Introduction to Engineering Design

Montgomery College Engineering Faculty

(Alphabetical order)

Uche Abanulo

Wendy He

C. Alex Hou

Muhammad Kehnemouyi

Charles Kung

Craig Mogren

GuangMing Zhang

Editor: C. Alex Hou

 Preface

The main goal of this book, "Introduction to Engineering Design" is to introduce the basic
concepts and computer tools in engineering design to freshmen in college for the ES100 course.
Montgomery College engineering transfer program has grown from 700 to 1300 students in last 6 years
and it offers more than 30 sections of ES100 (Introduction to Engineering Design) a year on three
campuses as well as the College Institute in selected high schools. It requires a common textbook that can
cover all topics that faculty teach in their classes and share their expertise in the areas. The objective of
this course is to inspire students in the engineering disciplines, have them learning some engineering
design tools, and finally practice what they have learned through a design project.

This book has been divided into four parts:

1. What is engineering and engineering design?

2. Design tools - Engineering Graphics, 3D Computer Modeling and Engineering Analysis using EXCEL

3. Engineering Design Process - Procedures, Team Work, Presentation and Documentation

4. Final design project with samples

The book would not have been possible without a great deal of supports. The work of this book
started three years ago and has overcome many difficulties in putting all various types of faculty work
together, since all materials are in different forms and it takes time to re-create manuscripts. I would like
to thank the school for giving me a half year sabbatical leave and allowing me to work on this book.
Special thanks go to Mr. Paul Bayhurst for his contributions to the Appendix in machine shop tools and
practice.

C. Alex Hou

July 2014
 Tables of Contents

Part I – Engineering and Engineering Design

1. Engineering Professions

1.1 What is Engineering 1‐1

1.2 Engineering Disciplines 1‐2

1.3 Engineering Functions in the Industry 1‐5

1.4 Engineering Experiences 1‐7

1.5 Engineering Ethics and Social Impact 1‐7

1.6 Engineering Advising 1‐8

Exercises and Activities 1‐15

2. Intro to Engineering Design

2.1 What is Engineering Design 2‐1

2.2 Characteristics of Engineering Design 2‐1

Exercise and Activities 2‐3

Part II – Engineering Design Tools

3. Engineering Graphics

3.1 Introduction to Engineering Graphics 3‐1

3.2 Basics of Engineering Graphics 3‐1

3.3 Orthographic Projection Views 3‐3

3.4 Pictorial Views 3‐6

 3.5 Dimensioning 3‐9

Exercise and Activities 3‐13

4. Introduction to Solid Modeling‐ CREO

4.0 Computer‐Aided Design 4‐1

4.1 Parametric Modeling Fundamentals 4‐2

4.2 Constructive Solid Geometry Concepts I 4‐22

4.3 Constructive Solid Geometry Concepts II 4‐35

4.4 Geometrical Constraints 4‐48

4.5 Symmetrical Features 4‐59

4.6 Datum Features 4‐75

4.7 Axial Symmetrical Features 4‐94

4.8 Three Dimensional Construction Tools 4‐112

4.9 Design to Manufacture 4‐132

Exercise and Activities

5. Engineering Analysis

5.1 EXCEL Basics 5‐1

5.2 Construction of Tables 5‐3

5.3 Example 1 – Beam Analysis 5‐5

5.4 Example 2 – Friction Force Analysis 5‐8

5.5 Example 3 – Numerical Integration 5‐12

Exercise and Activities 5‐16

Part III – Engineering Design Process

6. Design Procedures

6.1 Nature of Engineering Design 6‐1

6.2 Problem Identification 6‐1

6.3 Preliminary Design 6‐2

6.4 Detailed Design 6‐3

6.5 Implementation and Documentation 6‐3

Exercise and Activities

7. Project Management

7.1 Team Development 7‐1

7.2 Project Management Tools 7‐1

7.3 Oral Presentation 7‐4

7.4 Final Report 7‐7

Exercise and Activities 7‐9

Part IV – Case Studies (Design Projects)

8. Samples of Design Project 8‐1

Appendix

A – Manufacturing Process A‐1

B – Basic Machine Shop Practice and Tools A‐4

C ‐ NSPE Code of Ethics for Engineers A‐15

 Chapter 1
Engineering Professions
Chapter 1 - Engineering Professions
 Preface

The main goal of this book, "Introduction to Engineering Design" is to introduce the basic
concepts and computer tools in engineering design to freshmen in college for the ES100 course.
Montgomery College engineering transfer program has grown from 700 to 1300 students in last 6 years
and it offers more than 30 sections of ES100 (Introduction to Engineering Design) a year on three
campuses as well as the College Institute in selected high schools. It requires a common textbook that can
cover all topics that faculty teach in their classes and share their expertise in the areas. The objective of
this course is to inspire students in the engineering disciplines, have them learning some engineering
design tools, and finally practice what they have learned through a design project.

This book has been divided into four parts:

1. What is engineering and engineering design?

2. Design tools - Engineering Graphics, 3D Computer Modeling and Engineering Analysis using EXCEL

3. Engineering Design Process - Procedures, Team Work, Presentation and Documentation

4. Final design project with samples

The book would not have been possible without a great deal of supports. The work of this book
started three years ago and has overcome many difficulties in putting all various types of faculty work
together, since all materials are in different forms and it takes time to re-create manuscripts. I would like
to thank the school for giving me a half year sabbatical leave and allowing me to work on this book.
Special thanks go to Mr. Paul Bayhurst for his contributions to the Appendix in machine shop tools and
practice.

C. Alex Hou

July 2014
 Tables of Contents

Part I – Engineering and Engineering Design

1. Engineering Professions

1.1 What is Engineering 1‐1

1.2 Engineering Disciplines 1‐2

1.3 Engineering Functions in the Industry 1‐5

1.4 Engineering Experiences 1‐7

1.5 Engineering Ethics and Social Impact 1‐7

1.6 Engineering Advising 1‐8

Exercises and Activities 1‐15

2. Intro to Engineering Design

2.1 What is Engineering Design 2‐1

2.2 Characteristics of Engineering Design 2‐1

Exercise and Activities 2‐3

Part II – Engineering Design Tools

3. Engineering Graphics

3.1 Introduction to Engineering Graphics 3‐1

3.2 Basics of Engineering Graphics 3‐1

3.3 Orthographic Projection Views 3‐3

3.4 Pictorial Views 3‐6

 3.5 Dimensioning 3‐9

Exercise and Activities 3‐13

4. Introduction to Solid Modeling‐ CREO

4.0 Computer‐Aided Design 4‐1

4.1 Parametric Modeling Fundamentals 4‐2

4.2 Constructive Solid Geometry Concepts I 4‐22

4.3 Constructive Solid Geometry Concepts II 4‐35

4.4 Geometrical Constraints 4‐48

4.5 Symmetrical Features 4‐59

4.6 Datum Features 4‐75

4.7 Axial Symmetrical Features 4‐94

4.8 Three Dimensional Construction Tools 4‐112

4.9 Design to Manufacture 4‐132

Exercise and Activities

5. Engineering Analysis

5.1 EXCEL Basics 5‐1

5.2 Construction of Tables 5‐3

5.3 Example 1 – Beam Analysis 5‐5

5.4 Example 2 – Friction Force Analysis 5‐8

5.5 Example 3 – Numerical Integration 5‐12

Exercise and Activities 5‐16

Part III – Engineering Design Process

6. Design Procedures

6.1 Nature of Engineering Design 6‐1

6.2 Problem Identification 6‐1

6.3 Preliminary Design 6‐2

6.4 Detailed Design 6‐3

6.5 Implementation and Documentation 6‐3

Exercise and Activities

7. Project Management

7.1 Team Development 7‐1

7.2 Project Management Tools 7‐1

7.3 Oral Presentation 7‐4

7.4 Final Report 7‐7

Exercise and Activities 7‐9

Part IV – Case Studies (Design Projects)

8. Samples of Design Project 8‐1

Appendix

A – Manufacturing Process A‐1

B – Basic Machine Shop Practice and Tools A‐4

C ‐ NSPE Code of Ethics for Engineers A‐15

Chapter 1 – Engineering Professions
1.1 What is the Engineering
What is the engineering? If you ask different people, you may get different answers. According to
ABET (Accreditation Board of Engineering and Technology) the definition of Engineering is:

“Engineering is the profession in which a knowledge of the mathematical and natural sciences,
gained by study, experience, and practice, is applied with judgment to develop ways to utilize,
economically, the materials and forces of nature for the benefit of mankind. Engineering activities
include all of the infrastructure of conception, design, construction, refinement and how it will be
brought to the serviceable state for mass uses.”

However, here are some surveys from some of the engineering freshman students. What they said may
not be complete definition but have certain degrees of truth.

 Engineering is the application of scientific knowledge to solve practical problems”

 “Engineering is the bridge between pure science and practical application”

 “Engineering is the study of how things work and how we can make them work better”

 “Engineering is to use technology to perform tasks”

 “Engineering uses math as foundation and the truth/results from science to develop something that
will make the world better”

Why are you studying the engineering? Everyone may have his/her own reasons. Here are some reasons
that most of engineering students said:

1. Varied opportunities

2. Challenging work

3. Social impact

4. Creative thinking

5. Prestige

6. Understanding how things work

7. Financial security

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1.2 Engineering Disciplines
There are five engineering disciplines in early 1900; they are civil engineering, mechanical
engineering, electrical engineering, chemical engineering and industrial engineering. However, due to
emerging technology and the need of interdisciplinary research work, there are many new disciplines in
today’s engineering areas now.

1.2.1 Civil Engineering

Civil engineers are concerned with the design of large and

complex structures -- dams, bridges, transportation systems, and
the like. They also deal with hydraulics, pollution control, and
surveying. Subdivisions within the field include: construction
management, environmental engineering, geotechnical
engineering, structural engineering, transportation engineering,
and water resources engineering. More information, see The American Society of Civil Engineers (ASCE)
website: www.asce.org

1.2.2 Mechanical Engineering

Mechanical is the remaining member (with electrical and civil) of the

traditional big three options. Mechanical engineers design mechanisms -
- basically anything with lots of interconnected moving parts. They are
also concerned with the engines and motors which power these
mechanisms. Many mechanical engineers work in the areas of heating &
air conditioning, automotive, industrial, or manufacturing engineering.
More information, see The American Society for Mechanical Engineers
(ASME) website: www.asme.org

1.2.3 Electrical Engineering

Electrical Engineering is by far the largest option in overall

enrollment. It is probably also the discipline with the largest
diversity of sub-specialties. Topics range from the microscopic
devices connected with modern communications and computer
design, to the gigantic components associated with power
production and transmission. Many bioengineering fields also
encompass the application of electrical engineering principles. More information, see Institute of
Electrical, Electronics Engineers (IEEE) website: www.ieee.org

1.2.4 Chemical Engineering

Chemical engineers work to improve the efficiency of chemical

processes, and they design equipment for the chemical industry.
Subdivisions of the field include process engineering, polymer
science, biochemical engineering, petrochemical engineering,

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energy conversion, and environmental engineering, to name just a few. Many chemical engineers
ultimately find career opportunities in areas which are quite interdisciplinary, and may be employed in
industry, in an academic setting, or by many public and private institutes and agencies. More information,
see American Institute of Chemical Engineers (AIChE) website: www.aiche.org

1.2.5 Industrial Engineering

Industrial engineers design the systems that organizations use to produce goods and deliver services. Most
of engineering disciplines are focused on technology and products, but the industrial engineers are more
emphases on the human-human and human-product relations. The subfields include manufacturing
systems, system engineering, quality control, engineering management, occupational safety, ergonomics,
and engineering economics. More information, see Institute of Industrial Engineers (IIE) website:
www.iienet.org

1.2.6 Aerospace Engineering

Aerospace engineering deals with the design of flight vehicles to

operate both inside the earth's atmosphere and beyond.
Subdivisions within this field include: aerodynamics -- the flow
of air and the associated forces, pressures, etc; flight dynamics --
trajectories, rotational dynamics, sensors and controls; propulsion
systems, -- the design of engines and motors; structures -- issue
of weight, stress, strain, vibration, etc. that constrain the selection
of materials; and design -- the most interdisciplinary field, connected with overview of the design of a
specific vehicle to meet its performance goals. More information, see The American Institute of
Aeronautics and Astronautics (AIAA) website: www.aiaa.org

1.2.7 Bioengineering

Bioengineering, also known as biomedical engineering, is a rapidly

growing and developing profession. A Biomedical Engineer uses
traditional engineering expertise to analyze and solve problems in
biology and medicine, providing an overall enhancement of health care.
Students choose the biomedical engineering field so that they may help
develop devices that enable us to live more healthful and productive
lives. These devices include pacemakers, orthopedic implants, and
diagnostic instruments. Biomedical Engineers work with other health
care professionals including physicians, nurses, therapists, and technicians. Biomedical Engineers also
contribute to basic biological understanding, leading to new ways of preventing, diagnosing, and treating
disease and helping to solve complex clinical problems. Some examples of current research and
development areas are: formulation of synthetic biomaterials, the design of artificial tissues and organs,
and the development of new drug delivery systems. More information, see Biomedical Engineering
Society (BMES) website: www.bmes.org

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1.2.8 Computer Engineering

Computer engineering, sometimes mixed with systems engineering, is

one of the newest disciplinary specializations to be found in engineering
schools. It deals with all aspects, both hardware and software, of the
computer industry. Many of the topics covered by this field were
formerly spread out among a variety of departments, including electrical
engineering and computer science. Indeed many computer engineering
programs are still handled as subdivisions within an electrical
engineering department. More information, see IEEE Computer Society, website: www.computer.org

1.2.9 Fire Protection Engineering

Fire protection includes the design of systems and equipment for the
detection and fighting of fire, as well as the development of fire
retardant materials, and the fire safety of structures. Fire Protection is
closely related to both Chemical and Mechanical engineering, but with a
specific emphasis on applications to fire-related issues. More
information, see Society of Fire Protection Engineers (SFPE) website: www.sfpe.org

1.2.10 Material Engineering

New technologies developed through engineering and science will

continue to make startling changes in our lives in the 21st century, and
workers in Materials Science and Engineering will continue to be a key
in these changes and advances. These engineers deal with the science
and technology of producing materials that have properties and shapes
suitable for practical use. Materials include metals, ceramics, polymers
(plastics), semiconductors, and their combinations called composites.
The activities of these engineers range from primary materials production, including recycling, through
the design and development of new materials to the reliable and economical processing/manufacturing for
the final product. Such activities are found commonly in industries such as aerospace, transportation,
electronics, energy conversion, and biomedical systems. Many applications are limited by the operating
constraints imposed by the properties or behavior of the materials available. Higher quality products result
from improved processing and more emphasis will be placed on reclaiming and recycling. For these many
reasons, most surveys name the materials field as one of the careers with excellent future opportunities.
More information, see ASM International Society (formerly American Society for Metals, ASM) website:
www.asminternational.org

1.2.11 Nuclear Engineering

Nuclear engineers work on design, maintenance and repair of nuclear

power facilities. Fluid dynamics is a very fundamental component of this
program, because the proper functioning of nuclear reactors is critically
dependent upon the precise control of liquids (coolant, moderator,

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lubricants) and gasses (steam, coolant, etc.) -- often at extremes of temperature, pressure, and flow
velocity. More information, see American Nuclear Society (ANS) website: www.new.ans.org

1.2.12 Others

 Environmental Engineering,
 Agricultural Engineering,
 Automotive Engineering,
 Structural Engineering,
 Genetic Engineering,
 Mining Engineering, Petroleum Engineering,
 Manufacturing/Construction Engineering,
 System Engineering, and
 Marine and Ocean Engineering.

1.3 Engineering Functions in Industry

Even though a student needs to choose an engineering discipline in his/her study but when they
work in an engineering firm they may have to work with engineers in different disciplines and involve in a
wide variety of functions ranging from design to sales. The more common engineering functions are

 Research and Development (R&D) engineers

The role of R&D engineers is the one closest to that of a scientist. R&D engineers explore
fundamental principles of science (physics, chemistry, and biology) and apply them to more
specific products/applications. Comparing to the scientists, R&D engineers are more application
orientated. They bridge the gap between pure research and full-scale production. Most often, a
higher degree like Ph. D is required.

 Design engineers

Most of engineers are employed as design engineers. The design engineer is responsible for
providing the detailed specifications of the products society uses. Since entire product design is
getting more and more complicated, most design engineers is responsible for a component or part
of the product. The individual parts are then assembled into a product such as a computer, airplane
or automobile. Design engineers not only design a new product but also work with existing
products. They work on re-design the product to make it function better, cost cheaper and
manufacturing easier.

 Analysis/Testing engineers

Analysis/Test engineers provide verification of the product design. Analysis engineers typically are
specialists in a technology area important to the product or service. They may work with computer
models of products to make sure the design meets specification. Test engineers are responsible for
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 implementing tests to verify the integrity, reliability and quality of products before mass
production.

 Manufacturing/Construction engineers

Manufacturing engineers turn the design to reality. They are responsible to develop the processes
for taking raw materials and changing them into the finished products in the most efficient ways to
save time and cost. They are more concern about different manufacturing processes, introduction
to new technology in manufacturing, control of manufacturing time, inventory of raw materials,
and schedule of production, etc.

 Production/Maintenance engineers

Production and maintenance engineers must have a wide range of expertise dealing with the
mechanical and electrical issues involved with maintaining production operations. Production
engineers may also responsible for quality control of the product, inventory of raw materials and
schedule of production. Maintenance engineers are more responsible for non-manufacturing issues
such as safety inspections and equipment/tool repairs.

 Sales engineers and Technical support

Sales engineers or technical support must have interpersonal skills conducive to effective selling
and answering customer's technical concerns. Today's engineering products are more supplicated
and complicated than before; sales engineers have technical background to answer customers'
concerns and questions. Good technical and customer supports are essential to the successful of the
products.

 Management

In many cases, engineers work themselves into project leader and eventually into full-time
management positions. Engineers in these positions need to have technical ability, problem-solving
ability and leadership skills. Many engineers also take MBA degree before or after they are
promoted to the management positions.

 Education

Some engineers are working in research and teaching in schools. The one students are more
familiar with is engineering professors. College professors usually have their Ph. D

 Consulting engineers

Consulting engineers are either self-employed or they work project by project. They provide their
technical expertise or services to the company or organization but not directly to the consumers.

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1.4 Engineering Experience
For many years, engineering graduates have received relatively high starting salaries and most
have usually found interesting positions available upon graduation. Most of the engineering firms are
looking for the students who have engineering experiences. As students, it is hard to gain such experiences
while studying in the school. However, there are still something that a students can do to have some
experiences:

1.4.1 Summer internship

The Engineering Department at Rockville Campus offers a number of resources for students to
enhance their education through work experience in their field of study. Students may apply for an
internship or a research experiences for undergraduates (REU) to gain valuable experience. Montgomery
College has established transfer programs for students planning to pursue a bachelor’s degree after
graduation.

Comments or questions about SEM Internship Resources can be directed to the internship
Coordinator, Michael Mehalick, at Michael.Mehalick@montgomerycollege.edu.

1.4.2 School engineering clubs

At Montgomery College, Rockville campus, engineering students have organized many clubs that
related to engineering. It has wide range of interest and focus, leadership training, student chapters of
professional engineering organizations, specialties/integration of engineering disciplines:

 Aerospace Club (AIAA MC student Branch) - advisor: Dr. Charles Kung

 ASME MC Student Branch - advisor: Dr. Wendy He
 Engineering Without Borders (EWB) - advisor: Prof. Craig Mogren
 IEEE MC Student Branch - advisor: Dr. Lan Xiang
 MC Engineering Club - advisor: Dr. Nawal Benmouna
 Robotics Club - advisor: Dr. Alex Hou
 Woman in Engineering Science and Technology (WEST): advisor: Dr. Nawal Benmouna

1.5 Engineering Ethics and Social Impact

Engineering ethics is the study of moral decisions that must be made by engineers in the course of
engineering practice. It is important for engineering students to study ethics so that they will be prepared
to respond appropriately to ethical challenges during their careers. Often, the correct answer to an ethical
problem will not be obvious and will require some analysis using ethical theories. The types of problems
that engineers will encounter in studying engineering ethics are very similar to the design problems that
engineers work on every day. As in design, there will not be a single correct answer. Rather, engineering
ethics problems will have multiple correct solutions, with some solutions being better than others.

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 So what are the engineer ethics theories or rules? The National Society of Professional Engineers
(NSPE) has published the Code of Ethics for Engineers that provided the basic principles and practices for
engineers to understand their duty and obligations to the society and have a guideline when making a
decision involving professional ethics questions. This code of ethics is included in the Appendix of the
book.

There is no better way to study engineering ethics through case studies. NSPE has listed many real
world ethics cases through the year 2016 for studying engineering ethics. If anyone is interested in this
study, you can download the whole document (the NSPE Ethics Reference Guide) from
https://www.nspe.org/sites/default/files/resources/pdfs/Ethics/EthicsReferenceGuide.pdf

In addition to that, there are a few questions you should ask yourself when making an ethical decision:

1. Is it legal?
2. Is it safe to the society?
3. Is it the right time to do? Will I do it again?
4. Will this stand the test of public scrutiny? If this decision was published on newspaper, do I still
feel comfortable?
5. If something terrible happened, could I defend my actions?
6. Would I do this in front of my family (or someone I respect)?

1.6 Program Advising

Since engineering transfer programs at Montgomery College offer only first two-year courses in a
four-years BS degree program, most of students will transfer to a four-year engineering programs after
they complete Associate of Science (AS) degree. Due to requirements of receiving schools may be
different, discussing with engineering advisors to prepare individual academic plan will be vital for
students’ success in their career.

1.6.1 Engineering advising

Engineering students enroll in a variety of courses in several different disciplines such as engineering
science, computer science, physics, chemistry, biology, English and general education. Finding an
appropriate advisor often requires some effort on the part of the student. Try to talk to your advisor at least
once a year to ask any questions regarding engineering profession and career plan. Listed below are
names of current advisors along with a short description of their particular expertise and advising
strengths.

All campuses –

 Dr. Don Day: Advising for any engineering curriculum, transfer programs, pre-requisite overrides,
EL & RD students, new or returning students, physics courses, chemistry courses, math courses,
engineering courses.

Rockville campus –

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  Dr. Alex Hou: Advising for all engineering students and transfer programs. Engineering Program
Coordinator.
 Professor Mogren Craig: Advising for all engineering students. Faculty Coordinator for Engineers
Without Borders.
 Dr. Lan Xiang: Advising for electrical/computer engineering students and ASE degree seeking
students

Germantown campus –

 Dr. Charles Kung: Advising for all engineering majors.

 Dr. Monica Mallini: Advising for all engineering majors.

Takoma Park campus –

 Dr. Hailu Gebremariam: Advising for physics and engineering majors.

 Dr. Max Nam: Advising for physics and engineering majors.

1.6.2 Academic study plan

All students who are taking ENES100 are required to create the academic study plan through
MyMC and click the icon of “Student Academic Plan” (SAP). They also required to update it at least three
times when they taking PHYS161 (General Physics I) and PHYS 262 (General Physics II) and the last
semester before they plan to graduate. On the meantime, students can check their academic progress
anytime through the icon of “Student Advisory Report” (SAR).

Following is the instruction of creating an academic study plan (SAP):

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 Creation of Student Academic Plan of Completion

Assignment Due: One week before Priority Registration Begins

The goal of the Student Academic Plan Completion assignment is to promote undergraduate student
progress toward a degree. Each student must create and consistently review an Academic Plan for their
major.

