The Engineering Design Process,9780471136996

The Engineering Design Process

by ;
Edition: 2nd
ISBN13: 9780471136996
ISBN10: 0471136999
Format: Paperback
Pub. Date: 1996-10-11
Publisher(s): Wiley
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Summary

Combines all relevant techniques used in the thermal and materials sciences, fluid engineering, and engineering mechanics to foster an understanding of the engineering design process from the recognition of a need and the definition of design objectives, through product certification and manufacture of a prototype. Coverage includes insight on how to manage a project, safety and environmental protection, plus a unique chapter concerning ethics. This edition has been updated to incorporate current trends and environmental and economic issues. Mini projects stress such topics as codes and specifications, economical design, statistical data analysis, simulation and modeling, creativity, and innovation. Features actual case studies.

Author Biography

ATILA ERTAS is Professor of Mechanical Engineering and Director of the Academy of Transdisciplinary Studies, Texas Tech University, USA. Dr. Ertas has been the driving force behind the conception and development of the transdisciplinary model for education and research, and had 12 years of industrial experience prior to pursuing graduate studies.

Table of Contents

1 THE ENGINEERING DESIGN PROCESS
1(50)
1.1 The Definition of Design
1(1)
1.2 Design: Art or Science?
2(1)
1.3 The Design Process
3(34)
1.3.1 Recognition of Need
3(3)
1.3.2 Conceptualization and Creativity
6(5)
1.3.3 Feasibility Assessment
11(1)
1.3.4 Establishing the Design Requirements
12(2)
1.3.5 Synthesis and Analysis in the Design Process
14(1)
1.3.6 The Organizational/Work Breakdown Structure
14(1)
1.3.7 Preliminary Design
15(3)
1.3.8 Detailed Design
18(7)
1.3.9 Production Process Planning and Tooling Design
25(3)
1.3.10 Production
28(2)
1.3.11 The Product Realization Process
30(1)
1.3.12 Design for Manufacture and Assembly
30(7)
1.4 Other Important Design Considerations
37(3)
1.4.1 Product Distribution and Use
37(1)
1.4.2 Design Life
38(2)
1.4.3 Human Factors Considerations
40(1)
1.5 Advanced Technology for the Design Process
40(7)
1.5.1 Concurrent Simultaneous Engineering
40(1)
1.5.2 Computer-Aided Design/Computer-Aided Manufacturing
41(2)
1.5.3 Solids or Surfaces
43(3)
1.5.4 Rapid Prototyping
46(1)
1.5.5 Computer-Integrated Manufacturing
46(1)
1.6 The Design Process
47(2)
Bibliography
49(2)
2 MANAGING DESIGN PROJECTS
51(44)
2.1 The "Buck" Stops at the Manager's Desk
51(1)
2.2 Management Techniques
52(6)
2.2.1 Total Quality Management
54(4)
2.3 Effective Project Management
58(3)
2.4 Planning and Scheduling the Effort
61(7)
2.4.1 The Gantt Chart
61(3)
2.4.2 PERT Networks
64(1)
2.4.3 The Critical Path Method
64(4)
2.4.4 Summary
68(1)
2.5 Clarifying the Project Objectives
68(4)
2.5.1 The Objectives Tree Method
68(3)
2.5.2 Coordination with Client and Management
71(1)
2.6 Decision Making
72(7)
2.6.1 Decision Matrices
73(2)
2.6.2 Decision Trees
75(4)
2.7 Improving the Product
79(13)
2.7.1 Functional Cost Analysis
80(2)
2.7.2 Failure Mode, Effects, and Criticality Analysis
82(2)
2.7.3 Taguchi Methods
84(8)
2.8 Engineer or Manager?
92(1)
Bibliography
93(2)
3 MODELING AND SIMULATION
95(30)
3.1 Modeling in Engineering
95(2)
3.2 Heuristic Modeling
97(2)
3.3 Mathematical Modeling
99(2)
3.4 Dimensional Analysis
101(5)
3.5 Similarity Laws in Model Testing
106(1)
3.5.1 Geometric Similarity
106(1)
3.5.2 Kinematic Similarity
107(1)
3.5.3 Dynamic Similarity
107(1)
3.6 Wind and Water Tunnels
107(1)
3.7 Numerical Modeling
108(6)
3.7.1 The Finite Difference Method
108(4)
