Simulation Driven Product Design
2.1 – Product Design
Product design and manufacturing process has been developed over centuries. Many complex systems such as bridges, buildings, aircrafts, cars, etc. are excellent outcomes of this process. This process involves trial-and-error design method in which an initial design is created, tested and modified until a safe design is found.
In most cases, many designs can be safe designs but only one of them is the optimum design which is not only safe but also is the best with respect to a given criteria. Being centuries-old, trial-and-error design method has been developed in the abundance of natural resources and therefore does not directly aim to find the optimum design while it is searching for a safe design. As a result, within the current design process determining the optimum design is an expensive task if not an impossible one as the process does not have a systematic approach to analyzing and comparing different designs.
Let’s take a bridge design as an example. Function of a bridge is to facilitate the traffic between two areas that are separated by an obstacle. There are requirements on its safety, cost, durability,maintenance, manufacturability etc. that need to be satisfied. Using the trial-and-error method,engineers cannot evaluate all different possibilities with respect to these requirements, and find the optimum bridge design.
As a result, engineers usually adopt a previous design and modify this design until it meets the design requirements. Improvements to increase its value are only made when a new similar design task is started. As a result, evolution of design systems in the past required a lot of time and resources.
With the diminishing natural resources, increasing market competition and increasing computational power, trial-and-error method is being replaced by simulation driven design. Simulation driven design searches not only for a safe design but it also searches for an optimum design. It employs established mathematical procedures in this search eliminating the randomness in the trial-and-error process.

Design Objectives
Design performance can be defined as how a product satisfies the design requirements. Design performance is a function of design parameters. In the simulation driven design process, required design performance is divided into design objectives and design constraints.
This is a critical step for the engineers as the outcome will heavily depend on the selection of the objective and constraints.

Simulation Driven Product Design

Simulation Driven Product Design Process


DOE in HyperStudy

Exercise: DOE Study of the arm model

Definitions in Approximations

Approximation Methods

Post-Processing in Approximations

Exercise: Approximation on the arm model


Optimization Methods

Special Cases

Shape Optimization of the arm model


Probabilistic Nature of Design Parameters

Reliability and Robustness Assessment

Probabilistic Design Optimization

Stochastic study of the arm model


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