材料设计与生产课件

Design&ManufacturingofMaterialsProductdesign:Productdevelopment;designcore;marketanalysisandcompetitivebenchmarking;productdesignspecification;conceptdesign;detaildesign.Materialsselection:Developmentofmaterialsperformanceindiceswithandwithoutshape,materialsselectionmaps,casestudiesofmaterialsselection:oars,springs,pressurevessels,etc.;selectionwithmultipleconstraints.Processselection:Processselectioncharts,casestudiesofafan,ceramicvalve;processcostsandcostbreakdown.Manufacturingindustry:Plantlocation;plantlayout;criticalpathanalysis;productionscheduling;materialsrequirementplanning;JustinTimemanagement.Metalforminginthepackagingindustry:Forminglimitdiagrams;R-curves;formingprocesses(e.g.deepdrawing);Strainpathanalysis.6Lectures,TrinityTerm20032ndyearMaterials:EngineeringApplicationsofMaterialsDrIanStone(5lectures)&DrPaulButler(1lecture)SynopsisFurtherReadingS.PughTotalDesign,Addison-Wesley,1991(56PUG)M.F.Ashby&D.R.H.JonesEngineeringMaterials1,Pergamon,1980(50ASH/1)M.F.Ashby&D.R.H.JonesEngineeringMaterials2,Pergamon,1986(50ASH/2)M.F.AshbyMaterialsSelectioninMechanicalDesign,Butterworth&Heinemann,1992(56ASH/1)B.Derby,D.A.Hills&C.RuizMaterialsforEngineering,Wiley1992(50DER)E.J.AndersonTheManagementofManufacturing,Addison-Wesley,1994(56AND)ProductDevelopmentProductDevelopmentTeam Marketing Providesmarketassessment Identifiesmarketopportunities Manufacturing Assessesproductionprocess Assessesmanufacturingcostsandquality Design Definesproductformandfunction EngineeringDesign IndustrialDesignProduct

Development

Type Development

time 1-10yearsdependingonproduct Development

cost $100k-$5Bdependingonproduct Development

type Generic/Marketpull Technologypush Technologyplatform Processlimited CustomisedCompanyInnovation LargecompaniesvsSMEs(smallandmediumsizeenterprises)ProductDevelopmentTeamFinanceSalesLegalManufacturingEngineerTEAMLEADERMarketingProfessionalIndustrialDesignerPurchasingSpecialistMechanicalDesignerElectronicsDesignerExtendedTeam(includingsuppliers)ProductDevelopmentTypeGeneric(MarketPull)TechnologyPushPlatformProductsProcessIntensiveCustomizationDescriptionThefirmbeginswithamarketopportunity,thenfindsanappropriatetechnologytomeetcustomerneeds.Thefirmbeginswithanewtechnology,thenfindsanappropriatemarket.Thefirmassumesthatthenewproductwillbebuiltaroundthesametechnologicalsubsystemasanexistingproduct.Characteristicsoftheproductareconstrainedbytheproductionprocess.Newproductsareslightvariationsofexistingconfigurations.DistinctionswithrespecttothegenericprocessAdditionalinitialactivityofmatchingtechnologyandmarket.Conceptdevelopmentassumesagiventechnology.Conceptdevelopmentassumesatechnologyplatform.Bothprocessandproductmustbedevelopedtogetherfromtheverybeginning,oranexistingproductionprocessmustbespecifiedfromthebeginning.Similarityofprojectsallowsforahighlystructureddevelopmentprocess.Developmentisalmostlikeaproductionprocess.ExamplesSportinggoods,furniture,tools.Gore-Texrainwear,Tyvekenvelopes.Consumerelectronics,computers,printers.Snackfoods,cereal,chemicals,semiconductors.Switches,motors,batteries,containers.ProductDevelopmentExamplesStanleyToolsJobmasterscrewdriverRollerbladeBravobladeIn-LineSkatesHewlett-PackardDeskJet500PrinterChryslerConcordeCarBoeing777AeroplaneAnnualproductionvolume100,000units/year100,000units/year1.5millionunits/year250,000units/year50units/yearSaleslifetime40years3years3years6years30yearsSalesprice$3$200$365$19,000$130millionNumberofuniquecomponents33520010,000130,000Developmenttime1year2years1.5years3.5years4.5yearsInternaldevelopmentteamsize3people5people100people850people6,800PeopleExternaldevelopmentteamsize3people10people100people1400people10,000PeopleDevelopmentcost$150,000$750,000$50million$1billion$3billionProductioninvestment$150,000$1million$25million$600million$3billionInnovationinFirmsNumberofemployees1945-9(%)1950-4(%)1955-9(%)1960-4(%)1965-9(%)1970-4(%)1975-80(%)Total(%)1-1991612111113151714200-49996867977500-999327554341,000-9,999363625272317142310,000andover3644505152555952Total100100100100100100100100NumberofInnovations941912744054674014612293TotalDesignMarketAssessmentSpecificationConceptDesignDetailDesignManufactureSellisasystematicactivity:Identificationofthemarketneed→saleofproducttomeetthatneed.Product,Process,People,Organization,etc.DesignCoreMarketAnalysisSpecificationConceptDesignDetailedDesignManufacturingSalesProductDesignSpecification(PDS)EnvelopesallstagesofthedesigncoreTHEDESIGNCORETheDesignCoreMarketAssessmentSpecificationConceptDesignDetailDesignManufactureSellMARKETASSESSMENTInterviews,Questionnaires,FocusGroupsIntellectualPropertyandLiteratureSearchesCompetitiveBenchmarkingparametricanalysis,needsmatrixMarketAnalysis:Example1Tristar333AroughterraintelescopichandlerwithparallelliftMarketAnalysis:Tristar333MarketAnalysis:Example2Microm160AmicroscopemanipulatorforopthalmologyNo.MakeandModelFeatureandfunctionCOOPERVISIONZEISS(J)SLITLA.ZEISSUNIVERSALWILDMS-CWILDMS-BWILDMS-FWECK10108WECK(CEILING)AMSCO,AMSCOPEKEELERK-380FWZEISSE.M.CEILINGGraphicalrepresentationofpercentage%1Coaxialillumination

