School of Mechanical and
Manufacturing Engineering
MANF3100 PRODUCT AND MANUFACTURING DESIGN
COURSE OUTLINE
SEMESTER 1 2012
MANF3100 Product and Manufacturing Design
TABLE OF CONTENTS
Page
Semester 1 period
1
Course staff
1
Course Arrangement
1
Information about the course
2
Teaching Strategies
4
Suggested Approaches to Learning in the Course
4
Course Schedule and Assessment
4
Resources
6
Course evaluation and improvement
6
Other matters
6
SEMESTER 1 PERIOD
(Monday week 1) 27 February 2012 to (Friday week 13) 1 June 2012
Mid-semester break: 6 April 2012 to 15 April 2012.
Study Period: 2 – 7 June 2012
Examination Period: 8 - 26 June 2012
COURSE STAFF
Course Convenor:
Prof Jun Wang
Room: Mech Eng 205, Ph: 9385 5784, jun.wang@unsw.edu.au
Course Lecturers:
Prof Jun Wang
(Availability: Tuesday and Wednesday 14:00-15:00)
Dr Thai Nguyen
Mech Eng Rm 210
9385 5689
thai.nguyen@unsw.edu.au
(Availability: Thursday 11:00 -13:00)
Laboratory Demonstrators:
Mr Martyn Sherriff
Mech Eng Rm M4,
9385 4113
Mr Seetha Mahadevan Mech Eng Rm M2,
9385 4109
Additional staff may be allocated at the laboratory times.
COURSE ARRANGEMENT
6hrs/week Session 1
includes lectures and tutorials, additional time may be needed for
laboratory work
Tuesday
Part B:
15:00-17:00 Mech Eng Rm 405
Manufacturing Technology section
Wednesday 15:00-17:00 Mech Eng Rm 405
Part C:
Metrology section
Thursday
Part A:
24/02/2012
9:00-11:00 Elec Eng Rm G3 (G17-G3)
Product Design Section
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MANF3100 Product and Manufacturing Design
INFORMATION ABOUT THE COURSE
Units of credit
This is a 6 unit-of-credit (UoC) course, and involves 6 hours per week (h/w) of face-to-face
contact.
UNSW expects that you will put in, on average, 40-45 h/w for 24 UoC (including both in-class and
out-of-class time) for an effective 15 weeks of the session (thirteen weeks plus stuvac plus one
effective exam week) for an average student aiming for a credit grade. Various factors, such as
your own ability and your target grade, will influence the time needed in your case. Some
students spend much more than 45 h/w, but you should aim for not less than 40h/w on
coursework for 24 UoC.
This means that, for this course, you should aim to spend not less than an additional five hours
per week of your own time. This should be spent in making sure that you understand the lecture
material, completing the set assignments, further reading about the course material, and revising
and learning for the examinations.
Course summary and relationship to other courses in the Plan
This is one of the technology-based courses in the Manufacturing Engineering and Management
Plan. This course develops an appreciation of the concepts involved with product development
and manufacture. Product and Manufacture Design creates products. The other courses in the
plan are related to this subject by the fact that all other resources associated with manufacturing
are centred on a manufactured product.
Aims of the course
This course aims to develop the concept of product manufacturability based on the requirements
of the product, manufacturing processes and the measurement processes. To develop a fully
functional and quality product, it is important that quality is built into the product. The basis of
good quality lies in the design for manufacture, economic process design and product testing for
its characteristics. Therefore the students are introduced to product design methodology,
manufacturing process analysis and component measurement or Metrology. Product design is
introduced with a view to get the student to appreciate the requirements of the product based on
customer requirements and functionality and therefore the tolerances allocated for proper
functioning. The analysis, technology and economics of selected manufacturing processes will
be presented so the students will appreciate what needs to be considered when selecting
manufacturing processes. Finally, the technology and analysis of the measurement process is
presented so that the students can get an appreciation of the need for measurement and aspects
of the measurement process. This course is intended to give the students the fundamentals
associated with product manufacture.
