This module aims to develop your skills and knowledge to help develop an understanding of engineering processes, materials, and design methods that you can build upon and utilise for the remainder of your studies.


There are several aspects to the module:

CAD:

Parametric modelling using a variety of appropriate features, references, constraints, and dimensions to effectively capture the design intent and maintain associativity through data management.

Assembly Design – Using appropriate joints and constraints to control the degrees of freedom, Design Accelerator Tools (Gears, Cams, Pulleys, and Belts etc), use standard fixings and fixtures from content centre / McMaster-Carr library.

Simulation: Introduction to Finite Element Analysis FEA and Computational Fluid Dynamics (CFD)

Engineering Drawings- produce drawings conforming to BS 8888:2020 ISO Standards including Geometric Dimension and Tolerancing, Bill of Materials, Surface Finish, Limits and Fits.

Basics of G&M codes and NC tool-pathing data for CNC machining of a metal component, laser cutting and 3D printing pre and post processing.

Product Data Management (PDM)

CADCAM 3 – 5 axis machining capabilities and limitations

Materials:

Introduction to Classifications of Materials

Materials Selection for design

Atomic Bonding & Crystal Structure

Properties & Applications of material groups and Ferrous/Non-Ferrous Alloys, Ceramics

The Design Process:

Defining Design-Research

Concept Generation and Development

Concept Screening and Selection

Testing, Evaluation and Reflection

Manufacturing Processes:

Shaping Processes including turning, milling, casting, forging, injection moulding.

Joining Process including, brazing, welding, bonding, bolting, riveting.

Finishing Process grinding, lapping, painting, anodising, galvanising.

Property Enhancing Processes Ferrous Metals

Property Enhancing Processes Non-Ferrous Metals

A 1-hour examination weighted at 30%, assessing learning outcomes 1. Meeting AHEP 4 Outcome: C13

A 3000 words project-based assignment weighted at 70%, assessing learning outcomes 1, 2, 3 and 4. Meeting AHEP 4 Outcomes: C4, C5, C12, C13, C15, C17

Professional Body requirements mean that a minimum overall score of 40% is required to pass a module, with each element of assessment requiring a minimum mark of 30% unless otherwise stated.

This module will enable you to gain understanding, apply knowledge, analyse and evaluate problems and create solutions through a variety of activities. It will include formal lectures and tutorials where software demonstrations and practical exercises will be undertaken. Regular formative feedback for teams as the project work progresses will be provided.

Demonstrate understanding and knowledge of the role of materials and manufacturing processes in Engineering Design and Development. (AHEP 4: C13)¿

Knowledge and Understanding¿

Demonstrate a basic level of understanding of CAD and CAE applications using appropriate Industry Standard Software. (AHEP 4: C4, C15)¿

Learning

Enquiry

Develop and critically analyse solutions for project-based tasks by using a structured methodology in the engineering design process to meet the wider customer needs. (AHEP 4: C5, C17)¿

Problem Solving

Analysis

Communication

Apply the knowledge of engineering and workshop practices for realisation of physical prototypes and recognising limitations. (AHEP 4: C12, C13)¿

Application

Reflection

Blackboard VLE Resources, Library facilities, Google Scholar

Office 365, Computer Aided Design Software i.e., Autodesk Fusion360/Inventor/AutoCAD

SmartZone: Additive manufacturing facilities

You will be expected to engage with a range of reading, which should include texts, journals, websites that are pertinent to the learning outcomes and the issues or areas that form the focus of the module. Indicative texts:

Bolton, W. (1998) Engineering materials technology, 3rd Edition, Butterworth-Heinemann, ISBN: 0750639172

Ashby, M. F (2010), Materials engineering, science, processing and design, 2nd ed, Butterworth-Heinemann, Oxford, ISBN: 1282552619

Cottrell, S. (2019) The Study Skills Handbook, 5th Edition, Hampshire: Palgrave Study Guides, ISBN: 9781137610898

Shih, R. H. (2022), Parametric modeling with Autodesk Inventor 2023, SDC Publications, Mission, KS, ISBN: 978163057506

Land, K. M. (2023) Improving CAD Designs with Autodesk Fusion 360: A Project-Based Guide to Modelling Effective Parametric Designs. Packt Publishing, Limited ISBN:9781800564497

Lefteri, C. (2019) Making It: Manufacturing Technologies for Product Design, 3rd Ed., Laurence King. ISBN: ¿9781786273277

Ulrich, K. T. and Eppinger, S. D. (2016) Product Design and Development. 6th ed. New York: McGraw-Hill Education. ISBN: 9780078029066

Young, T. M. (2021) Technical Writing A-Z: A Commonsense Guide to Engineering Reports and Theses, British English 2nd Edn. Pub: American Society of Mechanical Engineers ISBN: 9780791884621

This module will provide you an opportunity to understand the advantages of design processes, research, analyse and develop potential design solutions that can be realised from concept through to prototyping. You will document the stages of the design and development process demonstrating methodology and project management skills to achieve the set aims and objectives of the project.