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Faculty of Engineering, Computing & Mathematics Mechanical and Chemical Engineering

Unit Outline

Mechanical Design MECH3403

SEM-1, 2013 Campus: Crawley Unit Coordinator: Associate Professor Adam Wittek
All material reproduced herein has been copied in accordance with and pursuant to a statutory licence administered by Copyright Agency Limited (CAL), granted to the University of Western Australia pursuant to Part VB of the Copyright Act 1968 (Cth). Copying of this material by students, except for fair dealing purposes under the Copyright Act, is prohibited. For the purposes of this fair dealing exception, students should be aware that the rule allowing copying, for fair dealing purposes, of 10% of the work, or one chapter/article, applies to the original work from which the excerpt in this course material was taken, and not to the course material itself The University of Western Australia 2001

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Unit Details
Unit title Unit code Availability Location Mechanical Design MECH3403 SEM-1, 2013 (25/02/2013 - 22/06/2013) Crawley Mode On-campus Credit points 6

Contact Details
Faculty School School website Unit coordinator Unit coordinator email Unit coordinator telephone number Consultation hours Lecturers

Faculty of Engineering, Computing & Mathematics Mechanical and Chemical Engineering http://www.mech.uwa.edu.au
Associate Professor Adam Wittek adam.wittek@uwa.edu.au 08 64887362

Wednesday, 5-6 pm

Name Adam Wittek (unit coordinator) Guiyong Zhang (lectures during unit coordinator absence) Andrew Guzzomi (lectures during unit coordinator absence) Peter Davies (specialised lectures; external lecturer)

Position Assoc. Prof. Assistant Prof.

Email adam.wittek@uwa.edu.au guiyong.zhang@uwa.edu.au

Telephone Number 08 6488 7362 08 6488 3125

Assistant Prof.

andrew.guzzomi@uwa.edu.au 08 6488 3883

Principal Pressure Equipment Engineer

Tutors

1) Milind SIDDHPURA email: 20489337@student.uwa.edu.au; ENCM 2) Yuxuan BAI email: 21234242@student.uwa.edu.au; room:3-13 EEEC room: 210 Civil and Mechanical Engineering

Unit contact hours Online handbook Unit website

Lectures: 39 hrs + 6 hrs of specialised lectures; tutorials: 26 hrs

http://units.handbooks.uwa.edu.au/units/MECH/MECH3403 Http://www.mech.uwa.edu.au/unit/MECH3403

Unit Rules
Prerequisites

CIVL2110 Statics and Solid Mechanics or ENSC3004 Solid Mechanics

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Advisable prior study

GENG1001 Engineering: Introduction to Engineering Mechanics (or equivalent), MATE2412 Materials Engineering 2 (or equivalent), MECH2401 Engineering Design and Visual Communication (or equivalent) and MECH2402 Manufacturing (or equivalent)

Unit Description
Description
This unit covers the analysis and synthesis of machine components and assemblies under steady and fluctuating loads. The lecture topics cover analysis and synthesis of failure and design models for materials and components under steady and dynamic loads. Lectures are complemented by design projects for which the students are required to form their own work groups and to submit a collectively prepared design report for their group. Further details can be accessed from the unit web page.
Welcome to Mechanical Design MECH3403. Engineers use scientific knowledge to achieve a specific objective. Mechanical engineering design can be defined as the process of applying mechanics and engineering methods to prescribe a component or a system in sufficient detail to permit its realisation. The methods we will be dealing with in this unit include models of fatigue and static failure as well as failure due to elastic instability (buckling). We will apply them to components such as shafts, pressure vessels and joints. You will learn that mechanical design is an iterative process that requires not only creativity but also a systematic approach. You will study different models mechanical engineers apply to represent world they work in. You will learn limitations of these models. Specific topics will include static and fatigue failure, elastic instability (buckling) as well as various components and assemblies (bolted joints). Where possible the unit aims also to prepare students for professional life through team work, open-book examination and the like. Design is a highly iterative process that involves decision making and communication with people of many disciplines. It requires practice and continuous learning. This unit emphasises that design problems should be approached in a systematic way and that there are models that can/should be used when solving specific design problems. Lecture notes, recommended reading, lectures and tutorials will explain some of these models (but cannot explain all of them). Conducting the projects is your own responsibility and will require from you to acquire the relevant knowledge/information by yourself as well to make design decisions based on incomplete and/or redundant information. The lecturers and tutors duty is to assist you and provide mentorship, but they cannot and will not do the project for you. DETAILED LEARNING OUTCOMES 1. Describe, with the assistance of principles of solid mechanics and mathematical models formulated using these principles, various common machine components (and assemblies) such as shafts and pressure vessels - and demonstrate appreciation of how these may be designed (or selected) optimally and used both economically and safely; 2. Quantitatively describe/explain the non-static failure mechanism of fatigue and be capable of incorporating it where appropriate into analysis or design; 3. Quantitatively describe/explain the failure mechanism due to elastic instability (buckling); 4. Explain/describe the development and limitations of the selected models used in machine component design and demonstrate ability to adapt them to changed circumstances/tasks; 5. Demonstrate ability to understand the behaviour of real components using practical insight in addition to mathematical models and numerical models; 6. Demonstrate ability to use selected design codes (including interdependence of different codes); 7. Demonstrate through group design projects a proficiency in applying the Rudimentary Design Process introduced in previous units (e.g. Engineering Design and Visual Communication), and ability to work as a member of a successful team; 8. Effectively communicate through written technical reports, using the discourse conventions relevant to the discipline (including technical drawing);