To prepare you to create your Student Academic Plan follow the instructions below:

A. Find and download the Program Advising Guide (in pdf format) for your major from this link:
http://cms.montgomerycollege.edu/EDU/plain.aspx?id=15000
Please note: Program Advisors (with their contact information) are listed in these guides.

B. Log into MyMC and click on the Student Academic Plan icon. We will refer to this tool as SAPC in the
instructions below. The acronym SAPC stands for “Student Academic Plan of Completion”.

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C. First view your academic history under the “Academic History tab” and using the Program Advising
Guide you downloaded for your major, identify the courses remaining for you to complete your degree.

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Now you are ready to follow the steps 1 through 3 in SAPC to create your Student Academic Plan:

D. Click on the tab “Academic Plan (Step 1)” as shown below. The proposed semesters are numbered
after the total number of semesters you have been at the college, so the numbers will be different for
each student. (The picture below shows a plan already completed. Your proposed semesters will be
empty when you first start.)

E. Using the sample academic plan in your major’s Program Advising Guide which you downloaded, fill
the proposed semesters with the courses you need to take in order to complete your degree. When your
plan is completed, click the Save/Update button at the bottom of the page (still in step 1).

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F. Print your plan using the print button at the bottom of the page or save as pdf. Your printed plan will look
like the picture below and will include your past and current semesters as well.

G. Before THE DEADLINE: Meet with a Program Advisor to discuss and review your plan. Have your
Program Advisor enter their name under the “Advisor Information (Step 2)” tab in the SAPC tool and
have your advisor sign a printout of your finalized Academic Plan.

H. After you have met with a Program Advisor, log back into the SAPC tool and in the “Complete (Step 3)”
tab enter any changes that you discussed about your academic plan. Click on “Submit as Complete” (you
WILL be able to modify and then resubmit your plan in the future, so don’t panic!)

I. Submit the signed copy of your Academic Plan to your course instructor by THE DEADLINE. (You can
submit a photo using Blackboard Course Mail.)

J. You are all set! Now you are ready to registration when priority registration starts! Remember register
EARLY to get the classes you need to complete your degree!

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Useful tools to help you create your academic plan:

1. STUDENT ADVISORY REPORT

This tool provides details on your
academic history.

Student Advisory Report

2. COURSES IN YOUR MAJOR PROGRAM

http://catalog.montgomerycollege.edu/content.php?catoid=6&navoid=606

- Change "Entire Catalog" to "Programs" (right-hand-side) to search for your major

3. PREREQUISITES (COURSE CATALOG)

http://catalog.montgomerycollege.edu/

- Check that you will have completed the prerequisites for the next semester courses
- Use the Catalog Search on the right-hand-side or click on the courses in your program

4. MATH COURSE SEQUENCE

https://cms.montgomerycollege.edu/EDU/Department2.aspx?id=34892

 Mathematics Courses Updated Flowchart

- Verify you are in the correct math sequence for your major

5. TRANSFER
a. ENGINEERING: https://cms.montgomerycollege.edu/EDU/Department2.aspx?id=11115
- Check the Transfer Sheets, which outline required courses for transfer to nearby schools
b. OTHER STEM:
- Meet with your Program Advisor or a Transfer Counselor to discuss requirements for
transferring to your preferred schools in your major program.

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EXERCISE AND ACTIVITIES
1. Contact an engineer in a discipline that interests you. Set up an interview and talk to him/her on
individual education experience, activities in schools and his/her job projects. Ask him/her to give an
advice to engineering students today. After the interview, write a one-page report.

2. Pick an engineering discipline that interests you and make a list of technical courses that you think them
are essential to the discipline. You can search your information through internet.

3. Visit two engineering professors during their office hours. Ask each for their engineering background
and experiences. Ask for any advises to engineering freshman students and why it is important.

4. Visit the website of Montgomery College Clubs in Engineering page:

http://www.montgomerycollege.edu/Departments/phengrv/clubs.html to find all clubs related to
engineering. Pick one you are interested and join it. Participate the activities and learn more about the
work of engineers doing.

5. Do you know how to calculate your GPA (general point average) at MC? Can you calculate this
student’s GPA after first semester and 2nd semester?
courses credits grade
Semester1 MATH181 5 B
PHYS161 3 C
Semester2 PHYS161 3 A
ENES102 3 B

6. As an engineering student, you may not face the professional ethical situation yet but you might
encounter the following situation. Read it and discuss how you would respond. What are your ethical
responsibilities?
You and your roommate are both enrolled in the same engineering class. Your roomate spent
the weekend parting and did not do the homework that is due on Monday. You did the homework,
and your roommate asks to see it. You ae afraid he or she will just copy it turn it in as his or her
own work. What are you ethically obligated to do?
a. Show your roommate the homework.
b. Show the homework but ask your roommate not to copy it.
c. Show the homework and tell the roommate that if the homework is copied, you will tell the
professor.
d. Refuse to show the homework.
e. Refuse to show the home work but offer to spend time tutoring the roommate.
f. Others. Explain it.

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 Chapter 2
Introduction to Engineering Design
Chapter 2 – Intro to Engineering Design
2.1 What is Engineering Design
What is engineering design? If you ask ten engineers, you may get ten different answers. A
formal definition of engineering design is found in the curriculum guidelines of the Accreditation Board
for Engineering and Technology (ABET). It says:

Engineering design is the process of devising a system, component, or process to meet design needs. It is decision-
making process (often iterative), in which the basic sciences, mathematics, and engineering sciences are applied
to convert resources optimally to meet a stated objective. Among the fundamental elements of design process are
the establishment of objectives and criteria, synthesis, analysis, construction, testing, and evaluation. The
engineering design component of a curriculum must include most of following features: development of student
creativity, use of open-ended problems, development of use of modern design theory and methodology, formulation
of design problem statements and specifications, consideration of alternative solutions, feasibility considerations,
production process, concurrent engineering design, and detailed system descriptions.

There are other definitions of the engineering design:

Design - the plan and arrangement of the form and structure of natural and man-made material to achieve a
desired function.

Engineering - the application of sciences to the construction of hardware or/and software.

Engineering design - an iterative decision making process in which sciences are applied to devise a system to meet
the needs of the client.

2.2 Characteristics of Engineering Design

According to this definition, there are a few characteristics of engineering design that can be
found:

1. It fully integrates the knowledge of basic science, math and engineering science.

Engineering design is strongly based on the knowledge of physics, chemistry, biology and math.
In school students learn structured curriculum courses by courses for different disciplines. However, in
real world, engineers need to integrate all knowledge what they learned in class and implement it in
design from all different aspects.

2. It solves open-ended problems.

In school, students are more familiar with analytical problem solving where there is one correct
answer. However, most problems engineers have to solve are open-ended and have several solutions. For
example, how to design an engine that uses renewable energy and makes it more efficient can have many
different options. The challenge is to identify an optimal solution by careful and systematic analysis of
multiple alternatives.

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3. It is an iterative learning process.

Engineering design process is a complicated and messy process. For most of the homework
problems, students may be able to find the answer using a logical approach such as need-know-how-
solve method. However, for a design problem at any stage in the process new idea may pop up and
requiring students to re-examine what they already done. It ends up that students may need to re-do it
using different data, materials, sizes and approaches. It can be very frustrated but students learned from
failure design.

4. It utilizes new technology and established methodology.

The information, new technology, materials and process that are available at time will
significantly impact the design solution. The best design of a product or process twenty years ago may
not be the case anymore since the technology, material or process change.

5. It is a team work and con-current process.

The engineering product design is getting more and more complicated in modern days. For
example, to design a car, you not only need mechanical engineers to design frame, engine, cooling,
transmission, you also need electrical engineers to design lighting, ignition systems. Therefore, a design
team usually consists of engineers from all different major and they have to work together to accomplish
the task. Concurrent design requires all team members involved think things simultaneously from
different aspects to avoid mistakes later. Even during the design stage, market expectation, product
safety, manufacturing cost, and assembly need to be considered at same time.

6. It uses limited resources to meet multiple goals.

One of the biggest challenges designers face is how to use limited resources and design a product
that successfully satisfies a number of criteria, many of which might seem to be conflicted. For example,
when you design a consumer electronic product, say iPod, you need to consider the cost, design time,
consumer’s needs, product life cycle, etc.

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EXERCISE AND ACTIVITIES
1. What is engineering design? Make a statement in your own words.

2. Take no more than 20 minutes to think about your dream car. Draw your dream car in a 3-D sketch
and indicate the special features of your car.

3. Design problem: Computer cables cross the floor of CAD

classroom. This causes a tripping hazard. Design the cross-
section of a cable cover. The minimum numbers of wires that
the cover must protect are two 3/8’’ network cables and one
1/2” extension cord.

Requirement: 1) three different cross-sectional sketches with

major dimensions; 2) three possible materials and 3) three
methods of attachment of keep the cover in place on the floor.

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 Chapter 3
Engineering Graphics
Chapter 3 – Engineering Graphics
3.1 Introduction to Engineering Graphics
Engineering graphics is a common language among engineers for exchanging their ideas. Through
graphical presentation, engineers are finding it to be much easier presenting their design products rather
than using words describing them. A good engineering designer not only needs to know how to present his
product from a three-dimensional product to a two-dimensional medium following graphics standard but
also by translating a 2-D drawing into a 3-D model as well. Traditionally, graphics skills have been taught
in a separate 2-3 credit hour course; however, some disciplines no longer require drafting class. Instead,
the computer 3-D modeling has been utilized to the full extent for design engineers in industry. No matter
what, the engineering graphics standard still remains the same, whether or not you draw sketch by hand or
model it using computer software.

3.2 Basics of Engineering Graphics

There are several types of engineering drawings in different engineering fields for different
purposes. In this chapter, detailed drawing for mechanical engineer will be discussed in more detail.

3.2.1 Paper Size, and Title Block

Depending on the printer, the paper sheet size is specified in ascending order:

FPS (inch) system: A (8½ x11) , B, C, D, E and F (28x40) .

SI (millimeter) system: A4 (210x297), A3, A2, A1 and A0 (841x1189).

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 A title block provides a variety of information about a drawing, such as the title of the drawing,
sheet size, part number and predominant scale and drafter information.

3.2.2 Types of Lines

There are many types of lines used in the engineering graphics to represent different situations. A
good design engineer should be able to see and interpret the product. Here are four types of lines that are
used the most in engineering graphics:

a) Visible Line – used to describe the visible surface boundary or edge of the object. It is drawn as
a thick continuous line.

b) Hidden Line – used to describe the invisible boundary of surface or edges of the object that is
blocked by other surfaces. It is drawn as a medium and dashed line.

c) Center Line – used to show and locate the centers of circles and arcs and to represent the center
axes of circular or symmetrical form. It is drawn as thin and short-long line. When used to define the
center of an arc and circle, two center lines are drawn and intersect on the short lines as shown in the
figure. When used to present as axial symmetrical line, only one centerline used.

d) Dimension Line, Leader and Extension Line – used to establish the extent of an object and label
the size of it. It is drawn in a thin and continuous line.

Besides these four major line types, there are many others. See any reference book in detail:

e) Cutting-Plane Line – used to identify where a section is taken and the show the view direction.
It is drawn in a thick line.

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 f) Section Line – used to show the area where the cutting plane passes through and indicate the
material used. Different line types on the area mean different materials. (The one in example is cast iron).

g) Break Lines – used to shorten the length of a long object or part or to provide a partial view of a
feature.

Occasionally, two different line types may fall on the same location in the drawing. If that
happens, the more important and thinker line will prevail and be drawn. For example, if a visible line and
hidden line fall on the same location, then the visible line will be drawn. In general, it follows the order:

cutting-plane line -> visible line -> hidden line -> center line

In this drawing, how many line types can you identify?

3.3 Orthographic Projection Views (Multi-views)

3.3.1 The Theory of Projection

In order to use a sheet of paper or the

computer screen which only has two-dimensions
to display a three-dimensional object in an accurate
way, orthographic projection or multi-views is
developed for this purpose. The theory of
orthographic projection (also called glass box
theory) can be considered by putting the three-

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dimensional product into a glass box and showing the projection views from each side of the box. There
will be six views in general (front, top, right side, left side, back and bottom views), however, most of the
time, we will use three views only; named FRONT view, TOP view and (right) SIDE view. The remaining
three views usually don’t add any new information. Among these three views, the front view is the most
important view and usually shows the most features or characteristic of the product. It usually contains the
least amount of hidden lines.

top view

left side view right side view back view

bottom view

3.3.2 Construction of Orthographic Views

Since these orthographic views are two-

dimensional, each view can only shows two dimensions
of the product, but when we look at all three views, we
will have a complete picture of the three dimensions of
the product. The front view shows the width and height
of the product and the depth dimension is suppressed.
The top view shows the width and depth of the product
and the height is not shown. Similarly, the side view
shows the height and depth of the product only. In other
words, each view only shows two dimensions of the
product but combined three views together, all three
dimensions (width, height and depth) are shown twice in
these views.

The location of each view relative to the other

views is extremely important in describing the product.
Since the front view is the most important view; once the

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front view is drawn, the top view must appear above the front view and the (right) side view must be
displayed to the right side of the front view.

There is no quick way to become a drawing expert. Practice, practice and practice is the only way
to get better. Here is a general procedure to construct orthographic views:

a) Choose a front view. This is the view that shows the most about the product.

b) Draw the visible surfaces of the front view.

c) Draw projections off of the front view horizontally and vertically in order to create the
boundaries for the top and (right) side views.

d) Draw the top view. Use the vertical projectors to fill in the visible and hidden features.

e) Double check the front and top views. These two views share the same dimensions in width.
Compare these two views and fill in all visible and hidden lines in width direction.

e) Draw a 45o projector off of the right upper corner of the front view.

f) From the top view, draw projectors over 45o line and down in order to create the boundaries of
the (right) side view.

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 g) Draw the (right) side view. Fill visible and hidden lines by using vertical projectors from top
view and horizontal projectors from front view.

h) Double check the front and side views. These two views share the same dimensions in height.
Compare these two views and fill all visible and hidden lines.

i) Draw center lines where necessary.

After all steps, finally check and insure following:

a) The front and top views are vertically aligned.

b) The front and (right) side view are horizontally aligned.

c) Every point or feature in one view is aligned on a projector in any adjacent view (front and top,
or front and right side).

3.4 Pictorial View

Pictorial view is a sketch that shows all three orthographic views in one. Since it uses one view to
show all three dimensions in a two dimensional view, all the angles and length may not be the true
dimensions (i.e. the dimension and geometry may be distorted). In some cases, it may not be able to show
detail features behind the visible surfaces. However, it is relatively easy to understand the general shape of
the product for non-engineers, so it is used for commercial advertising and assembly procedure.

There are generally two types of pictorial sketches that can be used. One is isometric view and the
other is oblique view. The main differences of these two are the angles between three axes (width, height
and depth) directions.

3.4.1 Isometric View

In isometric view, three axes are composed of two receding axes (width and depth) that measured
o
30 from the horizontal reference plus a vertical axis (height).

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 Here is a general procedure to convert orthographic
views to an isometric view:

a) Label all surfaces on the orthographic views.

Ignore all hidden lines. All surfaces on each view heigh
should be bounded by visible lines. width depth

b) Draw an isometric box size of the overall 30° 30°

dimensions of the product respectively to three axes.

c) Choose the most front surface in front view and define the points of every corner on that
surface.

d) Transfer all corner points of the surface to isometric box. Then connect all these corner points
by lines.

e) Repeat the procedures of c) and d) for every surface till all surface are drawn on the isometric
box.

f) Double check the drawing and erase the lines that are hidden. Usually hidden lines are not
shown in the pictorial view.

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3.4.2 Circular Feature on Isometric View

In isometric view, circles will always appear as ellipses. The

orientation of the ellipse depends on which surface (front, top or side) the
circle appears. To construct an ellipse on the top isometric surface follw
these steps:

a) Draw a square circumscribed bythe circle on the top view.

b) Transfer that square to the isometric top surface plane (it should looks like
an dimond shape). Sketch in the center lines on the isometric top surface plane too.

c) Draw a perpendicular bi-sector line from each side of the diamond shape. (i.e. draw a line from two
interior obtuse angles to the mid points of opposite sides). Total four lines.

d) Draw an arc that centered at the intersection point of any two perpendicular bi-sector lines with radius
from center to the midpoint of the side of diamond. There will be four arcs to draw.

3.4.3 Oblique Pictorial

Oblique view is similar to isometric view but there are some noticeable differences. Since the front
view is the most important view of a product, the isometric view is not going to show any of the three
orthographic views in true angles and areas. So engineering designers would like show the front view on
the oblique drawing similar to the front view in orthographic views with distorted top view and right side
view.

In oblique view, three axes are composed tow perpendicular height

axes (width and height) and a receding axis (depth) in any angle depth
needed. However, 45o is the most common.

The procedure to draw an oblique view is the same as

compared to isometric view except directions of three axes are
width
different.

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3.5 Dimensioning
In addition to the shape description of a product given by orthographic views, a complete
engineering drawing must also have detail size and location descriptions using numerical numbers. The
dimensioning standards are based on the ASME Y14.5 established in 1994.

Choosing dimensions involves many decisions based on how the product functions, how it relates
to other parts and how it is manufactured. There may be several ways to place a dimension so the concept
of “engineering intent” will often point to the most logical selection. Even there is no unique way to place
dimensions but there are certain rules need to be followed.

3.5.1 Lines in Dimensions

Dimension lines are always drawn in thin line so that they won’t be confused with visible lines.

a) Extension lines – extension lines should start a little gap from the product it will be measured
except if it starts from inside of the product view drawing.

b) Dimension line with arrowhead and text – dimension line extend exactly between extension
lines and the arrowhead always point to the extension lines. The text is always in the middle of the
dimension line and without unit. (NOTE: unit should be indicated on title block)

c) Leader lines – leader line is used for Dimension Text

circular features. It points to the centers of arcs or
circles and stops on the circle/arc.

3.5.2 Dimension Preferences and Rules Leader Line

a) The spacing between dimension lines

should be uniform throughout the drawing.

b) Do not draw a dimension line inside an

object or have the dimension line touch the
object unless clearness is gained.

c) Dimension number should be horizontal which means that it is read from the bottom of the
drawing.

d) Dimension lines should not cross extension lines or other dimension lines.(note: Extension lines
can cross other extension lines or visible lines but try to avoid if possible).

e) Extension lines and centerlines should not connect between views but they can be connected in a
same view.

f) Leader lines should point to the center of the arc/circle at angle between 30o – 60o.

g) Dimensions should not be duplicated or the same information given in two different ways/views.

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 h) Begin with smallest dimension close to the object and place dimensions that progressively increase
in size further away from the object.

i) Dimension to the view that provide that best shape descriptions.

j) Avoid to dimension on the hidden lines if possible.

k) Dimensions should be grouped and placed between views whenever possible.

Let’s practice it! There are some mistakes in the following dimension drawings. Can you correct
them? Answers are next to them.

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3.5.3 Special Dimensioning

A) A circle is dimensioned by its diameter and an arc by its radius using a leader line and a note.
Use radius to define an arc. Use R as radius symbol. Use diameter to define a full circle. Use Φ as
diameter symbol.

B) Dimensions of a circle/arc are given to the location of the center and diameter/ radius.

C) For round corners, the leader should pass through the center or point to the center of the arc.

D) Repetitive features or dimensions may be specified by

using the symbol “X” along with the number of times the feature is
repeated.

E) Use any one of these method to dimension the angle:

coordinate method, angular method and flat taper note.

3.5.4 Dimension Choices

Dimension placement and dimension text influence the manufacturing process used to make the
product. However, the choice of dimension should depend on the function of the product and the mating
relationship to other parts and then on the manufacturing. Usually there are two concepts for the
placement of dimensioning:

A) Datum dimensioning: All Dimensioning features are based on a common surface, or axis. Use
it to define/emphasize feature location.

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 B) Chain dimensioning: Dimensioning one feature from previous dimensions. Use it to
define/emphasize feature size.

In general practice, both datum and chain dimensioning are used in a detail engineering drawing
depending on the importance of location or size of the feature. Even there are many ways to dimension to
product, but only one dimension on a single feature on any view. So don’t place the same dimension text
of a feature on different views.

Datum Dimensioning Chain Dimensioning

Let’s practice it! There are some mistakes in the following dimension drawings. Can you correct them?
Answers are next to them.

3.5.5 Tolerance

All dimensions have a tolerance except the reference. Tolerance is the error range (for example, +
0.01). Tolerance is smaller means the accuracy is better but the manufacturing cost may also increase too.
For example, the dimension text “10.0” usually means “10.0 + 0.1”, so the size between 9.9 and 10.1 is
acceptable. If the dimension text “10.00”, it means “10.00 + 0.01”, so the size between 9.99 and 10.01 is
acceptable and it will be harder to manufacture and associated with higher cost.

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EXERCISE AND ACTIVITIES
1. Fill the missing lines (visible, hidden and center lines) on the following orthographic views.

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2. Draw the parts in orthographic views (front, top and side views) based on the following pictorial
isometric views.

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3. Draw the pictorial isometric view of the parts based on the following orthographic views.

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4. Draw the pictorial oblique view of this product.

5. Dimension following parts based on the rules and standard

discussed.

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3‐17
3‐18
 Chapter 4
Introduction to Solid Modeling
Chapter 4 – Introduction to Solid Modeling ‐ CREO
4.0 Computer Aided Design
The rapid changes in the field of Computer Aided Design (CAD) have brought exciting advances
in the engineering design. Today in the industry, computers are not only used in the design phase but also
used for analysis, simulation and manufacturing too. There are many advantages that engineers use CAD
specially the 3-D modeling for the design:

A creative and innovative method of representing a design conceived by design engineers

Facilitate design modifications and redesign

Execute long and complex engineering analyses

Integrated design with other tasks, such as manufacturing

An effective method of communicating design information

There are a lot of software that can be used for this purpose such as AutoCAD Inventor, SolidWorks,
CREO and others. Here, we are going to learn some basics for construction of a 3-D part from an
idea or engineering drawing using CREO.

Important Tips

Before starting, there are three important ideas used in all computer applications:

1. File Management: If you do not save your files to a safe location, then your work is lost. In
CREO, the first step must be Set File Directory. This is where your files will go when you save.
At Montgomery College, any files saved to the computer’s hard drive will be erased. You must
set your flash drive as the Working Directory.

2. File Names: Your file’s filename will need to be unique to you and the assignment. If you and
everyone else in the class send your instructor a file called Chapter-1.PRT.1, for example, no one
will get a grade for that work. Follow your instructor’s filename rules before submitting an
assignment. In CREO, there are some additional restrictions on filenames, such as do not used
spaces or non-alpha-numeric characters accept underscore _.

3. The three buttons on the mouse have three general functions: Left button selects and executes
actions that are under the cursor. Middle button (or pressing the wheel) is used to manipulate the
graphics under the cursor. Right button brings up a menu based on where the cursor is on the
screen. The position on the screen of the cursor will change what specific action happens.
Additional actions can be done when holding down one of the special keys Ctrl, Alt, and/or Shift.

4‐1
4.1 Parametric Modeling Fundamentals

Before starting a model, insert your flash drive and start CREO. Click or select (move curser arrow and
press the left mouse button) the File tab on the top-left of the CREO screen.

Click Manage Session, then Select Working Directory. You can also just click on Select Working
Directory under the Home tab.
Click on your computer’s name near the top of the Select Working Directory window. Double-Click
(select and execute) the Drive letter for your flash drive. Click OK near the bottom of the window.

These steps must be done every time you start CREO.

Task: Use CREO to create the adjuster shown in the figure. The default unit is in inch.

4‐2
Step 1: Create a new file for the 3D solid model.
Select the icon of New from the toolbar. In the New window, select the Part module. Type chapter_1 as
the file name. Click the box of OK. This will bring up the design window.

