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SUBJECT OUTLINE 48600 Mechanical Design 1 Course area

UTS: Engineering

Delivery

Spring 2020; standard mode; City

Subject Field of practice: Mechanical Engineering program and Mechanical and classification Mechatronics Engineering program Credit points 6cp Requisite(s)

48331 Mechanics of Solids AND 48621 Manufacturing Engineering AND 48240 Design and Innovation Fundamentals

Result type

Grade and marks

Attendance: 2hpw (combined large class), 2hpw (tutorial/workshop). Forms of attendance and mode of delivery in this subject have changed to enable social distancing and reduce the risks of spreading COVID-19 in our community. Recommended studies: 48510 Introduction to Electrical Engineering

Subject coordinator Dr. Lee 'Mickey' Clemon Email: [email protected] Room: CB11.09.127 Phone: (02) 9514 2681

Teaching staff Dr. Lee 'Mickey' Clemon Email: [email protected] Lab and workshop tutors

Rowan Smith Contacting teaching staff The Subject Coordinator may be contacted by email if you have matters of a personal nature to discuss, e.g. illness, study problems, and for issues to do with extensions, group problems or other matters of importance. Questions regarding assessment or content within the subject are welcome in lectures or tutorials or alternatively post them to the discussion board in UTSOnline. This helps ensure that all students get the benefit of the answers given. All email sent to subject coordinators, tutors or lecturers must have a clear subject line that states the subject number followed by the subject of the email [e.g. Subject 48600, Request for Extension], and must be sent from your UTS email address. All other emails will be deleted. Consultation hours: Check the UTSOnline Contact section for details on consultation hours. Requests for appointments outside the given consultation hours may be arranged where circumstances require, and to do so please contact the subject coordinator by email.

Subject description This subject is the first in a set of three engineering design subjects. It builds on and brings together the concepts introduced in earlier subjects (e.g. the prerequisite subject). Topics covered include the mechanical design process, graphical presentation of engineering ideas and components, computer-aided design, engineering materials and processes and aspects of engineering knowledge. A two-phase design-and-build project is a major component of this subject.

Subject learning objectives (SLOs) 22/07/2020 (Spring 2020)

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Upon successful completion of this subject students should be able to: 1. Use CAD solid modelling software to create part and assembly models and then generate detail and pictorial drawings of common engineering components to AS1100 requirements. 2. Describe and apply the concept of design intent when creating CAD solid and assembly models. 3. Apply the principles of geometric dimensioning and tolerancing. 4. Apply the principles of mechanism analysis and design. 5. Apply good mechanical design practice to design and build a mechanical device. 6. Apply mechatronics principles to develop a mechatronic system to control a mechanical device. 7. Communicate and document design ideas, decisions, justifications, calculations and outcomes effectively

Course intended learning outcomes (CILOs) This subject also contributes specifically to the development of the following Course Intended Learning Outcomes (CILOs): Socially Responsible: FEIT graduates identify, engage, interpret and analyse stakeholder needs and cultural perspectives, establish priorities and goals, and identify constraints, uncertainties and risks (social, ethical, cultural, legislative, environmental, economics etc.) to define the system requirements. (B.1) Design Oriented: FEIT graduates apply problem solving, design and decision-making methodologies to develop components, systems and processes to meet specified requirements. (C.1) Technically Proficient: FEIT graduates apply abstraction, mathematics and discipline fundamentals, software, tools and techniques to evaluate, implement and operate systems. (D.1) Collaborative and Communicative: FEIT graduates work as an effective member or leader of diverse teams, communicating effectively and operating within cross-disciplinary and cross-cultural contexts in the workplace. (E.1) Reflective: FEIT graduates critically self-review their performance to improve themselves, their teams, and the broader community and society. (F.1)

