Engineering Capstone Design: Project Planning, Organizing, and Executing

A concise and practical guide to succeeding in the undergraduate engineering capstone design project In Engineering Capstone Design Project: Planning, Organizing, and Executing, a team of accomplished engineers delivers a practical guide for engineering students undertaking their capstone design project course in the final year of their bachelor program. It covers two aspects of the capstone course: planning and the design process. You’ll explore how to organize your team, manage and develop your project, and communicate with clients, advisors, suppliers, and manufacturers. You’ll also discover a detailed, step-by-step approach to the design process following the milestones and requirements of engineering capstone design courses. The book focuses on the process of mechanical engineering design but also includes material covering electrical, chemical, biomedical, and control systems engineering design. It also offers several illustrative case studies of successful capstone design projects completed at McGill University. Readers will also find: A thorough introduction to the principles of organization of capstone design courses, including learning attributes and grade attribution Comprehensive step-by-step instructions to the design process Useful case studies from academic, industrial, and McGill student design competition capstone projects Examples and anecdotes drawn from the authorial team’s extensive professional and academic experience in engineering design and project advice Perfect for undergraduate students taking the capstone mechanical engineering project course, Engineering Capstone Design Project: Planning, Organizing, and Executing will also benefit students of other engineering design courses seeking a clear, step-by-step approach to the design process.