3.7.2 The Finite Element Method
112(2)
3.8 Monte Carlo Simulation
114(2)
3.9 Discrete Event Simulation
116(1)
3.10 Knowledge-Based Systems in the Design Process
117(7)
3.10.1 An Expert System for Preliminary Design of Structures
119(2)
3.10.2 Selection of Expert System Tools
121(1)
3.10.3 Determining the Suitability of the Candidate Problem
121(1)
3.10.4 Knowledge Representation Schemes
122(2)
Bibliography
124(1)
4 DESIGN ANALYSES FOR MATERIAL SELECTION
125(60)
4.1 Material Selection
125(9)
4.1.1 Analysis of Material Requirements
126(5)
4.1.2 Selection and Evaluation of Candidate Material
131(2)
4.1.3 Decision
133(1)
4.2 Design Analysis for Fatigue Resistance
134(12)
4.3 Design Analysis Using Fracture Mechanics
146(17)
4.3.1 Mode I Stress State in a Crack
146(2)
4.3.2 Stress-Intensity Factor Equations
148(4)
4.3.3 Leak before Break
152(5)
4.3.4 Fatigue Crack Propagation
157(5)
4.3.5 Design with Materials
162(1)
4.4 Design Analysis for Composite Materials
163(10)
4.4.1 Stress-Strain Relations in Composite Materials
165(6)
4.4.2 Failure Criteria of Composite Laminates
171(2)
4.5 Residual (Internal) Stress Considerations
173(5)
4.5.1 Sources of Residual Stress
173(2)
4.5.2 Effect of Residual Stresses
175(2)
4.5.3 Measurement of Residual Stresses
177(1)
4.6 Material Standards and Specifications
178(3)
4.6.1 Organizations Involved in Standards and Specifications Preparation
178(3)
4.7 Corrosion Considerations
181(2)
4.7.1 Atmospheric Corrosion
182(1)
4.7.2 Galvanic Corrosion
182(1)
4.7.3 Crevice Corrosion
182(1)
4.7.4 Pitting Corrosion
182(1)
4.7.5 Intergranular Corrosion
182(1)
4.7.6 Erosion Corrosion
183(1)
4.7.7 Stress-Corrosion Cracking
183(1)
Bibliography
183(2)
5 ENGINEERING ECONOMICS
185(44)
5.1 Project/Product Cost and the Engineer
185(4)
5.2 Cost Analysis and Control
189(9)
5.2.1 Cost Categories
190(3)
5.2.2 Cost Estimating
193(2)
5.2.3 Life-Cycle Costing
195(3)
5.3 Important Economic Concepts
198(11)
5.3.1 Interest
199(1)
5.3.2 Equivalence and the Time Value of Money
200(1)
5.3.3 Cash Flow
200(1)
5.3.4 Present Worth Analysis
201(2)
5.3.5 Internal Rate-of-Return Analysis
203(2)
5.3.6 Payback Period
205(1)
5.3.7 Depreciation and Taxes
206(1)
5.3.8 Inflation and Deflation
207(2)
5.4 Selecting an Appropriate Rate of Return
209(2)
5.5 Evaluation of Economic Alternatives
211(16)
5.5.1 Evaluation by Economic Equivalence
212(1)
5.5.2 The Economic Optimization Function
212(2)
5.5.3 Evaluation Using the Rate of Return on Incremental Investment
214(6)
5.5.4 Cost Model for Decision Making
220(7)
Bibliography
227(2)
6 OPTIMIZATION IN DESIGN
229(26)
6.1 Introduction
229(2)
6.2 Mathematical Models and Optimization Methods
231(23)
6.2.1 The Differential Calculus Method
231(3)
6.2.2 The Lagrange Multiplier Method
234(1)
6.2.3 Search Methods
235(6)
6.2.4 Multivariable Search Method
241(8)
6.2.5 Linear Programming
249(2)
6.2.6 Nonlinear Programming Problems
251(2)
6.2.7 Multicriterion Optimization
253(1)
Bibliography
254(1)
7 STATISTICAL DECISIONS
255(74)
7.1 Random Variable
255(1)
7.2 Measure of Central Tendency
256(4)
7.2.1 Mean or Arithmetic Average
258(2)
7.2.2 Median
260(1)
7.2.3 Mode
260(1)
7.3 Measure of Variability
260(3)
7.3.1 Range
260(1)
7.3.2 Mean Deviation
261(1)
7.3.3 Standard Deviation
261(1)
7.3.4 Variance
262(1)
7.3.5 Measure of Skewness
262(1)
7.4 Probability Distributions
263(8)
7.4.1 Discrete Distributions
263(2)
7.4.2 Important Continuous Life Test Distributions
265(6)
7.5 Sampling Distributions
271(2)
7.5.1 Sampling Distributions Based on Sample Means and the Central Limit Theorem (Sampling Distribution of the Mean)
271(1)
7.5.2 Student's t Distribution
272(1)
7.5.3 Chi-Square Distribution (X2 Distribution)
272(1)
7.5.4 F Distribution