xxxxxx542Moto.vert.coursemovement

xxxxxx543Moto.vert.finemovement

xx184X-Yattachment

xxxxxxx645Motorizedzoom(microscope)

xxxxxxxxxxx1006Motorizedzoom(arm)

xxx277Auto.stepmagnification

xxxxxxxx738Handswitchcontrols

xxxxxxxxxx829Mouthswitch010Footswitch

xxxxxxxxxxx10011Counterbalancedbyweight

x912Counterbalancedbyspring

xxxxxx5413Energizedlocking

xx1814Frictionlocking

xxxxxxxxx8215Steppedlocking

xxx2716Rotationfreearoundstand

xxxxxxxxxxx100MATRIXANALYSISNo.MakeandModelFeatureandfunctionCOOPERVISIONZEISS(J)SLITLA.ZEISSUNIVERSALWILDMS-CWILDMS-BWILDMS-FWECK10108WECK(CEILING)AMSCO,AMSCOPEKEELERK-380FWZEISSE.M.CEILINGGraphicalrepresentationofpercentage%17Vert.coursemov.ofassembly

xxxxxx5518Coursemov.inhoriz.plane

xxxxxxxxxxx10019Verticalmov.ofthearm

xxxxxx5520Tiltofmicroscopeattachment

xxxxxxxxxxx10021Rotationofmicros.attachm.

xxxxxx5522Yawofmicros.attachment

xxxx3523Connectionfacil.forattachm.

