Engineering Capstone Design

Alexei Morozov, P.Eng., Ph.D., is an Academic Associate in the Faculty of Engineering at McGill University. He’s a Design Engineer at the NSERC Chair in Design Engineering for Interdisciplinary Innovation of Medical Technologies in the Department of Mechanical Engineering. He has 40 years of experience working in R&D and advising in various innovative robotic, mechanical, and interdisciplinary engineering projects, and more than 20 years in teaching Design Graphics, Conceptual Design, Inter-Disciplinary Design, Capstone Design, and Hybrid and Electric Vehicles Drivetrain Design courses. Rosaire Mongrain, P.Eng., Ph.D., is a full Professor of Mechanical Engineering at McGill University, Canadian NSERC chair in Design Engineering. His principal research aims at the design, development, and evaluation of medical devices using numerical and experimental methods. He has taught design courses including Conceptual Design, Machine Elements Design, Inter-Disciplinary Design, and the Capstone Course for more than 25 years. Mark Driscoll, P.Eng., Ph.D., is a Professor of Mechanical Engineering at McGill University, Canadian NSERC chair in Design Engineering, and Chwang-Seto Faculty Scholar. He is an experienced engineer, expert in spine biomechanics, with in-depth background in innovation and product development. He has successfully taken several novel medical devices to market in industrial and academic settings and shares this knowledge as a design curriculum professor. Peter Radziszewski, P.Eng., Ph.D., former Associate Professor in engineering design at McGill University, pursued R&D and teaching activities in design and mineral processing. Joining Metso in 2012 as VP Solutions Offering Development, his conceptual design efforts encompassed mineral process equipment, wear, and consumables. 2021 saw him join Rampart Detection Systems as VP of Research & Innovation, where he worked on electric and magnetic field sensor applications in the mining industry. Benoit Boulet, P.Eng., Ph.D., FCAE, is a full Professor of Electrical and Computer Engineering at McGill University, the Chwang-Seto Engine Faculty Scholar, and co-founding Director of the McGill Engine technological innovation centre. He currently serves as McGill’s Associate Vice-President (Innovation and Partnerships). Professor Boulet is a former director and current member of McGill’s Centre for Intelligent Machines where he heads the Intelligent Automation Laboratory.

• Preface xiAbout the Companion Website xvIntroduction: Capstone Design Project1 Engineering Design: Definitions and Methods 1Types of Engineering Design 1Engineering Design Process 3Product Design 4Mechanical Design 4Electrical Design 4Industrial Design 4Civil Design 5Architectural Design 5Software Design 5Systems Engineering in Engineering Design Process 5Engineering Design Methods 6Axiomatic Design 6Biomimetic Design 6Concurrent Engineering 7Design for Assembly 7Design for Manufacturability (Design for Manufacture and Assembly) 7Design for Manufacture 7Design for Properties and Life Cycle 8Design for Scale 8Design for Six Sigma 8Design for Social Innovation 9Design to the Edges 9Efficiency Design 9Human Scale Design 9Interdisciplinary Design 9Mixed Use Design 10Modular Design 10Naïve Design 14Parallel Design 15Passive Design 15Quiet Design 15Regenerative Design 15Restorative Design 15Reverse Engineering 16Safety by Design 16Slow Design 16Social Design 16Strategic Design 16Sustainable Design 16System Design 17Transition Design 17User Experience Design 17Waterfall Design 172 Fundamental Design Principles 19Research and Analysis of Existing Solutions 19Ergonomics 19Occam’s Razor 20“Best Practices” of Product Development 21Independent Functions: Keep the Functions of a Design Independent from One Another 22Ideation, Creativity, and Brainstorming 22Lateral Thinking 23Duality of Innovation and Design 23Engineering Design Practice 24Units and Measurements 25Fasteners and Methods of Attachments 25Off-the-Shelf Components in Design 25Modular Design 26Freezes 26Accuracy, Repeatability, and Resolution 26Sensitive Directions 27Reference Features 27Managing Friction 28Heat Resistance 30Simplification of Model During Simulation 30Centers of Action 31Preloads and Press Fits 31Design for Reliability 31Factor of Safety Method 32Aesthetics in Engineering Design 33Engineering Verification and Validation 363 What Do You Need to Know Before Starting Capstone Project 