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MECH3460: Mechanical Design 2 (2019 - Semester 2)

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Unit: MECH3460: Mechanical Design 2 (6 CP)
Mode: Normal-Day
On Offer: Yes
Level: Senior
Faculty/School: School of Aerospace, Mechanical & Mechatronic Engineering
Unit Coordinator/s: Dr Lozzi, Andrei
Session options: Semester 2
Versions for this Unit:
Campus: Camperdown/Darlington
Pre-Requisites: AMME2301 AND MECH2400.
Brief Handbook Description: This unit aims to apply some newly acquired skills to begin to understand how stress and strain are distributed in the more common categories of machine parts. Reducing the loads in standard parts to just the most significant, leads to a range of relatively simple analyses. By using different degrees of simplification and a proportional amount of effort, the examination of components can provide results of corresponding accuracy. To lead the student to utilize and be aware of modern computer methods, to be aware of past methods and be prepared of future developments. Not all the analysis of mechanical components are covered in the course but the ones that are deal with exemplify principles that can be applied to novel items that our graduates may encounter in their professional life.

At the end of this unit students will be able to: apply fatigue life prediction in general to any component; design a bolted joint to carry tensile and or shear loads: use a numerical solver to arrive at the optimal dimensions of a component, given its loads and sufficient boundary conditions; design shafts to carry specified steady and alternating bending moments and torques; design and construct a space frame, such as that for a dune buggy, to meet requirements of strength and rigidity; be able to arrive at the principle parameters of a pair of matched spur gears, and to be able to extend this to helical gears.

Course content will include: stress and strain in engineering materials; yield and ultimate fail conditions in malleable and brittle materials; spatial, 3D frameworks; deflections due to forces, moments and torques.
Assumed Knowledge: Properties of engineering materials including fatigue failure theories. Statics and dynamics properties of machines.
Timetable: MECH3460 Timetable
Time Commitment:
# Activity Name Hours per Week Sessions per Week Weeks per Semester
1 Lecture 2.00 1 13
2 Tutorial 2.00 1 13
3 Independent Study 8.00 13
T&L Activities: Tutorial: Attending tutorials is compulsory, each missed tutorial will incur a penalty of 2% of the overall marks.

Learning outcomes are the key abilities and knowledge that will be assessed in this unit. They are listed according to the course goal supported by each. See Assessment Tab for details how each outcome is assessed.

(4) Design (Level 3)
1. Design a bolted joint to carry tensile and or shear loads.
2. Design and construct a space frame, such as that for a dune buggy, to meet requirements of strength and rigidity.
(3) Problem Solving and Inventiveness (Level 3)
3. Design shafts to carry specified steady and alternating bending moments and torques.
4. Arrive at the principle parameters of a pair of matched spur gears, and to be able to extend this to helical gears.
5. Application of FEA as an aid in design
(2) Engineering/ IT Specialisation (Level 3)
6. Calculate the weld thickness at a welded joint that is required to carry any combination of loads.
7. Apply fatigue life prediction in general to any component.
8. Use a numerical solver to arrive at the optimal dimensions of a component, given its loads and sufficient boundary conditions.
Assessment Methods:
# Name Group Weight Due Week Outcomes
1 Assignments No 100.00 Multiple Weeks 1, 2, 3, 4, 6, 7, 8,
Assessment Description: Assignment: There will be 4 assignments, which are all equally weighted. The assignments will be collected at the beginning of the tutorial session, when work on the next assignment will be due to start. A penalty will apply for failure to do so. Tutors will not discuss assignments that are due to be handed in.

The first assignment deals with the application of a modern CAD system, and its integrated Finite Element Analysis package, to the design of simple but diverse types of parts.

The second assignment examines the designs of a preloaded (pre tensioned) bolted joints and how such joints are tailored to withstand alternating loads.

The third, is devoted to the design of the sort of shaft used in many industrial applications. The shaft will typically be exposed to unsteady moments and torques.

The last will probably deal with the design of a springing system that has to provide appropriate stiffness, travel and fatigue life.

Preceding each assignments a wide range of real world designs and applications, are shown that exemplify the use of that category of parts. Among these designs good and not d examples are intentionally included. Leading the students to make value judgements in arriving at their designs. Attached to each assignment will be a guide indicating what is required achieve a pass to credit, to do better the advice is vague, enticing the student to do a little research themselves.
Assessment Feedback: When the assignments are marked and returned, the coordinator will discuss in a following lecture the range of solutions proffered, those that followed unadvisable paths, those that were rigorous in their analysis, as well as those that were inventive and shed novel light on possible solutions.
Grading:
Grade Type Description
Standards Based Assessment Final grades in this unit are awarded at levels of HD for High Distinction, DI (previously D) for Distinction, CR for Credit, PS (previously P) for Pass and FA (previously F) for Fail as defined by University of Sydney Assessment Policy. Details of the Assessment Policy are available on the Policies website at http://sydney.edu.au/policies . Standards for grades in individual assessment tasks and the summative method for obtaining a final mark in the unit will be set out in a marking guide supplied by the unit coordinator.
Policies & Procedures: See the policies page of the faculty website at http://sydney.edu.au/engineering/student-policies/ for information regarding university policies and local provisions and procedures within the Faculty of Engineering and Information Technologies.
Prescribed Text/s: Note: Students are expected to have a personal copy of all books listed.
  • Machanical Design 1 & 2 (MECH2400 & MECH3460)
  • Machine Design
Recommended Reference/s: Note: References are provided for guidance purposes only. Students are advised to consult these books in the university library. Purchase is not required.

