MSC Mechanical Engineering

AME7009

MECHANICS, MATERIALS AND

MANUFACTURE PROCESSES
Assignment 1

2023/2024
Semester 2

Level HE7

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Contents
1. Module Overview .......................................................................................................................... 2
2. Academic Misconduct ................................................................................................................... 2
3. Assessments .................................................................................................................................. 2
3.1 Learning Outcomes Assessed ...................................................................................................... 3
3.2 Assessment Brief ......................................................................................................................... 3

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 1. Module Overview
Module Tutor Dr Ma Mohin and Kingsley Bowoto

Tel. no. 01204903140

Email M.Mohin@bolton.ac.uk and k.bowoto@bolton.ac.uk

Office Location iZone (G9)

Drop-in Availability Please email us before dropping in to verify a meeting can

take place. Please bear in mind if dropping in without
notice we may be in class or busy due to other academic
duties. If so the meeting may have to be arranged for
another mutually agreeable time.

Web link to Moodle Class https://moodle.bolton.ac.uk/course/view.php?id=31109

Web link to Module Specification https://modules.bolton.ac.uk/AME7009

2. Academic Misconduct
Academic misconduct may be defined as any attempt by a student to gain an unfair advantage in
any assessment. This includes plagiarism, collusion, commissioning (contract cheating) amongst
other offences. To avoid these types of academic misconduct, you should ensure that all your work
is your own and that sources are attributed using the correct referencing techniques. You can also
check originality through Turnitin.

Please note that penalties apply if academic misconduct is proven. See the following link for further
details: https://www.bolton.ac.uk/about/governance/policies/student-policies/

3. Assessments
This Assignment constitutes 50% of the total assessment of the principal objectives of this unit.

Assessment Number
Assessment Type (and weighting)
Assessment Name
Assessment Date of issue:
1
Report (50%)
A plate with holes manufacturing using CAM technique (Section
1), and analysis of a simply supported beam using semi-empirical
and FEA technique (Section 2)
03/03/2023

Assessment Submission Date 15/04/2023

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3.1 Learning Outcomes Assessed

LO2: Formulate and analyse complex problems to reach substantiated conclusions. Evaluating available
data using first principles of mathematics, statistics, natural science and engineering principles, and
using engineering judgment to work with information that may be uncertain or incomplete, discussing
the limitations of the techniques employed. (M2)

LO3: Select and apply appropriate computational and analytical techniques to model complex problems,
discussing the limitations of the techniques employed. (M3)

LO4: Evaluate the environmental and societal impact of solutions to complex problems (to include the
entire life-cycle of a product or process) and minimise adverse impacts. (M7)

3.2 Assessment Brief

Introduction
The Assignment includes two Sections:
❖ Section 1: Computer-aided manufacturing (CAM) (50%) and
❖ Section 2: Mechanics of materials (50%).

Section 1: CAM (45%)

A plate with holes has a rectangular shape with step and hole features as shown in Figure 1.

Figure 1. A plate with holes (All dimensions are in mm).

Create the plate with holes using SolidWorks Part Design. This Part can be manufactured using CNC
machine from a rectangular stock with a size of 410mm X 160mm X 25mm, and a material of
Aluminium Alloy 2011-T3.

Keep the bottom part of the Stock unmachined. Prepare the toolpath and NC code using SolidWorks
CAM with the tools available in Table 1 and find the estimated machining time. Also, perform a

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modification of the cutting parameters to reduce the estimated machining time, assuming that the
cutting tool can be used up to the flute length.

Table 1. Detail of the cutting tools.

Tool type Key parameters

Face Mill 80MM 8FL FACE MILL
Flat End Mill 13MM CRB 3FL 22LOC
Centre Drill 10MM X 90 DEG CRB SPOT DRILL
Drill 9.9mm JOBBER DRILL
Ream 10.0mm CRB REAMER

The Section 1 of the report should contain:

1. Abstract and Introduction (5%)

Summary. Background including sustainability in CNC machining and CAM. Aim and
objectives.
2. Description of the CAM (40%)
➢ Machine (5%): Describe the machine, tool crib and postprocessor used. You should
provide appropriate Figures with the description.

➢ Stock (5%): Provide the detail of the stock manager. You should provide appropriate
Figures with the description.

➢ Machining feature, operation plan and toolpath (15%): Explain machining feature,
operation plan and toolpath in depth. These should include Figures of the SolidWorks
CAM Feature, Operation and Tools Tree.

➢ NC-code (5%): Provide the NC-Code (G-code) in a separate PDF file.

➢ Toolpath optimisation and discussion (10%): What is the estimated machining time of
the tool block without oplitimisation? What is the estimated machining time of the tool
brock after the optimisation? Explain the optimisation process along with time for each
step with appropriate Figure and Table. Further discuss the CAM process used and
finding of this study.
3. Conclusions and References (5%)
Main argument. Harvard referencing.