Table of Contents:
Preface xi About the Companion Website xv Introduction: Capstone Design Project 1 Engineering Design: Definitions and Methods 1 Types of Engineering Design 1 Engineering Design Process 3 Product Design 4 Mechanical Design 4 Electrical Design 4 Industrial Design 4 Civil Design 5 Architectural Design 5 Software Design 5 Systems Engineering in Engineering Design Process 5 Engineering Design Methods 6 Axiomatic Design 6 Biomimetic Design 6 Concurrent Engineering 7 Design for Assembly 7 Design for Manufacturability (Design for Manufacture and Assembly) 7 Design for Manufacture 7 Design for Properties and Life Cycle 8 Design for Scale 8 Design for Six Sigma 8 Design for Social Innovation 9 Design to the Edges 9 Efficiency Design 9 Human Scale Design 9 Interdisciplinary Design 9 Mixed Use Design 10 Modular Design 10 Naïve Design 14 Parallel Design 15 Passive Design 15 Quiet Design 15 Regenerative Design 15 Restorative Design 15 Reverse Engineering 16 Safety by Design 16 Slow Design 16 Social Design 16 Strategic Design 16 Sustainable Design 16 System Design 17 Transition Design 17 User Experience Design 17 Waterfall Design 17 2 Fundamental Design Principles 19 Research and Analysis of Existing Solutions 19 Ergonomics 19 Occam’s Razor 20 “Best Practices” of Product Development 21 Independent Functions: Keep the Functions of a Design Independent from One Another 22 Ideation, Creativity, and Brainstorming 22 Lateral Thinking 23 Duality of Innovation and Design 23 Engineering Design Practice 24 Units and Measurements 25 Fasteners and Methods of Attachments 25 Off-the-Shelf Components in Design 25 Modular Design 26 Freezes 26 Accuracy, Repeatability, and Resolution 26 Sensitive Directions 27 Reference Features 27 Managing Friction 28 Heat Resistance 30 Simplification of Model During Simulation 30 Centers of Action 31 Preloads and Press Fits 31 Design for Reliability 31 Factor of Safety Method 32 Aesthetics in Engineering Design 33 Engineering Verification and Validation 36 3 What Do You Need to Know Before Starting Capstone Project 37 Communications in Engineering Capstone Projects 37 Industrial Sponsors and IP in Capstone Projects 40 Types of Intellectual Property 41 Copyright 41 Industrial Design 41 Trademark 41 Patent 41 Trade Secret 42 Risk Management in Capstone Projects 42 Safety in Engineering Design 45 Engineering Ethics and Deontology 46 4 Design Phases in Mechanical Engineering Capstone Projects 49 Design Thinking Process 49 A Creativity Boosting Approach 50 Five Stages of Design Thinking 50 Design of Mechanical Systems: Iterative Process 51 Customer Statement 54 Principles of Team Forming 55 Work Organization: Gantt Chart and File with the Tasks 56 Problem Definition 60 Understanding the Problem 62 Clarification of Objectives 63 Establishing of User Requirements 65 Establishment of the Functions 67 Identification of Constraints 70 Formulation of Assumptions 77 Formulation of Design Requirements and Design Specifications 78 Project Definition 79 Collecting Information 79 Product Research 80 User Research 80 Market Research 80 Technical/Engineering Research 81 Literature and Other Sources of Information 81 Experimental and Test Data 86 Conceptual Design 89 The Core of Conceptual Design 89 Selection of Parameters for Conceptual Design 90 Development of Engineering Specifications 91 Brainstorming 92 Individual Brainstorming 93 Group Brainstorming 93 Selection of Evaluation Criteria and Contradiction Matrix 95 Generation of Alternatives 97 Engineering Analysis and Mathematical Modeling in Design 98 Types of Engineering Analysis 98 Main Stages of General Engineering Analysis 103 Tools for Engineering Analysis 104 Evaluation of Design Solutions and Decision Making 105 Criteria Selection 105 Decision-Making 105 Pugh Matrix 107 Layout at the Stage of Conceptual Design 108 Embodiment Design 108 Design Configuration and 3D CAD Modeling 109 Analysis of the Design 111 Detailed Design 112 Detailed Engineering Design 112 Detailed Design Iterations and Final 3D CAD Modeling of a Product 113 Selection of the Off-the-Shelf Components, Materials, and Suppliers 115 Compatibility of OTS Components with the Designed Product 116 Material Selection and Its Influence on Design 116 Ordering Standard Parts and Materials 117 Pre-production Adjustments (Corrections) 118 Manufacturing of the Product 120 5 Analysis and Optimization in Capstone Projects 121 Types of Analysis in Engineering Design 121 Strength and Other Load-related Characteristics 121 Static and Dynamic Loads 122 Stress and Stress Concentration 123 Strain 125 Hooke’s Law 126 FEA: Stress, Strain, and Displacement 126 Vibration Analysis 127 Potential Difficulties in Design for Vibrations 128 Methods of Elimination or Reducing Vibrations 129 Thermal Analysis 130 Fatigue Analysis 130 Computational Fluid Dynamics Analysis 131 Load Case Analysis 132 Worst-Case Scenario and Model Simplification 132 Optimization in Engineering Design 135 6 Design Graphics and Graphics Communication 137 Role of Graphics Communication in Engineering Design 137 Frequently Asked Questions on Graphics Communication 139 Principles of Presenting Good Manufacturing Drawings 146 View Placement and Formatting 146 Dimensioning 147 Assembly Drawings 148 Grading of Detailed Drawings: Typical Mistakes 148 7 Prototyping in Capstone Projects 151 Digital Manufacturing in Design Process and its Role in Capstone Project 151 Types of Traditional and Modern Manufacturing 153 Subtractive Manufacturing 153 Formative Processes 154 Additive Manufacturing 154 Additive Manufacturing and its Application to Product Development 155 Using Additive Manufacturing: Practical Hints and Warnings 160 Additive Manufacturing in Medical Applications 160 Test Assembling of the Prototype 162 8 Experiments, Testing, and Quality Control in Capstone Projects 163 Safety During Experiments and Testing 165 Design of Experiment or Test 165 Standardized Testing 165 Measurement Standards 166 Calibration and Certification 166 Types of Errors in Measurement Systems 166 Variables 168 Test and Experiment Plan 169 Quality Control 170 9 Design Process in Other Fields of Engineering 171 Design of Cardiovascular and Musculoskeletal Devices from Concept to Product 171 Introduction 171 Background: Vascular Structures 172 Vessel Anatomy and Blood Flow 172 Vessel Wall 172 Blood Flow 172 Cardiovascular Devices 174 Design of Cardiovascular Devices 176 Human Factor Engineering 177 Design in Software Engineering 178 Control System Design 179 Design in Electrical Engineering 180 Design in Chemical Engineering 181 Appendix: Design Definitions and Terminology 183 References 199 Index 203

About the Author :
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.