Design and Manufacturing 2

This subject is not offered in 2013.

120 hours

For the purposes of considering request for Reasonable Adjustments under the Disability Standards for Education (Cwth 2005), and Students Experiencing Academic Disadvantage Policy, academic requirements for this subject are articulated in the Subject Description, Subject Objectives, Generic Skills and Assessment Requirements of this entry. The University is dedicated to provide support to those with special requirements. Further details on the disability support scheme can be found at the Disability Liaison Unit

website: http://www.services.unimelb.edu.au/disability/

As a result of satisfactorily participating in this subject, students should be able to undertake design tasks at an intermediate level, considering performance under uncertain system integrity due to fatigue and wear, and have the ability to design or select suitable ameliorating solutions. Students also will be able to modify manufacturing systems to improve their performance. Students will have the ability to design or select suitable productive systems that are used in companies.

Topics covered in this subject may include: general concepts of function, integrity, value, quality, efficient use of resources in the synthesis of solutions to design problems; specific mechanical elements such as gears and other common means of power transmission, and their design; materials requirements planning; organising for flexible manufacturing; lean manufacturing, and Toyota Production System; quality systems, including six-sigma; automated flow lines; development of understanding, in the engineering paradigm, of general concepts such as: function, integrity, value, quality, the efficient use of resources in the synthesis of solutions to design problems.

Students will also be exposed to -

• Design for fatigue: characteristics of fatigue fracture, two-dimensional (2-D) and three-dimensional (3-D) stress conditions
• Management of the design process: initial appreciation, information flows and networks, characteristics of manufacturing processes affecting product design
• Cumulative damage hypothesis
• The Weibull distribution
• Design for wear: surface phenomena and tribology; its application to bearings and seals
• Quantitative measures of reliability
• Forensic case studies of failed engineered designs

On completion of this subject students should be able to -
• Provide in-depth explaination of and apply the concepts and methods of designing for system and component integrity under conditions of fatigue and wear
• Apply information-based techniques for the management of engineering design
• List , explain, evaluate and modify the function of the major components of manufacturing systems and how they interact with engineering design and clients
• Analyse the efficiency of some basic productive systems
• Describe in detail information-based techniques for the management of engineering design

Two 2-hour end-of-semester examinations (55% : 20% for Unit-1, 35% for Unit-2)

Unit-1: One group project, not exceeding 6,000 words (excluding computations, tables, graphs, diagrams) per student (30%) due in week 10 of the semester. Interim reports and associated team management meetings will be assessed: Initial Appreciation, Strategic Information Network (SIN) flow chart, Progress Reports.

Unit-2: One assignment not exceeding 2,000 words (excluding computations, tables, graphs, diagrams) per student (10%) due in week 10 of the semester, one 50-minute mid-semester test (5%).

Students must obtain a mark of at least 40% for all continuing assessment tasks in order to pass the subject.

Budynas, R.G. and Nisbett, J.K, Shigley's Mechanical Engineering Design, McGraw-Hill, 2009/2011

Groover, M.K, Fundamentals of Modern Manufacturing - materials, processes and systems, 4th edition, Wiley, 2010

This subject is not available as a breadth subject.

• The ability to undertake problem identification, formulation, and solution.
• The ability to utilise a systems approach to complex problems and to design and operational performance.
• Proficiency in engineering design.
• The ability to conduct an engineering project.
• The ability to communicate effectively, with the engineering team and with the community at large.
• The ability to manage information and documentation.
• The ability to function effectively as an individual and in multidisciplinary and multicultural teams, as a team leader or manager as well as an effective team member.