Product Design, Innovation, Reverse Engineering and Leadership

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1 Product Design, Innovation, Reverse Engineering and Leadership Dr. Om Prakash Singh Asst. Prof., School of Engineering, IIT Mandi

2 Jawaharlal Nehru Government Engineering College, Sundernagar Our Vision To become a world class institution to produce manpower with skills, creativity and passion dedicated to innovation and excellence with quest for continuous improvement.

3 What is an Engineer? Engineering is the profession in which knowledge of the mathematical and natural sciences gained by study, experience, and practice is applied with judgement to develop ways to utilize, economically, the materials and forces of nature for the benefit of mankind. E.g. Trouble shooting, Energy conversion, health sciences, aerospace, transportation, manufacturing. In fact, almost every type of industry employs mechanical engineers!

4 Engineers make design and products Interdisciplinary nature

5 Think out of box

6 The complex interconnection System level thinking is expected from engineers Component level design may not work in product Engineers should know how to work together in team

Invention: key for survival Human race survived as it has continuously invented/innovated Species those who have not innovated became extinct.

7 Invention: key for survival Human race survived as it has continuously invented/innovated Species those who have not innovated became extinct. Only innovative companies survive Lost top spot: Microsoft, BlackBerry, and Nokia Invention is absolutely a good thing, but even without inventions, a country or company or an individual can still come out ahead. After all, Japan didn t invent the car or the TV, but it certainly innovated on them and built world-leading companies and economies.

8 A movie on how technology determines who rules whom Movie: Planet of the Apes (2001) Entire movie is edited to 5 minutes Message from the movie: 1. A technologically advanced society are the rulers over other species (here Apes rule Human being) 2. Technology changes with time. 3. Innovation is the key for survival 4. After the movie, question will be asked.

9 What you study as an engg. student? Forces, motion, structures: statics, dynamics, kinematics, mechanics of solids and fluids. Energy: thermodynamics, heat transfer Materials: materials engineering & processing, manufacturing. Machines: graphics, design, machine elements, controls. Economics: engineering economic analysis, cost engineering. Human and Social Studies: arts, humanities, social sciences, history, government, ethics, law. Overall foundation: math, physics, chemistry, biology, analysis skills, communication skills, computation skills.

10 Convectional method of production 1. Design 2. Prototypes 3. Testing 4. Mass production Modern method of production 1. Design 2. CAE 3. Prototypes 4. Testing 5. Mass production Optimization loop Optimization loop More prototypes Less prototypes CAE: Computer Aided Engineering Material saving weight reduction

11 Design Changes and cost Initial design changes incurs less cost As the product reaches deployment phase, change in design proves very costly Numerical tools such as FEM, CFD etc. helps in improving designs during concept stage Such tools also helps in investigating failures after the product launched in the market

12 Design Changes Process

13 CFD applications External Aerodynamics of car Combustion External Aerodynamics of bike Tool cutting process Dragonfly CFD simulation

14 CFD applications in buildings design Solar collectors on roofs of industrial buildings

for Respiratory Function Assessment on a Clinical Time Scale, The Pennsylvania State University, Applied Research

15 CFD in Biomedical application: Predicting breathing cycle* Two time steps in an oxygen uptake simulation of a breathing cycle Contours and path lines at an inhalation time step * Progress Towards a Medical Image through CFD Analysis Toolkit for Respiratory Function Assessment on a Clinical Time Scale, The Pennsylvania State University, Applied Research Laboratory, Department of Mechanical Engineering, Department of Aerospace Engineering Drexel University, Department of Biomedical Engineering

16 Finite Element Analysis: medical implants

generation Boundary conditions Materials, element type etc.

