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MEC2007 : Design and Manufacturing II

  • Offered for Year: 2020/21
  • Module Leader(s): Mr Robert Davidson
  • Lecturer: Mr Peter Chapman
  • Owning School: Engineering
  • Teaching Location: Newcastle City Campus
Semester 1 Credit Value: 10
Semester 2 Credit Value: 10
ECTS Credits: 10.0


The aim of the course is to enable students to design and plan the manufacture of assemblies for real machines to:

- Meet the customer’s requirements, including functioning correctly.
- Be designed with the manufacturing and assembly processes in mind.

Outline Of Syllabus

Determine reaction forces and effects of loads.
- appropriately apply knowledge in design projects

Design appropriate shafts & rotating shaft assemblies, including:-
- Select appropriate rolling element bearings & standard mechanical components.
- Select appropriate engineering materials.
- Select appropriate designs for batch manufacture.
- Produce (individually) detail design of complete assembly using hand-sketching & 3D CAD, that is:-
- complete and ready to be “sent for manufacture”
- fully functional
- easily (economically) manufactured
- has a full set of drawings with:- all necessary views
- all necessary dimensions
- all necessary tolerances
- all necessary material and manufacturing details

Produce practical and economical manufacturing process routes for typical components and assemblies:-
- for manufacture singly, by the thousand and by the million (per year)

Appropriately use engineering science, manufacturing technology and manfacturing planning to design, built & (publically) test a real structure.

Teaching Methods

Teaching Activities
Category Activity Number Length Student Hours Comment
Guided Independent StudyAssessment preparation and completion33:009:00Timetabled hours to aid knowledge, skills or cw assmt submissions, mostly optional with assistance
Scheduled Learning And Teaching ActivitiesLecture361:0036:00Structured presentation of syllabus may include skills demonstration, formative feedback, etc
Scheduled Learning And Teaching ActivitiesPractical33:009:00Structure Design & Analysis:supervised with continuous feedback.
Scheduled Learning And Teaching ActivitiesPractical58:0040:00Machine Design and CAD: supervised with continuous feedback
Scheduled Learning And Teaching ActivitiesSmall group teaching34:0012:00Extended teaching activity to apply taught material, develop professional skills
Guided Independent StudyIndependent study194:0094:00Recommended regular personal study throughout teaching period to follow up taught classes
Teaching Rationale And Relationship

- Lectures provide case studies, the underlying design methodology and manufacturing methods and demonstrate the integration of engineering science and systems.
- Supervised classes and tutorials provide opportunities to seek advice and to present and discuss all stages of
the design project from concept generation and specification to communication of final design.
- Practicals allow students to practise and experience the material taught.

Assessment Methods

The format of resits will be determined by the Board of Examiners

Other Assessment
Description Semester When Set Percentage Comment
Report1M3Roller Assembly assignment
Report1M50Formula Student Car Suspension Design Assignment, Design logbook, analysis, hand sketches, 3D CAD model and drawings
Report2M25Manufacturing assignment
Report2M22FEA Structure Design-Make Test
Assessment Rationale And Relationship

Roller Assembly Assignment - students to produce & print out an A4 eng. drawing.
The main purposes are to prepare the students for the rest of the module work & for major project work to:
- remind students how to use the University's 3D CAD system and of the eng. drawing conventions of BS8888
- think about how 3D shapes (i.e. components) interact to carry loads compatible with eng. science (incl. equilibrium)
- think about the manufacture & assembly of small machines to ensure that each component can be manufactured, assembled correctly & the complete machine functions as intended.
As the assignment is short, it is intended primarily as both a recap of work from the previous Stage & an indication of the necessary knowledge & skills required to successfully complete the module.

Formula Student Car Suspension & Design Assignment forms the core of the module. The topics are chosen to reflect common/typical components & designs encountered in mechanical eng. being set in a Formula Student car context, this helps with motivation/understanding. Submission includes:
- design logbook with analysis, hand-sketches
- complete 3D CAD model & full set of eng. drawings.
Includes the following main purposes, all related to preparing the students for project work & industrial practice to enable students to:
- produce a fully detailed manufacturable machine design that complies with the requirements & eng. specification
- competently use the University's 3D CAD system to generate 3D CAD models of parts & assemblies & the associated 2D eng. drawing & parts lists
- communicate competently using the eng. drawing conventions of BS8888
- work with 3D forms (i.e. components & assemblies) & enable them to interact to carry loads compatible with eng. science (incl. equilibrium, materials science)
- produce a machine design where everything is practical to manufacture & assemble & where the machine functions as intended.

Manufacturing Assignment builds on the familiar Suspension Design components & assemblies, & requires the students to develop a variety of different manufacturing process routes for selected components/assemblies. Submission includes:
Format-controlled report in which the information required for each page is closely specified to require an appropriate attention to round & cuboidal components & fabrications, to be manufactured by different processes & different designs (possibly with different materials) in quantities of 1, 1000 & 1000000 per year.
The main purposes, preparing the students for major project work & industrial practice to enable them to:
- understand & use appropriately a wide range of common/typical manufacturing processes
- design (& select materials) appropriately for each manufacturing process
- appreciate & consider the major costs contributions for each of the manufacturing process routes
- realise that the detailing of source & manufacture of all the components & assemblies of their designs is crucial for a design to be implemented
- produce an appropriate, effective & well communicated assembly sequence for a machine assembly.

FEA Structure Design Assignment leads to the design, making & testing of an aluminium structure, typically a bridge.
Feedback is given during the development of the design & requires that each student initially work individually to produce a functional/efficient design structure and then to work together in a team.
Submission includes:
- effective & efficient design structure to meet the requirements
- complete design structure, with all details determined & communicated
- detailed manufacturing plan for the team's structure with step-by-step instructions
- physical structure manufactured, meeting the requirements
- physical test of the structure to its ultimate load capacity.
Enables students to:
- understand/use appropriately core eng. sci.
- generate an appropriate/effective manufacturing plan
- understand the necessity of working in teams

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