Chapter 1 Homework

Sebastián Acosta Andrade
Materials Selection
Homework #1: The Design Process
The selection of a correct material for a given design is a key step in the design process because
it can improve the service performance and thus is directly related with the design configuration
of a part.
Materials selection is performed for simple parts; therefore, the design engineer must identify
the application requirements of those parts such as mechanical, thermal, environmental,
chemical, etc. Material selection and design should fulfill all these requirements together and
suit each other to obtain an excellent a reliable product. It is becoming essential to develop a
much closer relationship between those who design a component and those who advise the
designer on materials selection. The integration of material, process, and product design relies
on individuals who are trained in materials selection and can work in a team environment;
therefore, individuals should be trained in many areas, including materials, thus their selection
should become a part of their daily design activity.
The selection process can range from simply re-specifying a previously used material (or one
used by a competitor) through the finite element analyses or modeling routines to precisely
identify property requirements. Nowadays, the selection of the material and its processing,
product design, cost, availability, recyclability and performance in final product form have
become inseparable.
The role of the design engineer is to transform relatively vague marketing goals into specific
information (drawings, CADs, instructions) needed to manufacture a machine that will make a
profit. A successful product design and development involves interdisciplinary activities and
should be aesthetically pleasing, safe to use, economically competitive, and complaint with legal
and environmental constraints.
The total development effort depends on the complexity of the product, but the following seven
phases can be identified in a variety of product design and development projects:
1) Identification of needs, feasibility study, and concept selection

2) System-level design, detail design, and selection of material and processes
3) Testing and refinement
4) Manufacturing the product
5) Launching the product
6) Selling the product
7) Planning for its retirement
1) Identification of The range of features and technical advantages and disadvantages of existing products, the mechanism of their operation, and the materials and processes used in
Identificati needs: consists of making them.
on of a market research Past and anticipated market growth rate and expected market share by value and volume
that involves a The number of companies entering and leaving the market over the past few years and reasons for those movements
needs, survey to evaluate
feasibility competing The reasons for any modifications that have been carried out recently and the effect of new technology on the product.
study, and products and their Patent or license coverage and what improvements can be introduced over the existing products
concept main Profile of the prospective costumers (income, age, sex, etc.) and their needs in the area covered by the product under consideration
selection characteristics in
addiction to Ranking of costumer need in order of their importance
identifying the How long will it take for the competition to produce a
customer needs. competitive product?
Elements of the
market research
include the
following:
Product analysis: reflects on the obvious mechanical and ergonomic requirements and how do
mechanical components work and interact. If the product has many components it is called a
system. It is preferable to analyze the system as a whole; however, it can be pulled apart and
think about each component and its function within the system to draft a design specification.
Customer needs and product Voice of the costumer: list of requirements from the product, usually gathered trough conversations, opinion surveys and market research.
specification: The house of
Prioritized customer requirements: degree of the customer satisfaction with various competing products relative to the different requirements.
quality (HOQ) is a structured Also based on opinions surveys and market research.
process for translating customer Voice of the company: list of technical parameters, product characteristics, from the POV of the manufacturer in terms of engineering specifications (including
requirements and market measurable quantities such as weight, dimensions, noise, power consumption, cost; or nontechnical parameters such as the look and feel of the product, fashion,
research into quantifiable the type of prospective customer and the culture of society in which the product will be sold)
product characteristics and Interrelation matrix: correlates the customer requirements with a technical parameter based on inputs from items i, ii and iii.
specifications to be met by the
product design. The HOQ Correlation matrix: it shows how the technical parameters support or impede one another
consists of six sections as Design targets: give the conclusions drawn from data in other sections of the HOQ
follows:
Concept selection: product specifications are used Customer needs

to develop different product concepts that satisfy Physical characteristics of size and weight
customer needs. An economic model provides de
development costs, initial investment, Expected life and reliability under service conditions
manufacturing costs, etc. Then, in a final stage, an Energy needs
optimum solution is identified usually based on
economics and technical specification, since the Maintenance requirements and operating costs
product is expected to satisfy the customer needs Environmental impact
at an acceptable price. This process involves trade-
Quantity of production
offs between a variety of factors, such as:
Expected delivery date
2) System- Mechanical design: the starting point is a market need or a new idea, and the end point is the full specification of a product that fills the need or
level design, embodies the idea. A need must be identified before it can be met and should be formulated as a statement often in the form of “a device is
detail required to perform a task”. This statement should be solution-neutral (it should not imply how the task will be performed) to avoid narrow
design, and thinking constrained by preconceptions. The product itself is called a technical system, that consists of sub-assemblies and components put
selection of together in a wat that performs the required task. This decomposition is a useful way to analyze an existing design and the best way to
material and accomplish this task is to consider the inputs, flows and outputs of information, energy and materials. The system is broken down into
processes connected sub-systems, each of which performs a specific function and the resulting arrangement is called the function structure or function
decomposition. The design proceeds by developing concepts to perform the function in the function structure, each based on a working
principle. The next stage, embodiment, takes the promising concepts and seeks their operation at an approximate level. This involves sizing the
components and selecting materials that will perform properly in ranges of stress, environment and temperature suggested by the design
requirements, examining the implication for performance and cost. The embodiment stage ends with a feasible layout, which is then passed to
de detailed design stage.
Detailed design: the specifications for each component are drawn up. Critical components may be subjected to precise mechanical or
thermal analysis. Optimization methods are applied to components and groups of components to maximize performance.
Selection of material and processes: a final choice of geometry and material is made, and the methods are
analyzed and costed. The stage ends with a detailed product specification.

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Sebastián Acosta Andrade

Homework #1: The Design Process

1) Identification of needs, feasibility study, and concept selection

Concept selection: product specifications are used Customer needs

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