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MECH3660: Manufacturing Engineering (2019 - Semester 1)

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Unit: MECH3660: Manufacturing Engineering (6 CP)
Mode: Normal-Day
On Offer: Yes
Level: Senior
Faculty/School: School of Aerospace, Mechanical & Mechatronic Engineering
Unit Coordinator/s: Mr Briozzo, Paul
Session options: Semester 1
Versions for this Unit:
Campus: Camperdown/Darlington
Pre-Requisites: MECH2400 OR ENGG1960 OR AMME1960 OR BMET1960 OR MECH1560 OR ENGG1800.
Brief Handbook Description: The unit aims to teach the fundamentals of manufacturing processes and systems in mechanical and mechatronic engineering, including traditional and advanced manufacturing technologies.

This unit aims to develop the following attributes: to understand the fundamental principles of manufacturing technologies for the above mentioned engineering areas; to gain the ability to select existing manufacturing processes and systems for direct engineering applications; to develop ability to create innovative new manufacturing technologies for advanced industrial applications; to develop ability to invent new manufacturing systems

At the end of this unit, students will have a good understanding of the following: merits and advantages of individual manufacturing processes and systems; principles of developing new technologies; comprehensive applications and strategic selection of manufacturing processes and systems.

Course content will include:

CAD / CAM: An introduction into the use of CAD and manual CNC coding as separate tools combined with an introduction into the kinematics and structural requirements in the construction of a CNC machine.

Rapid Engineering: An introduction into the most current Rapid Engineering methods currently in use.

Manufacturing Processes: Common processes and their science (machining, casting, powder metallurgy, metal working, welding) and their relative merits and limitations.

Automation: Data acquisition, analysis, and presentation using the LabVIEW graphical design platform, and automated inspection system and software design and in industry.
Assumed Knowledge: None.
Lecturer/s: Dr Chang, Li
Mr Briozzo, Paul
Tutor/s: Freddy Santiago Caro Diaz - Tutor

Musharraf Hossain - Tutor

Thai Nguyen - Tutor

Mark Lagana - Rapid Engineering Laboratory Demonstrator

John Gardenier - Robot Laboratory Demonstrator

Stephen Huang - CNC Mill Laboratory Demonstrator
Timetable: MECH3660 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 Rapid Engineering Laboratory 1
4 Robot Assembly Laboratory 1
5 CNC Mill Demonstration 1
6 Independent Study 5.00 13
T&L Activities: Laboratories:

1. The Rapid Engineering Laboratory will provide exposure to the link between mechanical design and a rapid engineering (FDM) process. Each student will be allocated one session of this laboratory.

2. The Robot Assembly Laboratory will introduce students to the assembly of a simple gearbox by the use of the teaching pendant. Each student will be allocated one session of this laboratory.

3. The CNC Milling Demonstration will introduce students to 3 and 5 axis milling plus a 3 axis router demonstration. Each student will be allocated one session of this demonstration.

Attributes listed here represent the key course goals (see Course Map tab) designated for this unit. The list below describes how these attributes are developed through practice in the unit. See Learning Outcomes and Assessment tabs for details of how these attributes are assessed.

Attribute Development Method Attribute Developed
Understanding of the common manufacturing processes and essential skills in planning the manufacture of a product. (2) Engineering/ IT Specialisation (Level 3)
Design of manufacturing processes. (4) Design (Level 3)
Participation in team assignments. (7) Project and Team Skills (Level 3)

For explanation of attributes and levels see Engineering & IT Graduate Outcomes Table 2018.

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.

