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"Engineering design Case studies."
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Understanding Design and Technology in Primary Schools
Teaching design and technology to young children has set new challenges for primary school managers, teachers, pupils and parents. Through the use of frank and detailed case studies, this book reveals the teaching aims and methods adopted by teachers, the issues they face in making their work effective, and the experiences of their pupils in learning design and technology. Extensive first hand evidence of classroon experience is provided by the teachers. The collection describes how action research can be done. It then provides practical examples of teachers introducing changes in the curriculum, in their teaching and in their use of evidence in monitoring teaching, as a result of this kind of research. Student teachers, teachers, parents and curriculum managers will all benefit from the insights offered by this wealth of practical accounts.
eBook
Power of a randomization test in a single case multiple baseline AB design
A randomization test can be used to statistically test hypotheses in multiple baseline designs to complement the commonly used visual inspection analysis. A crossed factor simulation study was performed to investigate the power of a randomization test in an multiple baseline design. The results show that the degree of autocorrelation of the observations, the number of participants, the effect size, the overlap of possible start moments of the intervention between participants, the ratio of the number of measurements in the baseline- and intervention phase, a gradually emerging effect, and the number of measurements had strong main effects on the power. The two-way interactions between number of participants and effect size, and between the number of measurements and the number of start moments of the intervention also had a large effect. An online tool was developed to calculate the power of a multiple baseline design given several design characteristics.
Journal Article
Digital design and manufacturing of a railway bogie demonstrator via multi-material wire arc directed energy deposition
The sequential digital design and manufacturing of components play a crucial role in realizing the industrial potential of directed energy deposition (DED), particularly when employing an electric arc as the energy source to melt a filler wire (DED-ARC). This study explores the application of DED-ARC for manufacturing large-scale, load-bearing structures, using a railway bogie as a case study. Originally a cast Bettendorf-type design, the bogie was redesigned using a multi-material approach. High-strength low-alloy (HSLA) steel was utilized in high-stress areas, while low-carbon steel was used elsewhere to reduce mass, enhance manufacturability, and improve repairability. The workflow included computer-aided design (CAD), topological optimization, finite element analysis (FEA), material selection, and iterative CAD modifications to address process constraints. The redesigned bogie underwent pre-manufacturing, fabrication, and a final scan of the as-built part. Representative multi-material wall samples were characterized, revealing typical microstructures and elastic limits of 468 MPa and 737 MPa for ER70S-6 and ER100S-G, respectively. These tensile properties were incorporated into FEA verification simulations, demonstrating a higher safety factor compared to the original design. A CAD-to-part analysis, including scan comparisons, highlighted manufacturing-induced deformation, material-dependent over-thickness, and localized geometric variations. This study offers a comprehensive overview of the DED-ARC process, from design through characterization, and demonstrates its capability to produce high-quality industrial components. The findings underscore the manufacturability and potential of DED-ARC for fabricating robust, multi-material structures for demanding applications.
Journal Article
Development of a diagnostic tool for product circularity: a redesign approach
The design of circular products is gaining relevance among academics, practitioners, and industry as a critical step to face material scarcity, the unsustainability of industrial processes, and excessive waste generation. Therefore, product design is a powerful research field to promote material, component, and product circularity throughout several lifecycles. However, there is a lack of formal methods to measure the circularity of products, especially from the early design stages. Therefore, this paper proposes a diagnostic tool for measuring circularity, identifying potential improvement opportunities, and redesigning interventions in the conceptual design phase. The tool consists of eight single indicators that measure disassemblability, reassemblability, durability, modularity, simplicity, standardization, commonality, relative costs, and the number of secondary functions of products. A case study is presented to validate the tool, considering several improvement scenarios around the 6R strategies. Finally, a list of redesign interventions for each improvement scenario was assembled as a primary output of the proposed tool.
Journal Article
A comprehensive review of digital twin—part 2: roles of uncertainty quantification and optimization, a battery digital twin, and perspectives
As an emerging technology in the era of Industry 4.0, digital twin is gaining unprecedented attention because of its promise to further optimize process design, quality control, health monitoring, decision- and policy-making, and more, by comprehensively modeling the physical world as a group of interconnected digital models. In a two-part series of papers, we examine the fundamental role of different modeling techniques, twinning enabling technologies, and uncertainty quantification and optimization methods commonly used in digital twins. This second paper presents a literature review of key enabling technologies of digital twins, with an emphasis on uncertainty quantification, optimization methods, open-source datasets and tools, major findings, challenges, and future directions. Discussions focus on current methods of uncertainty quantification and optimization and how they are applied in different dimensions of a digital twin. Additionally, this paper presents a case study where a battery digital twin is constructed and tested to illustrate some of the modeling and twinning methods reviewed in this two-part review. Code and preprocessed data for generating all the results and figures presented in the case study are available on
Github
.
