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ullman-38162 ull75741_fm December 18, 2008 16:19

The Mechanical Design Process

ullman-38162 ull75741_fm December 18, 2008 16:19

McGraw-Hill Series in Mechanical Engineering

Alciatore/Histand

Introduction to Mechatronics and Measurement System

Anderson

Fundamentals ofAerodynamics

Anderson

Introduction to Flight

Anderson

Modern Compressible Flow

Barber

Intermediate Mechanics of Materials

Beer/Johnston

Vector Mechanics for Engineers

Beer/Johnston

Mechanics of Materials

Budynas

Advanced Strength andApplied StressAnalysis

Budynas/Nisbett

Shigley"s Mechanical Engineering Design

Cengel

Heat Transfer:APracticalApproach

Cengel

Introduction to Thermodynamics & Heat Transfer

Cengel/Boles

Thermodynamics:An EngineeringApproach

Cengel/Clmbala

Fluid Mechanics: Fundamentals andApplications

Cengel/Turner

Fundamentals of Thermal-Fluid Sciences

Dieter

Engineering Design:AMaterials & ProcessingApproach

Doebelin

Measurement Systems:Application & Design

Dorl/Byers

Technology Ventures: From Idea to Enterprise

Dunn Measurement & DataAnalysis for Engineering and Science

Fianemore/Franzial

Fluid Mechanics with EngineeringApplications

Hamrock/Schmid/Jacobson

Fundamentals of Machine ElementsHeywoodInternal Combustion Engine Fundamentals

Holman

Experimental Methods for Engineers

Holman

Heat Transfer

Hutton

Fundamental of Finite ElementAnalysis

Kays/Crawford/Welgand

Convective Heat and Mass Transfer

Meirovioeh

Fundamentals of Vibrations

Norton

Design of Machinery

Palm

System Dynamics

Reddy

An Introduction to Finite Element Method

Schey

Introduction to Manufacturing Processes

Shames

Mechanics of Fluids

Smith/Hashemi

Foundations of Materials Science & Engineering

Turns

An Introduction to Combustion: Concepts and

Applications

Ugural

Mechanical Design:An IntegratedApproach

Ullman

The Mechanical Design Process

White

Fluid Mechanics

White

Viscous Fluid Flow

Zeid

CAD/CAM Theory and Practice

Zeid

Mastering CAD/CAM

ullman-38162 ull75741_fm December 18, 2008 16:19

The Mechanical

Design Process

Fourth Edition

David G. Ullman

Professor Emeritus, Oregon State University

ullman-38162 ull75741_FM December 30, 2008 9:25

THE MECHANICAL DESIGN PROCESS, FOURTH EDITION

Published by McGraw-Hill, a business unit of The McGraw-Hill Companies, Inc., 1221Avenue of the Americas, New York, NY 10020. Copyright © 2010 by The McGraw-Hill Companies, Inc.All rights

reserved. Previous editions © 2003, 1997, and 1992. No part of this publication may be reproduced or

distributed in any form or by any means, or stored in a database or retrieval system, without the prior

written consent of The McGraw-Hill Companies, Inc., including, but not limited to, in any network or other electronic storage or transmission, or broadcast for distance learning.

Some ancillaries, including electronic and print components, may not be available to customers outside

the United States.

This book is printed on acid-free paper.

1234567890

DOC/DOC 0 9

ISBN 978-0-07-297574-1

MHID 0-07-297574-1

Global Publisher:Raghothaman Srinivasan

Senior Sponsoring Editor:Bill Stenquist

Director of Development:Kristine Tibbetts

Senior Marketing Manager:Curt Reynolds

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Associate Design Coordinator:Brenda A. Rolwes

Cover Designer:Studio Montage, St. Louis, Missouri

Cover Image:Irwin clamp: © Irwin Industrial Tools; Marin bike: © Marin Bicycles; MER: © NASA/JPL.

Senior Photo Research Coordinator:John C. Leland

Compositor:S4Carlisle Publishing Services

Typeface:10.5/12 Times Roman

Printer:R. R. Donnelley Crawfordsville, IN

Library of Congress Cataloging-in-Publication Data

Ullman, David G., 1944-

The mechanical design process / David G. Ullman.—4th ed. p. cm.—(McGraw-Hill series in mechanical engineering)

Includes index.