Step 2: Create the first feature, which is a block and the 3 dimensions are 3.5 x 3.0 x 2.5 inches.
From the Model tab, click the icon of Extrude. Specify 2.5 as the height of the block feature.

Select the red Placement tab, the click on Define... . From the Model Tree, select the TOP datum plane
as the sketching plane, then Sketch. Click the icon of Sketch View to orient the sketching plane parallel
to the screen.

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Click the icon of Centerline and create a vertical centerline passing through the origin of the coordinate
system. Make 2 left clicks along the vertical dashed-line, which serves as a reference.

Click the icon of Rectangle to sketch a rectangle, which is symmetric about the vertical centerline.
Start with picking a point on the left side of the horizontal reference (horizontal dashed-line), and picking
the second point on the other side. Before making the second click, set the rectangle symmetric about
the vertical axis. A pair of arrows is displayed, indicating the symmetry, as shown below.

To modify the 2 dimensions, click the icon of Select or One by One. Afterwards, double click the
displayed numbers and change the 2 dimensions to 3.5 and 3, respectively. Notice the color change from
light blue to dark blue.

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Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the
creation of the block feature. Hold down the Ctrl button on the keyboard and press D (Ctrl-D) to see the
3-D shape.

Save your file now and every time you finish a sketch. When you Save while in the sketcher, you are
not saving the part. A file like SD0002.SEC will be in your working directory. To save your part, you
must finish (Apply and Save) your sketch, then Save.

Apply and Save

Save your file now and every time you finish a sketch. When you Save while in the sketcher, you are
not saving the part. A file like SD0002.SEC will be in your working directory. See Important Tips at the
end of this section on how to use saved sketches.
To save your part, you must finish (Apply and Save) your sketch, then Save.

Step 3: Create the second feature, which is a slot and the 3 dimensions are 2 x 2.25 x 2.5 inch.
Click the icon of Extrude. Select Cut because we are going to remove the material from the created
block. Specify 2.5 as the depth of cut. Select the red Placement tab, the click on Define... .
Cut

Select the top surface of the block feature as the sketching plane, and click the icon of Sketch View to
orient the sketching plane parallel to the screen.

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Click the icon of Centerline. Sketch a vertical centerline passing through the origin of the coordinate
system. To do so, make 2 left clicks on the vertical dashed line, which is a reference.

To create a rectangle, click the icon of Rectangle, and start the sketch by picking one point on the left
side of the horizontal axis, and the second point on the right side. Before making the second click, set
the rectangle symmetric about the vertical axis. A pair of arrows is displayed, indicating the symmetry,
as shown below. Afterwards, double click the displayed numbers and change the 2 dimensions to 2.25
and 2, respectively.

Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the
creation of the block cut feature. Save your part.

Apply and Save

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Step 4: Create a plate before creating the required hole feature. The plate size is 2.5 x 0.75 x 3 inch.
Click the icon of Extrude displayed on the toolbar. Specify 3 as the depth of extrusion. Select the red
Placement tab, the click on Define... .

Select the front surface of the block feature as the sketching plane, and click the icon of Sketch View to
orient the sketching plane parallel to the screen.

Click the icon of References. Click the surface on the right side of the block, as shown. After defining
this new reference, click Close.

New
reference

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Click the icon of Rectangle, and sketch a rectangle as shown below. The 2 size dimensions are 2.5 and
0.75, respectively.

Click the icon of OK.. Pay attention to the direction of extrusion. Users may click the arrow to reverse
the direction of extrusion. Click the icon of Apply and Save.

Step 5: Create the hole feature. The diameter is 1 inch and the 2 position dimensions are 1.5 and 1.25.
Click the icon of Hole displayed on the toolbar. Specify 1 as the diameter value and use Thru All as the
depth choice (a through hole). Specify Thru All, as shown below.

Type 1 as the Select Thru All

diameter dimension

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Click Placement, click or activate the box under Placement, and select the top surface of the plate as the
primary surface, and select Linear.

To define the center location of the hole, click or activate the box under Offset References, and hold
down the Ctrl key select the front surface of the block and the surface on the left side of the block.
Specify the values of offsets to be 1.5 and 1.25, respectively.

When you want to select more than one thing, hold down the Ctrl key.

Click the icon of Apply and Save to complete the creation of the hole feature, as shown below:

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You have successfully completed the design of an object with a block feature, a slot feature, and a hole
feature. Remember to save all of your work with the 3D solid model. Click Save from the main toolbar >
OK.

To prepare an engineering drawing based on the 3D solid model, we need to create a drawing file. First,
we click the icon of New, or “Create a new model”.

A New window appears, as illustrated below. This is the same step we used to open a new file when
creating the 3D solid model of chapter_1. However, this time, “Drawing” mode, instead of “Part”
mode, should be selected. Type chapter_1 as the name of the file. Clear the box of Use default
template because we do not want to use the default setting for the drawing work. Afterwards, click OK.
In the window of New Drawing, make sure that the file of the 3D solid model called chapter_1 is shown.
Otherwise, use “Browse” to locate it. Select Empty under Specify Template, and select the paper size to
be A. Afterwards, click OK.

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This brings up the drawing screen. Click the icon of Layout. Click the icon of General. In the Select
Combined State window, click OK to accept No Combined State.

Select a location on the drawing screen as the center point for the General View. A general view appears
on the screen.

Look at the lower left of screen and

you should see this message.

In the pop-up Drawing View window, select FRONT > Apply > Close, the construction of the Front
View is completed.

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To insert the right side view, pick the FRONT View just created so that the Front View is activated,
click the icon of Projection and make a left click at the right side of the Front View.

An alternative method to create a projection on the right side is to click the Front View for activation.
Afterwards, make a right-click and hold, and then select Insert Projection View > move the cursor to
the right side and click the left button. The construction of the right side view is completed.

Follow the same procedure to create the top view, as shown below.

Click the icon of General. In the Select Combined State window, click OK to accept No Combined
State. Select a location on the drawing screen as the center point for the 3D View (click the left button of
mouse). A general view appears on the screen. In the pop-up Drawing View window, select Standard
Orientation > Apply > Close, the construction of the 3D View is completed.

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Sometimes, users may notice that the names of the datum planes, such as FRONT, RIGHT and TOP,
appear on the drawing. The name of coordinate system, such as PRT_CSYS_DEF, also appears. To
clean the drawing screen, click the icon of Datum Display Filter.

Upon completing the layout, we start adding dimensions. Click the icon of Annotation. Select the icon
of Show Model Annotation.

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In the pop-up window, select the icon of Dimensions. To show the dimension of Extrude 1, click
Extrude 1 listed in the model tree. Click Accept and OK. The 3 dimensions of 2.5, 3.5 and 3.0 are shown.
Click the box of Accept All > OK.

Dimension

Accept all

To show the dimension of Extrude 2, click Extrude 2 listed in the model tree. Click Accept and OK. The
3 dimensions of 2.25, 2.0 and 2.5 are shown. Click the dimension 2.25 and dimension 2.0 and do not
click dimension 2.5 because there is 2.5 on display. Click the box of Apply > OK.

Dimensions

Accept all

4‐14
Users may use the left button of mouse to pick up a dimension and drag it for moving to an appropriate
location. For example, the dimension of 3.5 is repositioned.

To show the dimensions, for example of Extrude 3, an alternative way is to click the icon of Dimension -
New References > On Entity > Pick the relevant lines using the left clicks on the mouse > click the
middle button of the mouse to position the dimension at an appropriate location.

Click the middle button

Click the middle button to place the dimension
to place the dimension

Left click this line

Left click this line

Now let us add centerlines to the drawing. Select the icon of Show Model Annotation.
In the pop-up window, select the box of centerlines. Click the hole feature listed in the model tree. All
the centerlines are shown. Click Accept All > OK.

4‐15
Users may add the required dimensions on your own. Users may also move some of the dimensions
displayed on the Front View to the Right-Sided View. First, pick the dimension > right click and hold,
select Move Item to View. Afterwards, pick the Right-Sided View.

4‐16
At this time, the user has successfully completed the engineering drawing of the designed object with a
block feature, a slot feature and a hole feature. Select Save > OK.

Important Tips: If you need to fix mistakes that may happen.

Editing a feature:

You can fix mistakes you made in a feature (features are the things in the model tree) by right clicking
the feature and select Edit or Edit Definition. Edit only allows you to change just the numbers of a
dimension. Edit Definition allows you to go back into the feature.

For example, if Extrude 3 is step 4 was extruded in the wrong direction, right-click Extrude 3 in the
model tree and click Edit Definition. Now you can flip the direction and change the depth. You can also
click Placement to go back to the sketcher.

4‐17
Importing a Saved Sketch:

Sometimes you cannot finish a sketch when you need to leave the computer. If you click the Save icon,
like shown above, you will be saving a sketch (.SEC) file, not the whole part. A filename like
S2D0001.SEC will show as the Model Name. You can use that name or change it so you can
remember it.

Later you can restart CREO, set your working directory, and open the part file you were working on or
start a new one.

For Example: You couldn’t finish Step 4 (Extrude 3 in the part). Open the part file (Chapter_1.PRT.1).
Follow the instructions in Step 4 to get back to sketch mode.

4‐18
Click on File System and select the sketch file (like, s2d0001.sec) and open.

Click around where you want the center of your sketch to go. Change the Scaling Factor to 1 and click

the OK checkmark, .

Scaling Factor

Now you need to attach the sketch to the references you made. Click the Coincident button in the
Constrain tools. Click the bottom edge of your sketch, then the reference line at the bottom of your part.

4‐19
 Coincident

Repeat coincident constraint on the left edge of your sketch and the right reference line. You can now
continue with the instructions where you let off.

4‐20
EXERCISE AND ACTIVITIES
1. (unit: inch) 2. (unit: inch)

3. (note: wall thickness is uniform 0.25 inch)

4‐21
4.2 Constructive Solid Geometry Concepts
CREO uses extrusion features as a key tool for making parts. An extrusion is the area of a shape that keeps that
area over its entire length. Wood molding, metal pipes, and spaghetti are examples of extrusions. In the part
below, the cylinder on the left is one extrusion since it is a hollow cylinder, of the same diameter, from top to
bottom. The rectangular plate, with a notch cut out, is another extrusion.

To start a part, you must first choose a “Base Feature”. This is often an extrusion that all following features will
directly or indirectly be measured from. Cylinders are good base features since you often want the rest of the part
to be tangent (smooth transition) to the cylinder.

Task: Use CREO to create a locator part as shown in the figure. The unit is in millimeters.

Step 1: Create a new file for the 3D solid model.

Select File and click the icon of New from File. Type chapter_2 as the file name. Clear the box of Use default
template. Afterwards, click OK. In the New File Options window, select mmns_part_solid. Type student as
Modeled_by and type chapter 2 as Description. Click OK. This will bring up the design window.

4‐22
 Type chapter_2 as the
file name

Clear this box

Click OK

Step 2: Create the first feature, which is a 75 x 50 x 15 mm plate with circular end.
From the Model tab, click the icon of Extrude. Specify 15 as the height of the block feature.

From the Model Tree, select the TOP datum plane as the sketching plane, and click the icon of Sketch View to
orient the sketching plane parallel to the screen.

Let us create a 2D sketch. Click the icon of Circle, and sketch a circle, as shown below. Do not modify the
dimension.

Click the icon of Delete Segment. To remove the half circle on the right side, click the half circle on the right
side, as shown. Note the diameter dimension is changed to a radius dimension. Modify the value to 25.

4‐23
Click the icon of Line to sketch 3 lines, as shown. Specify 75 as the length value.

Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the creation
of the plate feature.

Step 3: Create the second feature, which is a cylinder and the 2 dimensions are Ø50 and 25 mm.
Click the icon of Extrude. Specify 25 as the height of the cylinder.

Select the top surface of the plate feature as the sketching plane, and click the icon of Sketch View to orient the
sketching plane parallel to the screen.

4‐24
Before sketching the circle, let us click the icon of References, and add a new reference. Pick the half circle on
the left side of the plate, as shown. After defining this new reference, click Close.

New
reference

Click the icon of Circle. Sketch a circle, as shown below. There is no need to specify the diameter value because
the sketched circle matches the half circle, as shown.

Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the creation
of the cylindrical feature.

4‐25
Step 4: Create a through hole and the diameter dimension is 40 mm.
Click the icon of Hole displayed on the toolbar. Specify 40 as the diameter value and use Thru All as the depth
choice. Activate Placement > pick the axis and, while holding down the Ctrl key, pick the top surface of the
cylinder. Click the icon of Apply and Save.

Step 5: Create the required slot feature. The 2 dimensions are R10 and 30 mm.
Click the icon of Extrude displayed on the toolbar. Select Remove Material and specify Thru All as the depth
choice.

Select the top surface of the plate feature as the sketching plane, and click the icon of Sketch View to orient the
sketching plane parallel to the screen.

4‐26
Before sketching the circle, let us click the icon of References, and add a new reference. Pick the line on the right
side. After defining this new reference, click Close.

New
reference

Click the icon of Circle, and sketch a circle, as shown below.

Pick the icon of Centerline. Draw a vertical centerline through the center of the circle, as shown.

Click the icon of Delete Segment. To remove the half circle on the right side, click the half circle on the right
side, as shown. Note the diameter dimension is changed to a radius dimension. Modify the value to 10. Also
modify the distance value to 30.

4‐27
Click the icon of Line to sketch 3 lines, as shown.

Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the creation
of the cut feature.

At this time, we have successfully completed the design. Remember to save all work with the 3D solid model.
Click Save > OK.

4‐28
To prepare an engineering drawing based on the 3D solid model, we need to create a drawing file. First, we select
the icon of New. Select Drawing and type chapter_2 as the name of the file. Clear the box of Use default
template because we do not want to use the default setting for the drawing work. Afterwards, click OK.

Select the
Locate the 3D
drawing
soild model
module
file

Select paper
Clear the size
default box

In the window of New Drawing shown above, make sure that the file of the 3D solid model called chapter_2 is
shown. Otherwise, use “Browse” to locate it. Select Empty under Specify Template, and select the paper size to
be A. Afterwards, click the button OK.
This brings up the drawing screen. Click the tab of Layout. Click the icon of General. In the Select Combined
State window, click OK to accept No Combined State.

Select a location on the drawing screen as the center point for the General View. A general view appears on the
screen.

4‐29
In the pop-up Drawing View window, select FRONT > Apply > Close, the construction of the Front View is
completed.

To insert the right side view, pick the FRONT View just created so that the Front View is activated, click the icon
of Projection and make a left click at the right side of the Front View.

To insert the top view we use an alternative method. Pick the FRONT View created, right-click and hold, and then
select Insert Projection View > move the cursor to a position above the Front view. Click the left button of
mouse, and the construction of the Top view is completed.

4‐30
Click the icon of General. In the Select Combined State window, click OK to accept No Combined State.
Select a location on the drawing screen as the center point for the 3D View (click the left button of mouse). A
general view appears on the screen. In the pop-up Drawing View window, select Standard Orientation > Apply
> Close, the construction of the 3D View is completed.

Upon completing the layout, we can start adding dimensions. Click the tab of Annotation. Select
the icon of Show Model Annotations.

In the pop-up window, select the icon of Dimensions. To show the dimension of Extrude 1, click Extrude 1 listed
in the model tree. Click Accept and OK. The 3 dimensions of 25, 75 and 15 are shown. Click the box of Accept
All > OK.

Dimension

Accept all

4‐31
Follow the same procedure to add the dimensions associated with Extrude 2 , Extrude 3 and Hole 1.
To add centerlines, select the box of centerlines. Click the hole feature listed in the model tree. All the centerlines
are shown. Click Accept All > OK.

Accept all

Let us insert the format to the drawing. From the Layout tab, click the icon of Sheet Setup. In
the Sheet Setup window, use Browse to locate a custom format file, which is mcformat> Open > select
Show format > OK.

4‐32
At this time, the user has successfully completed the engineering drawing of the designed part. Select Save > OK.

4‐33
EXERCISE AND ACTIVITIES

All parts below should be made with no more than 3 extrusions.

All units are in inches or degrees.

1. 2.

3.

4‐34
4.3 Constructive Solid Geometry Concept II - Model History Tree
The part you create starts with the three datum planes that defines the space you are working in. After
that you choose a base feature. As you build your model, the features you create are listed in the Model
History Tree in the left panel. The features at the top of the tree drive the shape of the features lower in
the tree. Choices you make while building your model affect how the shape changes when you edit
dimensions.

Task: Construct an L-support fixture using CREO. The units are inches.

Step 1: Create a new file for the 3D solid model.

Select File and click the icon of New.
Type chapter_3 as the file name. Clear the box of Use default template. Afterwards, click OK. In the
New File Options window, select inbs_part_solid. Type student in Modeled_by, and type chapter 3 in
Description. Click OK. This will bring up to the design window.

Type chapter_3 as
the file name

Clear this box

Click OK

4‐35
Step 2: Create the first feature, which is a plate. The 3 dimensions are R1.25 x 3.25 x 1.75 inch.
From the Model tab, click the icon of Extrude. Specify 1.75 as the height of the block feature.

From the Model Tree, select the TOP datum plane as the sketching plane and click the icon of Sketch
View to orient the sketching plane parallel to the screen.

Let us create a 2D sketch. Click the icon of Circle, and sketch a circle, as shown below. Do not modify
the dimension.

Click the icon of Delete. To remove the half circle on the left side, click the half circle on the left side,
as shown. Note the diameter dimension is changed to a radius dimension. Modify the value to 1.25.

Click the icon of Line to sketch 3 lines, as shown. Specify 3.25 as the length value.

4‐36
Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the
creation of the plate feature.

Step 3: Create the second feature, which cuts or removes the material from the created feature.
Click the icon of Extrude. Select Cut, and specify Thru All as the depth choice.
Thru All CUT

Select the front surface of the plate feature as the sketching plane, and click the icon of Sketch View to
orient the sketching plane parallel to the screen.

Click Sketch > References, and add 3 new references, as shown. Click Close.

4‐37
 3 New references

Click the icon of Rectangle. Sketch a rectangle, as shown below. The 3 dimensions are 0.5, 1.0 and 1.0,
respectively.

Click the icon of Rectangle, again. Sketch another rectangle, as shown below. The 2 dimensions are 2.5
and 1.25, respectively.

Upon completing this sketch, click the icon of OK and click the icon of Apply and Save.

4‐38
Step 4: Create a through hole and the diameter dimension is 1.0 inch.
Click the icon of Datum Axis. Pick the cylindrical surface and an axis is created, as shown.

Click the icon of Hole. Specify 1.0 as the diameter value and use Thru All as the depth choice.
Activate Placement. It should be noted that the created axis is already selected by the system default.
While holding down the Ctrl key, pick the top surface of the plate, the hole feature is created, as shown.

Step 5: Create the required slot feature. The 2 dimensions are 1.5 and 0.75 inch.
Click the icon of Extrude displayed on the toolbar. Select Cut and specify Thru All as the depth choice.
Activate Placement > Define.

4‐39
Select the surface on the right side of the wall, as shown, as the sketching plane, and click the icon of
Sketch View to orient the sketching plane parallel to the screen.

Before sketching the circle, let us click Sketch > References, and add 2 new references. Click the
FRONT datum plane and the surface as shown. After defining these 2 new references, click Close.

New
references

Pick the icon of Centerline. Draw a horizontal centerline through the new reference or FRONT, as
shown.

4‐40
Click the icon of Rectangle, again. Sketch a rectangle, as shown below. The 2 dimensions are 1.5 and
0.75, respectively.

Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the
creation of the slot feature.

4‐41
Step 6: Create the round at the corner. The radius value is 0.25 inch.
Click the icon of Round. Specify 0.25 as the radius value and select the edge. As shown. Click the icon
of Apply and Save.

Let us save the file. Click the icon of Save > OK.

To prepare an engineering drawing, click the icon of New. A New window appears, as illustrated below.
Type chapter_3 as the name of the file. Clear the box of Use default template. Afterwards, click OK.

Select
drawing Locate the 3D
solid model
file

Clear the Select paper

default box size

In the window of New Drawing shown above, make sure that the file of the 3D solid model called
chapter_3 is shown. Otherwise, use “Browse” to locate it. Select Empty under Specify Template, and
select the paper size to be A. Afterwards, click the button of OK.
This brings up the drawing screen. Click the icon of Layout. Click the icon of General. In the Select
Combined State window, click OK to accept No Combined State.

4‐42
Select a location on the drawing screen as the center point for the General View. A general view appears
on the screen.

In the pop-up Drawing View window, select FRONT > Apply > Close, the construction of the Front
View is completed.

To insert the right side view through, pick the FRONT View just created, right-click and hold, and then
select Insert Projection View > move the cursor to the right side and click the left button of mouse, and
the construction of the right side view is completed. Follow the same procedure to create the top view,
as shown below.

Click the icon of General. In the Select Combined State window, click OK to accept No Combined
State. Select a location on the drawing screen as the center point for the 3D View (click the left button of
mouse). A general view appears on the screen. In the pop-up Drawing View window, select Standard
Orientation > Apply > Close, the construction of the 3D View is completed.
In the pop-up Drawing View window, select Standard Orientation > Apply > Close, the construction
of the 3D View is completed.

4‐43
 Upon completing the layout, we start adding dimensions. Click the icon of Annotation. Select
the icon of Show Model Annotation.

In the pop-up window, select the icon of Dimensions. To show the dimension of Extrude 1, click
Extrude 1 listed in the model tree. Click Accept and OK. The 3 dimensions of 3.25, 1.75 and R1.25 are
shown. Click the box of Accept All > OK.

Dimension

Accept all

Follow the same procedure to add the dimensions associated with Extrude 2, Extrude 3, and Hole 1 and
Round 1.
To add centerlines, select the box of centerlines. Click the hole feature listed in the model tree. All the
centerlines are shown. Click Accept All > OK.

4‐44
 Accept all

Let us insert the format to the drawing. From the Layout tab, click the icon of Sheet Setup. In
the Page Setup window, use Browse to locate the format file, which is es100_fall_2012 > Open > select
Show format > OK.

4‐45
At this time, the user has successfully completed the engineering drawing of the designed part. Select
Save > OK.

4‐46
EXERCISE AND ACTIVITIES

4‐47
4.4 Geometric Constraints
Task: Create a gasket using CREO as shown in the figure. The unit is in millimeters.

Step 1: Create a new file for the 3D solid model.

From File, click New, and select Part. Type chapter_4 as the file name. Clear the box of Use default
template. Afterwards, click OK. In the New File Options window, select mmns_part_solid. Type
student under Modeled_by, and type chapter 4 under Description. Click OK. This will bring up
the design window.

Type chapter_4 as the

file name

Clear this box

Click OK

Step 2: Create the first feature, which is a plate.

Click the icon of Extruder. Specify 5 as the depth value of extrusion.

4‐48
From the Model Tree, Select FRONT as the sketching plane. Click the icon of Sketch View to orient
the sketching plane parallel to the screen.

Click the icon of Create a geometry point. Make a left click on the horizontal axis. Specify 180 as the
distance with respect to the origin.

Click the icon of Create a geometry point. Make a left click to create the second point. The two
dimensions are 200 and 110, respectively.

Click the icon of Circle, and sketch a circle. Specify 80 as the diameter value.

4‐49
Click the icon of Line. Sketch a horizontal line. Specify 115 as the distance with respect to the
horizontal axis, as shown.

Click the icon of Circular to create a circular fillet. Specify 25 as the radius value, as shown.

Click the icon of Line. Sketch a line, starting from the first created point and tangential to the sketched
circle, as shown.

4‐50
Click the icon of Delete to remove the segments from the sketched circle and the sketched horizontal
line, as shown.

Click the icon of Line. Sketch 4 lines and add 2 dimensions of 50 and 40, as shown below.

