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Progettazione di Materiali e Processi

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1 Progettazione di Materiali e Processi
Università degli Studi di Trieste Facoltà di Ingegneria Corso di Laurea in Ingegneria Chimica e dei Materiali A.A

2 CALENDAR: TEXTBOOKS: CONTACTS:
September 20th – November 29th (tentative) TEXTBOOKS: Ashby - Materials Selection in Mechanical Design Ashby – Materials and the Environment Ashby, Johnson – Materiali e Design Basic materials science and engineering textbooks (Smith, Callister, Shakelford,…) CONTACTS: Vanni Lughi Building B, Room 48 (228) Office:

3 Modalità d’Esame Per passare l’esame:
Verifiche di fine modulo (voto) ed esercizi (passa/non passa) Progetto-tesina finale: Presentazione di un progetto-tesina su uno degli argomenti del corso; tema da concordare con uno dei docenti del corso a scelta dello studente La tesina viene valutata dal docente che ha seguito la tesina e vale come esame finale Il voto del progetto-tesina determina il voto dell’esame per il 50% L’esame viene registrato con il prof. Lughi

4 PRODUCT (MATERIALS) AND PROCESS DESIGN
Intro Design, Product, Process Product Design; Process Design; Product and Process Design Material, process, shape, properties, function Example Fundamentals Identification of needs (market; coevolution; true need) Types of design Design tools Databases Analytical tools Simulation tools Design process simulazione di processo, fluidodinamica, impianti; reattori; termodinamica chimica; simulazione molecolare; ceramici e nanostrutturati; polimeri; TFC; Dinamica e controllo dei processi chimici; Chimica industriale; sistemi complessi (reologia); disegno di macchine; gestione industriale; meccanica applicata; metallurgia e corrosione; scienza delle costruzioni; tecnologia meccanica; … Selection and design of materials and processes (Lughi) Tools for optimal systematic selection Design of materials: case studies (nano, meso, microstructures; hybrid materials; composites) Design of thermal exchange processes (Cortesi) Advanced tools and methods (ad-hoc lectures and seminars: FEM, product/process economics, Life Cycle Assessment, …) Special topic seminars (Intellectual Property, product evaluation, materials in industrial design, theory of scenarios, rapid plant assessment, material selection in engines, design for recycle, refurbish, reuse) Previous classes + This course

5 Progettazione e selezione di materiali e processi (6 crediti) - Lughi
Programma del corso (1) Progettazione e selezione di materiali e processi (6 crediti) - Lughi Introduzione: Materiali come opportunità nel progetto; dati e strumenti per la progettazione; sommario delle principali famiglie di proprietà dei materiali. Selezione dei materiali: Indici dei materiali e indici strutturali; uso dei diagrammi di Ashby; selezione con obiettivi e vincoli multipli; selezione di materiali e forme; materiali ibridi; casi di studio. Utilizzo del programma CES. Cenni alla selezione di processi. Introduzione alla selezione dei materiali con vincoli ambientali. Esempi di design avanzato: metamateriali; bandgap engineering; materiali ibridi Analisi economica di processi chimici. Stime costi capitale e operativi. Analisi di profittabilità, ritorno di investimento. Seminari

6 Progettazione di scambiatori di calore (3 crediti) – Prof. Cortesi
Programma del corso (2) Progettazione di scambiatori di calore (3 crediti) – Prof. Cortesi Definizione di impianto chimico e stabilimento. Servizi. Normalizzazione: tipi di progetti e di rappresentazioni (disegni e schemi). Normativa nelle apparecchiature Metodo generale di progettazione di uno scambiatore di calore. Normative. Meccanismi di sporcamento e modalità di prevenzione. Scambiatori a fascio tubiero: Normative. Progettazione termica di uno scambiatore: definizioni di temperature di processo. Efficienza di uno scambiatore. T di approccio e di cross. Efficienza di scambio termico. Scambiatori in serie. Coefficienti di scambio termico e perdite di carico lato tubi e lato mantello. Applicazione di metodi di calcolo approssimati (esempio Kern) e rigorosi (esempio Bell).

