Mechanical engineering design

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Course: Mechanical Engineering Practice resources
Book: Mechanical engineering design
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Date: Wednesday, 11 December 2024, 7:04 AM

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Mechanical engineering design

The basic engineering design process


The engineering design process is a series of steps that engineers follow to come up with a solution to a problem. The process includes a number of standard steps, as Uddin explains here.

As you watch this video, try to think of resources which you would need or which could help you for the following steps:

Establishing the task specifications

Brainstorming initial ideas and concepts

Using simulation to check the feasibility of the design

Producing a prototype 

Testing and improving your design

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A worked example of the engineering design process


In this video, Uddin works through a example of using the engineering design process to solve a problem. 

As you watch the video, we will ask you for design ideas for a device which could solve this problem. Make sure that you stop the video when asked to, and scribble down your ideas before moving on to Uddin's recommendations.  

 

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Workplace health and safety in design


Workplace health and safety principles must be critical considerations in the design, and building, and testing of your device. Otherwise, not only may the device fail, but somebody may be badly hurt.

In this video, Mr Jim Toshach, the WHS Manager for the UniSA Engineering Division, talks about how to incorporate WHS into the engineering design process.

In the Your Project lecture series, you will also see a lecture in which Jim discusses the practical aspects of WHS and your design.

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Mind mapping and brain storming


Mind mapping and brainstorming are techniques that engineering designers use to generate, express and organise ideas.

Brainstorming is simply thinking aloud and suggesting as many ideas as possible, no matter how mad they seem, without analysing or criticising them. Mind mapping is a way to get all of the ideas in your head down onto paper - a visual representation of your ideas.

There are no right or wrong ways to brainstorm or to mind map - it's whatever works for you and your group. 

Before watching the video, try this exercise:

Use a piece of paper to brainstorm and/or mind map as many solutions as you can to the engineering problem of desiging a mechanical device which move to a metre high barrier, lift a payload over the barrier, and pass it to another device which will carry it another 2 meters along a horizontal track.  

When you have finished, watch the video to see Michael's ideas. Did any of his ideas match yours?

You will also find other videos on design ideas, and brainstorming in the Your Project lecture series

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Selection of materials


Your selection of material will more than likely have a big impact on many aspects of your design, including effectiveness, cost, build difficulty, and so on. Michael talks about some of the considerations you will need to think about when selecting materials for your design.

After you watch, do some basic online research to find sources of device materials in your local area. Make sure that you double check the sizes and dimensions which they have available. Knowing your standard sizes early may make the device build much easier! 

 

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Selection criteria to assess your ideas


When you have let your brain and mind run free, and come up with as many design ideas as possible (no matter how crazy!) it's time to start the cold, hard, analytical process of weeding out the worst ideas and deciding on the best. To do this, you need to use objective selection criteria. 

In this video, Michael talks about what type of criteria are important in evaluating your ideas and how to measure your ideas against these criteria. 

As you watch, think about the following questions:

Why do you think that some bad design ideas make it through the selection process, even when the designer has used selection criteria in the decision making?

How can you guard against this happening to you or to your group in this course?

 

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Calculations


When you have decided on the basic design for your device, you will need to do the calculations to make sure that the design will achieve the aim: how much force is required, what size parts are needed, and so on.

Make sure that you double-check your own calculations (or get a classmate to do it for you) and include all calculations in your project documentation.   

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Modelling and simulation


Modelling and simulation are good ways to check whether your design assembly works without all the hassle of building it.

Using a model or a simulation (for example, in Solidworks), you can easily and cheaply find the weaknesses or mistakes in your design. 

Modelling and simulation each demonstrate different aspects of a design prior to the build. What are two aspects which modelling will that simulation won't, and visa versa?  

 

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Tolerances


it is important to be aware of the tolerances of the various components in your assembly - specifically, those tolerances which may affect the success of your design. You also need to find out the degree to which you need to check the tolerances. 

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Drawing your design


Even with the most sophisticated CAD programs, there is still an important place for freehand drawings in the design process. Michael makes the point that drawing design well takes practice, and is a valuable skill to for a mechanical designer to develop.

After watching this video, practice your drawing: start by producing a drawing of a simple household mechanical device (such as a can opener) and then try to work up to more challenging designs! 

 

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Prototyping


A prototype is basically a demonstration of your device (in this course, the prototype may also be the final device). It is the fully operational version of the engineering solution, although it can be made with different materials (which are cheaper and easier to work with) than the final version. 

Prototypes allow you to test how your solution will work - and you can show the solution to others for feedback.

After watching this video, check out the Eight rules for prototyping. 

 

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Fundamental electronics for your mechanical design


Although we tend to classify engineers into different specialisations (such as mechanical, electrical, civil, etc), the reality is that there are very few mechanical projects these days which don't include any electronics. 

Your device will need to use electronic software and hardware for its operation. In these two videos, Michael talks about the best types to use, and how to make the most of them. 

You can find more information on electronics for your device in the Your Project lecture series, in the videos on Electronics Software and Hardware.

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Putting switches into your design


Your device will probably need to include momentary or latching switches. In this video, Michael talks about the types of switches available and what you need for the desired result. he also discusses the micro-controllers you will need. 

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Holding it all together: joining techniques, frames and brackets


Have you ever come across a device with quality individual parts which were let down by poor joining strategies, or by a weak frame? Joining and outer frameworks, although they may not have a big input into the achievement of the device aims, could be a major cause of its lack of success!

Quality effective components may be meaningless if they are not held together effectively.

In this first video, Uddin discusses different methods of joining components for your device assembly, and how to avoid assembly weaknesses. 

At one stage in the video on Joining techniques, you are asked to study a poorly joined device and come up with some possible improvements.  What lessons are there here for your own design and build? 

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In this video, Uddin talks about frames and brackets to hold your device together.

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Testing your design, interpreting results and improving efficiency 


So ... the design is done, the prototype is built and you are ready to see if it works.

The testing and improvement process needs to be very carefully organised and documented, as Uddin explains here ...

As you watch, think about what you need to consider when testing and improving your own mechanical device.

Under what conditions will the testing need to be conducted?

How will you best implement any necessary improvements? 

 

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Useful references 


In this video, Michael discusses some books which might help in your design project. 

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Note that there are no slides for this video.