Contents. Section 1: The Design Process... 1 Chairperson: John R. Dixon, Professor Emeritus, University of Massachusens

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1 Contents Section 1: The Design Process... 1 Chairperson: John R. Dixon, Professor Emeritus, University of Massachusens The Role of the Materials Engineer in Design... 3 The Design Process... 4 Criteria and Concepts in Design... 4 Design Tools... 5 The Materials Selection Process... 5 Effects of Composition, Processing, and Structure on Materials Properties... 6 Properties versus Performance of Materials... 6 Manufacturing Aspects of Design... 6 Overview of the Design Process... 7 From Marketing Goals to Engineering Requirements... 8 Engineering Stages... 8 Guided Iteration... 8 Engineering Conceptual Design... 9 The Configuration Design of Special-Purpose Parts Methods for Parametric Design Best Practices of Product Realization Conceptual and Configuration Design of Products and Assemblies Task Clarification Understanding and Satisfying the Customer Functional Decomposition: Modeling, Analysis, and Structure Competitive Benchmarking Forming Quantitative Specifications Generating Design Configurations and Form Concepts Product Application Example Conclusions Conceptual and Configuration Design of Parts Part Functions Relationship of Parts to Assemblies Material and Process Selection Determining the Configuration Qualitative Physical Reasoning to Guide Generation of Part Configuration Alternatives Qualitative Reasoning about Manufacturing to Guide Generation of Part Configuration Alternatives Tolerances Evaluating Trial Part Configurations Looking for Risks Redesign Guided by Evaluations Creative Concept Development Definitions of Creativity Understanding the Product Problem Creative Concept Generation Tools Applying Creative Concept Generation in New Product Design 47 Conclusions Cross-Functional Design Teams Background: The Changing Role of Product Design and Development in Industry Types of Teams Staffing a Development Team Organizing a Development Team The Specialist's Role on a Development Team Conclusions Section 2: Criteria and Concepts in Design Chairperson: Bruce Boardman, Deere and Company Concurrent Engineering Concurrent Process Multifunctional Teams Requirements, Concepts, and Improvement Conclusions Designing to Codes and Standards Historical Background The Need for Codes and Standards Purposes and Objectives of Codes and Standards How Standards Develop Types of Codes Types of Standards Codes and Standards Preparation Organizations Designer's Responsibility Statistical Aspects of Design Clarification of Statistical Terms Statistical Distributions Applied to Design Statistical Procedures Related ASTM Engineering Statistics Standards Reliability in Design Reliability Tasks Instantaneous Failure Rate and General Reliability Function Graphical Representation of Reliability Mortality Curve Mean Time to Failure Mean Time between Failures Useful Life Series and Parallel Systems Logic Diagrams More Complex Parallel Systems Standby Systems Conditional Probability Probabilistic versus Deterministic Design Distributions Reliability Testing Human Reliability Availability and Maintainability Reliability Growth Conclusions Life-Cycle Engineering and Design Life-Cycle Analysis Process Steps Application of Life-Cycle Analysis Results Case History: LCA of an Automobile Fender Conclusions Design for Quality What Is Quality? xiii

2 Management of Quality How Can Design Unfavorably Affect Product Quality? Evaluating a Product Design for Quality Guidelines for Promoting Quality Robust Design The "In Spec" Dilemma The On-Target Key A Philosophy of Loss The Quality Loss Function Justifying Costs Parameter Design Tolerance Design Technology Development Orthogonal Arrays Risk and Hazard Analysis in Design The Nature of Risk Failure Mode and Effect Analysis Fault Tree Analysis Event Tree Analysis Risk/Benefit Analysis Safety Analysis Probabilistic Estimates Conclusions Human Factors in Design The Human The Activity The Context Human-Machine Systems Broad Design Considerations Human-Machine Function Allocation Further Design Guidelines Other Information Sources Environmental Aspects of Design Generic (Structural) Concerns Tools for