Engineering Design: A Project-based Introduction

Dym, Little and Orwin's Engineering Design: A Project-Based Introduction, 4th Edition gets students actively involved with conceptual design methods and project management tools. The book helps students acquire design skills as they experience the activity of design by doing design projects.  It is equally suitable for use in project-based first-year courses, formal engineering design courses, and capstone project courses.

Clive Dym was a professor emeritus of Engineering Design and also Director of the Center for Design Education at Harvey Mudd College. He served as the chair of the engineering department at Harvey Mudd College from 1999 through 2002.

Foreword     

Preface                                                                                                                              

Acknowledgments                                                                                                          

Part I: Introduction                                                                                                       

Chapter 1 Engineering Design
What does it mean to “design” something? Is engineering design different from other kinds of design?

1.1 Where and when do engineers design?                                                                  

1.2 A basic vocabulary for engineering design                                                           

Defining engineering design                                                                                          

Assumptions underlying our definition of engineering design                                

Measuring the success of an engineering design                                                        

Form and function                                                                                                           

Design and systems                                                                                                         

Communication and design                                                                                            

1.3 Learning and doing engineering design                                                                 

Engineering design problems are challenging                                                             

Learning design by doing

1.4 Managing engineering design projects                                                                   

1.5 Notes      

Chapter 2 Defining a Design Process and a Case Study
How do I do engineering design? Can you show me an example?  

2.1 The design process as a process of questioning                                                   

2.2 Describing and prescribing a design process                                                        

2.3 Informing a design process                                                                                      

Informing a design process by thinking strategically                                                 

Informing a design process with formal design methods                                           

Acquiring design knowledge to inform a design process                                          

Informing a design process with analysis and testing                                                

Getting feedback to inform a design process                                                              

2.4 Case study: Design of a stabilizer for microlaryngeal surgery                          

2.5 Illustrative design examples                                                                                    

2.6 Notes      

Part II: The Design Process and Design Tools                                                         

Chapter 3 Problem Definition: Detailing Customer Requirements
What does the client require of this design?                                                             

3.1Clarifying the initial problem statement                                                                

3.2 Framing customer requirements                                                                              

Lists of desired attributes and of design objectives                                                   

3.3 Revised project statements: Public statements of the design project                

3.4 Designing an arm support for a CP-afflicted student                                           

3.5 Notes      

Chapter 4 Problem Definition: Clarifying the Objectives
What is this design intended to achieve?

4.1 Clarifying a client’s objectives                                                                               

Representing lists of objectives in objectives trees                                                   

Remarks on objectives trees                                                                                          

The objectives tree for the juice container design                                                      

4.2 Measurement issues in ordering and evaluating objectives                               

4.3 Rank ordering objectives with pairwise comparison charts                               

An individual’s rank orderings                                                                                      

Aggregating rank orderings for a group                                                                        

Using pairwise comparisons properly                                                                          

4.4 Developing metrics to measure the achievement of objectives                         

Establishing good metrics for objectives                                                                     

Establishing metrics for the juice container                                                                

4.5 Objectives and metrics for the Danbury arm support                                          

4.6 Notes      

Chapter 5 Problem Definition: Identifying Constraints
What are the limits for this design problem?                                                             

5.1 Identifying and setting the client’s limits                                                              

5.2 Displaying and using constraints                                                                            

5.3 Constraints for the Danbury arm support                                                              

5.4 Notes      

Chapter 6 Problem Definition: Establishing Functions
How do I express a design’s functions in engineering terms?

6.1 Establishing functions                                                                                              

Functions: Input is transformed into output                                                                

Expressing functions                                                                                                       

6.2 Functional analysis: Tools for establishing functions                                         

Black boxes and glass boxes                                                                                          

Dissection, or reverse engineering                                                                                

Enumeration                                                                                                                     

Function-means trees                                                                                                      

Remarks on functions and objectives                                                                           

6.3 Design specifications: Specifying functions, features and behavior                

Attaching numbers to design specifications                                                                

Setting performance levels                                                                                             

Interface performance specifications                                                                           

House of Quality: Accounting for the customers’ requirements                              

6.4 Functions for the Danbury arm support                                                                 

6.5 Notes      

Chapter 7 Conceptual Design: Generating Design Alternatives
How do I generate or create feasible designs?