Teaching and learning strategies Student learning in the subject is facilitated through a combination of online and on-campus activities. On-campus activities include a large class session (Lec1) that all students enrolled in the subject are expected to attend and a tutorial (Cmp1) / lab (Lab1) session that all students allocated to that activity are expected to attend. The large class session will typically involve individual and collaborative problem solving activities interspersed with presentations. Students are expected to read indicated material, view online resources such as video lectures/tutorials, webinars, online calculators, supplier websites and catalogues, etc before the on-campus activities so that this time can be more effectively used for problem solving and other collaborative activities rather than for presenting material that most people can understand on their own. The Cmp1 tutorial session is dedicated to improving the students' Computer Aided Design skills to produce mechanical part and assembly models. Students will produce and read engineering detailed part and mechanical assembly drawings to Australian Standard AS1100. The Lab1 tutorial session provides the opportunity for students to work together in their groups on their major design and build project. Teaching staff and tutors will be available in each session for consultation and advice.

Content (topics) The subject includes the following topics: • design process • computer aided design and solid modelling • drawing standards, dimensioning, tolerances, fits • mechanical systems and components (e.g. bearings, cams, springs) • structural details for strength and stiffness • fastening and joining

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• motor characteristics and selection • mechatronics

Program Week/Session

Dates

1

Description For all weeks you should complete introductory and pre-class learning activities before LEC1 activity sessions. Lec1 classes should not be considered to be traditional lectures where you just sit and listen and take notes. This sort of (in)activity is best suited to be delivered online. Instead, Lec1 classes should be thought of as 'design studios' where there will be demonstrations, discussions, application, interactive/collaborative activities and Q and A related to the week's content. This will be facilitated by the subject coordinator, but importantly, for a few weeks it will also be supported by a practicing mechanical design engineer. Pre-class: refer to UTSOnline Learning Materials Week 1. e.g. for this week read the Subject Outline; watch FUNdaMENTALs of Design Video Lecture Series: Topic01 Design is a Passionate Process. LEC1: Design process. Design specifications. Design and build project. CAMD SolidWorks, solid modelling, design intent, drawing templates and standards. CMP1: Computer Aided Design Assignment 1 with tutor and video assistance (e.g. Lynda.com SolidWorks 2016 Essential Training). Create your own personal drawing template. Part modelling and creating drawings to AS1100.

2

Pre-class: refer to UTSOnline Learning Materials Week 2. LEC1: Design process. Functional requirements. CAMD - Dimensioning, tolerance, functional and non-functional dimensions. CMP1: Work on CAD Assignment 1 with tutor and video assistance.

3

Pre-class: refer to UTSOnline Learning Materials Week 3. LEC1: Design process. Ideation. Morphology design. CAMD - sheetmetal and weldments. CMP1:Continue with CAD Assignment 1 with video assistance. Work on CAD Assignment 2 with tutor and video assistance.

4

Pre-class and online: refer to UTSOnline Learning Materials Week 4. LEC1: Design process - Analysis. Fundamental principles, load analysis, structural loops. Structure - layouts, stiffness, strength. CMP1: Work on CAD Assignment 2 with tutor and video assistance. Sheetmetal and weldment design.

5

Pre-class: refer to UTSOnline Learning Materials Week 5. LEC1: Motors in mechanical design: types, applications, selection, control. LAB1: Work on CAD Assignment 2 and 3 with tutor and video assistance. Sheetmetal and weldment design. Toolbox - bearings. Notes:

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Assistance with CAD assignments is available in LEC1 class. You are encouraged to BYOD to facilitate this.

6

Pre-class: refer to UTSOnline Learning Materials Week 6. LEC1: Mechatronics - sensing, feedback and control. LAB1: Workshop facilities inductions and training. Work on CAD Assignment 2 and 3 with tutor and video assistance. Sheetmetal and weldment design. Toolbox - bearings. Notes: Assistance with CAD assignments is available in LEC1 class. You are encouraged to BYOD to facilitate this.

7

Pre-class: refer to UTSOnline Learning Materials Week 7. LEC1: Weldments. Rolling element bearings: loading, life and selection. LAB1: Workshop facilities inductions and training. Work on CAD Assignment 3 with tutor and video assistance. Toolbox - bearings. Self-directed work on D&B project. Notes: Assistance with CAD assignments is available in LEC1 class. You are encouraged to BYOD to facilitate this.

