Lecture Series

on
Engineering Analysis and Design
By

Dr. Sarbjit Singh, (Mech.)

PEC University of Technology.
Flat Earth Society
People/Engineers who do not take care of optimum
utilisation of resources and water resources take
world flat, that is infinite and never ending. A round
world is convergent and constant and will have
limited resources, but a flat world will be non-
convergent and will be infinite and so shall have
infinite resources.
The word ‘engineer’
• Comes from the French word ‘ingenieur’ which
literally means ‘an ingenious one’ and ‘engine’.
• Both of which come from the Latin root in
generare meaning to create.
A professional engineer
Has been specially trained to use his powers of:-
• Observation
• Curiosity
• Experience
• Creativity
To solve the problems which others have failed to solve.
Scientist vs engineer
An engineer is a man who
A scientist is a man uses the earth and tries to
who weighs the capture the sun’s energy
earth and ascertains more effectively. he controls
the temperature of the rate of destruction of
the sun. He destroys matter and tries to find
matter and invents alternative sources of energy
new forms of matter and new materials. he
and one day he will invents new shapes of matter
invent new forms of and strives to improve the
life. quality of life in whatever
form he finds it.
Science has history of 300 years

Engineering can be traced back to B.C. years.

When primitive men tied logs together with reed ropes
to make rafts and soon learned to harness the wind by
putting masts and sails on them.
Design
• 1. To prepare the preliminary sketch or the plans for a work
to be executed. 2. To plan form and structure of. [Random
House Dictionary]
• Design is a general activity of human progress, and
particularly for the satisfaction of recognized needs. [Hubka,
1982]
• [To design is] to decide what the customer requires, decide
what product will meet the customer’s needs and provide all
the instructions that will enable the manufacturer to make the
product. [Leech, 1973]
Design
• ..seeds of human future. [Jones, 1970]
• .. relating product with situation to give satisfaction.
[Gregory, 1966]
• ..decision-making in the face of uncertainty with a
high penalty for errors. [Asimow, 1962]
• .. a goal directed problem solving activity. [Archer,
1965]
Design
• .. an iterative decision-making activity to produce plans by
which resources are converted into systems or devices,
preferably optimally, to meet human needs. [Woodson, 1966]
• Design [is] the creation of synthesized solutions in the form of
products, processes or systems that satisfy perceived needs.
[Suh, 1990]
• the optimum solution to the sum of the true needs of a
particular set of circumstances. [Matchet and Briggs]
What is design?
Keywords:
• it is a prescriptive activity,
• it is need oriented,
• it is iterative,
• it is concerned with optimality,
• it has to satisfy constraints.
Definition of Design

Design is an iterative process concerned with

generating ideas and prescribing ways to turn into
reality these ideas to satisfy optimally, under the
relevant constraints, some specified or perceived needs.
What does an engineer do?
Increasing Abstraction

Increasing Practicality
Sales Engineering

Production & Maintenance

DESIGN
Development

Engineering Research
Design by Evolution
Evolution in nature.
Craft Evolution
• Designs tend to evolve over long spans of time.
• Devices changed gradually.
• Each accepted change making a small improvement.
Early Design by Man
• Tools and weapons
Roman Aqueducts:

Built over a period of 500 years from 300 BC

to 200 AD
A Hobby Horse : 1791
A Draisiene: 1817
MacMillan’s Velocipede: 1839
Michaux Velocipede: 1863
The High Wheeler: 1870~90
Riding a Penny Farthing
The Header
Lawson’s Bicyclette: 1879
Rover Safety Bike: 1885
Rover Safety Bike:1889
Moulton Bike: 1963
A Modern Bicycle
Some interesting websites
• www.exploratorium.edu/cycling
• www.cycling.org/lists/hardcore-bicycle-science
Design by Innovation
• De Novo design
Gillette
Safety Razor
Adjustable Razor
Double-blade Razor
Design Idea-I:
Ball Pen
Design Idea-I:
Seat Belt
Design Idea-I:
Stapler

