Preface xi
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