17 Processes involved in FEM/CFD analysis Geometry pre-processing Clean up Remove unwanted features Mesh generation Boundary conditions Materials, element type etc. Solution Post processing: result visualization Reports and decision making

18 GEOMETRIC PRE-PROCESSING Extracting geometry from medical images MR (Magnetic Resonance) Stack of images from MRI (1mm) Contour extraction by segmentation (using B- Splines) Sample points on extracted geometry

grid quality (to avoid triangle distorsion) while keeping the desired

19 GEOMETRIC PRE-PROCESSING Generating a computational mesh Constrained optimization procedures are needed to maximize a suitable measure of the grid quality (to avoid triangle distorsion) while keeping the desired accuracy of surface representation Splines on sections Original grid Optimized grid

printing machines Reverse Engineering Courses Applied CFD

20 Design Innovation Center at IIT Mandi Design Studio CFD, FEM software: HyperWorks, Ansys, StarCCM+ Prototyping and 3D printing machines Reverse Engineering Courses Applied CFD Applied FEM Reverse Engineering Design Practicum CAE based final year projects

21 Projects based on FEM/CFD 1. Earthquake resistance building designs 2. Medical implants 3. Vehicle aerodynamics 4. Energy efficient buildings 5. Solar photovoltaic analysis 6. Engine design 7. Crankshaft design 8. Reverse engineering and 3D Printing 9..

22 Example XL Super, heavy duty, 95% market share, 15 year old engine Engines from different automotive companies

design Design changes 35 Prototype design

23 Example of real world problem: Multidisciplinary nature CAE driven product design Original design Original mass produced design Final mass produce d design Design changes 35 Prototype design 2 The Effect of rubber dampers on engine's NVH and thermal performance, 2014, O. P. Singh et al., Appl. Acoustics (Elsevier), 75(1), pp

24 Rubber dampers Rubber dampers are provided between the fins to reduce their vibration High vibration of fins produces undesirable noise. Undesirable noise leads to customer dissatisfaction. Proper design of the fins are necessary Rubber dampers add extra cost to the vehicle

25 Two-wheeler engine head TVS Moped Engine Rubber dampers Reliable engine: > 15 years in the market Holds 95% market share in moped class Lakhs of satisfied customers 16 dampers on the cylinder head. If dampers are removed, the new cylinder head should have noise level equal to or better than the existing cylinder head!!!

26 Radiated noise with and without rubber dampers Comparison of noise radiated from the engines with and without rubber dampers on the cylinder head at 3150 Hz.

27 Experimental verification All 16 dampers in place All 16 dampers removed Campbell diagram during gradual acceleration Noise levels have spread and are higher in magnitude in the 2 nd case

28 2 nd Stage design of Cylinder Head 1 st stage design Thinner part of the fins are fixed now

29 It was observed that the new head design may not be feasible from manufacturing point of view 2 nd stage cylinder head

30 Further design changes and analysis

31 Experimental verification: Campbell diagram Existing head with rubber dampers 3 rd stage head without rubber dampers Similar Campbell diagram in both the cylinder head 3 rd stage cylinder head can replace the existing cylinder head

32 Noise level comparison

33 Computational Fluid Dynamic analysis

chamber compared to the 1 st stage design of the head This is experimentally

34 Temperature distribution 1 st stage cylinder head 3 rd stage cylinder head 3 rd stage cylinder head shows lower temperature on the fins and in the combustion chamber compared to the 1 st stage design of the head This is experimentally verified 3 rd stage design without rubber dampers is implemented on the vehicle for mass production

35 Costs and environmental impact Among many benefits, few advantages are listed below 1. Rubber damper manufacturing process is eliminated completely; rubber production is harmful to the environment 2. Long term benefits; over a period of time typically after six months of use, rubber dampers properties deteriorates and it becomes brittle due high temperature of the fins. The initial grip between the dampers and fins reduces and finally these dampers come off the engine. The noise radiated from the engine increase again. Hence, putting rubber dampers on engines does not provide long-term benefits, 3. Logistics and inventory reduction; logistics of dampers involves the integration of information, transportation, inventory, warehousing, material handling, and packaging, 4. Man power saving; since rubber dampers are not an integral part of the engine, additional workman are needed to hammer down the rubbers between the fins 5. Part count reduction; rubber dampers are additional parts that needs to put on the engine before integrating on the vehicle and hence increases the number of part count of the engine, 6. Improves engine cooling; rubber dampers restricts the free flow of air around the engines and hence increases the overall engine temperature.