Legs of
the pin
Stapler pin
Design Idea-I:
Sachet
Design Idea II:
Seal opener in a tube of cream
Design Idea II:
Out-take from a cool pot
• The level of the tap is
at some distance from
the bottom . This is
made purposely such
that if our drinking
water contains any
amount of dust , the
dust just settles down
and we can get pure
(dust free) water.
Design Idea II:
Safety pin
A safety pin is a device used to attach two
pieces of cloth together. ... It is activated
by squeezing the parallel sides inwards. It
is safe because the sharp needle tip is
covered when the safety pin is closed. It is
used for clothing and other cloth that has
no special provision for attaching such as
button or zips. It is also used for
provisional repair in case of some
imperfections of clothing.
Design idea II:
Oil bottle
• first the bottle is thin at middle and thick
at top and bottom.
• Most important feature is that it has the
up down surface as shown in pic so that it
cant slip from the hand .
• Hence it is the best design as easy for the
consumer to use
Design Idea II:
Carry-bag clip
• In the carry bag clip, as soon as we push the
clip, it gets pushed inwards first and then takes
the space provided by expanding and hence
gives a very tight locking system.
Design Idea II:
Wire cutter
• Wire Cutters – meant to peel off the insulation of
the wires – are supposed to be operated like a
pair scissors.
• After peeling off a layer of wire, we have to open
them up and use them for further use.
• However, they are now available with a spring
attached to them, which causes them to open up
automatically as we release them.
• The work done in closing them is stored in the
spring which it later uses to open up the cutter.
Design Ideas – III
Zipper
Design Idea - III:
Pen Clip
A semicircular & a triangular extension in the
pen cap is very useful in holding the pen to
the shirt pocket.
The cloth of shirt is held between these
structures and it is strongly hold. Thus the
pen remains in hold with the pocket & not
fall down.
Design Idea - III:
Handle of a Cup
The handle of the tea cup
prevents heat transfer
from the hot contents of
the cup to the fingers. It is
also so designed such
that the weight of the cup
full with contents can be
supported with just the
fingers without much
effort. Also it is equally
convenient in use for a left
handed or right handed
person.
Tapered Train Wheels

1. It reduces wobbling of the train at high speeds.

2. It maintains the path of the train. In language of science it reduces
the displacement of centre of mass.
3. Provides ease at the turnings and prevents it from de-railing.
Dots on Key Board
• Along with mobile phones and
keyboards, these dots can also
be found in ATM machines as
well.
• Braille dots
Castor Wheels
ROLLING WHEEL
(Able to turn at any angle)
This kind of wheel is used in leg of
chairs or leg of stands of water
coolers. Wheel is connected to leg
from above with bearing balls.
Whenever we apply force to move the
chair in a specific direction, the wheel
F
turns in that specific direction
smoothly and there is no requirement
of lifting up the chair and then turn it.
Velcro
Velcro works on the principle that
enough hooks on one side of a
fastener would become tangled in
enough loops on the other side to
form a very strong bond.
Applying pressure to a section of
Velcro makes it stronger as more
loops and hooks connect.
Thus the Velcro is an excellent
design idea as it used the principle
of hooks at a microscopic level and
created a product which has vast
applications in everyday life.
Bubble Packing

The air bubble packets help us to keep, protect or

transport fragile objects like electronic parts.
The air bubble provides a greater time for change of
momentum to take place ,against an impact, and
thus protects the object.
Can Tab

It has internal rivet and pulled

Tab Rings which had a ring
attached at the rivet for pulling,
and which would come off
completely to be tossed aside.
Clutch Pencil
The clutch consists of a button at one end of the
pencil or at its side which is used to advance the lead
forward. When the button is pressed it pushes
forward three small separate pieces present in the
cap, held together by a ring, alongwith the lead that
they hold. Once the three pieces are pushed out of
the ring they separate and thus loosen their grip on
the lead. The pieces again grip onto the lead in its
new position once they take their original place back
into the ring.
•The mechanical pencil is of great use where a
uniform line is required.
• It is also more eco friendly as it doesn’t involve the
use of wood.
• It is a lot more convenient to use than the traditional
pencils.
Paper Soap
• There is a very good design in a paper
soap. In case of ordinary soap, a soap case
is required to keep it. After using such a
soap, soap and soap case remains wet for
some time. So user can not put it in his bag
immediately after its use. Again because of
its big size, user can not keep it in his
pocket.
• In case of a paper soap, if we keep it in our
pocket, as its thickness is very small it does
not let us feel uncomfortable. Again a
paper soap is capable of withstanding large
amount of sheer strain and it does not
break easily. 061286 Pradeep
061308 Priya
Boot Polish Tin
When we press on the point “PRESS”
written on the lid of a shoe polish lid, the
shoe polish lid comes off very easily.
When we see the inside of the lid
carefully, we see that there is a a little cliff
like structure at one side of it. The point of
“PRESS” is located just at the middle of
the other side. So when we press at that
point then we apply a force equally on
both sides on the two points denoted by
‘cross’ in the figure which in turn act as
fulcrum. Here the load point is situated at
a point opposite to the effort point. This
simple lever mechanism helps to open the
lid very easily.
Nib of a Fountain Pen
• The nib has one slit cut
through it,to get the ink
down to the paper by
capillary action.
• There is a hole in the
nib for the exchange of
the air for ink in the
pen’s reservoir.
• The nib narrows down
to a point where the ink
is transferred to the
paper.
Paper Clip
is usually a thin wire bent into a
looped shape that takes advantage
of the elasticity and strength of the
materials of its construction (usually
steel or some other metal) to
compress and therefore hold
together two or more pieces of
paper by means of torsion.
Design Idea-I:
Nail Cutter
Purpose of Design
• What do we design for?
• Function?
• Beauty?
• Value?
Papanek’s Function Complex
Victor Papenek:
Designing for the Real World
Function Complex
Purpose

