brochures，and Business Information171

5.5 Government Sources of Information171

5.6 Information From the Internet172

5.6.1 Searching with Google174

5.6.2 Some Helpful URLs for Design176

5.6.3 Business-Related URLs for Design and Product Development178

5.7 Professional Societies and Trade Associations180

5.8 Codes and Standards181

5.9 Patents and Other Intellectual Property183

5.9.1 Intellectual Property184

5.9.2 The Patent System185

5.9.3 Technology Licensing187

5.9.4 The Patent Literature187

5.9.5 Reading a Patent189

5.9.6 Copyrights191

5.10 Company-Centered Information192

5.11 Summary193

New Terms and Concepts194

Bibliography194

Problems and Exercises194

Chapter 6 Concept Generation196

6.1 Introduction to Creative Thinking197

6.1.1 Models of the Brain and Creativity197

6.1.2 Thinking Processes that Lead to Creative Ideas201

6.2 Creativity and Problem Solving202

6.2.1 Aids to Creative Thinking202

6.2.2 Barriers to Creative Thinking205

6.3 Creative Thinking Methods208

6.3.1 Brainstorming208

6.3.2 Idea Generating Techniques Beyond Brainstorming210

6.3.3 Random Input Technique212

6.3.4 Synectics：An Inventive Method Based on Analogy213

6.3.5 Concept Map215

6.4 Creative Methods for Design217

6.4.1 Refinement and Evaluation of Ideas217

6.4.2 Generating Design Concepts219

6.4.3 Systematic Methods for Designing221

6.5 Functional Decomposition and Synthesis222

6.5.1 Physical Decomposition223

6.5.2 Functional Representation225

6.5.3 Performing Functional Decomposition229

6.5.4 Strengths and Weaknesses of Functional Synthesis232

6.6 Morphological Methods233

6.6.1 Morphological Method for Design234

6.6.2 Generating Concepts from Morphological Chart236

6.7 TRIZ：The Theory of Inventive Problem Solving237

6.7.1 Invention：Evolution to Increased Ideality238

6.7.2 Innovation by Overcoming Contradictions239

6.7.3 TRIZ Inventive Principles240

6.7.4 The TRIZ Contradiction Matrix243

6.7.5 Strengths and Weaknesses of TRIZ247

6.8 Axiomatic Design249

6.8.1 Axiomatic Design Introduction249

6.8.2 The Axioms250

6.8.3 Using Axiomatic Design to Generate a Concept251

6.8.4 Using Axiomatic Design to Improve an Existing Concept253

6.8.5 Strengths and Weaknesses of Axiomatic Design257

6.9 Summary258

New Terms and Concepts259

Bibliography260

Problems and Exercises260

Chapter 7 Decision Making and Concept Selection262

7.1 Introduction262

7.2 Decision Making263

7.2.1 Behavioral Aspects of Decision Making263

7.2.2 Decision Theory266

7.2.3 Utility Theory269

7.2.4 Decision Trees273

7.3 Evaluation Methods274

7.3.1 Comparison Based on Absolute Criteria275

7.3.2 Pugh Concept Selection Method277

7.3.3 Measurement Scales280

7.3.4 Weighted Decision Matrix282

7.3.5 Analytic Hierarchy Process（AHP）285

7.4 Summary292

New Terms and Concepts294

Bibliography294

Problems and Exercises294

Chapter 8 Embodiment Design298

8.1 Introduction298

8.1.1 Comments on Nomenclature Concerning the Phases of the Design Process299

8.1.2 Oversimplification of the Design Process Model300

8.2 Product Architecture301

8.2.1 Types of Modular Architectures303

8.2.2 Modularity and Mass Customization303

8.2.3 Create the Schematic Diagram of the Product305

8.2.4 Cluster the Elements of the Schematic306

8.2.5 Create a Rough Geometric Layout307

8.2.6 Define Interactions and Determine Performance Characteristics308

8.3 Configuration Design309

