Exploring Engineering

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1 Exploring Engineering An Introduction to Engineering and Design Third Edition Philip Kosky Robert Balmer William Keat George Wise ELSEVIER AMSTERDAM BOSTON HI'IDIU.HURG LONDON * NliW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO Aiatk-iuic Prcsi.111 imprint u! Khcvirr

2 Table of Contents Preface Acknowledgments xvii xxiii PART 1: LEAD-ON CHAPTER 1: WHAT ENGINEERS DO Introduction What Is Engineering? What Do Engineers do? Where Do Engineers Work? What Is Engineering Technology? What Makes a "Good" Engineer? What This Book Covers Personal and Professional Ethics The Five Cornerstones of Ethical Behavior Top Ten Questions You Should Ask Yourself When Making an Ethical Decision What Are Professional Ethics? National Society of Professional Engineers (NSPE) Code of Ethics for Engineers Fundamental Canons Engineering Ethics Decision Matrix What Should You Expect from this Book? 15 Summary 15 Exercises 16 Final Thoughts 19 CHAPTER 2: ELEMENTS OF ENGINEERING ANALYSIS Introduction Variables Units The SI Unit System Significant Figures The "Need-Know-How-Solve" Method Spreadsheet Analysis Cell Addressing Modes Graphing in Spreadsheets 39 Summary 41 Exercises 42 CHAPTER 3: FORCE AND MOTION Introduction 51 vii

3 viii Table of Contents 3.2 What Is a Force? Newton's First Law Newton's Second Law Newton's Third Law Free-Body Diagrams Static Equilibrium Dynamic Equilibrium What Is Kinematics? Distance, Speed, and Acceleration The Speed versus Time Diagram Kinematics of Highway On-Ramps The Equations of One-Dimensional Kinematics 68 Summary 69 Exercises 69 CHAPTER 4: ENERGY CONVERSION Introduction Energy Is the Capability to Do Work Kinds of Energy Energy Conversion Conservation of Energy 85 Summary 87 Exercises 88 CHAPTER 5: ENGINEERING ECONOMICS Introduction Why Is Economics Important? The Cost of Money When Is an Investment Worth It? 96 Summary 99 Exercises 99 PART 2: MINDS-ON CHAPTER 6: CHEMICAL ENGINEERING Introduction Chemical Energy Conversion Atoms, Molecules, and Chemical Reactions The Mol and the Kmol Stoichiometry The Air-to-Fuel Ratio The Heating Value of Hydrocarbon Fuels The Heating Value of Fuels: The General Case 114

4 Table of Contents ix 6.7 Chemical Engineering: How Do You Make Chemical Fuels? Process Engineering Modern Chemical Engineering 121 Summary 121 Exercises 122 CHAPTER 7: CIVIL ENGINEERING Introduction What Do Civil Engineers Do? Structural Engineering Truss Structures and the Method of Joints Example Using the Method of Joints Solution of the Equations Using Excel Geotechnical Engineering Properties of Soils Effective Stress Principle Water Resources Engineering Reservoir Capacity Conservation of Mass Estimation of Required Capacity and Yield Transportation Engineering Highway Capacity Follow Rule for Estimating Highway Capacity Two-Second Rule for Estimating Highway Capacity 151 Summary 153 Exercises 154 CHAPTER 8: COMPUTER ENGINEERING Introduction Moore's Law Analog Computers From Analog to Digital Computing Binary Logic Truth Tables Decimal and Binary Numbers Binary Arithmetic Binary Codes How Does a Computer Work? 174 Summary 177 Exercises 177 CHAPTER 9: ELECTRICAL ENGINEERING Introduction Electrical Circuits 185

5 x Table of Contents 9.3 Resistance, Ohm's Law, and the "Power Law" Series and Parallel Circuits Kirchhoff s Laws Kirchhoff s Voltage Law Kirchhoff"s Current Law Switches 197 Summary '99 Exercises 200 CHAPTER 10: MANUFACTURING ENGINEERING Introduction What is Manufacturing? Early Manufacturing Industrial Revolution Manufacturing Processes Subtractive Processes Additive Processes Continuous Processes Net Shape Processes Modern Manufacturing Just-in-Time Manufacturing Flexible Manufacturing Lean Manufacturing Life Cycle Manufacturing Variability and Six Sigma 224 Summary 230 Exercises 230 CHAPTER 11: MATERIALS ENGINEERING Introduction Choosing the Right Material Strength Defining Materials Requirements Materials Selection Properties of Modern Materials 252 Summary 254 Exercises 254 CHAPTER 12: MECHANICAL ENGINEERING Introduction Mechanical Engineering Thermal Design Machine Design 260

6 Table of Contents xi 12.3 The Elements of Thermal Design Heat Transfer The Elements of Fluid Mechanics The Elements of Thermodynamics The Elements of Machine Design Mechanical Behavior Machine Elements Manufacturing Processes 276 Summary 277 Exercises 277 CHAPTER 13: NUCLEAR ENERGY Introduction Nuclear Fission Nuclear Energy Nuclear Power Reactors Neutron Moderation Fission Products and Nuclear Waste Nuclear Waste, the Achilles Heel of Nuclear Power Nuclear Accidents Is Nuclear Power a Viable Renewable Energy Source? 295 Summary 295 Exercises 296 PART 2.1: EMERGING ENGINEERING FIELDS CHAPTER 14: BIOENGINEERING Introduction What Do Bioengineers Do? Biological Implications of Injuries to the Head Why Collisions Can Kill The Fracture Criterion The Stress-Speed-Stopping Distance-Area Criterion Criteria for Predicting Effects of Potential Accidents 310 Summary 313 Exercises 313 CHAPTER 15: ELECTROCHEMICAL ENGINEERING Introduction Electrochemistry Principles of Electrochemical Engineering Lead-Acid Batteries The Ragone Chart 324