Environmentally Responsible Design Conclusions Safety in Design Definitions of Safety Hazard, Risk, and Danger Designer's Obligation Make It Safe Guarding Warnings Human Factors/Ergonomics Products Liability and Design Legal Bases for Products Liability Hazard, Risk, and Danger Definitions of Defects Preventive Measures Paramount Questions Acceptable Level of Danger Section 3: Design Tools Chairperson: Kenneth H. Huebner, Ford Motor Company Computer-Aided Design Computer-Aided Design: A Brief History Overview of CAD Technology Constraint- and Feature-Based Computer-Aided Design Data Associativity Assembly Design Capturing Design Intent Applications of CAD Systems Mechanism Dynamics and Simulation Definitions and Basic Concepts Performance and Function Load Prediction Direct, Concurrent Imerfacing of Multiple-Simulation Programs Direct Interfacing of CAD Data and Simulation Programs Interactions and Applications with Finite Element Analysis Synthesis, Optimization, Design Guidance, Design Improvement, and Other Factors Mechanism Dynamics/Simulation and Concurrent Engineering Finite Element Analysis A Beam Paradox The Basis of Finite Elements Continuum Elements Structural Elements Multipoint Constraints Linear versus Nonlinear Problems Solution of the System of Algebraic Equations Symmetry Superelements (Substructures) Finite Element Preprocessing Finite Element Postprocessing Finite Element Analysis Problems and Applications Computational Fluid Dynamics Introduction Fundamentals of Computational Fluid Dynamics Computational Fluid Dynamics for Engineering Design Issues and Directions for Engineering CFD Computer-Aided Electrical/Electronic Design Functional Phase Electrical Phase Physical Phase Standards Design Optimization Numerical Optimization Methods Computer-Aided-Engineering-B ased Optimal Design Structural Optimization Emerging Technologies Conclusions Dimensional Management and Tolerance Analysis Dimensional Management Process General Requirements and Simulation Conclusions Documenting and Communicating the Design Background The Overall Design Process and General Documentation Requirements Types of Documentation Understanding and Using Design Documentation Standards Conclusions Rapid Prototyping General Description Major Commercial Processes Numerical Control Machining for Prototyping Analyzing Speed and Accuracy Current Research Efforts Section 4: The Materials Selection Process Chairperson: George E. Dieter, University of Maryland Overview of the Materials Selection Process Relation of Materials Selection to Design..., The Process of Materials Selection Performance Characteristics of Materials Relation of Materials Selection to Manufacturing Costs and Related Aspects of Materials Selection Information about Materials Properties Methods of Materials Selection Conclusions xiv

3 Techno-Economic Issues in Materials Selection Cost Analysis Case Study: Cost Estimation for the Automotive Body-in-White Environmental and Social Costs Conclusions Material Property Charts Displaying Material Properties Types of Material Property Charts Use of Material Property Charts Performance Indices Performance Indices and Material Property Charts Case Studies in the Use of Performance Indices Decision Matrices in Materials Selection Alternatives, Criteria, and Weighting Factors Decision Matrix Techniques The Pahl and Beitz Method Conclusions Relationship between Materials Selection and Processing Characteristics of Manufacturing Processes Influence of Materials on Manufacturing Cost Design for Manufacturability Factors in Selecting a Material for Production Ease of Manufacture Conclusions Computer-Aided Materials Selection Expert Systems: General Description Quantitative Selection Systems... ~ Qualitative and Experiential Selection Systems Object-Oriented Systems Current Status and Outlook Value Analysis in Materials Selection and Design Value Analysis versus Total Quality Management Background and General Concepts The Value Analysis Process Examples Conclusions Use of Failure Analysis in Materials Selection Relationship between Failure Analysis and Materials Selection The Failure Analysis Process Methods for Analyzing Failures to Improve Materials Selection Historical Evolution of Improved Materials