Unit Name

Computer Aided Design and Manufacturing

Unit Code

MME 602

Unit Duration

12 weeks

Award

Master of Engineering (Mechanical) Duration: 2 years

Year Level

Two

Unit Creator/Reviewer

Henry Wickham

Core/Elective

Core

Pre/Co-requisites

All MME50X units (nested Graduate Diploma)

Credit Points

3

Masters total course credit points = 48

(12 credits (Thesis) + 3 credits x 12 (units))

Mode of Delivery

On-Campus or Online

Unit Workload

Student workload including “contact hours” = 10 hours per week: Lecture - 1 hour

Tutorial Lecture - 1 hours

Practical / Lab - 1 hour (where applicable) Personal Study recommended - 7 hours

Unit Description and General Aims

The unit means to enhance 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 will then undergo an advanced study of modern Manufacturing Process and costing structures as well as the environmental impact thereof. This knowledge will enable 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 will be honed to set up and evaluate motion simulation of assemblies and create photorealistic renderings to communicate their ideas to their customers.

The students will 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. In depth understanding of Manufacturing Processes. Able to evaluate mechanical components and select the appropriate manufacturing processes based on user requirements and environmental impact.

  2. Analyse, using standard software tools, parts particular to a specific modern manufacturing process as well as completing cost calculations.

  3. Use standard software tools to create assemblies, conduct clearance checks, produce and analyse motion simulations and generate photorealistic rendering

  4. Utilise Six sigma methodology to calculate and plot a statistical tolerance analysis.

  5. Evaluation of Additive Manufacturing technology and file preparation methodologies.

  6. Ability to read and interpret detailed work drawings with an understanding and application of limits and fits and geometrical tolerances.

  7. Creatively design a complete mechanical assembly including all calculations and produce work and assembly drawings to AS1100-101 drawing standards including BOM’s.

    Professional Development

    Completing this unit may add to students professional development/competencies by:

    1. Fostering the personal and professional skills development of students to:

      1. Be adaptable and capable citizens, who can communicate effectively, critically evaluate data from whatever source, work collaboratively and use innovative methods to solve complex problems.

      2. Equipping them with an increased capacity for lifelong learning and professional development.

      3. Enable them to plan and organise themselves and others in their sphere of work.

      4. To instil leadership qualities as far as possible in individual students.

      5. Making them aware of ethical issues in the commercial world.

    2. Enhance students’ investigatory and research capabilities through:

      1. Solving basic engineering problems

      2. Accessing, evaluating and critically analysing information

      3. Processes and procedures, also cause – effect investigations

    3. Develop the engineering application abilities of students through:

      1. Assignments

      2. Labs / practical / case studies / self-study (where applicable)

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.

Stage 1 Competencies and Elements of Competency

1.

Knowledge and Skill Base

1.1

Comprehensive, theory based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the engineering discipline.

1.2

Conceptual understanding of the mathematics, numerical analysis, statistics, and computer and information sciences which underpin the engineering discipline.

1.3

In-depth understanding of specialist bodies of knowledge within the engineering discipline.

1.4

Discernment of knowledge development and research directions within the engineering discipline.

1.5

Knowledge of engineering design practice and contextual factors impacting the engineering discipline.

1.6

Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the specific discipline.

2.

Engineering Application Ability

2.1

Application of established engineering methods to complex engineering problem solving.

2.2

Fluent application of engineering techniques, tools and resources.

2.3

Application of systematic engineering synthesis and design processes.

2.4

Application of systematic approaches to the conduct and management of engineering projects.

3.

Professional and Personal Attributes

3.1

Ethical conduct and professional accountability.

3.2

Effective oral and written communication in professional and lay domains.

3.3

Creative, innovative and pro-active demeanour.

3.4

Professional use and management of information.

3.5

Orderly management of self, and professional conduct.

3.6

Effective team membership and team leadership.

Graduate Attributes

Successfully completing this Unit will contribute to the recognition of attainment of the following graduate attributes aligned to the AQF Level 9 criteria, Engineers Australia Stage 1 Competency Standards for the Professional Engineer and the Washington Accord:

Graduate Attributes

(Knowledge, Skills, Abilities, Professional and Personal Development)

EA Stage 1 Competencies

Professional Development

Learning Outcomes

A. Effective Communication

A1. Cognitive and technical skills to investigate, analyse and organise information and ideas and to communicate those ideas clearly and fluently, in both written and spoken forms appropriate to the audience.

