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FACULTY OF ENGINEERING

SCHOOL OF MECHANICAL AND MANUFACTURING ENGINEERING

MMAN2100

ENGINEERING DESIGN

COURSE OUTLINE

SEMESTER 1 2011

CONTENTS

Page
Course staff 2
Course Information 2
Assessment 4
Academic honesty and plagiarism 5
Course schedule 5
Resources for students 6
Continual course improvement 7
Administrative matters 7
Overall 8
MMAN2100 Engineering Design

COURSE STAFF
Course Convener
Ningsheng Feng
Room ME320
Tel (02) 9385 5696
Fax (02) 9663 1222
Email n.feng@unsw.edu.au
Additional teaching staff
Alex Churches, ME219
Sangarapillai Kanapathipillai, ME120
Tim White, ME216
Shaokoon Cheng
Ali Moridi
Ann Lee

COURSE INFORMATION
Units of credit and student-centred and self-directed learning
This is a 6 unit-of-credit (UoC) course. It involves 6 hours per week (h/w) of face-to-face
contact, and it is expected that you will put in, on average, an additional minimum of 5
hours per week of your own time (including stuvac and exams). This time should be
spent in revising the lecture material and further reading, completing the project tasks
and assignments, and revising and learning for the examinations. This won’t always be
evenly spread throughout the session; inevitably with project work, there will be peak-
load periods, but starting early and working progressively will do a lot to minimise the
peaks. Remember that good work cannot be done in one night.
How the course relates to other course offerings in the program
You learnt some of the principles of design in ENGG1000 Introduction to Engineering
Design and Innovation. These skills will be expanded in this course. You learnt about
CAD skill in MMAN1130 Design for Manufacture. These skills will be applied to the
drawing parts for the design project. You learnt about free body diagram analysis in
MMAN1300 Engineering Mechanics 1. Free body diagrams will be used extensively in
analysing loadings in the design tasks.
This course focuses directly on the design of machine elements and component
assemblies, although we try to illustrate the design activity in a way which is as general
as possible. It forms the basics of mechanical design which will become the foundation
of your later design courses and future design activities. The course also includes a
design and build project from the National Warman competition to familiarize you with
real life design and manufacturing.
The objectives of the course
The objective of the course is to familiarise you with the approaches to design projects.
Design is an open-ended problem for which there is normally no single correct answer.
Basic design ideas about general design considerations are used so that, at the end of
the course, you are able to aim at good practical design outcomes which satisfy the
customer requirements at minimum cost and are as close to “optimum” as possible.

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MMAN2100 Engineering Design

The course also trains you for practical design consideration of common mechanical
elements such as flywheels, shafts and the supports and includes general
considerations in common machinery design. This is done via projects involving the
relevant machine elements so that you obtain first-hand experience of design. These
tasks also enable you to improve your written communication skills, drawing capability
through presentation of design reports including proper engineering drawings for
manufacturing and assembly.
The design and build project enables you to improve your ability in group cooperation,
project planning and budget consideration from concepts to completion (prototype
testing).
Teaching strategies that will be used and their rationale
The teaching strategies that will be used include:
 Presentation of the material in lectures so that you know how to approach various
design tasks.
 Discussion and practice in tutorials to answer queries and provide feedback on your
design work.
 Group projects to familiarise you with real life tasks.
Suggested approaches to learning in the course
Suggested approaches to learning in this course include:
 Careful reading, discussion and understanding of the material presented in lectures.
 Additional reading on and about the material presented in lectures to broaden your
knowledge base.
 Conscientiously working through the tutorial exercises and set assignments.
 Understanding the lecture material in preparation for examinations.
 Attending all lectures and tutorials every week to maintain the learning progress.
 Being prepared to participate, in class and in project groups. Specifically, be
prepared to contribute ideas. Ideas which have some thought behind them and are
conscientiously advanced will be well received and respected. If you “stand back”
and take a passive role, letting others do all the thinking, decision making and other
work, you will get little out of this experience opportunity, and it will be obvious in the
final exams that this has been the case – with a predictable outcome.

Expected learning outcomes; their association with the teaching strategies and
with the suggested approaches to learning
On completion of the course, it is expected that you will
 Be familiar with the basic approaches in simple design tasks involving design
considerations, constraints, process and management.
 Be familiar with the practical designs of basic machine components, taking into
account functionality, manufacturing and assembly, reliability, as well as
affordability.
 Be able to cooperate in group projects.
 Know how to apply the design approach to real life design problems.

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 Have improved written communication skills and drawing capabilities.

