An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

CHAPTER 2
Mechanical Design

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• Design is the process of translating a
new idea or a market need into the
detailed information from which a
product can be manufactured.

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Biomimicry in engineering
Biomimicry is an interdisciplinary design approach that provides
solutions to engineering problems by taking inspiration from
nature.
Biomimicry has similarities to biomimetics, which is the
“interdisciplinary cooperation of biology and technology or other
fields of innovation with the goal of solving practical problems.

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Biomimicry in design: Mosquito inspired
microneedle
• Mosquito proboscis is an ideal needle device which minimizes the
deformation and displacement of surrounding tissue during
insertion for accurate guidance to targeted vessels.

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Biomimicry in design: Bur seed inspired
velcro
• In 1941, a Swiss engineer named George
de Mestral was out hunting with his dog
when he realized small burrs from the
burdock plant were stuck to his dog’s hair.
• On closer inspection, he realized that
these tiny hooks and loops can be made
into clothing or garment fasteners which
led to the discovery of velcro.

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Biomimicry in design: Humpback Fins Inspired
more Efficient Wind Turbines
• When we think of reducing drag or increasing lift, we mostly picture
the smooth surface, but when researchers inspected the bumps on
the humpback whale fins, they discovered something rather
unlogical. The biomimetic model flippers reduced drag by 33% and
increased lift by 8%. Whale Power, Canada, has already implemented
them on their wind turbines and this has increased the efficiency by
over 40%.

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Biomimicry in design: Humpback Fins Inspired
more Efficient Wind Turbines

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Biomimicry in design: Slug Slime Inspired
Sticky Surgical Glue
• When the slug is scared, it releases a mucus which is so strong
that birds and other predators can’t pull this slug off of leaves,
even wet leaves.
• This inspired the scientists at Harvard’s Wyss Institute to create a
similar double-layered hydrogel surgical adhesive that has been
successfully tested on bloody pig hearts and other animal parts.

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 Order
Gathering information
Similar designs
Basic calculations
Customer requests
Sketchy drawings
Design

Operating mechanism
Production rate
Fasteners
Capacity
Sketch Approximate cost
drawing
Loading conditions
Vibration Abrasion
Corrosion etc. Lubrication
Service
Service temperature
conditions
Speed-acceleration Dimensions
analyses Tolerances
Stress analysis Detailed Service life of components
Surface texture drawings

Material
Heat treatment
Materials
selection Surface treatment

Trial
production

Production

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 Should the product be performance-
based or cost-based?
• Tennis racket: performance-based product
should be lightweight, ergonomic, rigid

Racket shaft under bending load

• Beverage can: cost-based product

should be cheap, available, formable

First five steps of

the forming process
of a beverage can.

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Design Process

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

1. Requirements Development
• Initially, a design engineer will develop a comprehensive
set of system requirements considering the following
issues:

• Functional performance – what the product must accomplish.

• Environmental impact – during production, use, and retirement.
• Manufacturing – resource and material limitations.
• Economic issues – budget, cost, price, profit.
• Ergonomic concerns – human factors, aesthetics, ease of use.
• Global issues – international markets, needs, and opportunities.
• Life cycle issues – use, maintenance, planned obsolescence.
• Social factors – civic, urban, cultural issues.

• These requirements essentially represent the constraints

that the design must eventually satisfy.

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1. Requirements Development:
Design of bicycles
• What is its function? (mountain bike? Racing bike?)
• Who will use it?
• What does it cost?
• How should be its appearance?
• Performance-based or cost-based?

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1. Requirements Development:
Design of beverage can
• Sealing
• Compliance with food standards! (materials selection)
• Pressure resistant
• Aesthetic appearance
• Easy to open
• Easy to carry and store
• Low-cost

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

2. Conceptual Design-Focus On: Innovation

• Innovation can help develop a

wide range of technologies to
provide better engineered
solutions.

