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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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Lead Media Project Manager:Stacy A. Patch

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.

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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

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