- •1. TABLE OF CONTENTS
- •DI:2. BASIC DESIGN
- •DI:2.1 REFERENCES
- •DI:3. COMMERCIAL
- •3.1 REFERENCES
- •DI:4. PRODUCT DESIGN
- •DI:4.1 LEGAL DESIGN AXIOMS
- •4.2 REFERENCES
- •DI:5. SPECIFICATIONS
- •5.1 REFERENCES
- •DI:6. DESIGN METHODS
- •DI:6.1 BLACK BOX DESIGN
- •DI:6.2 REFERENCES
- •DI:7. CONCEPTUAL DESIGN
- •DI:7.1 GENERATION OF CONCEPTS
- •DI:7.1.1 Brain Storming
- •DI:7.1.1.1 - Practice Problems
- •DI:7.1.2 Diagramming
- •DI:7.1.2.1 - Practice Problems
- •DI:7.1.3 Patents
- •DI:7.2 CONCEPT EVALUATION
- •DI:7.2.1 Decision Matrix
- •7.3 REFERENCES
- •DI:8. HUMAN FACTORS/ERGONOMICS
- •DI:8.1 ERGONOMICS
- •DI:8.2 SAFETY
- •DI:8.2.1 Environment
- •DI:8.2.2 MIL-STD 882B - System Safety Program Requirements
- •DI:8.3 HUMAN STRENGTH AND PROPORTIONS
- •DI:8.4 EQUIPMENT INTERFACES
- •8.5 REFERENCES
- •DI:9. MANAGEMENT
- •DI:9.1 PRACTICE PROBLEMS
- •9.2 REFERENCES
- •DI:10. DESIGN TEAMS
- •DI:10.1 TEAM PROFILES
- •DI:10.1.1 Personalities
- •DI:10.1.1.1 - Personality Traits
- •DI:10.1.1.2 - Personality Types
- •DI:10.1.2 Team Composition
- •DI:10.1.3 Team Success
- •10.2 REFERENCES
- •DI:11. ADMINISTRATION
- •11.1 REFERENCES
- •DI:12. CONCURRENT ENGINEERING
- •DI:12.1 OVERVIEW
- •DI:12.2 DOING CONCURRENT ENGINEERING
- •DI:12.3 FUTURE TOOLS FOR CONCURRENT ENGINEERING
- •DI:12.4 SOFTWARE CONCURRENT ENGINEERING
- •DI:12.5 METHODS
- •12.6 REFERENCES
- •DI:13. DESIGN FOR X (DFX)
- •DI:13.1 OVERVIEW
- •DI:13.2 DESIGN FOR ASSEMBLY (DFA)
- •DI:13.2.1 Design rule summary
- •DI:13.2.2 Rules for Manual/Automatic Assembly
- •DI:13.2.3 Reducing the Number of Parts
- •DI:13.2.4 Feeding and Orienting Parts
- •DI:13.2.4.1 - Part Tangling/Nesting
- •DI:13.2.4.2 - Handling Parts
- •DI:13.2.4.3 - Orienting Parts
- •DI:13.2.4.4 - Locating and Aligning Parts
- •DI:13.2.4.5 - Part Symmetry
- •DI:13.2.4.6 - Part Shape, Size and Thickness
- •DI:13.2.5 Mating Parts
- •DI:13.2.6 Adjustments
- •DI:13.2.7 Modular Assemblies
- •DI:13.2.8 Standard Parts
- •DI:13.2.9 Part Fixtures and Jigs
- •DI:13.2.10 Bottom Up Layered Assemblies
- •DI:13.2.11 Examples
- •DI:13.3 DESIGN FOR MANUFACTURING (DFM)
- •DI:13.4 DESIGN FOR RECYCLING (DFR)
- •DI:13.4.1 Reduce Materials and Energy
- •DI:13.4.2 Consolidated Parts
- •DI:13.4.3 Ease Of Disassembly
- •DI:13.4.4 Recycling Markings
- •DI:13.5 REFERENCES
- •DI:13.6 SAMPLE QUESTIONS
- •DI:13.7 AXIOMATIC DESIGN
- •DI:13.7.1 Suh’s Methodology
- •DI:13.7.1.1 - The Information Axiom
- •DI:14. DRAFTING
- •DI:14.1 CONVENTIONAL DRAFTING
- •DI:14.1.1 Manual Drafting
- •DI:14.1.2 Turning Three Dimensions Into Two (Multi View Drawings)
- •DI:14.1.2.1 - The Glass Box
- •DI:14.1.3 Lines
- •DI:14.1.4 Holes
- •DI:14.1.5 Special Cases
- •DI:14.1.5.1 - Aligned Features
- •DI:14.1.5.2 - Incomplete Views
- •DI:14.1.6 Section Views