Note that the "Weeks" referred to in this Schedule are those of the official university semester calendar https://web.timetable.usyd.edu.au/calendar.jsp

Week Description
Week 1 Finite Element analysis as applied using a modern CAD system. FEA assignment presented.
Week 2 Review of fatigue failure mechanisms, the use of fatigue strengths data in a variety of applications.
Week 3 Presentation of modern approaches in designing for a multitude or requirements. The writing of industrial standard reports.
Week 4 Pre-tensioned bolted joints and differences to bolts subjected to shear loads. Bolt assignment presented
Week 5 Inovations in bolt design and manufacturing. Pretension bolted joints in industry.
Week 6 Review of methods of bolt analysis and effects of modern innovations
Week 7 Shaft analysis, examination of simplifying assumptions in typical shafts
Week 8 Examination of alternative shaft design standards and their effects on industry
Week 9 Presentation of the designs of frames in particular 3D space frames
Week 10 Selection of rolling element bearings to suit loads and life requirements
Week 11 Spring design problem detailed and its possible approaches discussed.
Week 12 Variations in designs of spring elements, their uses and methods of analysis.
Week 13 Presentation on clutches and brakes as used in industry.

Course Relations

The following is a list of courses which have added this Unit to their structure.

Course Year(s) Offered
Mechanical Mid-Year 2016, 2017, 2018, 2019, 2020
Mechanical/ Project Management 2019, 2020
Mechanical 2015, 2016, 2017, 2018, 2019, 2020
Mechanical / Arts 2015, 2016, 2017, 2018, 2019, 2020
Mechanical / Commerce 2015, 2016, 2017, 2018, 2019, 2020
Mechanical / Medical Science 2015, 2016, 2017
Mechanical / Music Studies 2016, 2017
Mechanical / Project Management 2015, 2016, 2017, 2018
Mechanical / Science 2015, 2016, 2017, 2018, 2019, 2020
Mechanical/Science(Health) 2018, 2019, 2020
Mechanical / Law 2015, 2016, 2017, 2018, 2019, 2020
Mechatronic Mid-Year 2016, 2017, 2018, 2019, 2020
Mechatronic/ Project Management 2019, 2020
Mechatronic 2015, 2016, 2017, 2018, 2019, 2020
Mechatronic / Arts 2015, 2016, 2017, 2018, 2019, 2020
Mechatronic / Commerce 2015, 2016, 2017, 2018, 2019, 2020
Mechatronic / Medical Science 2015, 2016, 2017
Mechatronic / Music Studies 2016, 2017
Mechatronic / Project Management 2015, 2016, 2017, 2018
Mechatronic / Science 2015, 2016, 2017, 2018, 2019, 2020
Mechatronic/Science (Health) 2018, 2019, 2020
Mechatronic / Law 2015, 2016, 2017, 2018, 2019, 2020
Mechanical (till 2014) 2010, 2011, 2012, 2013, 2014
Mechanical Engineering / Arts 2011, 2012, 2013, 2014
Mechanical Engineering / Commerce 2010, 2011, 2012, 2013, 2014
Mechanical (Biomedical) (till 2014) 2010, 2011, 2012
Mechanical Engineering / Medical Science 2011, 2012, 2013, 2014
Mechanical Engineering / Project Management 2012, 2013, 2014
Mechanical Engineering / Science 2011, 2012, 2013, 2014
Mechanical Engineering / Law 2010, 2011, 2012, 2013, 2014
Mechatronic (till 2014) 2010, 2011, 2012, 2013, 2014
Mechatronic Engineering / Arts 2011, 2012, 2013, 2014
Mechatronic Engineering / Commerce 2010, 2011, 2012, 2013, 2014
Mechatronic Engineering / Medical Science 2012, 2013, 2014
Mechatronic Engineering / Project Management 2012, 2013, 2014
Mechatronic Engineering / Science 2011, 2012, 2013, 2014
Mechatronic Engineering (Space) / Medical Science 2011
Mechanical/Science (Medical Science Stream) 2018, 2019, 2020
Mechatronic/Science (Medical Science Stream) 2018, 2019, 2020

Course Goals

This unit contributes to the achievement of the following course goals:

Attribute Practiced Assessed
(6) Communication and Inquiry/ Research (Level 3) No 0%
(5) Interdisciplinary, Inclusiveness, Influence (Level 3) No 0%
(4) Design (Level 3) No 28.58%
(3) Problem Solving and Inventiveness (Level 3) No 28.58%
(2) Engineering/ IT Specialisation (Level 3) No 42.87%

These goals are selected from Engineering & IT Graduate Outcomes Table 2018 which defines overall goals for courses where this unit is primarily offered. See Engineering & IT Graduate Outcomes Table 2018 for details of the attributes and levels to be developed in the course as a whole. Percentage figures alongside each course goal provide a rough indication of their relative weighting in assessment for this unit. Note that not all goals are necessarily part of assessment. Some may be more about practice activity. See Learning outcomes for details of what is assessed in relation to each goal and Assessment for details of how the outcome is assessed. See Attributes for details of practice provided for each goal.