|Unit Name||Computer Aided Design and Manufacturing|
|Unit Duration||1 Term (online) or 1 Semester (on-campus)|
Master of Engineering (Mechanical)
Duration: 2 years
|Unit Creator / Reviewer||Henry Wickham|
Masters total course credit points = 48
|Mode of Delivery||Online or on-campus.|
10 hours per week:
Lecture - 1 hour
Tutorial Lecture - 1 hours
Practical / Lab - 1 hour (where applicable)Personal Study recommended - 7 hours (guided and unguided)
Unit Description and General Aims
The unit means to enhance engineering expertise and confidence in Computer Aided Design (CAD) to not only conceive innovative and efficient designs but also to communicate these designs to customers and manufacturers via AS1100-101 standard detailed work and assembly drawings.
The student will be introduced to the history and principles of Mechanical Computer Aided Design and will then undergo an advanced study of modern Manufacturing Process and costing structures as well as the environmental impact thereof. This knowledge will enable students to evaluate and select manufacturing processes for a particular application. The students will also be equipped with advanced modelling skills to purpose design parts for specific manufacturing processes and complete cost studies. Further skillsets will be honed to set up and evaluate motion simulation of assemblies and create photorealistic renderings to communicate their ideas to their customers.
The students will attain an in depth knowledge on Additive Manufacturing processes enabling them to evaluate these technologies against user requirements, and configure and export their design for rapid prototyping.
On successful completion of this Unit, students are expected to be able to:
1. Evaluate and make recommendations of Manufacturing Processes. Able to evaluate mechanical components and select the appropriate manufacturing processes based on user requirements and environmental impact.
Bloom’s Level 5
2. Recommend the use of standard software tools, parts particular to a specific modern manufacturing process as well as completing cost calculations.
Bloom’s Level 5
3. Adapt to a standard software tool to create assemblies, conduct clearance checks, produce and analyse motion simulations and generate photorealistic rendering
Bloom’s Level 6
4. Determine the best practice using Six Sigma methodology to calculate and plot a statistical tolerance analysis.
Bloom’s Level 5
5. Make judgements based on evidence and external criteria of Additive Manufacturing technology and file preparation methodologies.
Bloom’s Level 5
6. Create detailed work drawings with an understanding and application of limits and fits and geometrical tolerances.
Bloom’s Level 6
7. Construct a complete mechanical assembly including all calculations and produce work and assembly drawings to AS1100-101 drawing standards including BOM’s.
Bloom’s Level 6
(e.g. Assignment - 2000 word essay (specify topic) Examination (specify length and format))
|When assessed(e.g. Week 5)||Weighting (% of total unit marks)||Learning Outcomes Assessed|
Type: Multi-choice test (Proctored) / Group work / Short answer questions / Role Play / Self-Assessment / Presentation
Example Topic: Up to topic 4.
Type: Mid-semester test (Proctored) / Report / Research / Paper / Case Study / Site Visit / Problem analysis / Project / Professional recommendation
Example: Short/Long answers and Problems to solve
Example Topics: Review a detailed work drawing and interpret the information. Focus on Geometrical tolerance, limits and fits, welding symbols and post processing. Complete a statistical tolerance analysis for a defined production volume of a simple assembly. Calculate and plot the normal parameter distribution within a tolerance for each part and use this data to show the interrelations of distributed variables.
|25%||3, 4, 5, 6|
Type: Practical assessments, Remote labs, Simulation software or Case studies.
Example: Design of a cast aluminium bracket considering specific loading conditions and load cycles. File export for rapid prototyping (FDM)
Type: Report (Final Project)
Word length: 4000 (excluding makers’ diagrams and layout drawings.)
Topic: To submit a complete Mechanical design with work and assembly drawings based on project criteria and taking everything into account the student has learned to date. The student will be given project criteria that must be met. The student must show calculations - engineering, economic and statistical.
Attendance / Tutorial Participation
Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application.
|Continuous||5%||1 - 7|
Prescribed and Recommended readings
- C. Poli, Design for Manufacturing - A Structured Approach, Butterworth Heinemann, 2001. – ISBN 978-0-7506-7341-9
- G. Henzold, Geometrical Dimensioning and Tolerancing for Design, Manufacturing and Inspection - A Handbook for Geometrical Product Specification Using ISO and ASME Standards, 2nd Edition, Butterworth Heinemann, 2006. - ISBN 978-0-7506-6738-8
- Australian Technical Drawing Standard, AS1100-101, 1992.
- Part Cost estimators http://www.custompartnet.com
- Howard, William E; Introduction to solid modelling using SolidWorks 2012; 2012 (2010 version can also be used); McGraw-Hill Higher Education, 2012.