Failure Analysis Examples Conclusions Section 5: Effects of Composition, Processing, and Structure on Materials Properties Chairperson: Richard W. Heckel, Michigan Technological University Introduction Composition and Structure Determine Properties Elements of Structure Historical Perspective Fundamental Structure-Property Relationships in Engineering Materials Fundamental Characteristics of Metals, Ceramics, and Polymers Crystal Structure and Atomic Coordination Crystalline Defects Evaluation of Mechanical Properties Microstructure and Low-Temperature Strength Microstructure and High-Temperature Strength Microstructure and Low-Temperature Fracture Microstructure and High-Temperature Fracture Microstructure and Fatigue Failure Properties of Irons and Steels Basis of Material Selection Role of Microstructure Evolution of Microstructural Change in Steel Products Properties of Nonferrous Alloys Aluminum and Aluminum Alloys Copper and Copper Alloys Nickel and Nickel Alloys Cobalt and Cobalt Alloys Titanium and Titanium Alloys Zinc and Zinc Alloys Magnesium and Magnesium Alloys Beryllium and Beryllium Alloys Refractory Metals and Alloys Properties of Ceramics and Glasses Glass Traditional Ceramics Engineering Ceramics Properties of Engineering Plastics : Composition: Submolecular Structure Composition: Molecular Structure Composition: Intermolecular Considerations Composition: Supermolecular Considerations Thermal and Mechanical Properties of Solid Engineering Plastics Thermal and Mechanical Properties of Molten Engineering Plastics Viscoelasticity Properties of Engineering Plastics and Commodity Plastics Electrical Properties Optical Properties Chemical Properties Processing Properties of Composites Composition of Composites Manufacturing of Composites Mechanical Properties of Composites Effects of Composition Variations on Properties Effects of Processing on Properties Effects of Design Loadings and Environmental Conditions on Composite Properties Conclusions Effects of Surface Treatments on Materials Performance Solidification Surface Treatments Deposition Surface Treatments Heat Treatment Coatings Sources of Materials Property Data and Information Information Needs Locating Sources of Data Specific Sources of Data Evaluation and Interpretation of Data Obtaining and Reporting Test Data Conclusions Section 6: Properties versus Performance of Materials Chairperson: David A. Woodford, Materials Performance analysis, Inc. Properties Needed for the Design of Static Structures Effect of Component Geometry Factor of Safety Probability of Failure Designing for Static Strength Designing for Stiffness XV

4 Selection of Materials for Static Strength Selection of Materials for Stiffness Types of Mechaffcal Failure urder Static loading at Normal Temperatures Causes of Failure of Engineering Components Design for Fatigue Resistance The Fatigue Process High-Cycle Fatigue Low-Cycle Fatigue Thermal Fatigue High-Temperature Behavior Design for Fracture Toughness A Brief History of Fracture Mechanics Categories of Fracture Mechanics Variables Affecting Fracture Toughness Analysis, Detection, and Design Criterion Fracture Toughness and Design Philosophies Examples of Fracture Toughness in Design The Future Direction of Fracture Toughness in Design Design for Corrosion Resistance Basic Principles of Aqueous Corrosion Forms of Corrosion and General Mitigation Approaches Engineering Design Principles Life Prediction and Management Design for High-Temperature Applications Historical Development of Creep Deformation Analysis Basic Concepts of Elevated-Temperature Design Design Methodology Damage Accumulation and Life Prediction Limitations and Alternative Design Approaches Conclusions Design for Oxidation Resistance The Oxidation Process General Methodologies Alloy Design for Optimal Performance Performance Characteristics of SuperaUoys Performance Characteristics of Single-Crystal Superalloys Coating Concepts for Superalloys Performance Characteristics of Other High-Temperature Materials Degradation Due to Hot Corrosion and Particulate Ingestion Limitations: Testing Techniques and Life Prediction Design for Wear Resistance Wear Behavior Lubrication Material Selection for Wear Applications Wear Models Wear Design