436-384 Engineering Design & Processes 1

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

Students will be expected to be familiar with material covered in 436-285 Engineering Design and Materials 1 (or prior to 2006 436-221 Engineering Design & Materials 2).

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.

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.