fundamentals of engineering design prof lachmayer 2011

Institut für Produktentwicklung & Gerätebau

Prof. Dr. Roland J. Lachmayer

Fundamentals of Enineering

design

Lecture to Global Poduction Logistic students at JUB


Institute for product development and optomechatronic systems engineering


Welfengarten 1A, D-30167 Hannover

http://www.ipeg.uni-hannover.de

[email protected]

Phone: +49 511 762 3472

Seite 3


Engineering Design

Course Name 050131

Credits 2,5

Grade 90 min written test on Friday 28 January 2011 9:30-11:30

• Questions and answers (10-20)

• 3-4 calculations/drawings

Lectures:

Thursday 13th Jan. 2011 9:45 - 12:30 and 14:15 - 18:30

Friday 14th Jan. 2011 8:15 - 12:30 and 14:15 - 18:30

Friday 21st Jan. 2011 8:15 - 12:30

Friday 28th Jan. 2011 9:30 – 11:30 (Test of 90 min)

Lecture Hall Research II


Need: • Paper A3

• Set square / ruler

• pencil

Seite 4


Course Description

The course will provide a general understanding of innovation and development management and

the processes and methods used to develop and design machines with its context to logistics

engineering.

Basic aspects of development methods will be explained:

Development processes including specification, conceptual design and detailed design as

well as different types of modular approaches and development levels will be trained. The

use and need of design standards DIN/ISO, patents/IP and CAD systems will be shown.

An introduction to the general parts and elements of machines such and their function will be

given:

• Shafts, springs, screws, bearings, gears

For selected examples basic methods to dimension these elements and machines with respect to

material and tension will be explained.

Specific focus will be given to the interrelations between product modularization and logistics as

well as the importance of logistic planning during the development process.

The course contents lectures and exercises.


Seite 5


Engineering Design

1. Fundamentals/Introduction

Need to innovate

Fundamentals of technical systems

Products, costs and logistics

2. Product creation

Product planning and development processes

Clarification and specifications

Concepts and modular design

3. Embodiment design

Design standards DIN/ISO and drawings

Design rules and principles

Outlook to CAD use and CAE tools

4. Materials and mechanics

Material parameters

Fundamentals of mechanic stress calculation

5. Dimensioning of design elements

Shafts, springs, screws, bearings

Gears

6. Conclusion

Strategy and IP

Total Quality Management


Day 1

Day 2

Day 3

Seite 6


Targets of chapter 1

• Basic understanding of the development of industrial

production/products

• Product Lifecycle

• Innovations due to Software, Photonic and Nanotechnology

• Mechatronic Systems / Technical Systems

• Product Costs

• Link between product design and logistics


Seite 7


Material – Energy - Signal


Signal Energy Material

Quelle: Roth

Seite 8


Modell of Long Waves


Steam engine

Railway steel

Chemical

Industries

Mass

Production

Electronic

Communication

Nano

Bio

Health

Telecommunication

Today

Seite 9


Product Lifecycle


Quelle: Pahl/Beitz

Seite 10


Software related Innovations


Moore‘s law: • 2x number of transistors on chips

• 18 month

Mechatronics, „intelligent machines“

Microsystem- and Nanotechnology

Software agents

Optoelectronics and Photonics

Networked systems and Mobility

Light engineering

Virtual Reality/Augmented Reality

Seite 11


Virtual Reality


Seite 12


Technical systems


Quelle: Pahl/Beitz

Seite 13


Constraints during design


Seite 14


Structure of Mechatronics


Quelle: Gausemeier

Information

processing

Digital/analog

conversion

Analog/digital

conversion Amplification

Actuator(s)

Digital/analog

conversion

Sensor(s)

Basic system

Human Information

Processing

units

Communication

system

Energy

feed

Operator interface

(human-machine

interface)

Digital quantities

Analog quantities

Energy

feed Energy

feed

Flow of information Flow of material Flow of energy

Seite 15


„New“ Market-Constellation


Quelle: Gausemeier

Past Today

Costs and time to market

Only two reasons to buy a new product:

1. Value added

2. Cheaper

drive developments

Vertical integration is a risk

Seite 16


Costs to Market


Quelle: Pahl/Beitz

• Typical picture of project business

• For mass production design phase is

much larger related to building and

testing of products, but design costs and

may also be much higher than product

costs

Seite 17


Total costs of ownership


Cost of material

Maintenance costs

(Maintenance, repairs,

Inspection)

Manufacturing costs

(Cost of labor, production

overhead costs)

Cost of operation

(Energy, operating

materials, auxiliaries,

operation)

Costs for:

Management, marketing,

development, …

non-recurring costs for:

Transport, installation,

environmental protection,

scrapping

Production costs acquisition costs

Manufacturer

costs

Product user

costs

Requirements:

Funktion, Safety,…

Total cost of product

Quelle: Ehrlenspiel

Seite 18


Costs responsibility


Quelle: VDI 2235

Development Process

engineering Purchasing

Sales and

marketing

Cost responsibility and influence

Cost generation

Seite 19


Cost impact of design


Quelle: Pahl/Beitz

Seite 20


Impact of Complexity


Constriction to core business

Co-operation with „refiners“ for specific market niches

Options for action:

No. of

variants

Revenue Stock Stock Revenue

Variants cause a lot of stock but do not increase revenue significantly

No. of

variants

Plant A Plant B

Seite 21


Segments of Products


Intensity of technology is responsible for com-

plexity of production and process development in

R&D.

Intensity of labor provides information on amount

of manual labor in production.

Radius of market indicates reasonable

transportation of product from manufacturing

plant to customer

Seite 22


Function of a Company


Quelle: Gausemeier

Seite 23


Engineering Design


Need to innovate



2. Product creation









Material parameters




Gears

6. Conclusion

Strategy and IP



Seite 24



• Basic understanding of development process

• Specification Technologies

• Development of concepts

• Use of building blocks and modular design


Seite 25


Innovation drivers


Life cycle of a product

Quelle: Pahl/Beitz

Market driven innovation Technology driven innovation

Research

Advanced

development

Design

Planning

Production

Seite 26


General approach to design


Quelle: Pahl/Beitz

Types of designs:

• New design

• Modification design

• Adaptation design

Seite 27


Development for mass production


Quelle: Pahl/Beitz

Seite 28


Product Requirements List


Quelle: Pahl/Beitz

Seite 29


Specification Technologies

• Product checklist

• Brainstorming

• Analysis of Product Lifecycle

• Analysis of Product Use and Environment

• Market survey / User Clinic


Seite 30


Example of a specification list


• Quality of requirements

• Fixed

• Targeted

• Wishes

• Date changes

• Responsabilities

• Concrete and measurable

Quelle: Pahl/Beitz

Seite 31


Introduction to the examples


Seite 32


Checklist for specification


Performance

Geometry

Materials

Energy

Time

Cost

Manufacture

Standards

Safety

Transport

Ergonomics

Seite 33


Conceptual design


Quelle: Pahl/Beitz

Seite 34


Establish functional structure


Seite 35


Example car lifter

Seite 36


Search for working principles


Quelle: Pahl/Beitz

Seite 37




Different working principles that satisfy the function “store energy“ obtained by varying the type of energy

Quelle: Pahl/Beitz

Seite 38




Seite 39


Combination of principals


Quelle: Pahl/Beitz

Seite 40




Quelle: Pahl/Beitz

Seite 41




Seite 42




Seite 43


Evaluation of concepts


Seite 44


Parameter design


Seite 45


Modularity / Building Blocks


Quelle: Pahl/Beitz

Seite 46


Modularity / Building Blocks


Seite 47


Types of construction


Product Composite

construction

Seite 48


Engineering Design


Need to innovate



2. Product creation









Material parameters




Gears

6. Conclusion

Strategy and IP



Seite 49


Targets of chapter 3 - Drawings

• Basic understanding of technical drawing standards

• Ability to read and understand technical drawings

• Ability to draw technical scratches

• Basic understanding of tolerances and surface parameters

• Understanding of basic design values and principals

• Use and need of technical documents

• Basic understanding of computer aided engineering


Seite 50


CNC Machining Centre


Quelle: Hüller Hille GmbH

Seite 51


Component drawing


Seite 52


Assembly drawing


Bill of material

DIN 6771 Form A

Seite 53


Design drawing


Seite 54


Exploded assembly drawing


Seite 55


Important Standards for Drawings


35

15

50

Front view

Sid

e vi

ew

Top view

Top view

Side

view Front

view

1 2

3 4

(5) (6)