37Communications in Engineering Capstone Projects 37Industrial Sponsors and IP in Capstone Projects 40Types of Intellectual Property 41Copyright 41Industrial Design 41Trademark 41Patent 41Trade Secret 42Risk Management in Capstone Projects 42Safety in Engineering Design 45Engineering Ethics and Deontology 464 Design Phases in Mechanical Engineering Capstone Projects 49Design Thinking Process 49A Creativity Boosting Approach 50Five Stages of Design Thinking 50Design of Mechanical Systems: Iterative Process 51Customer Statement 54Principles of Team Forming 55Work Organization: Gantt Chart and File with the Tasks 56Problem Definition 60Understanding the Problem 62Clarification of Objectives 63Establishing of User Requirements 65Establishment of the Functions 67Identification of Constraints 70Formulation of Assumptions 77Formulation of Design Requirements and Design Specifications 78Project Definition 79Collecting Information 79Product Research 80User Research 80Market Research 80Technical/Engineering Research 81Literature and Other Sources of Information 81Experimental and Test Data 86Conceptual Design 89The Core of Conceptual Design 89Selection of Parameters for Conceptual Design 90Development of Engineering Specifications 91Brainstorming 92Individual Brainstorming 93Group Brainstorming 93Selection of Evaluation Criteria and Contradiction Matrix 95Generation of Alternatives 97Engineering Analysis and Mathematical Modeling in Design 98Types of Engineering Analysis 98Main Stages of General Engineering Analysis 103Tools for Engineering Analysis 104Evaluation of Design Solutions and Decision Making 105Criteria Selection 105Decision-Making 105Pugh Matrix 107Layout at the Stage of Conceptual Design 108Embodiment Design 108Design Configuration and 3D CAD Modeling 109Analysis of the Design 111Detailed Design 112Detailed Engineering Design 112Detailed Design Iterations and Final 3D CAD Modeling of a Product 113Selection of the Off-the-Shelf Components, Materials, and Suppliers 115Compatibility of OTS Components with the Designed Product 116Material Selection and Its Influence on Design 116Ordering Standard Parts and Materials 117Pre-production Adjustments (Corrections) 118Manufacturing of the Product 1205 Analysis and Optimization in Capstone Projects 121Types of Analysis in Engineering Design 121Strength and Other Load-related Characteristics 121Static and Dynamic Loads 122Stress and Stress Concentration 123Strain 125Hooke’s Law 126FEA: Stress, Strain, and Displacement 126Vibration Analysis 127Potential Difficulties in Design for Vibrations 128Methods of Elimination or Reducing Vibrations 129Thermal Analysis 130Fatigue Analysis 130Computational Fluid Dynamics Analysis 131Load Case Analysis 132Worst-Case Scenario and Model Simplification 132Optimization in Engineering Design 1356 Design Graphics and Graphics Communication 137Role of Graphics Communication in Engineering Design 137Frequently Asked Questions on Graphics Communication 139Principles of Presenting Good Manufacturing Drawings 146View Placement and Formatting 146Dimensioning 147Assembly Drawings 148Grading of Detailed Drawings: Typical Mistakes 1487 Prototyping in Capstone Projects 151Digital Manufacturing in Design Process and its Role in Capstone Project 151Types of Traditional and Modern Manufacturing 153Subtractive Manufacturing 153Formative Processes 154Additive Manufacturing 154Additive Manufacturing and its Application to Product Development 155Using Additive Manufacturing: Practical Hints and Warnings 160Additive Manufacturing in Medical Applications 160Test Assembling of the Prototype 1628 Experiments, Testing, and Quality Control in Capstone Projects 163Safety During Experiments and Testing 165Design of Experiment or Test 165Standardized Testing 165Measurement Standards 166Calibration and Certification 166Types of Errors in Measurement Systems 166Variables 168Test and Experiment Plan 169Quality Control 1709 Design Process in Other Fields of Engineering 171Design of Cardiovascular and Musculoskeletal Devices from Concept to Product 171Introduction 171Background: Vascular Structures 172Vessel Anatomy and Blood Flow 172Vessel Wall 172Blood Flow 172Cardiovascular Devices 174Design of Cardiovascular Devices 176Human Factor Engineering 177Design in Software Engineering 178Control System Design 179Design in Electrical Engineering 180Design in Chemical Engineering 181Appendix: Design Definitions and Terminology 183References 199Index 203