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MECHANICAL
ENGINEERING DESIGN
(MEC332)
Chapter
Chapter 5:
5:
Detail
Detail Design
Design

By:
Firdaus Sukarman
Fakulti Kejuruteraan Mekanikal
UiTM Pasir Gudang, Johor
 Lesson Outcome

 At the end of this session, students should be

able to:
 Understand the activities and decisions in detail
design.
 Understand the process of modeling and
simulation in design.
Contents

1 Activities and Decision in Detail Design

2 Modelling and Simulation

4
 Definition and Concept of Mech.
Design
 In engineering, information needs to be
passed on through drawings.
 The analysis, manufacturing and assembly
of the product is based on drawings.
 The objectives of the drawings:
 Drawings are preferred form of data
communications in engineering.
 Used to communicate the ideas between the
designers and between the designers and
manufacturing personnel.
 Simulate the operation of the product.
 Used to check for the completeness of the
product.
3 types of drawings:
1) sketches (layout drawing)
 Generated during conceptualization stage.
 They are working documents that support the
development of the major components and their
relations.
 They are made to scale but only the important
dimensions are shown.
 Tolerance are usually not shown
2. Detail drawing
 The important characteristic of a detail drawings:
• All dimensions must be tolerance.
• Materials and manufacturing detail must be clear
and presented in specific language.
 These drawings are made by CAD system such as
solidwork, AutoCAD, ProEngineer etc.
3. Assembly drawing
 The goal of assembly drawing is to show how
components fit together.
 The characteristics of assembly drawing:
• Each component is identified with a number
referenced to a list of all components.
• Necessary, detailed views are included to explain
information that is not clear in other view.
 Bill of Material

 BOM is an index of the parts that were used in the product.

 The information should be included in BOM:
 The item number:
• This is a key to the components on the assembly
drawings.
 The part number:
• This is a number used throughout the purchasing,
manufacturing and assembly system to identify the
component.
 The quantity needed in the assembly
 The name and description of the component
 The material from which the component is made.
 The source of the component. (which company??)
 The cost of the individual component.
 The experimental phase of the engineering
design requires the transformation of paper
drawings into hardware, which is
constructed and tested to verify the
concept’s workability.
 Four construction techniques are available
for designers:
1) Mock-up
• This is generally constructed to scale from plastics,
woods, cardboard to give the designer the feel for the
design.
• Used to check the clearance, assembly techniques,
manufacturing considerations and appearance.
• Least expensive.
• A solid model in the CAD system can replace the
mock-up.
• Mock-ups are referred to as a proof of concept
prototype.
2) Modelling
 It relates the physical behavior of the system through mathematical
similitude.
 Referred to as a proof of product prototype.
 3 different types of models used to predict the behavior of a real
system:
• True
» An exact geometric reproduction of a real system, built to
scale and satisfying all the constraints imposed by design
parameter.
• Adequate
» Constructed to test specific characteristics of the design and
is not intended to yield information of total design
• Distorted
» Purposely violates one or more design conditions.
» Required when it is difficult or impossible to satisfy the
specific conditions
3) Prototype
 The most expensive construction technique.
 Produces the greatest amount of useful information.
 The prototype is constructed, full-scale working physical
system.
 Prototype can be comprehensive or focused.
 Comprehensive corresponds to a full-scale, fully
operational version of a whole product.
 Focused corresponds to one or a few of the product
elements.
4) Virtual prototyping
 CAD and CAE
 Solid modelling has enabled the use of geometry to
visualize product models quickly and to detect gross
interference problems.
 Able to automate design changes.
 Parametric modelling allows the presentation of
dimensions of the parts in term of parameters.
 Visual prototyping can have its biggest payoff in
manufacturing and analysis.
 Analysis

 Once the product is well defined, a complete analysis is

conducted.
 In analysis, you need to evaluate the integrity of the
design in terms of its safety concerns, material
selection that fits the requirement and compute the cost
involved.
 Analysis proceeds as follows:
1) Check for the design safety in terms of computing the forces
that act on each component. Evaluate the stresses associated
with these components. Then list the materials that would
satisfy the stress requirements. CAE software can be used to
perform the stress analysis.
2) Manufacturability of the components needs to be checked.
Having a sketch of a component does not mean that the
machinist able to produce the component. Need to provide the
drawing to machinist.
3) Cost analysis of the components. You will be
able to vary among components listed in
morphological chart if certain components are
cost effective or fit the product better.
4) The aesthetics or the look of the product needs to
be maintained. Several customer surveys have
shown that customers value the look of the
product much more highly than its performance.
 Design for manufacturing (DFM)

 Design for manufacturing (DFM) is based on

minimizing the cost of production including
minimizing the time to market while maintaining
a high standard of quality for the product.
 DFM provides guidance in the selection of
materials and processes and generates piece
part and tooling cost estimates at any stage of
product design.
 There are several methods that have been
used in DFM to assess in analysis such as
process-driven design, failure mode and effect
analysis (FMEA), Taguchi method, design of
experiment (DOE).
 Design for Assembly (DFA)

 Design for assembly is the study of the ease of

assembling various parts and components into a
final product.
 A lower number of parts and an ease of assembly
contribute to reducing the overall cost of the product.
 With DFA, every part has to be checked. It must be
determined if it is a necessary part or would it be
better integrated into other parts or be replaced by a
similar function part that is simpler and costs less.
 Integrating both DFM and DFA helps contribute to
the competitive success of any given product by
matching that product’s demands to its
manufacturability and assembly capabilities.
 Design for Environment

 Design for environment is often called green

design, environmentally conscious design,
life-cycle design or design for recyclability.
 When a product’s useful life is over, one of
three things happens to its components:
 Disposed
 Reused
 Recycled
 3 factors contributed to design for
environment:
 Economics
 Customer expectation
 Government regulation
1) economic
 It is less expensive to recycle some material than it is
to pay the expense of processing new raw materials.
 Especially for the product that it is easily disassembled
into components made of single material.

2) customer expectation
 Consumers are increasingly more environmentally
conscious and aware of the value of recycling.
 Thus, company that produce the product that affect
the environment, are looked down by the public.

3) Government regulation
 Government regulation is forcing attention on the
environment.
 References

1. Rozaini Othman, Lecture Notes, MEC332

2. Engineering Design,G.E. Dieter and Linda C.
Schmidt, 4th Edition, McGraw-Hill, 2009.
3. D. G. Ullman, The Mechanical Design Process,
3rd edition, McGraw-Hill, 2003.
4. Machine Design, R-S-Khurmi-J-K-Gupta-S-
chand, 2005
5. S. Laguette, Lecture Notes, “Introduction to
Mechanical Engineering Design, ME 153”
Spring 2010
6. Wikipedia
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