ENGME380-22B (HAM)

Design and Manufacturing 2

15 Points

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Division of Health Engineering Computing & Science
School of Engineering

Staff

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Convenor(s)

Mike Duke

Mike Duke
4522
CD.1.02
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mike.duke@waikato.ac.nz

Lecturer(s)

Fei Yang

Fei Yang
9417
F.G.06D
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fei.yang@waikato.ac.nz

Leandro Bolzoni

Leandro Bolzoni
9381
F.G.06E
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leandro.bolzoni@waikato.ac.nz

Rahul Jangali

Rahul Jangali
D.G.12
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rahul.jangali@waikato.ac.nz

Administrator(s)

: mary.dalbeth@waikato.ac.nz
: natalie.shaw@waikato.ac.nz

Placement/WIL Coordinator(s)

Tutor(s)

Student Representative(s)

Lab Technician(s)

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You can contact staff by:

  • Calling +64 7 838 4466 select option 1, then enter the extension.
  • Extensions starting with 4, 5, 9 or 3 can also be direct dialled:
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    • For extensions starting with 3: dial +64 7 2620 + the last 3 digits of the extension e.g. 3123 = +64 7 262 0123.
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Paper Description

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This paper will furnish the student with a knowledge of modern manufacturing processes (not necessarily all of them directly related to building a working prototype machine) and how to use them when designing complex machines. The paper builds on the material taught in ENGME280 Design and Manufacturing 1. The paper will require elements taught in ENGME280 to be used in ENGME380. Dirty prototyping will be taught and applied to a design project. Students will be required to apply modern manufacturing methods such as laser cutting, CNC machining, and 3D printing to the design of a complex machine. Students will undertake a group design project and build a working prototype machine that meets a specification.

The learning outcomes for this paper are linked to Washington Accord graduate attributes WA1-WA11. Explanation of the graduate attributes can be found at: https://www.ieagreements.org/assets/Uploads/Documents/IEA-Graduate-Attributes-and-Professional-Competencies-2021.1-Sept-2021.pdf

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Paper Structure

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This paper is taught with lectures on design and advanced manufacturing processes and labs for the design projects. Case studies from design engineers will be part of the design lectures. Students work in groups of two or three to complete a Project Based Learning (PBL) design, build and test project. The project enables students to apply ENGME380 material and that from other Mechanical Engineering papers, to develop a fully functioning prototype to meet a specification. Other material, such as manufacturing techniques, is assessed by three tests.

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Learning Outcomes

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Students who successfully complete the paper should be able to:

  • Design and build a complex machine to meet a given specification (WA3, WA5, WA8, WA9, WA10)
    Linked to the following assessments:
    • Design Project - Concepts (assessment by interview) (1)
    • Design Project - CAD (3)
    • Design Project - Machine Manufacture and Cost (4)
    • Design Project - Machine Efficiency and Health & Safety (6)
    • Design Project - Performance at EDS during study week (8)
  • Apply health and safety requirements when designing machines (WA5)
    Linked to the following assessments:
    • Design Project - Machine Efficiency and Health & Safety (6)
  • Use traditional and modern manufacturing processes when designing parts and machines (WA3)
    Linked to the following assessments:
    • Manufacturing - Test 1 (2)
    • Design Project - Machine Manufacture and Cost (4)
  • Apply the scientific principles and basic relationships between process conditions, materials and product quality underlying modern manufacturing processes (WA1)
    Linked to the following assessments:
    • Manufacturing - Test 2 (5)
  • Select to most appropriate manufacturing process as a function of the engineering requirements of the part to be manufactured (WA1)
    Linked to the following assessments:
    • Manufacturing - Test 3 (7)
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Assessment

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The assessment of this paper comprises one group design project and three manufacturing tests. The design project has been split into 5 parts: concepts, CAD, manufacture & cost, efficiency & health and safety, machine performance. Details of the design project are given on a separate assignment sheet.

Samples of your work may be required as part of the Engineering New Zealand accreditation process for BE(Hons) degrees. Any samples taken will have the student name and ID redacted. If you do not want samples of your work collected then please email the engineering administrator, Natalie Shaw (natalie.shaw@waikato.ac.nz), to opt out.

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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. Design Project - Concepts (assessment by interview)
10 Aug 2022
9:00 AM
15
  • Other: Interview in Lab LSL.1.02
2. Manufacturing - Test 1
18 Aug 2022
12:00 PM
12
3. Design Project - CAD
26 Aug 2022
5:00 PM
15
  • Other: Moodle PDFs of 3D and 2D
4. Design Project - Machine Manufacture and Cost
23 Sep 2022
5:00 PM
10
  • Other: Moodle - spreadsheet
5. Manufacturing - Test 2
29 Sep 2022
12:00 PM
9
6. Design Project - Machine Efficiency and Health & Safety
19 Oct 2022
9:00 AM
10
  • Other: Test machine in lab LSL1.02
7. Manufacturing - Test 3
20 Oct 2022
12:00 PM
9
8. Design Project - Performance at EDS during study week
25 Oct 2022
No set time
20
  • Other: Perormance measured at EDS
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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The three recommended course texts are available on-line from the library. For those that have not yet studied electrical and mechanical machines (ENGME353), there is good information on gears and gearboxes, useful for your design project. Other course material, lecture notes, examples and videos are on Moodle.

  • Childs, Peter R. N.. Mechanical Design Engineering Handbook, Elsevier Science & Technology, 2013. ProQuest Ebook Central, https://ebookcentral-proquest-com.ezproxy.waikato.ac.nz/lib/waikato/detail.action?docID=1375437
  • Simmons, Colin, et al. Manual of Engineering Drawing : Technical Product Specification and Documentation to British and International Standards, Elsevier Science & Technology, 2009. ProQuest Ebook Central, https://ebookcentral-proquest-com.ezproxy.waikato.ac.nz/lib/waikato/detail.action?docID=913771
  • Design Engineering Manual, edited by Mike Tooley, Elsevier Science & Technology, 2009. ProQuest Ebook Central, https://ebookcentral-proquest-com.ezproxy.waikato.ac.nz/lib/waikato/detail.action?docID=631955
  • Slides and handouts available on Moodle to be studied prior to attend the lectures.
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Recommended Readings

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  • Budynas, Nisbett, J. K., & Shigley, J. E., 2015, Shigley’s mechanical engineering design (Tenth edition.). McGraw-Hill Education.
  • Boundy. (2007). Engineering drawing (7th ed.). McGraw-Hill.
  • Chang, Kuang-Hua. Design Theory and Methods Using CAD/CAE : The Computer Aided Engineering Design Series, Elsevier Science & Technology, 2014. ProQuest Ebook Central, https://www.proquest.com/legacydocview/EBC/1813980?accountid=17287
  • Fundamentals of modern manufacturing: Materials, processes, and, systems, Mikell P. Groover, 5th Edition, Wiley
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Other Resources

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Details of available resources is given on the design project assignment sheet.
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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 PPT’s of lecture notes and assessment materials.

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Workload

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This is a 15 point paper, requiring a total of approximately 150 hours of study.

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Linkages to Other Papers

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Prerequisites ENGME280

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Prerequisite(s)

Prerequisite papers: ENGME280 or ENGMT280

Corequisite(s)

Equivalent(s)

Restriction(s)

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