Solution Manual Engineering Design 6th Edition by Dieter Schmidt

Solution Manual Engineering Design 6th Edition by Dieter Schmidt – Updated 2024

Complete Solution Manual With Answers

Sample Chapter Is Below

 

 

Solutions Manual to Accompany

Engineering Design Sixth Edition

George E. Dieter and Linda C. Schmidt

TABLE OF CONTENTS

Chapter 1 Engineering Design 1

Chapter 2 Product-Development Process 7

Chapter 3 Team Behavior and Tools 14

Chapter 4 Gathering Information 23

Chapter 5 Problem Definition and Need Identification 27

Chapter 6 Concept Generation 33

Chapter 7 Decision Making and Concept Selection 41

Chapter 8 Embodiment Design 54

Chapter 9 Detail Design 68

Chapter 10 Materials Selection 72

Chapter 11 Design for Manufacturing 83

Chapter 12 Cost Evaluation 90

Chapter 13 Risk, Reliability, and Safety 107

Chapter 14 Quality, Robust Design, and Optimization 117

Chapter 15 Design for Sustainability and the Environment 126

Chapter 16 Design with Materials 128

Chapter 17 Economic Decision Making 135

Chapter 18 Legal and Ethical Issues in Engineering Design 148CHAPTER 1

ENGINEERING DESIGN

1.1. A major manufacturer of snowmobiles needs to find new products to keep the

workforce employed year-round. Starting with what you know or can find out about

snowmobiles, make reasonable assumptions about the capabilities of the company.

Then develop a needs analysis that leads to some suggestions for new products that the

company could make and sell. Give the strengths and weaknesses of your suggestions.

A company making snowmobiles should have the capability to design and build equipment

that stands up in an aggressive service environment. Working in the snowmobile business

should have resulted in expertise in small gasoline engines. The company probably sells to a

network of distributors, so there is no experience in selling directly to the customer.

Snowmobiles are part of the growing business market segment of recreational vehicles.

An obvious business opportunity that would extend the sales year around is to develop

water sport equipment like jet skis. The market is crowded with suppliers, but an innovative

design with an attractive entry price, or novel technology or features, could find acceptance.

Another market possibility is off-road vehicles like a small dune buggy or three-wheel

motorcycles. The same conditions for a new product would apply as for jet skis.

A related, but separate possibility for a new product would be specialized vehicles for

business and industry. Some examples are: a safe vehicle for bicycle messengers in

crowded city streets, a small logging vehicle, small construction machinery, and a parts-

picking vehicle for large warehouses.

1.2. Take a problem from one of your engineering science classes, and add and

subtract those things that would frame it more as an engineering design problem.

This is an individualized exercise for each student. In general, to make it a design problem

the student would remove specific data, like forces, material properties, and add constraints

like safety, reliability, and conformance to standards.

1.3. There is a need in underdeveloped countries for building materials. One approach

is to make building blocks (4 by 6 by 12 in.) from highly compacted soil. Your

assignment is to design a block-making machine with the capacity for producing 600

blocks per day at a capital cost of less than $300. Develop a needs analysis, a definitive

problem statement, and a plan for the information that will be needed to complete the

design.

Needs Analysis

Must be capable of being constructed with local materials and labor. Total cost to be less

than $300 (U.S.). Should be easily transportable to different locations. Must be powered

with human labor since you cannot count on availability of electricity. Hydraulic

components may be invalid solutions because of cost and/or maintenance (sand in seals,

etc.).

Musts Wants

1. Able to make tiles 2



6



12 in

2. Easily maintained

3. Easy and safe operation

4. Adaptable to a variety of soil mixes.

1. Cost less than $300 2. Weight less than 130 lb. 3. Human powered. 4. Made from local materials (mostly wood, plain carbon steel)5. Easily manufactured in local garage shop

6. Produce 4



6



12 in. blocks

7. Produce 600 blocks per day

8. Compressive strength at least 300 psi dry

Problem Statement

The objective of this project is the design and construction of a prototype model of a block

making machine. The blocks are to be made of soil with a minimum of cement added, and

are

4



6



12 inches. The machine must be human powered, weigh less than 130 lb., cost less

than $300 to build, and be capable of producing 600 blocks per day with a 5 person crew.

