436-311 Engineering Design & Processes 2

Students will be expected to be familiar with material covered in 436-286 Engineering Design and Materials 2, (or prior to 2006 436-220 Engineering Design and Materials 1) and 436-384 Engineering Design and Processes 1.

Unit 1, Engineering Design: 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.

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: 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 predict main forming parameters, such as loads, pressures and work of deformation for simple deformation.

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.

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 16000 words (40 pages excluding computations, tables, graphs, diagrams) (45%). All components of assessment must be satisfactorily completed to pass the subject.