Student learning outcomes
On completion of this course it is expected that the students will be
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Familiar with product design associated with manufacturing and tolerance technology
Able to develop the knowledge of some manufacturing processes and the analyses of
these processes
Able to extend the analysis methodology to other processes
Able to carry out measurements of components and determine their characteristics in
terms of manufacturing requirements and functionality
Able to relate to economic requirements for manufacturing and thus optimise the
production of the component
Able to relate the manufacturability of a component with the customer requirements which
incorporates economic considerations.
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MANF3100 Product and Manufacturing Design
Graduate attributes
The students will be encouraged to develop the following Graduate Attributes by
understanding the selected activities and knowledge content. At the conclusion of the course,
the students will be able to:
• an in-depth engagement with the relevant disciplinary knowledge in its
interdisciplinary context;
• the capacity for analytical and critical thinking and for creative problem solving;
• the ability to engage in independent and reflective learning;
• information literacy –– the skills to locate, evaluate and use relevant information;
• the skills required for collaborative and multidisciplinary work;
• the skills of effective communication.
TEACHING STRATEGIES
The course will be presented in the form of lectures and tutorials. In addition there will be
laboratory work for hands-on experience in understanding some of the principles of
manufacturing technology and measurements. These will enhance the understanding of the
material to the students. It is expected that the students will attempt the tutorials problems given
so that their understanding of the subject material is enhanced. The lecture notes and tutorial
problems will be made available on Blackboard E-learning system or by distribution in class.
SUGGESTED APPROACHES TO LEARNING IN THE COURSE
Suggested approaches to learning in this course include:
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Careful reading, discussion and understanding of the material presented in lectures.
Additional reading on and about the material presented in lectures to broaden the knowledge
base.
Paying attention throughout the tutorials, and asking questions when anything is not
understood.
Conscientiously working through the set tutorials and laboratory work.
Learning of the lecture material in preparation for examinations.
COURSE SCHEDULE AND ASSESSMENT
Part A:
Product Design Module (Dr Thai Nguyen)
Thursday 9:00-11:00 Elect Eng Rm G3
Week
1
2
3
4-7
8
9
10-12
13
Topic
Introduction to Product Design
Indentifying Product Functional Requirements
Loop Equations
Tolerance Analysis
Mid – Semester Test
Fit type Functional Requirements
Limit and Fits Analysis
Review
Please note: There may be minor changes to the schedule to suit exigencies.
Assessment:
In class assessment and assignment
Mid Session Test
End of session examination
24/02/2012
30%
20%
50%
3
MANF3100 Product and Manufacturing Design
Part B:
Manufacturing Technology Module (Prof Jun Wang)
Tuesday
15:00-17:00 Mech Eng Rm 405
Week
1 (28/02)
Topic
Introduction to manufacturing technology
Introduction to machining
Orthogonal and oblique cutting
Mechanics of chip formation, cutting forces and cutting power
Cutting Temperature and cutting fluids
Cutting tool materials, nomenclature of cutting tools
Tool wear and tool-life
Mid-semester break
Mid-semester test (covering weeks 1-6)
Practical machining operations – Turning operations
Lab based project (in 3 small groups), no lectures
Practical machining operations – Milling and grinding operations
Selection of cutting conditions, machining economics
Introduction of bulk deformation processes (extrusion)
Review (with Part C)
2 (06/03)
3 (13/03)
4 (20/03)
5 (27/03)
6 (03/04)
7 (17/04)
8 (24/04)
9 (01/05)
10 (08/05)
11 (15/05)
12 (22/05)
13 (29 May)
Please note: There may be minor changes to the schedule to suit exigencies. The experimental
work for the Lab based project may run over several days or weeks depending on Lab schedule
and may use other times other than those scheduled for the course.
Assessment:
Laboratory based project
10%
Mid Session Test
30%
End of Session Examination 60%
Part C:
Metrology Module (Prof Jun Wang)
Wednesday
15:00-17:00 Mech Eng Rm 405
Week
1 (29/02)
2 (07/03)
3 (14/03)
4 (21/03)
5 (28/03)
6 (04/04
7 (18/04)
8 (25/04)
9 (02/05)
10-12
13
Topic
Introduction, measurement errors and analysis
Length standards and linear measurement
Gauging and gauge design
Geometric errors, flatness and straightness measurement
Measurement of angles, squareness and Tapers
Surface texture, surface roughness & concentricity measurement
Mid-semester break
Mid-semester test (covering Weeks 1-6)
Public holiday
Lab project for Part B (no lecture)
Laboratory work (no lectures)
Revision (with Part B) on 29 May
Please note: There may be minor changes to the schedule to suit exigencies.