8.3.1 Generating Alternative Configurations312

8.3.2 Analyzing Configuration Designs315

8.3.3 Evaluating Configuration Designs315

8.4 Best Practices for Configuration Design316

8.4.1 Design Guidelines317

8.4.2 Interfaces and Connections321

8.4.3 Checklist for Configuration Design324

8.4.4 Design Catalogs325

8.5 Parametric Design325

8.5.1 Systematic Steps in Parametric Design326

8.5.2 A Parametric Design Example：Helical Coil Compression Spring328

8.5.3 Design for Manufacture（DFM） and Design for Assembly（DFA）336

8.5.4 Failure Modes and Effects Analysis（FMEA）337

8.5.5 Design for Reliability and Safety337

8.5.6 Design for Quality and Robustness338

8.6 Dimensions and Tolerances338

8.6.1 Dimensions339

8.6.2 Tolerances340

8.6.3 Geometric Dimensioning and Tolerancing350

8.6.4 Guidelines for Tolerance Design355

8.7 Industrial Design356

8.7.1 Visual Aesthetics357

8.8 Human Factors Design358

8.8.1 Human Physical Effort359

8.8.2 Sensory Input361

8.8.3 Anthropometric Data364

8.8.4 Design for Serviceability364

8.9 Design for the Environment365

8.9.1 Life Cycle Design366

8.9.2 Design for the Environment（DFE）368

8.9.3 DFE Scoring Methods370

8.10 Prototyping and Testing370

8.10.1 Prototype and Model Testing Throughout the Design Process371

8.10.2 Building Prototypes372

8.10.3 Rapid Prototyping373

8.10.4 RP Processes374

8.10.5 Testing377

8.10.6 Statistical Design of Testing378

8.11 Design for X（DFX）380

8.12 Summary382

New Terms and Concepts382

Bibliography383

Problems and Exercises383

Chapter 9 Detail Design386

9.1 Introduction386

9.2 Activities and Decisions in Detail Design387

9.3 Communicating Design and Manufacturing Information391

9.3.1 Engineering Drawings391

9.3.2 Bill of Materials394

9.3.3 Written Documents395

9.3.4 Common Challenges in Technical Writing398

9.3.5 Meetings399

9.3.6 Oral Presentations400

9.4 Final Design Review402

9.4.1 Input Documents402

9.4.2 Review Meeting Process403

9.4.3 Output from Review403

9.5 Design and Business Activities Beyond Detail Design403

9.6 Facilitating Design and Manufacturing with Computer-Based Methods406

9.6.1 Product Lifecycle Management（PLM）407

9.7 Summary408

New Terms and Concepts408

Bibliography409

Problems and Exercises409

Chapter 10 Modeling and Simulation411

10.1 The Role of Models in Engineering Design411

10.1.1 Types of Models412

10.1.2 Iconic，Analog，and Symbolic Models413

10.2 Mathematical Modeling414

10.2.1 The Model-Building Process414

10.3 Dimensional Analysis423

10.3.1 Similitude and Scale Models425

10.4 Finite-Difference Method429

10.5 Geometric Modeling on the Computer432

10.6 Finite Element Analysis434

10.6.1 The Concept Behind FEA435

10.6.2 Types of Elements439

10.6.3 Steps in the FEA Process442

10.6.4 Current Practice444

10.7 Simulation446

10.7.1 Introduction to Simulation Modeling446

10.7.2 Simulation Programming Software447

10.7.3 Monte Carlo Simulation449

10.8 Summary452

New Terms and Concepts453

Bibliography454

Problems and Exercises454

Chapter 11 Materials Selection457

11.1 Introduction457

11.1.1 Relation of Materials Selection to Design458

11.1.2 General Criteria for Selection460

11.1.3 Overview of the Materials Selection Process460

11.2 Performance Characteristics of Materials461

11.2.1 Classification of Materials462

11.2.2 Properties of Materials463

11.2.3 Specification of Materials470

11.2.4 Ashby Charts471

11.3 The Materials Selection Process472

