Introduction into Mechanical Design - Reverse Engineering.pptx
- 1. Introduction into Mechanical Design - Reverse Engineering
- 2. Agenda • Introduction • Design Process • Marketing analysis • Brainstorming • Preliminary design • Design review • Detailed Design • Design Evaluation • Iterations • Manufacturing • Design for Manufacturing / Assembly • Design for Environment • Reverse Engineering • Manufacturing trends in the research sector • IET Inspec Direct Database • IET Inspec Analytics • IET digital library
- 3. Design Process Marketing analysis Brainstorming Preliminary Design Design Review Detailed Design Design Evaluation Iterations / Optimization Manufacturing
- 4. Marketing analysis • Customer needs • Budget • Design restrictions • Specifications • Problem definition Brainstorming 1.Set a time limit. 2.Begin with a target problem/brief. 3.Refrain from judgment/criticism. 4.Encourage strange ideas. 5.Aim for quantity. 6.Build on others’ ideas. 7.Allow one conversation at a time. 8.Use a Decision matrix
- 5. Preliminary Design Preliminary design The preliminary design, or high-level design includes, often bridges a gap between design conception and detailed design, particularly in cases where the level of conceptualization achieved during ideation is not sufficient for full evaluation. So in this task, the overall system configuration is defined, and schematics, diagrams, and layouts of the project may provide early project configuration. An essential phase in new product design and development is defining the product’s exact characteristics. Impressions and conclusions from the research stage are integrated with performance expectations, to create the initial design, which defines the functional requirements and elements.
- 6. Design Review A design review is a milestone within a product development process whereby a design is evaluated against its requirements in order to verify the outcomes of previous activities and identify issues before committing to and if need to be reprioritize further work. In addition a design review checklist should be used in the review process.
- 7. Detailed Design Material selection Material selection is the act of choosing the material best suited to achieve the requirements of a given application. Many different factors go into determining the selection requirements, such as mechanical properties, chemical properties, physical properties, electrical properties and cost. Material Selection Charts
- 8. Detailed Design Material selection Material Selection Charts
- 9. Detailed Design Design Calculations When you have decided on the basic design for your device, you will need to do the calculations to make sure that the design will achieve the aim: how much force is required, what size parts are needed, and so on. Make sure that you double-check your own calculations (or get a college to do it for you) and include all calculations in your project documentation. Simulations Design simulation helps manufacturers verify and validate the intended function of a product under development, as well as the manufacturability of the product. • Structural • Thermal • Vibrations • Electrical • Magnetism
- 10. Detailed Design Prototype A prototype is an early sample, model or release of a product created to test a concept or process. Typically, a prototype is used to evaluate a new design to improve the accuracy of analysts and system users. The visual representation of the prototype demonstrates what the product is doing at any given point, what the interactive elements are, and how the product would function in the real world. 3D printing 3D printing, or additive manufacturing, is the construction of a three-dimensional object from a CAD model or a digital 3D model. The term "3D printing" can refer to a variety of processes in which material is deposited, joined or solidified under computer control to create a three-dimensional object, with material being added together, typically layer by layer.
- 11. Design Evaluation Engineers evaluate designs for effectiveness to see if they solve the problems that they were supposed to solve, for consistency to make sure that the design works the same way every time, and for efficiency to make sure that it solves the problem in the simplest way possible without any extra steps or pieces. Testing • Check for dimensional accuracy • Collect test data • Analyze test data • Performance • Usability • Durability • Validation of design Examples • Static structural • Dynamic Structural • Fatigue testing • Thermal testing • Drop shock testing
- 12. Iterations Design optimization The area of design optimization is where the performance of a design can be made drastically better than an initial naive implementation. Topology optimization Topology optimization is a mathematical method which spatially optimizes the distribution of material within a defined domain, by fulfilling given constraints previously established and minimizing a predefined cost function. For such an optimization procedure, the three main elements are design variables, the cost function and the constraints.
- 13. Manufacturing Manufacturing processes • Manufacturing Costs. • Manufacturing Technique Capabilities and availability. • Desired Look and Feel of Product. • Materials Needed for Production. • Desired Surface Finishing of Product and dimensional accuracy. Maintenance
- 14. Design for Manufacturing / Assembly Design for Manufacturing (DFM) is the process of designing parts, components or products for ease of manufacturing with an end goal of making a better product at a lower cost. This is done by simplifying, optimizing and refining the product design. Design for Manufacturing (DFM) and design for assembly (DFA) are the integration of product design and process planning into one common activity. The goal is to design a product that is easily and economically manufactured. For any business looking to make money and create products that are profitable, DFM is vital for efficiency, speed, and high rates of production. It is thought that approximately 70% of the manufacturing costs of a product derive from decisions made in the early design stages, such as materials used or method of manufacturing.