Blocks must have a compressive strength of 150 psi as formed and 300 psi when cured. The

machine should be easily constructed of local materials with local labor (assume a third

world tropical location). The machine also should be adaptable to a variety of soil cement

mixtures, and to making tiles

2



6



12 in. A crew of five persons should be capable of operating the machine to produce

600 blocks per day.

Information Needed

1. Determination of the processing conditions for making blocks.

What pressures must be generated? Curing temperature and time? Effect of different

soil mixtures on pressure.

2. Mechanisms for generating pressure.

3. Human Factors Engineering

Magnitude of force that can be produced by a human

Human fatigue

4. Materials handling

5. Available construction materials and their properties.

1.4. The steel wheel for a freight car has three basic functions: (1) to act as a brake

drum, (2) to support the weight of the car and its cargo, and (3) to guide the freight

car on the rails. Freight car wheels are produced by either casting or rotary forging.

They are subjected to complex conditions of dynamic thermal and mechanical stresses.

Safety is of great importance because derailment can cause loss of life and property.

Develop a broad systems approach to the design of an improved cast-steel car wheel.

This topic is covered in detail in a paper by M.R. Hanley, et.al, Trans. ASME, Journal of

Engr. Material, vol. 102, Jan. 1980, pp. 26–31.

1.5. The need for material conservation and reduced cost has increased the desirability

of corrosion-resistant coatings on steel. Develop several design concepts for producing

12-in.

-wide low-carbon-steel sheet that is coated on one side with a thin layer, e.g.,

0.001 in., of nickel.

Some possible concepts are:

• Vapor deposition, in a vacuum on a continuous (as opposed to batch) basis.

• Ion implantation.

• Slurry coating with nickel powder; sinter and hot roll to form a bond with the base

steel metal.

• Electroless nickel plating plus cold rolling.1.6. The support of thin steel strip on a cushion of air introduces exciting prospects for

the processing and handling of coated steel strip. Develop a feasibility analysis for the

concept.

This topic is treated in detail in a paper by W.G. Jaffrey and G.M. Boxal, Journal. Iron and

Steel Institute, May 1963, pp. 401–408.1.7. Consider the design of aluminum bicycle frames. A prototype model failed in

fatigue after 1600 km of riding, whereas most steel frames can be ridden for over

60,000 km. Describe a design program that will solve this problem.

This design problem is discussed in a paper by R. Davis and M.L. Hull, Trans. ASME,

Journal. of Mechanical Design, vol. 103, Oct. 1981, pp. 901–907. The need that an

aluminum bicycle frame fulfils is decreased weight. While the section modulus will have to

be greater for aluminum than steel because of its lower elastic modulus, 10



106 vs.

30



106 psi, preliminary finite element analysis shows about a 20% weight reduction. A

simple FEA using beam elements can establish the critically stressed joints. A more precise

FEA can map out the stresses at these joints, and from this the stress concentration factors

can be determined. The selection of the particular aluminum alloy will be based on cost and

fatigue properties. To give the problem a more current flavor, have the students find papers

on the use of fiber-reinforced composites in bicycle construction. This will introduce the

issue of material cost and difficulty in manufacturing the structural members.

1.8. You are a design engineer working for a natural gas transmission company. You

are assigned to a design team that is charged with preparing the proposal to the state

Public Utility Commission to build a plant to receive liquefied natural gas from ocean-

going tankers and unload it into your company’s gas transmission system. What

technical issues and societal issues will your team have to deal with?

(a) Societal impacts: supply of coal miners; accident rate of coal miners; long-term impact

of respiratory diseases in miners; damage to environment from surface mining, especially in

mountainous country; adequacy of railroads to transport coal; traffic interference, noise,

dirt, accidents from coal transport; adequacy of engineering design talent to design plants

since much of this expertise is now retired. A major deterrent to massive substitution of coal

produced gasoline, in addition to the cost of plant construction, is the need to control

greenhouse gases (CO2) created in coal processing. These costs are very substantial. It

should be noted that the country of South Africa provided all of it gasoline from coal using

the Sasol process for many years, but this was before the world-wide concern about global

warming.

