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Engineering

• Engineering a science or art ?

Design & Engineering
• Who is an Engineer ?
(BE 102)
• How a scientist differ from an engineer ?

Scientists & Engineers

Science – study of nature Scientists discover the world that exists;
engineers create the world that never was

Technology – application of science

Engineering - Process of collecting scientific

knowledge and converting them in a systematic
manner to technology

Engineering Design
• We are solving a problem – 2 way to look at it

1. Problem is new – so solution will be new

• It is a decision-making iterative process, in
2. Already a solution is available – we need to give an
which the basic sciences, mathematics, and improved solution
engineering are applied to optimally convert
resources to meet a stated objective.
• In Design we need to find an optimal solution that
satisfy certain constrains

• Constrains – time , money…….

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Design Levels
1. Adaptive Design
• Designer first studies working principle of certain existing
machines / System and slightly modifies the structure imposing
his ideas.

• Existing design can be adopted for new design with some

modification

• Design activity of this kind demands no special knowledge or

skill

• problems presented are easily solved by a designer with

ordinary technical training.

2. Development Design
• designer starts from an existing design, but the final
outcome may differ from the initial product

• scientific training and design ability are needed for

development design.

• Eg. development could be from a manual gearbox in

a car to an automatic one

• traditional tube-based television to the modern

plasma and LCD versions

3. New design
• Only a small number of designs are new designs

• generating a new concept involves mastering all the

previous skills in addition to creativity and
imagination, insight, and foresight.

• It is the most difficult level of design

• Eg. - design of the first automobile, airplane, or even

the wheel (a long time ago)

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• Japan is a world leader in high-speed trains

• These bullet trains travel safely at over 200 miles per

hour (322 km/hr)

• The Japanese rail system has many tunnels.

• When a high-speed train passes through a tunnel, Air

pushed along in front of the train.

• When the kingfisher hits the water, there is a major

pressure difference, somewhat similar to the pressure
changes caused by bullet trains

Objectives of design • To reduce the complexity of the component.

• To identify the need of the user.

• To increase the efficiency of the component.
• To do research and know about the various
possibilities of problem solving. • To increase the ergonomic features of the
designs there by making it more user friendly.
• To fix and formulate a working principle of the
solution.
• To increase the safeness of the component
under various static and dynamic conditions.
• To complete the product design with in the affixed
time period.
• To make an eco-friendly material.
• To reduce the cost of the design process.

Common design constraints

• Functional constraints Functional Constrain
1. Overall geometry
2. Kinematics involved • Limit on the working principle of a product
3. Energy requirement
4. Materials used
5. Control System 1. Overall geometry
6. Information flow
• Safety constraints • Components in a system should be designed
• Quality constraints with proper dimension , volume and space
• Manufacturing constraints requirement to satisfy its intended function
• Time constraints
• Economical constraints • Eg. Diameter of shaft should not be smaller than
• Ecological constraints bearing
• Legal and ethical constraints
• Ergonomical and Aesthetic constraints

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2. Kinetics involved
• Product should be able to withstand the static
and dynamic forces acting on it

3. Energy requirement
• Input energy requirement for a particular
function may vary for different products

• Use of appropriate transducers and amplifiers

help in proper functioning of product

4. Material constrains
Landing gear • Material used for product should have sufficient strength

• Some constrains in choosing material are availability of

materials , cost effectiveness , machinability , weldability
….

5. Control System
• It transfers signal from one part of product to another part

• It involves various mechanical and electrical components

• Main constrains in control system are the proper

positioning of sensors and other fragile components in
severe operating condition

DELHI IRON PILLAR- INDIAN

METALLURGICAL BEAUTY

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6. Information flow Safety Constraints

• Involve numerical and graphical data based on
input and output of device
• Main constrains are errors in display unit ,
measurements , calibration of devices etc…..
• Every component should have a factor of
safety limit for design
• Common safety constraints include
– Operational safety constraints
– Environmental safety constraints
– Constraints due to inevitable human errors during
operations

Manufacturing constraints
• Internal constrains in a manufacturing unit include
– Availability of raw materials
– Availability of proper machineries
– Machining time
– Amount of wastage and unused byproduct
– Labour shortage
• External constrains in a manufacturing unit include
– Quality and reliability of raw material
– Total quality management
– Assembly constraints due to installation
Quality constraints
• Product must be passed through several regulation
and testing to ensure its quality
Time constraints
• Design must be completed with in stipulated time
limit
Ecological constraints
• Design of product should be eco friendly to eliminate
its toxic effect
• Disposal of exhausts and bi-products to environment
should be properly monitored