Learning outcomes

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Students are able to apply knowledge of basic science and engineering fundamentals to the analysis and synthesis of failure and design models for mechanical components and assemblies. They can adapt the design models to novel circumstances and undertake problem identification, formulation and solution as part of the design process. The unit prepares students for professional life through the need to access design information from professional references, Codes of Practice and component suppliers' sources, and through open-book examination. Students develop the ability to practise as a designer, as an individual and in a team, with the capacity to be a leader or effective team member; communicate effectively, both in written and oral forms; appreciate the necessity and develop the capacity to stay informed of future developments in analysis and design; and design with logical reasoning and creativity.

Unit structure
Lectures: Assist the students in obtaining knew knowledge and mastering the contents. A series of six Specialised Lectures entitled Design codes, design safety factors and material selection. 40 years of engineering design experience in 6 lecture hours introduces practical (supported by the lecturers industrial experience) perspective of the mechanical design process. These lectures cover the contents that is not available in most textbooks. Tutorials: T1: Application of the lecture contents and newly acquired knowledge T2: Help with assignments. Question-and-answer sessions Assignments: ASSIGNMENT 1 (Design of a shaft or similar machine component) - Application of prior knowledge of solid mechanics in mechanical design context - Introductory experience in some key aspects of design process (working with uncertainties, insufficient and/or redundant information, design decision making)

ASSIGNMENT 2 (Pressure vessel design) - Design according to requirement of a legally binding code - Design optimisation (without emplyoing formal mathematical apparatus for optimisation)

Teaching and Learning Responsibilities

Charter of student rights and responsibilities
The Charter of Student Rights and Responsibilities upholds the fundamental rights of students who undertake their education at the University of Western Australia. The University's charter of Student Rights and Responsibilities is available at http://www.secretariat.uwa.edu.au /home/policies/charter.

Student Guild contact details

Contact details for the University Student Guild can be found at http://www.guild.uwa.edu.au.

ACE/AISE/CARS

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All students at any level undergraduate, postgraduate, onshore, offshore who are enrolled into a UWA course, are required to complete an online module which introduces them to the basic issues of ethical scholarship and the expectations of correct academic conduct that UWA has of its students. The unit is called Academic Conduct Essentials, or ACE for short, and is available through the Learning Management System (http://www.lms.uwa.edu.au) using your Pheme account. Those students required to complete ACE are automatically enrolled in the unit. Information about ACE is available in the UWA Handbook for both the undergraduate unit (http://units.handbooks.uwa.edu.au/units/aace/aace1000) and the postgraduate unit (http://units.handbooks.uwa.edu.au/units/aace/aace7000). You must complete the ACE module within the first 10 weeks of your enrolment. To pass ACE you need to obtain a minimum of 80 per cent in the quiz at the end of the module, but you may attempt the quiz as many times as necessary to pass.

Information for students with disabilities

The University has a range of support services, equipment and facilities for students with a disability. If you would like to receive advice on these services please email uniline@uwa.edu.au or visit http://www.studentservices.uwa.edu.au/information_about/disability_programme.

Assessment
Assessment overview
This comprises an open-book examination and design-project reports. Examination assessment concentrates on problem identification, solution formulation and methodology rather than numerical accuracy or memorisation. Project assessment concentrates on problem identification, formulation and solution; effective communication; the ability to function effectively as a member of a team; and an ability to understand the professional and ethical responsibilities of the engineering profession. Supplementary assessment is not available in this unit except in the case of a bachelor's pass degree student who has obtained a mark of 45 to 49 and is currently enrolled in this unit, and it is the only remaining unit that the student must pass in order to complete the course.

