ME 4054: Evaluating Your Design Fall 2011Evaluation in the Design ProcessRole of the PDSAdding EvaluationDifferent Types of Projects Require Different Types of Evaluation PlansYou have a functioning prototypeSample PDS for Large Bore Naval GunYou have a Detailed DesignAbbreviated PDSYou are Developing a Test StandardPDS for a Paint Test StandardEvaluation Methods when You have a Functioning PrototypeSlide 13Slide 14Testing a scaled prototypeReturn to PDSEvaluation Methods when you have a Detailed DesignThe Important Role of SimulationSlide 19Slide 20The entire system:subdivided into smaller partsSimulation of one stationEvaluation Methods when you are Developing a Test Apparatus or ProcedureSlide 25Build Test Apparatus and EvaluateSlide 27Return to the PDSDeveloping a Test StandardPDS for a Test Apparatus and ProcedureAdditional information for Evaluating DesignsThe Design ProcessME 4054: Evaluating Your DesignFall 2011IDENTOPPDEFINE PROBLEMGEN CONCEPTSGATHER INFOIMPLEMENTSCREEN CONCEPTSHANDOFFEvaluation in the Design ProcessRETURN to the DESIGN SPECIFICATIONAs part of implementation, you will be evaluating your designRole of the PDSMetric #Need #'s Metric Importance UnitsMarginal ValueIdeal Value Product Specifications Rev xxxIf you satisfy the PDS you will fulfill the customer needsReview each metric devise a techniqueAdding EvaluationMetric #Need #'s Metric Importance UnitsMarginal ValueIdeal Value Evaluation Product Specifications Rev xxxConsider EACH metric, how will you determine that the metric has been satisfied?Different Types of Projects Require Different Types of Evaluation PlansYou have a functioning prototypeYou have a Detailed Design, but not a functioning prototype. You are developing a test apparatus and/or test method.You have a functioning prototypeSample PDS for Large Bore Naval GunYou have a Detailed DesignAbbreviated PDSYou are Developing a Test Standard“Our goal is to develop a processfor testing paint adhesion whichcan be related to the current ASTMStandard D3359-02. In this test,the sample size and method is notwell define, but it is an industrywhich must be correlated back to.The process we develop must be arepeatable, reliable test that willbring this outdated test into a formthat has Gage R&R of 30%. Thedeliverable will be a testing methodand device which allow thecompletion of this goal under ourbudget of $1000.”PDS for a Paint Test StandardEvaluation Methods when You have a Functioning PrototypeFinal drawings have required dimensionsVisual inspection, weigh, measure sizeTest“Compare the specifications of your final prototype against your design goals. Describe how you tested your design or prototype to verify how well it worked. Include reactions from your client, assuming you had sufficient time to do a pilot test of your product with its intended client.”You have a functioning prototypeSample PDS for Large Bore Naval GunTesting a scaled prototype1.Designed and fabricated a scaled insert2.Shot 30 rounds3.Evaluated insert surface, compared with conventional profileEvaluation through prototype testingMaterial and profile must be selected for function and durability (high temp and pressure)Verified profile dimensionsReturn to PDSTABLE 2: Final SpecificationsEvaluation Methods when you have a Detailed DesignFinal drawings have required dimensionsSimulate function using prototypes and/or analysisbut not a functioning Prototype.The Important Role of Simulation"The problem we have with the nuclear stockpile is similar to one you might have at home with a car you've kept in the garage for 20 to 30 years," said Mark Seager, assistant department head for advanced technology at Lawrence Livermore National Laboratory. "How do you carefully maintain the car as it ages so that when you go to start the car, you can be very confident it will start? That the probability that it won't start is less than one in a million? That's a pretty high level of certitude." ….The massive computer will be used in the U.S. Department of Energy's Lawrence Livermore National Laboratory in California to crunch data in relation with America's military arsenal (nuclear simulation tests) although other civilian uses could be envisaged. IBM says that Sequoia could match in one hour, what the world population's armed with calculators could achieve in 40 years or so, delivering the processing power of 2 million laptopsYou have a Detailed DesignAbbreviated PDSThe entire system:A very complex device…subdivided into smaller parts… divided intomanageable pieces.Simulation of one stationEvaluation Methods when you are Developing a Test Apparatus or ProcedurePDS includes requirements for test apparatus and test procedure R&R is a concernDevelop/identify test method outcomes (benchmark could be an existing standard)Build apparatus and test samplesSuccess = test results repeatable (statistics required!)You are Developing a Test Standard“Our goal is to develop a processfor testing paint adhesion whichcan be related to the current ASTMStandard D3359-02. In this test,the sample size and method is notwell define, but it is an industrywhich must be correlated back to.The process we develop must be arepeatable, reliable test that willbring this outdated test into a formthat has Gage R&R of 30%. Thedeliverable will be a testing methodand device which allow thecompletion of this goal under ourbudget of $1000.”Build Test Apparatus and EvaluateBuild Test Apparatus and EvaluateReturn to the PDSDeveloping a Test StandardPDS for a Test Apparatus and ProcedureR&R=Additional information for Evaluating DesignsSensitivity Analysis: how sensitive is your design if a key parameter is not closely specifiedDesign of Experiments: Finding an optimum set of processing conditions (see book by Box, Design and Analysis of Experiments)Statistical Process Control: In a manufacturing process what is the range of variability that can be expected (D&M I manuafacturing text has overview)Measurement Error Analysis (Measurements lab)IDENTOPPDEFINE PROBLEMGEN CONCEPTSGATHER INFOIMPLEMENTSCREEN CONCEPTSHANDOFFThe Design ProcessRETURN to the DESIGN
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