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Product Design and Manufacturing
Chitale and R. All rights reserved. No part of this book may be reproduced in any form, by mimeograph or any other means, without permission in writing from the publisher. ISBN The export rights of this book are vested solely with the publisher. Fourteenth Printing Fifth Edition April, Published by Asoke K.
Contents Preface xv 1. Review Questions References References Preface The first printing of this book was undertaken in The authors were inspired to write on Product Design and Manufacturing because the AMIE had introduced a paper on the subject, common to 10 branches of Engineering.
At that time, no authentic book covering the syllabus of Product Design and Manufacturing existed, barring one or two books that were available more or less in the form of guide books to enable the AMIE students to jump the hurdle of the tough AMIE exams.
The concept of product design that emerged differed from purely technical mechanical design, electrical design or civil engineering design. The need for a qualified designer well-versed with a range of product designs was also felt by the Industry. A well-balanced treatment of the subject demanded inputs from morphology of the design process with inputs from strength and stiffness analysis, aesthetics, ergonomics, design for manufacturing ease and cost effectiveness, apart from reliability and durability and other considerations.
The Fifth Edition is a revised and enlarged version of the previous edition. We have included some chapters and sections and updated the material, which should benefit the readers considerably.
Chapter 1 begins with a definition of design as a process of conversion of ideas into concrete reality. The difference between design by evolution and design by innovation is explained. The chapter further discusses the seven phases of morphology of design process as proposed by the design philosopher Morris Asimov.
Next, the three primary design phases, namely Feasibility analysis, Preliminary analysis and Detailed analysis, are developed by considering the 25 steps with input, output and decision box at each step. Chapter 2 then discusses product design as practised by industry, focusing on product strategies, relationship between design, production and marketing, product characteristics, standardization and variety reduction.
Further, the role of a designer: myth and reality, various types of models used by the designer, aesthetics, including form elements and product message and functional design practice, are discussed.
The review questions of this chapter focus on functional design, production design, design for transportation, design for maintenance and ergonomic design, types of design work, such as adaptive design, variant design, creative design, configuration design and modular design explaining their characteristics.
Chapter 3 covers the strength aspects of design using an approach deviating from classical strength of materials which makes excessive use of mathematical models.
Here, concepts such as force flow lines and trajectories to represent principal stresses are used. Chapter 4 on stiffness based design uses analogies and physical models proposed by design philosophers like Euler, Prandtl and others to recommend material saving approaches.
The chapter develops formulae for ribbed plates, corrugated plates and membrane structures. These designs are rarely available in standard textbooks on applied mechanics even though industry makes profitable use of such material-saving approaches. Practising design engineers will find this chapter quite useful.
Forging, extruding and joining processes are also dealt with in detail to guide a designer to effectively use it. The scope of metal cutting and abrasive processes has been enlarged in this edition of the book.
A brief description of nontraditional machining is also given to guide the designer in contributing to effective process planning. Chapter 6 on design for production focuses on the desirable design aspects for forged components, pressed components, machining, powder metallurgy, expanded metals, and wire forms.
The details of this chapter should provide a guideline for a process engineer who is a connecting link between a designer and a production engineer.
Chapter 7 discusses the material science aspect, processing aspect, and the design aspects of plastics, rubber, glass and ceramics. These non-metallic materials considerably extend the repertoire of a designer. In several cases, metals cannot replace the above group of materials. In the review questions, details of design with fibre-reinforced plastics as well as metallic composites are also included which can be useful to a practising designer.
Chapter 8 gives design recommendations with plastics, rubber, ceramics and wood. Chapter 9 on optimization in design focuses on empirical and mathematical approaches such as linear programming, geometric programming, the calculus approach, and Johnsons method of optimal design. In this chapter a reliability based design is also taken up as an example.
Chapter 10 deals with economic factors of design and gives recommendation on how profit can be achieved through increasing the price or expanding the market or reducing the cost. Chapter 11 on human engineering considerations in product design deals with the well-known branch of Ergonomics, with special emphasis on a human being as occupant of space, as a reader of display, an applicator of force, and as a controller of machines. In the present enlarged edition, workplace layout design, noise, heating and ventilation, thermal comfort, air conditioning, heating methods, lighting, effect of glare, etc.
Chapter 12 explains the concept of the value of a product. Value is defined as the ratio of benefit provided by a product divided by the cost of the product.
The chapter explains various aspects of value engineering and value analysis of any product. The various steps of value analysis given by Miles, which include information analysis, creativity, judgment, are discussed in detail.
