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MechanicalDesign

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MechanicalDesign

TheoryandApplications

ThirdEdition

P.R.N.Childs

DysonSchoolofDesignEngineering

ImperialCollegeLondon,London,UnitedKingdom

Butterworth-HeinemannisanimprintofElsevier

TheBoulevard,LangfordLane,Kidlington,OxfordOX51GB,UnitedKingdom 50HampshireStreet,5thFloor,Cambridge,MA02139,UnitedStates

Copyright©2021ElsevierLtd.Allrightsreserved.

Nopartofthispublicationmaybereproducedortransmittedinanyformorbyanymeans,electronicormechanical,including photocopying,recording,oranyinformationstorageandretrievalsystem,withoutpermissioninwritingfromthepublisher.Detailson howtoseekpermission,furtherinformationaboutthePublisher'spermissionspoliciesandourarrangementswithorganizationssuchas theCopyrightClearanceCenterandtheCopyrightLicensingAgency,canbefoundatourwebsite: www.elsevier.com/permissions. ThisbookandtheindividualcontributionscontainedinitareprotectedundercopyrightbythePublisher(otherthanasmaybenoted herein).

Notices

Knowledgeandbestpracticeinthisfieldareconstantlychanging.Asnewresearchandexperiencebroadenourunderstanding,changesin researchmethods,professionalpractices,ormedicaltreatmentmaybecomenecessary.

Practitionersandresearchersmustalwaysrelyontheirownexperienceandknowledgeinevaluatingandusinganyinformation,methods, compounds,orexperimentsdescribedherein.Inusingsuchinformationormethodstheyshouldbemindfuloftheirownsafetyandthe safetyofothers,includingpartiesforwhomtheyhaveaprofessionalresponsibility.

Tothefullestextentofthelaw,neitherthePublishernortheauthors,contributors,oreditors,assumeanyliabilityforanyinjuryand/or damagetopersonsorpropertyasamatterofproductsliability,negligenceorotherwise,orfromanyuseoroperationofanymethods, products,instructions,orideascontainedinthematerialherein.

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AcataloguerecordforthisbookisavailablefromtheBritishLibrary LibraryofCongressCataloging-in-PublicationData AcatalogrecordforthisbookisavailablefromtheLibraryofCongress ISBN:978-0-12-821102-1

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ABOUTTHEAUTHOR

P.R.N.ChildsistheProfessorialLeadin EngineeringDesignatImperialCollege London.HeisafellowoftheRoyalAcademyof Engineering,theInstitutionofMechanical Engineers,andtheAmericanSocietyof MechanicalEngineers.Hisgeneralinterests includecreativitytoolsandinnovation,design processes,fluidflowandheattransfer,sustainable energy,androbotics.Priortohiscurrentpostat Imperial,hewasDirectoroftheRolls-Royce supportedUniversityTechnologyCentrefor Aero-ThermalSystems,DirectorofInQbate, andaProfessorattheUniversityofSussex.

Hehascontributedtoover200refereedjournalandconferencepapers,andseveralbooks includingtheHandbookonMechanicalDesign Engineering(Elsevier,2013,2019)aswellas

monographsonrotatingflowandtemperature measurement.Hehasbeenprincipalorcoinvestigatoroncontractstotalingover d100million.

HisrolesatImperialincludeProfessorat LargefortheInnovationDesignEngineering doublemasterdegreerunjointlybyImperial andtheRoyalCollegeofArtandEnterprise ChampionintheDysonSchoolofDesign Engineering.Hewasthefoundingheadofthe DysonSchoolofDesignEngineeringat Imperial.HeisEditoroftheJournalofPower andEnergy,ProfessorofExcellenceatMD-H, Berlin,andFounderDirectorandformer ChairmanatQ-BotLtd.HeisChairmanof BladeBUGLtd.

Heisverypassionateaboutresponsiblebusiness,andthewhat,how,andwhyofeducation.