Economic Constraints Ergonomical and Aesthetic constrains

• Product should be visually pleasing and
• Some factors influencing economic constraints
comfortable in handling
are
– Demand for product
– Design costs Legal and Ethical constraints
– Development cost • Product should be approved by various
– Manufacturing cost organization to ensure its safety and quality
– Distribution cost • Patent and copyright should be taken for design
– Availability of resources to avoid legal issues

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Activity 1: Identify which among the following is having a better

design . Justify ?
Hints
• Material required ?
• Stress acting on material ?
• Easiness of manufacturing ?
• Stability ?
• Cost of manufacturing ?
• Space occupied when packed ?

Spherical Can

• It has smallest surface area for a given volume so it

use least amount of material

• No corners, so uniform stress on the wall

• It is difficult manufacture

• It will roll off when we placed on the table

• 74% volume taken by the product and 26% is void

space

Square Shape can Cylinder can

• It won’t roll off-Stable when we placed on the table • No corners so uniform stress on the wall
• uncomfortable to hold and drink
• Cylinder can be easily manufactured
• Easy to manufacture
• Packing factor 91%
• corners are there and un equal distribution of stress

• 100% volume taken by the product 0% void space

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Design Function Portable drilling Machine - Design Functions

• This is about the specifics, the design is planned to do

• Function refers to the way a technical system works

Primary function – It is the basic operational outcome of

the device

Secondary required functions – It supports primary

functions

Secondary unwanted functions – Undesirable by

product eg. Generate heat , generate noise

Primary
Engineering Design Functions –
• The drill should switch off if the load exceeds. Broad Classification
• The drill should work in high humidity 1. Research Function
• Identifying the need for the product
Secondary • Defining the working principle
• Convert Energy • Collection of data required for the process
• Compact and less weight
• Research on better alternative

Secondary unwanted
2. Engineering Function
• Generate heat
• Generate Noise • Deals with the technical functioning of product

3. Manufacturing Functions Design Means

• Determines method of production , tools use
• It is about the approaches to make it function
• Purchase of raw material , labours needs
as proposed
4. Quality control Functions
• Two approaches for a design
• Involve quality control of product , safety
considerations, dimensional accuracy Evolutionary change - A product is allowed to
evolve over a period of time

5. Commercial Functions Innovation – Creative skills and analytical ability is

• Include relationship with client , marketing , sales , required
logistics…

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Design Form

Form is the shape of the design.

Often the design starts with form
Eg. A building design starts with sketches
Form has not much to do with the function.
For the same function the shape could be
different

Same function – Different forms

Automobiles Gate

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Role of Science ,Engineering and

Design & Engineering- Scheme
Technology in design
• First internal exam – closed book exam – 25 marks

• Second internal exam – open book exam – 25 marks

• Assignment and projects – 50 marks

• End semester exam – open book exam – 50 marks

( 2 hours duration – conducted by the University)

• Fields of science, engineering and technology are mutually

interdependent Optical Microscope
• Advances in science offers new capabilities, materials,
processes that can be applied through engineering to
produces advances in technology

• Advancement in technology provide scientists new

capability to probe natural world at larger or smaller scale

• Eg. Science gives the principal of thermal measurement –

thermal expansion of solids and liquids

• Engineer convert this principle to Technology by Designing a

thermometer

Scanning Electron Microscopy (SEM) Transmission Electron Microscopy (TEM)

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Atom probe Microscope Role of science & Technology in design

• Determining functions of a system

• Establishing units of measurements

• Technological advancement in field of computers made engineer to

not only draft but to analyze and simulate their products

• Development of various software packages aid in design and

analysis eg. auto-cad, solid works ,ansys

• Development of various quality control tools to measure variable

factors of a component

• Defining designers safety parameter

Functional and Strength Designs

FUNCTION
• Function and Strength are the two important aspects
of any design.

• Software designs are always functional.

STRENGTH
• Designs in electronics are predominantly functional

• However most designs consider these two aspects

often together.
FUNCTION & STRENGTH
• Engineers tend to be more oriented towards strength
designs.

