Unit Description and General Aims

The objective in presenting this unit is to make the students understand the design philosophy for solid modelling and assembly of different components. Students can develop CAD models, verify product subjected to different loads for safety and analyse parts for manufacturing. This unit will cover concepts of CAD modelling, finite element analysis, computer aided manufacturing and manufacturing system analysis.

Learning Outcomes

1. Choose suitable modelling technique to develop 3D CAD model.
   Bloom’s Level 5
2. Create appropriate assembly by mating different components and utilizing relations and equations.
   Bloom’s Level 6
3. Evaluate type of fits between two mating parts and stack tolerances.
   Bloom’s Level 5
4. Develop CNC programs by using manual and software-based methods.
   Bloom’s Level 6
5. Analyse manufacturing systems for single and multi-station production systems.
   Bloom’s Level 4
6. Develop finite element models with appropriate boundary and load conditions.
   Bloom’s Level 6

Student assessment

Overall requirements: Students must achieve a result of 50% or above in the exam itself to pass the exam, and must pass the exam to be able to pass the unit. An overall final unit score of 50% or above must be achieved to pass the unit once all assessment, including the exam, has been completed.

Prescribed and Recommended Readings

Textbook

• Bethune, J.D., 2019. Engineering Design Graphics with Autodesk Inventor 2020. Macromedia Press.

• D.L. Logan, A First Course in the Finite Element Method, Thomson-Engineering, 2022.

Reference

• Bordino, A., 2022. Autodesk Inventor 2023 Cookbook: A guide to gaining advanced modeling and automation skills for design engineers through actionable recipes. Packt Publishing Ltd.

• Zeid, Mastering SolidWorks, 3rd Edition. Peachpit Press, 2021.
• M. Groover, Automation, Production Systems, and Computer-Integrated Manufacturing, 5th Edition. Pearson, 2019
• G. Henzold, Geometrical Dimensioning and Tolerancing for Design, Manufacturing and Inspection, 2nd Edition. Butterworth Heinemann, 2020

Journal, website

Notes and Reference Texts

• IDC Technologies
• Other material advised during the lectures

Unit Content

Topic 1

Introduction to solid modelling

1. Introduction to CAD and CAM processes in industry
2. Brief history of CAD and CAM
3. Identify different dimensions from the blueprint
4. Importance of fully defined sketches
5. Understand advanced solid modelling techniques

Topic 2

Advanced solid modelling

1. Solid modelling using reference planes
2. Design intent for solid modelling
3. Parametric design using relations and equations
4. Different methods of creating configurations

Topic 3

Assembly concepts and drafting

1. Understand different mates for assembly
2. Develop bottom up and top down assembly
3. Develop different views as per drafting standards
4. Understand rules of dimensioning
5. Develop user-defined templates for drafting

Topic 4

Geometric dimensioning and tolerance

1. Understand different terminologies of tolerances for two mating parts
2. Calculate tolerances for mating parts and identify type of fit
3. Use of statistical and arithmetic methods for tolerance stack up calculations
4. Understand and apply different geometric dimensions and tolerances

Topic 5

Part programming for CNC machines

1. Understand the use of computer numerical control (CNC) system
2. Understand the process definition for CNC machining
3. Identify and understand different G and M functions
4. Develop different CNC programming for machining operations
5. Define machine, workpiece zero, and stocks
6. Apply different machining operations, tool paths, and tool machining simulations

Topic 6

Computer-aided manufacturing systems

1. Fundamentals of production lines
2. Different methods of work transport
3. Cycle time analysis and line balancing
4. Analysis of single station and multi-station production lines

Topic 7

Cellular and flexible manufacturing system

1. Fundamentals of cellular manufacturing and group technology
2. Methods to get part families
3. Convert layout of machines for cellular manufacturing
4. Decide layout of machines within manufacturing cells
5. Analyze flexible manufacturing cell

Topic 8

Fundamentals of finite element methods

1. Understand mathematical modelling for structural and heat transfer problems
2. Numerical solutions for mathematical models
3. Different steps for FEM
4. Solve differential equations by FEM

Topic 9

One dimensional truss element

1. Application of FEM for one-dimensional problems
2. Understand discretization by elastic spring system
3. Solve linear elastic structural bar and truss problems by finite element methods
4. Use FEM package/software for solving one-dimensional bar and truss problems

Topic 10

Beam and frame elements

1. Develop mathematical model for the beam structures
2. Develop mathematical equations for frame element
3. Solve beam and frame elements problems
4. Compare solutions of FEM with the exact mathematical solutions
5. Use FEM package/software for solving beam structural problems

Topic 11

2D and 3D structural problems

1. Apply boundary conditions for force, pressure, and supports for 2D and 3D structural problems
2. Apply mesh refinements for different structural engineering applications
3. Use FEM package to solve 2D and 3D structural problems

Topic 12

2D and 3D thermal problems

1. Apply boundary conditions for temperature, convection, and heat generation for thermal problems
2. Apply boundary conditions and mesh refinements to different heat transfer applications
3. Use FEM package to solve 2D and 3D thermal problems

Software/Hardware Used

Software

• Software 1: AutoDesk Inventor - It is a comprehensive 3D CAD software used for mechanical design, simulation, and documentation. It is crucial for mechanical engineers as it enhances design accuracy, reduces development time, and facilitates collaboration. Applications include creating detailed parts and assemblies, performing simulations, and generating technical drawings. 
  • Version: Latest
  • Instructions: N/A
  • Additional resources or files: N/A
• Software 2: ANSYS Workbench - It is an integrated platform for managing and automating engineering simulations, combining CAD, meshing, and physics solvers. It is crucial for mechanical engineers as it enhances design accuracy, reduces development time, and facilitates multiphysics simulations. Applications include structural analysis, fluid dynamics, and thermal management. 
  • Version: Latest
  • Instructions: N/A
  • Additional resources or files: N/A

Hardware

• N/A

Unit Changes Based on Student Feedback