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PREFACE

Engineeringinvolvestheapplicationoftechnical andmathematicalprinciplesincombination withprofessionalanddomainknowledgeto deliverproducts,service,andsystemstorealizea requirementoropportunity.Thisbookaimsto presentanoverviewofthedesignprocessandto introducethetechnologyandselectionofa numberofspecificmachineelementsthatare fundamentaltoawiderangeofmechanicalengineeringdesignapplications.

Thefirsteditionofthisbookwasproducedin 1998,withthesecondeditionin2004.Thetext wasexpandedtothemechanicaldesignengineeringhandbookwitheditionsin2013and 2018.Thisedition,whichdrawsonthecontent ofthehandbook,focusesonaseriesofkey machineelementsrelevanttostudents,including bearings,shafts,gears,beltsandchains,springs, andfasteners.Thesetechnologyelementsserve asbuildingblocksforasignificantquantityof machinedesignandprovideanexcellentbasisin

mechanicalengineeringeducation.Experience fromthepreviouseditionshasbeenusedtopreservefeaturessuchasdetailedworkedexamples andflowchartsillustratingstep-by-stepstrategies fordevelopingadesignforaspecificmachine element.

Thebookincludes200worksheetquestions andover350images,withlinedrawingscomplementedbysolidmodelillustrationstoaid understandingofthemachineelementsand assembliesconcerned.Thecontextforengineeringandmechanicaldesignisintroducedinthe firstchapter,whichalsopresentsablended designprocessincorporatingprinciplesfromsystematicandholisticdesignaswellaspractical projectmanagement.Thischapterisfollowedby ninechaptersfocusingonspecificmachineelements,andthebookconcludeswithachapter ontolerancingrelevanttocombiningmachine elementsinpracticaldesigns.

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ACKNOWLEDGMENTS

Iwouldliketoexpressmyspecialthanksto Dr.KamyarHazeriforhisassistanceinthegenerationofsomeoftheimagesforthisrevised editionandtoDr.MarcMasenforhisguidance

ontherollingelementbearingsandgear-stressing chapters.Particularly,Iwouldliketothank CarolineChildsforherpatienceandregular inputonproofreading.

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1 DESIGN

1.1Introduction

Theaimsofthisbookaretopresentanoverview ofthedesignprocess,andtointroducethetechnologyandselectionofanumberofspecificmachine elementsthatarefundamentaltoawiderangeof mechanicalengineeringdesignapplications.This chapterintroducesthedesignprocessfroman inventor’sperspective,thedoublediamondmodel, andmoreformalapproachessuchassystematic, total,andblendeddesign.Thechapteralsopresents anoverviewoftechnologies,whichservesasbuildingblocksformachineryandmechanicaldesign.

Theterm‘‘design’’ispopularlyusedtorefertoan object’sestheticappearancewithspecificreferenceto itsformoroutwardappearanceaswellasitsfunction.Forexample,weoftenrefertodesignerclothes, designicons,andbeautifulcars.Examplesofsome classicallyacclaimedvehiclesaregivenin Figs.1.1 and 1.2.Intheseexamples,itisbothvisualimpact, appealingtoourvisualperception,andtheconcept offunction,thattheproductwillfulfillarangeof requirements,whichareimportantindefiningthe so-calledgooddesign.Inthissection,wewillconsideranumberofdefinitionsandexplanationsrelevanttodesignandengineering.Suchdefinitionscan behelpfulinunderstandingthecontextfortheactivitiesassociatedwithdesignandengineering.

Theword‘‘design’’isusedasbothanounand averbandcarriesawiderangeofcontextsensitivemeaningsandassociations.Wecan,for example,refertoaproductormachineandsay thatwelikeorratethedesign.Alternatively,we

mightrefertoanactivityandtalkaboutdesigning aproductormachine.