CAD Drawings
While DESIGN as such is the real message of this course, the CAD system is the
medium which you are expected to use for the design work you do. If you insist on
producing drawings by hand because you believe you are experienced rather than
because it is fast, then the same quality standard is expected. This also applies to
using a CAD package in which drawings generated by computer are not automatically
of high quality. A good drawing is NOT done by just pressing a button on the computer.
It is the user who makes the outcome good or bad quality. As a result, you are asked to
remember the following:
 Follow the Australian drawing standards throughout your presentation.
 Provide only minimal outline representation for proprietary items, e.g. couplings,
pulleys, sprockets, gears, belts, chains, bearings, seals, nuts, screws, washers and
bolts, etc.
 Where features are repeated, show in full once only and indicate repeats notionally.
 Use symmetry to advantage where it exists. Centrelines are a vital feature to
achieve this.
Failure to abide by these guidelines will attract a significant penalty.

ASSESSMENT
Overall rationale for assessment components and their association with course
objectives
Tutorial exercises are relevant to the submitted assignments and project work. They
must be done in class in order to verify the comprehension of the ideas. If in doubt,
discuss with the tutors to clarify (Do not just believe whatever the tutors say. Be
convinced).
Other written assignments are to be submitted via the assignment boxes in the Printing
Room by 11am of the Monday of the week indicated except for the last one which will
be due by 11am, Thursday of week 13. Late submissions attract a penalty of TEN
percent of the allocated mark per day. No assignments will be accepted for marking
once the marked ones have been returned. The scheduled week due for an assignment
might change from time to time as the subject progresses.
A standard specification is available from the School Office to aid presentation of your
assignments (in all courses). All submissions should have a standard School cover
sheet. All submissions are expected to be neat, and clearly set out. All calculations
should be shown as, in the event of incorrect answers, marks are awarded for method
and understanding. The format of the assignment report, the design consideration and
technical drawings (if appropriate) will also contribute to the assignment marks. The
assignments will be marked with relatively few feedback comments. If in doubt, ask the
tutors for feedback.
There will be one TWO-hour examination at the end of the session. This examination
will contribute 40% of the total grade in the course. The tutorial work, drawing exercises
and design project will provide the remaining of the grade.

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MMAN2100 Engineering Design

Exam Individual Assignment Group Project Total


25% 35% 40% 100%
You will need to provide your own calculator, of a make and model approved by
UNSW, for the examination. The list of approved calculators is shown at
https://my.unsw.edu.au/student/academiclife/assessment/examinations/Calculator.html
It is your responsibility to ensure that your calculator is of an approved make and
model, and to obtain an “Approved” sticker for it from the School Office or the
Engineering Student Centre prior to the examination. Calculators not bearing an
“Approved” sticker will not be allowed into the examination room.
Special consideration and supplementary assessment
For details of applying for special consideration and conditions for the award of
supplementary assessment, see Administrative Matters for All Courses, available from
the School office as part of The Guide, or on the School website. Note that special
consideration, if granted, is for an alternative assessment, rather than free marks, for
the missing tasks

ACADEMIC HONESTY AND PLAGIARISM


The Learning Centre website is main repository for resources for staff and students on
plagiarism and academic honesty. These resources can be located via:
www.lc.unsw.edu.au/plagiarism

COURSE SCHEDULE
A table of lecture and tutorial or practical class topics for each week is listed below.
This schedule may be subject to change at short notice to suit exigencies.

Tutorial B Assignment
Wk Lecture <Mon.> Lecture <Wed.> Tutorial A
<Thur.> due
Design approach /
1 Introduction / Project
Documentation
Warman * Warman
Grouping, Grouping
2 Part modelling Warman approach General
Simple (0%)
Design
CAD
3 Drawing basics Flywheel General
exercise
* Concept
Report (10%),
CAD
4 Drawing views AC motor General CAD
assessment
Assessment
(3% in lab)
Simple Design
5 Keys and seals Flywheel General
Drawing dimensioning (2% in tut)
6 Linear and geometric tolerances Positioning and fastening Key General
Compliance * Compliance
7 Limits and fits Shaft layout and loading General
Test Test (5%)
Flywheel
Pictorial drawings / Auxiliary Shaft General
8 Static shaft Assembly
projections Basics
Report (10%)
Warman Warman * Final Test
9 Warman Heat Warman Heat
Heat Summary (15%)

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* Summary
Warman Presentation
10 Assembly drawing Support casing Summary General (10% in class)
Presentation Peer Review
(+-30%)
Part/Assembly
11 Drawing symbols Bedplate Static Shaft General Drawings
(10%)
Shaft
12 Descriptive geometry Design details General
Assembly
Shaft
Assembly
13 Summary Summary
Report
<Thu.> (10%)
Exam (2 hours) (25%)
Drawing specific
Warman Project
* Group assignment
Specific topics may be introduced and announced for the General tutorial sessions.

RESOURCES FOR STUDENTS


Textbook details (in bookshop, UNSW library, Open Reserve)
SHIGLEY’S MECHANICAL ENGINEERING DESIGN, R.G. Budynas and J. K. Nisbett,
8th ed., McGraw Hill.
ENGINEERING DRAWING, A.W. BOUNDY, 7th ed., McGraw Hill.
In addition, partial lecture notes (.ppt) will be available online to assist revision.
List of required and suggested additional readings and availability (in bookshop,
UNSW library, Open Reserve)
The following books contain material useful in supplementing that provided in the
textbook.
FUNDAMENTALS OF MACHINE DESIGN, Vols. 1 to 5, Orlov, R., MIR Publishers,
Moscow.