7.1 Generating the “design space,” a space of engineering designs

Defining a design space by generating a morphological chart                                 

Thinking metaphorically and strategically                                                                  

The 6–3–5 method                                                                                                           

The C-sketch method                                                                                                      

The gallery method                                                                                                          

Guiding thoughts on design generation                                                                        

7.2 Navigating, expanding and contracting the design space                                   

Navigating design spaces                                                                                                

Expanding a design space when it is too small                                                           

Contracting a design space when it is too large                                                          

7.3 Generating designs for the Danbury arm support                                                

7.4 Notes      

Chapter 8 Conceptual Design: Evaluating Design Alternatives and Choosing a Design
Which design should I choose? Which design is “best”?                 

8.1 Applying metrics to objectives: Selecting the preferred design                        

Numerical evaluation matrices                                                                                      

Priority checkmark method                                                                                            

Best of class chart                                                                                                            

An important reminder about design evaluation                                                        

8.2 Evaluating designs for the Danbury arm support                                                 

8.3 Notes

Part III: Design Communication                                                                                

Chapter 9 Communicating Designs Graphically
Here’s my design; can you make it?                                                     

9.1 Engineering sketches and drawings speak to many audiences                          

9.2 Sketching                                                                                                                    

9.3 Fabrication specifications: The several forms of engineering drawings          

Design drawings                                                                                                               

Detail drawings                                                                                                                

Some Danbury arm support drawings                                                                           

9.4 Fabrication specifications: The devil is in the details                                         

9.5 Final notes on drawings                                                                                            

9.6 Notes      

Chapter 10 Prototyping and Proofing the Design
Here’s my design; how well does it work?                                           

10.1 Prototypes, models and proofs of concept                                                          

Prototypes and models are not the same thing                                                            

Testing prototypes and models, and proving concepts                                              

When do we build a prototype?                                                                                     

10.2  Building models and prototypes                                                                          

Who is going to make it?                                                                                                

Can we buy parts or components?                                                                                

How, and from what, will the model/prototype be made?                                         

How much will it cost?                                                                                                    

10.3 Notes    

Chapter 11 Communicating Designs Orally and in Writing
How do we let our client know about our solutions?

11.1 General guidelines for technical communication                                              

11.2 Oral presentations: Telling a crowd what’s been done                                     

Knowing the audience: Who’s listening?                                                                    

The presentation outline                                                                                                 

Presentations are visual events                                                                                      

Practice makes perfect, maybe . . .                                                                                

Design reviews                                                                                                                 

11.3 The project report: Writing for the client, not for history                                

The purpose of and the audience for the final report                                                 

The rough outline: Structuring the final report                                                           

The topic sentence outline: Every entry represents a paragraph                             

The first draft: Turning several voices into one                                                          

The final, final report: Ready for prime time                                                              

11.4 Final report elements for the Danbury arm support                                          

Rough outlines of two project reports                                                                          

One TSO for the Danbury arm support                                                                         

The final outcome: The Danbury arm support                                                            

11.5 Notes    

Part IV: Design Modeling, Engineering Economics and Design Use                  

Chapter 12 Mathematical Modeling in Design
Math and physics are very much part of the design process!

12.1 Some mathematical habits of thought for design modeling                              

Basic principles of mathematical modeling                                                                 

Abstraction, scaling and lumped elements                                                                  

12.2 Some mathematical tools for design modeling                                                   

Physical dimensions in design (I): Dimensions and units                                         

Physical dimensions in design (II): Significant figures                                              

Physical dimensions in design (III): Dimensional analysis                                       

Physical idealizations, mathematical approximations and linearity                       

Conservation and balance laws                                                                                     

Series and parallel connections                                                                                     

Mechanical-electrical analogies                                                                                    

12.3 Modeling a battery-powered payload cart                                                          

Modeling the mechanics of moving a payload cart up a ramp                                 

Selecting a battery and battery operating characteristics                                          

Selecting a motor and motor operating characteristics                                              

12.4 Design modeling of a ladder rung                                                                         

Modeling a ladder rung as an elementary beam                                                          

Design criteria                                                                                                                  

12.5 Preliminary design of a ladder rung                                                                     

Preliminary design considerations for a ladder rung:

Preliminary design of a ladder rung for stiffness                                                        

Preliminary design of a ladder rung for strength                                                        

12.6 Closing remarks on mathematics, physics and design                                      

12.7 Notes    

Chapter 13 Engineering Economics in Design
How much is this going to cost?