Aesthetics Use

Method Association

Material
Function Complex
Purpose

Aesthetics Use

Method Association

Material
Function Complex
Purpose

Aesthetics Use

Method Association

Material
Function Complex
Purpose

Aesthetics Use

Method Association

Material
Function Complex
Purpose

Aesthetics Use

Method Association

Material
Materials
“Reinforced concrete has brought about a revolution in the aesthetics of
construction. By suppressing the roof [which needs to be quite
prominent in the wooden-frame construction, hitherto common in
European and American architecture] and replacing it by terraces,
reinforced concrete is leading us to a new aesthetics of the plan”. [Le
Corbusier, 1946].

Bicycle wheel
Selection of Material
Factors that govern the choice of material:

• Properties
• Production
• Price
Function Complex
Purpose

Aesthetics Use

Method Association

Material
Function Complex
Purpose

Aesthetics Use

Method Association

Material
Some Examples
Golden ratio [Le-Corbusier}

1, 1.618, 2.618, 4.236, 6.854, ...

Aesthetics
Balance
Symmetry
Unity
Rhythm
Form
(are words frequently used in evaluating any work aesthetically, and all
of them have origins in nature and its preoccupation with function and
efficiency.)
Concorde
Human arm
Human Arm
Swing tools
Swinging Arm
Stability
Levels of a Problem
Stake-holders of a Design Problem

Sources of Specifications:

•Client
• Designer
• State
• User(s)
Characteristics of Design Problems
Our understanding of a design situation and the 'fundamental' nature of
the problem at hand depends largely on our viewpoint and the general or
special skills that we possess. We should, therefore, realize that a
design problem cannot be stated with complete objectivity and, in fact,
demands a subjective interpretation.
Characteristics of Design Problems

It stands to reason that it is very difficult, if not impossible, to gather all

the information necessary for a design unless we know exactly the
direction in which the design would progress.
Characteristics of Design Problems
• Since a design problem can never be comprehensively stated,
and since each designer may select a different definition or
even the scope of the problem, it should follow that the design
solutions to a given situation are truly innumerable.
• Also, we can never be sure that there is no other way of looking
at the problem or that some important aspect of it has not being
missed, and, therefore, we can never say that we have covered
all the solutions of a given problem.
The Design Process
The Design Process
As a design project is conceived, certain events take place in more or
less chronological order, forming a pattern which is common to all
projects.
Three Phase of Design Projects
• Explorative phase
• Transformation phase
• Convergence phase
Design Process
The Iterative Cycle
Analysis of Need
Mission Statement, or
Preliminary Need Statement
A designer should identify, in plain language, the goal of the design
which does not pre-supposes a solution.
The preliminary statement should be as general as possible, which at the
same time must define the essential nature of the problem
Customer Need Process
• Define the Scope–Mission Statement
• Gather Raw Data–Observation–Interviews–Focus Groups
• Interpret Raw Data–Need Statements
• Organize the Needs–Hierarchy
• Establish Importance–Surveys–Quantified Needs
• Reflect on the Process–Continuous Improvement
Need Analysis: Desired Output

Functional Goals: Specifications

Add-on features: USPs
Standards of Performance: Utility measures
Constraints
 Development
capability

Characteristics of Successful
Product Development
Product cost

Product quality

Development cost

Development Time
Who Design and Develops Products?

Marketing

Design Manufacturing
 Manufacturing
Engineering
Marketing Purchasing
Professional Specialist

Team Leader
Industrial Electronic
Designer Designer

Mechanical
Designer
The Challenge of Product Development

• Trade off
• Dynamics
• Details
• Time Pressure
• Economics
• Creation
• Satisfaction of social and individual needs
• Team Diversity
• Team Spirit
Factory operation