7 PRODUCT (MATERIALS) AND PROCESS DESIGN
Intro Design, Product, Process Product Design; Process Design; Product and Process Design Material, process, shape, properties, function Example Fundamentals Identification of needs (market; coevolution; true need) Types of design Design tools Databases Analytical tools Simulation tools Design process simulazione di processo, fluidodinamica, impianti; reattori; termodinamica chimica; simulazione molecolare; ceramici e nanostrutturati; polimeri; TFC; Dinamica e controllo dei processi chimici; Chimica industriale; sistemi complessi (reologia); disegno di macchine; gestione industriale; meccanica applicata; metallurgia e corrosione; scienza delle costruzioni; tecnologia meccanica; … Selection and design of materials and processes (Lughi) Tools for optimal systematic selection Design of materials: case studies (nano, meso, microstructures; hybrid materials; composites) Design of thermal exchange processes (Cortesi) Advanced tools and methods (ad-hoc lectures and seminars: FEM, product/process economics, Life Cycle Assessment, …) Special topic seminars (Intellectual Property, product evaluation, materials in industrial design, theory of scenarios, rapid plant assessment, material selection in engines, design for recycle, refurbish, reuse) Previous classes + This course

8 PRODUCT (MATERIALS) AND PROCESS DESIGN
Intro Design, Product, Process Product Design; Process Design; Product and Process Design Material, process, shape, properties, function Example Fundamentals Identification of needs (market; coevolution; true need) Types of design Design tools Databases Analytical tools Simulation tools Design process

9 PRODUCT (MATERIALS) AND PROCESS DESIGN
Intro Design, Product, Process Product Design; Process Design; Product and Process Design Material, process, shape, properties, function The art or action of conceiving of and producing a plan or drawing of something before it is made A plan or drawing produced to show the look and function or workings of a building, garment, or other object before it is made Decide upon the look and functioning of (a building, garment, or other object), by making a detailed drawing of it Do or plan (something) with a specific purpose in mind Design An article or substance that is manufactured or refined for sale A substance produced during a natural, chemical, or manufacturing process Product A systematic series of mechanized or chemical operations that are performed in order to produce something Process

10 Product Design (…as seen by an engineer…)
Ashby, Jones – Materiali e Design

11 Product must work, be safe, economical
Technical, Industrial, and Product Design Product design Industrial design Aesthetics Associations Perceptions Satisfaction Product must be life-enhancing Technical design Usability Product must be easy to understand and use What are the ingredients of a successful product? First, its functionality: the product must work well, be safe and economical. Second, its usability: good functionality is not much use if the consumer for whom the product is intended is unable to make it work. Functionality and usability alone are not enough. To succeed in today’s markets, in which many nearly identical products compete, the product must give satisfaction, be life-enhancing. And here these three words appear again – satisfaction has to do with aesthetics, associations and perceptions. Product design, then, requires a combination of technical and industrial design. The lower part of the pyramid tends to be called “Technical design”, the upper part, “Industrial design” suggesting that they are separate activities. It is better to think of think of all three tiers as part of a single process that we shall call “Product design”. Functionality Product must work, be safe, economical

12 What gives a product its character?
Who, what Context where, when why Product design So let us examine what gives a product its character. The product – central circle in this diagram – performs a function for which a market need exists. The first step is to characterise this market, seeking answers to five questions that establish the context: Who? What? Where? Why? When? The next frame elaborates.

13 Establishing the context
«Intentions»: design according to… User Design for public use Design for women/men Design for elders/children Economic factors Design for minimum cost Design for easy assembly Design for mass production Sustainability Design for the environment Design for recycling Design for biodegradability Performance Design for minimum mass Design for max. insulation Men / Women Children / Elderly Sportsmen / Disabled ... Who? What ? Where ? When ? Why? Functionality? Context Home / Office Europe / Africa... Day / Night Occasionally / All the time... Here context is explained in more detail. Who? Who are the target consumers – men, women, children, the elderly, people that are active or disabled? What? What functionality will the product require? Where? Will the product be used in the home, the office, indoors, outside…..? When? When will the product be used: continuously or only occasionally? During the day or at night? Why? Does the product fill a basic need, is it a life-style statement, is it bought to enhance self-image….? The answers to these questions do not “design” the product, but they define the context, and inform or influence all the decisions that follow: they set the mood. To fill a basic need To meet an aspiration ... These steer all decisions that follow -- they set the MOOD

