The Engineering Design Process

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ISBN: 9780471136996 | 0471136999
Cover: Paperback
Copyright: 10/11/1996

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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.

1 THE ENGINEERING DESIGN PROCESS

(50)

1.1 The Definition of Design

(1)

1.2 Design: Art or Science?

(1)

1.3 The Design Process

(34)

1.3.1 Recognition of Need

(3)

1.3.2 Conceptualization and Creativity

(5)

1.3.3 Feasibility Assessment

(1)

1.3.4 Establishing the Design Requirements

(2)

1.3.5 Synthesis and Analysis in the Design Process

(1)

1.3.6 The Organizational/Work Breakdown Structure

(1)

1.3.7 Preliminary Design

(3)

1.3.8 Detailed Design

(7)

1.3.9 Production Process Planning and Tooling Design

(3)

1.3.10 Production

(2)

1.3.11 The Product Realization Process

(1)

1.3.12 Design for Manufacture and Assembly

(7)

1.4 Other Important Design Considerations

(3)

1.4.1 Product Distribution and Use

(1)

1.4.2 Design Life

(2)

1.4.3 Human Factors Considerations

(1)

1.5 Advanced Technology for the Design Process

(7)

1.5.1 Concurrent Simultaneous Engineering

(1)

1.5.2 Computer-Aided Design/Computer-Aided Manufacturing

(2)

1.5.3 Solids or Surfaces

(3)

1.5.4 Rapid Prototyping

(1)

1.5.5 Computer-Integrated Manufacturing

(1)

1.6 The Design Process

(2)

Bibliography

(2)

2 MANAGING DESIGN PROJECTS

(44)

2.1 The "Buck" Stops at the Manager's Desk

(1)

2.2 Management Techniques

(6)

2.2.1 Total Quality Management

(4)

2.3 Effective Project Management

(3)

2.4 Planning and Scheduling the Effort

(7)

2.4.1 The Gantt Chart

(3)

2.4.2 PERT Networks

(1)

2.4.3 The Critical Path Method

(4)

2.4.4 Summary

(1)

2.5 Clarifying the Project Objectives

(4)

2.5.1 The Objectives Tree Method

(3)

2.5.2 Coordination with Client and Management

(1)

2.6 Decision Making

(7)

2.6.1 Decision Matrices

(2)

2.6.2 Decision Trees

(4)

2.7 Improving the Product

(13)

2.7.1 Functional Cost Analysis

(2)

2.7.2 Failure Mode, Effects, and Criticality Analysis

(2)

2.7.3 Taguchi Methods

(8)

2.8 Engineer or Manager?

(1)

Bibliography

(2)

3 MODELING AND SIMULATION

(30)

3.1 Modeling in Engineering

(2)

3.2 Heuristic Modeling

(2)

3.3 Mathematical Modeling

(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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The Engineering Design Process

Summary

Author Biography

Table of Contents

Supplemental Materials