(7)

(8)

Front view Side view

Seite 56


Projection


Side view

from right

Side view

from left

Bottom view

Front view

Top view

Rear view

Seite 57


Dimensioning


Examples for Dimensioning of angles

Dimension arrow head

Linear dimension

Arrow head

Extension line

Measure

Dimendion line

Seite 58


Dimensioning


Seite 59


General tolerances


Seite 60


Types of sectional drawings


Full section Half section

Partial sections

Seite 61


Cutting lines


Seite 62


Screw threads


External screw thread: hexagon head screw ISO 4014

Internal screw thread: tapped blind hole

Seite 63



Seite 64



Seite 65


Tolerances


Ao = Go – N

Au = Gu – N

T = Go - Gu = Ao - Au

Seite 66


Tolerances


Seite 67


Often used tolerance classes


Seite 68


Surfaces


Rz: Mean Roughness Depth

Ra: Roughness Average

Seite 69


Surface symbols


Seite 70


Surface specifications


unmachined Roughed

down smoothed finished Very fine

machined

Seite 71


Reuse norm parts and solutions


Seite 72


Reuse norm parts and solutions


• Database of norm part as well in DIN/ISO but

also from suppliers

• Today geometries of norm parts can

automatically be copied into CAD programs

• Different types of export systems are in use

Seite 73


Design catalogue


Quelle: Roth

Seite 74


Influences on Notch Effect


Seite 75


Influences on Notch Effect


Seite 76


Bearing arrangements


a. O.K

b. Specific

c. Dangerous

Allow thermal expansion!

Seite 77


Avoiding double fits


Quelle: Pahl/Beitz

Seite 78


Self-reinforcing seals


Self-reinforcing seals:

a self-sealing washer

b tubeless tyre

c radial shaft seal

d sleeve seal

e sliding ring seal

Quelle: Pahl/Beitz

Seite 79


Reduce stiffness


Quelle: Pahl/Beitz To avoid breaking

Seite 80


Ensure guidance


Quelle: Pahl/Beitz

Seite 81


Parameters of embodiment design


Characteristic

Shape

Position

Size

Quantity

Variant

Seite 82


Rules for moulding


Seite 83


Design rules for manufacturing


Seite 84


Bill of material/drawings


Bill of

material

Construction Production/

Assembly

Purchasing/

Storage

Distribution After sales

service

Accounting

Process

planning

Production

planning and

control

Seite 85


Design Defense


Seite 86


Computer aided design


Virtual prototype

Digital Mock-up

Element design Product structure Kinematics,

dynamics, stability

Seite 87


Visualisation


Seite 88


Virtual Prototyping


Seite 89


Computer Aided Planning


Analysis of assembly line ergonomics

(Source: Siemens PLM Software)

3D-model of factory building (Source: Siemens PLM

Software)

Seite 90


Computer Aided Planning


Model components

SPS code of

production system

Gantt-chart with necessary states of

manufacturing steps

Seite 91


Engineering Design


Need to innovate



2. Product creation









Material parameters




Gears

6. Conclusion

Strategy and IP



Seite 92



• Basic understanding of Hooke’s law

• Understanding of fracture behavior of steel

• Dynamic influence on material strength

• Hardness

• Fundamentals of stress and strain


Seite 93


Material


Seite 94


Material


Material Design

Seite 95


Stress and Strain


Seite 96


Fracture Behaviour


Elastic / plastic brittle

Tensile strength Rm

Elastic strength Re

Elastic limit Rp 0.2

Elastic Modulus E

Ultimate strain A

Seite 97


Dynamic Fatigue Test


Seite 98


Stress


Seite 99


Stress


Seite 100



Comparison stress

Seite 101


Dynamic Fatigue Strength


Seite 102


Engineering Design


Need to innovate



2. Product creation









Material parameters




Gears

6. Conclusion

Strategy and IP



Seite 103



• Basic understanding of design elements

Springs

Bolted connections

Roller bearings


Seite 104


Design Elements


Axes:

stagnant revolving

Shaft:

