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    Aspects of The Designer

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    Sizuyise Mnisi

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    Aspects of The Designer

    Uploaded by

    Sizuyise Mnisi
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    Aspects of the Designer

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    © All Rights Reserved
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    2 views5 pages

    Aspects of The Designer

    Uploaded by

    Sizuyise Mnisi

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 5

    1

    ASPECTS OF THE DESIGNER’S WORK


    What is “DESIGN” ?
    Is it the desire to fulfil a particular Need or Task or simply to be employed in a Job? Or is it a “Way
    of Life”. It is definitely the latter, and can be perceived as the process of “Life-Long Learning”.
    Life and fulfillment in life are both similar to studying. You must learn as you progress and enjoy the
    experience as much as possible. You must see “Machine Design” as a means to an end. What end?
    The fulfillment of you as an individual and as part of the large “family of engineers”
    Design is the utmost importance in the training of an engineer, no matter in what field of activity
    he/she may subsequently be employed. A student, who has reached a certain standard of capability in
    design and has found pleasure in it, will find things considerably easier when he/she starts working,
    even though the path he/she takes does not lead to the design office. The lack of adequate design
    capability is a deficiency, which can be made good only in exceptiona l cases.
    The designer’s main task is to apply the fundamentals of science and technology in order to create
    some assemblage of components to perform a particular task. Generally, he/she will be considered
    with adaption of existing designs and only very rarely, will a designer have the opportunity to create
    something entirely new.
    Even when guided by an existing design, most students begin by groping around for formulae
    resulting in the “hit–and–miss” attempts as typical of the non-systematic approach. Experience has
    shown that in manual as well as intellectual work only a systematic method of working can guarantee
    success in the shortest possible time.
    The general approach is:
    - study the problem,
    - prepare a free-hand sketch or basic design to establish the required method of attack,
    - select the material,
    - carry out the design work giving consideration to form, manufacturing methods and
    cost.
    - the design is drafted on paper as a set of properly dimensioned drawings suitable for
    workshop use.
    The objective of this course then is to develop understanding of the design process, coupled with
    powers of logical deduction and judgement.

    TYPICAL PROCEDURE in DESIGN


    1. Make complete statement of the problem – purpose.
    2. Select possible groups of mechanisms - give desired motion.
    3. Find the forces acting on each member of the machine and energy transmitted by each
    member.
    4. Select the material best suited for each member of the machine.
    5. Find the size of each member of the machine by considering the forces acting and the
    permissible stresses for the material used.
    6. Modify the size of the member to agree with past experience and judgement to facilitate
    manufacture.
    7. Draw the detailed drawing of each component and assembly of the machine with complete
    specification for the material and manufacturing process suggested.
    2

    The Phases or Processes of Design

    The process begins with recognition of a need and a decision to do something about it. After
    many iterations, the process ends with the presentation of plans for satisfying the need, which
    are outcomes based.

    Recognition & Identification


    The of Need

    Definition of Problem

    Synthesis

    Analysis and Optimization

    Evaluation

    Presentation

    Recognition and Identification of Need - Often develops a highly creative act,


    because the need may be only a vague discontent, a feeling of uneasiness, or a sensing that
    something is not right. It is known that a sensitive person, one who is easily disturbed by
    things, is more likely to recognize a need and is also more likely to do something about it,
    hence the creativity. A need is easily recognized after someone else has stated it.

    Definition of the Problem - This include all the specifications of the design, (“the
    black box”), which are the input and output quantities, the characteristics and dimensions of
    the space the design is to occupy, and all the limitations on these quantities. The
    specifications define the cost, the number to be manufactured, the expec ted life, the range,
    material and manufacturing processes, speeds, feeds, dimensional and weight limitations, the
    operating temperature and limitations, and the reliability, etc. The labour skills available and
    the competitive situation also constitute implied specifications. Anything, which limits the
    designer’s freedom of choice, is a specification.
    3

    Synthesis - This is the creation, constructing and building the whole design to form
    an optimum solution. Synthesis cannot take place without both analysis and optimization,
    because the system under design must be analyzed to determine whether the performance
    complies with the specifications.

    Analysis and Optimization - This is the breakdown and improvement stage of the
    design solution. The analysis may reveal that the system is not an optimum solution. If the
    design fails either or both of these tests, the synthesis procedure must begin again, hence
    becoming an iterative process.