Assessment:
Laboratory Work
Mid Session Test
End of Session examination
30%
30%
40%
Additional assessment information
This course will be presented in three dependent sections: Product Design, Manufacturing
Technology and Metrology. These three sections are equally weighted, each section contributing
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MANF3100 Product and Manufacturing Design
33⅓% of the overall course mark. The minimum satisfactory performance requirement for the
course is an overall final mark of 50% and a total mark in each section of 40% or better. If the
total mark for each section is not greater than 40%, you will attain a mark of min {45%,
sum of marks for Parts A,B and C} and therefore fail the course. You will be required to
repeat the course in the following year (i.e. to repeat all the three components).
RESOURCES
Textbooks:
1.
Farmer, LE, Dimensioning and Tolerancing for Function and Economic Manufacture,
Blueprint Publications (1999)
Reference Books:
1.
2.
3.
4.
5.
6.
7.
Farmer, LE, Dimensioning and Tolerancing to AS1100.101-1992 and AS 1100.2011992, Standards Australia (SAA HB47-1993).
Williams, R A, Fundamentals of Dimensioning and Tolerancing, Edward Arnold,
1991.
Scarr, AJT, Metrology and Precision Engineering, McGraw Hill.
Gayler, JFW, and Shotbolt, CR, Metrology for Engineers, Cassell.
Kalpakjian, S and Schmid, SR, Manufacturing Engineering and Technology,
Prentice-Hall.
Kalpakjian, S, Manufacturing Processes for Engineering Materials, Addison Wesley.
Australian Standard AS1100, Parts 101 and 201, 1992.
COURSE EVALUATION AND IMPROVEMENT
Periodically student evaluative feedback on the course is gathered, using among other means,
UNSW's Course and Teaching Evaluation and Improvement (CATEI) process. Student feedback
is taken seriously, and continual improvements are made to the course based in part on such
feedback.
OTHER MATTERS
Administrative Matters
Information about each of the following matters is presented in a School handout, Administrative
Matters for All Courses, available from the School office separately or as part of The Guide. It is
essential that you obtain a copy, read it carefully and become familiar with the information, as it
applies to this course and to each of the other courses in which you are enrolled.
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Expectations of students (including attendance at lectures and tutorials/laboratory
classes/seminars; and computer use, for example, in the use of email and online discussion
forums)
Procedures for submission of assignments and the School’s policy concerning late
submission
Information on relevant Occupational Health and Safety policies and expectations:
www.ohs.unsw.edu.au
Examination procedures and advice concerning illness or misadventure
Use of Calculators
You will need to provide your own calculator, of a make and model approved by UNSW, for the
examination. The list of approved calculators is shown at
https://my.unsw.edu.au/student/academiclife/assessment/examinations/Calculator.html
It is your responsibility to ensure that your calculator is of an approved make and model, and to
obtain an Approved sticker for it from the School Office or the Engineering Student Centre prior to
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MANF3100 Product and Manufacturing Design
the examination. Calculators not bearing an Approved sticker will not be allowed into the
examination room.
Academic honesty and plagiarism
This is a serious matter and you must consider that whatever you submit does not contravene the
academic honesty and plagiarism policy of the university (http://www.lc.unsw.edu.au/plagiarism/).
If you do contravene this policy then the actions of the university can be severe to you as a
student.
Equity and diversity
Students who have a disability that requires some adjustment in their teaching or learning
environment are encouraged to discuss their study needs with the course convener prior to, or at
the commencement of, their course, or with the Equity Officer (Disability) in the Equity and
Diversity Unit (9385 4734 or www.studentequity.unsw.edu.au/content/default.cfm?ss=0). Issues
to be discussed may include access to materials, signers or note-takers, the provision of services
and additional exam and assessment arrangements. Early notification is essential to enable any
necessary adjustments to be made.
Professor Jun Wang
February 2012
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