MEA361B/101/0/2013

Tutorial Letter 101/0/2013

Machine Design III

MEA361B Year module

Department of Mechanical and Industrial Engineering
This tutorial letter contains important information about your module.

Bar code

CONTENTS
1 1.1 2 2.1 2.2 3 3.1 3.2 3.3 4 4.1 4.2 4.3 5 6 7 8 8.1 8.2 8.2.1 8.2.2 8.3 8.4 9 10 11 12 INTRODUCTION AND WELCOME ................................................................................................ 3 Tutorial matter ................................................................................................................................. 3 PURPOSE OF AND OUTCOMES FOR THE MODULE ................................................................ 3 Purpose .......................................................................................................................................... 3 Outcomes ....................................................................................................................................... 3 LECTURER AND CONTACT DETAILS......................................................................................... 3 Lecturers ......................................................................................................................................... 3 Department ..................................................................................................................................... 3 University ........................................................................................................................................ 3 MODULE RELATED RESOURCES............................................................................................... 4 Prescribed books ............................................................................................................................ 4 Recommended books ..................................................................................................................... 4 Electronic Reserves (e-Reserves) .................................................................................................. 4 STUDENT SUPPORT SERVICES FOR THE MODULE ................................................................ 4 MODULE SPECIFIC STUDY PLAN ............................................................................................... 4 MODULE PRACTICAL WORK AND WORK INTEGRATED LEARNING ..................................... 6 ASSESSMENT ............................................................................................................................... 6 Assessment plan ............................................................................................................................ 6 General assignment numbers ......................................................................................................... 6 Unique assignment numbers .......................................................................................................... 6 Due dates of assignments .............................................................................................................. 7 Submission of assignments ............................................................................................................ 7 Assignments ................................................................................................................................... 7 EXAMINATIONS .......................................................................................................................... 16 OTHER ASSESSMENT METHODS............................................................................................. 16 FREQUENTLY ASKED QUESTIONS .......................................................................................... 16 STUDENT AND MENTOR DECLARATIONS .............................................................................. 17

Please note / important notes:

You must have a mentor for this subject.

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INTRODUCTION AND WELCOME

Dear Student 1.1 Tutorial matter Some of this tutorial matter may not be available when you register. Tutorial matter that is not available when you register will be posted to you as soon as possible, but is also available on myUnisa.

PURPOSE OF AND OUTCOMES FOR THE MODULE

2.1 Purpose To complete a design project. 2.2 Outcomes Completed design project.

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3.1

LECTURER AND CONTACT DETAILS

Lecturers Your Lecturer is Mr. P Kruger Tel nr: (011) 471-2137 Fax nr: (011) 471 3054 e-mail: pkruger@unisa.ac.za Contact Times: Mondays to Fridays from 08h00 to 12h00 The Subject Lecturer will assist you with any problems regarding the academic content of you subject. Department Mechanical and Industrial Engineering Tel nr: (011) 471-2963 Fax nr: (011) 471-3054 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 identification purposes.

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3.3

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4.1

MODULE RELATED RESOURCES

Prescribed books There are no prescribed books for this module. Recommended books There are no prescribed books for Machine Design III. If you would like to know more about the 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, ISBN 9780627025570 Writing Great Research Papers by Laurie Rozakis, 2nd Edition, McGraw-Hill Book Company, 2007, ISBN 9780071488488 In addition, there are a number of books available from the UNISA at the Florida Campus library relating to the subject of design and its applications. These books give further examples and additional explanations on the various aspects covered in the course. I suggest that, whenever possible, you peruse these books. It will broaden your knowledge of the 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 it from either kalahari.net or amazon.com.

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4.3

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

STUDENT SUPPORT SERVICES FOR THE MODULE

Important information appears in your my Studies @ Unisa brochure.

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 your selected topic each time a particular phase of your design has been completed and as also discussed in the Design Project Flow Diagram plus a final project report on your design.

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USER REQUIREMENT SPECIFICATION

FIRST PROGRESS REPORT Due date: 2 May 2013 LITERATURE STUDY ALTERNATIVE CONCEPTS DECISION MAKING MATRIX FUNCTIONAL ANALYSIS

SECOND PROGRESS REPORT PRELIMINARY DESIGN REVIEW Due date: 3 June 2013

DESIGN DETAIL INCLUDING: ANALYSIS AND STRENGTH CALCULATIONS CHOICE OF MATERIALS MANUFACTURING SCHEDULE MAINTENANCE ANALYSIS RELIABILITY ANALYSIS COST ANALYSIS MASS FACTORS TECHNICAL SPECIFICATION DRAWINGS

THIRD PROGRESS REPORT DESIGN REVIEW Due date: 5 August 2013

FINAL REPORT Due Date: 30 September 2013

FINAL EVALUATION

MODULE PRACTICAL WORK AND WORK INTEGRATED LEARNING

There are no practicals for this module.

