Design Project Guidelines Sem II 2014_2015 - Copy

BDA 31203 Project 2nd Semester 2014/2015

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DEPARTMENT of MATERIAL & ENGINEERING DESIGN

FACULTY of MECHANICAL & MANUFACTURING ENGINEERING

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

BDA 31203 MECHANICAL COMPONENT DESIGN (MCD)

Instructions: This is a group based design project. Students caught for plagiarism

will be given ZERO (0) for the project.

MCD Project

Design project is one of the important aspects in this course where it brings 40% of marks.

This design project is target to meet the requirements of the University which offer high quality

learning through student-centered learning by implementation of a PO-PBL (Project Oriented -

Problem Based Learning) activity.

At the end of this project, students will be able to improve their technical report writing skills

with the ability to:

- justify a design project in a formal report.

- perform and present design calculations in a neat and organized manner.

- present the outcomes of the design in the form of engineering drawings.

The project will be carried out in groups where each group has 3 to 5 members. Theme of the

project is Designing a Gearbox / Transmission System. In this project, students have to

design a suitable gearbox / transmission system which applied whether at an escalator system,

motorised trolley or trommel machine that satisfied with power / torque requirement at the

machine and power / torque provide from the motor. Students also must analyze all mechanical

components inside the gearbox / transmission system such as shaft, bearing and gears in term of

their strength, static and fatigue safety, reliability, dynamic motion, life estimation and others

like what have been learned in the theory to predict or simulate the real physical system and

product behaviour. Then students also need to come out with engineering drawing of their

design (assembly drawing ; exploded drawing + BOM ; detail parts drawing) by using suitable

CAD Software.


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The project will be evaluated as follows:

Final Project Report (35 marks)

Soft Skill (Life Long Learning) ( 5 marks)

TOTAL (40 marks)

Example of gearbox

Example of Escalator system


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Example of motorised trolley

Example of Trommel Machine at gold mining industry


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DRAF of PROJECT REPORT ASSESSMENT

(BDA 31203)

NO CONTENTS MARKS

1.0

INTRODUCTION

1.1 Group Description 1.2 Product / Project Background 1.3 Objective & Design Scope 1.4 Milestone / Planning Chart

10 %

2.0

DESIGN & ANALYSIS

2.1 Concept Development (Sketching) 2.2 Engineering Analysis

Fundamental Analysis (Create Situation with basic analysis, Power Required, Motor selection, Gear Ratio needed)

Gear Fundamental Analysis (module, No. of teeth, Pitch Diameter, Torque, rpm, Acting load, contact ratio)

Gear Failure Analysis (AGMA Bending Failure, AGMA Pitting Failure, Bending and wear factors of safety are minimized, Gear

face width and Qv are reasonable. Material selection is discussed.

Shaft center-distance constraints met. Especially well done

drawings.)

Shaft Analysis (Shaft material selection discussed, min diameter required, stress concentration are included, Fatigue and yield

factors of safety are met., tolerances and fitting. Especially well

done drawings.)

Bearing Analysis (Bearing forces correctly resolved. Bearing sizes are consistent with other calculations. Correct procedures

used.)

Housing Analysis (Housing is designed so that all components can fit and be assembled. Sound engineering effort made to

reduce overall weight. Innovative design (clear and reasonable).

Especially well done drawings.)

2.3 Detail design (engineering drawing) - Assembly drawing

- Explode Drawing with BOM

- Component detail drawing

5 %

10 %

10 %

15 %

15 %

5 %

5 %

10 %

3.0 CONCLUSION & RECOMMENDATION 10 %

4.0 REFERENCES 5 %

TOTAL

100 %

W6 W7 W8 W9 W10 W11 W12 W13 W14

29-Mar 5-Apr 19-Apr 26-Apr 3-May 10-May 17-May 24-May 31-May

~ ~ ~ ~ ~ ~ ~ ~ ~

4-Apr 11-Apr 25-Apr 2-May 9-May 16-May 23-May 30-May 4-Jun

Done

Actual

Gear Fundamental Analysis

Gear Failure Analysis

Shaft Analysis

Bearing Analysis

Housing Analysis

7 Submit Report & Final Presentation

Marks Planning

2.1

2.2

Component Detail Drawing

2.3

5 Conclusion & Recommendation

6 Report Writing

1.1

1.4

3 Design & Analysis Concept Development

Engineering Analysis

Fundamental Analysis

Detail Design (Eng. Drawing)