Seite 105


Design Elements


(1) Bearing seat (2) Shaft-hub joint (3) Axial fixation (4) Shaft seal

Seite 106


Springs


Steel springs Rubber springs

Seite 107


Springs


progressive

linear

degressive

Stored work W

F, Mt

f, φ

Seite 108


Examples of Springs


Seite 109


Springs


Parallel

Series

Seite 110


Bolted Connections


Embodiment of bolted

connections:

a) Bolt and nut

b) Stud bolt

c) Headed screw

d) Extension bolt

Seite 111


Bolted Connections


Seite 112


Bolted Connections


F

f

FS

FSB

FPB

FB

fs fp

fg

FP

FV

cS cP

PS

Vgcc

Ff11

PBVP FFF

SBVS FFF

PS

SBSB

cc

cFF

PS

PBPB

cc

cFF

Seite 113


Fatigue Strength


+σ

zdw

-σ

zdw

Bolt:

e.g. property class 5.6 ( ≙ E295) ⇒ σAzul = ± 50 N/mm2

Construction steel:

e.g. E295, σm = 200 N/mm2 ⇒ σAzul = ± 95 N/mm2

Seite 114


Bolted Connections


Seite 115


Roller Bearings – DIN 625


Seite 116


Roller Bearings – DIN 625


Seite 117


Bearings – Design


Possibilities of axial fixation

Shaft nut with lock washer

Retaining rings for shafts and bore holes

Seite 118


Bearings – Design


Fixed and floating bearing arrangement

Semi-locating bearing arrangement

Seite 119


Gears


Normal efficiency ~ 97%

Seite 120


Gears – Example


Seite 121


Gears – Example


Seite 122


Engineering Design


Need to innovate



2. Product creation









Material parameters




Gears

6. Conclusion

Strategy and IP



Seite 123



• Basic understanding of quality

• FMEA

• Total quality and balanced Scorecards

• Strategy and innovation

• Patents

Integrated innovation


Seite 124


Errors


Develop and

plan

Buy and produce

Discovery of errors Prevention of errors

Err

or

Cost

s

Seite 125


Errors


Phases in product lifecycle

Err

or

rate

Errors fixed

Error cause

Seite 126


Failure Mode and Effect Analysis


Seite 127




Quality of products

Quality of processes

Quality of work

Quality of contact with

customers and suppliers

Implementing TQM in stages

DIN ISO 9001 certification as standard

Elements of TQM Targets of TQM

Optimal satisfaction of external

customers

Optimal satisfaction of internal

customers

Minimal costs

Increase of productivity

Increase of market

share

TQM expresses overall success

Seite 128


Balanced Scorecard


Strategic goals Indicator Oper. goals Activities

Seite 129


Competitive Ability


Competitive capability

Future orientation

Seite 130


Strategy


Seite 131


Impact on Strategy


Differentiation

Efficiency

Timing

Concentration of power

Build upon strengths

Take advantage of synergistic effects

Take advantage of environmental

chances

Balance of ressources and goals

Unité de doctrine

Seite 132


Innovation


Seite 133


Patents


Seite 134


Integrated innovation


Scenarios

Strategies

Processes

Systems

Seite 135


Literature

G. Pahl, u.a.: Engineering design, 3rd edition

Springer Verlag, Berlin, 2007, ISBN 978-1-84628-318-5

P. Kosky, u.a.: Exploring engineering, 2nd edition

Academic press, San Diego, 2010, ISBN 978-0-12-374723-5

J. Gausemeier, u.a.: Zukunftsorientierte Unternehmensgestaltung

Carl Hanser Verlag, München, 2009, ISBN 978-3-446-41055-8

W. Steinhilper, u.a.: Konstruktionselemente des Maschinenbaus 1 u.2, 6st edition

Springer Verlag, Berlin, 2008, ISBN 978-3-540-76646-9

K. Roth: Konstruieren mit Konstruktionskatalogen 1 u.2, 3rd edition

Springer Verlag, Berlin, 1994, ISBN 3-540-09815-1


fundamentals of engineering design prof lachmayer 2011

Documents

notch effect

siemens plm

technical

drawings design

development

design elements

working principles

gertebau errors