ENGME380-23B (HAM)

Design and Manufacturing 2

15 Points

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The University of Waikato
Academic Divisions
Division of Health Engineering Computing & Science
School of Engineering

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Convenor(s)

Lecturer(s)

Administrator(s)

: natalie.shaw@waikato.ac.nz
: janine.williams@waikato.ac.nz

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Student Representative(s)

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What this paper is about

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This paper will furnish the student with a knowledge of modern manufacturing processes (not necessarily all of them directly related to building a working prototype machine) and how to use them when designing complex machines. The paper builds on the material taught in ENGME280 Design and Manufacturing 1. Dirty prototyping will be taught and applied to a design project. Students will be required to apply modern manufacturing methods such as laser cutting, CNC machining, and 3D printing to the design of a complex machine. Students will undertake a group design project and build a working prototype machine that meets a design brief. The related Washington Accord graduate attributes are given in the Learning Outcomes.
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How this paper will be taught

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Much of this paper is project based and requires you to work in groups to design and build a machine to perform a given task. You will be given a design brief that explains what your machine has to do and the constraints you have to work within. Information related to the design project is on Moodle.

The group design project will be mostly undertaken in LSL1.02 where you will have materials and guidance to help you devlop feasible concepts (dirty prototypes) for your machine. You will then move to LSL.1.16 where you will develop your best dirty prototype concept into full 3D CAD models and 2D engineering drawings. You will then manufacture your parts and assemble, test and refine your machine in LSL.1.02. This will give you experience of designing a machine from design brief to fully functioning prototype. There will also be lectures on design and manufacture that will guide you through the project. The manufacturing part will mostly be assessed individually by tests.

Group Work: Students will work ideally in groups of four. All students in a group will get the same grade for the project, unless there is a major disagreement. Groups with disagreements will be required to negotiate amongst the group and complete a Group Participation Form (GPF), that states the amount of work each student contributed to the project assessment. No grades will be awarded without a GPF signed by all students in that group. This means you need to choose your group members carefully, because once you have signed up for a group, you are locked into a 'contract'. Also, please remember that in the real world, there is never a completely equal workload. If you cannot find a group, you will be randomly allocated into a group with other students who cannot find a group. The same GPF procedure applies if there are disagreements. It is up to groups to resolve issues as it is impossible for teaching staff to know exactly who is doing what in groups.We have developed a marking scheme that is mostly quantitative, i.e. marks will mainly be derived from things we can measure such as weight, cost, speed and task performance. Please bear this in mind when designing your machine.

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Required Readings

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The three recommended course texts are available on-line from the library. For those that have not yet studied electrical and mechanical machines (ENGME353), there is good information on gears and gearboxes, useful for your design project. Other course material, lecture notes, examples and videos are on Moodle.

  • Childs, Peter R. N.. Mechanical Design Engineering Handbook, Elsevier Science & Technology, 2013. ProQuest Ebook Central, https://ebookcentral-proquest-com.ezproxy.waikato.ac.nz/lib/waikato/detail.action?docID=1375437
  • Simmons, Colin, et al. Manual of Engineering Drawing : Technical Product Specification and Documentation to British and International Standards, Elsevier Science & Technology, 2009. ProQuest Ebook Central, https://ebookcentral-proquest-com.ezproxy.waikato.ac.nz/lib/waikato/detail.action?docID=913771
  • Design Engineering Manual, edited by Mike Tooley, Elsevier Science & Technology, 2009. ProQuest Ebook Central, https://ebookcentral-proquest-com.ezproxy.waikato.ac.nz/lib/waikato/detail.action?docID=631955
  • Slides and handouts available on Moodle to be studied prior to attend the lectures.
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Learning Outcomes

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Students who successfully complete the course should be able to:

  • Apply health and safety requirements when designing machines (WA5)
    Linked to the following assessments:
    Design Project - CAD (3)
    Design Project - Machine Efficiency and Health & Safety (6)
  • Apply the scientific principles and basic relationships between process conditions, materials and product quality underlying modern manufacturing processes (WA1)
    Linked to the following assessments:
    Manufacturing - Test 1 (2)
    Design Project - Machine Manufacture and Cost (4)
    Manufacturing - Test 2 (5)
    Manufacturing - Test 3 (7)
  • Design and build a complex machine to meet a given specification (WA3, WA5, WA8, WA9, WA10)
    Linked to the following assessments:
    Design Project - Concepts (assessment by interview) (1)
    Design Project - CAD (3)
    Design Project - Machine Efficiency and Health & Safety (6)
    Design Project - Performance at EDS during study week (8)
  • Select to most appropriate manufacturing process as a function of the engineering requirements of the part to be manufactured (WA1)
    Linked to the following assessments:
    Manufacturing - Test 1 (2)
    Design Project - Machine Manufacture and Cost (4)
    Manufacturing - Test 2 (5)
    Manufacturing - Test 3 (7)
  • Use traditional and modern manufacturing processes when designing parts and machines (WA3)
    Linked to the following assessments:
    Design Project - CAD (3)
    Design Project - Machine Manufacture and Cost (4)
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Assessments

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How you will be assessed

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The assessment of this paper comprises one group design project and three manufacturing tests. The design project has been split into 5 parts: concepts, CAD, manufacture & cost, efficiency & health and safety, machine performance. Details of the design project are given on a separate assignment sheet.

Samples of your work may be required as part of the Engineering New Zealand accreditation process for BE(Hons) degrees. Any samples taken will have the student name and ID redacted. If you do not want samples of your work collected then please email the engineering administrator, Natalie Shaw (natalie.shaw@waikato.ac.nz), to opt out.

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The internal assessment/exam ratio (as stated in the University Calendar) is 100:0. There is no final exam. The final exam makes up 0% of the overall mark.

The internal assessment/exam ratio (as stated in the University Calendar) is 100:0 or 0:0, whichever is more favourable for the student. The final exam makes up either 0% or 0% of the overall mark.

Component DescriptionDue Date TimePercentage of overall markSubmission MethodCompulsory
1. Design Project - Concepts (assessment by interview)
2 Aug 2023
9:00 AM
15
  • Other: Interview in Lab LSL.1.02
2. Manufacturing - Test 1
11 Aug 2023
10:00 AM
12
3. Design Project - CAD
18 Aug 2023
5:00 PM
15
  • Other: Moodle PDFs of 3D and 2D
4. Design Project - Machine Manufacture and Cost
15 Sep 2023
5:00 PM
10
  • Other: Moodle - spreadsheet
5. Manufacturing - Test 2
22 Sep 2023
10:00 AM
9
6. Design Project - Machine Efficiency and Health & Safety
11 Oct 2023
9:00 AM
10
  • Other: Test machine in lab LSL1.02
7. Manufacturing - Test 3
12 Oct 2023
12:00 PM
9
8. Design Project - Performance at EDS during study week
18 Oct 2023
No set time
20
  • Other: Perormance measured at EDS
Assessment Total:     100    
Failing to complete a compulsory assessment component of a paper will result in an IC grade
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