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Design for Manufacture

Unit Code: HES4250




Duration

Contact Hours

Campus

Prerequisite

Corequisite

1 Semester

60 hours

Hawthorn

200 credit points.

Nil

Credit Points: 12.5 Credit Points

Related Course/s:

A unit of study in Bachelor of Engineering (Product Design Engineering) and an elective unit of study in the Bachelor of Engineering (Robotics and Mechatronics) and Bachelor of Engineering (Robotics and Mechatronics)/Bachelor of Commerce, and Bachelor of Engineering (Mechanical Engineering).

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Aims & Objectives:

During the unit, we aim to:

  • Provide an understanding of the importance of Design for Manufacture in manufacturing industry
  • Develop a competence in the design of tooling, robot grippers, design for assembly and quality control systems
  • Give students the opportunity to develop an understanding of die design and heat transfer mechanisms
  • Provide students with the opportunity to experience peer reviewed oral presentations
  • Develop computer aided drafting skills for design purpose

At the completion of this unit, students should be able to:

  • Understand the need for product features to enable easier assembly
  • Select suitable equipment for transfer of products on assembly line
  • Carry out calculations for decision making in the design of forging dies
  • Design die-set parts for efficient forging of hot, warm or cold products
  • Analyse the need for plastic flow in die cavity
  • Design plastic mould cavity for efficient product manufacture
  • Apply knowledge of industrial robot effectors to manufacturing processes
  • Design drill jigs and fixtures for efficient manufacturing of products
  • Apply Australian Standards to design quality control processes
  • Carry out reliability calculations on block diagram design
  • Completion of computer aided project on parametric design of manufacturing tools

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Teaching Methods:

Lectures (48 hours), Computer lab/Project (12 hours)

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Assessment:

Design project (30%), Examination (70%)

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Generic Skills Outcomes:

In this unit, students are expected to enhance the Key Generic Skills below as recognised by Engineers Australia. The Unit Outline explains how these outcomes will be achieved.
  • Ability to apply knowledge of basic science and engineering fundamentals
  • Ability to communicate effectively, not only with engineers but also with the community at large
  • Ability to undertake problem identification, formulation and solution
  • Ability to utilize a systems approach to design and operational performance
  • Ability to function effectively as an individual and in a multi-disciplinary and multi-cultural teams, with the capacity to be a leader or manager as well as an effective team member
  • Understanding of the principles of sustainable design and development.
  • Understanding of professional and ethical responsibilities and commitment to them
  • Expectation of the need to undertake lifelong learning, and capacity to do so

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Content:

Design for assembly (10%):
Design for assembly, methods of assembly. Feed mechanisms; manual and automated, part transfer, insertion and fastening
 
Die design (24%):
Design of dies for metal forming processes: forging dies, cold, warm and hot forging, forging sequence. Design of diesets for die casting and plastic moulding, heat analysis
 
Design for industrial robots (10%):
Robot end effector design. Robot applications: materials handling, palletising, welding, glueing. Robot dynamics: cartesian and polar configurations, external load, acceleration and forces
 
Design of fixtures and gauges (8%):
Locating and clamping, jig types and construction, bushing types and application. Standard fixtures, special fixture designs. Design of gauges
 
Quality control and reliability (16%):
Control charts for variable and attribute data, process capability, Pareto diagrams, acceptance sampling, incoming and final inspection, quality rating. Reliability of systems, modes of failure, mean time to failure
 
Computer laboratory (32%):
Using parametric and CAD software for tooling design

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Reading Materials:

All notes and reading material will be provided through Swinburne Blackboard intranet.

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References:

Sherif, D. El Wakil, Processes and Desing for Manufacturing, 2nd ed., PWS Publ. Co.,1998
Hoffman, H., Fundamentals of Tool Design, 3rd ed., Society of Manufacturing Engineers, 1991
Dieter, G.E., Engineering Design: A Materials and Processing Approach, 2nd ed., McGraw
Smith, D., Die design / Metal forming, 3rd ed., Society of Manufacturing Engineers, 1990
Grover, MP et al., Industrial Robotics: Technology, Programming and Applications, McGraw Hill, 1986

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