ME 350 Design and Manufacturing II

Syllabus and General Course Information

Winter 2002

Course Information

Web Site: design.engin.umich.edu

Lectures

Lecture 1: Prof. Diann Brei Lecture 2: Prof. Elijah Kannatey Asibu

Time: TTH 10:30-12 pm Time: TTH 2:30-4pm

Location: Chrysler Auditorium Location: 1500 EECS

Instructors

Name: Prof. Diann Brei Name: Prof. Elijah Kannatey Asibu

Office: 2274 GG Brown Office: 3134 GG Brown

Phone: (734) 763-6617 Phone: (734) 936-0408

E-mail: dibrei@engin.umich.edu E-mail: asibu@engin.umich.edu

Office Hours: TTh 1:30-2:15 p.m. Office Hours: M,T 10-11:00 a.m.

Name: Paul Alexander Name: Joseph DiMambro

Office: 2203 GGB Office: TBD

Phone: 764-9156 Phone: TBD

E-mail: pwa@umich.edu E-mail: joedimam@umich.edu

Office Hours: M 2-3, W 4-5 Office Hours: W 10-11, F 10:30-11:30

Design Labs

Section Day Time Location Teaching Assistant

3 Monday 3:30-5:30 2233GGBrown Paul Alexander

4 Wednesday 1:30-3:30 2233GGBrown Paul Alexander

5 Wednesday 3:30-5:30 1371 GGB Joseph DiMambro

6 Tuesday 10:30-12:30 1005 Dow Joseph DiMambro

Textbook

Mechanical Engineering Design by J.E. Shigley and C.R. Mischke (custom edition) McGraw-Hill

Design of Machinery by R. L. Norton (custom edition) McGraw-Hill

Prerequisites

You are expected to have a basic working knowledge of (i) a basic working knowledge of elementary mechanics such as statics, dynamics and strength of materials, (ii) basic machine shop skills (i.e., lathe, mill, drill, etc.) and (iii) working knowledge of a commercial CAD program – IDEAS, Unigraphics, ProEngineer or AutoCAD (preferably unigraphics).

Course Objectives

The goal of this course is to give each student an understanding of the basic engineering principles behind mechanical machines and teach them how to integrate their engineering knowledge to synthesize and analyze simple mechanical systems and components. At the end of the course students should be able to do the following in either a team setting or individually:

1. Identify standard mechanical components and explain how they work.

2. Define the engineering requirements for a mechanical system or component.

3. Conceptualize a set of designs that will fulfill the specifications keeping in mind manufacturing issues and identify components needed for a given system design.

4. Derive and/or apply general mechanical engineering science in analyses specific to the design of mechanical components.

5. Anticipate the modes of failure and expected service lifetime of mechanical systems and the components within the system using engineering principles.

6. Weigh tradeoffs in concept and detail design from the perspectives of function, manufacture, design effort and nature of a posed problem to select standard components from a catalog and design special components as needed.

7. Prepare engineering instructions (toleranced drawings and text) to manufacture mechanical systems and components.

8. Build basic mechanical machines and components and assemble components using tools available in the machine shop.

9. Test and evaluate simple machine systems and components for performance and failure behavior.

10. Critique and redesign mechanical systems and components for enhanced performance and reliability.

Lecture and Recitation Schedule

Date Topic Chapter

Jan. 5 Introduction to Mechanical Design 1: Norton

Jan 10 Design Processes 1: Norton

DL Manufacturing Process Review

Jan 15 Power Transmissions-Power Screws 8-1: Shigley

Jan 17 Power Transmissions-Power Screws 8-2: Shigley

DL Shop Training; Team Dynamics

Jan 22 Power Transmissions-Belts Handout

Jan 24 Power Transmissions-Belts Handout

DL Shop Training; Creativity and Design Selection

Jan 29 Motors 2-16: Norton, Handout

Jan 31 Motors 2-16: Norton, Handout

DL Shop Readiness; Free Body Diagrams and Failure Mode Review

Feb 5 Bearings 11:Shigley

Feb 7 Material and Manufacturing Process Selection 5: Shigley

DL Optimization, Engineering Drawings and Tolerancing; Switches and Sensors

Feb 12 Statistical Review 2:Shigley

Feb 14 Tolerancing- 2: Shigley

DL Exam Review

Feb 19 Joining-Fasteners- Exam II (Evening) 8: Shigley

Feb 21 Springs 10:Shigley

DL Project 1

Feb 26 Spring Break

Feb 28 Spring Break

DL No Labs

Mar 5 Introduction to Mechanisms 2: Norton

Mar 7 Linkages: Position Analysis and Synthesis 4,5: Norton

Mar. 9 Project 1 Test Day

DL Exam Returned

Lecture and Recitation Schedule (Continued)

Date Topic Chapter

Mar 12 Linkages: Position and Velocity Analysis and Synthesis 6: Norton

Mar 14 Linkages: Acceleration Analysis and Synthesis 7: Norton

DL Functional Decomposition

Mar 19 Adams Web Tutorial

Mar 21 Adams Web Tutorial

DL Proj 2. Product Assessment and Dissection

Mar 26 Cam 8: Norton

Mar 28 Cam 8: Norton

DL Proj. 2. Product Recommendations and Redesign

Apr 2 Introduction to Gears and Gear Kinematics 13:Shigley

Apr 4 Gear Trains 13:Shigley

DL Proj. 2 Virtual Prototype

Apr 9 Gear Geometry and Manufacturing 14:Shigley

Apr 11 Gear Failure Modes 14:Shigley

DL Proj. 2. Virtual Prototype

Apr 16 Course Wrap Up - Exam II (Evening)

NOTE: This is intended only as a rough outline and adjustments may be necessary
to accommodate the expertise level of the class.