Assessment mechanism
# 1 Component In-class assessment (quizzes) in Specialised Lectures Weight 4% (Note: 2% for each quiz; Only two best marks taken into account) Due Date March 26, 2013; April 09, 2013; April 16, 2013 (between 5:00 pm and 5:45 pm WST, during Specialised Lectures) 28 March, 2013 (10 am WST) 23 May, 2013 (10 am WST) According to UWA Exam timetable Relates To Outcomes #1, #5

Assignment 1 Project 1 (Shaft design) Assignment 2 Project 2 (Pressure vessel design)* Exam (open book)

21%

#1, #4, #5, #7, #8

25%

#1, #4, #5, #6, #7, #8

50%

#1, #2, #3, #4 To Pass the Unit Students Must Achieve a Minimum Overall Mark of 50% AND a Minimum Mark of 50% for the Exam.

Assessment items

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Item Title Quizzes in Specialised Lectures Assignment 1 - Project 1

Description Related to topics introduced in Specialised Lectures and prior knowledge Shaft Design (detailed description will be available in LMS MOODLE). In this assignment you will apply the knowledge of solid mechanics to analyse and design a machine component (e.g. shaft) and obtain introductory experience in some aspects of the design process. This includes: - Stress analysis; - Determining forces, bending moments acting on a machine component; - Working with insufficient and/or redundant information; - Design decision making. The project is to be carried out in a group of 3-4 students, with a requirement to observe and review the operation of the group.

Submission Procedure for Assignments In-class quizzes

The reports, covering the complete list of points above, and professional/project diary of each member of the project team (diary records and documents student's own work and contribution to the project) are to be submitted by 10 am (WST) Thursday, 28 March to MECH3403 assignment box. Bind or staple all the report pages together. You must use the School of Mechanical and Chemical Engineering Assignment Cover Sheet as the report cover page. The Sheet must be signed by the all the members of the project team. Students who have not signed the sheet, will receive no marks for the assignment! The submission date should be stamped on the Sheet. Submissions without the School of Mechanical and Chemical Engineering Assignment Cover Sheet will not be accepted. Place the report and all diaries in the same large envelope or file and write the family name of project group members on the envelope/file. If appropriate, the subroutine source code should be placed in designated submission folder (details will be announced later).

As this project is a self-learning exercise, you will need to obtain by yourself majority of the information required to complete it. Support will be available from the teaching team but only in the form of answers to enquiries. We will conduct tutorials classes T2 (Friday, 11 am) as question-and-answer sessions and answer email enquiries. You have to be active in seeking the support: if you do not ask questions, you will get no answer. You will need to research appropriate reference material and organise your own learning and group coordination and problem solution strategies. These are themselves problems to solve. As failure of mechanical components (e.g. failure of a turbine shaft of aircraft engine or power plant) can have very severe consequences, errors/mistakes (including computation errors leading to grossly erroneous results) will be severely penalised in marking. Assignment 2 - Project 2 Pressure Vessel Design (detailed description will be available in LMS MOODLE) There are two major objectives in

The reports, covering the complete list of points specified in the assignment description, and professional/project diary of each member of the project team (diary records and documents student's own work and contribution to the project)

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this project: 1) To design according to the rules of a legally binding Code; 2) To attempt to optimise (without employing the formal mathematical apparatus for optimisation) against some criterion, here the economy of manufacture, within the constraints imposed by the rules of the Code. The second objective is as important in competitive, professional engineering design as the first one. The reports will be graded according to the degree to which they adequately cover the points listed above. Technical correctness and a serious attempt at optimisation of the design will be required. The project is to be carried out in groups of four to five students, with a requirement to observe and review the operation of the group. As failure/"rupture" of a pressure can have very severe consequences, errors/mistakes (including computation errors leading to grossly erroneous results) will be severely penalised in marking. Exam Open-Book

are to be submitted by 10 am (WST) Thursday, 23 May to MECH3403 assignment box. Bind or staple all the report pages together. You must use the School of Mechanical and Chemical Engineering Assignment Cover Sheet as the report cover page. The Sheet must be signed by all members of the project team (students who have not signed the sheet, will receive no marks for the assignment). The submission date should be stamped on the Sheet. Submissions without the School of Mechanical and Chemical Engineering Assignment Cover Sheet will not be accepted. Place the report and diaries of all team members in the same large envelope or file and write the family names of the all the team members on the envelope/file.