2.2, 3.2

A,B

5, 6

A2. Ability to professionally manage oneself, teams, information and projects and engage effectively and appropriately across a diverse range of international cultures in leadership, team and individual roles.

2.4, 3.2, 3.4,

3.5, 3.6

A

5, 6

B. Critical Judgement

B1. Ability to critically analyse and evaluate complex information and theoretical concepts.

1.1, 1.2, 1.3,

2.1

B

1, 3, 5

B2. Ability to creatively, proactively and innovatively apply theoretical concepts, knowledge and approaches with a high level of accountability, in an engineering context.

1.5, 2.1, 3.3,

3.4

A, C

1, 2, 3, 4, 5, 6

C. Design and Problem Solving Skills

C1. Cognitive skills to synthesise, evaluate and use information from a broad range of sources to effectively identify, formulate and solve engineering problems.

1.5, 2.1, 2.3

B, C

1, 3, 4, 6, 7

C2. Technical and communication skills to design complex systems and solutions in line with developments in engineering professional practice.

2.2, 2.3

A, B

1, 2, 3, 4, 6, 7

C3. Comprehension of the role of technology in society and identified issues in applying engineering technology ethics and impacts; economic; social; environmental and sustainability.

1.5, 1.6, 3.1

A

1, 2, 6

D. Science and Engineering Fundamentals

D1. Breadth and depth of mathematics, science, computer technology and specialist engineering knowledge and understanding of future developments.

1.1, 1.2, 1.3,

1.4

A

1, 2, 4

D2. Knowledge of ethical standards in relation to professional engineering practice and research.

1.6, 3.1, 3.5

A

1, 6

D3. Knowledge of international perspectives in engineering and ability to apply various national and International Standards.

1.5, 1.6, 2.4,

3.4

A, C

1, 5, 6

E. Information and Research Skills

E1. Application of advanced research and planning skills to engineering projects.

1.4, 2.4, 3.6

B, C

1, 4

E2. Knowledge of research principles and methods in an engineering context.

1.4, 1.6

B

1, 2, 3

Unit Competency and Learning Outcome Map

This table details the mapping of the unit graduate attributes to the unit learning outcomes and the Australian Engineering Stage 1 Competency Standards for the Professional Engineer.

 

Graduate Attributes

A1

A2

B1

B2

C1

C2

C3

D1

D2

D3

E1

E2

Engineers Australia Stage 1 Competencies and Elements of Competency

1.1

   

       

       

1.2

   

       

       

1.3

   

       

       

1.4

             

   

1.5

     

 

   

   

1.6

           

 

 

2.1

   

             

2.2

       

           

2.3

       

           

2.4

 

             

 

3.1

           

 

     

3.2

                   

3.3

     

               

3.4

 

 

         

   

3.5

 

           

     

3.6

 

               

 

Unit Learning Outcomes

LO1

   

LO2

     

 

     

LO3

   

         

LO4

     

 

   

 

LO5

         

   

LO6

 

 

   

LO7

       

           

Student assessment

Assessment Type

(e.g. Assignment - 2000 word essay (specify topic) Examination (specify length and format))

When assessed (eg Week 5)

Weighting (% of total unit marks)

Learning Outcomes Assessed

Assessment 1

Type: Multi-choice test / Group work / Short answer questions / Role Play / Self-Assessment / Presentation

Example Topics: Evaluate components and select the appropriate manufacturing processes based on user requirements. Costing estimations of components based on manufacturing process and volume.

Week 4

15%

1, 2

Assessment 2

Type: Report / Research / Paper / Case Study / Site Visit

/ Problem analysis / Project / Professional recommendation

Example Topics: Review a detailed work drawing and interpret the information. Focus on Geometrical tolerance, limits and fits, welding symbols and post processing. Complete a statistical tolerance analysis for a defined production volume of a simple assembly.

Calculate and plot the normal parameter distribution within a tolerance for each part and use this data to show the interrelations of distributed variables.

Week 11

25%

3,4, 5,6

Assessment 3

Type: Report (Final Project)

Word length: 4000 (excluding makers’ diagrams and layout drawings.)

Topic: To submit a complete Mechanical design with work and assembly drawings based on project criteria and taking everything into account the student has learned to date. The student will be given project criteria that must be met. The student must show calculations - engineering, economic and statistical.

Final Week

40%

3,4,5,6,7

Practical Participation

Type: May be in the form of quizzes, class tests, practical assessments, remote labs, simulation software or case studies

Example: Design of a cast aluminium bracket considering specific loading conditions and load cycles. File export for rapid prototyping (FDM)

Continuous

15%

1,2,4

Attendance / Tutorial Participation

Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application.