36 Life cycle cost benefit Each rubber damper cost = Rs. 1 Total cost dampers = 16 x 1 = Rs. 16 Additional benefit = Rs. 4 Total saving Sales Benefit/month Benefit/year Life cycle benefit = Rs (16 + 4) = Rs. 20/vehicle = 70,000 vehicles/month = Rs 20 x 70,000 = 14 Lakh/month = 12 x 14 lakh = 1.68 Crore/year = 10 x 1.68 crore = 16.8 crore

37 Product life cycle: Competitors upper hand

38 3D printing technology: Innovation in manufacturing

39 Recent news headlines on 3D printing technology How 3D Printing Is Revolutionizing Surgery

40 How 3D printing works

41 3D printed parts in space

42 Misuse of 3D printing technology: Making gun

43 3D printing machine by IIT Mandi students

44 A movie on how technology can save our life Movie: Jurassic Park III Entire movie is edited to 6 minutes Message from the movie: 1. Any technologically developed has multiple usages (here a 3D printed part saves Human from Dinosaurs) 2. Even though a technology developed keeping in mind an specific use, but it end in many other useful usages. 3. E.g. mobile was developed to transfer wireless voice but today is used for internet, photos, videos, doing business etc.

45 Options for an engineers Get a high paying job Aerospace Engineer Agricultural Engineer Automotive Engineer Biomedical Engineer Chemical Engineer Drafting and Design Engineer Environmental Engineer Geological Engineer Marine Engineer Petroleum Engineer Software Engineer You work for others Be an entrepreneur उद यम, उद य गपत Can you work for yourself, for your passion?

46 Definition of 'Entrepreneur' An individual who, rather than working as an employee, runs a small business and assumes all the risk and reward of a given business venture, idea, or good or service offered for sale. The entrepreneur is commonly seen as a business leader and innovator of new ideas and business processes.

News headlines Sachin Bansal, 32, a mere six years to

Binny Bansal in a small flat in southeast Bangalore in

47 News headlines Sachin Bansal, 32, a mere six years to build Flipkart, the country's best-known online retail brand. The IIT-Delhi alumnus started off with college friend Binny Bansal in a small flat in southeast Bangalore in 2007 with Rs 4 lakh. Started from selling books, now diversified many other areas such as electronics, house hold appliances etc

48 Budget 2014: Startups & entrepreneurs get Rs 10,000 crore backup Yes, we can

49 How India can become a developed nation? A student interview with APJ Abdul Kalam APJ Kalam ask students how India can become a developed nation? How? Any Idea?

50 How India can become a developed country? Oath for the Students

pressure: from peer group, teachers, employer, friends If you give in to external pressure, you

51 Life or death: it depends on you! When broken from INSIDE, its life When broken from OUTSIDE, its death Lots of external pressure: from peer group, teachers, employer, friends If you give in to external pressure, you are finished. Always say from within, I can do it, I ll win, I ll fight Mann ke Jite Jeet, Mann ke Hare Haar. If you think you will succeed, you will, its all in mind

52 What are the qualities of a leader? A journalist interview with APJ Abdul Kalam APJ Kalam was asked on what qualities a leader should possess? A leader should have vision, able to take risk, take his time together in success and failure. A leadership qualities can be developed with patience, practice

53 Be a leader APJ Abdul Kalam speaks on leadership with Arnab Goswami

54 You re the future of India, we look towards you to solve our society problems

55 Reverse Engineering Khul Ja Sim-Sim

56 Forward Engineering Concept Engineering a product Product Reverse Engineering Product Reverse Engineering Concept

57 Reverse Engineering Examining competitive or similar or prior products in great detail by dissecting them or literally taking them apart. - Dym & Little How does it do that? Why would you want to do that?

