Engineering Institute of Technology

 

Unit Name

MECHANICAL DESIGN

Unit Code

BME204S

 

Unit Duration

Term

Award

Bachelor of Science (Engineering)

 

Duration 3 years

Year Level

Three

Unit Creator/Reviewer

 

Core/Sub-discipline

Sub-discipline

Pre/Co-requisites

BSC105C, BSC203C

Credit Points

3

 

Total Program Credit Points 81 (27 x 3)

Mode of Delivery

Online or on-campus.

Unit Workload

(Total student workload including “contact hours” = 10 hours per week)

Lecture : 1.5 hours

Guided simulations, presentations, assessments : 2 hours Tutorial : 1.5 hours

Personal Study : 5 hours

The objective in presenting this unit is to provide students with an in-depth knowledge of the principles and practices of mechanical design, and the design process.

 

The subject matter covered in this unit will include basic design concepts such as: stress; strain; factor of safety; failure analysis; endurance; and, fracture mechanics. There will also be a systematic examination of the design and selection process involving mechanical system elements such as: fasteners power screws; riveted and welded joints; keys; couplings; shafts; pulleys; flywheels; belts; ropes; chains; gears; bearings; springs; clutches; and brakes.

 

Students will have the opportunity to discuss at length all design related issues including designing for strength, rigidity, and stiffness, and design based on varying load conditions; they will also complete a detailed analysis involving the design of internal combustion (IC) engine parts such as: piston; cylinder; connecting rod; and, crank shaft. The students will further learn to perform design calculations using simulation software. Students will also undertake project work involving designing a simple mechanical system.

 

At the conclusion of this unit, students will have been imparted with detailed knowledge of mechanical design concepts and the design process, and being equipped with the skills to design mechanical components.

 

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

  1. Demonstrate relevant knowledge of design related concepts such as stress, strain, factor of safety, endurance, and fracture mechanics.

  2. Design threaded fasteners and power screws for different load conditions.

  3. Detail the design procedures involving riveted and welded joints.

  4. Design cotters, keys, couplings, and shafts for varying loads.

  5. Evaluate the design requirements for pulleys, flywheels, belts, ropes, and chains.

  6. Outline the design procedures for gears, bearings, springs, clutches, and brakes.

  7. Explain the design methodology for IC engine parts such as piston, cylinder, connecting rod, and crank shaft.

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

    1. Fostering personal and professional skills and attributes in order to:

      1. Conduct work in a professionally diligent, accountable and ethical manner.

      2. Effectively use oral and written communication in personal and professional domains.

      3. Foster applicable creative thinking, critical thinking and problem solving skills.

      4. Develop initiative and engagement in lifelong learning and professional development.

      5. Enhance collaboration outcomes and performance in dynamic team roles.

      6. Effectively plan, organise, self-manage and manage others.

      7. Professionally utilise and manage information.

      8. Enhance technologist literacy and apply contextualised technologist skills.

    2. Enhance investigatory and research capabilities in order to:

      1. Develop an understanding of systematic, fundamental scientific, mathematic principles, numerical analysis techniques and statistics applicable to technologists.

      2. Access, evaluate and analyse information on technologist processes, procedures, investigations and the discernment of technologist knowledge development.

      3. Foster an in-depth understanding of specialist bodies of knowledge, computer science, engineering design practice and contextual factors applicable to technologists.

      4. Solve basic and open-ended engineering technologist problems.

      5. Understand the scope, principles, norms, accountabilities and bounds associated with sustainable engineering practice.

    3. Develop engineering application abilities in order to:

      1. Apply established engineering methods to broadly-defined technologist problem solving.

      2. Apply engineering technologist techniques, tool and resources.

      3. Apply systematic technologist synthesis and design processes.

      4. Systematically conduct and manage technologist projects, work assignments, testing and experimentation.

The Australian Engineering Stage 1 Competency Standards for Engineering Technologists, 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

Systematic, theory based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the technology domain.

1.2

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

1.3

In-depth understanding of specialist bodies of knowledge within the technology domain.

1.4

Discernment of knowledge development within the technology domain.

1.5

Knowledge of engineering design practice and contextual factors impacting the technology domain.

1.6

Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the technology domain.

2.

Engineering Application Ability

2.1

Application of established engineering methods to broadly-defined problem solving within the technology domain.

2.2

Application of engineering techniques, tools and resources within the technology domain.

2.3

Application of systematic synthesis and design processes within the technology domain.