ISBN 978-0-07-297574-1—ISBN 0-07-297574-1 (alk. paper)

1. Machine design. I. Title.

TJ230.U54 2010

621.8

15—dc222008049434

www.mhhe.com ullman-38162 ull75741_fm December 18, 2008 16:19

ABOUT THE AUTHOR

David G. Ullmanis an active product designer who has taught, researched, and written about design for over thirty years. He is president of Robust Decisions, Inc., a supplier of software products and training for product development and tion systems. He has published over twenty papers focused on understanding the mechanical product design process and the development of tools to support it. He is founder of theAmerican Society Mechanical Engineers (ASME)—Design Theory and Methodology Committee and is a Fellow in the ASME. He holds a Ph.D. in Mechanical Engineering from the Ohio State University. ullman-38162 ull75741_fm December 18, 2008 16:19 ullman-38162 ull75741_fm December 18, 2008 16:19

CONTENTS

Preface xi

CHAPTER1

Why Study the Design Process?1

1.1Introduction 1

1.2Measuring the Design Process with Product

Cost, Quality, and Time to Market 3

1.3The History of the Design Process 8

1.4The Life of a Product 10

1.5The Many Solutions for Design

Problems 15

1.6The BasicActions of Problem Solving 17

1.7Knowledge and Learning During Design 19

1.8Design for Sustainability 20

1.9Summary 21

1.10Sources 22

1.11Exercises 22

CHAPTER2

Understanding Mechanical

Design25

2.1Introduction 25

2.2Importance of Product Function, Behavior,

and Performance 28

2.3Mechanical Design LanguagesandAbstraction 30

2.4Different Types of MechanicalDesign Problems 33

2.5Constraints, Goals, andDesign Decisions 40

2.6Product Decomposition 41

2.7Summary 442.8Sources 44

2.9Exercises 45

2.10On the Web 45

CHAPTER3

Designers and Design Teams47

3.1Introduction 47

3.2The Individual Designer:AModel of Human

Information Processing 48

3.3Mental Processes That OccurDuring Design 56

3.4Characteristics of Creators 64

3.5The Structure of Design Teams 66

3.6Building Design Team Performance 72

3.7Summary 78

3.8Sources 78

3.9Exercises 79

3.10On the Web 80

CHAPTER4

The Design Process and Product

Discovery81

4.1Introduction 81

4.2Overview of the Design Process 81

4.3Designing Quality into Products 92

4.4Product Discovery 95

4.5Choosing a Project 101

4.6Summary 109

4.7Sources 110

4.8Exercises 110

4.9On the Web 110

vii ullman-38162 ull75741_fm December 18, 2008 16:19 viiiContents

CHAPTER5

Planning for Design111

5.1Introduction 111

5.2Types of Project Plans 113

5.3Planning for Deliverables—

The Development of Information 117

5.4Building a Plan 126

5.5Design Plan Examples 134

5.6Communication During the

Design Process 137

5.7Summary 141

5.8Sources 141

5.9Exercises 142

5.10On the Web 142

CHAPTER6

Understanding the Problem and

the Development of Engineering

Speci“cations143

6.1Introduction 143

6.2Step 1: Identify the Customers:

WhoAre They? 151

6.3Step 2: Determine the Customers"

Requirements:WhatDo the Customers

Want? 151

6.4Step 3: Determine Relative Importance of theRequirements:Who Versus What155

6.5Step 4: Identify and Evaluate the Competition:How SatisfiedAre the CustomersNow? 157

6.6Step 5: Generate EngineeringSpecifications:HowWill the Customers"

Requirement Be Met? 158

6.7Step 6: Relate Customers"Requirements toEngineering Specifications:Howto Measure

What?163

6.8Step 7: Set Engineering Specification Targetsand Importance:HowMuch Is Good

Enough? 1646.9Step 8: Identify Relationships BetweenEngineering Specifications: HowAre theHowsDependent on Each Other? 166