Methods for Wear Design Properties Needed fcr Electionic and Magnetic Applications Background Information Overview of Electric and Magnetic Parameters and Materials Properties Overview of Parameters and Materials Properties Other than Electric and Magnetic Electronic Applications Magnetic Applications Special Applications Design with Brittle Materials Time-independent Reliability Analyses Life Prediction Using Reliability Analyses Design with Plastics Mechanical Part Performance Manufacturing Considerations Design-Based Material Selection Conclusions Design with Composites Fiber-Reinforced Composite Materials Structure/Property Relationships Generic Composite Behavior Lamina Properties Laminate Properties Metal-Matrix Composites Ceramic-Matrix Composites Large Composite Structures: Joints, Connections, Cutting, and Repair Design for Manufacturing Section 7: Manufacturing Aspects of Design Chairperson: Howard A. Kuhn, Concurrent Technologies Corporation Introduction to Manufacturing and Design The Manufacturing Enterprise Manufacturing Processes Production Systems Interaction between Design and Manufacturing Design for Manufacture Practices Design for Manufacture and Assembly Introduction to Design for Manufacture and Assembly Results of DFMA Applications Roadblocks in Implementation of DFMA Design for Automatic Assembly Conclusions Manufacturing Processes and Their Selection Product Considerations Casting Processes Deformation Processes Powder Processing Machining Processes Joining Processes Processing of Ceramics and Glasses Polymer Processing Manufacture of Composites Manufacturing Process Selection: Example Modeling of Manufacturing Processes Classification of Models Important Aspects of Modeling Modeling of Deformation Processes Modeling of Casting Operations Modeling of Fusion Welding Processes Conclusions Manufacturing Cost Estimating General Concepts Parametric Methods Empirical Methods of Cost Estimation Complexity Theory Co~,t Estimation Recommendations Design for Casting Design Considerations The Effect of Casting Discontinuities on Properties Casting Tolerances Hot Isostatic Pressing Solidification Simulation and Its Use in Designing Castings Conclusions Design for Deformation Processes : Why Use a Deformation Process? Categories of Deformation Processes Fundamentals of Deformation Processing Flow Stress Workability Formability Microstructural Effects on Metal Flow Grain Flow Pattern Flow-Related Defects in Bulk Forming ~vi

5 Defects in Sheet Metal Parts Conclusions Design for Powder Metallurgy General P/M Design Considerations Powder Processing Techniques Comparison of Powder Processing Methods Design Issues Design for Machining Machining Costs Types of Machining Equipment General Design-for-Machining Rules Special Considerations Application of Design-for-Machining Rules Computer Aids Design-for-Machining Examples Design for Joining Joining Processes Basic Design Considerations Good Design Practices Case Histories Future Directions Design for Heat Treatment Overview of Component Heat Treatment Thermal and Transformation-Induced Strains in Heat Treated Components Component Design for Heat Treating: Experience-Based Design Rules Computer Modeling as a Design Tool for Heat Treated Components Design for Ceramic Processing Costs Design Approaches General Process Design Ceramic Raw Materials and Formulation Preparation of Materials Forming Processes Drying Firing Conclusions Design for Plastics Processing Plastics Processing Methods Design Features and Process Considerations Other Plastics Design and Processing Considerations Materials Selection Methodology Design for Composite Manufacture Composites Manufacturing Processes Process Considerations Conclusions Control of Residual Stresses Fundamental Sources of Residual Stresses Computer Prediction of Residual Stresses Measurement of Residual Stresses Residual Stresses Caused by Various Manufacturing Processes 815 Stress-Relief Methods Design for Surface Finishing Design as an Integral Part of Manufacturing General Design Principles Related to Surface Finishing Surface-Preparation Processes Organic Finishing Processes Inorganic Finishing Processes Conclusions Glossary of Terms Metric Conversion Guide Abbreviations and Symbols Index xvii