Cox(2005) inhisreviewoncreativityinbusiness stated‘‘Designiswhatlinkscreativityandinnovation.Itshapesideastobecomepracticalandattractivepropositionsforusersorcustomers.Design maybedescribedascreativitydeployedtoaspecific end.’’TheworddesignhasitsrootsintheLatin ‘‘designare,’’whichmeanstodesignateormarkout, andsuchnotionswillbefamiliartoanengineer developingatechnicaldrawingoranarchitectproducingaplanforabuilding.Designcanbetaken tomeanalltheprocessesofconception,invention, visualization,calculation,refinement,andspecificationofdetailsthatdeterminetheformofaproduct, service,orsystem.Thedesigngenerallybeginswith eitheraneedorrequirementor,alternatively,an idea.Itcanendwithasetofdrawingsorcomputer representationsandotherinformationthatenablesa producttobemanufactured,oraserviceorsystem toberealizedandutilized.Generically,designcan bedefinedasthetransformationofanexistingstate toapreferredstate.Whilerecognizingthatthereis nowidelyacceptedsingledefinition,toclarifywhat thetermdesignmeans,thefollowingstatementcan provideabasis:

Design istheprocessofconceiving,developing andrealisingproducts,artefacts,processes,systems, services,platformsandexperienceswiththeaimof fulfillingidentifiedorperceivedneedsordesires typicallyworkingwithindefinedornegotiated constraints.

Figure1.1 Piaggio’sVespalaunchedin1946.TheVespa wasanearlyexampleofmonocoqueconstructionwhere theskinandframearecombinedasasingleconstruction toprovideappropriaterigidityandmountingforthe vehicle’scomponentsandriders.

Thisprocessmaydrawuponandsynthesize principles,knowledge,andmethodskillsandtools fromabroadspectrumofdisciplinesdependingon thenatureofthedesigninitiativeandactivity. Designcanalsoberegardedas‘‘thetotalactivity necessarytoprovideaproductorprocesstomeet amarketneed.’’Thislatterdefinitioncomesfrom theSEED(SharingExperienceinEngineering Design,nowDESIGtheDesignEducationSpecial InterestGroupoftheDesignSociety)model,see Pugh(1990).

AccordingtoaRoyalAcademyofEngineering document,engineeringcanbedefinedas

Thediscipline,artandprofessionofacquiring andapplyingscientific,mathematical,economic, socialandpracticalknowledgetodesignandbuild structures,machines,devices,systems,materials andprocessesthatsafelyrealisesolutionstothe needsofsociety.

Thisdefinitionisnotattributedtoasingle sourceand ABET(2011) ,theInstitution ofMechanicalEngineersandthe National AcademyofEngineering(2004) allhave similardefinitionsforengineeringinvolving theapplicationofscientificandmathematic principlestodesign.Thefollowingstatement

Figure1.2 TheAudiTT,originallylaunchedin1998. CourtesyAudi.

providesanindicationofthescopeof engineering:

Engineering istheapplicationoftechnicaland mathematicprinciplesincombinationwithprofessionalanddomainknowledge,inorderto deliverproducts,serviceandsystemstorealisea requirementoropportunity.

Theterms‘‘engineeringdesign’’and ‘‘designengineering’’areoftenusedinterchangeably.Theinclusionofthewordengineeringinbothsuggeststhattheyinvolvethe applicationofscientific,technical,andmathematicalknowledgeandprinciples.Itmaybe usefultothinkof‘‘engineeringdesign’’sitting alongside‘‘engineeringscience’’asthestrand ofengineeringthatisconcernedwithapplication,designing,manufacture,andbuilding. Designengineeringsuggestsaprocessin whichengineering(scientificandmathematical)approachesareappliedintherealization ofactivitiesthatbeganwithadesignconcept orproposal( ChildsandPennington,2015 ). However,suchdistinctionsremainsubtleand subjecttocontext.InlaunchingtheDyson SchoolofDesignEngineeringatImperial

CollegeLondon,Childsdefineddesignengineeringasfollows(see Childs,2019 ):

Designengineeringisthefusionofdesignthinking, engineeringthinkingandpracticewithinacultureof innovationandenterprise.

