Engineering Design (5th edition)

912 Pages·2012·17.388 MB·English

by  George Dieter, Linda Schmidt

FIFTH EDITION
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Engineering Design provides a realistic understanding of the engineering design process. N
The book presents a detailed, eight-step process (Chapters 1 through 9) that gives prescriptive
guidance to the student from problem defi nition through detail design. Chapters 10 through 17 G
present more specifi c treatment of specialty topics (design for X). The text is appropriate for use
in either a junior or senior engineering course or a graduate-level course on the design process. I
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OUTSTANDING FEATURES INCLUDE:
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Use of uniform terminology throughout
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FIFTH EDITION
Expanded discussion of design tools like benchmarking, QFD, creativity methods, functional
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decomposition and synthesis, and the decision process and decision tools
ENGINEERING
Introduction of different approaches to the steps of design in Chapters 6 and 7 so students I
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appreciate the range of practice and scholarship on design
Separate chapters presenting in-depth treatment of design topics such as materials selection, G
design for manufacturing, sustainability, robust design, reliability, and cost evaluation
DESIGN
Many references to the literature have been included as well as suggestions for useful design
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software and references to websites.
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CHANGES TO THE FIFTH EDITION:
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S D
Reorganization and new material on QFD’s House of Quality, methods for conceptual design, A
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additional structure in selection of conceptual design alternatives, design for sustainability I IM
and environment, cost of quality, updated Internet references G #
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One additional chapter is available to the student at the text website: Chapter 18—Legal N 761
and Ethical Issues in Engineering Design 99
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Further resources that support the text are available on the website: www.mhhe.com/dieter /1
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Detailed guidelines on design team performance Y
Dieter A
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PowerPoint lecture slides for instructors George E. Dieter M
Schmidt A
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Linda C. Schmidt E
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ENGINEERING DESIGN
FIFTH EDITION
George E. Dieter
University of Maryland
Linda C. Schmidt
University of Maryland
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ENGINEERING DESIGN, FIFTH EDITION
Published by McGraw-Hill, a business unit of The McGraw-Hill Companies, Inc., 1221 Avenue of the
Americas, New York, NY 10020. Copyright © 2013 by The McGraw-Hill Companies, Inc. All rights
reserved. Previous editions © 2009, 2000, and 1991. Printed in the United States of America. No part of
this publication may be reproduced or distributed in any form or by any means, or stored in a database
or retrieval system, without the prior written consent of The McGraw-Hill Companies, Inc., including,
but not limited to, in any network or other electronic storage or transmission, or broadcast for distance
learning.
Some ancillaries, including electronic and print components, may not be available to customers outside
the United States.
This book is printed on acid-free paper.
1 2 3 4 5 6 7 8 9 0 DOC/DOC 1 0 9 8 7 6 5 4 3 2
ISBN 978-0-07-339814-3
MHID 0-07-339814-4
Vice President & Editor-in-Chief: Marty Lange
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Typeface: 10.5/12 Times Roman
Printer: R. R. Donnelley
Library of Congress Cataloging-in-Publication Data
Dieter, George Ellwood.
Engineering design. — 5th ed. / George E . Dieter, Linda C . Schmidt.
p. cm.
ISBN 978-0-07-339814-3 (acid-free paper)
1. Engineering design. I. Schmidt, Linda C. II. Title.
TA174.D495 2013
620'.0042—dc23
2011048958
www.mhhe.com
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ABOUT THE AUTHORS
GEORGE E. DIETER is Glenn L. Martin Institute Professor of Engineering at
the University of Maryland. The author received his B.S. Met.E. degree from Drexel
University and his D.Sc. degree from Carnegie Mellon University. After a stint in
industry with the DuPont Engineering Research Laboratory, he became head of the
Metallurgical Engineering Department at Drexel University, where he later became
Dean of Engineering. Professor Dieter later joined the faculty of Carnegie Mellon
University as Professor of Engineering and Director of the Processing Research Insti-
tute. He moved to the University of Maryland in 1977 as professor of Mechanical
Engineering and Dean of Engineering, serving as dean until 1994.