6.10Further Comments on QFD 168

6.11Summary 169

6.12Sources 169

6.13Exercises 169

6.14On the Web 170

CHAPTER7

Concept Generation171

7.1Introduction 171

7.2Understanding the Function of ExistingDevices 176

7.3ATechniqueforDesigningwithFunction 181

7.4Basic Methods of Generating Concepts 189

7.5Patents as a Source of Ideas 194

7.6Using Contradictions to Generate Ideas 197

7.7TheTheoryofInventiveMachines,TRIZ 201

7.8Building a Morphology 204

7.9Other Important Concerns During ConceptGeneration 208

7.10Summary 209

7.11Sources 209

7.12Exercises 211

7.13On the Web 211

CHAPTER8

Concept Evaluation and

Selection213

8.1Introduction 213

8.2Concept Evaluation Information 215

8.3Feasibility Evaluations 218

8.4Technology Readiness 219

8.5The Decision Matrix—Pugh"s Method 221

8.6Product, Project, and Decision Risk 226

ullman-38162 ull75741_fm December 18, 2008 16:19

Contentsix

8.7Robust Decision Making 233

8.8Summary 239

8.9Sources 239

8.10Exercises 240

8.11On the Web 240

CHAPTER9

Product Generation241

9.1Introduction 241

9.2BOMs 245

9.3Form Generation 246

9.4Materials and Process Selection 264

9.5Vendor Development 266

9.6Generating a Suspension Design for the

Marin 2008 Mount Vision Pro Bicycle 269

9.7Summary 276

9.8Sources 276

9.9Exercises 277

9.10On the Web 278

CHAPTER10

Product Evaluation for

Performance and the Effects

of Variation279

10.1Introduction 279

10.2Monitoring Functional Change 280

10.3The Goals of Performance Evaluation 281

10.4Trade-Off Management 284

10.5Accuracy, Variation, and Noise 286

10.6Modeling for Performance Evaluation 292

10.7ToleranceAnalysis 296

10.8SensitivityAnalysis 302

10.9Robust Design byAnalysis 305

10.10Robust Design Through Testing 308

10.11Summary 31310.12Sources 313

10.13Exercises 314

CHAPTER11

Product Evaluation: Design For

Cost, Manufacture, Assembly,

and Other Measures315

11.1Introduction 315

11.2DFC—Design For Cost 315

11.3DFV—Design For Value 325

11.4DFM—Design For Manufacture 328

11.5DFA—Design-For-Assembly

Evaluation 329

11.6DFR—Design For Reliability 350

11.7DFT and DFM—Design For Test andMaintenance 357

11.8DFE—Design For the Environment 358

11.9Summary 360

11.10Sources 361

11.11Exercises 361

11.12On the Web 362

CHAPTER12

Wrapping Up the Design Process

and Supporting the Product363

12.1Introduction 363

12.2Design Documentation and

Communication 366

12.3Support 368

12.4Engineering Changes 370

12.5PatentApplications 371

12.6Design for End of Life 375

12.7Sources 378

12.8On the Web 378

ullman-38162 ull75741_fm December 18, 2008 16:19 xContents

APPENDIXA

Properties of 25 Materials Most

Commonly Used in Mechanical

Design379

A.1Introduction 379

A.2Properties of the Most Commonly Used

Materials 380

A.3Materials Used in Common Items 393

A.4Sources 394

APPENDIXB

Normal Probability397

B.1Introduction 397

B.2Other Measures 401

APPENDIXC

The Factor of Safety as a

Design Variable403

C.1Introduction 403C.2The Classical Rule-of-Thumb Factor of Safety 405

C.3The Statistical, Reliability-Based,

Factor of Safety 406

C.4Sources 414

APPENDIXD

Human Factors in Design415

D.1Introduction 415

D.2The Human in the Workspace 416

D.3The Human as Source of Power 419

D.4The Human as Sensor and

Controller 419

D.5Sources 426

Index427

ullman-38162 ull75741_fm December 18, 2008 16:19

PREFACE

I easy for me. I have been fortunate in having whatever talents are necessary to design courses, I came to the realization that I didn"t know how to teach what I knew so well. I could show students examples of good-quality design and poor- quality design. I could give them case histories of designers in action. I could Additionally, I realized from talking with other mechanical design teachers that

I was not alone.

This situation reminded me of an experience I had once had on ice skates. As a novice skater I could stand up and go forward, lamely. A friend (a teacher by trade) could easily skate forward and backward as well. He had been skating since he was a young boy, and it was second nature to him. One day while we were skating together, I asked him to teach me how to skate backward. He said it was easy, told me to watch, and skated off backward. But when I tried to do what he did, I immediately fell down.As he helped me up, I asked him to tell me exactly what to do, not just show me. After a moment"s thought, he concluded that he couldn"t actually describe the feat to me. I still can"t skate backward, and I suppose he still can"t explain the skills involved in skating backward. The frustration that I felt falling down as my friend skated with ease must have been the same emotion felt by my design students when I failed to tell them exactly what to do to solve a design problem. This realization led me to study the process of mechanical design, and it eventually led to this book. Part has been original research, part studying U.S. in- dustry, part studying foreign design techniques, and part trying different teaching approaches on design classes. I came to four basic conclusions about mechanical design as a result of these studies:

1.The only way to learn about design is to do design.