2.4

Application of systematic approaches to the conduct and management of projects within the technology domain.

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.

Successfully completing this Unit will contribute to the recognition of attainment of the following graduate attributes aligned to the AQF Level 7 criteria, Engineers Australia Stage 1 Competency Standards for Engineering Technologists and the Sydney Accord:

 

Graduate Attributes

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

EA Stage 1 Competencies

Learning Outcomes

A. Knowledge of Science and Engineering Fundamentals

A1. Breadth of knowledge of engineering and systematic, theory-based understanding of underlying principles, and depth of knowledge across one or more engineering sub- disciplines

 

1.1, 1.3

 

1, 2, 3, 4, 5, 6, 7

A2. Knowledge of mathematical, statistical and computer sciences appropriate for engineering technology

 

1.2

 

1, 2, 3, 4, 5, 6, 7

A3. Discernment of knowledge development within the technology domain

1.4

1, 3, 5, 6

A4. Knowledge of engineering design practice and contextual factors impacting the technology domain

 

1.5

 

1, 2, 3, 4, 5, 6, 7

B. Problem Solving, Critical Analysis and Judgement

B1. Ability to research, synthesise, evaluate and innovatively apply theoretical concepts, knowledge and approaches across diverse engineering technology contexts to effectively solve engineering problems

 

1.4, 2.1, 2.3

 

2, 3, 4

B2. Technical and project management skills to design complex systems and solutions in line with developments in engineering technology professional practice

 

2.1, 2.2, 2.3, 3.2

 

C. Effective Communication

C1. 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

 

3.2

 

2, 3, 4

C2. Ability to engage effectively and appropriately across a diverse range of cultures

3.2

 

D. Design and Project Management

D1. Apply systematic synthesis and design processes within the technology domain

2.1, 2.2, 2.3

2, 4

D2. Apply systematic approaches to the conduct and management of projects within the technology domain

 

2.4

 

2, 4, 6

E. Accountability, Professional and Ethical Conduct

E1. Innovation in applying engineering technology, having regard to ethics and impacts including economic; social; environmental and sustainability

 

1.6, 3.1, 3.4

 

E2. Professional conduct, understanding and accountability in professional practice across diverse circumstances including team work, leadership and independent work

 

3.3, 3.4, 3.5, 3.6

 

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 Engineering Technologist.

 

 

 

Graduate Attributes

A1

A2

A3

A4

B1

B2

C1

C2

D1

D2

E1

E2

 

Engineers Australia Stage 1 Competency Standards for Engineering Technologist

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

When assessed

Weighting

 

(% of total unit marks)

Learning Outcomes Assessed

 

Assessment 1

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation

Example Topic: Stress, strain, factor of safety, failure analysis, fracture mechanics, design of threaded fasteners and power screws.

Students will complete a quiz and solve simple problems on stress-strain and failure analysis. They will also be required to describe how threaded fasteners and power screws are designed for different loads.

 

Week 3

 

15%

 

1, 2

 

Assessment 2

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation

Example Topic: Riveted and welded joints, keys, cotters, couplings, shafts, pulleys, belts, ropes, chains.

Students will provide answers to essay type questions and perform simple calculations using simulation software related to the design of shafts, pulleys, belt, rope and chain drives.

 

Week 6

 

20%

 

3, 4, 5

 

Assessment 3

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation / Project

/ Report

Example Topic: Gear and bearing design or Springs, clutches, brakes.

Students will provide evidence of their understanding of the principles of gear and bearing design, by solving design based problems or provide short answers to questions showing evidence of their understanding of the design of springs, clutches, and brakes.

 

Week 11

 

20%

 

6

 

Assessment 4

Type: Exam or Project

Example Topic: Mechanical system design.

Students will be given a project work that involves designing a simple mechanical system. The assessor will specify the format.

 

Final Week

 

40%

 

1 to 7

 

Attendance / Tutorial Participation

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

 

Continuous

 

5%

 

1 to 7

Prescribed and recommended readings

 

Required textbook

Budynas, R & Nisbett, K 2014, Shigley's Mechanical Engineering Design, 10th edn, McGraw- Hill Education, ISBN-13: 978-0073398204

 

Reference

Deutschman, AD, Michels, WJ & Wilson, CE 1975, Machine Design; Theory and Practice,

1st edn (Digitized 2007), Prentice Hall, ISBN: 978-23290008

 

Robert, LN 2013, Machine Design, 5th edn, Prentice Hall, ISBN: 978-0133356717

 