Continuous

5%

1 - 7

Prescribed and recommended readings

Required textbook(s)

  • C. Poli, Design for Manufacturing - A Structured Approach, Butterworth Heinemann, 2001. – ISBN 978-0-7506-7341-9

  • G. 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, 2006. - ISBN 978-0-7506- 6738-8

    Reference Materials

    • Australian Technical Drawing Standard, AS1100-101, 1992.

    • Part Cost estimators https://www.custompartnet.com

    • W. Boundy, Engineering Drawing, McGraw-Hill, 2002.

    • 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, with the exception of part-time 24-week units, where one topic is delivered every two weeks.

Topic 1

Introduction to Mechanical Computer Aided Design

  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

Topics 2 and 3

Manufacturing Process

  1. Be familiar with the different manufacturing processes: Machining, Casting, Moulding, Forming, Additive Manufacturing – understanding and ability to calculate their influence on stress and fatigue.

  2. Attain an in depth knowledge of the pros and cons of each process.

  3. Be familiar with corrosion, coating and plating options and calculating their influence on stress and fatigue.

  4. Understanding of the cost implications and environmental impact involved with each manufacturing process.

  5. Ability to calculate the component cost based on the manufacturing process and volume.

  6. Ability to evaluate a component and select the appropriate manufacturing process based on user requirements.

Topics 4 and 5

Feature Based Parametric Solid Modelling

  1. Applying general solid modelling techniques employed in design and manufacture

  2. Create fully constrained solid models that can be quickly modified using standard software tools.

  3. Identify design intent behind parts and features and develop an appropriate approach for modelling the parts and assemblies.

  4. Ability to use standard software tools to create assemblies, conduct a clearance checks, produce motion simulations and photorealistic renderings

Topic 6

Machining Process

  1. Understand machining/grinding limitations and acquiring evaluation and design skills to accommodate these.

  2. Understand surface finishes in relation to manufacturing processes, measurement thereof, symbols and drawing application.

  3. Understanding heat treatment, its adverse effect on the dimensional stability on a part and acquiring evaluation and design skills to optimise a design to limit these effects, post process machining and grinding.

  4. In depth understanding of the effects of Residual Stress Induced by these processes and stress relieving methods

  5. Applying this knowledge to evaluate requirements and design accurate and efficient machined parts and identifying and specifying post processes.

Topic 7

Sheet metal Process

  1. Understanding bend theory – neutral axis, bend radius, K-values.

  2. Understanding the stresses induced by bending, spring back, spring back factor

  3. Demonstrate how sheet metal parts are designed and used - Enclosures, Brackets, Structures or frames, Formed parts

  4. Describe the various construction techniques- Face Flange creation, Ripped Shelled Solids, Folded part to Flat Pattern, Flat Pattern export

  5. Ability to use sheet metal tools – Bends, Flanges, Hems, Corner seams and corner relief

  6. A good understanding of weld joints and their design applications

  7. Understanding of bend tolerance stack up and sheet metal detail drawings.

  8. Applying this knowledge to evaluate requirements and design accurate and efficient sheet metal parts and weld assemblies

Topic 8

Casting/Injection Moulding Process

  1. A basic understanding on design considerations for casting/moulding – material properties, shrinkage, distortion allowance, voids and sinking, wrapping

  2. Application of design features – uniform walls, draft angles, coring, gussets, ribs, live hinges, over moulding.

  3. A basic understanding of the feeding and gating system

  4. Understanding stress relieving and post machining process.

  5. Applying this knowledge to evaluate requirements and design accurate and efficient cast parts and specifying post machining and processes.

Topic 9

Additive Manufacturing

  1. Introduction to modern additive manufacturing processes – FDM, SLA, SLS, Polyjet, Laser Sintering.

  2. Ability to evaluate a component and select the appropriate additive manufacturing process based on user requirements.

  3. CAD file export and configuration – STL, Optimized Part orientation.

Topic 10

Drawing Practice – Working Drawings

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

  2. A 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 11

Understanding Tolerance

  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. Understanding of and ability to 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 12

Project and/or Unit Review

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.

The Engineering Institute of Technology (EIT) is dedicated to ensuring our students receive a world-class education and gain skills they can immediately implement in the workplace upon graduation. Our staff members uphold our ethos of honesty and integrity, and we stand by our word because it is our bond. Our students are also expected to carry this attitude throughout their time at our institute, and into their careers.