The module provides the student with the necessary tools and skills to tackle advanced product design tasks using real world engineering problems such as the design of a single seater race car. A number of product design briefs are presented to the class from which individuals can choose a project. These projects could include chassis design, body design, upright, suspension, air intake, brake box etc. The students will follow a systematic design approach to design defining the problem, generating concepts, analysing and evaluating these concepts, creating full 3d models and working drawings and final physical model using RP technologies. This module is 100% continuous assessment where a number of discrete assignments are assessed throughout the year.
Engineering design process: Definition of engineering design, players in the design process, user centered design, engineering design process, steps in engineering design process, determination of need and problem definition, conceptualisation, Preliminary design, detailed design.
Management of the design process: Project management, planning and scheduling, work breakdown, design structure matrix, activity network, analyses, time analyses, Gantt chart, directing.
Anthropometrics / Ergonomics/ Aesthetics: Distinguish between ergonomics and anthropometrics, man machine relationship, The “Average Person” / 95th percentile, use of Anthropometric data, types of displays/controls, aesthetic design.
Design Evaluation: Use of QFD (Quality Function Deployment) and house of quality analysis, decision matrices.
Advanced Solid Modelling techniques: Top-down/bottom assembly design strategies, design within the concept of an assembly, advanced surface modelling, collision detection, motion analysis, weldments, sheet metal design, advanced rendering techniques.
Computer Aided Engineering (CAE): FEA analysis, thermal analysis, fatigue, Computational Fluid Dynamics (CFD), sustainability analysis, parametric modelling.
Rapid Prototyping (RP): Selection of appropriate RP process (FDM, SLA, SLS, 3d printing) to post process solid model designs to create scaled rapid prototypes.
Detailed design and analysis: Application of engineering calculations within the design process, yield/ultimate strength, safety factor, fatigue loading, bearing selection, shaft design and torque analysis, deflection and stiffness.
Design presentation / Detailed drawings. Creating working drawings with detailed dimensions and tolerances. Generation of BOM files, weldment cut lists, exploded views, photo rendering.
Design presentations & report: Students will be required to present and justify their designs at the end of the module. They will also be required to produce a technical report in compliance with engineering reporting standards.