11.3.1 Design Process and Materials Selection474

11.3.2 Materials Selection in Conceptual Design476

11.3.3 Materials Selection in Embodiment Design476

11.4 Sources of Information on Materials Properties478

11.4.1 Conceptual Design479

11.4.2 Embodiment Design479

11.4.3 Detail Design482

11.5 Economics of Materials482

11.5.1 Cost of Materials482

11.5.2 Cost Structure of Materials485

11.6 Overview of Methods of Materials Selection486

11.7 Selection with Computer-Aided Databases487

11.8 Material Performance Indices488

11.8.1 Material Performance Index489

11.9 Materials Selection with Decision Matrices494

11.9.1 Pugh Selection Method495

11.9.2 Weighted Property Index496

11.10 Design Examples499

11.11 Recycling and Materials Selection503

11.11.1 Benefits from Recycling504

11.11.2 Steps in Recycling504

11.11.3 Design for Recycling506

11.11.4 Material Selection for Eco-attributes508

11.12 Summary510

New Terms and Concepts511

Bibliography512

Problems and Exercises512

Chapter 12 Design with Materials515

12.1 Introduction515

12.2 Design for Brittle Fracture516

12.2.1 Plane Strain Fracture Toughness518

12.2.2 Limitations on Fracture Mechanics522

12.3 Design for Fatigue Failure523

12.3.1 Fatigue Design Criteria524

12.3.2 Fatigue Parameters525

12.3.3 Information Sources on Design for Fatigue528

12.3.4 Infinite Life Design529

12.3.5 Safe-Life Design Strategy531

12.3.6 Damage-Tolerant Design Strategy536

12.3.7 Further Issues in Fatigue Life Prediction538

12.4 Design for Corrosion Resistance539

12.4.1 Basic Forms of Corrosion539

12.4.2 Corrosion Prevention541

12.5 Design Against Wear544

12.5.1 Types of Wear544

12.5.2 Wear Models546

12.5.3 Wear Prevention547

12.6 Design with Plastics549

12.6.1 Classification of Plastics and Their Properties549

12.6.2 Design for Stiffness552

12.6.3 Time-Dependent Part Performance553

12.7 Summary555

New Terms and Concepts556

Bibliography556

Problems and Exercises556

Chapter 13 Design for Manufacturing558

13.1 Role of Manufacturing in Design558

13.2 Manufacturing Functions560

13.3 Classification of Manufacturing Processes562

13.3.1 Types of Manufacturing Processes563

13.3.2 Brief Description of the Classes of Manufacturing Processes564

13.3.3 Sources of Information on Manufacturing Processes565

13.3.4 Types of Manufacturing Systems565

13.4 Manufacturing Process Selection568

13.4.1 Quantity of Parts Required569

13.4.2 Shape and Feature Complexity573

13.4.3 Size576

13.4.4 Influence of Material on Process Selection577

13.4.5 Required Quality of the Part579

13.4.6 Cost to Manufacture583

13.4.7 Availability，Lead Time，and Delivery586

13.4.8 Further Information for Process Selection586

13.5 Design for Manufacture（DFM）593

13.5.1 DFM Guidelines594

13.5.2 Specific Design Rules597

13.6 Design for Assembly（DFA）597

13.6.1 DFA Guidelines598

13.7 Role of Standardization in DFMA601

13.7.1 Benefits of Standardization601

13.7.2 Achieving Part Standardization603

13.7.3 Group Technology603

13.8 Mistake-Proofing606

13.8.1 Using Inspection to Find Mistakes606

13.8.2 Frequent Mistakes607

13.8.3 Mistake-Proofing Process608

13.8.4 Mistake-Proofing Solutions609

13.9 Early Estimation of Manufacturing Cost610

13.10 Computer Methods for DFMA617

13.10.1 DFA Analysis617

13.10.2 Concurrent Costing with DFM620

13.10.3 Process Modeling and Simulation624

13.11 Design of Castings624