• Considering different levels of

style and technology provides
a framework to strategically
develop innovative products
for a wide range of
customers.

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2. Conceptual Design-Focus On: Innovation

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2. Conceptual Design-Product Innovation
Product innovation is the introduction to the market by
making different and new changes on the existing
product.

Pizza scissors
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2. Conceptual Design-Product Innovation
Bag re-sealer

Cable drop clip

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2. Conceptual Design-Service Innovation

Introducing a new service approach or

significantly changing the existing
service is called service innovation.
Examples of service innovation
include:

• Ordering food online

• Bringing grocery shopping to your
door
• Broadcasting on the buses

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2. Conceptual Design-Process Innovation
The development of different methods in the production or
distribution of a product or the improvement of existing
methods is called process innovation. Examples of Process
Innovations include:

• Implementation of the production line method developed by

Ford, https://www.youtube.com/watch?v=7yT-k7IjZRk
• In today's manufacturing industry, the use of CNC Machines
in cases where it is necessary to remove cylindrical or
different forms of workpieces by means of cutting tools in
the areas we call machining
• When we look at the service sector, the implementation of
ATMs
• Starting to buy plane tickets, train tickets and bus tickets
online
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2. Conceptual Design-Marketing Innovation:
Renewing a product or its packaging with different
designs, using different marketing approaches or
developing existing approaches is called marketing
innovation. Marketing innovation encompasses all
innovation management activities that contribute to
supporting the market success of new products and
services.

Here, the product or service may be the same as

before, but the way it is presented to the consumer
may be very different. Examples of marketing
innovation include:
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Marketing Innovation:

• It can be counted among the most

successful examples of marketing
innovation: ready-to-assemble
furniture products.

• Marketing innovation example of

one of the cosmetics brands: Users
who want to buy cosmetics can see
their make-up digitally and refresh
their make-up on a product basis.

• Designing a bed model in the form

of a racing car for children can also
be an example of marketing
innovation.
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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

3. Detailed Design

• At this point in the design process, many design and

manufacturing details remain open, and each one must be
resolved in order to produce the hardware for the product.
• In the detailed design of the product, several issues must be
determined:

• Developing product layout and configuration

• Selecting materials for each component
• Optimizing the final geometry, including appropriate tolerances
• Developing completed digital models of all components and assemblies
• Simulating the system using digital and mathematical models
• Prototyping and testing critical components and modules
• Developing production plans

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Selection Strategy in Design

1.Translation: defines design requirements

(function), constraints, objective
2.Screening: eliminates candidates that
cannot do the job at all because one or
more of their attributes lies outside the
limits set by the constraints.
3.Ranking: orders the candidates with an
optimization criteria
4.Documentation: considers case studies
of use, and failure analyses

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

3. Detailed Design cont.

• In detailed design a number of “Design for X” issues must also
be addressed, including:

• Design for reliability,

• Design for manufacturing,
• Design for assembly,
• Design for variation,
• Design for costing,
• Design for recycling.

• Guiding principles in this stage are simplicity, iteration, and

usability.

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

The Importance of Documentation

• Engineers must diligently document the design process,
engineering drawings, written reports so that others will
understand the reasons behind each of the decisions made.
• A design notebook effectively captures the information and
knowledge created during a design process.
• Design notebooks also help support the process of patenting new
technology.
• Drawings, calculations, photographs, test data, and a listing of
the dates on which important milestones were reached are
important to accurately capture the development of an
invention.

