Module

DESIGN & ENGINEERING

(Reference)

2 hours lecture and 2 hour practical per week (Cre

Reference Books (T):

1.

Exploring Engineering - An Introduction to Engineering and Design:

Balmer, R. T., Keat W. D., Wise, G., and Kosky P., Third Edition; (ISBN13: 978-0124158917ISBN-10: 0124158919) .

2.

Engineering Design - A Project based introduction:

Dym, C. L., Little, P. and Orwin E. J. Wiley; (ISBN-978-1-118-32458-5).

3.

Design for X Concurrent engineering imperatives:

Eastman C. M., Springer 1996; (ISBN 978-94-011-3985-4).

4.

Engineering Design Process:

Haik, Y. And Shahin M. T., Cengage Learning; (ISBN-13: 978-0-495-66816-9).

DESIGN & ENGINEERING

(Reference)

2 hours lecture and 2 hour practical per week (Cre

Reference Books (T):

4.

Engineering Design: A Systematic Approach:

Pahl, G., Beitz, W., Feldhusen J. and Grote, K. H., 3rd ed. 2007; (ISBN
978-1-84628-319-2).

6.

Engineering by Design:
Voland, G., Pearson India; (ISBN 978-93-325-3505-3).

7.

A Textbook of Design & Engineering:

Subin P George & Arun K Varghese., Pentex.

8.

Engineering by Design:
Dieter & Schmidt, McGraw Hill Education ( India) Edition 2013.

DESIGN & ENGINEERING

(Reference)

2 hours lecture and 2 hour practical per week (Cre

E References (E):
i.

http://opim.wharton.upenn .edu/ ulrich/designbook.html.

E-Book (Free download).

ii.

http://www2.warwick.ac.uk/fac/sci/wmg/ftmsc/modules/modulelist/peu
ss/designforx/design_for_x_notes_s ection_5.pdf.
E-Resources (Free download).

DESIGN & ENGINEERING

02 (Course Plan)
2 hours lecture and 2 hour practical per week (Credits
Module 3 (Detailed) (4 hrs. Theory & 4 hrs. Practice); Mark Weightage: 15%

Theory:
Prototyping:
Rapid

prototyping;

testing

and

evaluation

of

design;

Design

modifications; Freezing the design; Cost analysis.

Engineering the design.
From prototype to product. Planning; Scheduling; Supply chains;
inventory; handling; manufacturing / construction operations; storage;
packaging; shipping; marketing; feed-back on design.

Practice:
List out the standards organizations:
Prepare a list

of standard items used in any engineering specialization.

Develop any design with over 50% standard items as parts..

5

Prototypes

Ref:T8,
Ch8.10/Pg370

o Prototypes are physical models of the product

o that are tested in some way to validate
o the design decisions that have been made
o upto that point in the design process.
o Prototypes come in various forms and
o are used in different ways
o throughout the design process.

10/24/16 10:15:56 AM

Prototypes
(Phase Zero: Product Concept Model)

Ref:T8,
Ch8.10/Pg371

o A full-scale or reduced-scale model of a

o new product is made to look like the final product.

o Prepared by technical designers and
o industrial designers working collaboratively.
o Emphasis is on appearance to gage customer reaction
o to a possible new product.
o E.g.:
o a defence contractor trying to stir up interest in a new fighter
plane
o

would make up glitzy models and pass them around

o

to the generals and politicians

10/24/16 10:15:56 AM

Ref:T8,
Prototypes
Ch8.10/Pg371
(Conceptual Design: Proof-of-Concept
o A physical model to show whether the concept performs
Prototype)

o the functions that satisfy the customers needs and

o

corresponding engineering specifications.

o There may have been a succession of proof-of-concept models,

o some physical and others rough sketches,
o

that serve as learning

o

the final

tools

proof-of-concept

until

reaching

prototype.

o The proof-of-concept model dont look like the product as far as

o size, materials, or manufacturing methods are concerned.
o The emphasis is on showing that
o the concept will deliver the needed functions.
o It is sometimes known as a string and chewing gum model.
10/24/16 10:15:56 AM

Prototypes
(Embodiment Design: Alpha-Prototype
o The end of the embodiment design phase is usually
Testing)

Ref:T8,
Ch8.10/Pg371

o capped off by testing product prototypes.

o These are called alpha-prototypes because
o while the parts are made to the final design drawings
o

with the same materials as the product,

o

they are not made using

o

the same manufacturing processes

o

as the productionrun parts.

o E.g.:
o parts that might be made as castings or forgings in the production run
o

will be machined from plates or bar stock because

o

the tooling for the production parts is still being designed.

10/24/16 10:15:56 AM

Ref:T8,
Prototypes
Ch8.10/Pg371
(Detail Design: Beta-Prototype Testing)
o Involves full-size functional part or product testing

o using the materials and processes

o that will be used in production.
o This is a proof-of-process prototype.
o Often customers are enlisted to help run these tests.
o The results of the beta-prototype tests are used
o to make any remaining changes in the product,
o complete the production planning, and
o try out the production tooling
10/24/16 10:15:56 AM

10

Ref:T8,
Prototypes
Ch8.10/Pg371
(Manufacturing: Preproduction Prototype
o Represents the first
several thousand of units
Testing)

o of production from the actual production line

o using the assigned production workers.
o , the output from the line represents the product that
o will shortly be shipped and sold to the customer.
o The tests on these products are made to
o verify and document the quality of
o the

design

and

production

and

assembly

processes.

10/24/16 10:15:56 AM

11

Prototypes
(Physical vs Simulated Prototype)

Ref:T8,
Ch8.10/Pg372

o There is a trade-off between the number of prototypes

o that will be built for a product design and tested and
o

the cost and length of the product development

cycle.

o Prototypes help to verify the product but they have

o a high cost in money and time.
o As a result, there is a strong trend, particularly
o in large companies, to replace physical prototypes with
o

computer models (virtual prototypes)

o

because simulation is cheaper and faster.

10/24/16 10:15:56 AM

12

Prototypes
(Physical vs Simulated Prototype)

Ref:T8,
Ch8.10/Pg372

o There is a trade-off between the number of prototypes

o that will be built for a product design and tested and
o

the cost and length of the product development

cycle.

o Prototypes help to verify the product but they have

o a high cost in money and time.
o As a result, there is a strong trend, particularly
o in large companies, to replace physical prototypes with
o

computer models (virtual prototypes)

o

because simulation is cheaper and faster.

10/24/16 10:15:56 AM

13