- 15. Design for Environment Design for the Environment (DfE) is a design approach to reduce the overall human health and environmental impact of a product, process or service, where impacts are considered across its life cycle. • Reducing the use of materials, maximizing the number of replaceable or recyclable components. • Reducing toxic or polluting materials. • Reducing emissions and waste in production processes. • Increasing energy efficiency in phases of production and use. • Increasing reliability and maintainability of the system. • Respecting current legal constraints and evaluating future regulations in preparation.
- 16. Design effort versus cost curve.
- 17. Reverse Engineering It is the process of creating a product by a deep investigation to the shape and the function of an existing production. The reverse engineering process enables you to determine how a part was designed so that you can recreate it. The reverse engineering process is named as such because it involves working backward through the original design process. The challenge is to gain a working knowledge of the original design by disassembling the product piece-by-piece or layer-by-layer. Applications • When the part malfunctions or breaks down completely, you replace the component, not the whole device. • Companies sometimes use reverse engineering to regain design data on their own long-discontinued products. Even if the company still has their paper blueprints, they may want to create a digital version of them to make the plans easier to access and use. • Design Improvement. • Product analysis (to examine how a product works, what components it consists of, estimate costs, identify potential)
- 18. Reverse Engineering • When reverse engineering a mechanical product, you start by analyzing the dimensions and attributes of the product. • Before disassembly, the reverse-engineering team has to photograph the product up close from the front and back to create a record of the product composition. • During disassembly, the design team removes each part from the product, one after another. The parts must be set aside for safekeeping and organized in the order they were removed. • With the various components removed from the old product, the design team then draws up a list of the materials of the product components.
- 19. 3D Scanning 3D scanning is the process of analyzing a real-world object or environment to collect data on its shape and possibly its appearance. The collected data can then be used to construct digital 3D models. After all the pertinent information has been gathered and recorded, you can use this data to create computer-aided design (CAD) drawings for subsequent analysis and development.
- 20. Material identification •Color •Texture •Mechanical properties •Spark test •Electrical properties •Thermal properties •Magnetic properties •Radiation - X-ray Fluorescence (XRF) analyser: The device scans the metal material and identifies its key elements. However, it cannot detect carbon and some lighter elements and is not suitable for identification of pure carbon steel materials. •Optical Emission Spectroscopy (OES): This method can detect almost all types of elements including carbon and lighter elements and carbon steel.
- 21. How can you access Inspec Analytics & Inspec Direct?
- 27. Inspec Direct
- 28. Inspec Direct Pinpoint relevant research fast Whether you’re looking for inspiration for your next research project or compiling a comprehensive literature review of your chosen field, your journey starts with Inspec, the definitive engineering and physics research database. Why to use Inspec? •Keep pace with developments in the fast-moving world of science, engineering and technology. Pinpoint the latest global research in your field. •Access quality data quickly. •Avoid research duplication and “reinventing the wheel”. •Track your competitor movements to stay one step ahead. •Accelerate your R&D activities by saving time and money.
- 29. 850,000 records added in 2019 Optional Archive adds another 873,699 Over 4,500 journals, and 3,000 other publications from 700 publishers Over 10% open access Inspec content Physics 10 million + Computing and control engineering 5.5 million Electrical and electronic engineering 7 million 2.2 million Production, manufacturing & mech. engineering 19.5m records (Feb 2020) 1969 To date Or 1898 with the Inspec Archive
- 30. IET Inspec
- 34. Controlled Terms
- 36. Thank You
Editor's Notes
- #30: The Inspec database has been the definitive engineering and physics research database for almost 50 years. Over that time our expert indexers have indexed over 19 million articles from journals across the world. There are currently more than 4,500 journals indexed in Inspec. Full: Built on Science Abstracts, which dates back to 1898, the IET’s research database, Inspec, has been delivering access to engineering intelligence since 1969. Owing to the precision and accuracy of its indexing, Inspec has become the authoritative resource for accessing scientific literature across engineering, physics and computer science, serving numerous prestigious institutions and tens of thousands of users around the world. Now, as the role of scholarly communications is evolving, the innovation that inspired the creation of the original Inspec is still in force. We’ve combined the latest in semantic technology with Inspec’s highly curated index to deliver Inspec Analytics; a dynamic new solution in response to the increasing need to assess the value and impact of research, and guide business strategy.