13.11.1 Guidelines for the Design of Castings626

13.11.2 Producing Quality Castings627

13.12 Design of Forgings629

13.12.1 DFM Guidelines for Closed-Die Forging631

13.12.2 Computer-Aided Forging Design632

13.13 Design for Sheet-Metal Forming633

13.13.1 Sheet Metal Stamping633

13.13.2 Sheet Bending634

13.13.3 Stretching and Deep Drawing635

13.13.4 Computer-Aided Sheet Metal Design637

13.14 Design of Machining637

13.14.1 Machinability640

13.14.2 DFM Guidelines for Machining640

13.15 Design of Welding643

13.15.1 Joining Processes643

13.15.2 Welding Processes643

13.15.3 Welding Design646

13.15.4 Cost of Joining649

13.16 Residual Stresses in Design650

13.16.1 Origin of Residual Stresses650

13.16.2 Residual Stress Created by Quenching652

13.16.3 Other Issues Regarding Residual Stresses654

13.16.4 Relief of Residual Stresses656

13.17 Design for Heat Treatment656

13.17.1 Issues with Heat Treatment657

13.17.2 DFM for Heat Treatment658

13.18 Design for Plastics Processing659

13.18.1 Injection Molding659

13.18.2 Extrusion660

13.18.3 Blow Molding661

13.18.4 Rotational Molding661

13.18.5 Thermoforming661

13.18.6 Compression Molding661

13.18.7 Casting662

13.18.8 Composite Processing662

13.18.9 DFM Guidelines for Plastics Processing663

13.19 Summary664

New Terms and Concepts666

Bibliography666

Problems and Exercises666

Chapter 14 Risk，Reliability，and Safety669

14.1 Introduction669

14.1.1 Regulation as a Result of Risk671

14.1.2 Standards672

14.1.3 Risk Assessment673

14.2 Probabilistic Approach to Design674

14.2.1 Basic Probability Using the Normal Distribution675

14.2.2 Sources of Statistical Tables677

14.2.3 Frequency Distributions Combining Applied Stress and Material Strength677

14.2.4 Variability in Material Properties679

14.2.5 Probabilistic Design682

14.2.6 Safety Factor684

14.2.7 Worst-Case Design685

14.3 Reliability Theory685

14.3.1 Definitions688

14.3.2 Constant Failure Rate688

14.3.3 Weibull Frequency Distribution690

14.3.4 Reliability with a Variable Failure Rate692

14.3.5 System Reliability696

14.3.6 Maintenance and Repair699

14.3.7 Further Topics700

14.4 Design for Reliability701

14.4.1 Causes of Unreliability703

14.4.2 Minimizing Failure703

14.4.3 Sources of Reliability Data706

14.4.4 Cost of Reliability706

14.5 Failure Mode and Effects Analysis（FMEA）707

14.5.1 Making a FMEA Analysis710

14.6 Defects and Failure Modes712

14.7.1 Causes of Hardware Failure713

14.7.2 Failure Modes713

14.7.3 Importance of Failure715

14.7 Design for Safety715

14.9.1 Potential Dangers716

14.9.2 Guidelines for Design for Safety717

14.9.3 Warning Labels718

14.8 Summary718

New Terms and Concepts719

Bibliography719

Problems and Exercises720

Chapter 15 Quality，Robust Design，and Optimization723

15.1 The Concept of Total Quality723

15.1.1 Definition of Quality724

15.1.2 Deming’s 14 Points725

15.2 Quality Control and Assurance726

15.2.1 Fitness for Use726

15.2.2 Quality-Control Concepts727

15.2.3 Newer Approaches to Quality Control729

15.2.4 Quality Assurance729

15.2.5 ISO 9000730

15.3 Quality Improvement730

15.3.1 Pareto chart731

15.3.2 Cause-and-Effect Diagram732

15.4 Process Capability734

15.4.1 Six Sigma Quality Program738

15.5 Statistical Process Control739

15.5.1 Control Charts739

15.5.2 Other Types of Control Charts742

15.5.3 Determining Process Statistics from Control Charts743

15.6 Taguchi Method743

