Unit Description and General Aims

The unit enhances 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 then undergoes an advanced study of modern Manufacturing Process and costing structures as well as the environmental impact thereof. This knowledge enables 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 are honed to set up and evaluate motion simulation of assemblies and create photorealistic renderings to communicate their ideas to their customers.

Students 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.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

1. Evaluate and make recommendations of computer aided manufacturing Processes. Evaluate mechanical components and select the appropriate computer aided manufacturing processes based on user requirements.
   • Bloom’s Level 5
2. Propose operations, using standard software tools, for parts particular to a specific computer aided manufacturing process with its cost calculations.
   • Bloom’s Level 5
3. Plan an assembly design in standard software, conduct clearance checks, perform motion simulations, and generate photorealistic rendering
   • Bloom’s Level 6
4. Optimise 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. Plan detailed work drawings with an understanding and application of geometrical dimensioning and tolerances.
   • Bloom’s Level 6
7. Construct a complete assembly drawing from a mechanical assembly with AS1100-101 drawing standards including BOM’s and exploded representations.
   • Bloom’s Level 6

Student assessment

Prescribed and Recommended readings

Suggested Textbook

• Zeid, Ibrahim. Mastering CAD/CAM. McGraw-Hill Higher Education (ISBN- 0072868457). 

Reference Materials

• Australian Technical Drawing Standard, AS1100-101, 1992.
• Zeid, Ibrahim. Mastering SolidWorks. Peachpit Press; 2 editions, 2014) (ISBN- 978-0133885941).
• Part Cost estimators http://www.custompartnet.com
• 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, ISBN 978-0-7506-6738-8
• Groover, Fundamental of modern manufacturing: Materials, Processes, and Systems (ISBN: 978-1-119-47521-7)
• Howard, William E;Introduction to solid modelling using SolidWorks 2012; 2012 (2010 version can also be used); McGraw-Hill Higher Education, 2012.
• Other texts, peer-reviewed journals, and websites. To be advised during lectures.

Unit Content

One topic is delivered per contact week 

Topic 1

Introduction to Mechanical Computer Aided Design and Manufacturing

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
4. Basic design methodology and tools used in early phase of the product development
5. Overview of computer aided manufacturing system, conversion of CAD file to CAM environment.

Topic 2

Solid Modelling – Strategy and Outputs

1. Identify design intent behind parts and features and develop an appropriate approach for modelling the parts and assemblies.
2. Applying general solid modelling techniques employed in design and manufacture.
3. Create fully constrained solid part and assembly models that can be quickly modified using standard software tools.

Topic 3

Solid Modelling – Configurations and Parametric Design

1. Create design table configurations for part and features
2. Develop mathematical relations between different dimensions and features
3. Implement expression for the design optimization

Topic 4

Solid Modelling – Assembly

1. Create assembly of different parts with their exploded views
2. Generate motion simulations for the kinematic and dynamic analysis of the assembly
3. Use standard software tools to conduct clearance checks.
4. Produce bottom-up and top-down assemblies and photorealistic renderings

Topic 5

Drafting

1. Identify the elements of a detail drawing and create a simple detail drawing complete with annotation
2. An 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

Topic 6

Geometric Dimensioning and Tolerancing

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. Understand, 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.

Topic 7

CAM – Manual Programming

1. Understand the use of computer numerical control (CNC) system
2. Understand the process definition for CNC machining
3. Identify and understand different M and G-Codes
4. Develop different CNC programming for milling, lathe and grinding operations

Topic 8

CAM – Software and Economics

1. Introduction to SolidCAM software – defining the coordinate systems, null-points.
2. Applying CAM in different machining operations and applying the software to create M-codes and G-codes.
3. Economics of machining using CNC machines

Topic 9

Computer Aided Manufacturing and Automation processes

1. Fundamentals of automated production lines
2. Working of manual and automated production lines
3. Introduction and analysis of cellular manufacturing
4. Applications of flexible manufacturing systems

Topic 10

Additive Manufacturing Processes

1. Different types of additive manufacturing processes
2. Understand different components for extrusion, fusion, jetting, lamination and decomposition AM processes
3. Material properties and strength characteristics of the product developed from AM processes

Topic 11

Additive Manufacturing- Economics and Selections

1. Ability to evaluate a component and select the appropriate additive manufacturing process based on user requirements.
2. Design for Additive manufacturing with its complexity and functionality
3. Software requirements and conversion for direct digital manufacturing

Topic 12

Unit Review

1. Research and technology advancement in CAD/CAM
2. 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.

Engineers Australia

The Australian Engineering Stage 1 Competency Standards for the Professional Engineer, approved as of 2013. This table is referenced in the mapping of graduate attributes to learning outcomes and via the learning outcomes to student assessment.

Software/Hardware Used

Software

• Software: Solid works with SolidCAM
• Software information: 

  SolidWorks is a versatile CAD and CAE software used for 3D modeling, 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.

• SolidCAM is an advanced CAM software integrated with CAD systems for CNC machining. It is crucial for mechanical engineers as it enhances precision, reduces machining time, and optimizes tool life. Applications include milling, turning, and multi-axis machining for various industries.
• Version:16 or above
• Instructions: Add in-solid cam
• Additional resources or files: N/A

Hardware

• N/A

Unit Changes Based on Student Feedback

• The due dates of unit assessments were spaced out, which alleviated student stress and provided sufficient time to work on assessments of various units in each semester. 
• Assessment 1 was converted from a traditional invigilated assessment to a more manageable ‘Weekly quizzes’ format.