Click the icon of Circular to create 3 circular fillets. Specify 10, 25 and 25 as the radius values,
respectively.

Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the
creation of the plate feature.
4‐51
Step 2: Create the second feature, which is a cut feature.
Click the icon of Extrude. Select Cut and use Thru All as the depth choice.

Select the front surface of the plate feature as the sketching plane, and click the icon of Sketch View to
orient the sketching plane parallel to the screen.

Click the icon of Offset. Click Loop and click the sketched curve. The system automatically selects the
entire curve. Specify -15 as the offset value.

4‐52
A new curve is created along the profile with a distance equal to 15, as shown below. Click the icon of
OK. Click the icon of Apply and Save to complete the creation of the cut feature.

At this time, we have successfully completed the feature design. Remember to save all work with the
3D solid model. You select Save from the main toolbar > OK.

Step 3: Create an engineering drawing.

To prepare an engineering drawing based on the 3D solid model, we need to create a drawing file. First,
we select the icon of New. Click Drawing. Type chapter_4 as the name of the file. Clear the
box of Use default template > OK.

4‐53
 Select
Drawing

Clear the
default box

In the window of New Drawing shown above, make sure that the file of the 3D solid model called
Chapter_4 is shown. Otherwise, use “Browse” to locate it. Select Empty under Specify
Template, and select the paper size to be A. Afterwards, click the button of OK.
This brings up the drawing screen. Click the icon of Layout. Click the icon of General. In the Select
Combined State window, click OK to accept No Combined State.

Select a location on the drawing screen as the center point for the General View. A general view appears
on the screen.

In the pop-up Drawing View window, select FRONT > Apply. To change the scale, click Scale >
Custom scale > type 0.5 > Apply > Close, the construction of the Front View is completed.

4‐54
To insert the top view through, pick the FRONT View just created, right-click and hold, and then select
Insert Projection View > move the cursor to a location above the front view, and click the left
button of mouse, and the construction of the top view is completed.

Click the icon of General. In the Select Combined State window, click OK to accept No Combined
State. Select a location on the drawing screen as the center point for the 3D View (click the left
button of mouse). A general view appears on the screen. In the pop-up Drawing View window,
select Standard Orientation > Apply > Close, the construction of the 3D View is completed.

4‐55
 Upon completing the layout, we start adding dimensions. Click the icon of Annotation. Select the
icon of Show Model Annotation.

In the pop-up window, select the icon of Dimensions. To show the dimension of Extrude 1, click
Extrude 1 listed in the model tree. Click Accept and OK. The dimensions associated with
Extrude 1 are shown. Click the box of Accept All > OK. Follow the same procedure to add the
dimension of 15 associated with Extrude 2.

Dimension

Accept all

Let us insert the format to the drawing. From the Layout tab, click the icon of Sheet Setup. In
the Page Setup window, use Browse to locate the format file, which is es100_mcformat > Open > select
Show format > OK.

4‐56
At this time, the user has successfully completed the engineering drawing of the designed part. Select
Save > OK.

4‐57
EXERCISE AND ACTIVITIES
1.

2.

4‐58
4.5 Symmetrical Features
Task: Create a U-bracket using CREO as shown in the figure. The unit is in millimeters.

Step 1: Create a new file for the 3D solid model.

From File, click the icon of New. In the New window, select Part.
Type U_bracket as the file name. Clear the box of Use default template. Afterwards, click OK. In the
New File Options window, select mmns_part_solid. Type student under Modeled_by, and U Cover
under Description. Click OK. This will bring up the design window.

Type U_bracket as the

file name

Clear this box

Click OK

Step 2: Create the first feature, which is a plate.

From the Model tab, click the icon of Extrude. Specify 30 as the height of the plate feature.

4‐59
Select the TOP datum plane as the sketching plane, and click the icon of Sketch View to orient the
sketching plane parallel to the screen.

Click the icon of Centerline and sketch a vertical centerline passing through the origin of the coordinate
system, as shown.

Create another vertical centerline, which is to the right of the sketched centerline. Click the icon of One
by One. Modify the distance dimension, which is 150, as shown below.

Click the icon of Circle and sketch a circle, as shown below.

4‐60
Click the icon of Delete. To remove the half circle on the left side, click the half circle on the left side,
as shown. Note the diameter dimension is changed to a radius dimension. Modify the dimension to 60.

Click the icon of Circle, and sketch a circle. Change the diameter value to 40, as shown below.

Pick both the sketched circle and arc while holding down the Ctrl key, click the icon of Mirror. Click
the vertical centerline. The sketched circle and are created on the left side of the vertical centerline.

Click the icon of Line to sketch 2 lines connecting the original geometry and the mirrored geometry, as
shown.

4‐61
Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the
creation of the plate feature.

Step 3: Create the second feature, which is a half cylinder.

Click the icon of Extrude. Select Symmetry and specify 150 as the depth value.
Symmetry

Select the FRONT datum plane as the sketching plane, and click the icon of Sketch View to orient the
sketching plane parallel to the screen.

Click the icon of Circle. Sketch a circle, as shown below.

4‐62
Click the icon of Delete. Remove the half circle on the lower side, as shown. Note the diameter
dimension is changed to a radius dimension. Modify the dimension to 110.

Click the icon of Line to sketch a line, which connect the 2 ends of the half circle to form a closed
sketch, as shown.

Upon completing this sketch, click the icon of Done and click the icon of Apply and Save to complete
the creation of the half cylinder feature.

Step 4: Create the third feature, which cuts or removes the material from the created feature.
Click the icon of Extrude. Select Cut, and specify Thru All as the depth choice.

Select the front surface of the half cylindrical feature as the sketch plane, and click the icon of Sketch
View to orient the sketching plane parallel to the screen.
4‐63
Pick the icon of Centerline. Sketch a vertical centerline, as shown.

Click the icon of Rectangle. Sketch a rectangle, which is symmetric about the vertical centerline, as
shown below. The 2 dimensions are 120 and 60, respectively.

Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the
creation of the cut feature.

Step 5: Create a through hole and the diameter dimension is 20 mm.

4‐64
Click the icon of Hole displayed on the toolbar. Specify 20 as the diameter value and use Thru All as
the depth choice. Activate Placement > pick the flat surface from the cut feature as the Placement.
Click Offset Reference. While holding down the Ctrl key, pick FRONT and RIGHT and select Align
for both. Click the icon of Apply and Save.

At this time, we have successfully completed the U_bracket design. Remember to save all work with the
3D solid model. You select Save from the main toolbar > OK.

Step 6: Prepare an engineering drawing

To prepare an engineering drawing based on the 3D solid model, we need to create a drawing file. First,
we select the icon of New. In the New window, click Drawing. Type U_bracket as the name of the file.
Clear the box of Use default template because we do not want to use the default setting for the drawing
work. Afterwards, click OK.

Select
Drawing

Clear the
default box

4‐65
In the window of New Drawing shown above, make sure that the file of the 3D solid model called
U_BRACKET is shown. Otherwise, use “Browse” to locate it. Select Empty under Specify Template,
and select the paper size to be A. Afterwards, click the button of OK.
This brings up the drawing screen. Click the icon of Layout. Click the icon of General. In the Select
Combined State window, click OK to accept No Combined State.

Select a location on the drawing screen as the center point for the General View. A general view appears
on the screen.

In the pop-up Drawing View window, select FRONT > Apply. To change the scale, click Scale >
Custom scale > type 0.25 > Apply > Close, the construction of the Front View is completed.

To insert the right side view through, pick the FRONT View just created, right-click and hold, and then
select Insert Projection View > move the cursor to the right side and click the left button of mouse, and
the construction of the right side view is completed. Follow the same procedure to create the top view,
as shown below.

4‐66
Click the icon of General. In the Select Combined State window, click OK to accept No Combined
State. Select a location on the drawing screen as the center point for the 3D View (click the left button of
mouse). A general view appears on the screen. In the pop-up Drawing View window, select Standard
Orientation > Apply > Close, the construction of the 3D View is completed.

Upon completing the layout, we start adding dimensions. Click the icon of Annotation. Select
the icon of Show Model Annotation.

4‐67
In the pop-up window, select the icon of Dimensions. To show the dimension of Extrude 1, click
Extrude 1 listed in the model tree. Click Accept and OK. The dimensions associated with Extrude 1 are
shown. Click the box of Accept All > OK. Follow the same procedure to add the dimensions associated
with Extrude 2, Extrude 3 and Hole.

Dimension

Accept all

To add centerlines, select the box of centerlines. Click the hole feature listed in the model tree. All the
centerlines are shown. Click Accept All > OK.

Accept all

4‐68
 How do you add the dimension defining the distance between the two centers of the 2 circles?
Click Dimension-New References from the top menu. In the pop up window, select Center. While
holding down the Ctrl key, pick the 2 circles.

Pick these 2 circles

Click the middle button of mouse to place the dimension > choose Horizontal > OK.

Users may use the icon of Pick to move the dimensions to appropriate locations, thus completing the
preparation of an engineering drawing.
Let us insert the format to the drawing. From the Layout tab, click the icon of Sheet Setup. In
the Page Setup window, use Browse to locate the format file, which is es100_mcformat > Open > select
Show format > OK.

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At this time the user has successfully completed the engineering drawing of the designed part. Select
Save from the main toolbar > OK.

Step 7: Add a section view to the front projection.

Users may notice that a section view is added to show the 3 hole features. Note that the 3 hole
features are invisible in the FRONT view before creating a section view.. In order to have a visible
version of the hole features, we have added a section view. How did it? The following procedure is to
modify the FRONT view to a full section view.
First, let us enable the display of datum planes. Click the icon of Datum Display Filter and
check the box of Plane Display and Repaint.

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 Now click the FRONT view through a left click of mouse. Afterwards, right click and hold,
select Properties.

In the Drawing View window, select Sections and 2D cross-section. Click the icon of Add (plus
sign) to add cross-section. In the pop up window, accept Planar and Single > Done.

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 The software system is asking the user to enter a name for cross-section. Type A as the name for
cross-section and press the Enter key. On the screen display, select the FRONT datum plane from the
Top View > click the box of Apply, a cross-section is added to the Front view.

Pick FRONT DATUM PLANE

To add an arrow indicating the direction of the cross-section view, activate Arrow Display from
the Drawing View window > click the Top view > Apply and two arrows marked as A appear together
with SECTION A-A > Close.

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At this time, the user has successfully added a section view to the front view of the designed U_bracket
part. Select Save from the main toolbar > OK.

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EXERCISE AND ACTIVITIES

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4.6 Datum Features
Task: Create a Rod-guide using CREO as shown in the figure. The unit is in inches.

Step 1: Create a new file for the 3D solid model.

From File, select the icon of New. In the New window, click Part.
Type rod_guide as the file name. Clear the box of Use default template. Afterwards, click OK. In the
New File Options window, select inlbs_part_solid. Type student under Modeled_by, and type rod guide
under Description. Click OK. This will bring up the design window.

Clear this box

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Step 2: Create the first feature, which is a plate.
Click the icon of Extrude displayed on the toolbar. Specify o.75 as the height of the plate feature.
Activate Placement > Define.

Select the TOP datum plane as sketching plane and click the icon of Sketch View to orient the sketching
plane parallel to the screen.

Click the icon of Center Rectangle and sketch a rectangle symmetric about the origin. Click the icon of
One by One. Modify the 2 dimensions to 3 and 2, respectively.

Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the
creation of the plate feature.

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Step 3: Create the second feature, which is a round feature.
Click the icon of Round. Specify 0.25 as the radius value. Pick the 4 edges at the 4corners. Click the
icon of Apply and Save.

Step 4: Create the datum plane at an angle equal to 30 degrees with respect to the FRONT datum plane.
Click the icon of Datum Axis. While holding down the Ctrl key, pick the FRONT and RIGHT datum
planes. Click OK.

Click the icon of Datum Plane. Pick the created axis and the FRONT datum plane while holding down
the Ctrl key. Type 30 and click OK.

Step 5: Create the third feature, which is a plate.

Click the icon of Extrude. Select Symmetry and specify 1.0 as the extrusion value on both sides of the
sketching plane.

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 Symmetry

From the Model Tree, select the DTM1 datum plane as the sketching plane, and click the icon of Sketch
View to orient the sketching plane parallel to the screen.

Click the icon of References, and add 2 new references. Click the surface on the top of the plate, as
shown. Pick the vertical axis, as shown. click Close.

New
references

Click the icon of Centerline. Sketch a vertical centerline, as shown.

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Click the icon of Circle. Sketch a circle, as shown below. Modify the position dimension to 0.75.

Click the icon of Centerline. Draw the horizontal centerline through the center, as shown.

Click the icon of Delete. Remove the half circle on the lower side, as shown. A radius dimension is
shown. Modify the radius value to 0.75.

Click the icon of Line to sketch 3 lines, which connect the 2 ends of the half circle to form a closed
sketch, as shown.

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Click the icon of Circle. Sketch a circle, as shown below. The diameter value is 0.75.

Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the
creation of the half cylinder feature.

Step 6: Create the third feature, which cuts or removes the material from the created feature.
Click the icon of Extrude. Select Cut, and specify Thru All as the depth choice.

Select the front surface of the angle plate as the sketch plane, and accept the TOP datum plane as the
default reference to orient the sketch plane, as illustrated below:

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lick References, and add 3 new references. Click the surface on the right side of the plate, as shown.
Pick the vertical axis, and the top surface of the plate, as shown. Click Close.

New
references

Click the icon of Centerline. Sketch a vertical centerline, as shown.

Click the icon of Rectangle. Sketch a rectangle, all the 3 dimensions are equal to 0.25, as shown.

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Pick this rectangle and click the icon of Mirror. Afterwards, click the vertical centerline to obtain the
rectangle sketch on the left side, as shown.

Upon completing this sketch, click the icon of Done and click the icon of Apply and Save to complete
the creation of the cut feature.

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Step 7: Create a through hole and the diameter dimension is 0.25 inch.
Click the icon of Hole displayed on the toolbar. Specify 0.25 as the diameter value and use Up to Next
as the depth choice. Activate Placement > pick the axis and, while holding down the Ctrl key, pick the
upper half cylindrical surface. Click the icon of Apply and Save.

Step 8: Create 4 holes on the base plate. The diameter dimension is 0.25 inch.
Let us first create an axis at the corner, as shown. Click the icon of Datum Axis. Pick the round surface
at the corner > OK. An axis is created.

Click the icon of Hole displayed on the toolbar. Specify 0.25 as the diameter value and use Thru All as
the depth choice. Activate Placement > pick the axis and, while holding down the Ctrl key, pick the top
surface of the plate. Click the icon of Apply and Save.

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Now let us use MIRROR to create the other 3 holes. In the model tree, highlight Hole 2. Click the icon
of Mirror Tool. Pick the RIGHT datum plane and click the icon of Apply and Save. A hole feature is
created through MIRROR, as shown.

Repeat this process two more times (use FRONT and RIGHT, respective) to obtain the other 2 holes, as
shown.

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At this time, we have successfully completed the angle feature design. Remember to save all work with
the 3D solid model. You select Save from the main toolbar > OK.

Step 9: Prepare an engineering drawing

To prepare an engineering drawing based on the 3D solid model, we need to create a drawing file. First,
we select the icon of New. Select Drawing. Type rod_guide as the file name. Clear the box of Use
default template because we do not want to use the default setting for the drawing work. Afterwards,
click OK.

Select
drawing Locate the 3D
solid model
file

Clear the
default box Select paper
size

In the window of New Drawing shown above, make sure that the file of the 3D solid model called
rod_guide is shown. Otherwise, use “Browse” to locate it. Select Empty under Specify Template, and
select the paper size to be A. Afterwards, click the button of OK.
This brings up the drawing screen. Click the icon of Layout. Click the icon of General. In the Select
Combined State window, click OK to accept No Combined State.

Select a location on the drawing screen as the center point for the General View. A general view appears
on the screen.

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In the pop-up Drawing View window, select TOP > Apply. To change the scale, click Scale > Custom
scale > type 0.75 > Apply > Close, the construction of the Front View is completed.

To insert an auxiliary view, click the icon of Auxiliary from the Layout tab. From the TOP projection,
left-click the edge of the inclined rectangle, and drag down to the position as shown. Note that the
auxiliary view is aligned to the inclined rectangle in the TOP projection view.

Step 10: Add a section view to the auxiliary view.

First, let us enable the display of datum planes. Click the icon of Datum Display Filter and
check the box of Plane Display and Repaint.

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 Now activate the auxiliary view by left clicking the mouse. Afterwards, right click and hold,
select Properties.

In the Drawing View window, select Sections and 2D cross-section. Click the icon of Add (plus
sign) to add cross-section. In the pop up window, accept Planar and Single > Done.

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 The software system is asking the user to enter a name for cross-section. Type A as the name for
cross-section and press the Enter key. On the screen display, select the DTM1 datum plane from the
Top View > click the box of Apply, a cross-section is added to the auxiliary view.

Pick DTM1 DATUM PLANE

To add an arrow indicating the direction of the cross-section view, activate Arrow Display from
the Drawing View window > click the Top view > Apply and two arrows marked as A appear together
with SECTION A-A > Close.

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 Upon completing the layout, we start adding dimensions. Click the icon of Annotation. Select
the icon of Show Model Annotation.

In the pop-up window, select the icon of Dimensions. To show the dimension of Extrude 1, click
Extrude 1 listed in the model tree. Click Accept and OK. The dimensions associated with Extrude 1 are
shown. Click the box of Accept All > OK. Follow the same procedure to add the dimensions associated
with Round 1, Extrude 2, Extrude 3, Hole 1 and Hole 2.

Dimension

Accept all

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To add centerlines, select the box of centerlines. Click the hole features listed in the model tree. All the
centerlines are shown. Click Accept All > OK.

Accept all

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 Let us insert the format to the drawing. From the Layout tab, click the icon of Sheet Setup. In
the Page Setup window, use Browse to locate the format file, which is es100_fall_2012 > Open > select
Show format > OK.

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At this time, the user has successfully completed the engineering drawing of the designed part. Select
Save from the main toolbar > OK.

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EXERCISE AND ACTIVITIES
1.

2.

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4.7 Axial Symmetrical Features
Task: Create a wheel using CREO as shown in the figure. The unit is in inches.

Step 1: Create a new file for the 3D solid model.

From File, click the icon of New. In the New window, select the Part module.
Type wheel as the file name. Clear the box of Use default template. Afterwards, click OK. In the New File Options
window, select inlbs_part_solid. Type wheel under Description and type student under Modeled_by. Click OK.
This will bring up the design window.

Clear this box

Step 2: Create the first feature, which is a circular plate. From the Model tab, click the icon of Revolve.

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From the Model Tree, select the FRONT datum plane as the sketching plane, and click the icon of Sketch View to
orient the sketching plane parallel to the screen.

Right click and pick Axis of Revolution from the pop up window, and sketch a horizontal centerline.

Click the icon of Line, and sketch a horizontal line, as shown. Modify the diameter dimension to 10 and the
length dimension to 1.25.

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Click the icon of Line, and make the following sketch. There are 2 diameter dimensions. Modify them to 2 and
3.5, respectively. Modify the width dimension to 1.75.

Upon completing this sketch, pick the icon of OK. Click the icon of Apply and Save.

Step 3: Use MIRROR to obtain the feature on the other side of the RIGHT datum plane.
From the Model Tree, highlight Revolve 1. Click the icon of Mirror. Pick the RIGHT datum plane and click the
icon of Apply and Save.

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Step 4: Create the second feature, which is a revolved feature with CUT (removal).
Click the icon of Revolve displayed on the toolbar. Select Remove Material.

From the Model Tree, select the Front datum plane as the sketching plane and click the icon of Sketch View to
orient the sketching plane parallel to the screen.

Right click and pick Axis of Revolution from the pop up window, and sketch a horizontal centerline.

Click the icon of References, and add 2 new references, as shown. click Close after defining them.
Click the icon of Line, and prepare the following sketch. The 2 diameter dimensions are 8.5 and 9.0. The width
dimension is 0.88.

New
reference

New
reference

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Click the icon of Centerline and sketch a vertical centerline.

Pick the 4 lines from the sketch while holding down the Ctrl key, click the icon of Mirror. Click the vertical
centerline to obtain the identical sketch on the other side.

Upon completing this sketch, pick the icon of OK. Click the icon of Apply and Save.

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Click the icon of Revolve displayed on the toolbar. Select Remove Material.

From the Model Tree, select the Front datum plane as the sketching plane and click the icon of Sketch View to
orient the sketching plane parallel to the screen.

Right click and pick Axis of Revolution from the pop up window, and sketch a horizontal centerline.

Click the icon of References, and add 3 new references, as shown. Click Close after defining.

New
reference

New
references

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Click the icon of Line, and prepare the following sketch. Modify the diameter dimension to 3.0.

Click the icon of Centerline and sketch a vertical centerline.

Pick the 3 lines from the sketch while holding down the Ctrl key, click the icon of Mirror. Click the vertical
centerline to obtain the identical sketch on the other side.

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Upon completing this sketch, pick the icon of OK. Click the icon of Apply and Save.

Step 5: Create a through hole with diameter of 1.5 inch.

Click the icon of Extrude. Select Cut and Thru All.

Select the inner flat surface as the sketching plane, and click the icon of Sketch View to orient the sketching plane
parallel to the screen.

Click the icon of Centerline. Sketch a centerline at an angle equal to 30 degrees, as shown.

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Click the icon of Construction Mode and click the icon of Circle. Sketch a circle, as shown below. The diameter
value is 6 or the radius value is 3.

Click the icon of Circle. Sketch a circle, as shown below. The diameter value is 1.5.

Upon completing this sketch, click the icon of OK and click the icon of Apply and Save to complete the creation
of the hole feature.

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Step 6: Create the other 5 holes through Pattern.
In the Model Tree, highlight Extrude 1. Right-click and hold to pick Pattern.

Select Axis as the pattern method. Pick the axis displayed on screen. Specify 6 as the number of holes including
the current one and specify 360 as angular extent of the pattern and 60 as the incremental value in angle. Click the
icon of Apply and Save to complete the pattern process.

At this time, we have successfully completed the wheel design. Remember to save all work with the 3D solid
model. You select Save from the main toolbar > OK.

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Step 7: Prepare an engineering drawing
To prepare an engineering drawing based on the 3D solid model, we need to create a drawing file. First, we select
the icon of New, click Drawing. Type wheel as the name of the file. Clear the box of Use default template
because we do not want to use the default setting for the drawing work. Afterwards, click OK.

In the window of New Drawing shown above, make sure that the file of the 3D solid model called wheel is shown.
Otherwise, use “Browse” to locate it. Select Empty under Specify Template, and select the paper size to be A.
Afterwards, click the button of OK.
This brings up the drawing screen. Click the icon of Layout. Click the icon of General. In the Select Combined
State window, click OK to accept No Combined State.

Select a location on the drawing screen as the center point for the General View. A general view appears on the
screen.

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In the pop-up Drawing View window, select FRONT > Apply. To change the scale, click Scale > Custom scale
> type 0.25 > Apply > Close, the construction of the Front View is completed.

To insert the right side view through, pick the FRONT View just created, right-click and hold, and then select
Insert Projection View > move the cursor to the right side and click the left button of mouse, and the construction
of the right side view is completed.

Step 10: Add a section view to the auxiliary view.

First, let us enable the display of datum planes. Click the icon of Datum Display Filter and check the box
of Plane Display and Repaint.

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 Now activate the front view through a left click of mouse. Afterwards, right click and hold, select
Properties.

In the Drawing View window, select Sections and 2D cross-section. Click the icon of Add (plus sign) to
add cross-section. In the pop up window, accept Planar and Single > Done.

