Kuliah 5 disrek 5

8/2/2019 Kuliah 5 disrek 5

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KuliahKuliah 55

Embodiment DesignEmbodiment Design

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Embodiment DesignEmbodiment Design

ConceptConcept -- An idea, a sketch, an abstraction that mayAn idea, a sketch, an abstraction that maybecome an engineering design.become an engineering design.

DesignDesign the form or shape of parts that will satisfythe form or shape of parts that will satisfythe required functions.the required functions.

DrawingsDrawingsthe communication mode for a designthe communication mode for a design


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Steps in Embodiment DesignSteps in Embodiment Design

Traditional:Traditional:

Sketch >> Layout & Analysis >> DetailSketch >> Layout & Analysis >> Detail

Contemporary:Contemporary:

Product ArchitectureProduct Architecture

Arrangement of physical elementsArrangement of physical elementsConfiguration DesignConfiguration Design

Selection of materials, sizing of partsSelection of materials, sizing of parts

Parametric DesignParametric Design

Robust design, final tolerances & dimensionsRobust design, final tolerances & dimensions


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Tahap perwujudan (embodiment)proses desain,konsep-konsep yang

telah dipilih dianalisis lebih detail.

-Desain pembentukan (form design),-Desain untuk manufaktur danperakitan (design for manufacture andassembly),

-Pemilihan material dan proses(process and materials selection),- Desain industri (industrial design).


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Steps in Developing ProductSteps in Developing Product

Create a schematic diagram of the productCreate a schematic diagram of the product

Cluster the elements of the schematicCluster the elements of the schematicCreate a rough geometric layoutCreate a rough geometric layout

Identify the fundamental and incidental interactionsIdentify the fundamental and incidental interactions


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DesainDesain PembentukanPembentukan


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Desain untuk Perakitan dan

Manufaktur

Kemudahan permesinan (Ease of machining)

Ekonomi (Economy)

Pemakaian mesin dan perkakas yang ada(Use of existing machinery and tooling)

Pencegahan kesesuaian yang berlebihan(Avoidance of redundant fits)

Kemudahan dicapai (Accessibility)

Kemudahan perakitan (Ease of assembly)


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Industrial DesignIndustrial DesignErgonomicErgonomic

Indikator getaran direproduksi di dalamGambar 5-12 dalam ukuran sebenarnya.Jelas bahwa ukurannya kecil, terutama

karena indikator ini harus dibaca oleh pilotketika pesawat bergetar.


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EstetikaEstetika

IlusiIlusi OptisOptis


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Product DevelopmentProduct Development


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Product DevelopmentProduct Development


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Configuration and Parametric DesignConfiguration and Parametric Design

Configuration DesignConfiguration Design to establish shape andto establish shape and

dimensionsdimensions Always start with sketchesAlways start with sketches

Preliminary engineering analysis toPreliminary engineering analysis to sizesize partsparts

Refine sketchesRefine sketchesmake less abstract drawingsmake less abstract drawings

PatchPatchchange design without changing level ofchange design without changing level of

abstractionabstraction

Parametric DesignParametric Design to improve robustnessto improve robustness

Failure Modes and EffectsFailure Modes and Effects Reliability CalculationsReliability Calculations

Taguchi StatisticsTaguchi Statistics

Tolerance AnalysisTolerance Analysis


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Best Practices for Configuration andBest Practices for Configuration and

Parametric DesignParametric Design

Clarity of FunctionClarity of Function

Maintain unambiguous relationship between functions andMaintain unambiguous relationship between functions and

flow of energy, material and informationflow of energy, material and information

SimplicitySimplicity

Design should be easily understood, readily producedDesign should be easily understood, readily produced

SafetySafety

Incorporate directly into functional design, do not useIncorporate directly into functional design, do not use

guards or warningsguards or warnings

Force TransmissionForce Transmission

Stiffness is a more common problem than stress,Stiffness is a more common problem than stress,

deflections cause jamming and weardeflections cause jamming and wear


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Establishing Design RiskEstablishing Design Risk

What are the most likely ways the part will fail in service?What are the most likely ways the part will fail in service?

Stress, Fatigue, Buckling, shock loadsStress, Fatigue, Buckling, shock loadsWhat are the most likely ways the part might not meet itsWhat are the most likely ways the part might not meet its

expected functionality?expected functionality?

TolerancesTolerances

Creep, Strain/Deformation, Thermal deformationCreep, Strain/Deformation, Thermal deformation

Handling, assembly difficultiesHandling, assembly difficulties

Will the available production machines be able to make the part?Will the available production machines be able to make the part?

Production runsProduction runs

Tooling, tooling wearTooling, tooling wear

Other design and materials factorsOther design and materials factors Geometric compatibility (with adjacent parts)Geometric compatibility (with adjacent parts)

Materials compatibilityMaterials compatibility

Design team knowledgeDesign team knowledge


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RobustnessRobustness

Design to achieve excellent performance under the wide range ofDesign to achieve excellent performance under the wide range of

conditions that will be experienced in service.conditions that will be experienced in service.

Robust design has the following steps:Robust design has the following steps:

System DesignSystem Design

product architectureproduct architecture

Parameter DesignParameter Design

Nominal values are established to minimize variability fromNominal values are established to minimize variability from

uncontrolled variables in the environmentuncontrolled variables in the environment

Tolerance DesignTolerance Design

Setting the widest possible tolerances without increasing variabSetting the widest possible tolerances without increasing variabilityility


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Design For Manufacturing (DFM)Design For Manufacturing (DFM)Design For Assembly (DFA)Design For Assembly (DFA)

1)1) Minimize the total number of parts.Minimize the total number of parts.2)2) Incorporate modularity.Incorporate modularity.