(7) Project and Team Skills (Level 3)
1. Ability to contribute to effective team processes.
(8) Professional Effectiveness and Ethical Conduct (Level 2)
2. Understanding the fundamental principles of manufacturing technologies for mechanical and mechatronic engineering.
(5) Interdisciplinary, Inclusiveness, Influence (Level 3)
3. Ability to discuss the major problems in the current manufacturing practice and your suggestions to overcome or improve them (highly encouraged to do an investigation, e.g., visit a manufacturer by yourselves).
(3) Problem Solving and Inventiveness (Level 3)
4. Ability to determine function requirement of a product in terms of application and suitability, etc.
5. Ability to discuss the merits and disadvantages of individual manufacturing method.
(2) Engineering/ IT Specialisation (Level 3)
6. Ability to determine the basic manufacturing considerations necessary to realize the function, including the selection of materials and the manufacturing method, taking into account the strength and reliability.
7. Familiarity with use of CNC machining in manufacturing.
Assessment Methods:
# Name Group Weight Due Week Outcomes
1 Quiz 1 - CNC Machining / Automation* No 15.00 Week 5 (Monday, 11 am) 2, 3, 4, 5, 6, 7,
2 Assignment 1 - CNC Machining / Automation* Yes 15.00 Week 6 (Friday, 11 pm) 2, 3, 4, 5, 6, 7,
3 Quiz 2 - Manuf Processes / Automation* No 15.00 Week 9 (Tuesday, 11 am) 2, 3, 4, 5, 6,
4 Assignment 2 - Manuf Processes / Automation* Yes 15.00 Week 9 (Friday, 11 pm) 2, 3, 4, 5, 6,
5 Quiz 3 - Composite / Nano Technology* No 15.00 Week 13 (Tuesday, 11 am) 2, 3, 4, 5, 6,
6 Assignment 3 - Composite / Nano Technology* Yes 15.00 Week 13 (Friday, 11 pm) 2, 3, 4, 5, 6,
7 Rapid Engineering Laboratory Group Report* Yes 5.00 Multiple Weeks 1, 2, 4, 5, 6,
8 Robot Assembly Laboratory Video* Yes 5.00 Multiple Weeks 1, 2,
Assessment Description: Assessment:

* indicates an assessment task which must be repeated if a student misses it due to special consideration.

Assignments:

Three group assignments where students concentrate on;

Assignment 1 has three parts and focuses on writing CNC code for a simple machine element, the basic design of a 3D printer and Automation System using LabView.

Assignment 2 has two parts and requires that students either compare Manufacturing Processes in the design of a component and Automation System using LabView.

Assignment 3 focuses on manufacturing using Composite and Nano Technology Manufacturing.

All Assignments will be submitted online through Blackboard and scanned for plagiarism using Turnitin.

Quizzes:

The course is composed of three Quizzes;

Quiz 1 - CNC Machining and Automation.

Quiz 2 - Manufacturing Processes and Automation.

Quiz 3 - Composite and Nano Manufacturing.

Quiz material is derived from course notes, tutorials and lectures.

Laboratory (CNC): Compulsory attendance of the CNC demonstration that is held within the School Workshop (Room S120). No report is required.

Laboratory (Rapid Engineering): Compulsory attendance and participation in the Rapid Engineering Laboratory held within the Bob Halliday Laboratory (Room S173a - located within S173).

A group report focusing on the Rapid Engineering Laboratory and individual research must be submitted no later than two weeks of attending the Rapid Engineering Laboratory.

Laboratory (Robotic Assembly): Compulsory attendance and participation in the Robotic Assembly Laboratory held within the Bob Halliday Laboratory (Room S173).

A group video focusing on the Robotic Pick and Place Assembly Laboratory must be submitted via the CANVAS ARC video submission system.
Assessment Feedback: Assessment feedback is by way of written comments on a marking sheet or via CANVAS. Feedback will be provided within two weeks of
assessment submission.

Feedback will also be provided during the lecture and as needed face-to-face.
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.
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 on Resources: The lecture notes, consisting of three parts, summarize the key issues of the subject and will be made available online.

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 Lecture: Introduction to Course and CNC Machining
Lecture: Manufacturing Automation - Introduction and Product Life Cycle
Week 2 Lecture: Manufacturing Automation - Data Acquisition and LabVIEW
Lecture: CNC Machining
Week 3 Lecture: Manufacturing Automation - Analogue Sampling and LabVIEW
Lecture: Cutting Forces plus Jigs and and Fixtures
Week 4 Lecture: Structure and Kinematics of CNC Machines
Lecture: Manufacturing Automation - Data Processing and LabVIEW
Week 5 Lecture: Quiz 1* (Monday)
Lecture: Manufacturing Automation - Automated Inspection Systems
Assessment Due: Quiz 1 - CNC Machining / Automation*
Week 6 Lecture: Manufacturing Automation - Vision Builder for Automation Systems
Lecture: Manufacturing Processes - Casting
Assessment Due: Assignment 1 - CNC Machining / Automation*
Week 7 Lecture: Manufacturing Processes - Welding
Lecture: Manufacturing Automation - Vision Builder for Automated Inspection
Week 8 Lecture: Manufacturing Processes - Metal Forming
Lecture: Manufacturing Automation - VBAI and Intro to Motion Control
Week 9 Lecture: Manufacturing Processes - Powder Metallurgy
Lecture: Quiz 2* (Tuesday)
Assessment Due: Quiz 2 - Manuf Processes / Automation*
Assessment Due: Assignment 2 - Manuf Processes / Automation*
Week 10 Lecture: Composites
Lecture: Composites
Week 11 Lecture: Composites
Lecture: Composites
Week 12 Lecture: Nano Technology
Lecture: Nano Technology
Week 13 Lecture: Nano Technology
Lecture: Quiz 3* (Tuesday)
Assessment Due: Quiz 3 - Composite / Nano Technology*
Assessment Due: Assignment 3 - Composite / Nano Technology*