The software system is asking the user to enter a name for cross-section. Type A as the name for cross-
section and press the Enter key. On the screen display, select the FRONT datum plane from the right-sided view
> click the box of Apply, a cross-section is added to the front view.

Pick FRONT DATUM PLANE

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 To add an arrow indicating the direction of the cross-section view, activate Arrow Display from the
Drawing View window > click the Right Side view > Apply and two arrows marked as A appear together with
SECTION A-A > Close.

Change the View Display property of the both views to No Hidden. Upon completing the layout, we start
adding dimensions. Click the tab of Annotation. Select the icon of Show Model Annotate.

In the pop-up window, select the icon of Dimensions. In the Show Model Annotation window, change All to
All Driving Dimensions. Click the Front view. Four dimensions are shown. Click Select All and Apply. Repeat
this procedure and pick the right-sided view to show the required dimensions.

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To add centerlines, select the box of centerlines. In the Show Model Annotation window, change All to Axes. In
the Model Tree, click WHEEL.PRT. All axes are shown on both Front and Right-sided Views.

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 Let us insert the format to the drawing. From the Layout tab, click the icon of Sheet Setup. In
the Page Setup window, use Browse to locate the format file, which is es100_mcformat > Open > select
Show Format > OK.

4‐109
At this time, the user has successfully completed the engineering drawing of the wheel component. Select Save
from the main toolbar > OK.

4‐110
EXERCISE AND ACTIVITIES
1.

2.

4‐111
4.8 Three-Dimensional Construction Tools
Task: Create a part of hair dryer housing using CREO as shown in the figure. The unit is in inches.

Step 1: Create a new file for the 3D solid model.

From File, click the icon of New. In the New
window, select the Part module.

Type hairdryer as the file name. Clear the box of Use default template. Afterwards, click OK. In
the New File Options window, select inlbs_part_solid. Type student under Modeled_by, and hair dryer
under Description. Click OK. This will bring up the design window.

Type hairdryer as the

file name

Clear this box

Click OK

Step 2: Create the first feature, which is a cylindrical feature.

From the Model tab, click the icon of Revolve.

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From the Model Tree, select the FRONT datum plane as the sketching plane and click the icon of
Sketch View to orient the sketching plane parallel to the screen.

Right click and pick Axis of Revolution from the pop up window, and sketch a horizontal centerline.

Click the icon of Circle and sketch a circle, as shown.

Click the icon of Delete and delete part of the circle. Change the radius dimension to 2.

Click the icon of Line, and sketch a horizontal line, as shown.

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Click the icon of Delete and delete part of the arc, as shown.

Click the icon of Line, and sketch 2 lines to form a closed sketch, as shown.

Upon completing this sketch, pick the icon of OK. Click the icon of Apply and Save to complete
the creation of the cylindrical feature, as shown below:

Step 3: Create the air channel using Extrude.

Click the icon of Extrude. Specify 5.5 as the distance value of extrusion.
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From the Model Tree, select the RIGHT datum plane as the sketching plane. Click the icon of Sketch
View to orient the sketching plane parallel to the screen.

Click the icon of Circle and sketch a circle, as shown.

Click the icon of Delete and delete the lower portion of the circle, as shown.

Click the icon of Line, and sketch a line to form a closed sketch, as shown. Change the 2 dimension
values to 0.75 and 1.125, respectively.

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 Upon completing this sketch, pick the icon of OK. Change the direction of the extrusion, as
shown. Pick the icon of Apply and Save to complete the creation of the air channel feature.

Add round features. Click the icon of Round. Specify 0.25 as the radius value.

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Step 4: Create the handle using Blend.
From the top menu, expand Shapes and click Blend. The window for picking a datum plane as
the sketching plane is on display.

Click the box called define. Pick FRONT as the sketching plan > click Sketch to accept the direction
for blend creation. Click Sketch View.

Sketch a vertical centerline.

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Click the icon of Rectangle, and select Corner Rectangle. Sketch a rectangle and the 2 dimensions are
1.50 and 0.5 respectively. Pay attention to the location of the starting point. Afterwards, click OK, thus
completing the first section sketch.

Starting
point

Now let us work on the second section. Click Sections and specify 2.5 as the distance between the first
section and the second section. Click the box called Sketch.

Starting
point

Section 2 is also a rectangle. The two dimensions are 1.40 and 0.5 respectively. Pay attention to
the location of the starting point. Users may need to use the Coincident constraint to align the right side
of the sketched rectangle with the right side of the rectangle in Section 1. When completing this sketch,
click OK.

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 Starting
point

Now let us work on the third section. Click Sections and click Insert. Afterwards specify 1.0 as the
distance between the second section and the third section. Click the box called Sketch.

Starting
point

Section 3 is also a rectangle. The two dimensions are 1.20 and 0.5 respectively. Pay attention to
the location of the starting point. Users may need to use the Coincident constraint to align the right side
of the sketched rectangle with the right side of the rectangle in Section 1. When completing this sketch,
click OK.

Starting
point

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Now let us work on the 4th section. Click Sections and click Insert. Afterwards specify 0.75 as the
distance between the third section and the 4th section. Click the box called Sketch.

Section 4 is also a rectangle. The two dimensions are 1.35 and 0.5 respectively. Pay attention to
the location of the starting point. Users may need to use the Coincident constraint to align the right side
of the sketched rectangle with the right side of the rectangle in Section 1. When completing this sketch,
click OK.

Starting
point

Upon completion of the section sketch, click the icon of OK. Click the box called Options and select
Straight. Click the check mark to apply and save the created blend feature, which is the handle, as
shown.

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Step 5: Add round features.
Click the icon of Round. Specify 0.25 as the radius value. Click the icon of Apply and Save.

Step 6: Use Shell to create a thin wall structure.

Click the icon of Shell. Specify 0.125 as the thickness value. Pick the 2 surfaces, as shown.

Step 7: Use Extrude to create a rectangular cut to be used as a pattern leader

Click the icon of Extrude. Select Cut and specify 0.13 as the depth of cut. Activate Placement >
Define.

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Select the top surface as the sketching plane, and click the icon of Sketch View to orient the sketching
plane parallel to the screen.

Click the icon of Rectangle. Sketch a rectangle and the 2 dimensions are 0.125 and 0.5 respectively. Pay
attention to the 2 position dimensions, which are 0.95 and 1.20, respectively. Click the icon of OK and
the icon of Apply and Save.

Step 8: Use pattern to generate a set of rectangular cuts.

In the model tree, highlight Extrude 2. Right click and pick Pattern.

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Pick the dimension of 1.20 as Direction 1. Specify -0.25 as the incremental value and specify 11 as the
total number, including the current one.

Pick the dimension of 0.95 as Direction 2. Specify -0.60 as the incremental value and specify 5 as the
total number, including the current one. Click the icon of Apply and Save.

Step 9: Create a sweep feature for assembly.

From the Model tab, click the icon of Sweep. Select Cut.

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To define the sweep trajectory, click References. Pick the straight edge. Click the arrow to flip the
sweep direction.

Click Detail. While holding down the Ctrl key, pick the tangential curve chain, shown. Click OK when
picking all segments.

4-124
Click the icon of Sketch. Click the icon of Rectangle and sketch a rectangle. The 2 dimensions are
0.125 and 0.0625. Click OK and click the icon of Apply and Save.

At the time we have successfully completed the hair dryer design. Remember to save all work with the
3D solid model. You select Save from the main toolbar > OK.

Step 10: Prepare an engineering drawing

From File, click New, click Drawing. Type hair_dryer as the name of the file. Clear the box of Use
default template because we do not want to use the default setting for the drawing work. Afterwards,
click OK.

4-125
In the window of New Drawing shown above, make sure that the file of the 3D solid model called
hair_dryer.prt is shown. Otherwise, use “Browse” to locate it. Select Empty under Specify Template,
and select the paper size to be A. Afterwards, click the button of OK.
This brings up the drawing screen. Click the icon of Layout. Click the icon of General. In the Select
Combined State window, click OK to accept No Combined State.

Select a location on the drawing screen as the center point for the General View. A general view appears
on the screen.

In the pop-up Drawing View window, select FRONT > Apply. To change the scale, click Scale >
Custom scale > type 0.40 > Apply > Close, the construction of the Front View is completed.

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To insert the right side view through, pick the FRONT View just created, right-click and hold, and then
select Insert Projection View > move the cursor to the right side and click the left button of mouse, and
the construction of the right side view is completed.

Step 10: Add a section view to the auxiliary view.

First, let us enable the display of datum planes. Click the icon of Datum Display Filter and check the
box of Plane Display and Repaint.

Now activate the right-sided view through a left click of mouse. Afterwards, right click and hold, select
Properties.

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In the Drawing View window, select Sections and 2D cross-section. Click the icon of Add (plus sign) to
add cross-section. In the pop up window, accept Planar and Single > Done.

The software system is asking the user to enter a name for cross-section. Type A as the name for cross-
section and press the Enter key. On the screen display, select the RIGHT datum plane from the right-
sided view > click the box of Apply, a cross-section is added to the front view.

Pick RIGHT DATUM PLANE

To add an arrow indicating the direction of the cross-section view, activate Arrow Display from the
Drawing View window > click the FRONT view > Apply and two arrows marked as A appear together
with SECTION A-A > Close.
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 Upon completing the layout, we start adding dimensions. Click the icon of Annotation. Select
the icon of Show Model Annotation.

In the pop-up window, select the icon of Dimensions. In the Show Model Annotation window, change
All to All Driving Dimensions. Users may also use another method to add dimensions. Just click the
icon of Click the icon of Dimension.

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To add centerlines, select the box of centerlines. In the Show Model Annotation window, change All to
Axes. In the Model Tree, click HAIR_DRYER.PRT. All axes are shown on both Front and Right-sided
Views.

Let us insert the format to the drawing. From the Layout tab, click the icon of Sheet Setup. In
the Page Setup window, use Browse to locate the format file, which is es100_fall_2012 > Open > select
Show Format > OK.

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At this time the user has successfully completed the engineering drawing of the HAIR DRYER
component. Select Save from the main toolbar > OK.

4-131
4.9 Design to Manufacture
The basic frame for your design project will use a method called “Development”. This method takes flat
materials, cuts out a pattern, then folds and attaches edges of the pattern to make the desired 3-D shape.
Some examples of Development are cardboard boxes, most clothes, and sheet metal air ducts. The flat
pattern must incorporate the flaps, seams, or flanges needed to attach one edge of the material to another
when it's folded into shape. Some things that must be taken into account are: the thickness of the
material when folding or bending it; bias or patterns (e.g.,corrugated cardboard or printed designs);
material properties like how the material bends or stretches.

Making any part in modeling requires that you think about what you want to end up with, how it will be
used, how it will be manufactured, and how your model will be used in the future. These are some of the
considerations that go into “Design Intent”. Choosing your base feature or First-Wall is the first step
implementing your Design Intent.

The SHEETMETAL subtype will assume that all

physical features of the part have the same thickness.

 In CREO, a Development PART is made using

the SHEETMETAL Sub-type.

 Change the name and use the default template.

Notice that the menu ribbon is different than with a

SOLID part.

Before starting the part, change the material.

 Select the File tab > Prepare > Model Properties

 Change the Material to al6061.mtl by selecting it and clicking on the right triple arrow. Select OK.
 In Model Properties, change the Thickness to 0.03 (be sure that the units are inches). Select
Regenerate.

The first or base feature in SHEETMETAL is called the “FIRST WALL”.

4-132
 Select Planar from the Model ribbon.

 Select References > Define.

 Select the TOP reference plane as the sketching plane and the RIGHT reference plane to face the
right of your screen. Select Sketch.

 Create the sketch below in the upper right quadrant from the reference lines (the Right and Front
planes define the reference lines). Note that the ends of the lines with the red dots are attached to
the reference lines. Be sure that the constraints match.

4-133
 Select the Centerline tool and click two places on the vertical (Right) reference line.

 Select all of the geometry that you made (use Crtl-Alt-A or the Select tool and drag a window over
all of the geometry).

 Select the Mirror Tool and click on the centerline that you just made.

 Repeat these steps with the centerline on the horizontal (Front) reference line.

 Select the checkmark to finish the sketch. Note that the thickness is already set (rounded up).

 Select the checkmark to finish the First-Wall.

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The next feature is an extrude that you will cut into the First-Wall. Instead of sketching the area, you
will import the finished sketch from a file. You must first download the sketch file “motorcutout.sec”
and put it your working directory.

 Select Extrude > Placement > Define and use the top of the First-Wall as the sketching plane and the
Right reference plane to point to the right of your screen.

 Select File System from the Sketch ribbon. Find the file motorcutout.sec that you downloaded and
select Open.

 Select a location somewhere on the upper part of the First-Wall.

 Make the angle to 0 and the scale to 1.0000. Move the sketch up so that it fits in the top flange of
the First-Wall. Finally, select the checkmark to set the sketch.

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 Select the references tool in the Sketch ribbon so we can properly locate the sketch. Select the top,
right, and bottom edges of the First-Wall as additional references.

 Delete the reference line that the imported sketch created (it is probably off the top of the screen).

 Insert a dimension from the top reference line to the top of the motorcutout sketch and change the
value to 0.1875 or 3/16.

 Import the motorcutout sketch two more times so that you have the arrangement below.

 Checkmark the sketch. Change the extrusion to cutout the sketch (you may need to flip the extrude
direction). Checkmark the extrude.

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 Change the name of the extrude to MOTOR_CUTOUT.

 Cut a ½ inch hole in the center of the First-Wall and rename it WIRE_HOLE.

Now the right and left flanges need to bent into place. When done all of the edges should be aligned.

 Select the Bend tool from the Model ribbon.

 The bend line for the left and right flanges will be sketched to align with the flaps. To do this select
the top surface of the First-Wall, the Bend Line tab, then Sketch.

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 In the sketcher choose the far right edge as a reference and the two short diagonal edges (or surfaces.

 Place a single, vertical line from one diagonal reference to the other as shown below. Insert the
dimension from the right edge to the line and make it 1.25.

 Select the checkmark to finish sketching the bend line.

 Select the first then second Flip-Direction buttons until you have just the flange rotated up 90o.

4-138
 Try some of the other buttons to see what they do. Set the buttons to the ones shown above and
select the checkmark.

 Repeat this for the left flange.

The next step is to bend the flaps that we will use to connect the flanges.

 Select the Bend tool and the top surface of the First-Wall.

 Select the top surface of the First-Wall, the Bend Line tab, and Sketch.

 Select the references, delete RIGHT and FRONT, and then select the top edge, the diagonal edge,
and the outside of the right flange that you just made.

 Sketch a line from the top edge to the diagonal edge, along the reference that runs outside of the
right flange.

 Checkmark the sketcher.

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 Make sure the bend around the inside edge and the second flip direction are selected.

 See what happens when you select different buttons on the Bend ribbon. Note that you can control
many other options from the tabs.

 Checkmark the Bend and rename the bend FLAP _1.

 Repeat this for the other three “Flaps”.

If you look at the TOP view, you will notice that the flaps line up just outside to the flanges.

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The last step is to bend the top and bottom flanges.

 Select the Bend tool and the top surface of the First-Wall.

 Drag the little green squares to the vertex on the top corner of the diagonal cutouts on both side of
the top flange.

 Drag the other green square to the diagonal edge below the vertex you just selected.

 Drag the new green box to the far right edge of the top flange.

 The First-Wall will flip around this “Bend line”. Select the first and second Flip-direction arrows in
the Bend Ribbon.

 Change the dimensions both to 1.25.

 Checkmark to finish the bend and change the name to TOP_BEND.

 Repeat this on the bottom flange.

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 Finally the developed pattern can be made. Select the Flat Pattern tool in the Model ribbon.

 CREO will layout the flat pattern that can be cut out and bent into the shape you made above.

Now, suppress the flat pattern and “drill” a 1/8 inch hole in the middle of each FLAP through the
RIGHT_BEND and LEFT_BEND.

These holes will be used to rivet the sides of the box together.

You can also “drill” holes to mount the microcontroller.

RESUME the Flat Pattern and the hole will be in the correct location to be cut out.

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 Chapter 5
Engineering Analysis
Chapter 5 – Engineering Analysis
There is lots of software that can be used for engineering analysis depending on what types of
analyses. The finite element software such as ANSYS, CREO, AUTOCAD could be used for
calculations of engineering simulation; MATLAB and Microsoft EXCEL could be used for numerical
calculations and graphical presentation.

Microsoft Excel, a spreadsheet program, is an extremely powerful tool in engineering analysis

because of its popularity and ease of use. Today, almost every personal computer has Microsoft Office
Suite that makes EXCEL so popular. EXCEL program has not only used in business but widely used in
engineering data analysis and presentation. It offers a number of features that have contributed to their
immense popularity. These features are:

 User friendliness
 Integrating graphics and computational routines
 Providing an organized record of your computation
 Automatic recalculation and updating when a particular data entry is modified
 Providing data analysis capabilities such as plotting and curve fitting
So far, spreadsheet software has been used by engineers primarily for data analysis involving
multicolumn displays similar to those used in financial calculations.

5.1 EXCEL Basic

When EXCEL program starts, the following default window layout will show up:

5‐1
 Name Box Formula Bar Ribbon
Active Cell

Worksheet

Workbook - a file created by EXCEL. It has .xlsx file extension.

Worksheet - each page in a workbook. The name of a page is on the tab under the lower left corner. You
can double click the left button of mouse and type the new name.

Ribbon - a new feature in Microsoft Office 2007 or later version. It is intended to provide convenient
access to commonly used commands. Ribbon has several tabs (Home, Insert, Page Layout, ...) which
contains group of commands for a single task. Each tab has several groups and each group has several
command/buttons. For example, under Home tab it has groups as Clipboard, Font, Alignment, etc.
Under Font group, it has command/button as font, size, border, special effect, etc.

Cell - a worksheet contains many cells. Cell is an essential area that user can type the data and save it.
When the cell is picked by a mouse it becomes an active cell and has a handle on the lower right
corner of that cell. Each cell has its own unique cell address.

Name Box - it shows the name of a cell. If there is no name defined, it will show cell address. Cell
address is defined by its column (A, B, C, ...) and its row (1, 2, 3, ...). For example, B3 means the
active cell is on the column B and row 3.

Formula Bar - it allows user to type in the data or formula on the active cell. Each cell can contains one
of the three:

1) Number - example: 5, 1.2, 3.5e4, ...

2) Text - anything not a number. Example: alex45, 3.5+6.7, position,...

3) Formula - it always starts with an "=" sign and contains a calculation formula. example: =A11+4,
=B3+B7, =$C$6+A11, =COS(B2)+D7, etc
5‐2
5.2 Construction of Table
On a table, each cell can contain its own information either a data number or a text string. These
information can be copied to other cells using copy-paste technique or “autofill” technique (discuss in the
example). However, the most important feature on EXCEL in engineering application is the formula.
Using formula in a cell is simply like writing a programming statement.

For example, if your active cell is on C11 and you type =A11+B11 on the formula bar, the C11
will shows the result of sum of number on cell A11 and number on cell B11. If you change the number
on A11, the result on C11 will re-do the calculation and automatic update without additional step.
However, when you copy the formula from one cell to another cell, you have to pay attention to the cell
address.

Two types of cell address can be used on a formula but they will return different results. One is
relative address (like A11, B11, etc) and the other one is absolute address (like $A$11, $B$11, etc). Let's
use examples to explain the differences.

copy C1 to C2

copy C1 to C2

You can see when you just type the formula into cell C1 there is no difference on the results on
the cell C1 no matter relative or absolute cell address used. However, when you copy the C1 formula to
cell C2, the result on C2 is different. In the first case, relative address A1+B1 used and after copy it down,
the row number will increase relative to the original location. So when we copy it down one cell, the
copied formula will increase its row number by 1. In the second case, the address $A$1+B1 used and
after copy it down, only the B1 will increase its row number to B2 but the $A$1 will keep the same. In
other word, when you use absolute address in the formula and copy it to other cells, the addresses will
remain the same but if you use relative address and after copy the formula to other cells, their addresses
will change depending on the relative locations of your original location and new copied locations.

5‐3
 So how do we know which address to use in engineering applications? The general rule is if you
are setting a formula, use relative address for variables and use absolute address for the constants.

There are many math functions already built-in in the EXCEL program to help users to get the
calculation done easily. All functions will have a name and a list of arguments in side ( ) after the name,
for example, COS(argument). Here are some commonly used math functions:

SIN ( ): Sine function. If the argument is an angle, it must be in radians.

COS ( ) : Cosine function. If the argument is an angle, it must be in radians.
TAN ( ) : Tangent function. If the argument is an angle, it must be in radians.
RADIANS ( ) : Converts degree to radians.
DEGREES ( ) : Converts radians to degree.
PI () : Constant π. Since PI is a constant, so there is nothing in the ().
LN ( ): Natural logarithm of a number.
LOG10 ( ) : The base-10 logarithm of a number.
SQRT ( ) : Positive square root of a number.
EXP ( ) : Exponential function.
SUM ( ) : Sum of all the numbers in the list of arguments.
AVERAGE ( ) : Average of its argument.
ABS ( ) : Absolute value of a number.

*note: IF the arguments in the trigonometry functions such as sin, cos, tan, the arguments need to be
convert to radians either manually or using function RADIANS.

examples:

SIN(A11) - sine function of the number on A11.

TAN(30) - tangent function of 30 radians.

COS(30/180*PI()) - cos function of 30 degrees. It can be used as COS(RADIANS(30)).

SUM(A11:A21) - average number for all the cells from A11 to A21.

5‐4
5.3 Example 1
Deflection of a Cantilever Beam
If a cantilever beam is supporting a point load at its free end, the deflection at any distance (x) measured
from the fixed end will be a vertical distance (y) given by the following beam formula:

 P (3Lx 2  x 3 ) d
y ( x)  b
6 EI
Where P = concentrated load (lb)

L = length of the beam (in)

E = Modulus of Elasticity (psi)

I = Moment of Inertia of the cross section (in4)

The moment of inertia for a beam with a rectangular cross section and circular cross section are

b d3
I b = breadth of beam (in), d = depth of beam (in)
12

 d4
I d = diameter of the beam (in)
64

Construct a spreadsheet to determine the deflection in a cantilever beam that is 120 inch long at 12 inch
intervals. The beam is subject to a concentrated load of 200 lb at the free end. The material has Elasticity
2.0 Msi ( 2 mega psi).

a) Use a rectangular cross section that has breadth of 12 in and a depth of 2 inch.
b) Plot the graph of beam deflection. Use proper heading and labels.

Modify the table (formula etc.) and try it by yourself:

c) Use same beam in problem a) but turn the beam 90o. (i.e. breadth of 2 inch and depth of 12 inch)
d) Use a circular cross section that has diameter 5.53 inch.

Construction of the Spreadsheet

We will use the worksheet area of Excel to construct a spreadsheet for the cantilever beam. In cell C3
enter “Deflection of a Cantilever Beam” and change the font to 16.

Change the width of column A to 12 and width of column B to 9. In cell A5 enter “Axial Distance” and
in cell B5 enter “Deflection”.
5‐5
A useful feature of using the mouse is called “autofill”. In cell A7 enter 0 and in cell A8 enter 12. Select
cells A7 and A8 together, place the mouse pointer on the handle that is on the lower-right corner of the
selected area and drag it downward to cell A17.

Select cells A5:A17 and center justify it.

Enter cells E7 “E =”, F7 “2e6” and G7 “psi”.

Enter cells E8 “B =”, F8 “12” and G8 “in”.

Enter cells E9 “D =”, F9 “2” and G9 “in”.

Enter cells E10 “L =”, F10 “120” and G10 “in”.

Enter cells E11 “W =”, F11 “200” and G11 “Lb”

Enter cells E13 ”I =” and G13 “in^4”

Select cells E7 : E13 and right justify it.