ASSESSMENT
MENTORSHIP Before a student can start his/her design project he/she will have to get a mentor in his/her workplace to guide them through the project process. The following requirements 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 number required with first assignment) If the mentor is not registered with ECSA he needs to have 6 years relevant experience and a CV must be sent with the first assignment before the mentor will be accepted. A mentor should be adequately qualified in the relevant engineering field.

ii)

iii)

8.1 Assessment plan All Three Assignments (Progress reports) have to be submitted by every student before his final report 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 June. 3. Development of Design specifications and procedures, including calculations, drawings and specifications. This assignment is due by the beginning of August. All assignments have to be submitted in typed format. No hand written assignments will be accepted. 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

ASSIGNMENT NUMBER YEAR MARK CONTRIBUTION CONTRIBUTION TOWARDS FINAL MARK

DUE DATES FOR ASSIGNMENTS

1 Compulsory 2 Compulsory 3 Compulsory Final Report 8.3

20 % 40 % 40 % 0

4.0% 18% 18% 60

2 May 2013 3 June 2013 5 August 2013 30 September 2013

Submission of assignments No Late Assignment Submissions Will Be Accepted. Keep A Clear Copy Of The Assignment For Your Own Reference. This Is Important, As Assignments 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 mentor details in this assignment. The most important step in a design process is to define what the problem is you are trying to address and solve. The definition of the problem must be as broadly defined as possible and should 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 report must include all the required details to prove that you are conversant with this process. The Users Requirement is merely the first step in this process. For Machine Design III, it is assumed that your client (and I happen to be your client) lacks the know-how and technical expertise to specify his particular requirements in technical terms. It is therefore left to you to do so and to present him with a non-technical report explaining how you understand the client's needs and how you intend going about satisfying them. Above all, ensure that your viewpoint agrees totally with that of your client otherwise you start off on the wrong premise and your final design may differ substantially from that which your client had actually expected. In Figure 1 this situation is explained graphically showing how a design depends on the viewpoint of the person defining the problem.

Figure 1 : What the final design will look like will depend on the viewpoint of the person defining the problem 8.4.1.2 ORIGIN OF REQUIREMENT

Needs are identified at many points and times in an organisation. They arise from an Research and Development division in an organisation whose job it is to create ideas that are relevant to keep the organisation competitive. They may arise from the inputs or requirements from operating personnel, sales and marketing people or from the customers. A Users Requirement typically originates from a dissatisfaction with an existing situation and is intended to reduce costs, increase reliability or performance. In particular it originates from : * a current or projected deficiency in an existing capability (process, mechanical component, machine or system or parts thereof). * an opportunity to enhance an existing capability using emerging technologies. * an opportunity to reduce the operating costs of an existing capability using technological innovation.

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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 intends to 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 basic problem is formulated. It describes the desired capability (process, component or system) in operational terms, i.e. how it is to operate in the user's environment. It is not a specification of a 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 more opportunities 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, improve reliability. 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 stating but 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 should address 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 external interfaces in cases where such co-functioning systems could constrain the design and eventual acquisition process.
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The physical environment in which the system is to operate and to be supported. Constraints to the design

8.4.1.3.4

Guidance and constraints should as far as possible be provided, stating what the design must not be or do. If this is not done the design is unconstrained and the designers/developers have a free hand, invariably designing/developing something that does not meet the users requirements. Pertinent constraints may include : * * * * * cash flow limitations. life cycle cost ceilings. initial capabilities i.e. dates by which system should be operational. total number of systems required and the rate of their introduction. phase out requirements of existing systems. Evaluation criteria

8.4.1.3.5

Specify figures of merit against which the final design will be evaluated. As far a possible state these performance requirements quantitatively. Also define methods or test procedures to verify whether or not mission requirements have been satisfied. 8.4.2 Assignment 2 The following information will assist you with the second assignment. The format of this assignment should adhere to the following format. Layout
Front Page (Project Title included) Abstract Table of Content (Page numbers) List of Figures (Page numbers) List of Tables (Page numbers) List of Symbols Page Numbers Numbering

Body of Report
Introduction Literature Study Alternative Concepts Decision Making Matrix Functional Analysis

References

Appendices
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8.4.2.1

GENERAL

This initiates the design and establishes the baseline from which the design will further develop. It is basically a feasibility study in which all technologically feasible, operationally practical and economically affordable concepts are evaluated. The most acceptable concept is decided upon by using a so-called decision-making matrix laying out the various alternative concepts and ranking them by some scheme in which the various design criteria affecting the decision are considered. A number of these decision matrices are available. One of these will be explained in detail. 8.4.2.2 DECISION-MAKING MATRIX Assume you are evaluating four different concepts 1 to 4 for your design. Furthermore, you have decided that in terms of the client's requirements the final design has to be evaluated in terms of the following eight performance criteria A through H : Criteria A : Technical Performance Criteria B : Reliability Criteria C : Maintainability Criteria D : Life Cycle Cost Criteria E : Development Risk Criteria F : Production Rate Criteria G : Schedules Criteria H : Safety Each of the four concepts will therefore have to be evaluated in terms of each of these eight criteria. In addition, these eight criteria have to be evaluated according to some order of importance, for instance : 0 : No difference in importance 1 : Minor difference in importance 2 : Major difference in importance 3 : Critical difference in importance Step 1 : The eight criteria are paired and then evaluated against each other according to the order of importance given above. The results will then typically look as shown in Table 1. For instance, if the difference in importance of Technical Performance A over Maintainability C is major, then the rating will be A2 (A for Technical Performance and 2 for "major difference in importance"). Similarly, if Technical Performance A is critically important over Development Risk E, the rating will be A3. Obviously, if Development Risk E had been the one that is critically important over Technical Performance A, then the rating would have been E3. The weighting factor W in Table 1 is obtained by adding the number of times the particular criteria was chosen in preference to its paired criteria, e.g. for Technical Performance A2 +