15.6.1 Loss Function744

15.6.2 Noise Factors747

15.6.3 Signal-to-Noise Ratio748

15.7 Robust Design749

15.7.1 Parameter Design749

15.7.2 Tolerance Design755

15.8 Optimization Methods755

15.8.1 Optimization by Differential Calculus758

15.8.2 Search Methods762

15.8.3 Nonlinear Optimization Methods767

15.8.4 Other Optimization Methods770

15.9 Design Optimization772

15.10 Summary774

New Terms and Concepts775

Bibliography775

Problems and Exercises775

Chapter 16 Cost Evaluation779

16.1 Introduction779

16.2 Categories of Costs780

16.3 Overhead Cost784

16.4 Activity-Based Costing787

16.5 Methods of Developing Cost Estimates789

16.5.1 Analogy790

16.5.2 Parametric and Factor Methods790

16.5.3 Detailed Methods Costing791

16.6 Make-Buy Decision795

16.7 Manufacturing Cost796

16.8 Product Profit Model797

16.8.1 Profit Improvement801

16.9 Refinements to Cost Analysis Methods802

16.9.1 Cost Indexes802

16.9.2 Cost-Size Relationships803

16.9.3 Learning Curve805

16.10 Design to Cost808

16.10.1 Order of Magnitude Estimates809

16.10.2 Costing in Conceptual Design809

16.11 Value Analysis in Costing811

16.12 Manufacturing Cost Models814

16.12.1 Machining Cost Model814

16.13 Life Cycle Costing818

16.14 Summary822

New Terms and Concepts823

Bibliography823

Problems and Exercises823

Chapter 17 Legal and Ethical Issues in Engineering Design（see www.mhhe.com/dieter）828

17.1 Introduction828

17.2 The Origin of Laws829

17.3 Contracts830

17.3.1 Types of Contracts830

17.3.2 General Form of a Contract831

17.3.3 Discharge and Breach of Contract832

17.4 Liability833

17.5 Tort Law834

17.6 Product Liability835

17.6.1 Evolution of Product Liability Law836

17.6.2 Goals of Product Liability Law836

17.6.3 Negligence837

17.6.4 Strict Liability837

17.6.5 Design Aspect of Product Liability838

17.6.6 Business Procedures to Minimize Risk of Product Liability839

17.6.7 Problems with Product Liability Law839

17.7 Protecting Intellectual Property840

17.8 The Legal and Ethical Domains841

17.9 Codes of Ethics843

17.9.1 Profession of Engineering844

17.9.2 Codes of Ethics844

17.9.3 Extremes of Ethical Behavior848

17.10 Solving Ethical Conflicts848

17.10.1 Whistleblowing850

17.10.2 Case Studies851

17.11 Summary852

New Terms and Concepts854

Bibliography854

Problems and Exercises855

Chapter 18 Economic Decision Making（see www.mhhe.com/dieter）858

18.1 Introduction858

18.2 Mathematics of Time Value of Money859

18.2.1 Compound Interest859

18.2.2 Cash Flow Diagram861

18.2.3 Uniform Annual Series862

18.2.4 Irregular Cash Flows865

18.3 Cost Comparison867

18.3.1 Present Worth Analysis867

18.3.2 Annual Cost Analysis869

18.3.3 Capitalized Cost Analysis870

18.3.4 Using Excel Functions for Engineering Economy Calculation872

18.4 Depreciation872

18.4.1 Straight-Line Depreciation873

18.4.2 Declining-Balance Depreciation874

18.4.3 Sum-of-Years-Digits Depreciation874

18.4.4 Modified Accelerated Cost Recovery System（MACRS）874

18.5 Taxes876

18.6 Profitability Of Investments880

18.6.1 Rate of Return880

18.6.2 Payback Period882

18.6.3 Net Present Worth882

18.6.4 Internal Rate of Return883

18.7 Other Aspects of Profitability887

18.8 Inflation888

18.9 Sensitivity and Break-Even Analysis891

18.10 Uncertainty in Economic Analysis892

18.11 Benefit-Cost Analysis894

18.12 Summary896

New Terms and Concepts898

Bibliography898

Problems and Exercises898