Activity 2: Identify which among the following is having functional

design , strength design or both . Justify ? Activity 3 Why ceiling fans have normally three blades?
Why not four? What about five or six? How about two blades?

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Hints Number of blades and It’s Design

The fan blades turn and push air downward • we want to maximize the downward flow of air while
minimizing local turbulence around the fan blades
1.Air flow
2.Cost • Each blade wants to pass through uninterrupted air
3.Weight
• With too many blades a trailing blade risks moving
4.Power consumption through the turbulence of the blade in front

• generating noise and reducing efficiency

• ceiling fans have 3 to 5 blades

Desirable qualities of a Design Engineer

1. Problem solving skills - able to identify and define the problem to be solved.
Initiating the Thinking process
2. Proficiency in STEM [ Science, Technology, Engineering and Mathematics]
How to initiate creative designs?
3. Creativity and Imagination In creative design we deal mostly with physical objects.
4. Technical and Computer skills.
However the same process is applicable to the design
5. Ethical, moral and professional values. of a business model or the design of a software.

6. Business and managerial skill .

If one encounters a totally new problem, the solution
ought to be termed as creative !
7. Excellent communication skills. If one solves the problem differently with an
improvement then also it can be termed as creative.
8. Cultural exposure- sensitivity, understanding and manners.

9. Self confidence and optimism.

• However today there are many designs

available to us, in all segments of engineering.
• So how one can be creative in design?
• Look at an existing design and think of a new
way of meeting the requirement

Q? Low priced water purifiers that don't require

running water or electricity

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How to initiate creative designs

Initiating creative design is to simply generate as many new ideas as
possible.
Steps in creative design process
1.Refinement and evaluation of ideas
• Refinement means adding information and comments to ideas in order to
make them better understandable and evaluable.
• Evaluation means assigning a judgment to an idea.
• The main objective of this step is to identify the new creative ideas, feasible
ideas and discover the ideas which are in practice.
2. Generating design concepts
• The primary aim of concept generation and evaluation is to ensure that
the product can perform all of the major functions.
• This may be done by simple calculations, sketches, circuit diagram, proof
of concept models or by detailed written description of the concept.
3. Systematic methods for designs
1. Functional Analysis
The principle of functional analysis is first to specify what the product
should do, and then to infer from there what the parts- which are yet to
be developed- should do.

• First step is to sort ideas in to three categories,

a) Ideas that are feasible as they stand.
b) Ideas that may have potential after more thought or research applied.
c) Ideas that are very unfeasible and have no chance of becoming good
solutions.

2.Morphological approach
Morphological analysis is a method for representing and exploring all the Activity 4 Think of any two design changes for an
relationships in multidimensional problems.
ordinary soap box that can add value to it.
Steps involved :
1. Divide the overall design problem into simpler sub-problems.
2. Generate solution concepts for each sub-problem.
3. Systematically combine sub-problem solutions into different complete
solutions and evaluate all combinations.

3. Axiomatic design
Some fundamental laws or principles of engineering design are used as the
basis for a rigorous theory of design.

4. Design optimization
An optimization problem is a problem in which certain parameters needed to
be determined to achieve the best measurable performance under given
constraints.

Factors affecting product Design ELEMENTS IN DESIGN FRAME WORK

1. Customers requirements
2. Production facilities • Need Identification
3. Raw-materials to be used
4. Cost to price ratio
• Problem statement
5. Quality policy • Design objectives and attributes
6. Plant and machineries
7. Effect on existing products
• Market Survey
8. Reputation of the company
• Brainstorming

