Engineering Design and Computing Lecture Notes PDF

ENGINEERING DESIGN AND COMPUTING Engineering Design and Material Selection Lecture 1 — Introduction and Sketching Prof. Dr. Kristina Shea Dr. Tino Stankovic Pr...

ENGINEERING DESIGN AND COMPUTING Engineering Design and Material Selection Lecture 1 — Introduction and Sketching Prof. Dr. Kristina Shea Dr. Tino Stankovic Prof. Dr. Kristina Shea 1  ENGINEERING DESIGN AND COMPUTING Welcome to mechanical engineering! Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 2  ENGINEERING DESIGN AND COMPUTING Engineering Design: Basic Process The Need Phase 1: Phase 2: Phase 3: Phase 4: Phase 5: Phase 0: Planning Concept System-Level Detail Design Testing & Production Development Design Refinement Ramp-Up Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 3  ENGINEERING DESIGN AND COMPUTING Topic Overview: Requirements Sketches Sustainable Design Design Process Ideation Technical Drawings 2D / 3D Representations Prototyping Computer-Assisted Design (CAD) Engineering Design Material Properties Additive Manufacturing Manufacturing Material Selection Ashby Diagrams Working in Small Teams Sustainable Materials Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 4  ENGINEERING DESIGN AND COMPUTING Practice-Oriented Course Addressing MAVT Grand Challenges Health Future mobility Sustainable materials breathe Kyburz Ski workshop Low-cost ventilators Electric vehicles Sustainable skis Concept generation exercise Balloon power car project Material selection exercises Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 5  ENGINEERING DESIGN AND COMPUTING Balloon Powered Car Project Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 6  ENGINEERING DESIGN AND COMPUTING Course Schedule Week/ Topic Case Study Quiz Lecturer Dates 1 Introduction and Sketching 2 Introducing Engineering Design Health Prof. Dr. Kristina Shea 3 Technical Drawing: Projections and Cuts 4 CAD: Introduction and Modeling Operations 5 CAD: Features and Parametric Modeling Future Mobility 6 CAD: Freeform Modeling Dr. Tino Stankovic 7 CAD: Assemblies and Standard Mechanical Parts X (45 min) 8 Technical Drawing: Dimensioning Health 9 Sustainability in Engineering Design 10 Materials and their Properties 11 Manufacturing Processes with Focus on Additive Manufacturing Sustainable Materials Prof. Dr. Kristina Shea 12 Material Selection 13 Review and Q+A X (75 min) Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 7  ENGINEERING DESIGN AND COMPUTING Learning Objectives § Creatively and systematically tackle design tasks, generate and evaluate concepts and select appropriate materials. § Accurately create and read technical drawings and 3D CAD models of mechanical parts and assemblies. § Understand the connections between engineering design, manufacturing (additive) and material selection. § Gain knowledge about the MAVT grand challenges in healthcare, mobility and sustainable materials. § Learn through hands-on, practice-oriented exercises connected to daily life. § Learn teamwork and critical thinking. Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 8  ENGINEERING DESIGN AND COMPUTING Course Information § Lecture (1h/week) § Exercises (3h/week) Mon Tue Wed Thu § All content available on Moodle 14:00-15:00 15:00-16:00 Lecture Exercises Exercises § 2 mandatory quizzes during 16:00-17:00 exercises 17:00-18:00 Exercises Exercises § Course fee of 14.- per student 18:00-19:00 § For printed course handouts, 3D printing Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 9  ENGINEERING DESIGN AND COMPUTING Exercises + Quizzes § Hand in excerises to get feedback from tutors. § Mandatory quizzes are held in the regular exercise sessions quiz nr. week dates tested content time number of questions weight 1 7 4.-7.11. Weeks 1-6 45 min 30 37.5 % 2 13 16.-19.12. Weeks 1-12 75 min 50 62.5 % § The quizzes are closed book, i.e. you are not allowed to bring any material. § Participation in course: § After participation in the first quiz, the course will be graded and the second quiz has to be taken. § A maximum of one quiz can be missed and taken at another date for a valid reason, i.e. illness with a doctor’s certificate § There will be a sample quiz on Moodle released in Week 6. Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 10  ENGINEERING DESIGN AND COMPUTING Exercises + Quizzes § The quizzes are online (on Moodle) § The quizzes are in English. Dictionaries for English-German, English-French and English-Italian are available if needed. § Quizzes test content of lectures and exercises § Max. 1 point per question, no negative points for wrong answers If you can’t attend a quiz... § Inform us about your absence (email to [email protected]) § Provide documentation for your absence: § Illness: doctor’s certificate § Military service: Marschbefehl § Doctor’s certificate can be sent later Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 11  ENGINEERING DESIGN AND COMPUTING EDAC Team for EDMS Exercise Head Lectures and Moodle Leader Martin Schütz Andreas Walker Exercise Leaders: Marc Wirth Rafaela Louis Maxime Escande Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 12 12  ENGINEERING DESIGN AND COMPUTING Course Relation to Bachelor Study § Main connections: § Mechanics I + II § Machine Design § Innovation Project § Engineering Materials and Production § Focus Project § Various Electives and Focus Courses Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 13  ENGINEERING DESIGN AND COMPUTING Learning Objectives – Lecture 1 § Gain knowledge about engineering design and an engineering design process. § Understand the need for a new mechanical ventilator and the basic design. § Learn fundamentals of sketching. § Learn fundamentals of projections and views. Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 14  ENGINEERING DESIGN AND COMPUTING https://www.telegraph.co.uk/global-health/climate-and-people/burying-africas-equipment-graveyards-50m-programme-launched/ Case Study on Health Introduction: A Mechanical Ventilator Need - Most current medical devices:... are too expensive for low-resource settings http://www.mikemiesen.com/tag/medical-device-graveyards/... can break in harsh environments... are difficult to maintain & repair... are designed for well-trained users in Images: high-resource settings Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 15  ENGINEERING DESIGN AND COMPUTING Mechanical Ventilators Help patients to breathe. Are commonly used for transport, trauma, post- surgical care, sepsis. Are needed in many Low- and Middle-Income Countries. 0.14 Ventilators / 100’000 people in Low-Income Countries 1) 8 - 36 Ventilators / 100’000 people in Europe 2) 1) Craig et al., National estimates of critical care capacity in 54 African countries, 2020 2) Our World in Data: Medical ventilators per 100,000 people, accessed 14. Jan. 2022 Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 16  ENGINEERING DESIGN AND COMPUTING Principle of a Mechanical Ventilator § Resuscitator bags are: § commonly used for manual resuscitation § are easily accessible and comparatively cheap § Automatic, cyclic compression of the bag by a mechanical ventilation system § Resuscitator bags connect to standard and already accessible parts § Air pathway already approved for medical use Adobe Stock picture Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 17  ENGINEERING DESIGN AND COMPUTING From a Need to a Product Sketch First Prototype First Concept First Functional and Form Prototype First Integrated Prototype Second Integrated Prototype Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 18  ENGINEERING DESIGN AND COMPUTING It takes an interdisciplinary TEAM to… Dr. Marianne Schmid Daners Dr. med. Adrian Marty... implement safe MEDICAL procedures Dr. Thomas Lumpe Christos Vasileiou... DESIGN for intuitive usability Milena Overhoff... develop robust HARDWARE Prof. Kristina Shea Leonie Korn... integrate reliable CONTROLS Dr. med. Vanessa Moll Prof. Melanie Zeilinger Martin Meier Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 19  ENGINEERING DESIGN AND COMPUTING What is needed to be a good engineer? § A. Raw talent: either you have it or not. § B. Hard work during weekends and nights alone. § C. Anyone can learn to be a good engineer. § D. You need to know everything about the latest technologies. Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 20  ENGINEERING DESIGN AND COMPUTING Conveying Ideas Graphically A device for use with an AMBU-bag having a flexible squeeze bag with a curved outer surface, comprising: § one holding region shaped to correspond to a portion of the curved outer surface of the squeeze bag; § a mechanical compression squeezer for cyclically squeezing the bag from its outside and releasing the bag for expansion; § a powered actuator; and, § one region shaped to hold the squeeze bag during squeezing. US Patent 2012/0145151 Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 21  ENGINEERING DESIGN AND COMPUTING Different Representations Sketch 3D model Technical drawing Photorealistic rendering Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 22  ENGINEERING DESIGN AND COMPUTING An Introduction to Sketching § Sketching is a simple idea communication tool (“napkin prototyping”) Sketch