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ullman-38162 ull75741_fm December 18, 2008 16:19
The Mechanical Design Process
ullman-38162 ull75741_fm December 18, 2008 16:19McGraw-Hill Series in Mechanical Engineering
Alciatore/Histand
Introduction to Mechatronics and Measurement SystemAnderson
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 & ProcessingApproachDoebelin
Measurement Systems:Application & Design
Dorl/Byers
Technology Ventures: From Idea to Enterprise
Dunn Measurement & DataAnalysis for Engineering and ScienceFianemore/Franzial
Fluid Mechanics with EngineeringApplications
Hamrock/Schmid/Jacobson
Fundamentals of Machine ElementsHeywoodInternal Combustion Engine FundamentalsHolman
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
PalmSystem Dynamics
ReddyAn Introduction to Finite Element Method
ScheyIntroduction to Manufacturing Processes
Shames
Mechanics of Fluids
Smith/Hashemi
Foundations of Materials Science & Engineering
TurnsAn Introduction to Combustion: Concepts and
Applications
Ugural
Mechanical Design:An IntegratedApproach
Ullman
The Mechanical Design Process
WhiteFluid Mechanics
WhiteViscous Fluid Flow
ZeidCAD/CAM Theory and Practice
ZeidMastering CAD/CAM
ullman-38162 ull75741_fm December 18, 2008 16:19The Mechanical
Design Process
Fourth Edition
David G. Ullman
Professor Emeritus, Oregon State University
ullman-38162 ull75741_FM December 30, 2008 9:25THE 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 rightsreserved. 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.
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DOC/DOC 0 9
ISBN 978-0-07-297574-1
MHID 0-07-297574-1
Global Publisher:Raghothaman Srinivasan
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Associate Design Coordinator:Brenda A. Rolwes
Cover Designer:Studio Montage, St. Louis, MissouriCover Image:Irwin clamp: © Irwin Industrial Tools; Marin bike: © Marin Bicycles; MER: © NASA/JPL.
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Library of Congress Cataloging-in-Publication DataUllman, David G., 1944-
The mechanical design process / David G. Ullman.4th ed. p. cm.(McGraw-Hill series in mechanical engineering)Includes index.
ISBN 978-0-07-297574-1ISBN 0-07-297574-1 (alk. paper)1. Machine design. I. Title.
TJ230.U54 2010
621.815dc222008049434
www.mhhe.com ullman-38162 ull75741_fm December 18, 2008 16:19ABOUT 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 16:19CONTENTS
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 282.3Mechanical 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 viiiContentsCHAPTER5
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 EngineeringSpecications143
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