58 Why Reverse Engineering? Sometimes, the best way to advance is in reverse, By Eldad Eilam

59 What is a Product? In general, the product is defined as a thing produced by labor or effort or the result of an act or a process Example: Fan, Computers, Software, Pen, Clock, Bottle etc.

60 Who make product? Entrepreneurs Engineers Designers Students Why make product? Earn money Get recognition Social service Personal satisfaction

Startup company by IIT students Company name: IdeaForge NETRA is a completely autonomous Unmanned

NETRA streams you real time video of the target area with spotless clarity.

Unmanned aerial vehicles are the best way to access risky terrain, especially cracked buildings

61 Startup company by IIT students Company name: IdeaForge NETRA is a completely autonomous Unmanned Aerial Vehicle for Intelligence, Surveillance and Reconnaissance of moving and fixed targets. NETRA streams you real time video of the target area with spotless clarity. Helped Nepal during Earthquake, saved many life Initially struggled, lots of failure in designs Unmanned aerial vehicles are the best way to access risky terrain, especially cracked buildings during an earthquake. Here rescue officials are inspecting a ramshackled building in the 2015 Nepal earthquake. Image: ideaforge Video

62 If you want to design a bird like machine, you have to study the bird first

63 Reverse Engineering Gain insight into our own design problem by looking at how other people have addressed the same issues. Restrictions: Expensive designs Protected by copyrights and patents May be the competitor s design Design may not work very well Design may be copied, difficult to copy knowledge

Creation of unlicensed/ unapproved duplicates Competitive

64 Reasons for reverse engineering Interfacing Obsolescence Bug fixing Military or commercial espionage Reverse Engineering Creation of unlicensed/ unapproved duplicates Competitive technical intelligence Saving money (Value Engineering Software modernization

65 Reasons for reverse engineering a part or product: 1. The original manufacturer of a product no longer produces a product 2. There is inadequate documentation of the original design 3. The original manufacturer no longer exists, but a customer needs the product 4. The original design documentation has been lost or never existed 5. Some bad features of a product need to be designed out. For example, excessive wear might indicate where a product should be improved 6. To strengthen the good features of a product based on long-term usage of the product 7. To analyze the good and bad features of competitors' product 8. To explore new avenues to improve product performance and features 9. To gain competitive benchmarking methods to understand competitor's products and develop better products 10.The original CAD model is not sufficient to support modifications or current manufacturing methods 11.The original supplier is unable or unwilling to provide additional parts 12.The original equipment manufacturers are either unwilling or unable to supply replacement parts, or demand inflated costs for sole-source parts 13.To update obsolete materials or antiquated manufacturing processes with more current, less-expensive technologies

66 Reverse Engineering for military applications World war II: Jerry can British and American forces noticed that the Germans had gasoline cans with an excellent design. They reverse-engineered copies of those cans

War II, and reverse engineered it to create the larger Panzerschreck.

67 Reverse Engineering for military applications World war II: Panzerschreck The Germans captured an American Bazooka during World War II, and reverse engineered it to create the larger Panzerschreck. See how the need of mask removed in improved design Original design Improved design

The Soviets, who did not have a similar strategic bomber, decided to copy the B-29.

68 Reverse Engineering for military applications World war II: Tupolev Tu-4 Three American B-29 bombers on missions over Japan were forced to land in the USSR. The Soviets, who did not have a similar strategic bomber, decided to copy the B-29. Within a few years, they had developed the Tu-4, a near-perfect copy. B-29 bombers Tupolev Tu-4

The missile became lodged within the airframe, and the pilot returned to base with what Russian scientists would describe as a

69 Reverse Engineering for military applications World war II: K-13/R-3S missile Soviet reverse-engineered copy of the AIM-9 Sidewinder, was made possible after a Taiwanese AIM-9B hit a Chinese MiG-17 without exploding. The missile became lodged within the airframe, and the pilot returned to base with what Russian scientists would describe as a university course in missile development. An AIM-9E Sidewinder missile on display at the National Air and Space Museum K-13: Short-range, infrared homing air-toair missile developed by the Soviet Union