xxxxxxxxxx9124Standlevellingfacilities

x925Standbrakingfacilities

xxxxxx5526Fibreopticillumination

xxxxxxx6427Downlimitingstop

xxxxx4528Manualstepmagnification

xxxxxxxx7329Slitillumination

xxxxxxx6430Manualzoom031Horiz.mov.onplaneofarms

xxxx3632Floormounted

xxxxxxx63MATRIXANALYSIScont’dTheDesignCoreMarketAssessmentSpecificationConceptDesignDetailDesignManufactureSellSPECIFICATIONProductDesignSpecification(PDS)DevelopSpecification(8stages)ConstructcustomerneedsmatrixDevelopperformancemeasuresCrosscorrelate(needs-measuresmatrix)Constructcompetitivebenchmarkcharttoassessmarketposition(basedoncustomerneedsandperformancemeasures)DefineaninitialsetoftargetspecificationsCarryoutengineeringdesignanalysistoassesstechnicalfeasibilityDevelopabillofmaterialsforinitialcostassessmentRedefinethesetofspecificationsProductDesignSpecification(PDS)PatentsEnvironmentMaterialsShelflifePackingCompetitionWeightDisposalShippingSizeProcessesCustomerTimescaleErgonomicsAestheticsInstallationPerformanceServicelifeQuantitySafetyTestingLegalMaintenancePoliticsPlantStandardsQualityassuranceStorageDESIGNCOREPartialPDSPatentsEnvironmentMaterialsShelflifePackingCompetitionWeightDisposalShippingSizeProcessesCustomerTimescaleErgonomicsAestheticsInstallationPerformanceServicelifeQuantitySafetyTestingLegalMaintenancePoliticsPlantStandardsQualityassuranceStorageDESIGNCOREElementtobeconsidered:InOutForindividualcomponents,sub-assemblies,differentstagesofthedesigncore.DesignSpecification:Stage1No.NeedImportance(1-5)1Theproductmust…..42Theproductis…..53Theproductallows…..34Theproductcan…..15Theproductlasts…..5etc.etc.etc.Stage1:CustomerneedsmatrixDesignSpecification:Stage2MetricNo.NeedNos.MetricImportance(1-5)UnitsA1,2Cost5£B2Totalmass5kgC3Compatibility3listD4Assemblytime1sE5Fatiguelife5cyclesetc.etc.etc.etc.etc.Stage2:DevelopperformancemeasuresDesignSpecification:Stage3ABCDEMETRIC NEEDCostTotalmassCompatibilityAssemblytimeFatiguelife1Theproductmust…..

2Theproductis…..

3Theproductallows…..

4Theproductcan…..

5Theproductlasts…..