14 What gives a product its character?
Who, what Context where, when why Product design Metals, ceramics Materials polymers, composites Shaping joining Processes surface treatment Aesthetics associations Personality perceptions Product “physiology” Product “psychology” Biometrics Usability Bio-mechanics Back to product character. Products are made of materials, shaped by processes, shown on the left. They provide the flesh and bones so to speak; they create what you might call the physiology of the product. Usability, as we have said, is important. It is a question of matching the product to the physical and mental capabilities of the user. And finally there is personality – the visual and tactile qualities of the product, its associations and they way it is perceived. They create what you might call the psychology of the product. The whole combination create the product character.

15 Plenty of tools to do this
Technical and industrial design Satis- faction Usability Functionality Product must work, be safe and economical What determines product value? Functionality, provided by sound technical design, clearly plays a role. The requirements pyramid shown here has this as its base: the product must work properly, be safe and economical. Sound technical design Proper choice of materials Proper choice of manufacturing process Plenty of tools to do this

16 Usability («ergonomics»)
Satis- faction Usability Functionality Product must be easy to understand and use Functionality alone is not enough: the product must be easy to understand and operate, and these are questions of usability, the second tier of the figure. This has three aspects, listed here. Three aspects Interaction with the human body -- biometrics Interaction with the mind -- intelligibility Interaction with the human environment Now much researched

17 Usability («ergonomics»)
Bio-metric Bio-mechanical Physical matching Scale, movement, posture, work height Force (<230 N, lifting), Attention span Text, Symbols Embossed keys, knobs Audible signals Visual signals Information transfer Operation Feedback Usability Environmental disturbance Noise Vibration Illumination Climate Toxicity 30DB < noise level < 80DB Acceleration < 0.2 m/s2 Light lumens Temp, humidity within limits No toxicity Aspects of usability are classified here following the broad families listed on the previous frame.

18 Examples of bio-mechanical matching
Examples of design to provide usability to compensate for impaired hand and wrist actions.

19 life-enhancing, rewarding
Industrial Design and satisfaction Satis- faction Usability Functionality Product must be life-enhancing, rewarding Three facets Aesthetics -- appealing to the senses -- sight, hearing, feel, taste, smell The third tier of the pyramid is the requirement that the product gives satisfaction: that it enhances the life of its owner. Creating satisfaction has three facets, listed here. They are explored in the frames that follow. Associations -- what does it remind you of ? What does it suggest ? Perceptions -- what is your reaction to it ? How does it make you feel ?

20 Product personality Aesthetics Product personality Associations
Colour, transparency Form Feel, texture Taste, smell Sound The reaction of the 5 senses Associations Wealth (Rolls Royce) Military hardware (Land Rover) Aerospace (many US cars) Plants/animals (VW Beetle) Children’s toys (Smart) What does it remind you of ? Product personality Perceptions Playful -- Silly Responsible -- Irresponsible Feminine – Masculine Rugged -- Threatening And - if you owned it ... Proud -- Disappointed Life-enhancing -- Life diminishing Really cool – Absolute rubbish How does it make you feel ? We are interested here in product personality and the ways in which materials contribute to it. It is a question of aesthetics, associations and perceptions. Anaesthetics dull the five senses. Aesthetics stimulate them. I will use the word here to mean just that: the reaction of the five senses. Thus aesthetics refers to colour, form, feel, texture, sound, smell and taste. Associations: what does the product suggest or remind you of? Wealth? A Rolls Royce is designed to do just that. Military hardware? SUVs like Land Rover exploit the form and colour of military vehicles to suggest ruggedness. Aerospace? American cars of the 1970s derived their styling from aircraft and rockets. Assigning associations is not controversial – most people would agree with those interpretations. Perceptions are another matter. What are your feelings about the product? Does it strike you as feminine or masculine – and do you like it if it does? Is it desirably rugged or undesirably threatening? Attractively playful or just silly? Here different user perceive products differently; the skilful designer creates associations and perceptions that are appeal to the user group for which the product is intended.