    Evaluation - It is the assessment criteria stage and is the significant phase of the
    total design process where the final proof of a successful design is tested. Here the questions
    are normally asked such as:-
    i. Is the need or needs satisfied?
    ii. Is it reliable?
    iii. Will it compete successfully with similar products?
    iv. Is it economical to manufacture and to use?
    v. Is it easily maintained and adjusted?
    vi. Can a profit be made from its sale or use?

    Presentation - Communicating the design to others is the final and vital step in the
    design process. Many great designs, inventions and creative works have been lost to
    mankind, simply because the originators were unable or unwilling to explain their
    achievements and accomplishments to others. Presentation is a selling job, (i.e., promoting
    the design and designer). Here, Communication Skills plays a paramount part at this stage.
    Basically, there are only three means of communication, (Oral, Written and Graphical). The
    competent engineer should be able to write letters, reports, memos, papers and articles for
    publication. Ability in public speaking can be obtained by participating in fraternal, civic,
    church and professional activities. To acquire drawing skills, pencil sketching and technical
    drawing practices should be employed to illustrate every idea possible.

    Design Conside rations:

    1. Strength 12. Noise


    2. Reliability 13. Styling
    3. Thermal considerations 14. Shape
    4. Corrosion 15. Size
    5. Wear 16. Flexibility
    6. Friction 17. Control
    7. Processing 18. Stiffness
    8. Utility 19. Surface finish
    9. Cost 20. Lubrication
    10. Safety 21. Maintenance
    11. Weight 22. Volume
    4

    FACTORS or BASIC CONSIDERATIONS in MACHINE DESIGN

    DESIGN FORM
    How a component will behave in service is greatly influenced by the shape or form given to
    the part. The choice of form must follow certain basic rules. These rules will depend on size,
    material, load-carrying criteria and cost limitations.

    ECONOMIC CONSIDERATIONS
    Every design is influenced, directly or indirectly by the question of Cost. The only costs
    which the designer can directly influence by his/her decisions are:-
    i) Material costs and
    ii) Labour costs.

    The indirect costs are the over- heads, which are made up of:-
    i) Purchasing and maintaining of machinery and equipment
    ii) Cost of running the workshop and office
    iii) Cost of the office staff
    iv) Cost of advertising
    v) Cost of transportation.

    The extent of the overheads depends on the size of the business and the type of manufacture
    conducted. The designer is often able without making a cost analysis to build into the design
    features which will lower manufacturing costs by:-

    i) Reducing the area of surface to be machined


    ii) avoiding extra work
    iii) design for accessibility
    iv) Design for ease of assembly.

    HUMAN FACTORS
    To ensure that the design can be operated with safety, comfort and efficiency, the designer
    must consider certain human factors. In direct man- machine relationship, the factors should
    be taken into account are:- Anthropometric; Ergonomic; Physiological and Psychological.

    1. Anthropometric factors - are those which are related to the physical size
    of humans.

    2. Ergonomic factors - are of concern when the human operator is involved


    with the machine in a dynamic sense in that he/she is required to exert a force or
    supply energy to the machine. The layout of controls is very important and all
    controls should be placed in positions from which they can be operated without
    unnecessary exertion. The size, shape and surface texture of the control buttons,
    handles, levers, etc., have a considerable influence on the effort which can be exerted.

    3. Physiological factors - influences the quality of information received


    through the senses, (visual, audio, touch, taste, etc).

    4. Psychological factors - influences the manner in which information is


    presented to the operator so as to minimize the possibility of error of interpretation.
    5

    OTHER FACTORS
    1. Type of load and stresses caused by the load.
    2. Motion of the parts or kinematics of the machine
    3. Selection of materials.
    4. Form and size of the parts.
    5. Frictional resistance and lubrication.
    6. Convenient and economical features.
    7. Use of standard parts.
    8. Safety of operation.
    9. Workshop facilities.
    10. Number of machines to be manufactured.
    11. Cost of construction.
    12. Assembly; Quality Assurance and Control.

    MANUFACTURING PROCESSES

    Various pre- machining processes are available to produce a component.

    1. Casting - a) Gravity casting


    b) Pressure die-casting
    c) Cold chamber die-casting
    d.) Investment casting

    2. Hot working - a) Hot rolling


    b) Forging
    c) Extrusion

    3. Cold working - a) Cold rolling


    b) Drawing
    c) Impact extrusion
    d) Sheet metal pressing

    4. Metal spinning

    5. Powder forging

    6. Welding

    7. Shaping of plastics

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