- •DI:14.1.6.1 - Full Sections
- •DI:14.1.6.2 - Offset Section
- •DI:14.1.6.3 - Half Section
- •DI:14.1.6.4 - Cut Away Sections
- •DI:14.1.6.5 - Revolved Section
- •DI:14.1.6.6 - Removed Section
- •DI:14.1.6.7 - Auxiliary Section
- •DI:14.1.6.8 - Thin Wall Section
- •DI:14.1.6.9 - Assembly Section
- •DI:14.1.6.10 - Special Cases
- •DI:14.1.6.11 - Fill Patterns
- •DI:14.1.7 Auxiliary Views
- •DI:14.1.7.1 - Secondary Auxiliary Views
- •DI:14.1.7.2 - Partial Auxiliary Views
- •DI:14.1.8 Descriptive Geometry
- •DI:14.1.9 Isometric Views
- •DI:14.1.10 Special Techniques
- •DI:14.2 NOTATIONS
- •DI:14.2.1 Basic Dimensions and Tolerances
- •DI:14.2.2 Geometric Dimensioning and Tolerancing (GD & T)
- •DI:14.2.2.1 - Feature Control Symbols
- •DI:14.2.2.2 - Symbols and Meaning
- •DI:14.2.2.3 - Datums
- •DI:14.2.2.4 - Modifiers
- •DI:14.3 WORKING DRAWINGS
- •DI:14.3.1 Drawing Elements
- •DI:14.3.1.1 - Title Blocks
- •DI:14.3.1.2 - Drawing Checking
- •DI:14.3.1.3 - Drawing Revisions
- •DI:14.3.1.4 - Bill of Materials (BOM)
- •DI:14.3.2 Drawing Types
- •DI:14.3.2.1 - Assembly Drawings
- •DI:14.3.2.2 - Subassembly Drawings
- •DI:14.3.2.3 - Exploded Assembly Drawings
- •DI:14.3.2.4 - Detailed Drawings
- •DI:14.4 PRACTICE PROBLEMS
- •14.5 REFERENCES
- •DI:15. COMPUTER AIDED DESIGN (CAD)
- •DI:15.1 DESIGN
- •DI:15.2 CAD HISTORY
- •DI:15.3 BASIC REQUIREMENTS OF CAD SYSTEMS
- •DI:15.4 EDITING AND CREATING
- •DI:15.4.1 2D Curves and Lines
- •DI:15.4.2 Surfaces
- •DI:15.5 USER INTERPRETATION OF THE GEOMETRIC MODEL
- •DI:15.6 USER DIRECTED CHANGES TO THE GEOMETRIC MODEL
- •DI:15.6.1 Modern Hardware for CAD Systems
- •DI:15.7 SELECTING A CAD SYSTEM
- •DI:15.7.1 An Example Plan for Selecting a CAD system
- •DI:15.7.2 A Checklist of CAD/CAM System Features
- •DI:15.8 DESIGN
- •DI:15.8.1 Graphical User Interfaces
- •DI:15.9 PRACTICE PROBLEMS
- •DQ:16. GEOMETRICAL MODELLING OF PARTS
- •DQ:16.1 OVERVIEW
- •DQ:16.2 GEOMETRIC MODELS
- •DQ:16.2.1 Elemental Depiction:
- •DQ:16.2.2 Surface Description
- •DQ:16.2.3 Solid - Swept
- •DQ:16.2.4 Solid - B-Rep (Boundary Representation)
- •DQ:16.2.5 Solid - CSG
- •DQ:16.2.6 Tessellated Models
- •DQ:16.2.7 Features
- •DQ:16.3 SOLID MODELERS
- •DO:16.4 MASS PROPERTIES
- •DO:16.5 NON-MANIFOLD PARTS
- •DO:16.6 NUMERICAL ACCURACY
- •DO:16.7 PRACTICE PROBLEMS
- •DM:17. GEOMETRICAL MODELLING FOR DESIGN
- •DG:18. CAD FILE FORMATS
- •DG:18.1 GRAPHICS FORMATS
- •DG:18.2 CAD FORMATS
- •DG:18.2.1 Proprietary “Standard” Formats
- •DG:18.2.2 Standard Formats
- •DG:18.2.2.1 - IGES
- •DG:18.2.2.1.1 - Flag section (optional)
- •DG:18.2.2.1.2 - Start section
- •DG:18.2.2.2 - Global section
- •DG:18.2.2.3 - Directory entry sections
- •DG:18.2.2.4 - Parameter entry section
- •DG:18.2.2.5 - Terminate section
- •DG:18.2.2.6 - A Sample IGES File
- •DG:18.2.3 A DXF File