Asembly Drawing

Explode Drawing with BOM

Group Logo

Project Title Selection

2 Introduction Group Description

Product / Project Background

1.3 Objective & Design Scope

Milestone & Planning Chart

1.0

1.4 PROJECT DESIGN PLANNING CHART

No. Activities Sub-topic

1 Form Group Select Team Members

Group Organization / Post

Group Name

FACULTY OF MECHANICAL & MANUFACTURING ENGINEERING

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

BDA 31203 - DESIGN PROJECT REPORT - GROUP NAME :-

(Evaluation Criteria, [5] - Very Good, [4] - Good, [3] - Intermediate, [2] - Weak, [1] - Very Weak )

Introduction (10%)

Group Description (W = 0.4) 5 4 3 2 1

Product / Project Background (W = 0.6) 5 4 3 2 1

Objective & Design Scope (W = 0.4) 5 4 3 2 1

Milestone / Planning Chart (W = 0.6) 5 4 3 2 1

Design and Analysis (75%)

Concept Development [Sketching] (5%) Addresses the entire system (global picture) (W = 0.2) 5 4 3 2 1(W = 0.2) Shows how each component fits together (W = 0.2) 5 4 3 2 1(W = 0.2) Labels components to identify key features and provides description (W = 0.2) 5 4 3 2 1(W = 0.2) Shows approximate dimensions (W = 0.2) 5 4 3 2 1(W = 0.2) Provides realistic visualization (3D sketching + shading) (W = 0.2) 5 4 3 2 1

Engineering Analysis

Fundamental Analysis (10%) Power required are determine with proper justification and calculation (W = 0.8) 5 4 3 2 1

Motor is been selected properly with proof and reasonable power (W = 0.6) 5 4 3 2 1

Gear ratio is determine accordingly (W = 0.6) 5 4 3 2 1

Gear Fundamental Analysis (10%) Number of gear teeth are determine properly (W = 0.4) 5 4 3 2 1

Diameter, torque and RPM are calculate properly (W = 0.6) 5 4 3 2 1

Module selection are reasonable (W = 0.2) 5 4 3 2 1

Contact ratio analysis are also included (W = 0.4) 5 4 3 2 1

Acting load at each gear are been calculated correctly (W = 0.4) 5 4 3 2 1

Gear Failure Analysis (15%) Material selection has been discuss properly (W = 0.4) 5 4 3 2 1

Determination of face width and Qv are reasonable (W = 0.2) 5 4 3 2 1

Correct prosedure used to calculate AGMA bending and pitting stress (W = 1.0) 5 4 3 2 1

Describe with details (W = 0.5) 5 4 3 2 1

Used proper justification and assumption (W = 0.5) 5 4 3 2 1

Bending and pitting safety factor are in acceptable range (W = 0.4) 5 4 3 2 1

Shaft Analysis (15%) Correct resolve forces at the shaft free body diagram (W = 0.6) 5 4 3 2 1

Calculate bending load with proper bending moment diagram (W = 0.6) 5 4 3 2 1

Shaft material selection is also been discussed (W = 0.2) 5 4 3 2 1

Include with proper stress concentration factor analysis (W = 0.4) 5 4 3 2 1

Calculated minimum diameter required at each gear (W = 0.4) 5 4 3 2 1

Fatigue and yield factors of safety are met (W = 0.4) 5 4 3 2 1

Included with tolerances and fitting analysis at each shaft (W = 0.4) 5 4 3 2 1

Bearing Analysis (5%) Bearing forces have been correct resolved (W = 0.4) 5 4 3 2 1