- W. Boundy, Engineering Drawing, McGraw-Hill, 2002.
- Other texts, peer-reviewed journals and websites. To be advised during lectures.
One topic is delivered per contact week, with the exception of part-time 24-week units, where one topic is delivered every two weeks.
Introduction to Mechanical Computer Aided Design
1. Review contents and outcomes of this course. End of term Project options
2. A brief review of CAD history; developments to date, 2D, 3D, Solids & Surfaces
3. CAD output: 2d Drawings, CAM, FEA, PDM, Motion Simulation, Photorealistic Renderings
Topic 2 and 3
1. Be familiar with the different manufacturing processes: Machining, Casting, Moulding, Forming, Additive Manufacturing – understanding and ability to calculate their influence on stress and fatigue.
2. Attain an in depth knowledge of the pros and cons of each process.
3. Be familiar with corrosion, coating and plating options and calculating their influence on stress and fatigue.
4. Understanding of the cost implications and environmental impact involved with each manufacturing process.
5. Ability to calculate the component cost based on the manufacturing process and volume.
6. Ability to evaluate a component and select the appropriate manufacturing process based on user requirements.
Topic 4 and 5
Feature Based Parametric Solid Modelling
1. Applying general solid modelling techniques employed in design and manufacture
2. Create fully constrained solid models that can be quickly modified using standard software tools.
3. Identify design intent behind parts and features and develop an appropriate approach for modelling the parts and assemblies.
4. Ability to use standard software tools to create assemblies, conduct a clearance checks, produce motion simulations and photorealistic renderings
1. Understand machining/grinding limitations and acquiring evaluation and design skills to accommodate these.
2. Understand surface finishes in relation to manufacturing processes, measurement thereof, symbols and drawing application.
3. Understanding heat treatment, its adverse effect on the dimensional stability on a part and acquiring evaluation and design skills to optimise a design to limit these effects, post process machining and grinding.
4. In depth understanding of the effects of Residual Stress Induced by these processes and stress relieving methods
5. Applying this knowledge to evaluate requirements and design accurate and efficient machined parts and identifying and specifying post processes.
Sheet metal Process
1. Understanding bend theory – neutral axis, bend radius, K-values.
2. Understanding the stresses induced by bending, spring back, spring back factor
3. Demonstrate how sheet metal parts are designed and used - Enclosures, Brackets, Structures or frames, Formed parts
4. Describe the various construction techniques- Face Flange creation, Ripped Shelled Solids, Folded part to Flat Pattern, Flat Pattern export
5. Ability to use sheet metal tools – Bends, Flanges, Hems, Corner seams and corner relief
6. A good understanding of weld joints and their design applications
7. Understanding of bend tolerance stack up and sheet metal detail drawings.
8. Applying this knowledge to evaluate requirements and design accurate and efficient sheet metal parts and weld assemblies
Casting/Injection Moulding Process
1. A basic understanding on design considerations for casting/moulding – material properties, shrinkage, distortion allowance, voids and sinking, wrapping
2. Application of design features – uniform walls, draft angles, coring, gussets, ribs, live hinges, over moulding.
3. A basic understanding of the feeding and gating system
4. Understanding stress relieving and post machining process.
5. Applying this knowledge to evaluate requirements and design accurate and efficient cast parts and specifying post machining and processes.
1. Introduction to modern additive manufacturing processes – FDM, SLA, SLS, Polyjet, Laser Sintering.
2. Ability to evaluate a component and select the appropriate additive manufacturing process based on user requirements.
3. CAD file export and configuration – STL, Optimized Part orientation.
Drawing Practice – Working Drawings
1. Identify the elements of a detail drawing and create a simple detail drawing complete with annotation
2. A understanding of the common elements of a title block ,revision tables and revision process
3. Understanding Bill of materials population, including purchased parts
4. Create a typical drawing sequence of numbers, Ability to construct an assembly drawing and exploded view of a machine unit
5. Construct a set of working drawings of a machine assembly including assembly drawings, according to AS 1100-101, bill of materials, revisions block, part specifications, and general notes
1. Interpret and create limit dimensions, describe the nominal size, tolerance, limits, and allowances of two mating parts
2. Identify a clearance fit, interference fit, and transition fit, describe the basic hole and basic shaft systems
3. Ability to dimension two mating parts using limit dimension, unilateral tolerances, and bilateral tolerances.
4. Understanding of and ability to interpret and apply geometric tolerances.
5. Introduction to Six sigma process. Statistical tolerance analysis, calculating and plotting parameter distribution within a tolerance and defining interrelation of distributed variables.
Project and/or Unit Review
In the final week students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.
Additional resources or files: N/A