ME 4054: Evaluating Your Design Spring 2009Evaluation in the Design ProcessRole of the PDSAdding EvaluationEvaluation Methods (1)Example: Product designTesting a scaled prototypeReturn to PDSEvaluation Methods (2)The Important Role of SimulationExample: Analysis and SimulationExamples of SimulationEvaluation Methods (3)Developing a Test StandardBuild Test Apparatus and EvaluateReturn to PDSAdditional information for Evaluating DesignsThe Design ProcessDeveloping a Test StandardPDS for a Test Apparatus and ProcedureME 4054: Evaluating Your DesignSpring 2009IDENTOPPDEFINE 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 #'sMetric Importance UnitsMarginal ValueIdeal ValueProduct 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 ValueEvaluationProduct Specifications Rev xxxConsider EACH metric, how will you determine that the metric has been satisfied?Evaluation Methods (1) Final drawings have required dimensions Visual inspection, weigh, measure size TestYou have a functioning prototype“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.”Arm, Biosensor, Bulkhead, Centering, CFD, Chamber….Example: Product designTesting 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 PDSEvaluation Methods (2) Final drawings have required dimensions Simulate function using prototypes and/or analysisYou have a Detailed Design, but not a functioning Prototype. Common challenge for designing equipment for a manufacturing processThe 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'sLawrence 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 laptopsExample: Analysis and SimulationAutoAssemblyExamples of SimulationEvaluation Methods (3) PDS includes requirements for test apparatus and test procedure R&R is a concern Develop/identify test method outcomes (benchmark could be an existing standard) Build apparatus and test samples Success = test results repeatable (statistics required!)You are developing a test apparatus and test method.Developing a Test StandardBuild Test Apparatus and EvaluateReturn to PDSAdditional information for Evaluating Designs Sensitivity Analysis: how sensitive is your design if a key parameter is not closely specified Design 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 SPECIFICATIONDeveloping a Test StandardPDS for a Test Apparatus and
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