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An Introduction to Mechanical Engineering, SI, Fourth Edition Number of
Patents Granted Percentag
in the United e Increase
Patents Country
Japan
States
54,170
from 2000
65%
Germany 16,605 53%
• Patents are a key aspect of the South Korea 15,745 353%
business side of engineering Taiwan 12,118 108%

because they provide legal Canada 7272 85%

China (PRC) 6597 3947%
protection to those who invent new France 6555 57%
technology. United 6551 60%

• Patents are one aspect of Kingdom

Israel 3152 277%
intellectual property, and they are a Italy 2930 49%
right to property, analogous to the Percentage
deed for a building or a parcel of Country
Increase from
2000
land. China (PRC) 3947%

• Patents are granted for a new and India 2900%

useful process, machine, article of Saudi Arabia

Poland
1158%
769%
manufacture, or composition of Malaysia 389%
matter or for an improvement of South Korea 353%

them. Czech Republic 329%

Israel 277%
Hungary 271%
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Singapore 254%
An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Utility Patents
• Most commonly encountered in mechanical engineering, the
utility patent protects the function of an apparatus, process,
product, or composition of matter.
• The utility patent generally contains three main components:

• The specification is a written description of the purpose,

construction, and operation of the invention
• The drawings show one or more versions of the invention
• The claims explain in precise language the specific features
that the patent protects.

• Utility patents become valid on the date the patent is granted,

and in the US, recently issued ones expire 20 years after the date
of the application.

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Patent and Utility Patents difference

• The most fundamental difference between a utility patent

and a patent is that while the invention step condition is
sought in the patent, in the utility patent is not sought.

• While the utility model is sought to be new and applicable to

the industry, it must also include an inventive step in order
for an invention to be patented.

• Protection period of utility patent documents is 10 years,

protection period of patent documents is 20 years.

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What Is Prototype Made For?
• To discover the interaction shortcomings and errors between the
product and the user,
• To easily compare different versions of the design,
• It is easier to collect comments due to the easy transfer of the idea
to the users,
• It can be used as a presentation tool and
can be a guide in complex products.

Prototyping is not a one-

step process. It's a cycle.

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What are the Advantages of Prototyping?
• Foreseeing mistakes saves time and money.
• It allows to organize the time scale and the next step by showing where you
are in the design processes.
• It is used in usability tests, renewed, redeveloped and thus continuous
improvement is ensured.
• Evaluation and feedback are central to interaction design.
• Users can interact with a prototype more easily.
• Unlike drawings and documents, they can hold it, see it, and test it if there
are working functions.
• It allows to see the whole system by combining the parts.
• Prototypes also increase connection and collaboration efficiency between
the design team, the manufacturing team and the marketing team.
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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Rapid Prototyping
• Rapid prototyping, 3D printing, and additive manufacturing enable complex
three-dimensional objects to be fabricated directly from a computer-
generated drawing, often in a matter of hours.
• Some rapid prototyping systems use lasers to fuse layers of a liquid polymer
together (a process known as stereolithography) or to fuse raw material in
powder form.
• Another prototyping technique moves a printhead to spray a liquid adhesive
onto a powder and “glue-up” a prototype bit-by-bit.

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Focus On: Global Design Teams

• Technological advances in simulation

and virtual prototyping are making
geographic separation between
product design teams irrelevant, as was
realized in the design and development
of the Boeing 787 Dreamliner.

• Virtual prototyping allows for new

prototypes to be created quickly at a
potentially greatly reduced cost

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 Focus On: Global Design Teams (cont.)

 Engineers can simulate and test many design scenarios at a

fraction of the cost, allowing for changes to be made rapidly.

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Production
• Once the detailed design has been completed, a designer will be
involved with the fabrication and production of the product.

• The fabrication techniques that an engineer selects will depend

on the time and expense of setting up the tooling and machines
necessary for production.

• Some systems—for instance, automobiles, air conditioners,

microprocessors, hydraulic valves, and computer hard disk
drives—are mass produced, a term that denotes the widespread
use of mechanical automation.

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Production cont.
The development of flexible
manufacturing systems
allows a production line to
quickly reconfigure to
different components for
different vehicles.

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Introduction to Manufacturing
• The desired shape of the products starts with the production of the
material, and it becomes usable after various design, production and
control stages.