Thisbookisprincipallyconcernedwith mechanicalengineeringdesignwithinthecontext ofapplicationsofamechanicalengineeringnature, particularlythoseusingarangeofmachineelementssuchasbearings,gears,shafts,beltsand chains,clutchesandbrakes,springs,andfasteners. Anexampleofanapplicationshowingtheuseofa rangeofthesemachineelementsforanautomotive transmissionisgivenin Fig.1.3.

1.2TheDesignProcess

Havingadefinedapproachtoundertakingdesign canaidtheactivity,helpingtoensuretheprocessis undertakentoaprofessionalandhighstandard, with,forexample,thoroughconsiderationof whatisrequiredandensuringthatdueconsiderationisgiventotechnical,esthetic,social,andeconomicfunction.Manydesignprocesseshavebeen

Figure1.3 Aseven-speedsportstransmissionincorporatingawiderangeofmachineelementsconsideredinthisbook. CourtesyDaimlerAG,releasedateNovember17,2014.

proposedovertheyearswithconsultancies,engineeringcorporations,andindustrybodiesaswellas academicgroupsdevelopingtheirownbrandof approaches(e.g.,see ClarksonandEckert,2005). Commonlycitedmethodsincludetheeducational approachCDIO(conceive,develop,implement, operate),totaldesign,doublediamond,concurrent engineering,sixsigma,multidisciplinarydesign optimization(MDO),andgatedreviews.Design processescanbebroadlycategorizedasactivitybased,involvinggeneration,analysis,andevaluation, andstage-based,involvingdistinctphasesof,for example,taskclarificationandconceptualdesign. Itisalsowidelyrecognizedthatexperiencedpractitionersapproachdesigninadifferentmannerto novicedesigners(e.g.,see Bjo ¨ rklund,2013),and thishasresultedintheuseofsomeapproaches ineducationthataredistinctfromcommercial engineeringpractice.

Probablyfromyourownexperienceyouwill knowthatdesigncanconsistofexamininganeed oropportunityandworkingontheproblemby meansofsketches,models,brainstorming,calculationsasnecessary,anddevelopmentofstylingas appropriate;makingsuretheproductfitstogether andcanbemanufactured;andconsideringcosts. Theprocessofdesigncanberepresentedschematicallytolevelsofincreasingformalityandcomplexity. Fig.1.4 representsthetraditionalapproach associatedwithloneinventors.Thismodelcomprisesthegenerationofthe‘‘brightidea,’’drawings, andcalculationsgivingformorshapetotheidea andjudgmentofthedesignandreevaluationif necessary,resultinginthegenerationoftheend product.Theprocessofevaluationandreworking anideaiscommonindesignandisrepresentedin themodelbytheiterationarrowtakingthedesign activitybackastepsothatthedesigncanbe improved. Fig.1.5 illustratesthepossibleresults fromthisprocessforabicyclelock.

Fig.1.6 showsamoreprescribeddescription ofadesignprocessthatmightbeassociatedwith engineersoperatingwithinaformalcompany managementstructure.Thevarioustermsused in Fig.1.6 aredescribedin Table1.1.

Thetraditionalandfamiliar‘‘inventor’s’’ approachtodesign.

Although Figs.1.4 and 1.6 atfirstsightsuggest designoccurringinasequentialfashion,withone taskfollowinganother,thedesignprocessmay actuallyoccurinastepforward,stepbackfashion. Forinstance,youmayproposeasolutiontothe designneedandthenperformsomecalculationsor judgments,whichindicatethattheproposalisinappropriate.Anewsolutionwillneedtobeputforwardandfurtherassessmentsmade.Thisisknown astheiterativeprocessofdesignandformsan essentialpartofrefiningandimprovingtheproduct proposal.Thenonlinearnatureofdesignisconsideredby HallandChilds(2009).

