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Tutorial Letter 101/0/2013Machine Design III

Year module

Department of Mechanical and Industrial

Engineering

This tutorial letter contains important

information about your module.

Bar code

MEA361B

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CONTENTS

1 INTRODUCTION AND WELCOME ................................................................................................ 31.1 Tutorial matter ................................................................................................................................. 32 PURPOSE OF AND OUTCOMES FOR THE MODULE ................................................................ 32.1 Purpose .......................................................................................................................................... 32.2 Outcomes ....................................................................................................................................... 33 LECTURER AND CONTACT DETAILS ......................................................................................... 33.1 Lecturers ......................................................................................................................................... 33.2 Department ..................................................................................................................................... 33.3 University ........................................................................................................................................ 34 MODULE RELATED RESOURCES............................................................................................... 44.1 Prescribed books ............................................................................................................................ 44.2 Recommended books ..................................................................................................................... 44.3 Electronic Reserves (e-Reserves) .................................................................................................. 45 STUDENT SUPPORT SERVICES FOR THE MODULE ................................................................ 46 MODULE SPECIFIC STUDY PLAN ............................................................................................... 47 MODULE PRACTICAL WORK AND WORK INTEGRATED LEARNING ..................................... 68 ASSESSMENT ............................................................................................................................... 68.1 Assessment plan ............................................................................................................................ 68.2 General assignment numbers ......................................................................................................... 68.2.1 Unique assignment numbers .......................................................................................................... 68.2.2 Due dates of assignments .............................................................................................................. 78.3 Submission of assignments ............................................................................................................ 78.4 Assignments ................................................................................................................................... 79 EXAMINATIONS .......................................................................................................................... 1610 OTHER ASSESSMENT METHODS ............................................................................................. 1611 FREQUENTLY ASKED QUESTIONS .......................................................................................... 1612 STUDENT AND MENTOR DECLARATIONS .............................................................................. 17Please note / important notes:

You must have a mentor for this subject.

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1 INTRODUCTION AND WELCOME

Dear Student

1.1 Tutorial matterSome of this tutorial matter may not be available when you register. Tutorial matter that is notavailable when you register will be posted to you as soon as possible, but is also available onmyUnisa.

2 PURPOSE OF AND OUTCOMES FOR THE MODULE

2.1 PurposeTo complete a design project.

2.2 OutcomesCompleted design project.

3 LECTURER AND CONTACT DETAILS

3.1 LecturersYour Lecturer is Mr. P KrugerTel nr: (011) 471-2137Fax nr: (011) 471 3054e-mail: pkruger@unisa.ac.zaContact Times: Mondays to Fridays from 08h00 to 12h00

The Subject Lecturer will assist you with any problems regarding the academic content ofyou subject.

3.2 DepartmentMechanical and Industrial Engineering

Tel nr: (011) 471-2963Fax nr: (011) 471-3054

3.3 University

General contact details for the university can be found in my Studies @ unisa brochure.When contacting the university remember to use your student number for identificationpurposes.

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4 MODULE RELATED RESOURCES

4.1 Prescribed booksThere are no prescribed books for this module.

4.2 Recommended booksThere are no prescribed books for Machine Design III. If you would like to know more aboutthe design process and its management, you will find the following book useful:Engineering Design - A materials and Processing Approach by Dieter, GE, 1st Edition.McGraw-Hill Book Company, 1987.ISBN 07-100185-9.

The following books will be useful to show you the format of a project report.Completing Your Thesis by Nelleke Bak , 1st Edition, Van Schaik Publishers, 2004, ISBN9780627025570

Writing Great Research Papers by Laurie Rozakis, 2nd

Edition, McGraw-Hill BookCompany, 2007, ISBN 9780071488488

In addition, there are a number of books available from the UNISA at the Florida Campuslibrary relating to the subject of design and its applications. These books give furtherexamples and additional explanations on the various aspects covered in the course. Isuggest that, whenever possible, you peruse these books. It will broaden your knowledge ofthe particular field and help you with your studies and preparation for the examinations.

These books should be available from bookstores. If you cannot find it, you can order itfrom either kalahari.net or amazon.com.

4.3 Electronic Reserves (e-Reserves)There are no e-Reserves for this module

5 STUDENT SUPPORT SERVICES FOR THE MODULE

Important information appears in your my Studies @ Unisa brochure.

6 MODULE SPECIFIC STUDY PLAN

Use your my Studies @ Unisa brochure for general time management and planning skills.

For Machine Design III you are required to submit three progress reports on yourselected topic each time a particular phase of your design has been completed and as

also discussed in the Design Project Flow Diagramplus a final project report on your

design.

