ME 340 - Mechanical Engineering Design

Methodology Course Introduction

Instructor’s Motto:

“ I do not teach anyone, I only provide the environment in which they can learn“

-Einstein

Catalog Description:

• The product design process;

• Development of design problem definitions by evaluating customer inputs, technology, and competitive products;

• Generation of conceptual design using structured and unstructured approaches;

• Evaluation of concepts using engineering modeling and decision matrices;

• Product detail design including design for manufacturability and profitability;

• Effective communication: • oral, • written, and • graphical.

• Credits: 3 (2 hours lecture + 2 hours lab/week)

• Prerequisites: EDSGN 100, ME320 (concurrent), prerequisite for ME440/441W

• Location: 314 Hammond

• Time: T-Th 10:10 – 12:05 Instructor:

• Dr. Andrew Hoskins, Ph.D.

ahh123@psu.edu

(814) 867-0430

• Dr. Kurt Hacker, Ph.D

(814) 867-3802

Kah53@psu.edu

• Office Hours: by appt.

• Communication: Please use the above email addresses for communication with instructors, DO NOT USE Angel – we do not check that often and response will be delayed.

• Req’d Items:

• Product Design and Development, 5 th Edition, by K. Ulrich and S. Eppinger, I r win

McGraw-Hill, 2007 (same text as ME440W/ME441W)

• Lab journal wi th numbered pages ($14 @ SBS)

• Shop safety glasses

Course Objectives: A. Develop proficiency in design skills and methodologies

B. Gain first-hand experience of the design process in the context of a ‘real’, open-ended multidisciplinary design project

C. Work effectively and professionally in a team while executing a design project

D. Apply engineering analysis tools in the design process

E. Understand the holistic context of design, including global, societal, ethical, economic and environmental concerns

F. Improve proficiency in professional communication skills

G. Understand that i t takes a minimum of three to five (and usually many more) iterations to get a design, or a writ ten document r ight

H. Realize that the first idea is almost never the best

Course Outcomes: After completing this course, each student should be able to:

1. Formulate a design problem by translating customer needs into design objectives and constraints

2. Construct and modify a Gantt chart using MS Project and use i t to plan and execute a project

3. Function effectively in a team environment; and can identify, assess and resolve team problems

4. Generate multiple design concepts and select and refine the best design concept using appropriate qualitative and quantitative techniques, (including brainstorming, decision matrix, and economic analysis)

5. Use a solid modeling CAD package to represent the geometry of a part or an assembly of parts

6. Produce professional-quality reports, oral presentations, web pages, and graphical illustrations for design communication and documentation purposes

7. Access multiple sources of design information, including patents, previous courses, catalog data, reverse engineering, web search, consumer focus groups, empirical tests, etc

8. Demonstrate professionalism and ethical conduct

9. Assess the ergonomics and aesthetics of a design

10. Identify the environmental, safety and societal implications of a design

11. Assess the manufacturability and assembly of a product and suggest improvements

12. Model and analyze design solutions and correlate to actual performance

13. Produce physical prototypes

Academic Integri ty: • I expect academic honesty of all of you.

• I f you have problems getting assignments done on time, please speak to

me as soon as possible so that we can agree on a way to deal with the problem.

• Please do not put yourself into a position where lack of preparation

tempts you to use the work of others as your own.

• In the event that evidence of academic dishonesty comes to my

attention, I wil l deal with i t immediately according to the r ules of the University. (http://www.engr.psu.edu/CurrentStudents/acadinteg.aspx)

Course Requirements:

• Homework: Homework problems based on the class lecture/discussions

and reading material wil l be assigned as needed. Most assignments wil l be related to the final design project.

• Class Participation: Preparation, attendance and participation are

expected at all class meetings. As a professional courtesy, please notify the instructor (by email) of any expected absence. You will be expected to make up any missed sessions or team duties on your own. Students are allowed a maximum of two unexcused absences. Each additional absence will result in a partial letter grade deduction (i.e. from A to A-, B

+ to B, etc). Additional absences to accommodate legitimate professional or personal reasons should be discussed with the instructor as soon as possible. Makeup quizzes will not be given. Several options will be provided to earn extra credit that can be used to drop low or missing quiz grades.

