Product Development

Detail Design

Carlos Andrés Miranda 1

Detail Design

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 Detail Design

Concept System-Level Detail Testing and Production

Planning Development Design Design Refinement Ramp-Up

▪ Detail design is the phase where all of the details are brought together, all decisions are
finalized, and a decision is made by management to release the design for production.

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Detail Design
The detail design phase includes the complete specification of the geometry, materials, and
tolerances of all of the unique parts in the product and the identification of all of the standard parts
to be purchased from suppliers.

A process plan is established and tooling is designed for each part to be fabricated within the
production system.

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The output of this phase is the control documentation for the product—the drawings or computer
files describing the geometry of each part and its production tooling, the specifications of the
purchased parts, and the process plans for the fabrication and assembly of the product.

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Detail Design

Models Engineering Bill of

• Physical Drawings Materials
• Analytical • Parts • For drawings
• Assemblies • For Project

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Detail Design
Bill of materials

The Bill Of Materials (BOM), or parts list, is like an index to the product.

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Detail Design
Bill of materials

The bill of materials (BOM) or the parts list is a list of each individual component in the product.

It lists the part description, quantity needed for a complete assembly, part number, the source of
the part, and purchase order number if outsourced to a supplier.

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Detail Design
Bill of materials

1. The item number or letter: This is a key to the components on the BOM.

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Detail Design
Bill of materials

2. The part number: This is a number used throughout the purchasing, manufacturing, inventory
control, and assembly systems to identify the component.

Numbering systems vary greatly from company to company. Some are designed to have context, the
part number indicates something about the part’s function or assembly. Most are simply a
sequential number assigned to the part.

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Detail Design
Bill of materials

3. The quantity needed in the assembly.

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Detail Design
Bill of materials

4. The name or description of the component: This must be a brief, descriptive title for the
component.

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Detail Design
Bill of materials

5. The material from which the component is made: If the item is a subassembly, then this does not
appear in the BOM.

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Detail Design
Bill of materials

6. The source of the component: If the component is purchased, the name of the company is listed.
If the component is made in-house, this line can be left blank.

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Detail Design
Bill of materials

The bill of materials has many uses:

• It is essential for determining the cost of the product.

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Detail Design
Bill of materials

The bill of materials has many uses:

• It is essential for determining the cost of the product.

• The bill of materials is vital for tracking the parts during manufacture and assembly.

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Detail Design
Bill of materials

The bill of materials has many uses:

• It is essential for determining the cost of the product.

• The bill of materials is vital for tracking the parts during manufacture and assembly.

• It is an important archival document for the design that needs to be preserved and be available
for retrieval.

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Detail Design
Bill of materials

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Detail Design
Bill of materials

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Detail Design
Models

Progress in a design project is measured by deliverables such as drawings, prototypes, bills of

materials, results of analysis, test results, and other representations of the information
generated in the project.

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Detail Design
Models

Progress in a design project is measured by deliverables such as drawings, prototypes, bills of

materials, results of analysis, test results, and other representations of the information
generated in the project.

These deliverables are all models of the final product.

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Detail Design
Models

During product development, many models are made of the evolving product.

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Detail Design
Models

During product development, many models are made of the evolving product.

Some of these models are

• analytical models—quick calculations on a bit of paper or complex computer simulations;
• graphical representations—simple sketches or orthographic mechanical drawings;
• CAD solid models;
• physical models—prototypes.

