Assignment 02: Design for manufacture


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*BEng in Mechanical Engineering
Assignment 02: Design for manufacture
MODULE CODE: MP3731
MODULE TITLE: Engineering design
MODULE TUTORS: Mr M. McPhillips (and Dr J. Whitty)
SEMESTER 2
Learning outcomes
The assignment should produce sufficient evidence for partial fulfillment of the following module learning outcomes:
Systematically analyse design problems, formulate and communicate solutions.
Appraise and justify the environment and business process framework of concurrent engineering.
Formulate and critically evaluate embodiment design solutions based on customer requirements, manufacturing
needs, and business objectives
Additional information
You may wish to use the LYXassignment/report template which you were shown in the workshop session for the presentation
of this assignment. On the title page of any submitted work a plagiarism/integrity statement should be in included, e.g.:
This assignment has not been submitted before at this or any other educational establishment of learning in the support
of a degree of any other award. As per the module specification, this second assignment accounts for 70% of the module
mark (the other 30% is by the first assignments). To pass the module, candidates must attain a minimum of 40% overall.
A threshold of 30% must be achieved in each of the assessments.
Resources: All resources required for this assessment are fully described in the main text of the assignment brief.
Special requirements: provided on a one-to-one basis for candidates requiring these.
Release date: 22 February 2017
Submission dates: Presentation 06 April 2017, Report 07 April 2017.
1 Background
As explored by candidates in the first assignment in order to produce a model/prototype of any product it is necessary to
ascertain the customer needs using a variety of techniques. The relative importance of the needs must then be established
by the design team and then from these data the PDS established. The team will then need to suggest a number of
accepted techniques, in order to produce a variety of marketable concepts. Moreover, any design must be supported by
necessary working drawing so that the product can be effectively manufactured as well as attempt to predict where the
component is likely to fail during service. These findings are then reported via an industrial standard report [1].
It is the purpose of this assignment to produce a concise Design for Manufacture (DfM) report in response to a clear
market need utilizing subject-specific techniques that arise from a specific design problem [1]. Candidates must report
on a pertinent conceptual design processes employed to produce a decent number of concept using if possible innovative
techniques. Given the number of particular product opportunities detailed in the appendix, it is the purpose here to
expose candidates to modern creative problem solving principles as detailed in the classic treatise [2] including TRIZ.
An appropriate unbiased method should be used to establish which concept best adheres to the target PDS. Using the
Computer Aided Three-dimensional Interactive Application (CATIA), AutoDesk-Inventor and in some cases ANSYSWorkbench
(i.e. not SolidWorks) to produce a basic conceptual model of the chosen concepts.
This assignment is an exercise in to producing relevant analysis of component designs and using these analyses in order
to finalize the design drawings and dimensions. The assignment also provides a vehicle by which to introduce the use of the
FE method within design to produce realistic prototypes which can be subjected to a variety of virtual testing protocols.
There is further scope to assesses particular methods and approaches employed by candidates, with an Assessment for
Learning (AfL) rationale. To this end a number of workshops with instruction given on how to set out documents in
specific academic and industrial document preparation systems (e.g. LYX) will be conducted as well as specialized CATIA
training. Students will be expected to produce a set of engineering drawings from CATIA (or AutoDesk-Inventor) using a
Design for Manufacture (DfM) philosophy. Candidates are actively encouraged to use a wide range of the universities LIS
facilities for seeking literature. Constructing a reference database in Reference Manager; importing references from WoK,
as well as writing a referenced article, i.e. cite while you write [4], thus avoiding Plagiarism (précis and peculiarity).
Note that as with all academic work the reference section must be adherence to with our preferred Vancouver [3] (or
Harvard) standard [5]. Where possible the completed document should not exceed fifty sides (say 8000 words) of A4
(excluding the title page, Figures, Tables and References). Any extra material not directly related to the demonstration/
achievement of the module descriptor learning outcomes should be include in an appendix proceeding the reference
section.
2 Tasks
In order to to produce evidence of the first three specific learning outcomes of the University of Central Lancashire’s
module descriptor MP3731, candidates are expected to complete the following tasks.
1. Given the results from your previous assignment QFD [1, 2] produce at least twenty (yes 20!) key concepts using
TRIZ [1], In each case detailing in a log-book how TRIZ method(s) were employed to develop each of the concept.
2. By using salient concept screening and scoring methods [2] critically evaluate each of the concepts you have developed
hence finalize one to take forward for prototype development.
3. Using a valid product architectural method [2] to identify the main components producing a prototype of the your
product. {Task 3: 20 marks}
4. Use an Ashby’s material selection technique or otherwise in order to objectively decided on the materials required
to produce each component.
5. Use a basic FMEA to determine which of the components are most likely to fail under static and/or dynamic
conditions and perform an appropriate FEA on the component using the ANSYS software.
2
6. Verify one key analysis result empirically and/or using a complementary FE code (e.g. CATIA).
7. Produce a sales pamphlet and presentation introducing the launch of your product.
{Task 7: 10 marks}
8. Using the portfolio you have developed and appropriate literature (ispso-facto the reference section of this document)
together with dialogue with prospective stakeholder(s) produce and industrial report of your findings.