• Late Assignments: All assignments are due at the time and on the date

specified. Late submittals within 24 hours will receive an automatic 10% grade reduction. Items will not be accepted more than 24 hours after the due date.

Course Requirements:

• Reading Assignments: Deep reading (not just web skimming) is stil l one of the

most effective ways of learning on your own, and is an essential professional skill that will directly benefit your career. In order to practice this skill, you will be required to complete regular reading assignments from the text and other handout materials. Class sessions are too valuable to spend on things that you can do on your own. Class sessions will be used to add further examples not covered in the reading, for group activities, and to apply the material in realistic situations. Quizzes will be given on the reading material.

• Design Journal: Each individual is required to keep a design journal. A design

journal is a permanently bound (no three ring or spiral) notebook with pre- numbered pages. I t contains dated entries of all your notes, sketches, CAD drawings, calculations, doodles, and any other record of thoughts and activities related to this course. In other words, i t is a complete record of all activities in the course, writ ten in such a way that i t • has archival value to you • can be used as a legal record for intellectual property purposes.

• The teaching staff wil l review journals at the beginning of random class period.

The journal grade is based on content, completeness and neatness.

Course Requirements:

• Learning by Doing: The best way to learn design is by doing it. Hands-on

activities will be the pr imary instructional tool of this course. Most of the work will be team and project oriented. The first several weeks consist of applications that illustrate the important issues in the design cycle. The last half of the semester will be devoted to a significant design activity, culminating in a design competition. The output of the design activity will be several writ ten reports and a functioning hardware system. The final project will provide an opportunity for you to demonstrate your proficiency with the concepts learned in this course.

• Team Effectiveness: Many of the activities of this course will be done in teams

and will receive a team grade. Each individual is expected to participate fully and equally in all team activities. Each individual will complete peer evaluations of their team members that will be a factor in the final grade.

• Angel wil l be used for posting of course materials.

Calculation of Final Grade: A weighted average grade will be calculated as follows:

• Homework

• Quizzes

• Design Journal

• Bracket Rev. Eng.

• Drill Dissection

• Project

• Peer Evaluation

• Team Checkup

5%

25%

10%

10% (team grade)

5% (team grade)

30% (team grade)

12%

3%

We do not curve grades in this course. I t is theoretically possible for everyone in the class to receive an A (or an F). Your performance depends on how well you perform, not on how everyone in the class does. I t is therefore in your best interests to help your classmates, while acting within the bounds of the university’s academic integr i ty policy. Education research has shown that helping others also increases your own learning.

Final Average >93 90–93 87–90 83–87 80–83 77–80 73–77 65–73 <65

Letter Grade A A- B+ B B- C+ C D F

1. Use bound journals with consecutively numbered pages. Number journal volumes sequentially.

2. Use permanent ink.

3. Never tear or cut pages from a laboratory journal.

4. Do not leave blank pages. Draw a diagonal line across any intentionally blank pages or sections, and date and initial

5. Identify the project to which all data relate. I f possible, indicate the project or experiment number, or at a minimum give a brief descriptive heading.

6. Date and sign all entries. I f you do not work on the project for a period of time, indicate the reasons and dates spent away from the research.

7. Record all concepts, drawings, calculations, experimental data and other observations on a daily basis.

8. Define all abbreviations and acronyms when first used.

9. Avoid fragmentary diagrams and sketches. Include explanatory notes with all figures. Draw circuit diagrams, for instance, as comprehensively as possible, using blocks or similar notations to indicate conventional parts.

10. Make notations of the progress and completion of compounds, assemblies, or models being prepared for testing. Relate these entries to previous sketches or entries that explain how the compound or equipment is being made.

