June 14, 2015
June 14, 2015
June 17, 2015
26.52.1 - 26.52.9
A Hands-on Approach in Teaching Machine DesignThe purpose of this paper is to recognize active engagement of students within a Machine Designcourse. The modified curriculum is not based on a theoretical design project but a hands-onapproach. The added material aims to duplicate practices that are usually included in the designand development of new products in the industry. The laboratories listed below are given onlyafter covering an introduction to the design philosophy presented by Eggert in  and the firsttwo parts of the textbook by Budynas and Nisbett . The design philosophy in  splits thedesign process in five phases (formulation, concept design, configuration design, parametricdesign and detail design). The first two parts in  cover fatigue and theories of failure. Partthree of the textbook  is given in lecture and will be supported by the practically orientedlaboratories listed below and their associated content:Injection Molding Laboratory: Part and mold design in Computer Aided Design environment Part and mold optimization through Moldflow analysis NC Code generation in Mastercam for manufacturing the mold Manufacture of the mold with a CNC machine Use of a Coordinate Measurement Machine for quality assurance of the plastic parts made in the mold.Sand Casting Laboratory: Finite Element Analysis of a bracket design using topology optimization 3D printing of optimized bracket pattern Sand casting of the bracket Stress test of the bracket Fatigue test of the bracket – review of the procedureQuality Assurance/Reliability Laboratory: Additional Coordinate Measurement Activity Design for Manufacturing and Assembly Activity Failure Mode and Effects Analysis ActivityWritten reports will be used to evaluate students as well as the quality outcome of their practicalwork and their active participation levels. Student feedback and observations of activities willalso be employed in continuous improvements of the efforts. With this project, the authors willfocus on a rare approach to machine design by including necessary Industrial and ManufacturingEngineering tools for improving Machine Design Education. The authors will believe that theinitiative will also strengthen the impact on the following ABET outcomes of the course infocus: (c) an ability to design a system, component, or process to meet desired needs within realisticconstraints - manufacturability(e) an ability to identify, formulate, and solve engineering problems(k) an ability to use the techniques, skills, and modern engineering tools necessary forengineering practice.References Eggert, R. J. Engineering Design. Pearson Prentice Hall, Upper Saddle River, NJ., 2005, Richard G. Budynas, J. Keith Nisbitt (2010), Shigley’s Mechanical Engineering Design,Mcgraw Hill 9th edition, ISBN: 978-0-07-352928-8.
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