3)3) Minimize number of part variations.Minimize number of part variations.

4)4) Incorporate multiIncorporate multi--functional designs.functional designs.

5)5) Incorporate parts designed for multiIncorporate parts designed for multi--use.use.6)6) Simplify fabrication.Simplify fabrication.

7)7) Minimize number of fasteners.Minimize number of fasteners.

8)8) Minimize assembly directions and time.Minimize assembly directions and time.

9)9) Maximize compliance.Maximize compliance.10)10) Minimize part handling.Minimize part handling.

11)11) Eliminate or Simplify adjustments.Eliminate or Simplify adjustments.

12)12) Minimize the use of nonMinimize the use of non--rigid components.rigid components.


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1)1) Minimize the total number of parts.Minimize the total number of parts.

Benefits:Benefits: Decreased CostDecreased Cost

Eliminates fasteners, instructions, interfacingEliminates fasteners, instructions, interfacing

information and problems.information and problems.

Reduced weight, complexity and materialReduced weight, complexity and material

2)2) Incorporate modularity.Incorporate modularity.

Benefits:Benefits: Allows for parallel manufacturingAllows for parallel manufacturing

Maintain simplicity in each module, with eachMaintain simplicity in each module, with each

module remaining generic as long as possible.module remaining generic as long as possible.

3)3) Minimize number of part variations.Minimize number of part variations.

Benefits:Benefits: Use of Standardized partsUse of Standardized partsminimize inventory.minimize inventory.

minimize specialized inspection.minimize specialized inspection.

maximize reliability and quality.maximize reliability and quality.


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4)4) Incorporate multiIncorporate multi--functional designs.functional designs.

Benefits:Benefits: Minimizes number of subassemblies.Minimizes number of subassemblies.

Minimizes connections, interfaces etc.Minimizes connections, interfaces etc.

5)5) Incorporate parts designed for multiIncorporate parts designed for multi--use.use.

Benefits:Benefits: Leads to standardized parts programs.Leads to standardized parts programs.

Basic parts lend themselves to more than one use, increasingBasic parts lend themselves to more than one use, increasing

volume.volume.

6) Simplify fabrication.6) Simplify fabrication.

Fabrication processes that minimize secondary processesFabrication processes that minimize secondary processes(grinding etc.) and surface treatments (painting, plating etc)(grinding etc.) and surface treatments (painting, plating etc)

should be targeted.should be targeted.

Benefits:Benefits:

Lower cost materials used.Lower cost materials used.

Minimize waste and processing time.Minimize waste and processing time.


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7)7) Minimize number of fasteners.Minimize number of fasteners.

Benefits:Benefits:Fasteners increase cost.Fasteners increase cost.

When used minimize variations.When used minimize variations.

Large numbers of fasteners increase possible errors ofLarge numbers of fasteners increase possible errors of

incomplete/wrong assembly.incomplete/wrong assembly.

8)8) Minimize assembly directions and time.Minimize assembly directions and time.

Parts should be assembled in a logical,Parts should be assembled in a logical, uniuni--directionaldirectional

manner.manner.

9)9) Maximize compliance.Maximize compliance.

Benefits:Benefits:

SubSub--assembly attachment easier.assembly attachment easier.

Tolerance stackTolerance stack--ups eliminated.ups eliminated.

Alignment problems minimized.Alignment problems minimized.


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10) Minimize part handling.10) Minimize part handling.

Positioning of parts during assembly is costly.Positioning of parts during assembly is costly. Use asymmetric designs for orientationUse asymmetric designs for orientation

identification.identification.

11) Eliminate or Simplify adjustments.11) Eliminate or Simplify adjustments.

Benefits:Benefits:

Minimize fabrications costs.Minimize fabrications costs. Minimize assembly problems.Minimize assembly problems.

Minimize test problems.Minimize test problems.

Increase reliability.Increase reliability.

12) Minimize the use of non12) Minimize the use of non--rigid components.rigid components.Benefits:Benefits:

Flexible components tend to increase time and errors inFlexible components tend to increase time and errors inassembly. Need for increased guidance andassembly. Need for increased guidance andattachment with greater errors in location.attachment with greater errors in location.


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Design GuidelinesDesign Guidelines

1)1) Avoid arbitrary decisionsAvoid arbitrary decisions

2)2) Search for alternativesSearch for alternatives

3)3) Use solid models when practicalUse solid models when practical

4)4) Increase the level of abstractionIncrease the level of abstraction

5)5) Make tables of design functions and optionsMake tables of design functions and options

6)6) Pursue design concepts to the limit.Pursue design concepts to the limit.

(physical/economic constraints)(physical/economic constraints)

7)7) Aim for clarity of functionAim for clarity of function

8)8) Exploit materials and manufacturing methods.Exploit materials and manufacturing methods.

9)9) Develop a logical chain of reasoning for the design.Develop a logical chain of reasoning for the design.

10)10) Ask questions. (Necessary?, Failure will induce what?)Ask questions. (Necessary?, Failure will induce what?)


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Design ReviewsDesign Reviews

An efficient method to monitor theAn efficient method to monitor the

progress of a project and facilitateprogress of a project and facilitate

reporting and recording of results toreporting and recording of results tomanagementmanagement

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