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A3 = 5 times whereas Safety was chosen H1 + H1 + H3 + H3 + H1 = 9 times in preference to its paired criteria. TABLE 1 : PAIRING OF CRITERIA ACCORDING TO IMPORTANCE A B B1 C A2 B3 D D1 B2 C2 E A3 B2 C3 D3 F F1 F1 C2 D2 F2 G G2 B2 C2 D3 G2 G2 H H1 B1 C2 H3 H3 H1 H1 A B C D E F G H Step 2 : The influence of each performance criteria, A through H, on each concept individually must now be determined. This can be done by rating each criteria of each concept according to the following rating priority : 7 : Complete satisfaction 6 : Extensive satisfaction 5 : Considerable satisfaction 4 : Moderate satisfaction 3 : Minor satisfaction 2 : Minimal satisfaction 1 : Marginal satisfaction Criteria Technical Performance Reliability Maintainability Life Cycle Cost Development Risk Production Rate Schedule Safety W 5 11 11 9 0 4 6 9

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Step 3 : The rating R for each criteria and for each concept is now multiplied with the weighting 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 18 Safety 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. On the basis of your rating this concept is therefore the most suitable.

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8.4.3 Assignment 3 For assignment 3 your report should cover the following details: Layout
Front Page (Project Title included) Abstract Table of Content (Page numbers) List of Figures (Page numbers) List of Tables (Page numbers) List of Symbols Page Numbers Numbering

Body of Report
Introduction Analysis and Strength Calculations Choice of Materials Manufacturing Schedule Maintenance Schedule Reliability Analysis Cost Analysis References

Appendices Technical Drawings

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8.4.4 Portfolio For the final report you need to submit 2 bound copies plus a PowerPoint presentation. The following should be covered in your report. If the following four items are not adhered to you cannot pass the subject. Bound 2 Copies PowerPoint presentation Mentor Information Layout
Front Page (Project Title included) Abstract Table of Content (Page numbers) List of Figures (Page numbers) List of Tables (Page numbers) List of Symbols Page numbering Numbering

Body of Report
Introduction Literature Study Alternative Concepts Decision Making Matrix Functional Analysis Analysis and Strength Calculations Choice of Materials Manufacturing Schedule Maintenance Schedule Reliability Analysis Cost Analysis Bibliography / References

Appendices Technical Drawings Mentor information Student declaration

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EXAMINATIONS

Use your my Studies @ Unisa brochure for general examination guidelines and examination preparation guidelines. DUE DATE FOR THE SUBMISSION OF THE FINAL REPORT Examination session October/November 2013 Due date 30 September 2013

Two bound copies of your final design project report, and the PowerPoint presentation, must be submitted to UNISA on or before the due date. It will then be evaluated by your lecturer and the moderator in accordance with the evaluation criteria set out in the Evaluation form available on my Unisa, after which a preliminary mark will be given. With your final report you must also send a PowerPoint presentation of your work for evaluation. This presentation together with your final report will give you your final exam mark. Your final report must contain the following two documents : a declaration by you stating that the content of the report is your own work ; and a declaration by your mentor stating that to the best of his/her knowledge the work presented in your report is your own. Samples of these declarations are given in the study guide. They are reproduced for your convenience and attached to this tutorial letter under point 12. Your final report will not be evaluated unless these two declarations form part of the report. Also note that all three progress reports must have been submitted and a minimum average mark of 50% obtained, before you can submit your final design report . The Final Report has to be submitted by 30 September 2013. Late reports will not be marked. Students who received 40% to 49% for their reports will be eligible for a supplementary and these supplementary reports have to be submitted by middle January. Two copies are required. Final reports have to be professionally bound.

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OTHER ASSESSMENT METHODS

There are no other assessment methods for this module.

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FREQUENTLY ASKED QUESTIONS

The my Studies @ Unisa brochure contains an A-Z guide of the most relevant study information.

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STUDENT AND MENTOR DECLARATIONS

UNISA
DEPARTMENT OF MECHANICAL ENGINEERING MACHINE DESIGN III (MEA361B) DECLARATION BY STUDENT
I .............................................................. declare that the work contained in my design project report entitled. ...................................................................................................................................... for the subject Machine Design III, is my own work and has not been submitted to any other tertiary institution as a design project. ...................................... ..................................... Date Signature of student ..................................... Name in print ..................................... Student number Witnesses : ..................................... .....................................

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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 to the 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

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