70 Product (re)design begins with Reverse Engineering Methodology Investigation, Prediction and Hypothesis Concrete Experience: Function & Form Reverse Engineering Design Models Design Analysis Modeling & Analysis Parametric Redesign Adaptive Redesign Original Redesign Redesign Adapted from Otto and Wood s Reverse Engineering and Redesign Methodology UT Austin

model Use / Experience product List assumed working

71 Reverse Engineering Methodology 1. Investigation, Prediction and Hypothesis Develop black box model Use / Experience product List assumed working principles Perform economic feasibility of redesign State process description or activity diagram

72 Car Crash

73 Example Engine Oil consumption measurement Dipstick Drain cap

74 Engine Oil consumption measurement methods Method Advantages Disadvantages Error in measurement Simple and economical Approx 25 hrs to run Drain & No complicated equipment Impossible to drain all oil practically measure required Increase in viscosity due to degradation increases No skilled labor required time of drain Very costly equipment and special handling procedures for radioactive material Tracer Measurement time order of Secondary measurements and calibration of air Radioactive minutes and fuel flow Sulfur Transient effects can be measured Oil deposited on piston, valves, and exhaust after treatment devices not accounted for in final measurement Smart Oil Level sensor to gauge level of oil in Accuracy of level sensor is of concern Consumption crankcase Requires addition of new oil Meter Measurement time of the order of Suitable for diesel engines hours Transient effects cannot be measured Cheap to build and use New Method Portable Accuracy of the scale Run time of the order of hours Vibrations need to be handled better Pump flow characteristics can be Leakages have to be monitored studied Addition of new oil not required Comparison of various oil consumption measurement techniques.

75 Example: Engine oil measurement Engine Drain cap Dipstick Tube Metal scale Slider Glass tube Tube Metal stand Crankcase Engine stand 1. Investigation, Prediction and Hypothesis

76 Level of oil (cm) Example: Engine oil measurement Volume in crankcase (ml) Oil Consumption (ml/h) New Method Drain & Measure Time (hours) Calibration and measurement

components Develop free body diagrams Identify

77 Reverse Engineering Methodology 2. Concrete Experience: Function and Form Plan and execute product disassembly Group defined systems and components together Experiment with product components Develop free body diagrams Identify function sharing and compatibility Transform to engineering specs and metrics RE

78 Reverse Engineering Methodology 3. Design Models Identify actual physical principles Constantly consider the customer Create engineering models and metric ranges Alternatively or concurrently build prototype to test parameters Ethical issues IPR issues

79 Reverse Engineering Methodology 4. Design Analysis Calibrate model Create engineering analysis, simulation or optimization Create experiment and testing procedures

80 Reverse Engineering Methodology 5. Parametric Redesign Optimize design parameters Perform sensitivity analysis and tolerance design Build and test prototype Parametric design Prototypes testing

81 Reverse Engineering Methodology 6. Adaptive Redesign Recommend new subsystems Search for inventive solutions Analyze force flows and component combinations Build and test prototype

82 Reverse Engineering Methodology 7. Original Redesign Develop new functional structure Choose alternatives Verify design concepts Build and test prototype

83 System Level Design Reverse Engineering requires understanding the product or design as a system or set of systems that work and interact together. This concept is known as System Level Design.

84 System Level Design System = Components + Connections Components Physical - pick-up, measure, draw on CAD Functional - flowcharts, difficult to define Connections Fundamental - intended design Incidental - created by physical proximity of components (vibration, heat transfer, etc.)

85 System Level Design

Innovation and Leadership: Think out of box. Dr. Om Prakash Singh Asst. Prof., School of Engineering, IIT Mandi

Innovation and Leadership: Think out of box Dr. Om Prakash Singh Asst. Prof., School of Engineering, IIT Mandi www.omprakashsingh.com What is an Engineer? Engineering is the profession in which knowledge