CONTENTS
1 THE ENGINEERING DESIGN PROCESS = 1
1.1 The Definition of Design = 1
1.2 The Design Process = 2
1.2.1 Recognition of Need = 3
1.2.2 Conceptualization and Creativity = 5
1.2.3 Feasibility Assessment = 9
1.2.4 Establishing the Objectives and Criteria = 10
1.2.5 Synthesis and Analysis in the Design Process = 11
1.2.6 The Organizational/Work Breakdown Structure = 12
1.2.7 Preliminary Design = 14
1.2.8 Detailed Design = 15
1.2.9 Production Planning and Tooling Design = 20
1.2.10 Production = 22
1.2.11 Design for Manufacture and Assembly = 24
1.3 Other Important Design Considerations = 26
1.3.1 Product Use = 26
1.3.2 Design Life = 26
1.3.3 Human Factors Considerations = 27
1.4 Advanced Technology for the Design Process = 28
1.4.1 Computer-Aided Design/Computer-Aided Manufacturing = 28
1.4.2 Solids or Surfaces = 30
1.4.3 Computer-Integrated Manufacturing = 31
1.5 The Design Process = 34
2 MANAGING DESIGN PROJECTS = 37
2.1 The "Buck" Stops at the Manager's Desk = 37
2.2 Management Techniques = 38
2.2.1 Total Quality Management = 39
2.3 Effective Project Management = 41
2.4 Planning and Scheduling the Effort = 47
2.4.1 The Gantt Chart = 47
2.4.2 PERT Networks = 48
2.4.3 The Critical Path Method = 48
2.4.4 Summary = 52
2.5 Clarifying the Project Objectives = 52
2.5.1 The Objectives Tree Method = 52
2.5.2 Coordination with Client and Management = 54
2.6 Decision Making = 55
2.7 Decision Matrices = 56
2.7.1 Decision Trees = 58
2.8 Improving the Design Product = 62
2.8.1 Functional Cost Analysis = 63
2.8.2 Failure Mode and Effects Analysis = 63
2.8.3 Taguchi Methods = 65
2.9 Engineer or Manager? = 70
3 MODELING AND SIMULATION = 73
3.1 Modeling in Engineering = 73
3.2 Heuristic Modeling = 75
3.3 Mathematical Modeling = 77
3.4 Dimensional Analysis = 80
3.5 Similarity Laws in Model Testing = 84
3.5.1 Geometric Similarity = 84
3.5.2 Kinematic Similarity = 84
3.5.3 Dynamic Similarity = 85
3.6 Wind and Water Tunnels = 85
3.7 Numerical Modeling = 86
3.7.1 The Finite Difference Method = 86
3.7.2 The Finite Element Method = 89
3.8 Monte Carlo Simulation = 90
3.9 Discrete Event Simulation = 94
3.10 Knowledge-Based Systems in the Design Process = 96
3.10.1 An Expert System for Preliminary Design of Structures = 96
3.10.2 Selection of Expert System Tools = 99
3.10.3 Determining the Suitability of the Candidate Problem = 99
3.10.4 Knowledge Representation Schemes = 99
4 DESIGN ANALYSES FOR MATERIAL SELECTION = 103
4.1 Material Selection = 103
4.1.1 Analysis of Material Requirements = 104
4.1.2 Selection and Evaluation of Candidate Material = 109
4.1.3 Decision = 110
4.2 Design Analysis for Fatigue Resistance = 112
4.3 Design Analysis Using for Fatigue Mechanics = 118
4.3.1 Mode Ⅰ Stress State in a Crack = 118
4.3.2 Stress-Intensity Factor Equations = 120
4.3.3 Leak Before Break = 124
4.3.4 Fatigue Crack Propagation = 128
4.3.5 Design with Materials = 134
4.4 Design Analysis for Composite Materials = 135
4.4.1 Stress-Strain Relations in Composite Materials = 137
4.4.2 Failure Criteria of Composite Laminates = 142
4.5 Residual (Internal) Stress Considerations = 144
