Course Outline
Engineering Design

Hutchinson Central Technical High School
Buffalo, New York

Instructor:
J.DiCorso
Class hours: 2 Periods
Unit hours: 2


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Course Contents

1 Introduction to Design Procedures

1.1 Computer Drafting

Students will be on-line utilizing the basic CAD ( AutoCad) commands within the first week of this course of study. An adequate level of competency will be developed throughout the courses time frame enabling the student to draw comprehensive multi-view , detailed and assembly mechanical drawings. This will comprise of approx. 100 computer commands from the CAD software programs. Mastery will develop as practicing the CAD program evolves throughout the full semester. An abbreviated list of the more often used commands follows:


1.2 Vector Analysis

Students will utilize their physic, math and acquired mechanical drawing abilities in determining various applied forces on structural members of a simple mechanical support structure. Extremely precise vector force diagrams will be constructed ( utilizing the AutoCAD program) in determining various moments on structural members. The following list of terms will be reviewed in detail and their use in practical real-life projects will be demonstrated and assigned as class problems.



1.3 V-belt and Pulley Design

Students will be responsible for the complete design selection of V-belts and pulley sheaves from selected class problems. Final selection data will be graphically represented with a single CAD drawing. The following concepts will be implemented and completely understood by the student:

a) Pulley Groove Design
b) Belt Design
c) Selected Power Duties
d) Service Factors
e) Horsepower Ratings
f) Speed Ratio Calculations

1.4 Gear Ratios Analysis and Design
Student will design a 5 ( optional 10) speed bicycle using the mechanical advantage, concepts and theories associated with gear ratios. Final calculated data will be graphically represented with a single AutoCAD drawing presenting the findings. The following concepts will be completely understood by the student upon completion of this phase of the course.

a) Gear Tooth Design-Ratio & Sizes
a1) Diametrical Pitch
a2) Circular Pitch
a3) Circular Thickness
a4) Addendum
a5) Dedendum

1.5 Cam Design and Analysis
Students will layout and design a Plate Cam Profile complete with its' associated Cam Displacement Diagram. Student will utilize each of the four (4) types of motions as outlined in class. ( i.e.. Dwell, Parabolic, Harmonic and Constant Velocity). In addition, a complete written, technical report will be required outlining the students cam design, the 2-dimensional cam profile and displacement diagram.

1. 6 Product Re-Design

Students will consider various design solutions for the assembly of an existing product.( eg.adjustable wrench, table vise ). The purpose of this exercise has two major objectives. First, the student is responsible for the complete and accurate identification of the design problem utilizing a CAD software program. Once accomplished, the student will consider their various design solutions by taking into account the cost involved in machine operations, re-tooling and labor costs. Although several design solutions may be well suited, students begin to understand why some are more efficient and considered better designs than others.

2. Advanced Design using Solid Modeling- (Optional )

Students will be introduced to theory and concept of Solid Modeling using the Inventor CAD package. Students will follow the click by click Inventor tutorial available in the CD rom included in the text book. Weekly home works will be supplemented project requiring students to construct a parametric model of one of the above mentioned product re-designs. (see section 1.5). Students will also get the opportunity to visualize their re-designed projects in a solid 3 dimensional model format. The principle concepts in the creation of solid modeling are reviewed and practiced. Fabrication steps include the following:




· Creation of simple objects using parametric modeling
· Creating Holes, cuts, model tree and relationships
· Creating Shafts, Rounds, Chamfers and Slots
· Advanced Modeling utilities such as regeneration, parent-child relationship, Feature referencing etc.
· Sketcher tools and datum
· Revolved features and patterns
· Sweeps and blends
· Assembly modeling using ProE
· Advanced assembly operations


3. Product Design Concepts

3.1 Product Design- "The Design Process"

Students will each design a functional, pragmatic product from the design inception to the manufacturing and marketing stages. In addition the System Design process will be reviewed and contrasted to the process of Product Design Theory. Design considerations will include Human Factors, Appearance , Installation, Maintenance / Serviceability, Costs, Reliability and Safety. The following series of steps are covered in detail in order to actualize the desired outcome(s) of this segment of study:

a) Problem Identification:
b) Preliminary Ideas
c) Refinement
d) Analysis
e) Decision
f) Implementation

As part of the Product Design segment of this topic, a working knowledge of Detailed and Assembly drawings is required in the preparation and completion of the final design project. ( Prerequisite EAS-150 covers this material and students are required to reference text ,"Engineering Graphics" by Giesecke , 2nd. Ed. 1994 if required ). A brief outline of each follows:

3.2 Working Drawings
Students have acquired the essential skills to interrupt and construct appropriate working drawings. Drawings will include all the necessary dimensions, sections, auxiliaries and detail for complete manufacturing .

3.3 Assembly Drawings
Students have acquired the necessary skills to interpret and construct appropriate assembly drawings. The process of visualizing component parts to yield an assembled product will be stressed. All the required fits / limits, revisions, title block information, exploded views and bill of materials should be reviewed in detail. In addition, when clearer detail is required for proper assembly, various sectioning techniques will be required.


Evaluation Criteria

All projects assigned throughout the course will be evaluated.
1) Final Project / Exam
2) Assignments throughout the course

a) A final senior project ( detailed / assembly drawing(s)) - will be required in the 4th marking period. Drawing accuracy will determine the students understanding of drawing details, dimensioning, sectioning, tolerances , Bill of Materials etc. In addition, the understanding and application of the CAD software program ( AutoCad) will be evaluated. Accuracy, completeness, design function , layout , and the ability to understand the design of the project will be the primary criteria in the evaluation process.

b) Written Technical Report - will accompany the final project. Report should include the following segments :
b1) Cover: The report should be inserted in a binder, with its title and author indicated on the cover.
b2) Title Page: The title page contains the title of the report, the name of the person or team that prepared it, and the date.
b3) Table of Contents: The major headings in the report and their page numbers are listed.
b4) Problem identification: Explains the importance of and need for a solution to the problem.
b5) Bibliography: ( Optional for our classroom assignment)
b6) Body ( includes findings and conclusions ): ( Actual heading should be appropriate to the report rather than this general term.) This section is the main part of the report. It describes the data collected and analyzed and the steps taken to solve the problem.
b7) Appendix: The appendix includes information ( such as drawings, sketches, raw data, brochures, surveys, etc. ) that supplements your final design . In addition, a brief breakdown of your products approximate manufacturing costs and marketing scheme must be included.

c) Written Report Evaluation: Student's product design will be evaluated using the form "Evaluation Written Report". Form will indicate the various segments of the report being reviewed and detail the number of points awarded to each.

d) Assigned Projects - Several class projects will be required throughout each marking period. Proposed topics include Vector Analysis, Product Re-design, V-belt drive design and Gear Ratio analysis.


Note: All projects will be due on the date announced in class. Particular attention should be given to proper time management in scheduling the completion dates for your projects. Since printer "down time" is unpredictable, please don't wait until the due date before you elect to print your assignments. A project turned in late will have a percentage of points deducted for each class session it is late.