Professional Documents
Culture Documents
Design
1) Creativity in design
Creativity:
Creativity is a mental process involving the generation of new ideas or concepts, or new associations of the
creative mind between existing ideas or concepts
* Creativity techniques:
-
inventorying
intuitive
associative
provocative
analytic-systematic
Rhodes distinction:
Creative
person
product
process
press or environment
4. illumination
5. verification
Time (faster)
Cost (cheaper)
Quality (better)
As the design process progresses, you gain knowledge but you lose freedom to use what you know. Time
and cost normally drive the design project, so there is rarely an opportunity to start over or to redo a design.
Project Planning
Identify the tasks (type of design project*)
Form a Team Design (available ressources)
Develop a project plan
Product discovery:
-Technology push
- Market push
- Product change
what is NOT about the QFD, 3 random good ones and Determine ABSOLUT importance of
requirements which is false
Resource concerns
Manufactory / Assembly requirements
Patents
Reference books
Trade journals
Research journals
Existing products
Contradiction = trade-off when you can improve something without something else gets worse
Axiomatic Design
Design is a logical process based on this relationship, according to Pr. Nam Suh of MIT
Process
Customer
Physical
Function
* Concept evaluation
-
Develop specifications
Generate concepts
Go/No-go screening:
-> Can the customer be satisfied by the given concept?
-> Is the technology (engineering & manufacturing) mature enough?
The field of mechanics relating to the motion of bodies under the action of forces is often
referred to as Dynamics.
Kinematics, which is the study of motion without reference to the forces which cause motion
Kinetics, which relates the action of forces on bodies to their resulting motions
** Reverse Engineering:
During the Reverse Engineering process, we create the CAD model of an existing object (engineering
elements, statue, etc.). Then in the same form or with the extension of necessary changes they can be
reproduced.
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Topology optimization
Numerical (FEA)
Shape optimization
**From the mathematical point of view two types of design variables can be distinguished:
Continuous or discrete design variables.
**From the physical point of view there are four types of the design variables or parameter
1. Mechanical or physical properties of the material (Material design variable)
2. Topology of the structure, connecting members of the scheme, or the number of members of the
interface schema; (Topology Design Variables)
3. The shape of the structure (Configurational or Geometric Design Variables)
4. Cross-Sectional Design Variables or the dimensions of the built-in elements
2) Optimization constraint
The restrictions that must be satisfied in order to produce a feasible design are called constraints.
Types of optimization constraints
-
The objective function (or cost function) is the function whose least value is usually wanted in an
optimization procedure. It is used to compare feasible designs in function of weight, cost, and any other
type of criterion.
Stochastic programming
** Pareto optimality:
a design is Pareto optimal if there does not exist any other design that satisfies all of the objectives better.
* The analysis step-by-step
Initial planning
Define the analysis problem
Select key variables for evaluation based on the criteria
Required solution accuracy, time allowed, number of analysis cycles
Approximate engineering analysis
Developing a conceptual FE model
Prepare first model: detailed mesh plan, apply BC, prepare load case(s)
deformation goes
5) Design Production
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Manufacturing
1)
MRP
Merits:
Just in time
MRP
60s = Material Requirements Planning
80s = Manufacturing Resource Planning
*MRP simplifying assumptions
Capacities (human, machine..) are infinite
Fixed lead times
Materials and components are available
**MRP concepts
Time: discrete bucket of time, finite horizon
Order (demand): product, quantities, external independent demand, internal demand, running jobs
Inventories: On-hand + projected inventories
Product structure: BOM= Bill Of Material
PORelease..)
Item master data (BOM, PLT)
scheduled
receipts
notice..)
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(change
MRP Process
2) Manufacturing systems
Manufacturing Technologies
- Component production
-material removal/separation (metal cutting*)
-additive technologies (3D printing, rapid-prototyping)
-Forming and shaping (rolling, forging, extrusion..)
-Casting
-Material joining (welding, soldering, mechanical joining)
-
- Assembly
* Metal cutting Machining
- Power source needed
- Relative motion between the Tool and the Workpiece
- Material removal = chips
Primary motion: Speed (rotating) of the Workpiece
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Types of manufacturing
Single (small number of product -1 to 100 a year- by using universal machines/cutting tools/fixtures
Series (small-medium or large series 100 to 10 000/year- using semi-automatic machines or NC, CNC
machine tools)
Mass (more than 10,000 work pieces/year, special machine tools, special tools, process oriented ans
preparation manufacturing)
Process Layout (product/sub-product goes to the different machines in the order of the process, batch or
job-shop syst., more complex material flow, higher flexibility, lower efficiency, more complex production
control, higher inventory level)
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Product Layout (Product to the machines, most regular for mass production simple production control,
highly reliable equipement)
** Group Technology:
It is a method of grouping parts to be produced according to similarities.
- Design similarities:
shape
size
functions
- Manufacturing process similarities
process type
surface roughness, tolerances
machine tool types
- Classification and coding using IT tools
- GT connects the design and production databases
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Flexibility in
product variety
production quantity
Improve productivity
Improve quality
*Types of Automation:
Hard Automation
-
Soft Automation
-
high flexibility
cutting
welding
heat treatment
melting
material deposition
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Lathe
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Tools Store:
-
Drum
Chain
Matrix
Robots Kinematics
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Application of Robots
Selection of Robots
Technical factors (Load-carrying capacity, Speed of movement, Reliability, Repeatability, Arm
configuration, Degrees of freedom, Control system, Work envelope
Economics (cost, benefit)
Robot safety
Conveyors types:
3)
* Aggregated production and capacity planning (tomb une fois mais TOUT savoir, jusqu
rsolution graphique type simple exemple slide 12, le tout pour 10pts !)
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Components of the machining time (tree diagram) (once asked but on 10pts !)
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Setup time
Preparation
Program loading, tools approaching, tools pre-setting, fixture positioning, work piece clamping,
alignment, zero-point determination, and program writing/editing
Finishing
Unclamping, cleaning, measuring inspection
** Direct costs of the manufacturing:
Material
Operation, machining: Setup time,
Measuring, inspection
Repairing, refuse replacement
Transportation
* Indirect costs:
Process planning, NC programming, scheduling
*** Tolerancing method
Tolerancing on the middle part.
1) Define the nominal tolerance
T=A+BC
2) Define the relative tolerance (- = enemy, it inverses max and min)
( Phy(A)-Phy(B) if 0<A<B )
Phy(A)+Phy(B) if A<0<B
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