Professor Dieter is a fellow of ASM International, TMS, AAAS, and ASEE. He
has received the education award from ASM, TMS, and SME, as well as the Lamme
Medal, the highest award of ASEE. He has been chair of the Engineering Deans
Council, and president of ASEE. He is a member of the National Academy of Engi-
neering. He also is the author of Mechanical Metallurgy, published by McGraw-Hill,
now in its third edition.
LINDA C. SCHMIDT is an Associate Professor in the Department of Mechani-
cal Engineering at the University of Maryland. Dr. Schmidt’s general research inter-
ests and publications are in the areas of mechanical design theory and methodology,
design generation systems for use during conceptual design, design rationale capture,
and effective student learning on engineering project design teams.
Dr. Schmidt completed her doctorate in Mechanical Engineering at Carnegie Mellon
University with research in grammar-based generative design. She holds B.S. and M.S.
degrees from Iowa State University for work in Industrial Engineering. Dr. Schmidt is a
recipient of the 1998 U.S. National Science Foundation Faculty Early Career Award for
generative conceptual design. She co-founded RISE, a summer research experience that
won the 2003 Exemplary Program Award from the American College Personnel Asso-
ciation’s Commission for Academic Support in Higher Education. Dr. Schmidt was
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iv engineering design
awarded the American Society of Engineering Education’s 2008 Merryfi eld Design
Award.
Dr. Schmidt is active in engineering design theory research and teaching engi-
neering design to third- and fourth-year undergraduates and graduate students in
mechanical engineering. She has coauthored a text on engineering decision-making,
two editions of a text on product development, and a team-training curriculum for
faculty using engineering student project teams. Dr. Schmidt was the guest editor of
the Journal of Engineering Valuation & Cost Analysis and has served as an Associ-
ate Editor of the ASME Journal of Mechanical Design. Dr. Schmidt is a member of
ASME, SME, and ASEE.
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BRIEF CONTENTS
Chapter 1 Engineering Design 1
Chapter 2 Product Development Process 36
Chapter 3 Problem Defi nition and Need Identifi cation 70
Chapter 4 Team Behavior and Tools 118
Chapter 5 Gathering Information 158
Chapter 6 Concept Generation 191
Chapter 7 Decision Making and Concept Selection 244
Chapter 8 Embodiment Design 299
Chapter 9 Detail Design 386
Chapter 10 Design for Sustainability and the Environment 411
Chapter 11 Materials Selection 437
Chapter 12 Design with Materials 487
Chapter 13 Design for Manufacturing 526
Chapter 14 Risk, Reliability, and Safety 628
Chapter 15 Quality, Robust Design, and Optimization 680
Chapter 16 Economic Decision Making 734
Chapter 17 Cost Evaluation 776
Chapter 18 Legal and Ethical Issues in Engineering
Design www.mhhe.com/dieter
Appendices A-1
Author & Subject Indexes I-1
v
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DETAILED CONTENTS
Preface xiii
Chapter 1 Engineering Design 1
1.1 Introduction 1
1.2 Engineering Design Process 3
1.3 Ways to Think about the Engineering Design Process 6
1.4 Description of Design Process 14
1.5 Considerations of a Good Design 17
1.6 Computer-Aided Engineering 22
1.7 Designing to Codes and Standards 24
1.8 Design Review 26
1.9 Societal Considerations in Engineering Design 28
1.10 Summary 32
New Terms and Concepts 33
Bibliography 33
Problems and Exercises 33
Chapter 2 Product Development Process 36
2.1 Introduction 36
2.2 Product Development Process 36
2.3 Product and Process Cycles 44
2.4 Organization for Design and Product Development 48
2.5 Markets and Marketing 55
2.6 Technological Innovation 61
2.7 Summary 66
New Terms and Concepts 67
Bibliography 67
Problems and Exercises 67
vi
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detailed contents vii
Chapter 3 Problem Defi nition and Need Identifi cation 70
3.1 Introduction 70
3.2 Identifying Customer Needs 72
3.3 Customer Requirements 80
3.4 Gathering Information on Existing Products 86