Other tools of value analysis such as cost-worth approach, checklisting, product and process analysis and multivariable chart developed by M. A case study as per the value analysis job plan is also discussed to highlight the application of the theory. In the review questions to this chapter, the use of. Chapter 13 highlights the role of computer in Product Design, Manufacturing and Management. Finally, flexible manufacturing centre, FM cell, and an FM system are discussed.
In the review questions to this chapter, an example on FMS for hobbing and broaching a gear is given. This section also contains a numerical example illustrating the use of FEM for a stepped bar with axial load.
The working of open loop and closed loop NC systems is also explained. Chapter 14 on modern approaches to product design covers concurrent design, quality function deployment because it is a step by step approach to customer driven design and various rapid prototyping methods.
Chapter 15 on quality assurance in product design contains an introduction to quality evolution and is followed by theory and application of sampling plans, quality control charts, reliability and allied topics such as FMEA and fault tolerance analysis.
The coverage of this topic is fortified with many numerical examples. Chapter 16 on new product development and product management deals with pre-market and marketing phases of a new product.
The pre-market phases deal with seven phases of new product development, i. The marketing phases are concerned with that part of product life cycle which involves product introduction, growth, maturity and decline.
These aspects are covered in the chapter with descriptive and mathematical models. Chapter 17 contains design for environment. With the passage of time, the pressure on industry to produce eco-friendly products has increased.
We received some feedback from students indicating the need for inclusion of certain materials to enhance the utility of the book: End of chapter review questions so that the readers have a better understanding of the subject. More information on metal machining as well as micro-machining processes. They also highlighted the need for covering in detail the topic of Welding Processes considering its importance.
The need was felt for additional input for the topic of Human Factors in Engineering so as to include the design of work place, effect of noise, light and glare, heat and humidity on human operators. Besides the above feedback from the students, the authors also observed certain changes in the syllabi. This updated and enlarged edition takes into account the changes that have taken place ever since the previous edition was published.
Most of the requirements of the students and the proactive universities have now been taken care of. Devasia, Senior Editor; Mr. Pankaj Manohar, Assistant Production Manager, for the support provided by them.
Any suggestions for further improvement of the book will be warmly appreciated. Chitale R. Introduction to Product Design Asimows Model 1. A designer does not usually produce the goods or services which immediately satisfy consumers needs. Rather, he produces the prototype which is used as a sample for reproducing the particular goods or services as many times as required. A design may be of a pattern on upholstery or of a dress in the world of fashion.
If the producer believes that a sufficient number of customers will be satisfied by the product, then mass production of the item or service may be taken up by the production department. In the course of production, an error made by the producer in manufacturing an item may lead to its rejection; but an error in design, which will be repeated in all products, may lead to an economic misadventure of enormous proportions.
The designers responsibility is therefore serious. The leisurely pace of technological change reduced the risk of making major errors. The circumstances rarely demanded analytical capabilities of the designer. This was design by evolution. Development of the bicycle from its crank operated version to its present day chain and sprocket version over a period of about a century is a typical example of design by evolution. The disadvantages of evolutionary design are: Unsuitability for mass production.
An evolved design is rather crude and is more oriented towards design by masses for Production by masses Gandhian philosophy rather than mass production. It is acceptable at village level but unacceptable at urban level. Difficulty in modification. A design by evolution is shaped by demands of time. On the other hand, design by invention and creative process uses sophisticated tools and techniques such as CAD Computer-Aided Design workstation.
The CAD workstation helps generate a large number of design alternatives within minutes. Inability to tap new technologies. A new technology can result in a totally new design based on a different working principle as compared with evolutionary design which relies heavily on small modifications in an existing design.
It is well known that the new technology has made artisans and craftsmen of certain categories redundant. Every skill, which the designer or the design team can muster in analysis and synthesis, is instrumental in a totally.
Product design, Fundamentals and Methods.pdf
Account Options Sign in. Top charts. New arrivals. This well-established and widely adopted text, now in its Sixth Edition, continues to provide a comprehensive coverage of the morphology of the design process. It gives a holistic view of product design, which has inputs from diverse fields such as aesthetics, strength analysis, production design, ergonomics, reliability and quality, Taguchi methods and quality with six sigma, and computer applications. The text discusses the importance and objectives of design for environment and describes the various approaches by which a modern, environment-conscious designer goes about the task of design for environment.
A K Chitale R C Gupta
List of ebooks and manuels about Product design and manufacturing by a k chitale and r c gupta prdf. Ulrich and Steven D. Eppinge r 2nd Edition, Irwin McGraw Design fo r Manufacturing.
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