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Design & Manufacturing Seminar Series

Melding human centric product design with engineering analysis and simulation

JR Rowland & Dan Wisniewski
Priority Designs, Columbus, OH

February 22nd 2019, 2:00 – 3:30 pm
Scott Lab E100

Product development requires diligence from many disciplines throughout each step, from the product’s inception and initial research through manufacturing. Dan and JR are engineers at Priority Designs, a product development firm that has been bringing medical devices, sporting goods, consumer products, and industrial equipment to market for over 25 years. Their collective experience has shown the extreme variance of this process: each product is unique, and often their development paths reflect that uniqueness. A product design engineer’s role is often to negotiate conflicting needs, such as optimization for a manufacturing process, maximizing usability, and integrating the desired aesthetic. Very rarely does one product need fully eclipse all others. There are many challenges and approaches to finding the correct balance required for successful development of innovative products.

About the Speakers

JR Rowland, Systems Engineer, UX Design Specialist - JR obtained his BS and MS in Mechanical Engineering from the Ohio State University between 2009 - 2015. His graduate research focused on model predictive control systems and product design, centered around ultra-energy efficient homes. JR has spent the past 4 years working as an engineer at Priority Designs, applying human centered design principles to medical device and sporting goods development.

Dan Wisniewski, Senior Mechanical Engineer - Dan obtained his BS and MS at OSU from 2001-2008. His graduate studies covered a combination of Mechanical Engineering and Design to further his passion for product design. He has more than 11 years of experience as a mechanical engineer developing products in the sporting goods, consumer electronics, home and garden, and medical markets. He has spent the past 9 years at Priority Designs working with companies like Nike, American Standard, Scotts, and many others helping bring their ideas and products to market.


Towards Automatic Tolerancing of Mechanical Assemblies: First-Order GD&T Schema Generation and Tolerance Allocation

Payam Haghighi
Research Scholar, Digital Design and Manufacturing Lab
Mechanical & Aerospace Eng., OSU

January 25th 2019, 1:30 – 2:45 pm
Scott Lab E525

Geometric and dimensional tolerances must be determined not only to ensure proper achievement of design function but also for manufacturability and assemblability of mechanical assemblies. We are investigating the degree to which it is possible to automate tolerance assignment on mechanical assemblies received only as nominal geometry CAD files. First-order tolerance schema development is based purely on assemblability conditions. This includes selecting features to be toleranced, tolerance types, datums, and datum reference frames (DRFs), and tolerance value allocation. We start with automated assembly analysis comprising: assembly feature recognition, pattern recognition, and extraction of dimensional constraints and directions of control (DoC) for all parts in the assembly. This is followed by iterating between tolerance allocation and tolerance analysis using Monte Carlao simulations. Tolerance schema generation is done with a combination of geometric analysis and heuristics, while value allocations are treated as a constraint satisfaction problem in which proposed GD&T values are sent to a stack analysis module and iterated upon until desired acceptance rates are reached.
If time permits, the feasibility of second-order schema development will be developed, one that takes intended design function into account.

Payam Haghighi is a Lab Manager and a research scholar at Digital Design and Manufacturing lab at Ohio State; His research is in Design Automation, Precision Engineering, and Metrology. He received his BS from Sharif University in 2011 and MS from Arizona State in 2015. At OSU he has participated in several projects with industry partners such as Honda R&D, Rolls Royce, and Siemens. He is the author of 16 journal and conference papers on GD&T.


The History of Aircraft Electrical Power Systems and the Dawn of Electric Propulsion

Eric J. Kline,
Engineering Manager, Generators & Ram Air Turbines
SAFRAN Electrical & Power, Twinsburg, Ohio

November 30th, 2018, 10:00 – 11:15 am
Scott Lab E525

Electrical power systems are critical to all modern aircraft for communication, control, sensing, lighting, heating, ventilation, pressurization, de-icing, actuation, and many other functions. Aircraft had no electrical power for the first decade of powered aviation, while today the largest commercial aircraft have about 1 MW of installed electrical generating capacity. Yet, aircraft still only convert 1-2% of the rated engine power to electrical power. In the next decade, from 10-100% of the power used on hybrid-electric and fully-electric aircraft will pass through the electrical system. So there are many challenges ahead to develop and industrialize the high-power generators, motors, and electrical distribution systems that these aircraft will require.