Design Labs Assigned Test Due Date Report Due Date

Project 1 Jan. 10 March 9 March 15

Project 2 Feb. 5 Apr. 8-10 April 12

Exams Coverage Exam Date

Exam 1 Shigley 5,8,11; Norton 1,2, Motors Feb. 19 at 6 pm

Exam 2 Shigley 2, 10, 13, 14; Norton 2,4,5,6,7,8 April 16 at 6 pm

Course Format and Policies

Lecture

Cooperative Learning methods will be used during this course. These methods depend heavily on teamwork. Students will be assigned to groups of three to four that will work together the entire semester. It is expected that the students within a team will work together on homework, projects and in-class activities. Students are requested to sit together with their team mates in class to help facilitate them working together on in-class activities. It is expected that each team during the semester will experience some conflict. What is important is that the teams deal with this conflict in a positive and constructive manner. Teams having problems working together should make every effort to resolve them by themselves. If that doesn’t work, see the course instructor for help. Students who consistently fail to pull their weight can as a last resort be fired with permission of the instructor and unanimous vote of the remaining team members. Firing a student is a serious procedure and should not be taken lightly. Please consult the course instructor for the procedure. Students repeatedly carrying the load for their teammates can as a last resort quit with permission from the instructor. Students who either are fired or quit must find another group with three members willing to unanimously take them on.

Design Labs

The design labs are two hours long and the format will vary for each. The focus of these design labs will be on the projects and in class exercises. Some of the period will be used to hand out, explain and discuss the projects. Time will be available for student groups to work on in class exercises and project (design, analysis, building, etc). All projects will be tested and evaluated during the design labs. Since the projects are an integral part of the course attendance at the design labs is required. This period will also be used for clarification of course material, problem solving and questions on homework and exams.

Homework and Projects

Homework and project descriptions will be assigned in class and discussed in the design labs. Both homework and projects are to be completed by your class team and cooperation among everyone in the class is encouraged. This is the time to learn. However, you are not allowed to possess, look at, use or in anyway derive advantage from the existence of solution (paper or apparatus) prepared in prior years whether these solutions were former students’ work or copies of solutions that had been made available by me or other instructors. Violation of this policy will be considered violation of the honors policy and will be filed with the Honor’s Council.

Penalties may be imposed on homeworks, project reports and exams for lack of neatness, legibility or clear organization of your work. On each assignment, put the names and roles of the participating group members and the problem set number on the outside. If a student’s name appears on a solution set, it certifies that he/she has participated in solving the problems. Students whose names do not appear on a solution set will receive zeros.

Exams

There will be two exams given. Exams are to be completed individually and students are not allowed to work together on the exams. For each exam the students are expected to sign the Honor Code. Since the course material builds upon previous material all exams will be comprehensive. You may use your textbook for the exam but it will be closed notes. Make-up exams will be given only in exceptional cases (determined by the instructor). If you have a conflict with the exam day you must see the instructor BEFORE the exam so that arrangements for a make-up exam may be made. Once the exam has started no make-up exams will be granted and the missed exam will receive a zero score.

Grading Policy

Projects: 40%

Exam 1: 20%

Exam 2: 20 %

Homework, Quizzes and In-class Activities: 10%

Group and Participation Evaluation: 10%

Total 100%

Projects, homeworks and in-class activities will be submitted and graded as a team grade. The exams, group and participation evaluation will be graded on an individual basis.

Machine Shop Usage

It is expected that you have received machine shop training during ME 250 and are certified to use the machines in the MEAM machine shop. If you do not have this certification then it is your responsibility to gain it as soon as possible since it will be needed for completion of the projects. Incomplete machine shop training will not be accepted as an excuse for your projects. If you do not have this training, please inform the course instructor immediately so that arrangements can be made for training.

The machine shop is a highly used resource in the department and shop time is very valuable. Missing a machine-shop time slot will be considered a serious offense. There will be a 5% penalty accessed your team project for each two-hour machine-shop slot missed. In addition, there will be a 2 point penalty (out of 100) applied to the final course grade total of the offending individual for every two-hour machine-shop time slot missed. If missing machine-shop slots becomes habitual, machine shop privileges will be revoked.

Additional Reading

There are many other texts that have the same scope as Shigley & Mischke that you may want to consult

· K.S. Edwards and R.B. McKee, Fundamentals of Mechanical Component Design, McGraw-Hill (1991)

· R.C. Juvinall and K.M. Marshek, Fundamentals of Machine Component Design, Wiley (1991)

· M.F. Spotts, Design of Machine Elements (6th ed.), Prentice Hall (1985).

· A.D. Deutschman, W.J. Michels and C.E. Wilson, Machine Design: Theory and Practice, Macmillan (1975).

· R.M. Phelan, Fundamentals of Mechanical Design (3rd ed.), McGraw-Hill (1970).

Finally, for both fun and enlightenment, I recommend:

· M.J. French, Invention and Evolution: Design in Nature and Engineering, Cambridge University Press (1988).

· H. Petroski, Design Paradigms: Case Histories of Error and Judgment in Engineering, Cambridge University Press (1994).

· H. Petroski, To Engineer is Human: The Role of Failure in Successful Design, St. Martin ’s Press (1985).

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