21 Do they write 375 times better?
Product Value A product has a cost C the true cost of manufacture, marketing etc. a price P the price at which it is offered to the consumer a value V what the consumer thinks it is worth Parker special edition 3000 euros My Parker pens, 8 euros each Do they write 375 times better? This Unit concerns industrial design – the aspect of design that relates to the visual, tactile, and aesthetic qualities of a product. Successful products use materials not only to fulfil a function, but also to provide satisfaction. The pens on the left cost 8 Euros each. Those on the right cost about 3000 Euros. Do they write 375 times better? Unlikely – those on the left write perfectly well. Yet there is a market for the expensive pens. Why? It is a question of aesthetics, associations and perceptions, words that are explained in a moment. Our interest is in exploring how materials are used to provide these. We start by examining the ingredients of product design, shown on the next viewgraph. Product success requires that C < P < V What determines cost? Technical design, materials, processes, labour What determines price? Cost plus margin What determines value? Both technical and industrial design; -- aesthetics, associations, perceptions

22 Why is Industrial Design important?
Products tend to converge in performance and price ID allows differentiation, enhanced value Product maturity and market saturation ID creates corporate image ID creates brand loyalty Corporate identity ID contributes to quality of life The environment, in the broadest sense Why is industrial design important? Because it is central to creating product identity, maintaining corporate image and providing the consumer with products that satisfy. As products mature and markets saturate, the products of competing manufacturers converge technically -- hardly differ in performance or cost Corporate and product identity are partly created and largely maintained through innovative industrial design Products are part of our environment. Products that give no sensual satisfaction damage the environment

23 Intro Design, Product, Process
Product Design; Process Design; Product and Process Design Material, process, shape, properties, function

24 Function – Material – Shape - Process
Iterative process

25 Function – Material – Shape - Process
Iterative process

26 Function – Material – Shape - Process
MICROSTRUCTURE Iterative process

27 Function – Material – Shape - Process
NANOSTRUCTURE Iterative process

28 Function – Material – Shape - Process
HYBRID MATERIALS Combining: Materials – relate properties to microstructure: controlled nature, scale through alloy design and processing. Mechanics – accept properties as “given”, optimise the geometry Iterative process Textile technology – exploit unique strength and blending properties of fibers

29 Function – Material – Shape - Process
Composites Unidirectional Quasi-isotropic Particulate Cellular structures Foams Honeycombs Triangulated lattices Iterative process Sandwich structures Symmetric sandwiches Many more

30 Function – Material – Shape - Process
MULTISCALE Iterative process

31 PRODUCT (MATERIALS) AND PROCESS DESIGN
Intro Design, Product, Process Product Design; Process Design; Product and Process Design Material, process, shape, properties, function Example Fundamentals Identification of needs (market; coevolution; true need) Types of design Design tools Databases Analytical tools Simulation tools Design process

32 ? Iterative process

33 Need – Concept – Embodiment - Detail
Concepts Embodiments Direct pull Levered pull Spring-assisted pull Geared pull Iterative process

34 Need – Concept – Embodiment - Detail
How are those choices made? Iterative process

35 Iterative process

36 PRODUCT (MATERIALS) AND PROCESS DESIGN
Intro Design, Product, Process Product Design; Process Design; Product and Process Design Material, process, shape, properties, function Example Fundamentals Identification of needs (market; coevolution; true need) Types of design Design tools Databases Analytical tools Simulation tools Design process

37 IDEA VALUE ? OPPORTUNITY VISION

38 researach work, work, research research VISION IDEA VALUE OPPORTUNITY

39 VISION IDEA OPPORTUNITY VALUE
researach work, work, research research VISION IDEA Product / service OPPORTUNITY Market segment VALUE Revenue model