Journal Article
Multiple technology infusion assessment: a framework and case study
High-technology businesses face severe competition in their respective industries, necessitating constant innovation of their systems through the infusion of new technologies. To this end, these companies incorporate multiple technologies into new successful systems to improve key requirements that can ultimately affect the overall revenue and profitability of their systems. In many cases, comprehensive effects of infused technologies including improvements to the overall system performance, the extent of engineering design change, total investment cost, and profitability, are assessed a posteriori. In this study, a structured assessment framework was introduced for the infusion of multiple technologies into a parent system. The framework was conceived to address the requirements of companies for technology-based system development that need to assess the impact of infusing multiple technologies into their system. The proposed technology infusion framework is demonstrated through a printing system case study.
Journal Article
Navigating complexity beyond collaborative design: the PSI network model and case studies
In our earlier papers, we developed the PSI (Problem/Product, Social, and Institutional Spaces) framework to address complex design contexts incorporating diverse social, managerial, cultural, and other concerns. Experience using the framework in cases involving multiple social entities, from people to organizations, evolving to deal with various design challenges, revealed that we need a network model to account for this complexity. With the addition of the network model, the PSI framework allows for studying complex design scenarios requiring different levels of granularity for various contexts, including hierarchical, recursive, and temporal models. Further, our case studies demonstrate that the framework reveals that inherent to design is the simultaneous design of the product, the social and institutional aspects involved inside an organization, and its relations to others participating in a design endeavor. In what follows, we demonstrate the network version of this framework, its use, and insights that one can glean. The diversity and complexity of situations covered and not covered in this paper, including collaborations between industry and university and substantially complex multi-organizational projects, demonstrates the potential and value of the PSI framework.
Journal Article
Assessment of virtual reality-based manufacturing assembly training system
Digital manufacturing concept is gaining a lot of attention and popularity due to its enormous benefits. It is considered as one of the pillars or component of Industry 4.0. With the advancements in technology, digital manufacturing is becoming a reality rather than a concept only. It is applied to various stages of the manufacturing process such as design, prototyping, and assembly training. Virtual reality (VR) is a cog in a wheel of digital manufacturing. It can be used in various phases of manufacturing. Planning and conducting assembly operations account for the majority of the cost of a product. It is difficult to design and train assembly operations during the early stages of product design. Assembly is a vital step in manufacturing, so firms provide training to their employees and it costs them time and money. Therefore, this research work extends VR applications in manufacturing by integrating concepts and studies from training simulations to the evaluation of assembly training effectiveness and transfer of training. VR provides a platform for “learning by doing” instead of learning by seeing, listening, or observing. A series of user-based evaluation studies are conducted to ensure that the virtual manufacturing assembly simulation provides an effective and efficient means for evaluating assembly operations and for training assembly personnel. Different feedback cues of VR are implemented to evaluate the system. Moreover, several case studies are used to assess the effectiveness of VR-based training. The results of the study reveal that participants trained by VR committed fewer errors and took lesser time in actual product assembly when compared against the participant from traditional or baseline training group.
Journal Article
Product family platform selection using a Pareto front of maximum commonality and strategic modularity
Product family design offers a cost-effective solution for providing a variety of products to meet the needs of diverse markets. At the beginning of product family design, designers must decide what can be shared among the product variants in a family. Optimal design formulations have been developed by researchers to find one optimal component sharing solution based on commonality, cost or technical performance of a product family. However, these optimization methods may not be able to apply in consumer product design because some metrics (e.g., visual appeal and ergonomics) of a consumer product cannot be formulized. In this paper, we suggest a tradeoff between commonality and the quality of the modular architecture in product family platform selection. We introduce a method for designers to identify multiple component sharing options that lie along a Pareto front of maximum commonality and strategic modularity. The component sharing options along the Pareto front can be evaluated, compared, and further modified. We demonstrate the method using a case study of product family platform selection of high-end and low-end impact drivers and electric drills. In the case study, the quality of the modular architecture is evaluated using a design structure matrix (DSM) for each of product variants. Three architectures along the Pareto front with maximum commonality, optimal modularity, and a balanced solution of the two metrics are highlighted and further examined to validate the effectiveness of our method.
Journal Article