7 xii Table of Contents 15.6 Electrochemical Series Advanced Batteries Fuel Cells Fuel Cells Using Novel Fuels Ultracapacitors 332 Summary 333 Exercises 334 CHAPTER 16: GREEN ENERGY ENGINEERING Introduction Solar Energy Photovoltaic Power Solar Thermal Power Plants Solar Thermal Heating Windmills Hydropower Other "Green" Energy Sources 353 Exercises 354 PART 3: HANDS-ON CHAPTER 17: INTRODUCTION TO ENGINEERING DESIGN Introduction The Nature of Engineering Design Design Problems vs. Homework problems Benefits of a Hands-On Design Project Qualities of a Good Designer How to Manage a Design Project Two Ground Rules for Design Ground Rule Number 1. Use a Design Notebook Ground Rule Number 2. Team Effectively The Need for a Systematic Approach Steps in the Engineering Design Process Hands-On Design Exercise: "The Tower" Setup Rules Scoring After the Exercise 365 CHAPTER 18: DESIGN STEP 1. DEFINING THE PROBLEM Introduction Problem Definition List of Specifications 368

8 Table of Contents xiii 18.4 Design Milestone: Clarification of the Task Design Competition Tips 371 CHAPTER 19: DESIGN STEP 2. GENERATION OF ALTERNATIVE CONCEPTS Introduction Brainstorming Concept Sketching Hands-On Design Exercise: "The Tube" Setup Rules Procedure Research-Based Strategies for Promoting Creativity Analogies Reverse Engineering Literature Search Functional Decomposition for Complex Systems Step 1. Decompose the Design Objective into a Series of Functions Step 2. Brainstorm on Alternative Concepts for Each Function and Assemble the Results in a Classification Scheme Step 3. Combine Function Concepts to Form Alternative Design Concepts Step 4. Sketch Each of the Most Promising Combinations Design Milestone: Generation of Alternatives Design Competition Tips 382 CHAPTER 20: DESIGN STEP 3. EVALUATION OF ALTERNATIVES AND SELECTION OF A CONCEPT Introduction Minimize the Information Content of the Design Maintain the Independence of Functional Requirements Design for Ease of Manufacture Design for Robustness Design for Adjustability Hands-On Design Exercise: "Waste Ball" Scenario Design Objective Setup Rules After the Exercise The Decision Matrix Evaluation Criteria Procedure for Filling out a Decision Matrix Additional Tips on Using Decision Matrices 393

9 xiv Table of Contents 20.9 Design Milestone: Evaluation of Alternatives Design Competition Tips 396 CHAPTER 21: DESIGN STEP 4. DETAILED DESIGN Introduction Analysis Experiments Models Detailed Drawings Design Milestone: Detailed Design Design Competition Tips 405 CHAPTER 22: DESIGN STEP 5. DESIGN DEFENSE Introduction How to Prepare an Oral Defense Design Milestone: Oral Design Defense Design Competition Tips 409 CHAPTER 23: DESIGN STEP 6. MANUFACTURING AND TESTING Introduction Manufacturing and Testing Strategies Materials Joining Methods Useful Hand Tools Tools for Measuring Tools for Cutting and Shaping Tools for Drilling Holes Tools for Joining Parts Tools for Wiring Design Milestone: Design for Manufacture Assessment Design Competition Tips Design Milestone: Design for Manufacture Assessment II 420 CHAPTER 24: DESIGN STEP 7. PERFORMANCE EVALUATION Introduction Individual Performance Testing The Final Competition Design Milestone: Individual Performance Testing 424 CHAPTER 25: DESIGN STEP 8. DESIGN REPORT Introduction Organization of the Report Writing Guidelines Design Milestone: Design Report 429

10 Table of Contents xv CHAPTER 26: EXAMPLES OF DESIGN COMPETITIONS Introduction Design Competition Example 1. A Bridge Too Far Design Milestone Solutions for "A Bridge Too Far" Design Milestone 1. Clarification of the Task Design Milestone 2. Generation of Alternative Concepts Design Milestone 3. Evaluation of Alternative Concepts Design Milestone 4. Detailed Design Official Rules for the "A Bridge Too Far" Design Competition Objective Constraints The Game Scoring Other Rules Design Competition Example 2. Mars Meteorite Retriever Challenge Some Design Milestones for the "Mars Meteorite Retriever Challenge" Design Milestone 3. Performance Testing Design Milestone 4. Design Report Official Rules for the "Mars Meteorite Retriever Challenge" Design Competition Objective Constraints Scoring Rules Additional Supplies 446 CHAPTER 27: CLOSING REMARKS ON THE IMPORTANT ROLE OF DESIGN PROJECTS 449 Index 451

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