Course Details in 2021/22 Session

Module Title	Mechanical Design A
School	School of Engineering
Department	Mechanical Engineering
Module Code	04 23808
Module Lead	K.D. Dearn
Level	Intermediate Level
Credits	20
Semester	Semester 1
Pre-requisites
Co-requisites
Restrictions	None
Contact Hours	Lecture-20 hours Tutorial-10 hours Project supervision-20 hours Practical Classes and workshops-10 hours External Visits-7 hours Guided independent study-133 hours Total: 200 hours
Exclusions
Description	The aim of the module is to enhance students' knowledge and understanding of the mathematics and scientific principles related to mechanics, materials, manufacturing and design processes, and to develop their ability to apply this knowledge in a number of topics. SYLLABUS COMPUTER AIDED DESIGN AND MATERIALS SELECTION: Use of Solidworks, Use of CES Edupack DESIGN: Product Design Specification, Engineering drawings to BS8888 MATERIALS: The concept of systematic material, shape and process selections that takes into account formal constraints and objectives derived from the products’ functional/technical specifications is introduced to students based on CES EduPack functionality. Also, the formal approaches for managing multiple constraints and objectives in engineering design of products are introduced to students and case studies are provided. The complex relations between materials, product functionality, component shapes and the processes for their cost-effective manufacture are elaborated and examples are given. SUSTAINABILITY: The scientific principle of using life-cycle product data to inform the product design and material and process selections are elaborated. Systematic eco-design approaches for selecting engineering designs and re-designing products are introduced that take into account eco-fingerprints of design decisions and allow “what-if” studies to be carried out employing the CES EduPack build-in capabilities. IN-SERVICE FAILURE: The concept of finite and infinite life of machine components. The stress-strain curve and its relationship to fatigue. Understanding different fatigue regimes. Fatigue analysis using Soderburg and Goodman diagrams. Stress raisers and fatigue initiation. Identifying the features of a fatigue fracture. Effect of surface and other processes on fatigue, peening/blasting, welding, geometry and size. MACHINE ELEMENT THEORY: Theory of gears - nomenclature, conjugate sliding motion, sliding velocities, contact ratios, numbers of teeth, geometric relationships. Types of gear, Gear trains. Shafts - Sizing and failure analysis, DET and MSST theories, design methods, stress analysis, shear force, bending moment and deflection analysis. MECHANICAL DESIGN: Procedures for the practice of mechanical design, concepts of axial, radial, circumferential location, basic bearing design, lubrication, static and dynamic seals. Selection of component bought out from specialist suppliers, design and validation of components to be manufactured in-house, selection of materials, manufacturing methods or systems concepts that are related to more than component. Use of appropriate software in the design process. MATERIALS PROCESSING: The students are introduced to the following manufacturing processes: Machining - Conventional machining, turning, drilling, milling, grinding, EDM. Metal forming - bulk forming, forging, extrusion, sheet metal forming - rolling, pressing. Casting - sand, HP die, investment, gravity die, low pressure die. Joining - fusion welding, resistance welding, adhesive bonding, rivets. Special Processes - prototyping, laser deposition, CVD - surface coatings, plasma spraying.
Learning Outcomes	By the end of the module the student should be able to: Understand and apply appropriate codes of practice and international standards i.e. BS 8888. Demonstrate knowledge and understanding of the mathematics and scientific principles related to the analysis of machine elements, components, and systems. Design and realize a physical system or component to meet desired needs within realistic constraints such as economic, environmental, social, political, ethical, health and safety, manufacturability, and sustainability. Manage the engineering design process, identify, formulate, and solve engineering problems and evaluate outcomes. Demonstrate an ability to communicate effectively and work well on team-based engineering projects. Identify and manage cost drivers applied to the design and selection of components and systems constrained by a brief. Work with technical uncertainty to develop technical solutions. Understand the impact of design decisions on scale up production potential of products and manufacturing unit costs. Conduct a critical analysis of existing product designs taking into account product life cycle considerations. Understand the importance of engineering drawings, especially general assembly and detailed component drawings, as a formal means to communicate technical requirements for assembly and process designs. Present a case for a chosen assembly and process designs for a given product formally and persuasively, including the use of British Standards. Interface design and manufacturing phases in product development with viable process planning decisions.
Assessment	23808-05 : Mechanical Design A Validation Report : Coursework (25%) 23808-06 : Mechanical Design A Comp Drawing : Coursework (10%) 23808-07 : Mechanical Design A CAM Assessment : Coursework (10%) 23808-08 : Mechanical Design A General Assembly Drawing : Coursework (30%) 23808-09 : Mechanical Design A Manufacturing Report : Coursework (25%)
Assessment Methods & Exceptions	Assessment: 100% continuous assessment, comprising of a Mechanical Design project (100%) at end of Semester 1 Reassessment: 100% coursework during the University supplementary period. Reassessment to match the main assessment method with due consideration made to any restrictions imposed at the time of reassessment. Students can carry forward passed assessment components from main assessment.
Other	Duplicate of Dubai-based module 30334
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