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USER REQUIREMENT SPECIFICATION

FIRST PROGRESS REPORTDue date: 2 May 2013

LITERATURE STUDYALTERNATIVE CONCEPTSDECISION MAKING MATRIX

FUNCTIONAL ANALYSIS

SECOND PROGRESS REPORTPRELIMINARY DESIGN REVIEW

Due date: 3 J une 2013

DESIGN DETAIL INCLUDING:ANALYSIS AND STRENGTH CALCULATIONS

CHOICE OF MATERIALSMANUFACTURING SCHEDULE

MAINTENANCE ANALYSISRELIABILITY ANALYSIS

COST ANALYSISMASS FACTORS

TECHNICAL SPECIFICATIONDRAWINGS

THIRD PROGRESS REPORTDESIGN REVIEW

Due date: 5 August 2013

FINAL REPORTDue Date: 30 September 2013

FINAL EVALUATION

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7 MODULE PRACTICAL WORK AND WORK INTEGRATED LEARNING

There are no practicals for this module.

8 ASSESSMENT

MENTORSHIPBefore a student can start h is/her design project he/she will have to get a mentor inhis/her workplace to guide them through the project process. The followingrequirements relating to the mentor must be met:

i) The mentor should be registered with the Engineering Council of South Africa(ECSA) and have at least 4 years relevant experience. (Registration numberrequired with first assignment)

ii) If the mentor is not registered with ECSA he needs to have 6 years relevantexperience and a CV must be sent with the first assignment before the mentorwil l be accepted.

iii) A mentor should be adequately qualified in the relevant engineering field.

8.1 Assessment planAll Three Assignments (Progress reports) have to be submitted by every student before his finalreport can be submitted. The contents of these three assignments will be:1. Project Proposal and Mentor information. This assignment is due by the beginning of May.

2. Literature Study and decision matrix. This assignment is due by the beginning of J une.3. Development of Design specifications and procedures, including calculations, drawings andspecifications. This assignment is due by the beginning of August.

All assignments have to be submitted in typed format. No hand written assignments will beaccepted. Drawings can be done by hand.

8.2 General assignment numbers

Assignments are numbered consecutively per module, starting from 01

8.2.1 Unique assignment numbers

The unique number for assignment 1 is: 179806.The unique number for assignment 2 is: 384472.The unique number for assignment 3 is: 320655.The unique number for the Portfolio (Final Report) is: 350090.

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8.2.2 Due dates of assignments

ASSIGNMENTNUMBER

YEAR MARKCONTRIBUTION

CONTRIBUTIONTOWARDS FINALMARK

DUE DATES FOR

ASSIGNMENTS

1 Compulsory 20 % 4.0% 2 May 2013

2 Compulsory 40 % 18% 3 June 20133 Compulsory 40 % 18% 5 August 2013Final Report 0 60 30 September 2013

8.3 Submission of assignments

No Late Assignment Submissions Will Be Accepted.

Keep A Clear Copy Of The Assignment For Your Own Reference. This Is Important, AsAssignments Do Get Lost.

Submissions of Assignments Must Be In Accordance to the My Studies @ UNISA.

It Is Your Responsibility To Check Whether Unisa Has Received Your Assignment By

Contacting The Call Centre Two (2) Weeks After Submission.Assignments 1, 2 and 3 may be submitted through my Unisa. The final report (assignment 4) must

be submitted through the post. Remember that for the final report 2 bound copies and the

PowerPoint presentation must be submitted.

8.4 Assignments

8.4.1 Assignment 1

For assignment 1 the following will help you with the proposal. Remember to include your mentordetails in this assignment.

The most important step in a design process is to define what the problem is you are trying toaddress and solve. The definition of the problem must be as broadly defined as possible andshould include writing down a formal problem statement also known as a Users Requirement.

8.4.1.1 GENERAL

In order for you to learn and understand the complete design process, your final design reportmust include all the required details to prove that you are conversant with this process. TheUsers Requirement is merely the first step in this process. For Machine Design III, it is assumedthat your client (and I happen to be your client) lacks the know-how and technical expertise tospecify his particular requirements in technical terms. It is therefore left to you to do so and topresent him with a non-technical report explaining how you understand the client's needs andhow you intend going about satisfying them. Above all, ensure that your viewpoint agrees totallywith that of your client otherwise you start off on the wrong premise and your final design maydiffer substantially from that which your client had actually expected. In Figure 1 this situation isexplained graphically showing how a design depends on the viewpoint of the person defining theproblem.