MATERIALS AND PROCESSING IN MANUFACTURING, De Garmo, E.P., Collier


MacMillan, New York/London.
MACHINE DESIGN, Deutschman, A.D., Michels, W.J. and Wilson, C.E., Collier
MacMillan, New York.
STEEL DESIGNERS HANDBOOK, Gorenc, B.E. and Tinyou, R., NSWUP, Sydney.
MANUFACTURING ENGINEERING AND TECHNOLOGY, Kalpakjian, S., Addison-
Wesley, New York.
MANUFACTURING PROCESSES, Yankee, H.Y., Prentice-Hall, New Jersey.
Manufacturers’ catalogues are required for selecting proprietary components for the
design project.
Some catalogues are available from some web sites, but students should beware of the
availability and applicability of the products to the local market.

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Additional materials provided on Web


Lecture notes, assignment information, progress marks, announcements, class/group
discussion forums, etc.
Recommended Internet sites
UNSW library site for past exam papers and data sheets.

CONTINUAL COURSE IMPROVEMENT


Periodically student evaluative feedback on the course is gathered, using among other
means, UNSW's Course and Teaching Evaluation and Improvement (CATEI) Process.
Student feedback is taken seriously, and continual improvements are made to the
course based in part on such feedback.
The recent major change includes the shift of the Warman Design and Build
Competition from this course to ENGG1000 as well as a shift of the detailed shaft
design to later design courses. This has made available more time for drawing training
and practice, as well as more project time and corresponding progress feedback. To
cater for different CAD packages, apart from continuing facilitation of CATIA, resource
is also supplied for Pro/E training.
ADMINISTRATIVE MATTERS
Please note that disruption of any sort will not be tolerated. This includes
straggling into class late. The staff will be at class punctually, and so should you. If you
can’t get to class by 5 minutes past the hour, either slink in like a ghost or stay away.
However, genuine questions during lectures are quite permissible and in fact
encouraged. These do a lot to clear up points that may be bothering quite a few
people, so if you need to have something clarified, put up your hand and wait for the
lecturer to take your question.
If you have some special problems relating to or affecting your progress in these
courses, especially of administrative issues, speak to the lecturer in charge to avoid
confusing or contradictory answers from different tutors. Earlier is better than later!
Information about each of the following matters is presented in a handout available
from the School office. It is essential that you obtain a copy, read it carefully and
become familiar with the information, as it applies to this course and to each of the
other courses in which you are enrolled.
 Expectations of students (including attendance at lectures and tutorials/laboratory
classes/seminars; and computer use, for example, in the use of email and online
discussion forums)
 Academic honesty (including misconduct, plagiarism)
 Procedures for submission of assignments and the School’s policy concerning late
submission
 Examination procedures and advice concerning illness or misadventure

Student support services


Students who have a disability that requires some adjustment in their teaching or
learning environment are encouraged to discuss their study needs with the course
convener prior to, or at the commencement of, their course, or with the Equity Officer
(Disability) in the Student Equity And Disabilities Unit (SEADU): 9385 4734,

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seadu@unsw.edu.au, www.studentequity.unsw.edu.au, Ground floor of the John


Goodsell Building (F20). Issues to be discussed may include access to materials,
signers or note-takers, the provision of services and additional exam and assessment
arrangements. Early notification is essential to enable any necessary adjustments to be
made.
Information on relevant Occupational Health and Safety policies and
expectations
The OHS link is: www.ohs.unsw.edu.au

OVERALL
Remember that as a designer, it helps to:
1. Be a collector of design ideas, configurations and methods (sources, references,
photos, etc.). Engineering is everywhere, so look around you!
2. Be prepared to be technologically devious (indirect) with your creativity; avoid
problems in the first instance, rather than having to deal with their results later.
3. Decouple problems; integrate solutions.
4. Have confidence in your own creativity and abilities in design.
5. Keep your nerve when it gets difficult.
6. Know your own strengths and weaknesses, and how you work best.
7. Know when you need help
- to generate ideas, or
- in specialist areas of practice,
and
- be prepared to get it, and
- know where to go to get it (network with other designers).
And particularly remember that:
1. Ultimately it’s the marketplace that defines success or failure for a product or
design.
2. An ounce of imagination will beat a tonne of computing any day (most days!).
3. No amount of theoretical analysis will save a design from the bad results of a
poor configuration, so get the configuration right first.
4. A superior product (specification, quality) at a competitive price and in an
attractive format always succeeds.
5. Simplicity is still, and always will be, the surpassing hallmark of design
excellence.
6. Simplicity is often not easy to achieve.
Finally, this is a subject to be enjoyed! We enjoy presenting it, and we hope you
enjoy developing in it.

Ningsheng Feng
February 2011

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