Notethattheflowchartsshownin Figs.1.4 and 1.6 donotrepresentamethodofdesign butratheradescriptionofwhatactuallyoccurs withintheprocessofdesign.Themethodof designusedisoftenuniquetotheengineering ordesignteam.Designmethodologyisnotan

Figure1.4

exactscience,andthereareindeednoguaranteedmethodsofdesign.Somedesignerswork inaprogressivefashion,othersworkonseveral aspectssimultaneously.Anexampleofdesign followingtheprocessidentifiedin Fig.1.6 is giveninthefollowingexampleinorderto

Figure1.5 TheLiteLokbicyclelock. Courtesy(A)NeilBarron,(B)and(C)LiteLokLtd.

Figure1.6 Thedesignprocessillustratingprincipalphasesandsomeoftheiterativestepsinvolvedintheprocess.

introducesomeofthetypicalactivitiesthat mightoccur.

Example1.1

Followingsomeinitialmarketassessments, theboardofaplantmachinerycompany hasdecidedtoproceedwiththedesignof

anewproductfortransportingpallets aroundfactoriesandwarehouses.The boardhasinmindaforklifttruckbutdoes notwishtoconstrainthedesignteamto thisconceptalone.Theprocessofthe designcanbeviewedintermsofthelabels usedin Fig.1.6 .

Table1.1 Designphases.

PhaseDescription

Recognitionof need

Definitionof problem

Oftendesignbeginswhenanindividualorcompanyrecognizesaneedoridentifiesapotentialmarket,fora product,device,orprocess.Alternatively,‘‘need’’canbedefinedaswhenacompanydecidestoreengineer oneofitsexistingproducts(e.g.,producinganewcarmodel).Thestatementofneedissometimes referredtoasthebrieformarketbrief.

Thisinvolvesallthespecificationoftheproductorprocesstobedesigned.Forexample,thiscouldinclude inputsandoutputs,characteristics,dimensions,andlimitationsonquantities.

SynthesisThisistheprocessofcombiningtheideasdevelopedintoaformorconcept,whichoffersapotential solutiontothedesignrequirement.Thetermsynthesismaybefamiliarfromitsuseinchemistrywhereitis usedtodescribetheprocessofproducingacompoundbyaseriesofreactionsofothersubstances.

AnalysisThiscaninvolvetheapplicationofengineeringscienceusingsubjectsexploredextensivelyintraditional engineeringcoursessuchasstaticsanddynamics,mechanicsofmaterials,fluidflow,andheattransfer.These engineering‘‘tools’’andtechniquescanbeusedtoexaminethedesigntogivequantitativeinformationsuch aswhetheritisstrongenoughorwilloperateatanacceptabletemperature.Analysisandsynthesis invariablygotogether.Synthesismeansputtingsomethingtogetherandanalysismeansresolvingsomething intoitsconstituentpartsortakingittopieces.Designershavetosynthesizesomethingbeforeitcanbe analyzed.Thefamouschickenandtheeggscenario!Whenaproductisanalyzedsomekindofdeficiencyor inadequacymaybeidentifiedrequiringthesynthesisofanewsolutionpriortoreanalysisandrepetitionof theprocessuntilanadequatesolutionisobtained.

OptimizationThisistheprocessofrepetitivelyrefiningasetofoften-conflictingcriteriatoachievethebestcompromise.

EvaluationThisistheprocessofidentifyingwhetherthedesignsatisfiestheoriginalrequirements.Itmayinvolve assessmentoftheanalysis,prototypetesting,andmarketresearch.

Solution

Recognitionofneed(ormarketbrief)—Thecompanyhasidentifiedapotentialmarketfora newpallet-movingdevice.

Definitionofproblem Afullspecificationof theproductdesiredbythecompanyshouldbe written.Thisallowsthedesignteamtoidentify whethertheirdesignproposalsmeettheoriginal request.Herealistofinformationneedstobe developedandclarifiedbeforedesigncanproceed.Forexample,forthepallet-movingdevice beingexploredhere,thiswouldlikelyinclude aspectsforconsiderationsuchas

Whatsizesofpalletaretobemoved?

Whatisthemaximummassonthepallet?