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8.4.1.3 ASPECTS TO BE ADDRESSED IN REQUIREMENT

The Users Requirement should address as specifically as possible what the design intendsto accomplish. It must include

* Background to the requirement : Reasons for introducing it.* Objectives and goals of the requirement : What will it be used for.* Environment in which the requirement is to operate.* Any constraints placed on the design.* Evaluation criteria against which the final design will be evaluated.

A Users Requirement is the main output of the initial phase of a design in which the basicproblem is formulated. It describes the desired capability (process, component or system) inoperational terms, i.e. how it is to operate in the user's environment. It is not a specification ofa system. Of course, in a fair amount of cases the user may totally or at least in part, specify the

system. Obviously, the more a Users Requirement becomes a specification, the moreopportunities for optimisation are pre-empted.

8.4.1.3.1 Background to the Requirement

The reasons for introducing the requirement must be given, e.g. to reduce costs, improvereliability.

8.4.1.3.2 Objective and goal of the Requirement

The ultimate aim for which the requirement is to be used must be stated. It must include a set of

requirements that must be met. It may also include further requirements that are worth statingbut are not hard and fast. It will help to understand certain particular preferences by the client.

8.4.1.3.3 Environment in which Requirement is to operate

This is to be described in terms of :

* The support policy, describing how the user would like to support the system. It shouldaddress the following :

- maintenance and repair policies.

- operating and support personnel and required skills.- training and training equipment.- documentation for operations and support.- provision of spares, repair parts and supplies.- facilities.- packaging, handling, storage and transportation.

* The external interfaces to other co-functioning systems, specifying only those externalinterfaces in cases where such co-functioning systems could constrain the design andeventual acquisition process.

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Step 3 :

The rating R for each criteria and for each concept is now multiplied with theweighting factor W obtained in Table 1 to obtain a final value weight as shown in

Table 2 :TABLE 2 : WEIGHTING OF CRITERIA PER CONCEPT

Concept 1 Concept 2 Concept 3 Concept 4

Criteria W R WxR R WxR R WxR R WxR

Technical Performance 5 6 30 3 15 4 20 2 10

Reliability 11 5 55 4 44 4 44 3 33

Maintainability 11 4 44 1 11 2 22 4 44

Life Cycle Cost 9 3 27 3 27 2 18 5 45

Development Risk 0 5 0 1 0 1 0 4 0

Production Rate 4 1 4 6 24 2 8 3 12

Schedule 6 2 12 4 24 2 12 3 18Safety 9 3 27 4 36 1 9 5 45

TOTAL 199 181 133 217

Step 4 :

From Table 2 it is obvious that concept 4 has received the highest weighting. Onthe basis of your rating this concept is therefore the most suitable.

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8.4.4 Portfolio

For the final report you need to submit 2 bound copies plus a PowerPoint presentation. Thefollowing should be covered in your report.

If the following four i tems are not adhered to you cannot pass the subject.Bound

2 CopiesPowerPoint presentationMentor Information

LayoutFront Page (Project Title included)Abstract

Table of Content (Page numbers)List of Figures (Page numbers)List of Tables (Page numbers)List of SymbolsPage numberingNumbering

Body of ReportIntroductionLiterature StudyAlternative ConceptsDecision Making MatrixFunctional Analysis

Analysis and Strength CalculationsChoice of MaterialsManufacturing ScheduleMaintenance ScheduleReliability AnalysisCost AnalysisBibliography / References

AppendicesTechnical Drawings

Mentor informationStudent declaration

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12 STUDENT AND MENTOR DECLARATIONS

UNISA

DEPARTMENT OF MECHANICAL ENGINEERING

MACHINE DESIGN III (MEA361B)

DECLARATION BY STUDENT

I .............................................................. declare that the work contained in my designproject report entitled....................................................................................................................................... forthe subject Machine Design III, is my own work and has not been submitted to anyother tertiary institution as a design project....................................... .....................................Date Signature of student

.....................................Name in print

.....................................

Student numberWitnesses :

.....................................

.....................................

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UNISA

DEPARTMENT OF MECHANICAL ENGINEERING

MACHINE DESIGN III (MEA361B)

DECLARATION BY MENTOR

I, ................................................ acting as mentor for........................................................... in the subject Machine Design III, declare that tothe best of my knowledge the work contained in the design project report entitled.................................................................................................................................... by........... ................................... Student No. ............................ is his/her own work.

...................................... .....................................Date Signature of mentor

.....................................Name in print

.....................................Telephone No.

.....................................ECSA Registration No