of a helicopter by § Often used in concept generation phase Leonardo da Vinci § Common tools: pen, pencil, tablet § Can be learned (like sports or music) Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 23  ENGINEERING DESIGN AND COMPUTING Process from Mental Model to a Sketch 1. Define goals 2. Build mental representation 3. Select representation mode 4. Sketch 5. Validate Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 24  ENGINEERING DESIGN AND COMPUTING Define Goals for Sketches § What do I want to show? § Who is the target audience? § What is the goal? § Concept sketch § Function-oriented sketch § Design sketch § Support sketch Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 25  ENGINEERING DESIGN AND COMPUTING Define Goals for Sketches § What do I want to show? § Who is the target audience? § What is the goal? § Concept sketch § Function-oriented sketch § Design sketch § Support sketch Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 26  ENGINEERING DESIGN AND COMPUTING Define Goals for Sketches § What do I want to show? § Who is the target audience? § What is the goal? § Concept sketch § Function-oriented sketch § Design sketch § Support sketch Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 27  ENGINEERING DESIGN AND COMPUTING Define Goals for Sketches § What do I want to show? § Who is the target audience? § What is the goal? § Concept sketch § Function-oriented sketch § Design sketch § Support sketch Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 28  ENGINEERING DESIGN AND COMPUTING Define Goals for Sketches § What do I want to show? § Who is the target audience? § What is the goal? § Concept sketch § Function-oriented sketch § Design sketch § Support sketch Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 29  ENGINEERING DESIGN AND COMPUTING Projections: What do I want to show? Different projections Different viewpoints Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 30  ENGINEERING DESIGN AND COMPUTING Taxonomy of Projections Planar Geometric Projections Parallel Orthogonal Axonometric Oblique Perspective Isometric Cabinet One-point top front side Two-point 1st Angle and 3rd Angle Dimetric Cavalier (Lecture 3) Trimetric Three-point Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 31  ENGINEERING DESIGN AND COMPUTING Perspective Projection projectors y z x view center projection what viewer sees plane Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 33  ENGINEERING DESIGN AND COMPUTING Sketching One and Two-Point Perspective Projections vanishing points horizon line 1-point 2-point Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 34  ENGINEERING DESIGN AND COMPUTING Parallel Projection parallel projectors y z x view direction what viewer sees projection plane Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 35  ENGINEERING DESIGN AND COMPUTING Parallel vs Perspective Projection § Used in technical drawings § Closer to the eyes’ perception § Elements with equal length are equally § Used in “photorealistic” rendering (design, dimensioned architecture) § Dimensions can be measured on drawing § Elements with equal length can have different dimensions Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 36  ENGINEERING DESIGN AND COMPUTING Orthogonal Projection top parallel projectors front side Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 37  ENGINEERING DESIGN AND COMPUTING Axonometric Projections Isometric projection a:b:c=1:1:1 a = b = 30° Dimetric Projection Most commonly: a:b:c=1:1:1/2 a=42° b=7° Trimetric Projection a:b:c=free 30°≤a≤45° b≤30° Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 38  ENGINEERING DESIGN AND COMPUTING Oblique Projections Cavalier Projection a:b:c=1:1:1 a = 45° b = 0° Cabinet Projection a:b:c=1:1:1/2 a = 45° b = 0° Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 39  ENGINEERING DESIGN AND COMPUTING Circular Shapes in Parallel Projections Circles in isometric projection a:b:c=1:1:1 a=b=30° Circles in cabinet projection a:b:c=1:1:1/2 a=45°b=0° Circles in orthogonal projection Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 40  ENGINEERING DESIGN AND COMPUTING Sketching Circles and Ellipses Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 41  ENGINEERING DESIGN AND COMPUTING Sketching Techniques: Two different approaches § Outline and refine (outside to inside) § Reduce to basic structure and complete (inside to outside) Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 42  ENGINEERING DESIGN AND COMPUTING Outline and Refine Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 43  ENGINEERING DESIGN AND COMPUTING Reduce to