The final document should be type-written, using the LYX template (or otherwise) produced in workshops, and
contain the following main sections:
(a) Pre-report (title-page, Executive Summary, List of Contents, List of Figures, List of Tables etc) {3}
(b) Introduction (incl. the DfM process employed and Mission statement) {4}
(c) Market research {6}
(d) Conceptual design method {8}
i. Concept generation
ii. Conceptual development using TRIZ.
iii. Concept selection and reasoning
(e) Detailed design {10}
i. Design for Manufacture (DfM) philosophies
ii. Three-dimensional modelling
iii. Engineering drawings
(f) Product appraisal {6}
(g) Conclusions {5}
(h) Referencing {8}
i. Quality and discussion within the main text
ii. Adherence to acceptable standard
{Total task 8: 40 marks}
Individual Performance {20 marks}
References
[1] French, M. J., Conceptual design for engineers, Springer, London UK, 1998.
[2] Ulrich and Eppinger, Product Design and Development, McGraw Hill, 2004.
[3] Thiel D. V., Research Methods for Engineers, Cambridge University Press, Cambridge UK, 2014.
[4] Holman, J.P., Experimental methods for engineers (seventh edition). McGraw-Hill Higher Education, 2000.
[5] ISO 960, ISO copyright office, Information and documentation — Guidelines for bibliographic references and citations
to information resources, Geneva 20, Switzerland, 2010.
[6] Anon, School of Computing, Engineering and Physical Sciences- Assessment handbook, University of Central Lancashire,
2012.
[7] Ashby M. F., Materials selection in mechanical design, Butterworth-Heinemann, Oxford UK, 2005.
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Appendix
A Design projects 2015
Code Title Stakeholder
SIP Student initiated project TBC
Using specific dialogue with academic and/or industrial staff propose an investigation
pertaining to analysis, design, implementation / simulation, evaluation, test, manufacture,
with aspects involving the study of current research or advanced developments (academic
or industrial) leading to the use of new knowledge, methods or applications, as
appropriate for the chosen topic. The project should provide a group of candidates with a
suitable platform in order to produce a quality design, applying modern technology to the
embodiment in a concurrent engineering context thus satisfies customer needs leading to
profitable (reduced-cost) manufacture.
JF1 Photo-elastic mini-experimental roof truss MP2784
A mini experimental roof truss for use in the class-room or laboratory is required by a
university or college. The mini-truss should be lightweight and easy to handle and adhere
to any necessary health and safety requirements. Some of the members should have the
ability to electronically record strain values when certain loads are applied to the truss.
Hence the displacements and loads in the members can be determined and compared with
theoretical and FEA predication’s using suitable software (e.g. ANSYS). It is also
envisaged by the sales department that there is also a market for a deluxe version of the
mini-truss made from photo-elastic materials; thus investigating the stress fringes in the
truss during loading.
Dr J. Francis
Dr M. Wulan
JW1 Spring-damper system MP3395
The customer wishes to construct a bespoke design in order to predict the damping
properties of different fluids. One way of achieving this is to construct a spring-damper
arrangement as detailed in most decent engineering science texts. The system could then
set to vibrate and hence the damping properties of the fluid determined. The system
should be modelled in a suitable software package initially. The engineer requires that
displacement reading are read electronically via a suitable sensor which can be developed
as an integral part of the system or brought in. Readings from the device should have the
ability to be transfer to PC for further analysis using suitable Math software such as
SciLab or Labview
Dr J. Whitty
Mr J.
Calderbank
MW1 Mini-lead creep test machine MP2784
With in the School of Engineering here at UCLan is the need for a creep testing machine.
The machine should have the ability to test the creep properties of a standard lead
specimen. Initially a full market analysis should be conducted to ascertain possible
numbers. The machine should be simple to operate so that children could use it in
schools. Hence, health and safety requirements are of utmost importance here. In addition
either an analogue or digital measuring device is required in order to record the
displacement-time curve of the specimen. The product should be portable and lightweight.
Initially the properties of the specimen should be modelled using non-linear FEA or
similar method. Finally, to aid the marketing process a static analysis of the product
should be conducted prior to prototype production.
Dr M. Wulan
Dr J. Francis
4
Code Title Stakeholder
JF2 Cylinder strain measuring device MP2784
A portable desktop device is required for the demonstration of the radial, hoop and
longitudinal stresses induced by an internal pressure applied to cylindrical components of
different inside and outside diameters. The strain (or stress) should be measured
electronically at several different positions which can be post-processes by the Scilab,
MAXIMA and/or Labview software. Demonstrations should also be repeated using
suitable FE software such as ANSYS-Workbench
Dr J. Francis
Dr M. Wulan
BB1 Mini-wind tunnel MP2576
Design and develop a mini-wind for use in the class-room or laboratory, similar to others
emerging on the market. It should have the ability to continuously pump a fluid (ideally
no toxic say water or colored air) at a variety of velocities and give pressure readings at
the outlet. The product should also be lightweight, portable and easy to handle and
adhere to any necessary health and safety requirements. At the point of fully developed
flow the device should have a variety of inserts including a number of cylinders and a few
correctly scaled aerofoils. The system should be initially modelled a suitable CFD package.
The models then made available to customers as part of the overall product concept.

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