3.5 Establishing the Engineering Characteristics 94
3.6 Quality Function Deployment 99
3.7 Product Design Specifi cation 111
3.8 Summary 113
New Terms and Concepts 115
Bibliography 115
Problems and Exercises 116
Chapter 4 Team Behavior and Tools 118
4.1 Introduction 118
4.2 What It Means to be an Effective Team Member 119
4.3 Team Leadership Roles 120
4.4 Team Dynamics 121
4.5 Effective Team Meetings 123
4.6 Problem-Solving Tools 125
4.7 Time Management 144
4.8 Planning and Scheduling 146
4.9 Summary 154
New Terms and Concepts 154
Bibliography 155
Problems and Exercises 155
Chapter 5 Gathering Information 158
5.1 The Information Challenge 158
5.2 Types of Design Information 160
5.3 Sources of Design Information 161
5.4 Library Sources of Information 164
5.5 Government Sources of Information 168
5.6 Information From the Internet 169
5.7 Professional Societies and Trade Associations 174
5.8 Codes and Standards 176
5.9 Patents and Other Intellectual Property 178
5.10 Company-Centered Information 187
5.11 Summary 188
New Terms and Concepts 189
Bibliography 189
Problems and Exercises 189
Chapter 6 Concept Generation 191
6.1 Introduction to Creative Thinking 192
6.2 Creativity and Problem Solving 196
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viii engineering design
6.3 Creative Thinking Methods 202
6.4 Creative Methods for Design 212
6.5 Functional Decomposition and Synthesis 216
6.6 Morphological Methods 226
6.7 TRIZ: The Theory of Inventive Problem Solving 229
6.8 Summary 240
New Terms and Concepts 241
Bibliography 242
Problems and Exercises 242
Chapter 7 Decision Making and Concept Selection 244
7.1 Introduction 244
7.2 Decision Making 245
7.3 Evaluation Processes 257
7.4 Using Models in Evaluation 262
7.5 Pugh Chart 279
7.6 Weighted Decision Matrix 283
7.7 Analytic Hierarchy Process (AHP) 286
7.8 Summary 294
New Terms and Concepts 295
Bibliography 295
Problems and Exercises 295
Chapter 8 Embodiment Design 299
8.1 Introduction 299
8.2 Product Architecture 302
8.3 Steps in Developing Product Architecture 306
8.4 Confi guration Design 311
8.5 Best Practices for Confi guration Design 318
8.6 Parametric Design 328
8.7 Dimensions and Tolerances 340
8.8 Industrial Design 358
8.9 Human Factors Design 361
8.10 Life-Cycle Design 368
8.11 Prototyping and Testing 369
8.12 Design for X (DFX) 379
8.13 Summary 381
New Terms and Concepts 382
Bibliography 382
Problems and Exercises 383
Chapter 9 Detail Design 386
9.1 Introduction 386
9.2 Activities and Decisions in Detail Design 387
9.3 Communicating Design and Manufacturing Information 391
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detailed contents ix
9.4 Final Design Review 402
9.5 Design and Business Activities Beyond Detail Design 403
9.6 Facilitating Design and Manufacturing with
Computer-Based Methods 406
9.7 Summary 408
New Terms and Concepts 408
Bibliography 409
Problems and Exercises 409
Chapter 10 Design for Sustainability and the Environment 411
10.1 The Environmental Movement 411
10.2 Sustainabilty 416
10.3 Challenges of Sustainability for Business 420
10.4 End-Of-Life Product Transformations 422
10.5 Role of Material Selection in Design for Environment 427
10.6 Tools to Aid Design for the Environment and Sustainability 431
10.7 Summary 436
New Terms and Concepts 435
Bibliography 436
Problems and Exercises 436
Chapter 11 Materials Selection 437
11.1 Introduction 437
11.2 Performance Requirements of Materials 440
11.3 The Materials Selection Process 451
11.4 Sources of Information on Material Properties 455
11.5 Cost of Materials 460
11.6 Overview of Methods of Materials Selection 462
11.7 Material Performance Indices 463
11.8 Materials Selection with Decision Matrices 471
11.9 Selection with Computer-Aided Databases 476
11.10 Design Examples 477
11.11 Summary 481
New Terms and Concepts 482
Bibliography 483
Problems and Exercises 483
Chapter 12 Design with Materials 487
12.1 Introduction 487
12.2 Design for Brittle Fracture 488
12.3 Design for Fatigue Failure 494
12.4 Design for Corrosion Resistance 506
12.5 Design Against Wear 511
12.6 Design with Plastics 516
12.7 Summary 523
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