Whatisthemaximumsizeoftheloadonthepallet? Whatrangeofmaterialsaretobemovedandare theypackaged?

Whatisthemaximumheightthepalletneedstobe lifted?

Whatterrainmustthepallet-movingdeviceoperateon?

Whatrangeisrequiredforthepallet-movingdevice?

Isaparticularenergysource/fueltobeused?

Whatlifetimeisrequired?

Aretheremanufacturingconstraintstobe considered?

Whatisthetargetsalesprice?

Howmanyunitscanthemarketsustain?

Isthedevicetobeautomaticormanned?

Whatlegalconstraintsneedtobeconsidered?

Thislistisnotexhaustiveandwouldrequire furtherconsideration.Thenextstepistoquantify eachofthecriteria.Forinstance,thespecification mayyieldthatstandardsizepallets,see Fig.1.7, areinvolved,themaximumloadtobemovedis 1000kg,themaximumvolumeofloadis2m3, thereachmustbeupto3m,useisonfactory floorandasphaltsurfaces,thedevicemustbe capableofmovingasinglepallet100mandmust beabletorepeatthistaskatleast100timesbefore refuelingorrechargingasnecessary,thedesignlife fortheproductis7years,productionisina Europeancountry,thetargetsellingpriceis 20,000Euros,theproductionrunis3000units

Figure1.7 Palletdimensionsandterminology(seeBSISO509).

peryear,thedeviceistobeoperatedbyaperson, andthedesignmustbecomplianttoISO (InternationalOrganizationforStandardization) andtargetcountrynationalstandards(e.g.,seeBS ISO509,BSISO6780,BSENISO445,BSEN 13545,BSISO18334,BS5639-1,andBSISO 2330).

Synthesis—Thisisoftenidentifiedastheformativeandcreativestageofdesign.Someinitial ideasmustbeproposedorgeneratedinorderfor themtobeassessedandimproved.Conceptscan begeneratedbyimagination,experience,orby theuseofdesigntechniquessuchasmorphologicalcharts.Someevaluationshouldbemadeat thisstagetoreducethenumberofconcepts requiringfurtherwork.Varioustechniquesare availableforthis,includingmeritandadequacy assessments.

Analysis—Onceaconcepthasbeenproposed, itcanthenbeanalyzedtodeterminewhether constituentcomponentscanmeetthedemands placedonthemintermsofperformance,manufacture,cost,andanyotherspecifiedcriteria. Alternatively,analysistechniquescanbeusedto determinewhatsizecomponentsneedtobeto meettherequiredfunctions.

Optimization—Inevitably,thereareconflicts betweenrequirements.Inthecaseoftheforklift truck,size,maneuverability,cost,estheticappeal,

easeofuse,stability,andspeedarenotnecessarily allinaccordancewitheachother.Costminimizationmaycallforcompromisesonmaterialusage andmanufacturingmethods.Theseconsiderations formpartoftheoptimizationoftheproductproducingthebestormostacceptablecompromise betweenthedesiredcriteria.Optimizationisconsideredfurtherin Section1.4

Evaluation—Onceaconcepthasbeenproposed andselected,andthedetailsofcomponentsizes, materials,manufacture,costsandperformance workedout,itisthennecessarytoevaluateit. Doestheproposeddesignfulfillthespecification? Ifitappearsto,thenfurtherevaluationbypotential customersanduseofprototypedemonstrators maybeappropriatetoconfirmthefunctionalityof thedesign,judgecustomerreaction,andprovide informationofwhetheranyaspectsofthedesign needtobereworkedorrefined.