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Detail Design
Models

Looks-like model for customer Wheel prototype under load

communication and approval during creep testing

Sand test 26
Detail Design
Models

3D CAD rendering Finite-element analysis

Mathematical model 27
Dynamic simulation model
Detail Design
Models

Uses:

• Learning
• answering questions about performance or feasibility
• e.g., proof-of-concept model

• Communication
• demonstration of product for feedback
• e.g., 3D physical models of style or function

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Detail Design
Models

Uses:

• Integration
• combination of sub-systems into system model
• e.g., alpha or beta test models

• Milestones
• goal for development team’s schedule
• e.g., first testable hardware

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Detail Design
Physical Alpha Prototype for
System Integration
Wheel Impact Test
Models Gripper Geometry and Pad System-Level
Drop Test
Beta Prototype
for Field Testing
Coating Pull Test
Testbed with New Software
on Old Model
Full-Scale Foam Model

Focused Comprehensive
User Interface Hardware Linked
to Dynamic Simulation

Color Rendering
3-D CAD Model Not
Beam Bending Equations of
Generally
Wheel Spoke Geometry Full Dynamic Feasible
FEA of Heat Dissipation Simulation
Math Model of Motor
Performance Analytical

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Models – Physical models

Physical models of products are often called prototypes.

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Detail Design
Models – Physical models

The four purposes for prototypes are

• proof-of-concept,
• proof-of-product,
• proof-of-process,
• and proof-of-production.

Solid models in CAD systems can often replace these prototypes with less cost and time.

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Detail Design
Models – Physical models

A proof-of-concept, or proof-of-function prototype focuses on developing the function of the

product for comparison with the customers’ requirements or engineering specifications.

This kind of prototype is intended as a learning tool, therefore, exact geometry, materials, and
manufacturing process are usually not important.

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Detail Design
Models – Physical models

A proof-of-product prototype is developed to help refine the components and assemblies.

Geometry, materials, and manufacturing process are as important as function for these prototypes.

The development of rapid prototyping has greatly improved the time and cost efficiency of building
proof-of-product prototypes.

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Detail Design
Models – Physical models

A proof-of-process prototype is used to verify both the geometry and the manufacturing process.

For these prototypes, the exact materials and manufacturing processes are used to manufacture
samples of the product for functional testing.

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Detail Design
Models – Physical models

A proof-of-production prototype is used to verify the entire production process.

This prototype is the result of a preproduction run, the products manufactured just prior to
production for sale.

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Detail Design
Models – Analytical models

Often the level of approximation of an analytical model is referred to as its fidelity.

Fidelity is a measure of how well a model or simulation analysis represents the state and behavior
of a real-world object.

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Detail Design
Models – Analytical models

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Detail Design
Models – Analytical models

Engineering courses teach first principles in subjects like statics, dynamics, mechanics of materials,
fluids, and thermodynamics by describing a physical system and its immediate environment in a
complex word problem that you learned to solve using a variety of analytical, logical, mathematical,
and empirical methods.

The key to finding a solution is to understand the mathematical model appropriate for the problem.

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Detail Design
Models – Analytical models

A steady-state model is one in which the input variables and their properties do not change with
time.

In a dynamic (transient) model the parameters change with time.

Models based on continuous media, such as solids or fluids, assume that the medium transmitting a
stress or flow vector does not contain voids or holes, while a discrete model deals with individual
entities, such as cars in a traffic model or digital packets in a wireless transmission.

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Models – Analytical models

The following is a listing of the general steps required to build a mathematical design model.

Step 1. Determine problem statement

Step 2. Define the boundaries of the model

Step 3. Determine which physical laws are pertinent to the problem and identify the data that is
available to support building the model

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Models – Analytical models

The following is a listing of the general steps required to build a mathematical design model.

Step 4. Identify assumptions

Step 5. Construct the model

Step 6. Perform computations and verify the model

Step 7. Validate the model

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Detail Design
Models – Analytical models

Step 1. Determine problem statement

• Determine the purpose of the model, its inputs and desired outputs.
• Write out the questions that you expect the model to help you answer.
• Determine the desired inputs and outputs of the model.

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Models – Analytical models

Step 2. Define the boundaries of the model

• The boundary of the design problem distinguishes a part of the model from the model’s
environment. The boundaries of the model are often called the control volume.

• The control volume can be drawn either as a finite control volume, which defines the overall
system behavior, or a differential control volume at some point in the system.