(b). In the past there was a big difference between the way society views the impacts of

energy generated from nuclear materials and coal. Nuclear is more difficult to consider on a

rational unemotional basis due to fear of nuclear weapons and nuclear radiation leaks. Look

how long it is taking to establish a national repository for spent fuel rods in the Nevada

desert. On the other hand, some people remember when their homes were heated by coal.

There is a romanticism associated with the coal miner. People are generally more

comfortable with energy from coal than from nuclear sources. This is changing with the

great concern about global warming from greenhouse gases, to which CO2 resulting from

coal combustion is a major contributor. Nuclear energy does not contribute to global

warming. The safe disposal of nuclear waste remains the main concern of many people, as

is the possibility of terrorist acquisition of nuclear material and using it to make a “dirty”

bomb. Alternative energy sources like wind, solar power, and biofuels will grow, but at this

time they do not appear capable of reaching the magnitude needed for electric power

generation by the nation. Thus, the path remains clear for resumption in building nuclear

power plants. The greatest obstacle from this happening is the growing cost of construction

of a nuclear generation plant, although the 2011 nuclear accident in Japan due to earthquake

and tsunami has produced a cloud over further international growth of nuclear generation of

electricity.1.9. You are a design engineer working for a natural gas transmission company. You

are assigned to a design team that is charged with preparing the proposal to the state

Public Utility Commission to build a plant to receive liquefied natural gas from ocean-

going tankers and unload it into your company’s gas transmission system. What

technical issues and societal issues will your team have to deal with?

It is interesting how quickly things change in the energy field. When answers to the 4th

edition were being prepared in 2008 it was correct to state that increased use of natural gas

(NG) for generation of electricity had increased the price of NG such that it was economical

to ship NG to the United States or Europe from Algeria, the Middle East, and the

Caribbean. Now, in 2012 the situation is reversed. Application of directional drilling

methods and the use of high-pressure fluids (fracking) to increase the permeability of the

shale formations holding the gas, have uncovered massive amounts of NG in shale deposits

in the Appalachia states, Texas, and North Dakota. This is more gas than can be utilized in

the United States, so the local price of NG is severely depressed below the current price in

Europe and Asia. Therefore, plants built to receive NG from overseas are being refitted to

ship NG from U.S. sources overseas.

Natural gas is liquefied with refrigeration techniques to -260 F, which reduces its volume by

a factor of 600. In the liquefaction process impurities such as water, hydrogen sulfide, and

CO2 are removed to leave nearly 100 percent methane. The liquefied natural gas (LNG) is

transported in special doubled-hulled tankers with insulated tanks to maintain the LNG at

proper temperature.

At the tanker terminal the LNG is transferred to double-walled storage tanks with

insulation between the walls. The pressure must be regulated to minimize vaporization, for

both economic and environmental reasons. The next step in the process is to pump the LNG

to the vaporizer units, where it is heated under controlled conditions and introduced into the

gas transmission pipeline.

Technical Issues

a. b. c. d. Design of the transfer piping system

Design of the storage vessels

Design of the vaporizer unit

As discussed below, safety is a paramount issue, but so is cost. A LNG transfer terminal

can easily cost $5B. There needs to be careful balance between these issues, with safety

given top consideration.

Societal Issues

Safety is a major concern in working with LNG. Although LNG is not flammable or

explosive, when exposed to 5 to 15 volume percent air it becomes highly flammable. If

LNG hits water it vaporizes violently and rapidly, forming a gas cloud that can travel for

several miles before dispersing to a safe level. If the gas cloud is ignited the flame can

travel through the cloud back to the source of the vapor. Thus, the area covered by the fire

can be extensive. A leak of LNG or a spill, if ignited, is called a pool fire. This is more

localized than a cloud fire, but of longer duration. If LNG is accidently released from a

pressurized containment the leak usually takes the form of a spray of liquid droplets and

vapor. This is called a torch fire and delivers greater radiant heating than a pool fire. If the

LNG is confined when ignited, it can result in a violent explosion.

When the transportation of LNG was first developed in the 1960s there were several

major explosions and fires. Public concern arose over this new technology and as a result

the U.S. government developed safety standards (49-CFR-193) and the National Fire

Protection Association issued consensus standards (NFPA-59A) which have been

continually updated. Since most LNG transfer terminals have been sighted in narrow

harbours or waterways, there has been concern that a ship collision or grounding mightcause a LNG release. More recently there is been concern that a terrorist attack could cause

a fire or explosion. Accordingly, the U.S. Coast Guard has issued regulations dealing with

the site selection and design of LNG terminals (33-CFR Part 127). Thus, the design of the

LNG plant will be highly constrained by codes, regulations,

and standards.