1.3DesignModels

Theprocessofdesignhasbeenthefocusof researchanddevelopmentformanyyears,anda numberofdesignmodelsandmethodologieshave beenformalized.Designmethodologyisaframeworkwithinwhichthedesignercanpracticewith thoroughness.Takinga standardapproachto undertakingdesigncanbeusefulinhelpingto

ensureimportantaspectsareaddressedandleverage priorexperience.Followingaformalizedapproach ormodelisnotnecessarilygoingtomeanthat ahigh-qualitydesignoutcomeisguaranteed. Nevertheless,amodelorformalapproachcanaid managementoftheactivity.Variousapproachesto thedesignprocessareintroducedhere,including systematicdesign,doublediamond,CDIO,and totaldesign.Inthesectionon‘‘Totalandblended design’’anupdatedmodelispresented.blending aspectsofprojectmanagementsuchascontemporarytopicsofneedandopportunityanalysis,virtual realization,sustainability,andresponsiblebusiness.

Systematicdesign

Asystematicapproachtodesignhasbeendevelopedandproposedby PahlandBeitz(1996) whodividetheirmodelintofourphases:

1.productplanningandclarifyingthetask

Table1.2 Systematicdesignstages,activities,andphases.

2.conceptualdesign

3.embodimentdesign

4.detaildesign

Theactivitiesassociatedwithsystematicdesignare outlinedin Table1.2.Althoughtheactivitiestake placeinphases,iterationdoesoccurbetweeneachof theactivities.Forexample,informationarisingfrom workontherequirementslistcanservetohelpclarifythetaskandopportunitydefinedintheoriginal requirementthatgavetheinitialimpetusfortheprojectconcerned.Similarly,worktowardaconceptwill resultinnewinformationthatcanhelpclarifythe requirementlist.Similariterationswithanactivity informingandresultinginflowsofinformationand clarificationofwhatactuallyneedstobedone,can occurbetweeneachoftheactivitiesdefinedin Table1.2.Theintendedoutcomeisforthearising insightsandinformationtoenableoptimizationof therequirement,layout,andproduction.

StageActivitySystematicdesignphase

Requirement Planandclarifythetask

Analyzethemarketopportunity

Requirementslist

Formulateaproductproposal

Elaboratearequirementslist

Concept Identifyessentialproblems

Establishfunctionstructures

Searchforworkingprinciples

Combineandfirmupinconceptvariants

Evaluateagainsttechnicalandeconomiccriteria

Productplanningandclarifyingthe task

Productplanningandclarifyingthe task

Conceptualdesign

Preliminarylayout

Developtheconstructionstructureforthesolution

Preliminaryformdesign,materialselection,andcalculations

Selectthebestpreliminarylayouts

Refineandimprovelayouts

Evaluateagainsttechnicalandeconomiccriteria

Definitivelayout

Definetheconstructionstructureforthesolution

Eliminateweakspots

Checkforerrors

Preparepreliminarypartlistsandproductdocuments

Product documentation

Prepareproductionandoperatingdocuments

Elaboratedetaildrawingsandpartlists

Completeproduction-readycomponent,assembly,transport,andoperating instructions

Embodimentdesign

Embodimentdesign

Detaildesign

Theapproachtakeninsystematicdesign acknowledgesthatduetothecomplexnatureof moderntechnology,itisnowrarelypossiblefora singlepersontoundertakethedesignanddevelopmentofamajorprojectontheirown.Instead, alargeteamwillbeinvolvedintheactivity,and thisintroducesthechallengesoforganizationand communicationwithinalargernetwork.The aimistoprovideacomprehensive,consistent, andclearapproachtosystematicdesign.

Designmodelsandmethodologiesencourage ustoundertakecarefulmarketingandspecification.Becauseoftheirsequentialpresentation, ‘‘designstartswithaneed’’or‘‘designstartswith anidea,’’theyinherentlyencourageustoundertaketaskssequentially.Thisisnotnecessarilythe intentionofthemodels,andindeedthisapproach iscounteredwithinthedescriptionsandinstructionsgivenbytheproponentsofthemodel,who insteadencourageaniterativefeedbackworking methodology.

Acriticismofthesystematicandotherdesign modelsisthattheytendtobeencyclopedicwith considerationofeverythingpossible.Assuch,their usecanbeviewedasachecklistagainstwhicha personalmodelcanbeverified.Afurthercriticism ofdesignmodelsisthattheyareoverlyserialisticas opposedtoholisticandthatbecauseoftheserious mannerinwhichthemodelsareportrayedand documented,theycanhaveatendencytoputthe intuitiveandimpulsivedesigneroff!