4.5.1 Sources of Residual Stress = 144
4.5.2 Effect of Residual Stress = 145
4.5.3 Measurement of Residual Stress = 148
4.6 Material Standards and Specifications = 149
4.6.1 Organizations Involved in Standards and Specifications Preparation = 149
4.7 Corrosion Considerations = 152
4.7.1 Atmospheric Corrosion = 153
4.7.2 Galvanic Corrosion = 153
4.7.3 Crevice Corrosion = 153
4.7.4 Pitting Corrosion = 153
4.7.5 Intergranular Corrosion = 153
4.7.6 Erosion Corrosion = 153
4.7.7 Stress-Corrosion Cracking = 154
5. ENGINEERING ECONOMICS = 157
5.1 Project/Product Cost and the Engineer = 157
5.2 Cost Analysis and Control = 161
5.2.1 Cost Categories = 162
5.2.2 Cost Estimating = 165
5.2.3 Life-Cycle Costing = 166
5.3 Important Economic Concepts = 170
5.3.1 Interest = 170
5.3.2 Equivalence and the Time Value of Money = 171
5.3.3 Cash Flow = 172
5.3.4 Present Worth Analysis = 173
5.3.5 Internal Rate-of-Return Analysis = 175
5.3.6 Payback Period = 176
5.3.7 Depreciation and Taxes = 178
5.3.8 Inflation and Deflation = 180
5.4 Selecting an Appropriate Rate of Return = 181
5.5 Evaluation of Economic Alternatives = 183
5.5.1 Evaluation by Economic Equivalence = 184
5.5.2 The Economic Optimization Function = 185
5.5.3 Evaluation Using the Rate of Return on Incremental Investment = 185
5.5.4 Cost Model for Decision Making = 187
6 OPTIMIZATION IN DESIGN = 197
6.1 Introduction = 197
6.2 Mathematical Models and Optimization Methods = 199
6.2.1 The Differential Calculus Method = 199
6.2.2 The Language Multiplier Method = 202
6.2.3 Search Methods = 203
6.2.4 Multivarianle Search Method = 209
6.2.5 Linear Programming = 215
6.2.6 Nonlinear Programming Problems = 218
6.2.7 Mulitvriterion Optimization = 220
7 STATISTICAL DECISIONS = 223
7.1 Random Variable = 223
7.2 Measure of Central Tendency = 224
7.2.1 Mean or Arithmetic Average = 225
7.2.2 Mondrian = 227
7.2.3 Mode = 227
7.3 Measure of Variability = 227
7.3.1 Range = 227
7.3.2 Mean Deviation = 228
7.3.3 Standard Deviation = 228
7.3.4 Variance = 229
7.3.5 Measure of Skewness = 229
7.4 Probability Distributions = 230
7.4.1 Discrete Distributions = 230
7.4.2 Important Continuous Life Test Distributions = 232
7.5 Sampling Distributions = 238
7.5.1 Sampling Distributions Based on Sample Means and The Central Limit Theorem (Sampling Distribution of the Mean) = 238
7.5.2 Student's Distribution = 238
7.5.3 Chi-Square Distribution (X²Distribution) = 239
7.5.4 F Distribution = 240
7.6 Statistical Inference = 240
7.6.1 Estimation = 241
7.7 Statistical Hypothesis Testing = 241
7.8 Statistical Experimental Design = 243
7.8.1 Up-and-Down Method = 253
7.8.2 Taguchi Technique (Orthogonal or Factorial Experiment) = 257
7.8.3 Regression and Correlation Analysis = 270
7.8.4 Introduction on Statistical Methods Using the SAS Package = 272
8 DESIGN FOR RELIABILITY = 285
8.1 Introduction = 285
8.2 Definitions and Probability Laws = 286
8.2.1 Independent Events = 286
8.2.2 Conditional Events = 288
8.2.3 Bayes' Theorem = 288
8.3 Basic Reliability Equation = 289
8.3.1 Mean Time to Failure (MTTF) = 290