Basic Structure and Complete – Bike Frame I Source: Meier, M. (2005) Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 44  ENGINEERING DESIGN AND COMPUTING Reduce to Basic Structure and Complete – Bike Frame II Source: Meier, M. (2005) Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 45  ENGINEERING DESIGN AND COMPUTING Sketching Tips Make cuts Preserve to show what is proportions Use outlines necessary Strap Use Focus on Ear cover annotations Use meshing as an aid important aspects and comments Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 46  ENGINEERING DESIGN AND COMPUTING Examples from Student Work - “Mechanized Latrine Emptying” Team: Bregenzer, Feser, Ramazani, Sartor, Yu Team: Dewan, Dorner, Hurst, Hüssy, and Peng Product Development and Engineering Design (PDED), 3rd year or Master, 2023 Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 48  ENGINEERING DESIGN AND COMPUTING Checklist for Validating Sketches Here are some questions that enable you to check the sketch quality: § Is the object/function sketched clearly? § Is the sketch aligned with the goals set? § Is the sketch technically sound and clean? § Are the proportions and scale correct? § Is the perspective clear? § Are annotations needed to understand the sketch? § Are you satisfied with it? (“Review”) Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 49  ENGINEERING DESIGN AND COMPUTING Validate: Scale and proportion H h b B b~B/2.5 h~H/2.5 Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 50  ENGINEERING DESIGN AND COMPUTING What is the most important aspect when sketching for concept generation? § A. I should only use perspective projections. § B. I need to know what I am trying to convey to create the sketch accordingly. § C. I should omit the details that are not needed to understand the concept. § D. Only pencils are allowed for sketching. Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 51  ENGINEERING DESIGN AND COMPUTING Engineering Design and Sketching: Wrap-up Engineering design starts from a need and follows a systematic process. Sketches are an important part of the design process and everyone can learn how to sketch. There are many different types of perspectives that objects can be drawn in and the most suitable must be selected. Sketching techniques can help you with your first sketches. Check your sketch quality with the validation questions. Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 52  ENGINEERING DESIGN AND COMPUTING Exercise 1: Sketching and Engineering Design Can you sketch these objects? Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 53  ENGINEERING DESIGN AND COMPUTING Stand up for respect! https://www.youtube.com/watch?v=vViDmLltxwE Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 18.09.24 54 54  ENGINEERING DESIGN AND COMPUTING Where does the joking end? What is mobbing and bullying? § In mobbing or bullying, a person is, for example, systematically targeted, sneered at, deliberately ignored, constantly interrupted, slandered, treated unfairly or threatened, over a long period of time. § Mobbing goes too far! What is sexual harassment? § Sexual harassment includes any behavior that is unwelcome by the recipient; this ranges from crude remarks about appearance, sexist jokes to sexual assault. § Sexual harassment is not flirting! ETH Zurich and D-MAVT do not tolerate disrespectful behavior. We interact with each other in a supportive, fair and constructive manner! Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 55  ENGINEERING DESIGN AND COMPUTING Where can I find help? How do I avoid disrespectful behavior? -> First consider whether my behavior can be hurtful towards others (even unintentionally!). What should I do if my behavior is interpreted as disrespectful? -> Apologize! (“I didn't know I would hurt you with that.”) What do I do when I observe disrespectful behavior? -> Stand up, step in and offer support to the person concerned. Contact and advice services § ETH internal advice and conciliation service respect Contact: +41 44 632 20 38 | [email protected] § More advice services: https://respekt.ethz.ch/en/contact-and-advice-services.html § MAVT Code of Conduct: https://mavt.ethz.ch/the-department/code-of-conduct.html Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 56  ENGINEERING DESIGN AND COMPUTING Ellipses and Circles § Consider the orthogonal projection of the shown object when seen from the top. Which of the statements is correct? § A. The circular shape is shown as a circle. § B. The circular shape is shown as an ellipse. Prof. Dr. Kristina Shea Engineering Design + Computing Laboratory 57