According to the UWA's examination procedures

Academic literacy and academic misconduct

The University of Western Australia takes the matter of academic misconduct by students very seriously and has policies in place that define misconduct (including plagiarism) and the penalties that apply. The consequences for misconduct can be severe, including exclusion from the University. All students are expected to make themselves aware of the definitions and the policies relating to academic misconduct, found at the website below, and with any additional requirements or stipulations that may be provided by individual coordinators: http://www.teachingandlearning.uwa.edu.au/staff/policies/conduct. Student Services provides an on-line plagiarism portal that includes a definition of plagiarism and a link to FAQ: http://www.studentservices.uwa.edu.au/ss/learning/online_services/plagiarism_portal.

Textbooks and Resources

Recommended texts

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Texts Lecture notes: Wright, D. C. Design and Analysis of Machine Elements, latest edition: UWA School of Mechanical and Chemical Engineering Accessible on the web via http://school.mech.uwa.edu.au/~dwright/DANotes/. Note. During lectures important modifications will be made to the part of the content included in DANotes sections on Threaded Fasteners, Buckling and Compound Cylinders. It will be clearly indicated when we depart from the approaches presented in DANotes. In such a case, using in the exam the approaches presented in the DANotes will be treated as an error. Budynas, R. G. and Nisbett, J. K. Shigleys Mechanical Engineering Design, 8th edn (or newer) in SI Units: McGraw-Hill 2008 (or newer) Beer F. P. and Johnston Jr. E. R., Mechanics of Materials, McGraw-Hill College Gere J. M. & Timoshenko S., Mechanics of Materials, Stanley Thornes Budynas, R.G., Nisbett, J.K. (2008) Fatigue failure resulting from variable loading, In Shigleys Mechanical Engineering Design, 8th Edition, McGrawHill, Boston, p. 257-345, ISBN 978-0-07-312193-2. (or newer edition) PDF available through UWAs Library Course Material Online CMO. Shigley, J.E., Mischke, Ch.R. (2001) Screws, fasteners and the design of nonpermanent joints, In Mechanical Engineering Design, 6th Edition, McGrawHill, Boston, p. 446-525, ISBN 0-07-365939-8. PDF available through UWAs Library Course Material Online CMO. Gere, J.M. (2001) Shear forces and bending moments, In Mechanics of Materials, 5th SI Edition, Brooks/Cole Thomson Learning, Australia, p. 271-310, ISBN 0 534-37133-7. PDF available through UWAs Library Course Material Online CMO. Timoshenko, S.P., Gere, J.M. (1999) Stresses in beams (basic topics), In Mechanics of Materials, 4th SI Edition, Stanley Thornes, p. 303-390, ISBN 07487 3998 X PDF available through UWAs Library Course Material Online CMO. Beer F.P., Johnston Jr. E.R., Dewolf, J.T., Mazurek, D.F. (2009) Transformation of stress and strain, In Mechanics of Materials, 5th SI Edition, McGrawHill, Boston, p. 423-494, ISBN 978-007-128422-6. PDF available through UWAs Library Course Material Online CMO. Goetsch, D.L., Chalk, W.S., Nelson, J.A., Rickman, R.L. (2010) Dimensioning and notation, In Technical Drawing and Engineering Communication, 6th Edition, Delmar Cengage Learning, p. 371-442, ISBN-13 978-1-4354-8340-8. PDF available through UWAs Library Course Material Online CMO.

Software requirements
You do not have to purchase the following software but you may find it useful to be aware of how to use them: EXCEL MATLAB MATHEMATICA. Please note that EXCEL is much more widely used by the industry than MATLAB and MATHEMATICA. Therefore, you are encouraged to learn and use EXCEL

Additional resources and reading

Guzzomi, A. S., Maraldi, M., and Molarim P. G. (2012) A historical review of the modulus concept and its relevance to mechanical engineering design today, Mechanism and Machine Theory, Vol. 50, p. 1-14. PDF available through UWAs Library Course Material Online CMO Costlow, T. (2009) Linking design and manufacture, Aerospace Engineering Online, SAE International, one page. PDF available through UWAs Library Course Material Online CMO

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Shutz, W. (1996) A history of fatigue, Engineering Fracture Mechanics, Vol. 54, p. 263-300. PDF available through UWAs Library Course Material Online CMO

Other Important Information

To Pass the Unit Students Must Achieve a Minimum Overall Mark of 50% AND a Minimum Mark of 50% for the Exam.

Late Submission Penalties

Marks for assignments submitted after the due date and time will be reduced by 10% of the maximum possible mark for the assignment for each working day after the deadline up to a maximum of 100%. Zero marks will be awarded for assignments handed in after marked submissions have been returned to students.

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