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Models – Analytical models

Step 3. Determine which physical laws are pertinent to the problem and identify the data that is
available to support building the model

• With all the thought that has gone into defining the problem, we should now know what physical
knowledge domain(s) we will use to represent the physical situation.

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Models – Analytical models

Step 4. Identify assumptions

• Remember that design modeling is always a balance between the necessary resources and the
required precision of outputs.

• Some common modeling simplifications are: (1) neglecting changes in physical and mechanical
properties with temperature, (2) starting with a two-dimensional model when it is really a 3-D
problem, (3) replacing the distributed properties of a variable with “lumped” parameters, (4)
assuming a linear model when most realworld behavior is nonlinear.

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Models – Analytical models

Step 5. Construct the model

• Usually the analytical description of the model starts with either appropriate conservation laws,
like the conservation of energy, or balance equations like the summation of the forces and
moments equal zero.

• A helpful first step in building the model is to make a careful sketch of the physical elements of
the problem.

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Models – Analytical models

Step 6. Perform computations and verify the model

• For simple models hand calculators will suffice, but spreadsheet computation is often very
helpful.

• The model needs to be tested to see that it contains no mathematical errors and gives
reasonable answers

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Models – Analytical models

Step 7. Validate the model

• Validation is checking to see if the model gives an accurate representation of the real world.

• A common way to validate a model is to vary the inputs over a wide range to see if the
outputs of the model appear to be physically reasonable, especially at the limits of
performance.

• Find how sensitive the outputs are to the inputs.

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Models – Analytical models

Aids to mathematical models

Dimensional Analysis: There are usually fewer dimensionless groups than there are physical
quantities in the problem, so the groups become the real variables of the problem.

The importance of dimensional analysis is that it allows you to express a problem with a minimum
number of design variables.

Also, representing a complex phenomenon in a concise way can make difficult problems
understandable.

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Models – Analytical models

Aids to mathematical models

Similitude: Scale models are often used in design because they can be made more quickly and at
less cost.

By similitude we mean the condition of physical response is similar between the model and the
prototype.

There are several forms of similitude: geometric, kinematic (similar velocities), and dynamic (similar
forces). Geometric similarity is the form most usually encountered in product design.

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Example

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Example

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Graphical models and CAD

The graphical models are not only the preferred form of data communication for the designer, they
are also a necessary part of the design process.

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Detail Design
Graphical models and CAD

The graphical models are not only the preferred form of data communication for the designer, they
are also a necessary part of the design process.

The development of the drawings is synergistic with the evolution of the product geometry and
further refinement of its function. As drawings are produced, more knowledge about the product is
developed.

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Detail Design
Graphical models and CAD

Sketches.

Sketching as a form of drawing is an extension of the short-term memory needed for idea
generation.

As the shape of components and assemblies evolve, drawings that are more formal are used to keep
the information organized and easily communicated to others.

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Graphical models and CAD

Sketches.

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Graphical models and CAD

Layout drawings.

A layout drawing is a working document that supports the development of the major components
and their relationships.

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Graphical models and CAD

Layout drawings.

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Graphical models and CAD

Layout drawings.

• A layout drawing is a working drawing and as such is frequently changed during the design
process.
• A layout drawing is made to scale.
• Only the important dimensions are shown on a layout drawing.
• Tolerances are usually not shown, unless they are critical.
• Notes on the layout drawing are used to explain a design feature or the function of the product.

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Detail Design
Graphical models and CAD

Detail drawings.

The historical goal of detail design has been to produce drawings that contain the information
needed to manufacture the product.

These drawing should be so complete that they leave no room for misinterpretation.

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Detail Design
Graphical models and CAD

Detail drawings. The information on a detail drawing includes:

• Standard views of orthogonal projection—top, front, side views

• Auxiliary views such as sections, enlarged views, or isometric views that aid in visualizing the
component and clarifying the details
• Dimensions—presented according to the standards
• Tolerances
• Material specification, and any special processing instructions
• Manufacturing details, such as parting line location, draft angle, surface finish

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Models – Choosing the best models

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