Since the data on cell F7:F11 are constants and

will be used for calculation in formula, we need
to refer them using absolute address or given
unique names. Let’s try to give names on these cells.

Select cell F7 and define the name of this cell from Ribbon-Formula tab-Define Names group-Define
Name. Enter “E” on the Name on the pop-up window, then click OK. Repeat same procedure and name
F8 as “B”, F9 as “D”, F10 as “L”,F11 as “W” and F13 as “I”.

In cell F13 enter the formula “=(B*D^3)/12”

Select cells F7 : G13 and left justify it.

In cell B7 enter the formula “ = -W*(3*L*A7^2-A7^3) / (6*E*I)” and using the autofill process, copy
the formula all the way to cell B17.

Select cell B5:B17 and center justify it.

Select A5:A17 and add vertical border line

from Home tab-Font group-border button.

Double click the sheet1 tab and rename it

“Beam”.

Turn off the gridlines from View tab-

Show/Hide group-check off Gridlines.

Save your worksheet named it “projct1”.

5‐6
Creating the Graph:

The ChartWizard is the easiest way to create a chart. Simply drag the mouse over the cells that contain
data series, in this case cells A5 through B17.

From the Insert tab-Chart group, pick scatter button with smooth line and marker. The chart will be
created automatically.

Use chart tools Design tab-Location group-Move Chart button to move the chart to a new sheet. Choose
new sheet option and enter the name “chart” and OK button.

Once you create a new chart sheet, you can customize it in several ways. You can change the chart type,
add or remove gridlines, add or remove a legend, change the axis label and its formatting, add arrows and
text. On the new chart sheet, click the chart and use Chart Tools- Layout tab with Labels and Axes
groups. Try them by yourself.

From the Insert tab-Illustration group-Shape button, pick a rectangle shape and insert it on the graph to
symbolize the beam.
Insert a line and arrow
for the wall and load.

Save your workbook as

“projct1”.

5‐7
5.4 Example 2

Friction Force on the Incline Plane

An inclined plane is related to a method that the ancient Egyptians probably used to build the pyramids,
because it effectively diluted the force of gravity. Using an inclined plane you can raise an object by
exerting a smaller force through a greater distance to reach the same height that would be achieved by
exerting a larger force through a smaller distance in the vertical
direction.

An object sits on an inclined plane that has an angle of θ. Due

to frictions between the surfaces of the object and inclined
plane; the object may not slide down even as the inclined angle
θ increases. The weight of the object can be decomposed into
the force down the plane (parallel to the plane) and the normal
force (perpendicular to the plane). If the friction force is enough
to counter balance the down force, the object will be able to
stay in equilibrium. Otherwise, the object will start the slide
down the inclined plane.

Assume the weight of the object W and friction coefficient μ , the down force (FD), normal force (FN)
and maximum friction force (FF) can be calculated by:

FD ( )  W sin( )
FN ( )  W cos( )
FF ( )   FN

Construct a spreadsheet to determine the maximum inclined angle θ

in which the object can still be in equilibrium. The object has a mass
of 10 kg and the friction coefficient μ = 0.404. Use angles from 0 to
30 degrees and an increment of 1 degree.

Plot the graph of down force FD and maximum friction force FF v.s. inclined angle θ . Use proper
heading and labels.

Use your table (may need to change some constant number) to answer following questions:

a) What will be the maximum inclined angle in which the object keeps equilibrium?
b) Does the mass of the object affect the maximum inclined angle?
c) If the friction coefficient is changed from 0.404 to 0.05 (i.e. metal object to icy surface), how much
does the maximum inclined angle change?

5‐8
Construction of the spreadsheet

We will use the worksheet area of Excel to construct a spreadsheet for the inclined plane. In cell C1 enter
“Inclined Plane” and change the font to 14. Click the underline to emphasize the title.

Change the widths of column A to 8.7, column B to 10.5, column C to 15, column D to 12.7, column E
to 15.2. In cell A9 enter “Angle (d)” , cell B9 enter “Angle (rad), cell C9 enter “Normal Force (N)”, cell
D9 enter “Down Force (N) and cell E9 enter “Max Friction (N)”.

In many engineering problems, there will be some information given. Those information will be used as
constants in the calculation. So we will construct the constant table that contains all given number. One
of the advantages of using this way is that we can analyze the similar problem if only the information
given changed. What we need to do is to change these constant number and the results will update
automaticlly.

In cell C4 enter “Mass =”, cell E4

enter “10”, and cell F4 enter “kg”.

In cell C5 enter “Acceleration of

gravity=”, cell E5 enter “9.81”, and
cell F5 enter “m/s^2”.

In cell C6 enter “Friction coefficient

=”, and cell F6 enter “0.404”.

In cell C7 enter “Angle increment

=”, cell E7 enter “1” and cell F7
enter “degree".

Select C4:F7 and add thick box

border from Ribbon-Home tab-Font
group.

Select E4:E7 and highlight in

different color from Ribbon-Home
tab-Font group.

In cell A11 enter “0”

In cell A12 enter the formula

“=A11+$D$7”, then enter

Click the cell A12 and place the

mouse pointer to the right lower
corner of the cell. Click and hold
the left button of the mouse, then
5‐9
drag it to the cell A41. This process is called “auto fill”.

In cell B11 enter “=RADIANS(A11)”

In cell C11 enter “=$E$4*$E$5*COS(B11)”

In cell D11 enter “=$E$4*$E$5*SIN(B11)”

In cell E11enter “=$E$6*C11”

Select all cells you enter formula (cells B11 to E11) and use the “auto fill” process, copy the formula all
the way to cell E41.

Select cells A9:E41 and center justify it from Home tab-Alignment group.

Select cells A9:E41 and add vertical border lines from Home tab-Alignment group-border button-more
borders.

Select cells B11:E41 and make all numbers 4 decimals from Home tab-Number group.

Select A9:E9 and add thick bottom border line from Home tab-Font group.

Insert any related picture from Insert tab-Illustration group-picture button.

Select Double click the sheet1 tab and rename it “Analysis”.

Turn off the gridlines from View tab-Show/Hide group-check off Gridlines.

If your table is too long and can’t be displaced complete on screen you can use vertical scroll bar to slide
the table up so you can see the bottom part of the table. However, the best way is to use freeze panes
before you scroll vertical bar so the top portion (title and constant table etc) of the table won’t move.
Select row 11 from left side of table, then from View tab-Window group-Freeze Panes- choose Freeze
Top Row.

Analysis

As we know the max angle that the object still keeps equilibrium is when the down force and max
friction become equal. According to the table, it happens at angle 22 degree, so let’s insert a comment on
the cell indicate this result.

Select the cell A33 and add comment on it from Review tab-Comment group-New Comment button.
Move the comment to the area so it won’t interfere with the data on the table.

Change the mass of the object from constant block; does the max angle the object hold equilibrium
change? Change the friction coefficient; does the max angle the object hold equilibrium change?

5‐10
Creating the Graph:

We are going to create the chart for the down force and max friction vs. the angle (two curves on the
chart). Select cells A9:A41, then HOLD Ctrl KEY on the keyboard, continue to select cells D9:D41,
then cells E9:E41. From the Insert tab-Chart group, pick scatter button with smooth line and marker. The
chart will be created automatically.

Use chart tools Design tab-Location group-Move Chart button to move the chart to a new sheet. Choose
new sheet option and enter the name “chart” and OK button.

Once you create a new chart sheet, you can customize it in several ways. You can edit the chart type,
gridlines, legend, axis label and text. On the new chart sheet, click the chart and use Chart Tools- Layout
tab with Labels and Axes groups. Try them by yourself.

Save your workbook as “projct2”.

5‐11
5.5 Example 3

Where is the Particle?

In order to describe the motion of an object, you must be able to specify its position at all times using a
reference coordinate system and origin. The position (s) is defined as location from a reference origin
and the average velocity (v) is defined as change of the position (Δs) divided by the time interval (Δt).
The average acceleration (a) is defined as change of the velocity (Δv) divided by the time interval (Δt).

Using numerical integration, the position s(t) and velocity v(t) can be obtained by formula

a (ti )  a (ti 1 ) v (ti )  v (ti 1 )

v (ti )  v (ti 1 )  ( ) t s (ti )  s (ti 1 )  ( ) t
2 2
where ti is time at step i and ti-1 is time at step i-1 or ti = ti-1 + Δt.

A particle, subjected to the magnetic force F(t), is traveling on a straight line. If the particle has mass 1
kg and initial velocity v0 = 0 m/s and position s0 = 0 m, find the velocity and position of the particle after
50 second. The magnetic force F(t) (in Newton) is

 
cos( 25 t ) 0  t  25
s

F (t )  0.2(t  25)  1 25  t  40 v
2 40  t



Construct a spreadsheet to calculate the velocity and position. Set time range from 0 to 50 seconds with
increment 1 second.

a) What are the velocity and position of the particle at t = 50 s?

b) When will the velocity of particle become 0?
c) Plot acceleration (a)-time, velocity (v)-time and position (s)-time separately.
d) Do a regression analysis to the position (s). What order of polynomial will fit the data reasonable?
Show the equation.
e) If the initial velocity v0 = -8 m/s and position s0 = -20 m, what will be velocity and position at t =
5 s?

Construction of the spreadsheet

We will use the worksheet area of Excel to construct a spreadsheet for the problem. In cell C1 enter
“Where is the Particle?” and change the font to 14 and bold font. Click the underline to emphasize the
title.

Change the widths of column A to 8.5, column B to 12, column C to 12, and column D to 12.

5‐12
Let's construct constant block. In cell D4 enter “initial velocity =”, cell F4 enter “0”, and cell G4 enter
“m/s”.

In cell D5 enter “initial position =”, cell F5 enter “0”, and cell G5 enter “m”.

In cell D6 enter “time increment =”, cell F6 enter “1”, and cell G6 enter “s”.

Box the constant block and highlight cells F4:F6 and fill in any color.

Use technique learned in example 1 to name the cells F4, F5 and F6 as "v0", "s0" and "det", respectively.

In cell A8 enter “time (s)” , cell B8 enter “acceleration, cell C8 enter “velocity”, cell D8 enter “position”.

Enter cell A10 "0" and A11 "=A10+det". Copy the cell formula in A11 to A12:A60.

Enter cell B10 "=COS(PI()*A10/25)". Copy the cell formula to B11:B35.

Enter cell B36 " =0.2*(A35-25)-1". Copy the cell formula to B37:B50.

Enter cell B50 "=2". Copy the cell formula to B52:B60.

Enter cell C10 "=v0".

Enter cell C11 " =C10+det/2*(B10+B11)". Copy the cell formula to C12:C60.

Enter cell D10 "=s0".

Enter cell D11 " =D10+det/2*(C10+C11)". Copy the cell formula to D12:D60.

Select A8:D60 and make all number to 4 decimals and right justify. Add vertical border lines to separate
the columns.

Creating the Graph:

We are going to create the three charts for the acceleration v.s. time, velocity v.s. time and position v.s.
time separately. Select cells A8:B60 and create acceleration history curve from the Insert tab-Chart group,
pick scatter button with smooth line and marker. Select cells A8:A60, then HOLD Ctrl KEY on the
keyboard, continue to select cells C8:C60. From the Insert tab-Chart group, pick scatter button with
smooth line and marker. This will create a velocity history chart. Arrange the charts to the locations you
prefer.

Select cells A8:A60, then HOLD Ctrl KEY on the keyboard, continue to select cells D8:D60. From the
Insert tab-Chart group, pick scatter button with smooth line and marker. This will create a position
history chart. Move the chart to the new sheet as we discussed in example 1 and name it "chart".

Edit the chart type, gridlines, legend, axis label and text by yourself on all three charts.
5‐13
5‐14
Analysis

We can see from table, the velocity and position will be 27.5 m/s and 125.87 m when t = 50 s.

Check the velocity column, we can see the velocity becomes 0

when t = 25 and 35 s. Let's insert comments on these two cells.
See example 2 to see how to do that.

Let's take a look on the position chart. Even we have the chart
that we can used to find the position of the particle during this
time period but it will be difficult to find the equation s(t) that
can describe the relationship of position s and time t. Very often
we try to use an approximation simple equation to describe s(t).
This approximation function is called curve fit (or regression)
function; in EXCEL, it's called trend line.

Click any data point on the curve from the chart to add a trend
line from Chart Tools-Layout tab-Analysis group-Trend line
button- more trend line option. Click polynomial, increase order
to 4 from Trend line Option and check on the Display Equation on chart.
5‐15
EXERCISES AND ACTIVITIES
1. Cost Calculation for Attending College
Create the following spreadsheet in excel – it must be formatted (automatically) the same way (including
the dollar sign.

a. Insert a new column for winter ’08 after Fall ’08 and include your own budget values
b. Copy the data entries in the same format and paste it a new sheet in the same book
c. Name the first sheet ‘ budget 1’, and the second sheet ‘budget-copy’

2. Damped Waves
Damped waves are calculated according to the following formula:

 kt
Y  e sin t

Where t is the time and is measured in seconds, and k is the damping constant and is equal to 0.1.

Construct a spreadsheet to calculate the value of the function Y for t values ranging from 0 to 30 seconds

in increments of . Plot the function Y versus the time t.
10

Choose proper headings for your worksheet.

Use proper chart title, legend, and axis titles for your chart.

3. Resultant Force
Construct a spreadsheet to determine the magnitude and direction of the resultant of the force system
shown.

F1 = 900 N @ 45o F2 = 600 N @ 100o

F3 = 450 N @ 180o F5 = 350 N @ 270o

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F4 = 500 N @ 300o

Note: All the angles are measured relative to positive x-axis (see the free body diagram on the attached
sheet).

Choose proper headings for your worksheet.

4. Trigonometry Functions
Construct a spreadsheet to calculate the value of the function

y(θ) = a sin(θ) + b cos(θ) – c sin(θ) cos(θ)

For θ values ranging from 0o to 360o in 20o increments. Construct a parameters’ block that have three
variables a , b, and c.

1. Create a control block that contains parameters a, b and c.

2. Try a = 0.2, b = 0.3 and c = 0.4, and print your analysis worksheet (use four decimals for function
value y).
3. Plot the function y verses the angle θ (in degree). Use proper chart title, legend and axis title for your
chart.
4. Change the parameters, a = 0.4, b = 0.3 and c = 0.2, and repeat steps 1 to 3.

5. Object Projectile
When an object is launched from the ground with an initial velocity of V0 at an angle of θ, the
horizontal and vertical displacements of the object travel before it hits ground can be written as functions
of time t :

X(t) = V0 t cos (θ)

Y(t) = V0 t sin (θ) – 1/2 g t2

A baseball has been tossed with the initial
velocity 15 m/s with the angle 30o from the ground.
Use g = 9.81 m/s2.

1. Construct a spreadsheet to calculate the horizontal and vertical displacements of the ball for time t
ranging from 0 to 1.52 seconds in increments of 0.02 sec. Name your worksheet as “Analysis”.
2. Plot the functions X and Y verse time t (i.e. X-t and Y-t graphs) on a same graph.
3. Plot the trajectory of the baseball (ie. Y v.s. X graph).

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 4. Using the graph and your data to determine the maximum height reached by the ball and the
horizontal distances it travels before it strikes the ground. Insert comments on the cells that have
maximum height and the longest distance it travels.
5. Print your spreadsheet results with comment from 4) and charts from 2) and 3).
6. If the initial velocity changes to 20 m/s and the tossing angle changes from 30o to 45o, what will
be the maximum height reached by the ball? When will the ball hit the ground? Use time
increment 0.04 sec. Adjust your numbers in the analysis worksheet accordingly (maybe you need
to add more time in your time t too, since it will take longer time for the ball to reach the ground).
Print your worksheet.

6. Free-Fall
The Cenco-Behr is an apparatus that is used to measure the acceleration of gravity. In this experiment an
electromagnet holds a plummet in position until it is released. A spark timer supplies an oscillating high
voltage across two wires between which a sensitive paper tape is positioned. As the plummet falls, it
leaves a mark on the tape at regular intervals, every 1/60th of a second. By measuring the distance
between the holes, we can calculate the velocity and acceleration of the plummet
as it is falling freely.

0.00 1.94 4.07 6.47 9.17 12.20 15.40 18.92

22.74 26.84 31.14 35.68 40.52 45.67 51.07 56.75

The following numbers represent the distance of the holes from the first
clear spark holes on a sensitized paper tape. Since the distances are in centimeters,
you need to convert them in meters.

The time interval between successive spark is assumed to be 1/60 seconds.

Construct a spreadsheet:

1.Choose proper headings for your worksheet.

2.Calculate the average velocity for each displacement change.
(note: v2 = (Distance2 – Distance1 )/ time interval, etc., but leave v1 blank)

3.Calculate the average acceleration for each velocity change.

(note: a3 = (v3 – v2)/ time interval, etc., but leave a1 and a2 blanks)

4.Plot the velocity-time graph on a separate sheet (only data points, no curve between points). Plot linear
regression line (linear trend line). Use proper chart title, legend, and axis titles for your chart.
5.Acceleration due to gravity (gravity constant g) can be calculated by two different ways. a) find the
slope of the regression line in velocity-time graph b) Obtain an average value from acceleration table.
6.Compare the values from a) and b) in step 4 with accepted value (9.81 m/sec2) and calculate the
percentage error.

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7. Normal Shock Wave
Background: Consider the flow of a compressible fluid through a duct. If the flow is steady (not
changing in time), adiabatic (no heat transfer into or out of the fluid), and

One-dimensional (flow along a straight line duct), then under proper conditions, a normal shock wave
will develop in the duct at some location (see sketch). If the compressible fluid is of low or moderate
density, then the fluid can be treated as an ideal gas, so that its properties are essentially functions of
temperature only. With the simplifications that follow from such a treatment, it is possible to derive
expressions for the change in temperature, pressure and Mach Number (the ratio of the speed of the flow
through the duct to the speed of sound in the gas) through the shock wave.

The expression that relates the Mach Numbers before and after the shock wave is given by

1
 M 2 K  1  2  2
M2   1 2 
 2 KM 1  K  1 
M1 and M2 are the Mach Numbers before and after the normal shock wave, and K is the specific heat
ratio for the gas in question. Different gases (e.g. - Air, Hydrogen, Carbon Dioxide, etc.) have different
values for K.

Problem: Using Microsoft Excel, create a graph that shows the variation of M2 with M1 for the following
gases:

Carbon Dioxide (at 100 oF), K = 1.283

Hydrogen (at 100 oF), K = 1.399

(a) Calculate M2 for values of M1 beginning with 1.00 and increasing in steps of 0.50 (i.e. 1.00, 1.50,....)
to 10.00.

(b) Label each curve on the graph with the appropriate name of the gas and its K value.

(c) Label each axis.

(d) Put the following title on the graph:

Downstream Mach Number as a Function of Upstream Mach Number for Flow Through a
Normal Shock wave

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 Chapter 6
Design Process
Chapter 6 – Design Process
6.1 The Nature of Engineering Design
When we talk about engineering design, we might talk about either 1) re-design an existing
product using available technology to improve performance, lower cost or reduce risk or 2) design of a
product from new concepts. To achieve the design goals, a general systematic approach might have to
follow even the detail procedures might be different. There are two main goals of the systematic approach
to engineering design: (1) to eliminate personal bias from the process and (2) to maximize the amount of
thinking and information gathering that is done up front, before committing to the final design. The result
is fewer costly design changes late in the product development stages.

The engineering design process also

provides a blueprint for design of complex
systems. For example, your might be able
to get along without a formalized design
procedure when designing a new paper clip,
but when taking on the daunting design of
designing a complex system like airplane,
brain gridlock can set in. The design
process offers a step-by-step procedure for
getting started as well as strategies for
breaking down complex problems into
smaller manageable parts.

In this chapter, we will talk about a

general design procedure for engineering
design: 1) Problem Identification, 2)
Conceptual Design, 3) Preliminary Design,
4) Detailed Design and 5) Implementation
and Documentation. Don’t forget, design is
an iterative process, that at any design
stage, you may need to go back to any previous stage according to feedback and redo it.

6.2 Problem Identification

The problem definition phase is devoted to clarifying the objectives set out by the client and
gathering the information needed to develop an engineering statement of what the client wants. It may
contain following tasks:

1) Clarifying objectives for the design: You should read the client statement carefully and try to
understand exact what the client ask for. Ask as many questions as possible such as what the function of
the product, client intents, the history of the product design, time constraints, etc…
6‐1
 2) Establishing user requirements: Read product specifications. Try to understand the all detail
information required for the product such as size, shape, color, weight, material, anything mentioned in the
specification document.

3) Establishing function and design criteria: Try to rewrite the problem statement by using your
own words. This can help you to really understand the objectives if the product design. Establish the
design function criteria or important requirements that can be used for judging the success of the design or
not.

6.3 Preliminary Design

The goal of the conceptual design stage of the design process is the generation of concepts or
schemes of candidate designs. It may contain following tasks:

4) Do the research: Look for any possible solutions from any resources you can find.

a) Existing solutions: Study the existing design or similar design to identify the problem and
learn how others have done. This can help you to avoid the same mistakes when you do your
design.

b) Internet: Try to use internet to explore more possible solutions to your problem. Use research
engine GOOGLE, or Bin to get more information of the similar product. You can even use
YouTube to see many video clips to show you how their design works. This is probably the
most of powerful tool for today’s engineering students in research.

c) Others: Visit your university library, search government documents, read professional
publication and talk to any individuals whom you believe are experts in the field.

5) Conducting brainstorming meeting to gather information: Call a brainstorming meeting for the
team. A crucial rule should be implemented in the meeting: criticism of ideas is not allowed. This enables
each team member to put forth ideas without fear of immediate rejection. There is no stupid, crazy idea
during the brainstorming meeting. Actually, bolder, unconventional ideas should be encouraged; don’t
forget many great inventions came from crazy ideas in the beginning.

Record all ideas during the meeting. Use sketch technique you learn from chapter 3 and draw some
pictures to explain the ideas. Only when brainstorming is complete should the team eliminate concepts
that are not feasible, can’t be done due to constraints, or combine a few concepts because of not much
fundamentally different.

6) Evaluate the design concepts: Examine the strengths and weakness of the design concepts to
select the best concept to proceed and keep at least two alternatives for future use. To avoid the selection
bias, evaluation criteria combined with decision matrix is used. The Pugh method is the one used the
most. More detail information will be discussed in chapter 7.

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 7) Construct project schedule: Set the project schedule plan ahead. At this point, you should have
some ideas what activities you should do now and it is the time to plan the work schedule and assign the
tasks to team members now. There are many tools that you can use but the Gantt chart is probably the one
the project manager used the most. More detailed information will be in chapter 7.

8) Write a proposal: Write a proposal to client based on the design you choose and the activities
you planed. This proposal allows your client/customer to know what you plan to do and when you will
finish it as well as the detail activities and schedule for your design team.

6.4 Detailed Design

The goal of this stage is to specify the details of the design so that it can be manufactured and
being tested. If problems occur unexpected, the design has to be modified or re-design to make sure it will
fulfill the original goal. Size, materials and other details need to be accomplished here. It may consist
following tasks:

9) Do analysis: Use all resources, knowledge to verify the design working as you planned.
Analytical skills are essential for the successful design project. It is based on the knowledge of all
engineering sciences and math background you learned in school. At this moment, you are just in the
beginning of the sequences engineering courses; you may use any common senses and any experiences
you have learned from other places or machine shop. All the design tools we learned in class should be
able to help you to start.

