About the Companion Website xv

Introduction: Capstone Design Project

1 Engineering Design: Definitions and Methods 1

Types of Engineering Design 1

Engineering Design Process 3

Product Design 4

Mechanical Design 4

Electrical Design 4

Industrial Design 4

Civil Design 5

Architectural Design 5

Software Design 5

Systems Engineering in Engineering Design Process 5

Engineering Design Methods 6

Axiomatic Design 6

Biomimetic Design 6

Concurrent Engineering 7

Design for Assembly 7

Design for Manufacturability (Design for Manufacture and Assembly) 7

Design for Manufacture 7

Design for Properties and Life Cycle 8

Design for Scale 8

Design for Six Sigma 8

Design for Social Innovation 9

Design to the Edges 9

Efficiency Design 9

Human Scale Design 9

Interdisciplinary Design 9

Mixed Use Design 10

Modular Design 10

Naïve Design 14

Parallel Design 15

Passive Design 15

Quiet Design 15

Regenerative Design 15

Restorative Design 15

Reverse Engineering 16

Safety by Design 16

Slow Design 16

Social Design 16

Strategic Design 16

Sustainable Design 16

System Design 17

Transition Design 17

User Experience Design 17

Waterfall Design 17

2 Fundamental Design Principles 19

Research and Analysis of Existing Solutions 19

Ergonomics 19

Occam’s Razor 20

“Best Practices” of Product Development 21

Independent Functions: Keep the Functions of a Design Independent from One Another 22

Ideation, Creativity, and Brainstorming 22

Lateral Thinking 23

Duality of Innovation and Design 23

Engineering Design Practice 24

Units and Measurements 25

Fasteners and Methods of Attachments 25

Off-the-Shelf Components in Design 25

Modular Design 26

Freezes 26

Accuracy, Repeatability, and Resolution 26

Sensitive Directions 27

Reference Features 27

Managing Friction 28

Heat Resistance 30

Simplification of Model During Simulation 30

Centers of Action 31

Preloads and Press Fits 31

Design for Reliability 31

Factor of Safety Method 32

Aesthetics in Engineering Design 33

Engineering Verification and Validation 36

3 What Do You Need to Know Before Starting Capstone Project 37

Communications in Engineering Capstone Projects 37

Industrial Sponsors and IP in Capstone Projects 40

Types of Intellectual Property 41

Copyright 41

Industrial Design 41

Trademark 41

Patent 41

Trade Secret 42

Risk Management in Capstone Projects 42

Safety in Engineering Design 45

Engineering Ethics and Deontology 46

4 Design Phases in Mechanical Engineering Capstone Projects 49

Design Thinking Process 49

A Creativity Boosting Approach 50

Five Stages of Design Thinking 50

Design of Mechanical Systems: Iterative Process 51

Customer Statement 54

Principles of Team Forming 55

Work Organization: Gantt Chart and File with the Tasks 56

Problem Definition 60

Understanding the Problem 62

Clarification of Objectives 63

Establishing of User Requirements 65

Establishment of the Functions 67

Identification of Constraints 70

Formulation of Assumptions 77

Formulation of Design Requirements and Design Specifications 78

Project Definition 79

Collecting Information 79

Product Research 80

User Research 80

Market Research 80

Technical/Engineering Research 81

Literature and Other Sources of Information 81

Experimental and Test Data 86

Conceptual Design 89

The Core of Conceptual Design 89

Selection of Parameters for Conceptual Design 90

Development of Engineering Specifications 91

Brainstorming 92

Individual Brainstorming 93

Group Brainstorming 93

Selection of Evaluation Criteria and Contradiction Matrix 95

Generation of Alternatives 97

Engineering Analysis and Mathematical Modeling in Design 98

Types of Engineering Analysis 98

Main Stages of General Engineering Analysis 103

Tools for Engineering Analysis 104

Evaluation of Design Solutions and Decision Making 105

Criteria Selection 105

Decision-Making 105

Pugh Matrix 107

Layout at the Stage of Conceptual Design 108

Embodiment Design 108

Design Configuration and 3D CAD Modeling 109

Analysis of the Design 111

Detailed Design 112

Detailed Engineering Design 112

Detailed Design Iterations and Final 3D CAD Modeling of a Product 113

Selection of the Off-the-Shelf Components, Materials, and Suppliers 115

Compatibility of OTS Components with the Designed Product 116

Material Selection and Its Influence on Design 116

Ordering Standard Parts and Materials 117

Pre-production Adjustments (Corrections) 118

Manufacturing of the Product 120

5 Analysis and Optimization in Capstone Projects 121

Types of Analysis in Engineering Design 121

Strength and Other Load-related Characteristics 121

Static and Dynamic Loads 122

Stress and Stress Concentration 123

Strain 125

Hooke’s Law 126

FEA: Stress, Strain, and Displacement 126

Vibration Analysis 127

Potential Difficulties in Design for Vibrations 128

Methods of Elimination or Reducing Vibrations 129

Thermal Analysis 130

Fatigue Analysis 130

Computational Fluid Dynamics Analysis 131

Load Case Analysis 132

Worst-Case Scenario and Model Simplification 132

Optimization in Engineering Design 135

6 Design Graphics and Graphics Communication 137

Role of Graphics Communication in Engineering Design 137

Frequently Asked Questions on Graphics Communication 139

Principles of Presenting Good Manufacturing Drawings 146

View Placement and Formatting 146

Dimensioning 147

Assembly Drawings 148

Grading of Detailed Drawings: Typical Mistakes 148

7 Prototyping in Capstone Projects 151

Digital Manufacturing in Design Process and its Role in Capstone Project 151

Types of Traditional and Modern Manufacturing 153

Subtractive Manufacturing 153

Formative Processes 154

Additive Manufacturing 154

Additive Manufacturing and its Application to Product Development 155

Using Additive Manufacturing: Practical Hints and Warnings 160

Additive Manufacturing in Medical Applications 160

Test Assembling of the Prototype 162

8 Experiments, Testing, and Quality Control in Capstone Projects 163

Safety During Experiments and Testing 165

Design of Experiment or Test 165

Standardized Testing 165

Measurement Standards 166

Calibration and Certification 166

Types of Errors in Measurement Systems 166

Variables 168

Test and Experiment Plan 169

Quality Control 170

9 Design Process in Other Fields of Engineering 171

Design of Cardiovascular and Musculoskeletal Devices from Concept to Product 171

Introduction 171

Background: Vascular Structures 172

Vessel Anatomy and Blood Flow 172

Vessel Wall 172

Blood Flow 172

Cardiovascular Devices 174

Design of Cardiovascular Devices 176

Human Factor Engineering 177

Design in Software Engineering 178

Control System Design 179

Design in Electrical Engineering 180

Design in Chemical Engineering 181

Appendix: Design Definitions and Terminology 183

References 199

Index 203