Unit information: Principles of Design for Manufacture of Composites in 2020/21

Unit name	Principles of Design for Manufacture of Composites
Unit code	AENGM0041
Credit points	10
Level of study	M/7
Teaching block(s)	Teaching Block 2 (weeks 13 - 24)
Unit director	Dr. Ward
Open unit status	Not open
Pre-requisites	None
Co-requisites	None
School/department	School of Civil, Aerospace and Design Engineering
Faculty	Faculty of Engineering

Description including Unit Aims

Design for Manufacturing is a key skill for the composites engineer, as the design details impact on every element of a part’s manufacture and performance - from its costs to the probability of defects. The unit contents will be based around the analysis of the product design and development process, and how that product design and development process is modified by the differences between conventional and advanced composite materials. Extensive use will be made of case study material to equip students in how to identify in what way design requirements can be met in multiple ways and how to select between the various options. This will be built on by considerations of issues such as Design for Assembly, Repair, Maintenance, Recycling, and other industrially critical issues (known as “Design for X”).

Thus the unit provides a comprehensive study of the principles of “Design for Manufacturing” and other “Design for X” elements in advanced composites, to promote the understanding of the increased complexity of materials properties, design, and manufacture; and the behaviour and analysis methods used for the Design for Manufacture of advanced composite structures. Design for Manufacturing information and methods are presented in a series of lectures, including illustrations, and worked examples. Practical understanding of basic and advanced manufacturing processes are also supported by laboratory and in-class demonstrations. The overall aims of the unit are to:

• Provide students with sufficient background in the principles of “Design for Manufacturing” and other “Design for X” elements in advanced composites
• Provide students with the tools to analyse the design of composite products with regards to manufacturability and other “Design for X” elements
• Provide students with the framework to support their development of specific composite products
• Provide students with information on the future directions of advanced composites and Design for Manufacturing, and offer opportunities to experience these in the unit content

Intended Learning Outcomes

On successful completion of the unit students will be able to:

1. Identify and understand the key issues and methods in Design for Manufacture of advanced composite structures
2. Apply the basic principles for Design for Manufacturing to distinguish clearly between competing design options (whether conceptual, manufacturability, sizing, preliminary analysis) for advanced composite parts
3. Apply basic and advanced principles for Design for Manufacturing in order to select the preferred options related to a range of “Design for X” issues in composite parts design and manufacturing
4. Generate and employ development schemes through experiment and/or simulation, to demonstrate routes to achieve preferred options to produce prototype advanced composite parts

These learning outcomes align to A1, A2, B1, B2, and B3 of the UK-SPEC 2014 (see: https://www.engc.org.uk/engcdocuments/internet/website/20160307_HEA_Professional_recognition_for_engineering_final.pdf).

Teaching Information

This unit’s taught content totals 30 hrs; through a combination of Design for Manufacturing of composites lectures (20 hrs), revision (1 hr) & case study/example classes (4 hrs), and laboratory demonstrations (5 hrs). The remainder of the unit’s time, of a maximum of 70 hrs, is attributed to the planned assessments which are made up of two group workshop activities totalling 7.5 CP (supported by lab demonstrators/teaching assistants), an individual online test of 2.5CP, and student self-study practices. Other than the provision of course content via UoB tools (Blackboard etc.) there are no significant e-learning components to this unit. No distance learning is expected as part of this unit.

Assessment Information

The unit is assessed through 100% coursework contribution over the Teaching Block, comprising three (3) group assignments - two case studies marked as a group effort, and one as an individual online test:

1. Individual online test based on course content to evaluate student understanding; 2.5 CP or 25% contribution, 1.5 hours total test duration plus student self-study practise
2. First case study group assignment based on a set requirement for a component build through laboratory activity, presentation, and product delivery; 2.5 CP or 25% contribution, 30 minute group presentation and questions plus laboratory time of approx. 16 hours per student
3. Second case study group assignment based on a set requirement for a manufacturing process simulation and test through laboratory activity, a report (10 pages) and a video or self-play presentation (5 min), and product delivery; 5CP or 50% contribution, total time approx. 35 hours per student

Summative assessment:

• ILO 1: Through the two case study assignments carried out in teams, plus the individual assessment by online test
• ILO 2: Through the two case study assignments carried out in teams, plus the individual assessment by online test
• ILO 3: Through the first case study assignment, plus wide ranging design for manufacturing in composites example questions related to the presentation
• ILO 4: Through the second case study assignment, plus specific design for manufacturing in composites processes example questions related to the report and video

Formative assessment:

• ILO 1, 2, 3: Through example questions, problems, and case-studies with solution checks and personal as well as online feedback
• ILO 4: Through examples and specialist lab demonstrator/teaching assistant support during the assignment to guide students to appropriate solutions

Reading and References

• O. Molloy, E. A. Warman, S. Tilley (1998) Design for Manufacturing and Assembly: Concepts, Architectures and Implementation
• K. G. Swift, J. D. Booker (2003) Process Selection: From Design to Manufacture (2^nd ed.)
• G. Boothroyd, P. Dewhurst, W. A. Knight (2010) Product Design for Manufacture and Assembly (3^rd ed.)
• C. McMahon, J. Browne (1998) CADCAM: Principles, Practice and Manufacturing Management
• K. Potter (1997) Introduction to Composite Products
• K. Potter (1997) Resin Transfer Moulding
• A. B. Strong (2007) Fundamentals of Composites Manufacturing: Materials, Methods, and Applications
• P. Boisse (2015) Advances in Composites Manufacturing and Process Design