40 VISION IDEA OPPORTUNITY VALUE
researach work, work, research research VISION Strategy IDEA Product / service Core team OPPORTUNITY Market segment Customers VALUE Revenue model

41 VISION IDEA OPPORTUNITY VALUE
researach work, work, research research VISION Strategy Mission IDEA Product / service Core team Operations OPPORTUNITY Market segment Customers Segment size Segment trend Competitors VALUE Revenue model Intellect. Property

42 VISION IDEA OPPORTUNITY VALUE
researach work, work, research research VISION Strategy Mission Specific objectives IDEA Product / service Core team Operations Human resources Organziation OPPORTUNITY Market segment identif. Customers Segment size Segment trend Competitors Market Share identific. VALUE Revenue model Intellect. Property Marketing plan Organization

43 PRODUCT (MATERIALS) AND PROCESS DESIGN
Intro Design, Product, Process Product Design; Process Design; Product and Process Design Material, process, shape, properties, function Example Fundamentals Identification of needs (market; coevolution; true need) Types of design Design tools Databases Analytical tools Simulation tools Design process

44 PRODUCT SPECIFICATION
Design Process NEED Functional Solution-neutral “What”, not “how” Define specifications Determine function Structure Seek working principles Evaluate and select concepts Concept Desing types: Original Adaptive Variant Develop layout, scale, form Model and analyze assemblies Optimize the functions Evaluate and select layout Embodiement Iterate Iterative process Analyze components in detail Select processing route Optimize performance and cost Prepare detailed drawings Detail PRODUCT SPECIFICATION M. F. Ashby

45 Design Process: Available Tools
NEED Design Tools Function modeling Feasibility studies Approximate analysis Geometric modeling Simulation Optimization methods Cost modeling Component modeling Finite Element Analysis Concept Embodiement Iterative process Detail PRODUCT SPECIFICATION M. F. Ashby

46 Design Process: The materials selection point of view
NEED Material selection OUR FOCUS!! Concept All materials (broad selection, low precision) Embodiement Subset of materials Iterative process Detail One material (high precision data) PRODUCT SPECIFICATION M. F. Ashby

47 Product as a technical system
Assembly 1 Component 1.1 Component 1.2 Component 1.3 Technical system Assembly 2 Component 2.1 Component 2.2 Component 2.3 Assembly 3 Component 3.1 Iterative process Component 3.2 Component 3.3 M. F. Ashby

48 Technical system’s analysis - Systems approach: the concept of function -
Energy Materials Information Function 3 Function 1 Energy Materials Information Function 2 Function 6 Function 4 Function 5 Iterative process Subsystems M. F. Ashby

49 Technical system’s analysis - Systems approach: the concept of function –
The bottle opener example Energy Materials Information Generate Force Energy Materials Information Transmit Force Apply Force to Cork Iterative process Direct Pull Levered Pull Geared Pull Direct Push Levered Push Shaft Linkage Gas injection Screw Shear blades Gas pressure M. F. Ashby

50 FUNCTION relation with properties Properties
i.e. material, process, shape Function Shape EXAMPLES OF FUNCTIONS IN MECHANICAL DESIGN: Carry load Transmit load Transmit heat Transmit current Store energy Material Iterative process Process

51 PRODUCT (MATERIALS) AND PROCESS DESIGN
Intro Design, Product, Process Product Design; Process Design; Product and Process Design Material, process, shape, properties, function Example Fundamentals Identification of needs (market; coevolution; true need) Types of design Design tools Databases Analytical tools Simulation tools Design process Selection and design of materials and processes (Lughi) Tools for optimal systematic selection Design of materials: case studies (nano, meso, microstructures; hybrid materials; composites) Design of thermal exchange processes (Cortesi) Advanced tools and methods (ad-hoc lectures and seminars: FEM, product/process economics, Life Cycle Assessment, …) Special topic seminars (Intellectual Property, product evaluation, materials in industrial design, theory of scenarios, rapid plant assessment, material selection in engines, design for recycle, refurbish, reuse) Next lecture: selection strategy and tools…


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