Stage3:Crosscorrelate(needs-measuresmatrix)DesignSpecification:Stage4No.NeedImportance(1-5)Comp1Comp2Comp3Comp41Theproductmust…..4xxxxxxxxxx2Theproductis…..5xxxxxxxxxxx3Theproductallows…..3xxxxxxxxx4Theproductcan…..1xxxxxxxxx5Theproductlasts…..5xxxxxxxxxxxxetc.etc.etc.etc.etc.etc.etc.Stage4:Constructcompetitivebenchmarkcharttoassessmarketposition(basedoncustomerneeds)DesignSpecification:Stage4cont’dMetricNo.NeedNos.MetricImportance(1-5)UnitsComp1Comp2Comp3Comp4A1,2Cost5£60807090B2Totalmass5kg2.32.22.52.3C3Compatibility3listw,xw,yw,x,y,zwD4Assemblytime1s70909085E5Fatiguelife5cycles22k23k23k24ketc.etc.etc.etc.etc.etc.etc.etc.etc.Stage4:Constructcompetitivebenchmarkcharttoassessmarketposition(basedonperformancemeasures)DesignSpecification:Stage5MetricNo.NeedNos.MetricImportance(1-5)UnitsMarginalValueIdealValueA1,2Cost5£<80<60B2Totalmass5kg<2.4<2.2C3Compatibility3listww,x,y,zD4Assemblytime1s<90<70E5Fatiguelife5cycles>23k>24ketc.etc.etc.etc.etc.etc.etc.Stage5:InitialsetoftargetspecificationsDesignSpecification:Stage6FatigueModelGeometryMaterialsPropertiesFasteningMethodsSurfacefinishCyclestoFailureDESIGNMODELS(ModelInputs)METRICS(ModelOutputs)Stage6:EngineeringdesignanalysistoassesstechnicalfeasibilityDesignSpecification:Stage7ComponentQty/PartHigh(£ea.)Low(£ea.)HighTotal(£/Part)LowTotal(£/Part)HandleSubframeHousingSealBoltNutAssembly@£10/hrOverhead@25%ofdirectcost2111445.0035.0025.001.500.300.156mins3.5028.0018.001.000.200.104mins10.0035.0025.001.501.200.601.0018.587.0028.0018.001.000.800.400.6713.97TOTAL92.8869.84Stage7:DevelopabillofmaterialsforinitialcostassessmentDesignSpecification:Stage8MetricNo.NeedNos.MetricImportance(1-5)UnitsValueA1,2Cost5£<70B2Totalmass5kg<2.3C3Compatibility3listw,x,yD4Assemblytime1s<80E5Fatiguelife5cycles>24ketc.etc.etc.etc.etc.etc.Stage8:RefinedsetofspecificationsExampleNo.NeedImportance1Thesuspensionreducesvibrationtothehands.32Thesuspensionallowseasytraversalofslow,difficultterrain.23Thesuspensionenableshigh-speeddescentsonbumpytrails.54Thesuspensionallowssensitivityadjustment.35Thesuspensionpreservesthesteeringcharacteristicsofthebike.46Thesuspensionremainsrigidduringhardcornering47Thesuspensionislightweight.48Thesuspensionprovidesstiffmountingpointsforthebrakes.29Thesuspensionfitsawidevarietyofbikes,wheelsandtyres.510Thesuspensioniseasytoinstall.111Thesuspensionworkswithmudguards.112Thesuspensioninstilspride.513Thesuspensionisaffordableforanamateurenthusiast.514Thesuspensionisnotcontaminatedbywater.515Thesuspensionisnotcontaminatedbymudanddirt.516Thesuspensioncanbeeasilyaccessedformaintenance.317Thesuspensionallowseasyreplacementofwornparts.118Thesuspensioncanbemaintainedwithreadilyavailabletools.319Thesuspensionlastsalongtime.520Thesuspensionissafeinacrash.5Stage1:CustomerneedsmatrixAMountainBikeSuspensionForkMetricNo.NeedNos.MetricImp.UnitsA1,3Attenuationfromdropouttohandlebarat10Hz3dBB2,6Springpreload3NC1,3MaximumvaluefromtheMonstertest5gD1,3Minimumdescenttimeontesttrack5sE4Dampingcoefficientadjustmentrange3Ns/mF5Maximumtravel(26in.wheel)3mmG5Rakeoffset3mmH6Lateralstiffnessatthetip3kN/mI7Totalmass4kgJ8Lateralstiffnessatbrakepivots2kN/mK9Headsetsizes5inL9Steertubelength5mmM9Wheelsizes5listStage2:DevelopperformancemeasuresMetricNo.NeedNos.MetricImp.UnitsN9Maximumtyrewidth5inO10Timetoassembletoframe1sP11Mudguardcompatibility1listQ12Instilspride5subj.R13Unitmanufacturingcost5US$S14Timeinspraychamberwithoutwaterentry5sT15Cyclesinmudchamberwithoutcontamination5k-cyclesU16,17Timetodisassemble/assembleformaintenance3sV17,18Specialtoolsrequiredformaintenance3listW19UVtestdurationtodegraderubberparts5hoursX19Monstertestcyclestofailure5cyclesY20JapanIndustrialStandardstest5pass/failZ20Bendingstrength(frontalloading)5kNStage2:Developperformancemeasures(cont’d)METRICABCDEFGHIJKLMNOPQRSTUVWXYZNEED1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Stage3:Crosscorrelate(needs-measuresmatrix)No.NeedImp.STTritrackManiray2RoxTahxQuadraRoxTahxTi21TonkaProGunhillHeadShox1reducesvibrationtothehands.3xxxxxxxxxxxxxxxxx2allowseasytraversalofslow,difficultterrain.2xxxxxxxxxxxxxxxxxxxxxx3enableshigh-speeddescentsonbumpytrails.5xxxxxxxxxxxxxxxxxx4allowssensitivityadjustment.3xxxxxxxxxxxxxxxxx5preservesthesteeringcharacteristicsofthebike.4xxxxxxxxxxxxxxxxx6remainsrigidduringhardcornering4xxxxxxxxxxxxxxxx7islightweight.4xxxxxxxxxxxxxxxxx8providesstiffmountingpointsforthebrakes.2xxxxxxxxxxxxxxxxxx9fitsawidevarietyofbikes,wheelsandtyres.5xxxxxxxxxxxxxxxxxxxxx10iseasytoinstall.1xxxxxxxxxxxxxxxxxxxxxxx11workswithmudguards.1xxxxxxxxxxxx12instilspride.5xxxxxxxxxxxxxxxxxxxxx13isaffordableforanamateurenthusiast.5xxxxxxxxxxxxxxx14isnotcontaminatedbywater.5xxxxxxxxxxxxxxxxxxx15isnotcontaminatedbymudanddirt.5xxxxxxxxxxxxxxxx16canbeeasilyaccessedformaintenance.3xxxxxxxxxxxxxxxxxxxxxxx17allowseasyreplacementofwornparts.1xxxxxxxxxxxxxxxxxxxxxxx18canbemaintainedwithreadilyavailabletools.3xxxxxxxxxxxxxxxxxxxxxxx19lastsalongtime.5xxxxxxxxxxxxxxxxxxxxxxxx20issafeinacrash.5xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxStage4:Constructcompetitivebenchmarkcharttoassessmarketposition(basedoncustomerneeds)Specification:AMountainBikeSuspensionForkMetricNo.NeedNos.MetricImpUnitsSTTritrackManiray2RoxTahxQuadraRoxTahxTi21TonkaProGunhillHeadShoxA1,3Attenuationfromdropouttohandlebarat10Hz3dB8151015913B2,6Springpreload3N550760500710480680C1,3MaximumvaluefromtheMonstertest5g3.63.23.73.3l.73.4D1,3Minimumdescenttimeontesttrack5s1311.312.611.213.211E4Dampingcoefficientadjustmentrange3Ns/m00020000F5Maximumtravel(26in.wheel)3mm284843463338G5Rakeoffset3mm41.539383843.239H6Lateralstiffnessatthetip3kN/m59110858565130I7Totalmass4kg1.4091.3851.4091.3641.2221.100J8Lateralstiffnessatbrakepivots2kN/m295550425425325650K9Headsetsizes5in1.0001.1251.0001.1251.2501.0001.1251.0001.1251.2501.0001.125N/AL9Steertubelength5mm150180210230255140165190215150170190210150170190210230150190210220N/AStage4:Constructcompetitivebenchmarkcharttoassessmarketposition(basedonperformancemeasures)MetricNo.NeedNos.MetricImpUnitsSTTritrackManiray2RoxTahxQuadraRoxTahxTi21TonkaProGunhillHeadShoxM9Wheelsizes5list26in26in26in26in700C26in26inN9Maximumtyrewidth5in1.51.751.51.751.51.5O10Timetoassembletoframe1s353545453585P11Mudguardcompatibility1listZefalnonenonenonenoneallQ12Instilspride5subj.143535R13Unitmanufacturingcost5US$651058511580100S14Timeinspraychamberwithoutwaterentry5s13002900>3600>36002300>3600T15Cyclesinmudchamberwithoutcontamination5k-cycles151915251835U16,17Timetodisassemble/assembleformaintenance3s160245215245200425V17,18Specialtoolsrequiredformaintenance3listhexhexhexhexlonghexhex,pinwrenchW19UVtestdurationtodegraderubberparts5hours>400250>400>400>400250X19Monstertestcyclestofailure5cycles>500k>500k>500k480k>500k330kY20JapanIndustrialStandardstest5pass/failpasspasspasspasspasspassZ20Bendingstrength(frontalloading)5kN5.58.97.57.56.210.2Stage4:Constructcompetitivebenchmarkcharttoassessmarketposition(basedonperformancemeasures)(cont’d)MetricNo.NeedNos.MetricImpUnitsMarginalValueIdealValueA1,3Attenuationfromdropouttohandlebarat10Hz3dB>10>15B2,6