ENGME280-21B (HAM)

Design and Manufacturing 1

15 Points

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Division of Health Engineering Computing & Science
School of Engineering


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Paper Description

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This paper builds on the introduction to engineering design taught in ENGEN180 and applies other material taught in years 1 and 2. The paper gives students an understanding of the fundamental principles and basic relationships underlying selected major manufacturing processes widely used in industry. Students undertake an engineering design project with a focus on design for manufacture which is taught through workshops. Engineering design methods are demonstrated through case studies. Knowledge on metrology and non-destructive testing techniques, which are critically important in modern manufacturing, will also be introduced. The paper also covers the practical aspects of selected major manufacturing processes via workshop and practical sessions where students have plenty of opportunities to build up their practical skills and apply their theoretical knowledge on manufacturing processes to solving practical problems.

To pass the paper, students must achieve a minimum mark of 40% in both TESTS.

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Paper Structure

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The course is taught through a combination of lectures, practical design tutorials, and workshop sessions. The scheduled lecture and workshop session content are provided in the attached paper outline. Details of the workshop session will be provided at the beginning of the semester.

Flipped learning and blended teaching could be used meaning that students need to read the lecture notes provided prior to any official lecture discussion/tutorial/review.

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Learning Outcomes

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Students who successfully complete the paper should be able to:

  • apply an engineering design process to the high level design of complex engineering systems
    Linked to the following assessments:
  • apply design specifications to the design of complex engineering systems
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  • find solutions to address the basic metrology needs and issues in manufacturing operations
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  • explain the scientific principles underlying each of the major non-destructive testing and inspection techniques used in manufacturing
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  • explain the scientific principles and basic relationships between process conditions, materials and product quality underlying the major manufacturing processes
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  • master basic practical skills for the practical operations in major manufacturing processes covered in the paper including turning, drilling, sheet metal forming, and welding
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While design requires application of appropriate technical procedures, competency in technical communication will also be assessed in this paper. In practice it is largely accomplished by teamwork. Even in situations where (component design etc) it may be undertaken by one engineer, it needs to be checked by a peer. The presentation is as important as the technical analysis. Therefore, all assessed items must be presented in a way so that another student or an engineer will be able to follow the analysis and rationale for the design choices. Correct answers should be supported by clear reasoning. Any ambiguity in the reports or examination scripts may be heavily penalised. Late work will be penalised 5% of its mark for every working day after the hand in date.

2 x Tests on manufacturing processes (30%)

Manufacturing workshop sessions (20%)

CAD project (10%)

Design project (40%):

  • Mechanical advantage report (5%)
  • Concept generation and selection (5%)
  • Drawings and manufacturing plan (5%)
  • Engineering design report (10%)
  • Design show demonstration of prototype (15%)
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Assessment Components

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The internal assessment/exam ratio (as stated in the University Calendar) is 100:0. There is no final exam. The final exam makes up 0% of the overall mark.

The internal assessment/exam ratio (as stated in the University Calendar) is 100:0 or 0:0, whichever is more favourable for the student. The final exam makes up either 0% or 0% of the overall mark.

Component DescriptionDue Date TimePercentage of overall markSubmission MethodCompulsory
1. Test 1
18 Aug 2021
8:00 AM
2. Test 2
13 Oct 2021
8:00 AM
3. Workshop sessions on manufacturing
4. CAD project
5. Design project - see breakdown above
Assessment Total:     100    
Failing to complete a compulsory assessment component of a paper will result in an IC grade
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Required and Recommended Readings

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Required Readings

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Moodle Lecture Notes

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Recommended Readings

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  • Fundamentals of modern manufacturing: Materials, processes, and, systems, Mikell P. Groover, 5th Edition, Wiley
  • Engineering Drawing, Boundy, A. W., McGraw-Hill, 2007
  • Mechanical Design Engineering Handbook, Peter R. N Childs, 2013
  • Mechanical Engineering Design, Joseph Edward Shigley Charles R Mischke; Richard G Budynas, 2004
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Other Resources

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SolidWorks CAD software will be available to all students.
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Online Support

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This paper has a Moodle page (http://elearn.waikato.ac.nz) where you will be able to access lecture notes and assessment materials. There are also discussion forums where you can both ask and answer questions.

PLEASE NOTE: Moodle will be used for class notices etc and it is your responsibility to check the site regularly. Instructions provided on Moodle and in lectures are considered to be given to the class as a whole.

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This 15pt paper emphasizes on the theories, fundamental principles, and workshop experience of manufacturing processes.

The paper has a total workload of approx. 160 hours as below:

Two 2 hour lecture per 12 weeks (24 hours), six 8 hours workshop sessions plus six 4 hours design project workshops (72 hours), and self-directed study - 50 hours of design project (CAD, calculations, concept and presentation) and 14 hours of reading and revision for the test.

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Linkages to Other Papers

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This paper builds on the engineering design taught in ENGEN180 / ENGG180.
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Prerequisite papers: ENGEN180 or ENGEN302




Restricted papers: ENGG282 or ENMP214 or ENMP215

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