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
Semesters
| Semester 1 Credit Value: | 10 |
| Semester 2 Credit Value: | 10 |
| ECTS Credits: | 10.0 |
Aims
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 Study | Assessment preparation and completion | 3 | 3:00 | 9:00 | Timetabled hours to aid knowledge, skills or cw assmt submissions, mostly optional with assistance |
| Scheduled Learning And Teaching Activities | Lecture | 36 | 1:00 | 36:00 | Structured presentation of syllabus may include skills demonstration, formative feedback, etc |
| Scheduled Learning And Teaching Activities | Practical | 3 | 3:00 | 9:00 | Structure Design & Analysis:supervised with continuous feedback. |
| Scheduled Learning And Teaching Activities | Practical | 5 | 8:00 | 40:00 | Machine Design and CAD: supervised with continuous feedback |
| Scheduled Learning And Teaching Activities | Small group teaching | 3 | 4:00 | 12:00 | Extended teaching activity to apply taught material, develop professional skills |
| Guided Independent Study | Independent study | 1 | 94:00 | 94:00 | Recommended regular personal study throughout teaching period to follow up taught classes |
| Total | 200:00 |
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 |
|---|---|---|---|---|
| Report | 1 | M | 3 | Roller Assembly assignment |
| Report | 1 | M | 50 | Formula Student Car Suspension Design Assignment, Design logbook, analysis, hand sketches, 3D CAD model and drawings |
| Report | 2 | M | 25 | Manufacturing assignment |
| Report | 2 | M | 22 | FEA 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
Reading Lists
Timetable
- Timetable Website: www.ncl.ac.uk/timetable/
- MEC2007's Timetable