Springpreload3N480-800650-750C1,3MaximumvaluefromtheMonstertest5g<3.5<3.2D1,3Minimumdescenttimeontesttrack5s<13.0<11.0E4Dampingcoefficientadjustmentrange3Ns/m0>200F5Maximumtravel(26in.wheel)3mm35-5045G5Rakeoffset3mm37-4538H6Lateralstiffnessatthetip3kN/m>65>130I7Totalmass4kg<1.4<1.1J8Lateralstiffnessatbrakepivots2kN/m>325>650K9Headsetsizes5in1.0001.1251.0001.1251.250L9Steertubelength5mm150170190210150170190210230M9Wheelsizes5list26in26in700CStage5:InitialsetoftargetspecificationsMetricNo.NeedNos.MetricImpUnitsMarginalValueIdealValueN9Maximumtyrewidth5in>1.5>1.75O10Timetoassembletoframe1s<60<35P11Mudguardcompatibility1listnoneallQ12Instilspride5subj.>3>5R13Unitmanufacturingcost5US$<85<65S14Timeinspraychamberwithoutwaterentry5s>2300>3600T15Cyclesinmudchamberwithoutcontamination5k-cycles>15>35U16,17Timetodisassemble/assembleformaintenance3s<300<160V17,18Specialtoolsrequiredformaintenance3listhexhexW19UVtestdurationtodegraderubberparts5hours>250>450X19Monstertestcyclestofailure5cycles>300k>500kY20JapanIndustrialStandardstest5pass/failpasspassZ20Bendingstrength(frontalloading)5kN>6>10Stage5:Initialsetoftargetspecifications(cont’d)AssessTechnicalFeasibilityDynamicModelofSuspensionPerformance(Analytical)SuspendedMassUnsprungMassOrificeDiameterSpringConstantOilViscosityAttentuationat10HzEstimatedMonsterg’sStaticModelofBrakeMountingStiffness(Analytical)SupportGeometryMaterialsPropertiesTubeGeometryMountingPointsLateralStiffnessFatigueModelofSuspensionDurability(Physical)ForkGeometryMaterialsPropertiesFasteningMethodsSuspensionGeometryCyclestoFailureDESIGNMODELS(ModelInputs)METRICS(ModelOutputs)Stage6:EngineeringdesignanalysistoassesstechnicalfeasibilityComponentQty/forkHigh($ea.)Low($ea.)HighTotal($/fork)LowTotal($/fork)SteertubeCrownBootLowertubeLowertubetopcoverMainlipsealSlidebushingSlidebushingspacerLowertubeplugUppertubeUppertubetopcapUppertubeadjustmentknobAdjustmentshaftSpringUppertubeorificecapOrificespringsBrakestudsBrakebraceboltBrakebraceOil(litres)Misc.snaprings,o-ringsDecalsAssemblyat$20/hrOverheadat25%ofdirectcostTOTAL11222242222222142210.11042.504.001.003.002.001.500.200.500.505.503.002.004.003.003.000.500.400.255.002.500.150.2530min2.003.000.752.001.501.400.180.400.354.002.501.753.002.502.250.400.350.203.502.000.100.1520min2.504.002.006.004.003.000.801.001.0011.006.004.008.006.003.002.000.800.505.000.251.501.0010.0020.84$104.192.003.001.504.003.002.800.720.800.708.005.003.506.005.002.251.600.700.403.500.201.000.606.6715.74$78.68Stage7:DevelopabillofmaterialsforinitialcostassessmentMetricNo.MetricUnitsValueAAttenuationfromdropouttohandlebarat10HzdB>12BSpringpreloadN600-650CMaximumvaluefromtheMonstertestg<3.4DMinimumdescenttimeontesttracks<11.5EDampingcoefficientadjustmentrangeNs/m>100FMaximumtravel(26in.wheel)mm43GRakeoffsetmm38HLateralstiffnessatthetipkN/m>75ITotalmasskg<1.4JLateralstiffnessatbrakepivotskN/m>425KHeadsetsizesin1.0001.125LSteertubelengthmm150170190210230MWheelsizeslist26inStage8:RefinedsetofspecificationsMetricNo.MetricUnitsValueNMaximumtyrewidthin>1,75OTimetoassembletoframes<45PMudguardcompatibilitylistZefalQInstilspridesubj.