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Section 2 (50%):
A simply supported beam is a type of beam which rests on two supports and is free to move
horizontally. This type of beam has numerous applications in bridges, buildings, crane, conveyor,
balanced beam used for sports, etc.
The simply supported beam for this study is of rectangular cross-section as shown in Figure 2.
The beam is made of a type of Mild Steel with unknown Young’s modulus, 𝐸 and Poisson’s ratio,
𝜈 of 0.3. A point load is acting on the middle of the top surface.

Figure 2. Simply supported beam test rig.

Tasks:
➢ Experimental:
• Measure the geometry of the beam using sliding calliper.
• Perform beam deflection test using gradual load increments of: 100g, 400g, 500g
and 900g and take the readings of the corresponding deflections, and plot the
Force (N) vs Displacement (m) graph.
• Calculate the semi-empirical Young’s modulus, 𝐸 (GPa) of the material using Force
(N) vs Displacement (m) graph and Equation 1.
𝐹 𝐿3
𝐸= × … … … … (1)
𝛿 48𝐼
Here, 𝐹 is the Force (N), 𝐼 is the Second Moment of Area (m4), 𝐿 is length of the
beam (m) (between two supports) and 𝛿 is Deflection (m) for that 𝐹.

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 ➢ FEA:
• Using the semi-empirical Young’s Modulus, 𝐸 and given Poisson ratio, 𝜈, develop
FEA model in ANSYS. Validate the FEA result by comparing it with the experiment
𝐹
data including % of error (i.e., comparing the stiffness, ( )).
𝛿𝑚𝑎𝑥
• If the Yield strength of the material is 345 MPa and safety factor is 1.5, how much
maximum allowable load in kg the beam can take up (Hint: Use incremental loading
to find the appropriate normal stress).
• What would be the corresponding maximum allowable deflection (mm) before
yielding?

The Section 2 of the report should include:

1. Abstract and Introduction (5%)
➢ Summary.
➢ Background including sustainability in the field of mechanics of material for beam
application. Aim and objectives.
2. Methodology (10%)
Details how the tasks were conducted and the methods used along with
➢ Geometrical definition.
➢ Material and equipment used.
➢ Semi-empirical and FEA techniques.
➢ Use appropriate Figures, e.g. 3D design, material, meshing, boundary condition,
loading, etc.
3. Results and Analyses (20%)
➢ Load (N) vs displacement (m) graph.
➢ Semi-empirical Young’s modulus.
➢ FEA simulation and validation.
➢ Maximum allowable load capacity (Kg) using FEA.
➢ Maximum allowable deflection (mm) using FEA.
➢ Use appropriate Figures, e.g., stress contour plot, displacement contour plot, etc.
4. Discussion (10%)
Describes, analyse, and interpret the findings.
5. Conclusions and References (5%)
➢ Restate main argument.
➢ Harvard referencing.

*Recommendations for the Report writing:

➢ Page number, Header and Footer, Font: Calibri, Font size: 12, Line spacing: 2.
➢ Report Body: Title Page, Table of Contents, Section 1 and Section 2
➢ Word Limit: 3000 +/- 300 words.
➢ Ensure that you use Harvard referencing and provide minimum of 15 appropriate
references.

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Submission procedure

The electronic copy of the Assignment in PDF format needs to be uploaded via Turnitin in Moodle.
This includes the main assignment copy and a copy of the NC Code.

Grading Scheme

First class (70% and above)

Students will provide an in-depth appraisal of the characteristics of particular materials, equipment,
processes or products, demonstrating excellent critical reasoning skills. Focused and justified
recommendations will be made as to how problems/weaknesses identified in the design may be
overcome, and cost drivers improved. Extensive research demonstrating use of a wide range of
current secondary research sources will be evident. Academic style and referencing will be
excellent.

Second class (50-69%):

Students will provide a comprehensive appraisal of the characteristics of particular materials,

equipment, processes or products, demonstrating critical reasoning skills. Justified
recommendations will be made as to how problems/weaknesses identified in the design may be
overcome, and cost drivers improved. Research demonstrating use of a wide range of current
secondary research sources will be evident. Academic style and referencing will be good.

Third class (40-49%):

Students will provide a satisfactory appraisal of the characteristics of particular materials,

equipment, processes or products, demonstrating critical reasoning skills. Considered
recommendations will be made as to how problems/weaknesses identified in the design may be
overcome, and cost drivers improved. Research demonstrating use of a range of current secondary
research sources will be evident. Academic style and referencing will be fair.

Fail (39% and below):

Students who do not meet the requirements of a third class grade will not successfully complete
the assessment activity.