S1

StuVac - no classes unless otherwise notified by announcement on UTSOnline

8

Pre-class: refer to UTSOnline Learning Materials Week 8. LEC1: Rolling element bearings: mounting, retention, housing, tolerances and fits. LAB1: Workshop facilities inductions and training. Work on CAD Assignment 3 with tutor and video assistance. Toolbox - bearings. Self-directed work on D&B project. Notes: Assistance with CAD assignments is available in LEC1 class. You are encouraged to BYOD to facilitate this.

9

Pre-class: refer to UTSOnline Learning Materials Week 9. LEC1: Lifting devices, power screws LAB1: Self-directed work on D&B project. Work on CAD Assignment 4 with tutor and video assistance. Notes: Project phase 1 documentation and self-reported results due. Assistance with CAD assignments is available in LEC1 class. You are encouraged to BYOD to facilitate this.

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10

Pre-class: Make use of online resources to assist with D&B project and CAD assignment. LEC1: Design studio for D&B project and/or further work on previous weeks' topics. LAB1: Self-directed work on D&B project. Work on CAD Assignment 4 with tutor and video assistance. Notes: Assistance with CAD assignments is available in LEC1 class. You are encouraged to BYOD to facilitate this.

11

Pre-class: Make use of online resources to assist with D&B project and CAD assignment. LEC1: Design studio for D&B project and/or further work on previous weeks' topics. LAB1: Self-directed work on D&B project. Work on CAD Assignment 4 with tutor and video assistance. Notes: Assistance with CAD assignments is available in LEC1 class. You are encouraged to BYOD to facilitate this.

12

Pre-class: Make use of online resources to assist with D&B project and CAD assignment. LEC1: Design studio for D&B project and/or further work on previous weeks' topics. LAB1: Self-directed work on D&B project. Work on CAD Assignment 4 with tutor and video assistance. Notes: Assistance with CAD assignments is available in LEC1 class. You are encouraged to BYOD to facilitate this.

S2

StuVac - no classes Notes: Schedule subject to minor change due to staff/facilities availability and other unforseen circumstances.

A1, A2

Final Assessment Period Final opportunity for Design and Build Project prototyping assessment. Design and Build Project documentation submission.

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Additional information Tutorial Attendance Participation and attendance at LAB1 tutorials is encouraged due to group work on the Design and Build project.

Additional subject costs Extra costs may be incurred in the design and build project as students will need to purchase electronic components for the mechatronics module and may need to purchase materials and components to build their vehicle. This usually amounts to around $200 per group (i.e. about $4/week per person for a group of 5).

Assessment Assessment task 1: Computer Aided Design (CAD) Intent:

Through this assessment task students further develop and demonstrate their skills in Computer Aided Design using Solid Modelling software. Tasks include the creation of parts and assembly models and the generation of Detailed and Assembly drawings to Australian Standard AS1100. Students will apply the principles of dimensioning and tolerancing. Parts and assemblies will include common mechanical components and sub-assemblies. These skills are essential in development of students' ability to design, synthesize, apply abstraction and develop models in the context of mechanical design. This assessment task will be divided into several sub-tasks/projects with staged submission to enable students to obtain feedback on their progress.

Objective(s): This assessment task addresses the following subject learning objectives (SLOs): 1, 2, 3, 5 and 7 This assessment task contributes to the development of the following Course Intended Learning Outcomes (CILOs): C.1, D.1 and E.1 Type:

Design/drawing/plan/sketch

Groupwork: Individual Weight:

50%

Task:

In total there are four separate CAD exercises ranging from a detailed drawing of a component to the computer aided analysis of a mechanism. For each task the student is required to apply his or her acquired knowledge gained from the video lecture series, LEC1 sessions and CMP1, and, when suggested, references and further reading to achieve a feasible design outcome. Details will be provided in separate document that may be downloaded from UTSOnline.

Length:

Calculations for component design as required. Drawing production of designed components and assemblies as required.

