Engineering Design & Processes 2

This subject has the following teaching availabilities in 2010:

436-286 Engineering Design and Materials 2, and 436-384 Engineering Design and Processes 1.

Unit 1, Engineering Design: Topics covered include general concepts of function, integrity, value, quality, efficient use of resources in the synthesis of solutions to design problems; gears and gear design; design for fatigue: characteristics of fatigue fracture, 2-D and 3-D stress conditions, cumulative damage hypothesis, Weibull distribution; design for wear: surface phenomena and tribology in design, application to bearings and seals; quantitative measures of reliability; and management of the design process: initial appreciation, information flows and networks, characteristics of manufacturing processes affecting product design.

Unit 2, Manufacturing Processes: Topics covered include principles, performance characteristics and process selection of manufacturing processes. Metals: metal forming as a system; metal forming processes including sheet metal forming, drawing forging, net shape manufacturing; process modelling; casting and moulding processes; and ceramics and powder metallurgy: pressing, plastic forming, injection moulding and casting; drying and firing.

Unit 1: Upon completion of this unit, students should have gained -

• An appreciation of methods for synthesising solutions to open-ended design problems at an intermediate level of complexity in mechanical and manufacturing engineering;
• A deep understanding of the concepts and methods of designing for system and component integrity under conditions of fatigue and wear;
• And a deep understanding of information-based techniques for the management of engineering design.

Unit 2: Upon completion of this unit, students should understand -

• The basic principles, objectives and performance characteristics of some major methods of shaping components;
• The variables affecting the performance of the various processes and the process capabilities;
• And be able to predict main forming parameters, such as loads, pressures and work of deformation for simple deformation.

Assessment includes:

• Two 2-hour end-of-semester examinations (55%);
• Tests, continuous assessment throughout the semester of group and individual projects, ssignments and laboratory reports not exceeding 16000 words (40 pages excluding computations, tables, graphs, diagrams) (45%).
• All components of assessment must be satisfactorily completed to pass the subject.

Unit-1 - G. Budynas and .K. Nisbett “Shigley’s Mechanical Engineering Design” (2008)

This subject is not available as a breadth subject.

• Advanced integrated mechanism design and failure prediction
• Middle-term, team-based project work