2.In engineering design, the designer uses three types of knowledge: knowl-edge to generate ideas, knowledge to evaluate ideas and make decisions, andknowledge to structure the design process. Idea generation comes from ex-perience and natural ability. Idea evaluation comes partially from experienceand partially from formal training, and is the focus of most engineering ed-ucation. Generative and evaluative knowledge are forms of domain-specificknowledge. Knowledge about the design process and decision making islargely independent of domain-specific knowledge.

3.A design process that results in a quality product can be learned, provided

there is enough ability and experience to generate ideas and enough experi- ence and training to evaluate them. xi ullman-38162 ull75741_fm December 18, 2008 16:19 xiiPreface

4.A design process should be learned in a dual setting: in an academic envi-

ronment and, at the same time, in an environment that simulates industrial realities. I have incorporated these concepts into this book, which is organized so that readers can learn about the design process at the same time they are developing a product. Chaps. 1-3 present background on mechanical design, define the terms that are basic to the study of the design process, and discuss the human element of product design. Chaps. 4-12, the body of the book, present a step-by-step development of a design method that leads the reader from the realization that there is a design problem to a solution ready for manufacture and assembly. This material is presented in a manner independent of the exact problem being solved. The techniques discussed are used in industry, and their names have become buzzwords in mechanical design: quality function deployment, decision-making methods, concurrent engineering, design for assembly, and Taguchi"s method for robust design. These techniques have all been brought together in this book. Although they are presented sequentially as step-by-step methods, the overall process is highly iterative, and the steps are merely a guide to be used when needed. As mentioned earlier, domain knowledge is somewhat distinct from process knowledge. Because of this independence, a successful product can result from the design process regardless of the knowledge of the designer or the type of design problem. Even students at the freshman level could take a course using this text and learn most of the process. However, to produce any reasonably realistic design, substantial domain knowledge is required, and it is assumed book is intended for upper-level undergraduate students, graduate students, and professional engineers who have never had a formal course in the mechanical design process.

ADDITIONS TO THE FOURTH EDITION

Knowledge about the design process is increasing rapidly. A goal in writing the fourth edition was to incorporate this knowledge into the unified structure—one of the strong points of the first three editions. Throughout the new edition, topics have been updated and integrated with other best practices in the book. Some specific additions to the new edition include:

1.Improved material to ensure team success.

2.Overtwentyblanktemplatesareavailablefordownloadfromthebook"sweb-site (www.mhhe.com/ullman4e) to support activities throughout the designprocess. The text includes many of them filled out for student reference.

3.Improved material on project planning.

ullman-38162 ull75741_fm December 18, 2008 16:19

Prefacexiii

4.Improved sections on Design for the Environment and Design for

Sustainability.

5.Improved material on making design decisions.

6.Anew section on using contradictions to generate ideas.

7.New examples from the industry, with new photos and diagrams to illustratethe examples throughout.

Beyond these, many small changes have been made to keep the book current and useful.

ELECTRONIC TEXTBOOK

CourseSmart is a new way for faculty to find and review eTextbooks. It"s also a great option for students who are interested in accessing their course materials adopted textbooks across hundreds of courses from a wide variety of higher text of a textbook online, providing immediate access without the environmental impact of requesting a print exam copy. At CourseSmart, students can save up to 50% off the cost of a print book, reduce their impact on the environment, and gain access to powerful Web tools for learning including full text search, notes and highlighting, and email tools for sharing notes between classmates. www.CourseSmart.com

ACKNOWLEDGMENTS

I would like to thank these reviewers for their helpful comments: Patricia Brackin,Rose-Hulman Institute of Technology

William Callen,Georgia Institute of Technology

Xiaoping Du,University of Missouri-Rolla

Ian Grosse,University of Massachusetts-Amherst

Karl-Heinrich Grote,Otto-von-Guericke University, Magdeburg, Germany

Mica Grujicic,Clemson University

John Halloran,University of Michigan

Peter Jones,Auburn University

Mary Kasarda,Virginia Technical College

Jesa Kreiner,California State University-Fullerton

Yuyi Lin,University of Missouri-Columbia

Ron Lumia,University of New Mexico

Spencer Magleby,Brigham Young University

Lorin Maletsky,University of Kansas

quotesdbs_dbs17.pdfusesText_23

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