11. Record significant events. Successful testing of a compound or particular setup or piece of equipment is “reduction to practice” and the date of such an accomplishment is important. Make notations of such tests, identifying the compound or equipment and commenting on the results of the test. Give tabulated test data, if available.

12. Make corrections by drawing a single thin line through the entry. Do not erase or obliterate mistakes.

13. Avoid loose pages and inserts. I f a sketch or note is made on a loose piece of paper, and you wish to place i t in your book without making another entry, permanently affix i t in the journal and have its placement witnessed by another investigator.

14. Permanently attach additional material or data, such as computer printouts and photographs, and refer to the attached information in a journal entry.

15. Use photographs. Photographs are useful in keeping a complete journal. Particularly when a model has been made, i t is desirable to take photographs that will serve as future identification. Permanently paste the photographs into the lab journal, giving the date, the identification, and the name of the photographer.

16. Have entries witnessed. At least one other person—not a co-investigator or joint inventor—should review and witness the entries by signing and dating the journal pages on a regular basis (weekly, if not daily).

17. Avoid splitting entries between books. When two or more investigators are working on the same project, they should not split entries between laboratory books. One book should be complete in itself, and investigators should initial and date their own entries.

18.Keep lab journals in a safe place when not in use.

19.Keep lab journals relating to patent applications for at least 20 years. The term of most patent applications filed in recent years is 20 years. Because laboratory journals can help establish the date an invention was conceived, and by whom, the journals should be kept for at least as long as the term of the patent.

http://www.lf.psu.edu/Facilities/Training.html

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http://www.signupgenius.com/go/60B0549A5AF0-learning1

Examples of Innovative Design

Examples of Innovative Re-Design

Examples of Innovative Re-Design

ASME survey of industry – Most important skills for new engineering graduates

1. Teams/Teamwork 2. Communication 3. Design for Mfg 4. CAD Systems 5. Professional Ethics 6. Creative Thinking 7. Design for Performance 8. Design for Reliability 9. Design for Safety 10. Concurrent Engineering 11. Sketching/Drawing 12. Design for Cost

• Design

• Project Management

• Communication

• Working in teams

• Creativity

• Learning on your own

• Prototyping

• Facility with design and analysis tools

(CAD, etc)

There are four critical things I would l ike you to

get from this course:

1) It takes at least three to four iterations to get a document or a product right

2) Everything takes longer than you think

3) Don’t marry your first idea

Famous product flops

1. Ben-Gay Aspirin 2. Apple Newton PDA

3. New Coke

4) Your work will have social consequences

At least 89 people have died from unintended acceleration in Toyota vehicles

The GM ignition switch issue has caused many fatalities, cost GM money and goodwill, cost a few people their jobs.

Recalls in the automotive industry seem to occur on a monthly basis now.

While viewing the video, list five things that you think are the most significant or interesting. Put these reflections in your design journal. 1. 2. 3. 4.

5.

The Gossamer Albatross completed a successful crossing of the English Channel on June 12, 1979. It completed the 22.2 mile crossing in 2 hours and 49 minutes, achieving a top speed of 18 mph and an average altitude of 5 feet.

ME 340 is a design course, and as such, it must be

approached with a different attitude than a traditional

lecture-style course.

In Textbook Problems:

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•

One “right” solution

Instructor knows all the answers,

tells you what you need to know

In Real Life:

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• • •

•

• Continuous effort is required, this is not a cram for the

exam class

Strong emphasis on professional skills & behaviors • - - -

Initiative

Team cooperation

Planning and time management

•

•

•

•

You will be doing real engineering

You will get some hands-on experience

You will be using knowledge from other courses

You are beginning the transformation from being a student to a practicing professional

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-

-

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want to learn,

take responsibility for their own learning,

take pride in their work,

welcome feedback.

Food for thought...

The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong, i t usually tu rns out to be impossible to get at and repair. - Douglas Adams

Questions?

Homework: Read Chap 1.

Quiz # 1 on Thursday.

Reflections on video in journal.