Doublediamond

The DesignCouncil(2007,2019) reporteda studyofthedesignprocessin11leadingcompaniesandidentifiedafour-stepdesignprocess calledthe‘‘doublediamond’’designprocess model,involvingphasesofdiscovery,definition, development,anddelivery.Theprocessinvolves progressionfromidentificationofaninitialproblemtowardconceptsandsolutionsviatwophases ofdivergentandconvergentactivityasillustrated in Fig.1.8

Inthediscoverydivergentphase,manydifferentideasandaspectscanbeencouragedto emergeandbeconsidered,forexample,using varioustypesofbrainstorming.Inadivergent phase,theemphasisissometimesonthequantity ofideasinordertohavemanyitemsfromwhich tomakeaselectionandtoenableconsideration ofwhatthecompetitionmightconsider.Ina convergentphase,theemphasisisonselection andrefinementofanideaanditsembodiment anddefinitionwithconsiderationofdetails.The developmentphasealsoinvolvesdivergentactivitywithsimultaneousconsiderationofdifferent optionstofulfillthefunctionalrequirementsof theproduct,service,orsystemconcerned,beit technical,esthetic,social,oreconomicorsome combination.Inthedivergentdevelopment phase,usecanbemadeofmodelingandanalysis ofdifferentoptions.Inthefinaldeliveryconvergentphase,theemphasisisonrefinementand detailingofeachaspectinordertoprovidethe finaloutcomefortheproduct,service,orsystem concerned.

Conceive,design,implement,operate

Theconceive,design,implement,operate (CDIO)frameworkiswidelyusedindesignand engineeringeducationandwasdevelopedin recognitionofadivergencebetweenacademic cultureandpracticalengineeringrequirements. Theframeworkexplicitlyrecognizestheimportanceofholisticconsiderationsforeffective designoutcomeswiththeapplicationofboth engineeringpracticeskillssuchasdesign,manufacture,personal,professional,interpersonnel, andbusinessincombinationwithdisciplinary knowledgefromthesciencesandmathematicsas wellasthehumanities(see Crawley,2001).

IntheCDIOframework,attentionisgivento eachoftheprincipalphasesandthedevelopmentofskillsneededinordertoaddressthe holisticrequirementsfortheproduct,service,or systemconcerned.Eachofthephasesrelatesand

Figure1.8 Schematicillustratingthedoublediamonddesignprocess. CourtesytheDesignCouncil.(2019).Whatisthe frameworkforinnovation?DesignCouncil’sevolvedDoubleDiamond , https://www.designcouncil.org.uk/news-opinion/whatframework-innovation-design-councils-evolved-double-diamond . (lastaccessedOctober13,2020).

feedsintoeachother.Intheconceivestage, considerationisgiventocustomer’sneeds,technologyavailability,regulations,andthebusiness requirementsinordertodevelopanoutline concept.Inthedesignphase,attentionisgiven totheproductionofdetailedplans,technical drawings,andalgorithmsasappropriatetothe specificchallenge.Intheimplementphase,productionissuesareaddressedwithattentiongiven tomanufacturingpracticalitiesandplanning, codingandtesting,andvalidation.Intheoperate phase,attentionisgiventodeliveryoftheproduct,service,orsystemandtherealizationofthe expectedvaluefromtheinvestment,alongwith

considerationofmaintenanceandservicing,and futureevolutionsfortheproductandassociated business.

Totalandblendeddesign

The‘‘totaldesign’’modelwasoriginallyproposed bytheSEEDprogram (1985) and Pugh(1990), comprisingcoreactivitiesofdesign:marketing, specification,conceptualdesign,detaileddesign, andmarketing/selling.Thismodelwasdeveloped fromextensiveindustrialconsultationandexperience,andthephasesassociatedwithtotaldesign

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