>4RUnitmanufacturingcostUS$<80STimeinspraychamberwithoutwaterentrys>3600TCyclesinmudchamberwithoutcontaminationk-cycles>25UTimetodisassemble/assembleformaintenances<200VSpecialtoolsrequiredformaintenancelisthexWUVtestdurationtodegraderubberpartshours>450XMonstertestcyclestofailurecycles>500kYJapanIndustrialStandardstestpass/failpassZBendingstrength(frontalloading)kN>10.0Stage8:Refinedsetofspecifications(cont’d)TheDesignCoreMarketAssessmentSpecificationConceptDesignDetailDesignManufactureSellCONCEPTDESIGNConceptGenerationClarifyproblem analyseintosub-problems determinebasicrequirementsExternalsearch interviewusers,consultexperts, patentsearchInternalsearch brainstorming,analogy,inversion, staffconsultationCombinationConceptAnalysisControlledconvergenceRating&weightingmethodConceptDesign:CarHornConceptDesign:EvaluationCriterion Concept1234567891011121314Easeofachieving105-125DbAS-+-++----S+Easeofachieving2000-5000HzSSN+SS+S---S+Resistancetocorrosion,erosionandwater--OS--S-+---SResistancetovibration,shockandaccelerationS-TS-S--S----ResistancetotemperatureDS-S---SS--SSResponsetimeAS-E+----S----Complexity:numberofstagesT-+VS++---++--PowerconsumptionU--A+--+----S+EaseofmaintenanceMS+L+++--S++S-Weight--U+---S----+Size--AS---------NumberofpartsSST+SS--+--S-LifeinserviceS-E+-S-------Manufacturingcost-SD-++--S----EaseofinstallationSSSS+-S---S-ShelflifeSSSS--SSSSSSΣ+Σ-ΣS06102958173945743121011528621312131088493ConceptDesign:Evaluation/GenerationInitialnumberofconceptsbasedonPDSInitialnumberreducedNewonesaddedFurtherreduction(FR)Furtheraddition(FA)FRFACCCCCCCGCGApplycontrolledconvergence(CC)Applyconceptgeneration(CC)CONCEPTSELECTEDConceptDesign:Rating&WeightingObjectiveWeightFactorRatingRatingxWeightFactorC’pt1C’pt2C’pt3C’pt4C’pt1C’pt2C’pt3C’pt4Make20,000brushesper8-hourshift455052020020Endofbrushsafety505550252525Easeofmanufactureofmachine34034120912Reliabilityofoperations5424420102020Overallsizeofmachine234336866Cost332339699Goodfilamentdensity4355512202020Total798989112Example:DesignofamachinetomakebottlebrushesTheDesignCoreMarketAssessmentSpecificationConceptDesignDetailDesignManufactureSellDETAILDESIGNTotalDesignMarketAssessmentSpecificationConceptDesignDetailDesignManufactureSellisasystematicactivity:Identificationofthemarketneed→saleofproducttomeetthatneed.Product,Process,People,Organization,etc.DesignCoreMarketAnalysisSpecificationConceptDesignDetailedDesignManufacturingSalesProductDesignSpecification(PDS)EnvelopesallstagesofthedesigncoreTHEDESIGNCORETheDesignCoreMarketAssessmentSpecificationConceptDesignDetailDesignManufactureSellDETAILDESIGNAvastsubject.Wewillconcentrateon:MaterialsSelection ProcessSelectionCostBreakdownMaterialsSelectionMetalsandAlloysPolymersCeramicsandGlassesSteel-cordtyresCFRPGFRPFilledpolymersWire-reinforcedcementCermetsMMCsCompositesMaterialsPropertiesMATERIALMechanical tribology fatigue KIC σy UTS EThermal α K H Tm TTransitionEnvironmental recycling energyconsumption wasteOther feel lookPhysical optical magnetic electricalChemical corrosion oxidationFUNCTIONAL

MATERIALSSTRUCTURALMATERIALSYoung’sModulus,EMaterialE(GPa)MaterialE(GPa)MaterialE(GPa)DiamondTungstencarbide,WCCobalt/WCcermetsBoridesofTi,Zr,HfSiliconcarbide,SiCBoronTungstenAlumina,Al2O3Beryllia,BeOTitaniumcarbide,TiCMolybdenumandalloysTantalumcarbide,TaCNiobiumcarbide,TaCSiliconnitride,Si3N4ChromiumBerylliumandalloysMagnesia,MgOCobaltandalloysZirconia,Zr0NickelandalloysCFRPIronIronbasedsuperalloysSteels1000450-650400-530500450441406390380379320-365289200-289250200-284160-241130-23470-200196193-214196-207CastironsTantalumandalloysPlatinumUraniumBoron/epoxycompositesCopperandalloysMulliteVanadiumTitaniumandalloysPalladiumBrassesandbronzesNiobiumandalloysSiliconZirconiumandalloysSilicaglass,SiO2(quartz)ZincandalloysGoldAluminiumandalloysSilverCalcite(marble,limestone)SodaglassGraniteTinandalloysConcrete,cement170-190150-186172172125120130124103-12480-110107969443-968269-79763