273(1)
7.6 Statistical Inference
273(3)
7.6.1 Estimation
273(3)
7.7 Statistical Hypothesis Testing
276(9)
7.8 Statistical Process Control
285(7)
7.8.1 Process Capability
290(2)
7.9 Statistical Experimental Design
292(46)
7.9.1 Up-and-Down Method
292(5)
7.9.2 Taguchi Technique (Orthogonal or Factorial Experiment)
297(19)
Analysis of Variance (ANOVA) Table Setup
316(8)
7.9.3 Regression and Correlation Analysis
324(1)
7.9.4 Introduction to Statistical Methods Using the SAS Package
325(13)
Bibliography
338
8 DESIGN FOR RELIABILITY
329(48)
8.1 Introduction
329(1)
8.2 Definitions and Probability Laws
330(3)
8.2.1 Independent Events
330(2)
8.2.2 Conditional Events
332(1)
8.2.3 Bayes' Theorem
332(1)
8.3 Basic Reliability Equation
333(1)
8.3.1 Mean Time to Failure (MTTF)
334(1)
8.4 Probability Distribution Functions Used in Reliability
334(8)
8.4.1 Bathtub Hazard Distribution
334(2)
8.4.2 Exponential Distribution
336(1)
8.4.3 Weibull Distribution
337(5)
8.5 Basic System Reliability
342(6)
8.5.1 Series System
343(1)
8.5.2 Parallel System
344(1)
8.5.3 Multistage System with Parallel Redundancy
345(1)
8.5.4 Parametric Method in System Reliability Evaluation
346(2)
8.6 Optimization of System Reliability
348(12)
8.6.1 Reliability Optimization for a Given Cost Constraint
348(2)
8.6.2 Cost Minimization for a Given Reliability Constraint
350(2)
8.6.3 Reliability Optimization for a Given Cost and Weight Constraint
352(8)
8.7 Maintainability
360(2)
8.7.1 Maintenance
360(2)
8.8 Availability
362(2)
8.9 Dependability
364(3)
8.10 Fault-Tree Analysis
367(2)
8.11 Probabilistic Design
369(5)
8.11.1 Safety Factor
370(2)
8.11.2 Interference Model
372(2)
8.12 Worst-Case Design
374(2)
Bibliography
376(1)
9 SAFETY AND ENVIRONMENTAL PROTECTION
377(50)
9.1 Our Contaminated Environment
377(3)
9.2 The Engineer and the Environment
380(1)
9.3 The Environmental Protection Agency
381(2)
9.4 Groundwater Contamination
383(5)
9.5 Soil and Groundwater Restoration
388(9)
9.6 Design of a Packed Tower
397(8)
9.6.1 Sizing the Tower Diameter
400(2)
9.6.2 Determining the Height of the Tower
402(3)
9.7 Air Pollution and Toxic Chemical Exposure
405(14)
9.7.1 Particulate Contamination
406(7)
9.7.2 Air Contamination from Hazardous Chemical Spills
413(6)
9.8 Occupational Safety and Health
419(2)
9.8.1 Occupational Safety and Health in Design
420(1)
9.9 Safety and Loss Prevention
421(1)
9.10 The Safety Engineer
422(2)
9.11 Closure
424(1)
Bibliography
424(3)
10 ENGINEERING ETHICS
427(42)
10.1 Ethics in Industry
427(1)
10.2 Ethics and the University
428(1)
10.3 The Foundation of Ethics
429(3)
10.4 Ethics in Engineering
432(2)
10.5 Legal Responsibilities of Engineers
434(2)
10.6 Codes of Ethics
436(4)
10.7 Codes Rules and Interpretations
440(22)
10.8 The NSPE Code of Ethics for Engineers
462(7)
11 COMMUNICATIONS IN ENGINEERING
469
11.1 Effective Communications
469(1)
11.2 The Formal Engineering Report
470(10)
11.2.1 The Abstract
472(1)
11.2.2 The Introduction
473(1)
11.2.3 Technical Approach (Theory)
473(2)
11.2.4 Test Setup
475(1)
11.2.5 Procedure
476(1)
11.2.6 Results and Discussion
477(1)
11.2.7 Conclusions
478(1)
11.2.8 References
479(1)
11.2.9 Appendix
480(1)
11.3 Proposal Preparation
480(3)
11.3.1 Background Problem Statement
481(1)
11.3.2 Objectives
482(1)
11.3.3 Technical Approach
482(1)
11.3.4 Budget
482(1)
11.3.5 Organization and Capabilities
483(1)
11.4 Oral Communications
483(2)
11.5 Oral Presentations
485(3)
11.5.1 Organizing the Oral Presentation
486(1)
11.5.2 Use of Visual Aids
487(1)
11.5.3 Types of Visual Aids
487(1)
11.5.4 Preparation of Slides and Transparencies
488(1)
11.6 A Final Word on Communication
488

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