Eric obtained his Bachelors and Masters of Science in Mechanical Engineering from The Ohio State University from 1992-1999. His graduate school on light-weight structures was funded by NASA through an Ohio Space Grant Fellowship.
Since 2002, Eric has been involved in the development of electric motors and generators for consumer, industrial, and aerospace applications. Eric joined Safran in 2012, where he manages the product development engineering and research for Electric Machines (generators and motors) and Ram Air Turbine Systems. Safran is global aerospace technology company that produces aircraft engines, rockets, landing gear, avionics, and electrical systems.


Manufacturability-driven, multi-component topology optimization (MTO) for top-down design of structural assemblies
Kazuhiro Saitou
Professor, Mechanical Engineering, University of Michigan, Ann Arbor

October 26th, 2018, 10:00 – 11:15 am
Scott Lab E525


This talk presents a manufacturability-driven, multi-component topology optimization (MTO) framework for simultaneous design and partitioning of structures assembled of multiple components. Constraints on component geometry imposed by chosen manufacturing processes are incorporated in the conventional density-based topology optimization, with additional design variables specifying fractional component membership which enables continuous relaxation of otherwise discrete partitioning problems. The geometric constraints imposed by various manufacturing processes, such as size, perimeter length, undercut, and enclosed cavities, are also relaxed to enable the manufacturability evaluation of “gray” geometries that occur during the density-based topology optimization. Examples on minimum compliance structural assembly design for sheet metal stamping (MTO-S), die casting (MTO-D), additive manufacturing (MTO-A), and tailored-fiber composite process (MTO-C) show advantages over the conventional monolithic topology optimization. In particular, manufacturing constraints previously applied to monolithic topology optimization gain new interpretations when applied to multi-component assemblies, which can unlock richer design space for topology exploration. The talk will conclude with a brief overview of the latest developments on the MTO framework for continuous fiber printing and for “4D” printing processes.

About the Speaker
Kazuhiro Saitou is Professor of Mechanical Engineering at the University of Michigan, Ann Arbor. He received BEng degree from University of Tokyo, and MS and PhD degrees from the Massachusetts Institute of Technology (MIT), all in Mechanical Engineering. His research interest includes algorithmic and computational design synthesis and design for manufacture and assembly, with applications in mechanical, industrial, and biomedical systems. Prof. Saitou was the recipient of several awards including ASME DfM Kos-Ishii Toshiba Award, Innovative Design Component Award from ARPA-E Lightweighting Technologies Enabling Comprehensive Automotive Redesign (LITECAR) Challenge, Design and Systems Division Achievement Award from Japan Society of Mechanical Engineers, CAREER Award from NSF. He has served as an Associate Editor for ASME Journal of Computing and Information Science in Engineering (JCISE), ASME Journal of Mechanical Design (JMD), and IEEE Transactions on Automation Science and Engineering (T-ASE), and is currently serving as an Associate Editor for JCISE and a Senior Editor for T-ASE. He was a past Chair of the ASME Design Automation Technical Committee (DAC) and the ASME Design for Manufacturing and the Life Cycle Technical Committee (DFMLC), and the Editor-In-Chief for Conference Editorial Board of IEEE Conference on Automation Science and Engineering. He is Fellow of ASME and IEEE.

Product liability analysis in medical device design,

Sandra A. Metzler, D.Sc., P.E.

Professor, Mechanical Engineering, University of Michigan, Ann Arbor

Product liability issues are a concern for engineering designers in every industry, but there are certain liability and legal issues that are unique to medical devices. Distinguishing product liability from medical malpractice can be difficult in certain situations, and the relevant aspects of FDA device approval are also a consideration. It is important for design engineers to understand the theories of product liability used in the U.S. justice system, as well as the tools for investigating and evaluating product liability. Concepts of product liability relevant to medical devices will be presented and discussed in this talk, and several case studies will be used to illustrate some of the pertinent investigative and analysis tools used by forensic engineers in this field.

About the Speaker
Dr. Metzler received her Doctor of Science degree in Mechanical and Biomedical Engineering and her Master of Science in Mechanical Engineering from Washington University, and her Bachelor of Science degree in Mechanical Engineering from Purdue University. Dr. Metzler’s areas of expertise and research center on the design of intelligent devices and systems, and medical device design. She is a faculty member in the Ohio State University Department of Mechanical and Aerospace Engineering, where she teaches courses in mechanical and biomedical design, rehabilitation engineering, and intelligent systems. In addition, Dr. Metzler has courtesy appointment in the School of Health and Rehabilitation Sciences in the Ohio State University College of Medicine. She also has over 14 years of consulting experience as a forensic engineer and expert witness, with a focus on biomedical injury analysis and product liability.