Design, Material and Production

• One of the most debated issues for engineers is how much
mechatronics/manufacturing engineers should know about
manufacturing.
• The engineer is not the person who performs the production, it is
the machine operators who will carry out this work.
• The engineer, on the other hand, is able to manage and control the
production. However, in order to know what they are managing
and to be able to find solutions to problems on the bench, they
need to have a certain level of practical knowledge beyond
theoretical knowledge.
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Importance of Production

• Technologically

• Economically

• Historically

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Technological Importance of Production
• Technology – The application of science to provide
society and its members with what they need or want.

• Technology provides our society and its members with

products that help them live better.

• What do these products have in common?

– All manufactured

• Manufacturing is the key factor that makes technology

possible.

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Technological Importance of Production
• The application of physical or chemical processes to change the
geometry, properties and/or appearance of the starting material
to make parts or products.

• Manufacturing includes assembly.

• Most are implemented in a specific sequence of actions.

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Technological Importance of Production

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Economic Importance of Production

• Manufacturing is one way nations create material value.

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Economic Importance of Production
Conversion of materials into higher value parts through one or
more manufacturing and/or assembly processes.

Manufacturing adds value to a material by changing its shape or

properties, or by combining it with other materials.

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Historical Importance of Production

• Throughout history, human cultures that were better at

creating objects were more successful.

• Making things better meant making better tools and

weapons.
**Better gadgets made people live better
**Better weapons allowed them to outdo other cultures
in conflict situations.

• Importantly, the history of civilization is the history of man's

ability to make objects.

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The Role of Engineers in Manufacturing

Design engineer:
Purpose, needs, material selection, dimensions, manufacturing
method selection,

Manufacturing engineer:
Preparation for manufacturing method, material behavior, equipment
selection and coordination

Matters to consider:
Design, material selection, production method selection,
manufacturing and control

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 The Role of Engineers in Manufacturing
• Materials Selection Identification of needs
• Design • Shape and geometry of the part
• Manufacturing • Mechanical properties
• Evaluation • Physical properties
• Redesign • Other factors affecting the manufacturing
• Change method
• Relations with service and working conditions

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Importance of Production Quantity

The number of parts is one of the most effective factors

in deciding which production method a part should be
produced.

Short period production (1-100 units)

Medium period production (100-10,000)
Long-term production (10,000-millions)

The amount of product produced by a factory has a significant

impact on the organization of production procedures.

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Production Industries
Industry (industry) consists of establishments or organizations
that produce or provide goods and services.

Industry can be classified as follows:

1. Primary industries – those that generate or realize national

resources such as agriculture, mining

2. Secondary industries – those that take the outputs of

primary industries and convert them into consumer or
capital goods – manufacturing is the core activity.

3. Tertiary industries – service sector

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Production Industries (cont.)

• Secondary industries include manufacturing, construction and

electrical power generation.

• Manufacturing, products whose products do not fall within the

scope of mechanical engineering, e.g. It includes different sectors
such as consumption, chemicals and food processing.

• For us, manufacturing means the production of technical

equipment.
– Bolts and rivets, forged products, cars, airplanes, digital
computers, plastic parts and ceramic products etc.

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Summary
• Engineers reduce an open-ended problem into a sequence of
manageable steps:
• Defining system requirements,
• Conceptual design where concepts are generated and narrowed
down, and
• Detailed design where all the geometric, functional, and production
details of a product are developed.
• Engineering is ultimately a business venture, and you should
be aware of that broader context in which mechanical
engineering is practiced.
• In the end, successful design is a function of creativity,
elegance, usability, and cost.

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An Introduction to Mechanical Engineering, SI, Fourth Edition Wickert/Lewis

Summary cont.
• Throughout design, engineers use their judgment
and make order-of-magnitude calculations to move
ideas to concepts and concepts to detailed designs.

• Mechanical engineers also specify the methods

that will be used to produce hardware, and those
decisions are based on the quantity that will be
produced, the allowable cost, and the level of
precision necessary.

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