Unit information: Design & Manufacture 1 in 2015/16

Unit name	Design & Manufacture 1
Unit code	MENG16000
Credit points	20
Level of study	C/4
Teaching block(s)	Teaching Block 4 (weeks 1-24)
Unit director	Professor. Booker
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

This course is in four main parts. First, students learn about the creation, interpretation and use of Engineering Drawing, including first and third angle orthographic projection and pictorial projection through manual and computer-aided design practices. The second part is an introduction to Manufacturing Processes, including forging, casting, welding, brazing, soldering, fasteners, sheet metal working, machining and polymer processing. The third topic, Design for Manufacture and Assembly, covers design guidelines for specific manufacturing, assembly and joining processes, process selection methodologies and costing approaches and apply them to a team-based exercise. The fourth element is the Design and Make Project (DMP) which is a team-based exercise lasting eight weeks, including a post-examination build phase. Here many of the principles learned will be applied in order to conceive, detail, cost, plan and build a microcontroller-based vending machine to a set of detailed specification, mirroring industrial product development. Workshop Practice exercise provides further skills required for this module.

Aims:

The objectives of this first year course are to:

• Introduce the role of the design methods and production processes in engineering.
• Introduce graphical communication in design through an understanding and application of pictorial projection, orthographic projection and engineering diagrams.
• Introduce principles and capabilities of the main process groups: casting, machining, forming, joining, metrology, surface engineering and non-conventional machining.
• Introduce design for manufacture and assembly best practice guidelines.
• Improve verbal communication through familiarisation with and precise use of engineering terms and taxonomy
• Improve business appreciation thorugh consideration of engineering problems in a business context

To give experience of:

• Specifying fits, tolerances, surface finishes and geometrical tolerancing requirements through relevant standards and manufacturing data.
• Manufacturing artefacts and the use of metrology equipment.
• Design, development and manufacture of artefacts to a Product Design Specification (PDS) through team-based exercises.
• Creative and holistic approaches to engineering problems.

Intended Learning Outcomes

By the end of the course, students should be able to:

• Be proficient in the creation and interpretation of engineering drawings.
• Apply best practice manufacturing and assembly guidelines to their designs
• Understand the capabilities and limitations of the main production processing groups.
• Problem-solve and work in teams on design projects.
• Disseminate technical material proficiently in both written and oral form.
• Apply process selection, component costing, manufacturing planning and design strategies to their projects.
• Be proficient in the precise use of written and verbal language to communicate ideas.
• Demonstrate an open minded, creative approach to the solution of open ended engineering problems.
• Demonstrate an understanding of the business context framing an engineering project.

Teaching Information

Students receive a one-hour lecture for 8 weeks on Engineering Drawing to support the three-hour practical design classes Engineering Drawing exercises. Also, each week, one-hour lecture/videos/presentations are conducted for Manufacturing Processes. In the second term, students receive seven one-hour lectures on Design for Manufacture and Assembly to support a group design exercise at the end of term. Workshop Practice is a hands-on exercise where students create a hole punch in Week 7 working to engineering drawings. They also receive seven three-hour practical classes on a group Design and Make Project (DMP).

Two lab sessions (3 hours each) will beheld, one in each semester, to introduce approaches to creativity, problem solving and business appreciation. Teaching will be through design exercises and engineering games organised within groups of no more than 20 students. The outcomes will be discussed and debriefed at the end of each session.

Bound lecture handbooks are given to the students at the start of each topic for Engineering Drawing, Manufacturing Processes, Design for Manufacture and Assembly and Design and Make Project (DMP). These contain:

• Partly completed notes for the lectures to save students having to copy all technical material during the lectures.
• Comprehensive coverage of each topic, with examples, with extensive bibliography and reference to standards for further study.
• Copies of all exercises used during the practical classes to support the lectures.
• Assessment criteria used for presentations, written submissions and exercises.

Assessment Information

100% assessed by coursework 30% Engineering Drawing Exercises x 3 30% Design & Make Project (Group Portfolio Submission) 10% Manufacturing Processes Presentation 10% Manufacturing Processes Submission 10% Design for Manufacture and Assembly Presentation 10% Workshop Practice

The laboratories in communication, creativity and business appreciation will be formative, although attendance will be mandatory and active participation in both the exercises and the ensuing discussion is expected.

Reading and References

Engineering Drawing

• McMahon, C. A. & Browne, J. (1998) CADCAM Principles, Practice and Manufacturing Management, Harlow Addison-Wesley (TS155.6 MAC).
• Simmons, C. H. & Maguire, D. E. (1995) Manual of Engineering Drawing, Arnold (T353 SIM).
• Parker M.A. & Dennis, L. J. (1992) Engineering Drawing Fundamentals, Cheltenham Stanley Thornes (T353 PAR).

Manufacturing Processes

• Black, R. (1996) Design and Manufacture: an integrated approach. Macmillan, Basingstoke(TS171.4 BLA).
• Swift, K. G. & Booker, J. D. (2003) Process Selection: from design to manufacture. 2nd Edition,Butterworth-Heinemann, Oxford (TS183.3 SWI).
• Schey, J. A. (2000) Introduction to Manufacturing Processes. McGraw-Hill, New York (TS183SCH).
• Kalpakjian, S (2003) Manufacturing Processes for Engineering Materials. 4th Edition, Pearson Education (TS183 KAL).

Design for Manufacture and Assembly

• Black, R. (1996) Design and Manufacture: an integrated approach. Macmillan, Basingstoke(TS171.4 BLA).
• Boothroyd, G., Dewhurst, P. & Knight, W. (1994) Product Design for Manufacture & Assembly.Marcel Dekker, NY (TS171.4 BOO).
• Bralla, J. G. (1998) (Editor) Design for Manufacturability Handbook. 2nd Edition, McGraw-Hill,New York (TS176 DES).
• Cross, N. (2000) Engineering Design Methods: strategies for product design. 3rd Edition, Wiley,Chichester (TA174 CRO).
• Dieter, G. E. (2000) Engineering Design: a materials and processing approach. 3rd Edition,McGraw-Hill, New York (TA174 DIE).
• Otto, K. N. (2001) Product Design: techniques in reverse engineering and new product development. Prentice-Hall, NY (TS171 OTT).
• Pahl, G. & Beitz, W. (1996) Engineering Design: a systematic approach. 2nd Edition, Design Council, London (TA174 PAH).
• Pugh, S. (1991) Total Design: integrated methods for successful product engineering, Addison-Wesley, Wokingham (TA174 PUG).
• Swift & Booker (2003) Process Selection: from design to manufacture, 2nd Edition Butterworth-Heinemann, Oxford (TS183.3 SWI).
• Ullman, D. G. (1997) The Mechanical Design Process. 2nd Edition, McGraw-Hill, NY (TS171 ULL).