Product Design and Management Assignment: Product Design Analysis

Learning outcomes -

1. Demonstrate an awareness of the generic processes involved in New Product Development.

2. The student will be able to further apply the modelling tools and techniques associated with the engineering design process.

3. The student will have a fundamental understanding and application of Analysis in the design prior to physical prototypes.

Assessment of the Product Design and Management module consists of 3-Items of student work:

1. Design Analysis assignment

2. Group Design Project and written questions

Assignment 1 - Design Analysis Assignment

PART-A -

i) The aims of the assignment are to understand the principals of 3D - Design Analysis and to carry out Finite Element Analysis on Simple Plate of size to be individually determined Y- between 100mm and 200mm, Z = Y/2; X = Y/2; C=Z/2 and D = 20% to 40% of Z, See figure below. The plate has uniform thickness of Z/5. (PLEASE ENSURE INDIVIDUALITY). Further aim is understand any effects of different feature in a component and mesh density.

The objective is to produce a Simple Plate in the design package such as Creo5 and transferring the model into an Analysis package as and carrying out simulation of tensile stress.

Methodology requires applying fixed boundary conditions at one end and force/presser at the other end of the plate. You are to perform static stress analysis with linear material models on a classical problem by testing for different mesh densities.

Attempt various mesh sizes starting from course to fine. Fix one end of the plate and apply force of 60KN on the opposite surface (convert to Pressure initially). Compare analysis results with classical stress calculations.

Further analysis can be carried out on a different size holes and section, such as a plate with Semi-circle notch (see below) on opposite edges and Square hole and also, different material and applying the same pressure to smaller area of 25% of the length Z in the middle. This will enable you to understand the effects of different type of features/parameters in a component.

ii) Look for an actual product which has a component that is under tensile loading. Apply this type of analysis to a component and discuss the results.

This will develop your ability to understand the application of design packages, the effects of mesh density and to formulate decisions based on results obtained.

Create the 3D design model in Creo5.

Part B -

The aim of the assignment is to develop your ability to model and analyze a component using design tools. The objective is to produce a design using a CAD package and to carry out Finite Element Analysis on an everyday engineering component. The product to consider is a common Bicycle Crank. Initial Dimensions for the Crank are as shown below.

Crank is modelled in PTC Creo 3D design package and can be saved as a *.PRT file. CAD Data exchange file *.STEP is imported and analyzed in Autodesk Mechanical Simulation FEA package. It is possible to read *.PRT files in FEA software.

This will introduce you to creating a bicycle crank in a CAD package using PTC Creo3 transferring data into an FEA package such as Autodesk Simulation 2016. This will highlight the benefits that can be gained from using design tools in the design process.

Conditions: Fixed Boundary Conditions to be applied to the surface on the 18mm hole in the 55mmdia Boss initially.

Force of 1000N to be applied to the inner Nodes/Surface on the 12mm hole in the 32mm boss on the Right Hand Side

Material to be used is Medium carbon Steel listed in the materials library.

Design Safety Factor to consider is 3:1 at the Radii.

Part C -

Bending Stress Analysis of structural Section - Such as a Universal Beam - I-Section. One Method of reducing weight of an I- Section and increase the load carrying capacity is to cut in Hexagon profile and weld the 2- sections as shown below.

Carryout Bending Stress on standard section and a modified section with Beam of 3-times the length given in the supplied model

For 1st analysis consider it as Cantilever with force 10KN; Consider the effects of temperatures in extreme conditions.

Attempt Modal Analysis.

Compare beam element type.

For 2nd Analysis consider it as a Simply Supported Beam.

Part D - Bell Crank for Formula Student car in the workshop is given.

Look at the assembled components and discuss the loading conditions. Model the part with appropriate conditions and carry out analysis to determine the optimised the design with a safety factor of 3:1

Assemble pins in the holes and carry out further analysis for comparison. Look at the new design on the current car and compare.

Part E -

Discuss types of FEA methods and the benefits of applying design analysis in the Product Life Cycle, use examples to illustrate your discussion.

Assignment 2 - Product Design and Development - Group Project

Group Design - The last few years have seen a number of devastating natural disasters, ranging from the Tsunami in the Indian Ocean to the Kashmiri earthquake. Each of these disasters requires a huge expenditure to ensure the minimum loss of life. The acute phase of recovery is the most widely publicised, but the ongoing, chronic, phase can last months or years where people need to live in poorer accommodation without the facilities that would normally be taken for granted. Your project is to research, design and (at least) model a product that can have a positive humanitarian impact in the aftermath of a natural disaster. This may range from a hand-powered mini-crane for rescue teams to a solar powered water purifier.

An alternative design project would be to look at a product to support the Physically Disadvantaged, such as motorised attachment for wheelchairs etc. or general product to improve everyday life.

You will be expected to draw on all aspects of this course and be able to demonstrate this in your assessment. You will be expected to research the product (need, potential market and competition) thoroughly and use sound design principles to reduce a number of possible solutions down to one that will be developed fully.

The group size should around 5-people. You should submit the names of people in your group by the end of week 18 together with the nature of the product you are working on and what you see as the initial project scope, no more than two sides.

Report should include minutes of project review meetings as the project progresses. The report should contain all of the above elements with clear drawings and text. You should try to use as many of design tools as possible for this project.

The investigation should include: -

Project Plan for the project for the group

Market research

Assessment of the market

Appraisal of the competition

Design specification

Criteria by which the product is to be judged and placed in ranking order.

Safety requirements etc. (regulation or standards)

Consider IPR

Possible solution and evaluation

Final Design proposal

Product Design Specification.

Manufacturing Methods

FEA Analysis - Product Verification

Full design and detail of the product. (3D models and detail drawings) together with possible prototypes.

Your report will be submitted to the Faculty of Technology Advisory Centre office (FOTAC).

Attachment:- Assignment File.rar