- •DG:18.3 PDES/STEP
- •DG:18.4 PRACTICE PROBLEMS
- •DC:19. COMPUTER AIDED ENGINEERING (CAE)
- •DC:19.1 FINITE ELEMENT ANALYSIS (FEA)
- •DC:19.2 ASSEMBLY AND KINEMATICS
- •DC:19.2.1 Tolerancing
- •DC:19.3 ASSEMBLIES
- •DC:19.4 OPTIMIZATION
page 23
noise - direct hearing or annoyance. (e.g., piercing tones, just too noisy)
1.special hearing protection equipment
2.redesign workspace to reduce noise reverberation
3.redesign equipment to reduce sound emmisions
DI:8.2 SAFETY
•It is natural for a machine to have hazardous parts/functions/flows.
•If the risk (probability) of comming in contact is high we call this danger
•Typical hazards include,
-pinch points
-crushing
-collision with moving objects
-falling from heights
-slippery surfaces
-explossion
-electric shock
-temperature/fire
-toxicity
-physical strain
•When possible it is best to eliminate hazards. If this is not possible we want to reduce the risk of access (hence danger).
•OSHA (Occupational Safety and Health Administration) regulates workplace procedures.
•Danger can be reduced by,
-signs
-safegaurds (e.g. barriers)
-policies and procedures
-worker training
-special protective equipment (e.g. earplugs)
•Typical additions to machines include,
-barrier gaurds - physical blocks to separate operators and equipment. Interlocks are used to disable the machine when the barrier is open.
-passive safety devices - for example seat belts
-active safety devices - these include
-hand pull-backs
-dead-man controls
-presence sensing devices
page 24
-maintenance safety devices - these additions (and procedures) ensure that the machine is still safe, even though the normal safety equipment is disabled.
-warnings - large warning signs, buzzers, status lights, etc. are used to promote awareness.
•Note: It is important to place safety considerations at the top of the design priorities. It is so obvious that it is quite often assumed.
DI:8.2.1 Environment
•Environmental considerations are a natural consideration of the design process and can be considered an extension of safety.
•design factors that will impact the environment include,
-discharges/waste (gas, liquids, solids) from production processes
-energy/fuel utilization in production
-aging of the product - decay, inert, toxic, etc.
-energy/fuel efficiency in use
•There are a wide variety of laws, agencies and organizations that influence manufacturing and consumer products,
OSHA (Occupational Safety and Health Administration) EPA (Environment Protection Agency)
NIOSH (National Institute for Occupational Safety & Health) UL (Underwriters Laboratory)
CSA (Canadian Safety Association)
DI:8.2.2 MIL-STD 882B - System Safety Program Requirements
•This standard addresses the likelyhood and acceptability of hazards.
•The basic tables are,