13.1 Cost estimation: How much does this particular design cost?                         

Labor, materials and overhead costs                                                                            

Economies of scale: Do we make it or buy it?                                                            

The cost of design and the cost of the designed device                                             

13.2 The time value of money                                                                                       

13.3 Closing considerations on engineering and economics                                    

13.4 Notes    

Chapter 14 Design for Production, Use and Sustainability
What other factors influence the design process?

14.1 Design for production: Can this design be made?                                             

Design for manufacturing (DFM)                                                                                  

Design for assembly (DFA)                                                                                            

The bill of materials and production                                                                            

14.2 Design for use: How long will this design work?                                               

Reliability    

Maintainability                                                                                                                 

14.3 Designing for sustainability: What about the environment?                            

Environmental issues and design

Global climate change                                                                                                     

Environmental life cycle assessments                                                                          

14.4 Notes    

Part V: Design Teams, Team Management and Ethics in Design                        

Chapter 15 Design Team Dynamics
We can do this together, as a team!                                                                             

15.1 Forming design teams                                                                                             

Stages of group formation                                                                                              

Team dynamics and design process activities                                                             

15.2 Constructive conflict: Enjoying a good fight                                                      

15.3 Leading design teams                                                                                             

Leadership and membership in teams                                                                          

Personal behavior and roles in team settings                                                              

15.4 Notes    

Chapter 16 Managing a Design Project
What do you want? When do you want it? How much are we going to spend?        

16.1 Getting started: Establishing the managerial needs of a project                      

16.2 Tools for managing a project’s scope                                                                  

Team charters                                                                                                                   

Work breakdown structures                                                                                           

16.3 The team calendar: A tool for managing a project’s schedule                         

16.4 The budget: A tool for managing a project’s spending                                     

16.5 Monitoring and controlling projects: Measuring a project’s progress           

16.6 Managing the end of a project                                                                               

16.7 Notes    

Chapter 17 Ethics in Design
Design is not just a technical matter.                                                   

17.1 Ethics: Understanding obligations                                                                       

17.2 Codes of ethics: What are our professional obligations?                                 

17.3 Obligations may start with the client . . .                                                             

17.4  . . . but what about the public and the profession?                                            

17.5 On engineering practice and the welfare of the public                                     

17.6 Ethics: Always a part of engineering practice                                                    

17.7 Notes    

Appendices                                                                                                                       

Appendix I: Practical Aspects of Prototyping                                                             

AI.1 Working safely in a shop                                                                                       

AI.2 Selecting materials                                                                                                  

AI.3 Building techniques                                                                                                

AI.4 Selecting a fastener                                                                                                 

Fastening wood                                                                                                                

Fastening polymers                                                                                                          

Fastening metals                                                                                                               

What size temporary fastener should I choose?                                                         

AI.5 Notes    

Appendix II:  Practical Aspects of Engineering Drawing                                           

AII.1 Dimensioning                                                                                                          

Orthographic views                                                                                                         

Metric vs. Inch

Line types     

Orienting, spacing and placing dimensions                                                                 

Types of dimensions                                                                                                       

AII.2 Geometric tolerancing                                                                                           

The 14 geometric tolerances                                                                                          

Feature control frames                                                                                                    

Material condition modifiers                                                                                         

Datums          

Position tolerance                                                                                                            

Fasteners      

AII.3 How do I know my part meets the specifications in my drawing?                 

AII.4 Notes   

Appendix III: Exercises

References and Bibliography                                                                                       

Index

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