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Need Identification
• Client- a person or group of company that want a design conceived
• User – one who will employ or operate whatever is being designed
• Designer – job is to solve client’s problem in a way that meets user’s
need
• Whose need? Designer ,User or Client;
• Aircraft - Designer - Boeing or Airbus
Client - Air India or IndiGo
User - Passengers
• At times the user, the client and the designer could be the same or
different.
Means of need identifications
• Interviews with customers: Active marketing and sales forces should be
continuously meeting with current and potential customers.
• Focus groups: A focus group is a moderated discussion with 6 to 12
customers or targeted customers of a product. The moderator is a
facilitator who uses prepared questions to guide the discussion about
the merits and disadvantages of the product.
• Customer complaints: A sure way to learn about needs for product
improvement is from customer complaints.
• Warranty data: Product service centres and warranty departments are a
rich and important source of data on the quality of an existing product.
• Customer surveys: A written questionnaire is best used for gaining
opinions about the redesign of existing products or new products that
are well understood by the public.
FRAMING CUSTOMER REQUIREMENTS
• we want to clarify what the client requires, account for the
project stakeholders, and identify contexts within which our
design will function
• we will be defining or framing the design problem clearly
and realistically.
• A design team may ask questions of the clients and
stakeholders who might have varying degrees of interest in
the design, including potential users or experts in the field
• The experts may be versed in relevant technology or
knowledgeable about the market for which the design is
aimed.- Market research
30/04/2016
• To start with, the Designer has to meet the needs of the
Client as well as the User.
• They provide the synergy for a good design.
• In addition the Designer should be aware of professional and
social ethics and values.
• For any Design to be taken up, there should be a need gap
or a problem that needs a solution.
• This gap or need could be identified by the user, an observer
or by an organization
Problem Statement
CLARIFYING THE INITIAL PROBLEM STATEMENT
• Most design projects begin when a client sets out a problem to be solved,
typically in a verbal problem statement
• Eg. “Design a bottle for new children’s fruit juice product.”
• One response to this challenge is to design a clever new label for an
existing bottle and declare the work done.
• is this a good design? Is it the right design?
• There is no way to answer these questions because the problem
statement is so brief
• that it gives no hint of other considerations Eg. for example, the intended
market, the shape or materials choice of the container, and so on.
• Design teams may also hold their own internal
discussions in which they ask each other questions to
identify and list ideas that they can then organize into
some problem-relevant structure- Brainstorming
• It is important that such team discussion sessions
remain focused, particularly as they shift from the more
general notion of overall design requirements toward
the specifics of objectives, constraints, or functions.
• The best outcome of this work is a list of attributes from
which separate lists of objectives (i.e., features or
behaviors), constraints (i.e., limits), and functions (i.e.,
things the design must do) can be extracted.
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Lists of Design Attributes

Design a new ladder for electricians or other maintenance
and construction professionals working on conventional
job sites.”

1. What features or behaviours would you like the ladder

to have?
2. What do you want this ladder to do?
3. Are there already ladders on the market that have
similar features?

And while asking these three questions, we might also ask:

What do you mean by that?
How are you going to do that?

• objective a feature or behavior that the design

should have or exhibit.

• constraint : a limit or restriction on the design’s

behaviors

• function : a specific thing a designed device or

system is expected to do.

• means : a way or method to make a function

happen

Representing in Objectives Trees

• The indented outline of objectives is one way to represent the information
contained in that list.

• That same information can also be represented or portrayed graphically in a

hierarchy of boxes, each of which contains an objective for the object being
designed.

• Each layer or row of objective boxes corresponds to a level of indentation

(indicated by the number of digits to the right of the first decimal point) in the
outline.

• Thus, the indented outline becomes an objectives tree: a graphical depiction of

the objectives for the device or system.

• The graphical tree display is very useful for portraying design issues, and for
highlighting things we need to measure, since these objectives will provide our
basis for choosing between alternatives.

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Market survey - customer requirements

REVISED PROBLEM STATEMENTS
• We can formalize our new understanding by drafting
a revised problem statement that reflects our fuller
understanding of the design problem
• It expresses in clear, unambiguous terms the design
problem that the designers are trying to solve.
• This revised problem statement will often appear in
public presentations and reports as well.
• Market survey are used to identify the needs of
customers
• A designer must be aware of customer
requirement
• Some market survey methods include
– Direct Customer interview
– Market survey – circulating questionnaire among
customers regarding their expectation and feedback
– Reviewing Customer complaints

Brainstorming
Activity 5
Brainstorming is a group activity technique by
which efforts are made to find a conclusion for a Q? Sketch design form for a common room door in a
specific problem by gathering a list of ideas house and for a bank store room door
spontaneously contributed by its members.

EXERCISE 1
Q1? Define engineering design in your own words.

Q2? List at least three questions you would ask if you were,
respectively, a user (purchaser), a client (manufacturer),
or a designer who was about to undertake the design of a
portable electric guitar.

Q3? List down examples for different design levels

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