Correct prosedures used to determine bearing load rating (W = 0.4) 5 4 3 2 1

Suitable bearing size have been selected (W = 0.2) 5 4 3 2 1

Housing Analysis (5%) All component are fit well and assemble properly (W = 0.2) 5 4 3 2 1

Fitting analysis are also included at bearing support (W = 0.3) 5 4 3 2 1

Engineering effort to reduce overall weight (W = 0.2) 5 4 3 2 1

Innovative design (clear and reasonable) (W = 0.3) 5 4 3 2 1

2.1

2.2

1.3

1.4

TOTAL (10%)

2

No. Evaluate Item Marks

1

1.1

1.2

(Evaluation Criteria, [5] - Very Good, [4] - Good, [3] - Intermediate, [2] - Weak, [1] - Very Weak )

No. Evaluate Item Marks

Detail Design - Project Drawing (10%) Show assemble component in 3D drawing with adequate clarity (W = 0.3) 5 4 3 2 1

Use exploded views with BOM to show assemble of parts (W = 0.3) 5 4 3 2 1

Provide adequate dimensioning and tolerances to build part properly (W = 0.4) 5 4 3 2 1

Adheres to ANSI standard (W = 0.4) 5 4 3 2 1

Arrange the drawing in systematic approach (W = 0.3) 5 4 3 2 1

Fill all the information required in the drawing title block (W = 0.3) 5 4 3 2 1

Conclusion and Recommendation (10%) Conclude on Project Understanding, results and Achievement (W = 1.0) 5 4 3 2 1

Recommendation (W = 1.0) 5 4 3 2 1

References (5%)

Use proper format (W = 0.5) 5 4 3 2 1

Well presented and organized (W = 0.5) 5 4 3 2 1

Bonus

Report Appearance Follow the format / Have table of contents (W = 0.5) 5 4 3 2 1

Contents are organize well & report is binding properly (W = 0.5) 5 4 3 2 1

TOTAL (5%)

OVERALL MARKS (100%)

TOTAL (10%)

4

TOTAL (5%)

5

2.3

TOTAL (75%)

3

Criteria 1 2 3 4 5

Met

ho

d u

se t

o f

ind

info

rmat

ion

Uses a limited number of

different technologies, locates

basic resource and ineffective

use of skimming and scanning

given information

appropriately with assistance

Usually use a variety of

technologies, obtains relevant

information but less effective

use of skimming and scanning

Consistently and accurately

uses a variety of technologies

to access and obtain relevant

wide-ranging information

quickly using skimming and

scanning

Org

aniz

ing

, E

val

uat

ing

and

In

teg

rati

ng

Info

rmat

ion

Uses given information

appropriately with assistance

Adds given information

appropriately to own

information

Integrates given information

with own information

Sel

f-es

teem

Limited skills of listening,

sharing/connecting ideas,

communication technique, self-

focus and uses a variety of

productivity tools.

Requires skills of listening,

sharing/connecting ideas,

communication technique, self-

focus and uses a variety of

productivity tools.

Consistently uses skills of

listening, sharing/connecting

ideas, communication

technique, self-focus and uses

a variety of productivity tools.

Mo

tiv

atio

n Sets priorities to achieve goals

and directs own learning only

with assistance and rarely

begins without prompting

Usually sets priorities to

achieve goals, directs own

learning with minimal

prompting and begins work

without prompting

Consistently sets priorities to

achieve goals, directs own

learning with minimal

prompting and begins work

without prompting

Ind

epen

den

t Use of time and uses outside

sources for learning are

moderately effective, and

occasionally needs

encouragement to do work.

use of class time is

effective,find and use some

outside resources effectively

and requires no encouragement

to do work.

Use of class time in highly

effective, incorporates a

variety of resources in a highly

effective manner and works in

a self-directed manner and

encorages others.

SOFT SKILL ASSESSMENT WITH CUMMULATIVE RUBICC

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Documents

Design Project Guidelines Sem II 2014_2015 - Copy