ME 490 Mechical Engineering Senior Design Project

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ME 490Mechical EngineeringSenior Design Project

• Fall 2006
• W. Farrow

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• Notes
• All handouts in this course are available at
• http//people.msoe.edu/farroww/

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Senior Design Overview

• Mandatory two-quarter (six credit) experience
  (ME490-ME491), optional third quarter (ME492)
• ME492 is a Technical Elective
• Deliverables of Senior Design
• ME490 Detailed Design Proposal
• ME491 Design Report, Formal Presentation
• ME492 Design Report, Poster Presentation

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Objectives of the Senior Design Experience

• Engineering Design can be defined as
• The process of applying scientific and
  mathematical principles for the purpose of
  defining a device, process or system that meets a
  given set of performance specifications and is
  optimal in some respect.

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• Senior Design (per ABET/EAC)
• Students must be prepared for engineering
  practice through the curriculum culminating in a
  major design experience based on the knowledge
  and skills acquired in earlier coursework and
  incorporating engineering standards and realistic
  constraints that include most of the following
  considerations economic environmental
  sustainability manufacturability ethical
  health and safety social and political.

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• At the conclusion of the Senior Design
  experience, the student will
• Have applied principles of mathematics and
  science in the design of a mechanical engineering
  system
• Have prototyped a process or component for
  evaluation.
• Have designed and/or selected components for a
  mechanical or thermal system.
• Have served an engineering function on a design
  team.
• Have applied modern computer tools (i.e.
  CAD/solid modeling, FEA, programming,
  spreadsheets) to an engineering design problem.
• Have written a design report and made an oral
  presentation of the design work.
• Have acquired independent learning skills by
  exposure to engineering literature.
• The performance of each student will be evaluated
  with respect to these objectives.

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Engineering Design

• The process of applying scientific and
  mathematical principles for the purpose of
  defining a device, process or system that meets a
  given set of performance specifications and is
  optimal in some respect.
• Engineering design is both a business process and
  a technical process

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The Design Process

• Many different versions, we will discuss a
  typical process
• Small companies may have an informal,
  undocumented process
• Medium/large companies will certainly have a
  complex, formal process
• ISO9000 certified companies must have a formal,
  well-documented process

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Step 1 Recognition of Need

• Creating a description of why the design needs to
  be undertaken
• May involve
• Customers
• Marketing departments
• Engineering departments
• Includes a verbal description, including
• Objectives Must or Should targets
• Constraints Hard limitations

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Step 2 Specifications and Requirements

• Putting numbers to the objectives and
  constraints
• Specs will come from
• Customers
• Government regulations (OSHA, EPA)
• Outside agencies (ASME, AGMA, ANSI)
• Company policies

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• Development of the specifications is critical to
  the success of the project
• It defines success therefore,
• It must include all constituents
• Customers
• Engineering
• Marketing
• Manufacturing
• Etc
• There must be a formal process for approving and
  modifying the document

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Step 3 Creative Design Synthesis

• Brainstorming of concepts
• Results in a list of several conceptual solutions
  to the design problem

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Step 4 Feasibility Study

• Validation of the specifications from a technical
  and economic standpoint
• Are any laws of physics being violated?
• Is some undeveloped technology required?
• Are scarce materials required?
• Will costs be unacceptable?
• Tools
• Reverse engineering
• Patent analysis
• Mathematical modeling
• Prototyping

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• Will result in
• Project approval
• Project cancellation
• Specification revision (most likely)

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Step 5 Preliminary Design and Development

• Analysis of the conceptual designs, and selection
  of the best design concept
• A suggested tool Tradeoff Matrix

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Step 5 Preliminary Design and Development

• Analysis of the conceptual designs, and selection
  of the best design concept
• A suggested tool Tradeoff Matrix
• The selected design will be developed to the
  point where
• The overall configuration is defined
• System inputs/outputs are defined
• Important dimensions/values are determined

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Step 6a Detailed Design

• Finishing the design, to the point where it can
  be produced
• Selecting all dimensions and tolerances
• Specifying all materials and processes
• Specifying purchased components
• Producing all design documentation

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Step 6b Design for Production

• Designing the production process for the
  completed design
• Design/specification of manufacturing equipment
• Design of tooling, fixturing, etc.
• Redesign of the parts to accommodate
  manufacturing or reduce costs

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Step 7 Prototyping and Testing

• Building small quantities to validate both the
  design and the manufacturing processes

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Some Comments

• Detailed design and design for production should
  happen concurrently---but they often dont
• The flow through the process is not as linear
  as it looks --- there is lots of iteration and
  looping!