10) Develop the prototype: Construct a prototype product and test it to make sure it works.
Analysis can help you to eliminate many possible mistakes, modify your design and confirm your final
design. However, no matter form theoretical analyses or computer simulations, they are all based on
certain assumptions and approximation and may not be 100% accurate. Construct a prototype and test it to
make sure it will meets all design criteria is very important. Depending on your design project, you may
need to use 3-D modeling skill to show detail design of each piece of your product, purchase materials and
spent time in machine shop to make your prototype product.

6.5 Implementation and Documentation

The goal of this stage is to wrap up your design and prepare for your presentation to the clients and
have your final report ready for future use. It may consist following tasks (detail will be in chapter 8):

11) Evaluate your design to make sure it satisfy all criteria: Do experiments and testing and
analysis whatever necessary to make sure it fulfill all requirements in the problem statement and meet all
specifications.

12) Present the final design to the clients: Discuss how you are going to present to your clients in
the team meeting and use all possible tools (PowerPoint, video clips, photo, prototype, etc) to impress

6‐3
customers and show off your design. Rehearse you presentation before it happens. Detail will be discussed
in chapter 8.

13) Write a final report or portfolio: Keep all design data, information, meeting log and start to
write your final report. This is a very important document that you will keep for future use. No matter
what you have done when time passes, the only document or proof that you have worked on this project is
this final report only. Keep all information, reference, results you like to keep and organize it into a nice
format you will be proud of it. Detail will be discussed in chapter 8.

Reference
1. Exploring Engineering: An Introduction to Engineering and Design, 2nd ed, by Philip Kosky, G. Wise,
R. Balmer and W. Keat, Academic Press.

2. Engineering Design: A Project-Based Introduction, by Clive Dym and P. Little, John Wiley & Sons,
Inc.

3. Tools and Tactics of Design, by Peter Dominick, J. Demel, W. Lawbaugh, R. Freuler, G. Kinzel and E.
Fromm, John Wiley & Sons, Inc.

4. Introduction to Engineering Design and Problem Solving, 2nd ed, by Arvid Eide, R. Jenison, L. Mashaw
and L. Northup, McGraw Hill.

5. Engineering your future: A Compressive Introduction to Engineering,7th ed, by William Oakes, L

Leone, and G Gunn, Oxford University Press.

EXERCISE AND ACTIVITIES

6‐4
 Chapter 7
Project Management
Chapter 7 – Project Management
7.1 Team Development
7.1.1 Team vs. Collection of Individual

Engineering design in industry is getting more and more complicated. The knowledge and
resources of a single person is not enough to handle to whole activities in design process any more. The
team work and cooperation among the team member will determination the fate of a design project. But
what is the team? A collection of individual like the shoppers, sport audience is not considered as a team
because they don’t have obligation and can’t make contribution to the team. A team is a group of
individuals whose work is inter-dependent and who are collectively responsible for accomplishing a
performance outcome.

An engineering team usually consists of a few individuals who has different skills depended on
what types of the project. If you are going to design a vehicle engine, your team may have a few
mechanical engineers, electrical engineer, industrial engineer and manufacturing engineers, etc. Different
background of knowledge can help you look at problems from different angle and prevent blind side of
the design in advance. There are many factors when you need to consider before you form your design
team such as the knowledge of cross-disciplinary, wide range of skill, work styles and personality of
each individuals but a successful team always have following characteristics:

All team members share a clear, challenging goal

Team has a result-driven structure

Team consists of competent, talented of individuals and they respects to each other

All team members has unified commitment to solve the problems together

Whole team has a positive team culture and high standard.

The team has an effective leadership

7.1.2 Team Member Responsibilities

Members of a design team have two different sets of responsibilities – one to his/her functional
task and the other to the team. A team member is responsible for whatever tasks you have been assigned
to and is to provide your technical expertise on the tasks. However, you are a member of the team; you
also have to share your responsibilities with others for whatever the team’s success or failure. A
successful design or product may not because every member did their best individual but definitely
because all members work together and help each other. In order to make sure the team reaches to its
highest output, all team members need to understand what roles they have in the team and what
behaviors they should or should not have:

1. Members will acknowledge problems and willing to deal with them together.

7‐1
 2. Members will respect each other and all difference among them.

3. Members will be supportive rather than judgmental.

4. Members will provide an open environment so everyone feel free to say.

5. Members will share any criticism and praise to the team.

6. Members will contribute their individual expertise to the team success.

7. Members recognize the importance of team meetings and agree to

a) Attend meeting on time always,

b) Use meeting time wisely, start meeting on time and end the meeting on time,

c) Keep focused on the goals,

d) Avoid side issues, personality conflicts and hidden agenda,

e) Present your work and brief it to others.

There are a few things a team member should do:

1) Should treat every team member with respect, trust their judgment and value their friendship.

2) Should encourage everyone to talk and share their ideas and opinions.

3) Should help and support each other if someone needs it. Team progress will be hindered when
anyone in the team is short of his/her work or anyone dominates the whole project.

4) Should be comfortable with your disciplinary skill but also study more to improve it.

5) Should avoid the arguments among members. Find a positive way to resolve a dispute.

7.2 Project Management Tools

7.2.1 Pugh Method

Pugh method is a quantitative technique used to rank the multi-dimensional options of an option
set. It is frequently used in engineering for making design decisions. A decision matrix consists of
establishing a set of criteria options may or may not with weigh factors which are scored and summed to
gain a total score. The resultant scores better reflect the importance to the decision maker of the criteria
involved. The more important the criteria the higher the weighting it should be given. Each of the
potential options are scored and also multiplied by the weighting given to each of the criteria in order to
produce a result.
The advantage of the decision making matrix is that subjective opinions about one alternative
versus another can be made more objective. Another advantage of this method is that sensitivity studies

7‐2
can be performed. Even there are several different versions of this method, here we are going to look at
one.
First step is to identify the design evaluation criteria. Then weigh the evaluation criteria and
assign them a number on each criterion depending on the importance of the criteria. Bigger number
assigned means more important on evaluation. After this, set up the decision matrix as in the figure. You
can use EXCEL technique you learned in chapter 5 to do this.

Sometimes we use one the design as a reference (or datum) and all other design concepts are
compared to this reference one. Assign numbers (from -5 to +5) to cells on each criterion on every
design concept when comparing to the reference design. If the comparing design concept is much better
than the reference, we assign a bigger positive number to it and if it is not as good as reference, we will
assign a negative number. Then we calculate overall score for each concept and interpret the results.
After the discussion among the team members, the best design can be selected for farther evaluation.

7.2.2 Gantt Chart

A Gantt chart is a type of bar chart, developed by Henry Gantt in the 1910s, that illustrates
a project schedule. Gantt chart plots the start and finish dates of each task/activity in design and can show
your current status of the project on timeline. Here is an example for a semester freshman design project
schedule using Gantt chart.
The Gantt chart breaks down all possible activities of the project to smaller tasks and identifies
the order of these tasks and starting/ending time. It may require some experiences to set up the chart
more practical and realistic but you should not be afraid to learn how to do it.

7‐3
7.2.3 Personnel Distribution

The tools that have been described can help order tasks but project management means getting
the right people on the right tasks. The people on your team will need to be assigned tasks that allow the
project plan to be met. For example, one person can’t do all of the tasks in the first month. Sketching out
who is the most qualified for and/or interested in each task is a great way to start. The team must look at
the work distribution and make an equitable assessment. The work needs to be balanced whenever
possible and must account for the team members’ expertise.

7.3 Oral Presentation

After your team finish the project, construct the prototype model, test it and confirm it satisfy all
requirements, next step you need to sell your product to your clients. An oral presentation is used for the
design team to introduce their design/product. This presentation can be compared with an opening night
for the new movie premium. Your team may only have 10 to half an hour time to show the best feature
of your product and give a good impression to the audience. In order to achieve this goal, preparation of
the oral presentation is essential.

7.3.1 Overcome the Fear

Being nervous about doing a presentation is normal. The fear of public speaking happens to most
of people and it is almost no way you can avoid it in life. So prepare your talk, practice it and rehearse it
again and again before presentation. Take a deep breath before you start to talk and give a joke to make
the atmosphere less formal.

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7.3.2 Preparation before the Presentation

Preparation is the key to successful oral presentations. To prepare for a presentation, you can do
following:

1) Identify your purpose and audience: First of all, you need to know the background of your
audience and what they are looking for. How much they know about this topic? If you give a
presentation to your classmates who are doing the same project, you may not need to spend a lot of time
to talk about problem statements and specifications. You should focus more on your special features in
your design. If you give a presentation to the middle school students who has no clue what you are
doing, you may need to spend some time to explain why and what you are doing in the project. You need
to keep the purpose of your talk in mind when you preparing.

2) Organize the presentation: You need to organize all information you are going to present in a
logical order. Here is an example outline for a presentation:

 Introduction: Who you are and why you did this

 Need: Why your engineering design is needed
 Solution: You show your design (this is the major part of your presentation). Tell audience why
your design is the best solution to the need. Give more detail information and show the proof.
 Conclusion: Give a summary and wrap up your project
 Question and Answer: You always leave some time for the audience to ask questions. Think
about questions audience may ask and prepare for it.

7‐5
 3) Create presentation materials: After you gather your information for presentation, you may
think about how to disseminate your information to audience. Microsoft PowerPoint is the most common
one for visual presentation. Besides visual presentation, auditory, prototype demonstration can also be
included if necessary. Here are some tips when you preparing your PowerPoint slides:

 Show logic order of all your slides.

 Present one central idea per slide.
 Be as brief, simple as possible. Slide is a reminder for the speaker what to talk and it is not a full
report, so don’t copy the written report in it. Maybe the bullet list is the best one to use.
 Use the font size at least 18-point and same size through all slides. You can highlight the
keywords in different color.
 Don’t use any information you are not quite understand. You don’t like to be embarrassed if
someone asks question regarding to that.

4) Rehearse the presentation: When you have your slides created, give every member in the team
a copy so they can practice their parts. Try to rehearse a couple times before the official presentation.
Here are some tips for doing rehearsal:

 Proofread your material. Use auto spelling check from PowerPoint. Always ask different people
to do proofreading for you.
 Learn how to use the equipment. Every PC and projector is different. Learn how to use it before
official presentation to avoid delay in the real one.
 Think about back-up procedures if something goes wrong. No matter how you prepared, you
always don’t know what will happen on the presentation day, so think about back-up plan ahead.
For example, what should we do if one of team member absent, if projector not working, if slides
accidentally deleted, etc…

7.3.3 Making Presentation: Finally, it is the presentation day. The first 15 to 30 seconds of a presentation
are critical; you need to attract attention immediately otherwise you may lose the audience forever. On
the other hand, pay attention to other presentations on dual respects. If you don’t pay attention to other’s
presentation, how can you expect others to pay attention to yours. Here are some tips during
presentation:

 Dress appropriately. Don’t wear t-shirt, short and sandals. Keep it professional.
 Introduce your team, team members and yourself.
 Follow the logic order of the presentation.
 Give a brief overview of you parts of the presentation before you give detail.
 Make a smooth transition between speakers.
 Speak clearly and loudly. You are not talking to one person; you talk to the whole audience.
 Keep within the time allocated to prevent overtime.
 Face the audience and keep eye contact if possible.
 Leave enough time for questions. No questions means a) you explained so clear and everyone
understands or b) nobody understands it and they don’t care. You know which one is more likely.

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7.4 Final Report
The types of reports that you will write as an engineer will varies, so the precise outline that will
serve for all the reports can’t be supplied. However a general outline of the report still can be given but
each individual section can be shrinking to a few sentences or enlarging to many pages is based on the
project and report required by the client. Keep in mind this report is your final document (and may be the
last) that going to tell other people what you have done on your design, so make it good and you will be
proud of showing people in the future. In general, a technical report will have following parts:

1) Appropriate cover page 2) Abstract

3) Table of contents 4) Main body of the report

5) Conclusions and recommendations 6) Appendixes

Here we are going to discuss more detail on freshmen design project report outline for ES100
course:

1) Cover Page and Table of Contents: The title should be brief, clear as possible. Put down team
name, each individual name and date. In general, if your report has more than 6 pages, you may need a
table of contents.

2) Abstract/Summary: Short summary of the design emphases on the key features and
approaches. Most of the time, half page is sufficient.

3) Problem Statements: Answer following questions: what problems are you solving? What
requirements need to be met? Re-write your problem statements and specification. One page is sufficient.

4) Introduction/Background: Give a brief introduction and research results you got from all
resources. Show the existing products available and why they won’t meet requirements.

5) Design Overview: Explain how your design works in words and pictures. Try to emphasize the
special features on the design.

6) Analysis and Design: How did you arrive to your design? What were your alternative designs?
What problems did you encounter and how did you solve them? Answer these important questions to let
readers understand what and how your design works so they can follow your logic.

Did you calculate any values for your design? Did you collect any empirical data to help you
arrive to your design? If so, show the formula and the calculation on spreadsheet- EXCEL. This is the
main body of your report, so give more detail explanations.

7) Prototype Model and Drawing: How you build your model? What material you use? What
dimensions or size of your design piece? Have you use 3-D printer to make any piece? Use CREO to
render your 3-D model and 2-D detail drawings. Is there any programming part involved in your design?
Show your program listing or a snap shot of the program. Give a picture of your final prototype model.
You may also include the table of Bill of materials to list the cost of the material piece by piece.

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 8) Conclusions and Recommendation: What are the results? What did you accomplish? What
lesions did you learn? What did you do right? What would you do differently if you had to do it again?
These answers can help you and readers for further study.

9) Appendixes: Anything not included in the previous sections can be put on this section. It can
include computer printouts, communication letters, pictures, experimental raw data, etc. Other
information may be included too. For example, Reference is the citation for any information you got
from some others results; Acknowledgement is a brief paragraph you showing your appreciation to those
who helped you; Personnel is the brief team member’s vita.

Reference
1. Exploring Engineering: An Introduction to Engineering and Design, 2nd ed, by Philip Kosky, G. Wise,
R. Balmer and W. Keat, Academic Press.

2. Engineering Design: A Project-Based Introduction, by Clive Dym and P. Little, John Wiley & Sons,
Inc.

3. Tools and Tactics of Design, by Peter Dominick, J. Demel, W. Lawbaugh, R. Freuler, G. Kinzel and
E. Fromm, John Wiley & Sons, Inc.

4. Introduction to Engineering Design and Problem Solving, 2nd ed, by Arvid Eide, R. Jenison, L.
Mashaw and L. Northup, McGraw Hill.

5. Engineering Your Future: A Comprehensive Introduction to Engineering, 7th ed, by William Oakes, L.
Leone and C. Gunn, Oxford University Press.

7‐8
EXERCISE AND ACTIVITIES
1. This assignment requires student teams to design a traveler’s spill-proof cup. The student teams
(assigned using thinking-preference screening tools) will work together to define the problem criteria,
brainstorm possible solutions, and generate an initial design. The entire class will evaluate all of the team
designs and then each team will improve its design based on the class evaluation.

GOALS AND OBJECTIVES:

For this assignment students will:

 learn about thinking-preference styles
 determine "design criteria" for a design problem
 perform a critical evaluation of Pugh Analysis

PROBLEM STATEMENT

Students will work in your own final project team to design a traveler’s cup. Students will be instructed in the
concepts of different thinking preferences (structured versus free-form, detailed versus holistic), and how the
various thinking preferences are important in the overall design process. Each team will be formed with an
effort to provide at least three different thinking preferences.

The design exercise in the lab will follow the following approximate sequence:

1. Individual team creation of design criteria list.

2. Class discussion of the criteria; a final set of common criteria agreed upon.
3. Group brainstorming of design ideas; one design agreed upon and sketched for presentation to the
class.
4. Presentation of the team designs; Pugh Method comparison led by instructor.
5. Instructions to the teams to refine their own designs based on the Pugh analysis.

OUTCOMES/DOCUMENTATION:

Each team must submit a typed report at next week’s lecture session. Each team must include sketches
that are neat and clearly labeled (computer-generated drawings should be considered for the report).
This report will be worth 25 points and the total in-lab design effort will be worth 25 points. The report
should include:

1. A description of the cup design requirements and criteria (as was decided in the lab)
2. A description of the team's original design and how well it satisfied the criteria (refer to a sketch)
3. A discussion of the enhancements to the design that were generated from the Pugh Method exercise
(again, refer to a sketch which shows the enhancements)
4. A discussion of the other important aspects of the design necessary to actually implement the project
(manufacturing, marketing, etc.)
5. Any suggestions for improvements, given additional resources.
7‐9
 Chapter 8
Examples of Design Projects
Chapter 8 – Samples of Design Project

1. Toy Transporter

The Veco Toy Company is seeking proposals from engineering firms to design a special purpose
toy transporter. The winning bid should be able to furnish a prototype model along with necessary
documentation. For this purpose, the company will sponsor a competition for all bidders at the end of the
due date which will be announced later.

The purpose of the transporter is to move two objects which have the size and weight of golf balls,
and uphill slope of 0.25 for a distance of 72 inches. Once the transporter delivers the objects to the top of
the hill, it will automatically throw the object to the other side of the hill in the designated area. The
loading platform and delivery dock each measure 11.5 inches wide and 7 inches long. The roadway
between the two is 11.5 inches wide and has a 1.5 inches curb on each side. The transporter is to be held in
place at the loading dock by a block gate. The transporter will be stopped at the hill top by a soft bumper
that is 2.5 inches high. The designated area for the objects to be delivered is measures 15x15x15 inches
and 12 inches away from the top of the hill and level with the floor. The two objects will be loaded by
hand at loading platform and unloaded automatically at the top of the hill. The company would like to see
which model can accomplish the task as fast as possible. They are also looking for a transporter design
that can climb the steepest slope possible.

The following guidelines are provided for your consideration in the preparation of your design.

1) Meet size requirements to fit inside the track. No part of your design can exceed over the limits of
the track.
2) Use whatever power sources (electrical, solar, mechanical, etc…) to move your transporter.
3) Design a mechanism that will deliver the object to the specified area.
4) Construct your model that has no loose parts.
5) Doesn’t exceed 2 pound in weight.
6) Consider the travel time and the friction between transporter and track surfaces.
7) Cost of material used is not to exceed $20.00 (exclude Lego Mindstorm if you use it)
8) Transporter should be capable of making 1000 runs.
9) Simplicity of design
10) Ingenuity
11) Ease of loading

Your design package should include following:

1) prototype of the transporter

2) complete documentation of the design (include explanation of how it works)
3) 3D model and complete working drawing of a component
4) unit cost and analysis with sample calculation

8‐1
 2. Slowpoke Toy Transporter

The Veco Toy Company is seeking proposals from engineering firms to design a special purpose
toy transporter. The winning bid should be able to furnish a prototype model along with necessary
documentation. For this purpose, the company will sponsor a competition for all bidders at the end of the
due date which will be announced later.

The purpose of the transporter is to move two objects which have the size and weight of golf balls,
and down a ramp which has a slope of 0.5 for a distance of 72 inches. Once the transporter delivers the
objects to the bottom of the ramp, it will automatically throw the object to a box that is measured
15x15x15 inches and 15 inches away from the delivery dock. The ramp roadway is 11.5 inches wide and
has a 1.5 inches curb on each side. There will be a guide stick attached to the middle of the ramp and
measured 0.5 in high and 1.5 in wide. The loading platform and delivery dock each measure 11.5 inches
wide and 7 inches long. The transporter is to be held in place at the loading dock by a block gate. The
transporter will be stopped at the delivery dock by a bumper that is 2.5 inches high. The two objects will
be loaded by hand at loading platform and unloaded automatically at the delivery dock at bottom of the
hill. The company would like to see which model can run down the ramp with the slowest speed but not
less than 1.2 in/sec.

The following guidelines are provided for your consideration in the preparation of your design.

1) Meet size requirements to fit inside the track. No part of your design can exceed over the limits of
the track.
2) Electrical power (motor) can be used to deliver the ball but not allowed to move your transporter.
3) The speed of transporter should be in approximate constant speed.
4) Design a mechanism that will deliver the object to the box.
5) Construct your model that has no loose parts.
6) Total weight should not exceed 2 pound.
7) Consider the friction between transporter and track surfaces.
8) Cost of material used is not to exceed $20.00 (exclude Lego Mindstorm if you use it)
9) Transporter should be capable of making 1000 runs.
10) Simplicity of design
11) Ingenuity
12) Ease of loading

Your design package should include following:

1) Prototype of the transporter

2) Complete documentation of the design (include explanation of how it works)
3) 3D model in Pro/Engineer and complete working drawing (at least one component)
4) Unit cost and analysis with sample calculation

8‐2
 3. Smart Vehicle

The Veco Toy Company is seeking proposals from engineering firms to design a smart vehicle.
The winning bid should be able to furnish a prototype model along with necessary documentation. For this
purpose, the company will sponsor a competition for all bidders at the end of the due date which will be
announced later.

The purpose of the smart vehicle is to escape from a large square field track without using any
remote control. The vehicle should be fit in the space of 8 x 5.5 inches but no height restriction. The track
will be measured 48 x 48 inch and constructed by plywood with 3 inches high fences around the track
borders and black path line inside as shown in the following figure. The only opening gate is located in the
middle of a side and measured as 6 inch wide. The company would like to see which vehicle model can
run out of the track as fast as possible. The vehicle will start on anywhere inside of the field track and time
will be measured. The best design award will be given based on the best average time of the two.

The following guidelines are provided for your consideration in the preparation of your design.

1. Meet size requirements to fit in the space. No part of your design can exceed over the limits of the
space.
2. Use whatever robotic vehicle you can get. However, you can’t purchase a commercial robotic
vehicle without any major modification.
3. There will be several sets of LEGO MindStorm Robotic Kit available, and the company will be
glad to let you borrow one.
4. Design a vehicle that can go forward, backward and turn.
5. Design a piece of your model (any piece you choose) using Pro/Engineer.
6. Use a 3D printer to make a useable part.
7. Construct your model that has no loose parts.
8. Learn some programming skills and program your vehicle.
9. Cost of material used is not to exceed $20.00 besides Lego MindStorm if you use it.
10. Vehicle should be capable of making 1000 runs.
11. Make you design simple and creative.

Your design package should include following:

 prototype of the vehicle

 complete report of the design (include explanation of how it works and unit cost analysis)
 3D piece model you designed in Pro/Engineer and complete working drawing
 presentation materials (may include PowerPoint file and other related materials)

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8‐4
 4. One Thing Leads to Another

The Veco Toy Company is seeking proposals from engineering firms to design a special contraption
that incorporates a minimum of four (4) simple machines to set off a chain reaction of events that
initiated by a golf ball. A simple machine is a device that is used to change the amount, speed or direction
of an applied force (this is also known as gaining mechanical advantage). The winning bid should be able
to furnish a prototype model along with necessary documentation.

The contraption may consist of any safe appropriate materials.

Construction Criteria:

o The operation of the contraption must be accomplished within a 2' x 2' x 2' work envelope
o Each simple machine must trigger one the following devices:
1. pop a balloon
2. pour .5 liters of water (or safe liquid)
3. release a vehicle which travels at least 10 feet (no high speed or pointed projectiles)
4. turn on or off an electrical device (this device must be battery operated, no house current)
o The golf ball must enter the contraption at a height of 12" from the bottom of the base and 3" from
one edge of the base
o The golf ball must exit the contraption at a height of 12" from the bottom of the base and 3" from
the same entrance edge of the base
o The contraption must be safe to operate and properly guarded to prevent personal injury
o The vehicle may not be launched or released from the entrance or exit sides of the contraption

The following guidelines are provided for your consideration in the preparation of your design.

o Meet size requirements to fit inside the 2 feet cube. No part of your design can exceed over the
limits of the envelope with the exception of the travel of the vehicle
o The contraption must be capable of performing repeatedly
o Each event must be triggered by the action of the preceding event
o The initial event must be activated by a golf ball
o More than 4 simple machines are encouraged
o The golf ball that enters the contraption must be the same ball that exits
o Cost of material used is not to exceed $20.
o Each team will have 3 trial runs and all events must successfully be activated
o Simplicity of design
o Ingenuity

Your design package should include following:

1. prototype of the contraption

2. complete documentation of the design (include explanations in math and science concepts and
principles of how they work)
3. 3D model in Pro/Engineer and complete working drawing (at least one machine)
4. unit cost and analysis with sample calculation

8‐5
 5. Cargo Boat

The Veco Toy Company is seeking proposals from engineering firms to design a cargo boat that
can carry and deliver the load (a golf ball) to the other side of the pond. The winning bid should be able to
furnish a prototype model along with necessary documentation. For this purpose, the company will
sponsor a competition for all bidders at the end of the due date which will be announced later.

A load must be transported across a stretch of water. This load must be safe and dry when it gets to its
destination. An electric motor will be provided for your design.

The design will be judged in three categories: 1) speed and accuracy of the boat, 2) completion of
load delivery and 3) beauty esthetics. More detail information will be provided later.

The following guidelines are provided for your consideration in the preparation of your design.

1. The boat must completely fit within a Xerox paper box (see box in classroom).
2. Additional energy can be used besides the batteries, but no combustion reactions.
3. Once the stopwatch is started the design is completely automatic, no remote control allowed.
4. The boat and all parts must be safe, nontoxic and can’t be left in the pond.
5. The boat must have a “tether”, so if the boat get stuck or sinks, it can be pulled out.
6. A 4.5 volt electric motor and three D cell batteries will be supplied, but the motor should not get
wet.
7. The golf ball must stay on the shore once delivered.
8. A total of $45.00 per group is the maximum estimated cost of each design. Even if you don’t buy
the parts, you must account for an accurate estimate of the cost of every part.
9. Extra credit for boats that return to the starting post on their own.
10. If no one makes it across the pond, distance will judged by the tether.

Your design package should include following:

1. prototype of the boat

2. complete documentation of the design (include explanation of how it works)
3. 3D model and complete working drawing of a component
4. unit cost and analysis with sample calculation

8‐6
 6. Automata Challenge

The Veco Toy Company is seeking proposals from engineering firms to design an automaton toy.
The winning bid should be able to furnish a prototype model along with necessary documentation.

The design of automaton should be an original mechanical device using at least three (3) simple
mechanisms (see attached document). The following guidelines/restrictions are provided for your
consideration in the preparation of your design.

1. The total size of the design should not exceed the box of 6x8x12 inches.
2. It must have a “hand crank” to turn the movement of internal parts.
3. All parts must be drawn on the CAD (Pro/Engineers) and the parts are to be dimensioned.
4. Drawing of parts can be printed full size using printer and glued to material for cutting accurately
with saw or other tools.
5. Bonus will be give if an assembly drawing is made to show how internal parts fit together.
6. A prototype will be constructed to test design ideas.
7. Each team need to make a presentation to show your efforts and explain what is being designed on
the due date. You can take digital photos to document your group’s progress.
8. The chosen completed automata maybe put on display in the display cases in the college.
9. The electrical motor and other devices can be used after approval by the company.
10. A total of $45.00 per group is the maximum estimated cost of each design. Even if you don’t buy
the parts, you must account for an accurate estimate of the cost of every part.

Your design package should include following:

1. Prototype of your design of automata.

2. Complete documentation of the design (include explanation of how it works)
3. Presentation package may include PowerPoint file, poster, video or any other components.
4. 3D model and complete working drawing of components.
5. Unit cost and analysis with sample calculation.

8‐7
 7. Solar Cooker

The Veco Outdoors Equipment Company is seeking proposals from engineering firms to design an
environmentally friendly portable solar cooker to reduce the burning of fuel that increases global
warming. The winning bid should be able to furnish a prototype model along with necessary
documentation. For this purpose, the company will sponsor a competition for all bidders at the end of the
due date which will be announced later.

The solar cooker must be able to boil 1 cup of water (in a specific pot) that will then be used to
cook a hot dog. The cooker should be effective in all but extreme weather.

The design will be judged in three categories: 1) cooking efficiency, 2) easy to setup and 3) easy to
operate. More detail information will be provided later.

The following guidelines are provided for your consideration in the preparation of your design.

1. All energy must come from the sun with no previous charged energy storage devices.
2. The solar energy can be converted into electrical energy, however batteries are not allowed.
(unless they are solar batteries charged during the 2 hours of demonstration)
3. A total of $45.00 per group is the maximum estimated cost of each design. Even if you don’t
buy the parts, you must account for an accurate estimate of the cost of every part. (max $45 is
refundable from the company with receipts)
4. Outside resources for ideas are allowed as long as appropriate credits and references to the
originators are made.
5. No ready-to-make commercial solar cooker is allowed.
6. The cooker should be portable to some degree and easy to setup.

Your design package should include following:

1. prototype of the solar cooker

2. complete documentation of the design (include explanation of how it works)
3. 3D model and complete working drawing of a component
4. unit cost and analysis with sample calculation
5. presentation and promotion materials (Powerpoint file, video clip, flyer, etc…)

8‐8
 8. Trash Collector

The Veco Toy Company is seeking proposals from engineering firms to design a robot that will
collect the trash bags from grounds and dump to the trash bin. The winning bid should be able to furnish a
prototype model along with necessary documentation. For this purpose, the company will sponsor a
competition for all bidders at the end of the due date which will be announced later.

The task of this project is to design a toy robot that will collect balls (trash bags) on the ground of a
large square field track and throw them to the basket (trash bin) on the four corners of the field without
using any remote control. The vehicle should be fit in the space of 8 x 5.5 inches or smaller but no height
restriction. The track will be measured 48 x 48 inch and constructed by plywood with 3 inches high fences
around the track borders and black path line inside as shown in the following figure. For the competition,
every design will have two trials and the one which collects the most balls in the basket within a specified
time will win.

The following guidelines are provided for your consideration in the preparation of your design.

1. There will be several sets of LEGO Mindstorm Robotic Kit available, and the company will be
glad to let you borrow one.
2. Design a vehicle that can go forward, backward and turn.
3. Design a collector piece using Pro/Engineer.
4. Use a 3-D printer to make a useable part OR use machine shop to make a prototype.
5. Construct your model that has no loose parts.
6. Total weight should not exceed 4 pound.
7. Learn some programming skills and program your vehicle.
8. Extra cost of material should not exceed $20.00 besides Lego Mindstorm Robot Kit and
collector. Attach the receipt to get reimbursed.
9. Vehicle should be capable of making 1000 runs.
10. Make you design simple and creative.

Your design package should include following:

1. Prototype of the robot.

2. Complete documentation of the design (including final report and your presentation, both in
electronic and hard copies)
3. The 3D model in Creo and complete working drawing of collector you designed.
4. The unit cost and analysis with sample calculation

8‐9
8‐10
 Appendix A
Manufacturing Processes
APPENDIX A – Manufacturing Process
Following information is copied from websites:
http://en.wikipedia.org/wiki/Manufacturing

http://en.wikipedia.org/wiki/List_of_manufacturing_processes

Manufacturing is the transformation of raw materials into finished goods

for sale, or intermediate processes involving the production or finishing of semi-manufactures. It may
include following categories:

 1 Casting:
Casting is a manufacturing process by which a liquid
material is usually poured into a mold, which contains a
hollow cavity of the desired shape, and then allowed to
solidify. The solidified part is also known as a casting,
which is ejected or broken out of the mold to complete
the process. Casting materials are usually metals or
various cold setting materials that cure after mixing two
or more components together; examples
are epoxy, concrete, plaster and clay. Casting is most
often used for making complex shapes that would be
otherwise difficult or uneconomical to make by other methods.

 2 Molding
Molding is a process of manufacturing by shaping pliable
raw material using a rigid frame or model called a pattern.
A mold or mould is a hollowed-out block that is filled with
a liquid like plastic, glass, metal, or ceramic raw materials.
The liquid hardens or sets inside the mold, adopting its
shape. A mold is the counterpart to a cast. Typical uses for
molded plastics include molded furniture,
molded household goods, molded cases, and structural
materials.

 3 Forming
Forming, or metal forming, is the metalworking process of
fashioning metal parts and objects through mechanical
deformation; the workpiece is reshaped without adding or
removing material, and its mass remains unchanged. Forming
operates on the materials science principle of plastic deformation,
where the physical shape of a material is permanently deformed.

A‐1
 4 Machining

Machining is any of various processes in which a piece of raw

material is cut into a desired final shape and size by a controlled
material-removal process. The processes used the most are turning,
boring, drilling, milling, broaching, sawing, shaping and tapping. In
these "traditional" or "conventional" machining processes, machine
tools, such as lathes, milling machines, drill presses, or others, are
used with a sharp cutting tool to remove material to achieve a desired
geometry.

A person who specializes in machining is called a machinist. A room,

building, or company where machining is done is called a machine
shop. Much of modern day machining is carried out by computer numerical
control (CNC), in which computers are used to control the movement and
operation of the mills, lathes, and other cutting machines.

 5 Joining

Joining process is a process that joins the materials together. The most
common one is the all types of welding (arc welding, laser welding,
shielded metal gas welding, gas tungsten arc welding, resistance welding,
etc), brazing, soldering, adhesive bonding (glue, epoxy, etc), fastener (bolt
and nut, nails, etc), press fit.

 6 Rapid manufacturing
Rapid manufacturing is a process of making a three-dimensional solid
object of virtually any shape from a digital model. 3D printing is achieved using an additive process,
where successive layers of material are laid down in different shapes. 3D printing is also considered
distinct from traditional machining techniques, which mostly rely on the removal of material by methods
such as cutting or drilling (subtractive processes).
A materials printer usually performs 3D printing processes using digital technology.
The first working 3D printer was created in 1984 by Chuck Hull of 3D Systems
Corp. Since the start of the 21st century there has been a
large growth in the sales of these machines, and their
price has dropped substantially.
The 3D printing technology is used for
both prototyping and distributed manufacturing with
applications in architecture, construction
(AEC), industrial design, automotive, aerospace,
military, engineering, civil engineering, dental and
A‐2
medical industries, biotech (human tissue replacement), fashion, footwear, jewelry, eyewear, education,
geographic information systems, food, and many other fields. It has been speculated[5] that 3D printing
may become a mass market item because open source 3D printers can easily offset their capital costs by
enabling consumers to avoid costs associated with purchasing common household objects.

Reference
Following are video clips:

How Products Are Made: vol 1, 2, 3, 4, 5, 6 ,7

http://www.madehow.com/

AIM Manufacturing Videos and virtual factory tours

http://manufacturing.stanford.edu/

eFunda: Engineering Processes: hot forming, cold forming, heat treatment, etc.
http://www.efunda.com/processes/processes_home/process.cfm

Innovations at Work ‐ Extreme Testing ‐ BMW North America:

http://www.bmwusa.com/Standard/Content/Innovations/Engineering/Default.aspx

Metal, Plastic, and Ceramic Search Index

Searchable list of plastics, metals, and ceramics leading to detailed data sheets with dielectric
constants, dissipation factors, poisson's ratio, glass transitions, and Vicat softening points.
http://www.matweb.com/search/SearchSubcat.asp

How Everyday Things Are Made

http://manufacturing.standford.edu/

A‐3
APPENDIX B – Basic Machine Shop Practice and Tools
B.1 Hand Tools

B.1.1 Tools for Measuring

1. Carpenter’s Square
 Utility tool for measuring, squaring, and figuring pitch
2. Divider
 Used for quick and easy layouts in design
3. Dial Caliper
 Used the measure the inside/outside thicknesses of materials
4. Three‐Sided Drafter’s Ruler
 Used to scale drawings
5. Combination Alidade Protractor
 Used for measuring navigation
6. Try Square
 Square used for measuring inside and outside angles of 90 degrees
7. Outside Calipers
 Used to measure the external size of an object
8. Round 360 degree Protractor
 Used to establish any angle
9. Folding Stick Ruler
 Hard ruler used to measure distance
10. Rafter Angle Speed Square
 Utility square used to mark and cut pitches and angles
11. Metal Ruler
 12 inch metal ruler used for measuring and drafting
12. 16 Inch Combination Square
 Long combination square used to measure distance and 45 and 90 degree angles
13. 100 foot Metal Roll Tape
 Used for measuring longer distances up to 100 feet
14. 26 Foot Tape Measure
 Tape usually worn on a belt or pouch used to measure distance up to 26 feet
15. Six Inch Combination Square
 Mainly used for marking and measuring small pieces
16. Center Head
 Used on combination blade to measure center lines on round dowels
17. Protractor Head
 Used with combination blade to mark any angle
18. Inside Calipers
 Used to measure the internal size of an object
19. Compasses
 Used to measure and draw circles

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B.1.2 Tools for Cutting and Shaping
1. Handsaw
 Used for straight cuts through wood
2. Hacksaw
 Used for cutting metal and PVC plastic
3. Hand Plane
 Used for smoothing and shaping wood surfaces
4. Drywall Saw
 Used for cutting Drywall with special teeth that don’t clog with dust
5. Utility Knife
 Used for cutting numerous materials when a knife is needed
6. Backsaw
 Used for specialized cutting of wood for joints and joinery
7. Dremel Tool
 Used for cutting and shaping wood, metal, and plastics
8. Hole Saws
 Used for cutting holes in materials for piping and grommets

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9. Exacto‐Knives
 Used for specific cuts in balsa wood, paper, and other soft materials
10. Wire Stripper/Cutter
 Used for cutting lengths of copper wire and removing their sheaths
11. Tin Snips
 Used for cutting sheet metal
12. Industrial Scissors
 Used for cutting through tough, thick materials
13. Coping Saw
 Used for cutting shapes and shaping wood to fit
14. Wood Chisels
 Used to remove wood by cutting material with a sharp edge
15. Files
 Used to smooth and shape metal and wood finely
16. Rasps
 Used to aggressively remove and shape wood

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B.1.3 Tools for Drilling Holes
1. Right Angle Drill
 Drill used in small areas that a normal drill would not fit into
2. Small Two‐Speed 12 Volt Drill
 Used for drilling holes with a limited 3/8 inch chuck for home use only
3. Medium Variable Speed 14 Volt Drill
 Used for drilling and screwing in a higher capacity than a hobbyist’s drill
4. Industrial 18 Volt Variable Speed Drill with Clutch and ½ Inch Chuck
 Used in a professional capacity for heavy duty use
5. Twist Drill Bit Index
 Index holding bits that range in size from 1/8 inch to ½ inch
6. Paddle Bits
 Aggressive bit used to bore through wood to fit wiring or small pipe through
7. Forstner Bits
 Bits used in a drill press to cut smooth, clean holes
8. Lip and Spur(Brad Point) Drill Bits
 Used to cut clean and clear holes through wood and soft materials without blowout

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B.1.4 Tools for Joining Parts
1. Contact Cement
 Placed on both surfaces being joined resulting in a strong bond
2. Carpenter’s Wood Glue
 Used for a strong bond when joining wood pieces
3. Heavy Duty Epoxy Resin
 A two‐part resin when mixed together creates a very strong bond
4. Duct Tape
 Tape for sealing duct work that also has numerous other uses
5. Drywall Screws
 Used in drilled holes to joining two pieces of material together
6. Nails
 Used with a hammer to join two pieces of wood together
7. Staple Gun
 Gun that shoots staples into the material being joined together to form a strong bond
8. Tape
 Has one sticky side to help bond light materials to each other
9. One‐Handed small clamp
 Uses slight pressure to hold two pieces together
10. C‐Clamp
 Used to clamp tools to a bench also used when gluing pieces together
11. Spring Clamps
 Usually used as a third hand to lightly hold pieces in place
12. Corner Clamp
 Holds together two 45 degree pieces forming a tight corner
13. Three‐Point Clamp
 Used to clamp edges onto a surface
14. Spring Clamp
 Used for lightly holding materials in place
15. Small Flat Bar Clamp
 Used to secure tools or materials to a bench
16. Longer Flat Bar Clamp
 Great for securing materials together within a longer range of thickness

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B.1.5 Tools for Wiring
1. Soldering Gun
 Portable corded gun that can be used without a station
2. Soldering Gun Replacement Tips
 Tips to replace burned out tips
3. Heat Shrink Tubing
 Sleeve fits over new wire and is heated to cover any bare wires
4. Soldering Replacement Tip
 Used to replace tips when they burn out
5. Soldering Station
 Permanently set station used for soldering on a workbench
6. T‐Stripper
 Used for stripping wires and cutting them
7. Wire Stripper/Cutter
 Used for stripping wires and cutting them
8. V‐Notch Stripper
 Used for removing the outside casing on copper wire

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9. Scissor Style Crimping Tool
 Used to crimp terminals together and size screws
10. Stripmaster
 One step stripping action reducing stripping time
11. Weighted Base with Alligator Clips
 Holds wires so they can be soldered together
12. Silver Bearing Solder
 Lead‐Free solder
13. Solder
 Rosin core .5 oz weight
14. Solder
 Rosin core 15 gram weight
15. Solder
 Solder on a spool
16. Water Soluble Flux
 Used in the soldering of two wires with lead‐free solder
17. Solder removing tool
 Removes excess solder from the wires being soldered together

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B.2 Power Tools
B.2.1 Saw

A bandsaw is a power tool which uses a blade consisting of a

continuous band of metal with teeth along one edge to cut various
work pieces. It's also a useful machine in a woodworking shop.
The band usually rides on two wheels rotating in the same plane,
although some band saws may have three or four wheels. Band
sawing produces uniform cutting action as a result of an evenly
distributed tooth load. Bandsaws are used for woodworking,
metalworking, or for cutting a variety of other materials. They are
particularly useful for cutting irregular or curved shapes, but can
make straight cuts. The minimum radius of a curve that can be cut
on a particular saw is determined by the width of the band and its
kerf.

A compound miter saw has a rotating vertical pivot

allowing the cutter head & blade to be tilted (or
beveled) sideways in addition to the horizontally
rotating table. This allows vertical & horizontal angled
cuts as well as cuts angled in both planes, such as often
required in crown molding. Many compound miter
saws are single action, meaning that they tilt only to
one side of the vertical and not both sides. Some
compound miter saws are dual action, meaning they
can tilt both ways. Both saws can make identical cuts,
but single action saws may require the workpiece to be
flipped between cuts.

B.2.2 Drill

A drill press (also known as a pedestal drill, pillar drill, or

bench drill) is a fixed style of drill that may be mounted on a
stand or bolted to the floor or workbench. A drill press consists
of a base, column (or pillar), table, spindle (or quill), and drill
head, usually driven by an induction motor. The head has a set
of handles (usually 3) radiating from a central hub that, when
turned, move the spindle and chuck vertically, parallel to the
axis of the column. The table can be adjusted vertically and is
generally moved by a rack and pinion; however, some older
models rely on the operator to lift and re-clamp the table in
position. The table may also be offset from the spindle's axis
and in some cases rotated to a position perpendicular to the
column. The size of a drill press is typically measured in terms
of swing. Swing is defined as twice the throat distance, which
is the distance from the center of the spindle to the closest edge
of the pillar. For example, a 16-inch (410 mm) drill press has an
8-inch (200 mm) throat distance.

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B.2.3 Sander

An oscillating spindle sander

is a sander mounted on a
spindle that both rotates and
oscillates in and out or up and
down along the axis of the
spindle. Good for sanding
curves and contours that
would be difficult with hand
or orbital sanding.

A disc sander is most

commonly implemented as a
stationary machine that consists of a replaceable circular shaped
sandpaper attached to a wheel turned by an electric motor or
compressed air. These are usually used in conjunction with a belt sander which gives a flat, larger surface
with a table and belt that moves along two rollers. The usually wooden work piece, (although other
materials can be shaped and worked on such as plastics, metals and other soft materials), is sat on a front
bench that can be adjusted to various angles. It can be used for rough or fine sanding depending on the
sanding grit used.

B.2.4 Lathe

Lathes are used in woodturning, metalworking, metal

spinning, thermal spraying, parts reclamation, and glass-
working. Lathes can be used to shape pottery, the best-known
design being the potter's wheel. Most suitably equipped
metalworking lathes can also be used to produce most solids
of revolution, plane surfaces and screw threads or helices.
Ornamental lathes can produce three-dimensional solids of
incredible complexity. The workpiece is usually held in place
by either one or two centers, at least one of which can
typically be moved horizontally to accommodate varying
workpiece lengths. Other work-holding methods include
clamping the work about the axis of rotation using a chuck or
collet, or to a faceplate, using clamps or dogs.

B.2.5. CNC Machine

A CNC router is a computer controlled cutting machine. These are related to the hand held router. Instead
of hand held routing, the tool paths can be controlled via computer numerical control. It is a computer-
controlled machine for cutting various hard materials, such as wood, composites, aluminum, steel,
plastics, and foams. It is one of many kinds of tools that have CNC variants. A CNC router is very similar
in concept to a CNC milling machine.

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CNC routers are generally available in 3-axis and 5-axis
CNC formats. Every axis is controlled by a separate motor
to create an independent motion. Overall, it can make the
tool path in any curves in 3-D space.
The CNC router is controlled by a computer. Coordinates
are uploaded into the machine controller from a separate
CAD program. CNC router owners often have
two software applications—one program to make designs
(CAD) and another to translate those designs into a 'G-
Code' program of instructions for the machine (CAM). As
with CNC milling machines, CNC routers can be
controlled directly by manual programming, and
CAD/CAM opens up wider possibilities for contouring,
speeding up the programming process and in some cases
creating programs whose manual programming would be,
if not truly impossible, certainly commercially impractical.
A CNC router typically produces consistent and high-
quality work and improves factory productivity. Unlike a
jig router, the CNC router can produce a one-off as
effectively as repeated identical production. Automation and precision are the key benefits of CNC router
tables.
A CNC router can reduce waste, frequency of errors, and the time the finished product takes to get to
market. For example, CNC routers can perform the tasks of many carpentry shop machines such as
the panel saw, the spindle moulder, and the boring machine. It can also cut mortises and tenons.
A CNC router can be used in the production of many different items, such as door carvings, interior and
exterior decorations, wood panels, sign boards, wooden frames, moldings, musical instruments, furniture,
and so on. In addition, the CNC router helps in the thermoforming of plastics by automating the trimming
process. CNC routers can help ensure part repeatability and sufficient factory output.

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B.3 3-D Printer
The 3D printer is getting more and more popular
these days because it can easily make product and make
it fast with low cost. Stratasys invented FDM
Technology in 1980s and developed a range of systems
that appeal to large manufacturers, designers, engineers,
educators and other professionals. The Dimension
1200es 3D printing system from Stratasys in Rockville
campus will allow instructors to print the product of students’ design quickly.

The 3D printers that run on FDM Technology build parts layer-by-layer

by heating thermoplastic material to a semi-liquid state and extruding it
according to computer-controlled paths. It uses two materials to execute a print
job: modeling material (ABSplus) , an industry type of plastic material which
constitutes the finished piece, and support material, which acts as scaffolding.
Material filaments are fed from the 3D printer’s material bays to the print head,
which moves in X and Y coordinates, depositing material to complete each
layer before the base moves down the Z axis and the next layer begins. Once

the 3D printer is done building, the user breaks the support material away
or dissolves it in detergent and water, and the part is ready to use.

After the 3D solid model is created using Creo or other 3D CAD

software, it is saved as STL file. Then the STL file will be imported to the
Stratasys software and user can determine the tool path for the 3D printer
and specify the layer thickness to create the model from durable
thermoplastics. It may take a few hours to complete the printing for the
model size around 2x2 inches. After the supporting materials removed, a
useable product is done.

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 Chapter 8
Examples of Design Projects