Engineering Design & Processes 1

This subject has the following teaching availabilities in 2010:

436-285 Engineering Design and Materials 1

Unit 1, Engineering Design: Upon completion of this unit, students should be skilled in synthesising solutions to open-ended design problems at an intermediate level of complexity in mechanical engineering, skilled in the management of design projects requiring the solution of such problems; have gained an appreciation of computer-based methods in concurrent design; and have gained a deep understanding of the concepts and methods of designing for quality, of managing variability and of integrating design with downstream manufacturing operations. Students who choose to can also gain a deep understanding of concepts and methods employed in assessing and moderating environmental impacts in the context of the wider design process. Topics include concurrent design of systems and products; computer-based techniques for geometric modelling, materials selection, service simulations and representation of manufacturing knowledge; management of variability in product geometry and performance; tolerance technology in 1-D, 2-D and 3-D applications, techniques for robust design; quality assurance in engineering design; and life cycle design, quality function deployment, causal networks and failure modes and effects analyses, ISO 9001 and traceability of critical decisions. Unit 2, Manufacturing Processes: Upon completion of this unit, students should understand the basic principles, objectives and performance characteristics of some major methods of shaping components; understand the variables affecting the performance of the various processes and the process capabilities; and be able to develop cutting analyses for 'classical' and practical turning operations. Topics covered include principles, performance characteristics and process selection of manufacturing processes. Metals: machining as a means of shaping components, chip formation and mechanics of cutting; prediction of force, torque power, chip flow and surface finish for single point turning operations; finishing operations and fabrication methods.

Assessment includes:

• Two 2-hour end-of-semester examinations (55%);
• Tests, continuous assessment throughout the semester of group and individual projects, assignments and laboratory reports not exceeding 16 000 words (40 pages excluding computations, tables, graphs, diagrams) (45%).
• All components of assessment must be satisfactorily completed to pass the subject.

• Fundamentals of Modern Manufacturing, 3rd Ed. MP Groover, Wiley. R.
• G. Budynas and .K. Nisbett “Shigley’s Mechanical Engineering Design” (2008)

This subject is not available as a breadth subject.

On completion of this subject students should have the following skills
• Understand the concepts and methods of designing for quality and managing variability
• Manage design projects at an intermediate level of complexity
• Written and oral progress reports and design presentations
• Individual and group problem solving
• Critical thinking and critical judgement of assumptions adopted
• Abstract mathematical reasoning
• Interpretation and analysis of data
• Application of theory to practice
• Effective communication skills, not only with engineers but also with the community at large
• Ability to use a systems approach to design and operational performance
• Ability to function effectively as an individual and in multi-disciplinary and multi-cultural teams, with the capacity to be a leader or manager as well as an effective team member
• Understanding of the social, cultural, global and environmental responsibilities of the professional engineer, and the need for sustainable design and development
• Understanding of professional and ethical responsibilities and commitment to them
• Capacity for independent critical thought, rational inquiry and self-directed life-long learning
• Openness to new ideas and unconventional critiques of received wisdom
• Visualization of three dimensional motion
• Ability to apply knowledge of basic science and engineering fundamentals
• Ability to undertake problem identification, formulation and solution
• Able to clearly communicate the process and outcome of a technical investigation.

Students may only gain credit for one of 436-384 Engineering Design and Processes 1 or 436-203 Manufacturing Studies 1.