Due:

CAD exercise 1 - Week 3; CAD exercise 2 - Week 6; CAD exercise 3 - Week 9; CAD exercise 4 Week 12; In all cases submission is online via UTSOnline anytime before 11:59pm Friday of the week indicated.

Assessment task 2: Design and Build Project

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Intent:

Students work in teams to apply problem solving techniques and mechanical and mechatronic design principles to construct (synthesise) a mechanical device to meet a set of performance criteria and limiting specifications (constraints). Students are required to prioritize tasks in order to manage their time, skills and knowledge to complete the project tasks. Students employ research skills to assist them to make informed choices and decisions (decision making) and be able to justify and document them (communicate effectively).

Objective(s): This assessment task addresses the following subject learning objectives (SLOs): 1, 4, 5, 6 and 7 This assessment task contributes to the development of the following Course Intended Learning Outcomes (CILOs): B.1, C.1, D.1, E.1 and F.1 Type:

Project

Groupwork: Group, group and individually assessed Weight:

50%

Task:

Demonstrate and apply theoretical and practical knowledge of mechanical and mechatronic design and related engineering principles to design and construct a mechanical and/or mechatronic device - Prototyping (Warman competition or equivalent) 20% - Phase 1 documentation 10% - Final documentation 20% Details will be provided in separate document that may be downloaded from UTSOnline.

Due:

Phase 1 documentation of project is due according to the documentation describing it on UTSOnline. Design and build project prototyping may be assessed at anytime in your LAB1 class time during or before Assessment Week 1. If D&B prototyping has not been assessed before the end of Assessment Week 1 you will be allocated a time during Assessment Week 2. This allocated assessment time should be considered in the same way as a Formal Exam time. Final design documentation to be submitted by 11:59 pm Friday of Week 12.

Further All group marks will be modified through self and peer assessment in SPARKPlus to generate information: individual marks for each group member.

Moderation of marks Group marks will be modified for individual group members through self and peer assessment rating tools such as SPARKPlus. Groups will not receive marks until self and peer assessment ratings have been submitted. Students who have not submitted self and peer assessment ratings by the notified deadline will receive individual mark modification factor based on their peers' assessment only.

Assessment feedback Assessment Task 1: Feedback will be provided via marks and comments entered into Grade Centre on UTSOnline. Students may also talk to their tutor about their work during classes. Assessment Task 2: Feedback on your group's device design will be provided immediately during Design Studio sessions. Immediate feedback is available during your group's device's performance assessment. Marks will be entered into Grade Centre on UTSOnline. Feedback on your group's design documentation will be 22/07/2020 (Spring 2020)

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provided immediately during Design Studio sessions as well as via marks and comments entered into Grade Centre on UTSOnline.

Minimum requirements In order to pass the subject, a student must achieve an overall mark of 50% or more.

Required texts No required texts. MIT Course notes that accompany the MIT video Lecture series are provided.

Recommended texts The following two texts will be helpful and digital editions are available for FREE via the UTS Library link on UTSOnline. Childs, Peter R.N., Mechanical Design Engineering Handbook, Butterworth-Heinemann, 2014 (this is the recommended text) Simmons, Colin H. et al., Manual of Engineering Drawing: Technical Product Specification and Documentation to British and International Standards, Elsevier, 2012 Simmons, Colin H. & Phelps, Neil, Essential Guide to Technical Product Specification - Engineering Drawing, BSI Standards Ltd., 2009 For SolidWorks assistance - if you prefer a textbook to online videos: Bethune, J.D., Engineering and Design Graphics with SolidWorks 2016, Pearson, 2016 (but it's $$$$$$)

References Ullman, D.G., The Mechanical Design Process, McGraw-Hill Boundy, A.W., Engineering Drawing, McGraw-Hill Norton, R.L., Design of Machinery – An introduction to the Synthesis and Analysis of Mechanisms and Machines, 5th Ed. , McGraw-Hill, 2012

Other resources References for drawing and CAD Digital editions of the Standards Australia Online are available to you for free via the UTS Library link: 1. 2. 3. 4.

AS 1100.101-1992 Technical Drawing. Part 101: General Principles, Standards Australia AS 1100.20...