8.4 Probability Distribution Functions Used in Reliability = 290
8.4.1 Bathtub Hazard Distribution = 290
8.4.2 Exponential Distribution = 292
8.4.3 Weibull Distribution = 293
8.5 Basic System Reliability = 295
8.5.1 Series System = 295
8.5.2 Parallel System = 296
8.5.3 Multistage System with Parallel Redundancy = 297
8.5.4 Parametric Method in System Reliability Evaluation = 298
8.6 Optimization of System Reliability = 300
8.6.1 Reliability of System Reliability = 301
8.6.2 Cost Minimization for a Given Reliability Constraint = 302
8.6.3 Optimization Reliability for a Given Cost and Weight Constraint = 306
8.7 Maintainability = 311
8.7.1 Maintenance = 312
8.8 Availability = 313
8.9 Dependability = 316
8.10 Fault Tree Analysis = 318
8.11 Probabilistic Design = 320
8.11.1 Safety Factor = 321
8.11.2 Interference Model = 322
8.12 Worst-Cast Design = 324
9 SAFETY AND ENVIRONMENTAL PROTECTION = 329
9.1 Our Contaminated Environment = 329
9.2 The Engineer and the Environment = 331
9.3 The Environmental Protection Agency = 332
9.4 Groundwater Contamination = 334
9.5 Soil and Groundwater Restoration = 340
9.6 Design of a Packed Tower = 348
9.6.1 Sizing the Tower Diameter = 351
9.6.2 Determining the Height of the Tower = 353
9.7 Air Pollution and Toxic Chemicla Exposure = 355
9.7.1 Particulate Contamination = 357
9.8 Air Contamination from Hazardous Liquid Spills = 364
9.9 Occupational Safety and Health = 370
9.9.1 Occupational Safety and Health in Design = 371
9.10 The Safety Engineer = 372
9.11 Closure = 374
10 ENGINEERING ETHICS = 377
10.1 Ethics in Industry = 377
10.2 Ethics and the University = 378
10.3 The Foundation of Ethics = 379
10.4 Ethics in Engineering = 382
10.5 Legal Responsibilities of Engineers = 384
10.6 Codes of Ethics = 386
10.7 Codes Rules and Interpretations = 390
10.8 Codes of Ethics for Engineers = 408
11 COMMUNICATIONS IN ENGINEERING = 415
11.1 Effective Communications = 415
11.2 The Formal Engineering Report = 416
11.2.1 The Abstract = 418
11.2.2 The Introduction = 418
11.2.3 Technical Approach (Theory) = 419
11.2.4 Test Setup = 421
11.2.5 Procedure = 422
11.2.6 Results and Discussion = 423
11.2.7 Conclusions = 424
11.2.8 References = 425
11.2.9 Appendix = 426
11.3 Proposal Preparation = 426
11.3.1 Background/Problem Statement = 427
11.3.2 Objective(s) = 428
11.3.3 Technical Approach = 428
11.3.4 Budget = 428
11.3.5 Organization and Capabilities = 428
11.4 Oral Commuications = 429
11.5 Oral Presentations = 430
11.5.1 Organization the Oral Presentation = 431
11.5.2 Use of Visual Aids = 433
11.5.3 Types of Visual Aids = 433
11.5.4 Preparation of Slides and Transparencies = 434
11.6 A Final Word on Communications = 434
APPENDICES = 435
A PROBLEMS = 435
B DESIGN PROJECTS = 459
C STATISTICAL TABLES = 477
D COMPUTER PROGRAMS = 495
D.1 Program listing for Maple for Evaluatinf the Eigenvalues = 495
D.2 Maximization of Reliability for a Given Cost Constraint = 498
D.3 Maximization of a Cost for a Given Reliability Constraint = 500
D.4 Reliability Maximization with Multiple Constraint = 503
E A PROPOSAL : THE EFFECT OF THE LONG-TERM USE OF METHANOL = 509