Journal, website

Peer-reviewed journals and websites (advised during lectures)

 

Notes and Reference texts

IDC notes and Reference texts as advised Other material advised during the 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 and General Considerations

  1. Engineering materials, their mechanical properties, and selection

  2. Principal stresses

  3. Stress-strain diagrams, stress analysis

  4. Design stress and factor of safety

  5. Stress concentration factor in tension, bending, and torsion

  6. Theories of failures

  7. Design for variable and repeated loadings

  8. Fatigue stress concentration factor, endurance diagrams

  9. Fracture mechanics

 

Topic 2

Threaded Fasteners and Power Screws

  1. Geometry of thread forms

  2. Terminology of screw threads and thread standards

  3. Stresses in threaded fasteners

  4. Effect of initial tension

  5. Relation between bolt tension and torque

  6. Design of threaded fasteners under static, dynamic, and impact loads

  7. Design of bolted joints due to eccentric loading

  8. Mechanics and stresses of power screw

  9. Efficiency of thread

  10. Design of power screw

 

Topic 3

Riveted and Welded Joints

  1. Types of rivet heads and riveted joints

  2. Strength of rivet joint

  3. Failure of riveted joint

  4. Design of riveted joint

  5. Eccentrically loaded riveted joint

  6. Types of welded joints

  7. Stresses in butt and fillet welds

  8. Strength of welded joints

  9. Eccentrically loaded joint

  10. Welded joint subjected to bending moment

  11. Fillet welds under varying loads

 

Topic 4

Design of Basic Elements, Couplings and Shafts

  1. Design of Cotter and Knuckle joints

  2. Design of keys and splines

  3. Design of rigid, flexible and flange couplings, compression coupling, muff coupling, bush and pin type coupling, Oldham’s coupling

  4. Transmission shafts

  5. Torsion of shafts

  6. Design against static load

  7. Design for strength, rigidity, and stiffness

  8. Design under continuous loading for fatigue

 

Topic 5

Pulleys, Flywheels, Belts, Ropes and Chains

  1. Flywheel inertia

  2. Stresses in flywheels and pulleys

  3. Failure criteria

  4. Design of flat and round belt drives, V-belts, timing belts, and wire ropes

  5. Chain drives

  6. Roller chains

  7. Geometric relationships

  8. Dimensions of chain components

  9. Power rating of roller chains

 

Topics 6 and 7

Design of Gears

  1. Spur gear terminology and definitions

  2. Types of failure

  3. Stress concentration

  4. Lewis equation and form factor

  5. Design for strength, dynamic, and wear loads

  6. Helical gear definitions

  7. Effective load on gear tooth

  8. Helical gear design based on strength, dynamic, and wear loads

  9. Bevel ear definitions

  10. Effective load on gear tooth

  11. Bevel gear design based on strength, dynamic, and wear loads

  12. Worm gear definitions

  13. Worm gear design based on strength, dynamic, wear loads

  14. Efficiency of worm gear drives

 

Topic 8

Bearings

  1. Types of ball and roller bearings

  2. Rolling contact bearings – selection of bearings for radial and axial loads, bearing life

  3. Design procedure

  4. Mounting and lubrication for rolling contact bearings

  5. Plain or journal bearings – types of lubrication, viscosity, hydrodynamic theory of lubrication

  6. Somerfield number

  7. Heat balance

  8. Design procedure

 

Topic 9

Springs

  1. Types of springs

  2. Stresses in helical coil springs of circular and non-circular cross sections

  3. Equation for stress and deflection

  4. Tension and compression springs

  5. Springs under fluctuating loads

  6. Stresses in leaf springs

  7. Equalized stresses

  8. Energy stored in springs

  9. Torsion, Belleville, and rubber springs

 

Topic 10

Clutches and Brakes

  1. Introduction to clutches

  2. Friction materials

  3. Torque transmitting capacity

  4. Design of single plate, multiple plate, centrifugal, and cone clutches

  5. Introduction to brakes

  6. Design procedure for block brake, internal expanding shoe brake, band brake, disc brake

  7. Heat generation in brakes

 

Topic 11

Curved Beams, Cylinders, and Cylinder Heads, IC Engine Parts

  1. Stresses in curved beams of standard cross sections used in crane hook, punching presses, and clamps, closed rings and links

  2. Lame’s equations for cylinders

  3. Compound cylinders

  4. Stresses due to different types of fits, cylinder heads, flats

  5. Design of piston, connecting rod, and crank shaft

 

Topic 12

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.

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