Course Relations

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

Course Year(s) Offered
Biomedical Engineering / Law 2013, 2014
Biomedical Engineering / Arts 2013, 2014
Biomedical Engineering / Commerce 2013, 2014
Biomedical Engineering / Medical Science 2013, 2014
Biomedical Engineering / Project Management 2013, 2014
Biomedical Engineering / Science 2013, 2014
Biomedical - Chemical and Biomolecular Major 2013, 2014, 2015
Biomedical - Electrical Major 2013, 2014
Biomedical - Information Technology Major 2013, 2014, 2015
Biomedical - Mechanical Major 2013, 2014, 2015
Biomedical - Mechatronics Major 2013, 2014, 2015
Biomedical Mid-Year 2016
Biomedical / Arts 2015, 2016
Biomedical / Commerce 2015, 2016
Biomedical / Medical Science 2015, 2016
Biomedical / Project Management 2015
Biomedical /Science 2015
Biomedical - Electrical Major 2015
Biomedical / Law 2015, 2016
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
Mechanical (Space) 2015
Mechanical (Space) / Arts 2015
Mechanical (Space) / Commerce 2015
Mechanical (Space) / Medical Science 2015
Mechanical (Space) / Project Management 2015
Mechanical (Space) / Science 2015
Mechanical (Space) / Law 2015
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
Mechatronic (Space) 2015
Mechatronic (Space) / Arts 2015
Mechatronic (Space) / Commerce 2015
Mechatronic (Space) / Medical Science 2015
Mechatronic (Space) / Project Management 2015
Mechatronic (Space) / Science 2015
Mechatronic (Space) / Law 2015
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
Mechanical (Space) (till 2014) 2010, 2011, 2012, 2013, 2014
Mechanical Engineering (Space) / Arts 2011, 2012, 2013, 2014
Mechanical Engineering (Space) / Commerce 2010, 2011, 2012, 2013, 2014
Mechanical Engineering (Space) / Medical Science 2012, 2013, 2014
Mechanical Engineering (Space) / Project Management 2012, 2013, 2014
Mechanical Engineering (Space) / Science 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 2011, 2012, 2013, 2014
Mechatronic Engineering / Project Management 2012, 2013, 2014
Mechatronic Engineering / Science 2011, 2012, 2013, 2014
Mechatronic (Space) (till 2014) 2010, 2011, 2012, 2013, 2014
Mechatronic Engineering (Space) / Arts 2011, 2012, 2013, 2014
Mechatronic Engineering (Space) / Commerce 2010, 2011, 2012, 2013, 2014
Mechatronic Engineering (Space) / Medical Science 2011, 2012, 2013, 2014
Mechatronic Engineering (Space) / Project Management 2012, 2013, 2014
Mechatronic Engineering (Space) / Science 2011, 2012, 2013, 2014
Mechatronic Engineering (Space) / Law 2010, 2011, 2012, 2013, 2014
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
(7) Project and Team Skills (Level 3) Yes 3.5%
(8) Professional Effectiveness and Ethical Conduct (Level 2) No 21.5%
(5) Interdisciplinary, Inclusiveness, Influence (Level 3) No 16.5%
(4) Design (Level 3) Yes 0%
(3) Problem Solving and Inventiveness (Level 3) No 33.5%
(2) Engineering/ IT Specialisation (Level 3) Yes 25%

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.