One final societal concern deals with the emission of methane, which is a potent

greenhouse gas. Clearly, the design must give high priority to preventing venting or escape

of methane to the environment. We started this discussion with the statement that natural

gas is a preferred fossil fuel from the standpoint of global warming. However, there are

some who claim that after all of the energy consuming processes of refrigeration and

transportation are taken into account the net benefit of using LNG may not be beneficial to

the environment.

1.10. You are a senior design engineer at the design center of a major U.S.

manufacturer of power tools. Over the past 5 years your company has outsourced

component manufacturing and assembly to plants in Mexico and China. Although

your company still has a few plants operating in the United States, most production is

overseas. Think about how your job as the leader of a product development team has

changed since your company made this change, and suggest how it will evolve in the

future.

Outsourcing manufacturing to a foreign country usually is done to take advantage of lower

manufacturing wages. A secondary objective can be to increase sales in the country of

manufacture.

Most product development depends on fine-tuning the design once it gets into

production to improve upon design features that make assembly difficult and some parts

more expensive to manufacture than expected. Occasionally, customer usage uncovers

functional issues that need correction. These follow-on design activities often involve the

modification of tools and fixtures used in production, or even the design of a modified part.

Often these design tasks are performed by a small design staff that is in residence at the

manufacturing location. There are also issues with maintaining quality standards with a

workforce where language and culture are much different from the home country.

Therefore, moving the manufacturing plant offshore greatly increases the

communication task of leader of the product development team. Early on he/she must visit

the new plant and gain the confidence of the plant manager and the top engineer. It is also

important to bring that engineer back to the home office to be trained in company values

and procedures. Much communication will be done via the Internet, so effective

communication protocols must be established.

1.11 The oil spill from BP well Deepwater Horizon is one of the world’s greatest

environmental disasters. Nearly 5 million barrels of crude oil spewed into the Gulf of

Mexico for 3 months. As a team, do research on the following issues: (a) the technology

of drilling for oil in water deeper than 1000 feet; (b) the causes of the well blowout;

(c) the short-term damage to the U.S. economy; (d) the long-term effects on the United

States; and (e) the impact on the owner of the well, BP Global.

The oil spill from the blow-out of British Petroleum (BP) well Deepwater Horizon is one of

the world’s greatest environmental disasters. Nearly 5 million barrels of crude oil spewed

into the Gulf of Mexico for more than three months. Information for the specific questions,

(a) through (d) can be found in the following places.(a) The technology for drilling in water deeper than 10,000 ft. see HowStuffWorks:

How Offshore Drilling Works. For general information on oil well drilling see

Wikipedia: Oil well drilling.

(b) For information on the Deepwater Horizon accident see Wikipedia: Deepwater

Horizon

(c) Sort-term impact: Damage largely affected people living in the Gulf Coast

(Louisiana, Alabama, Mississippi, and the Florida panhandle). Immediate jobs lost in

the fisheriesindustry, fishing for shellfish and processing for sale nationwide. Since the

accident happened May through August, which is the height of the tourist season for

Gulf Coast beach resorts people lost jobs in hotels, restaurants, gift shops, and

entertainment facilities. Most of these businesses depend on the summer months for

most of their annual revenues. The Federal moratorium on deep sea drilling in the gulf

affected people who work on drilling platforms or supply and service the platforms. All

told, 50,000 to 100,000 highly paid jobs.

(d) Long-term impact on the United States: There is a major impact to the U.S. oil

supply. The deep waters in the Gulf of Mexico are the largest largely undeveloped but

proven source of crude oil in the U.S. Although drilling has been re-established it is

with increased federal regulations that significantly increase costs, which drives out

the smaller capitalized independent oil companies. The cost to rent a deep-water

drilling platform is many hundred thousand dollars per day. With the moratorium in

place for many months, these platforms could not afford to wait around unproductive,

so many were moved to oil fields in Africa and South America. All these issues make it

more difficult for the U.S. to become self-sufficient in oil production