EGB316 Design of Machine Elements

Unit Outline: Semester 1 2024, Gardens Point, Internal

Overview

Mechanical design within professional engineering practice requires that graduates bring together the various analytical techniques they know in a systematic way to develop confidence in a design or analysis. In this unit students will learn advanced theories of mechanical design analysis, and will apply this in the design and analysis of a variety of machine elements. Methodical design process is emphasized, as is the application of relevant design standards, and advanced simulation using the Finite Element Analysis package ANSYS. A key focus of the unit is the repeated application of a practice based design analysis workflow to real machine components. Weekly application of the design skills being developed, make you comfortable with both mechanical systems as a whole, and the determination, estimation, or selection of open ended quantities within the design process.

Learning Outcomes

On successful completion of this unit you will be able to:

1. Evaluate and analyse a range of key machine component categories following fundamental engineering analysis that includes evaluation of component function, complex and advanced fatigue loading, failure, and life, at a developed level.
2. Implement design standards in the assessment and specification of machine components and systems, appreciating the role and context of standards in design, and being exposed to examples that highlight how and why standards are formulated in engineering practice, at a developed level.
3. Develop practical experience using commercial ANSYS Finite Element Analysis software within the mechanical engineering design workflow, and apply this to a range of design analysis problems, including the effective communication of modelling results, at a developed level.
4. Integrate systematic approaches to mechanical engineering design analysis procedures, employing a practice-oriented design workflow, and developing engineering judgement through this practice, at a developed level.

Content

Learning Approaches

In this unit you can expect to experience the following timetabled activities:

• Formal lectures from experienced professional engineers where short phases of content delivery alternate with in-class short-form problem solving aligning with each delivered concept, as they are delivered. You will have the opportunity to ask questions during these lectures.
• Design workshops that will be carried out in the design laboratory where students are given a real machine component to measure, estimate appropriate loading scenario for using reason or operational measurement, carry out hand calculations on key characteristics of the design, and orally defend why their answer is reasonable to the supervising tutor.
• Practical computer class where the commercial Finite Element Analysis package ANSYS will be taught through guided screencasts or workbook instructions, accompanied by an analysis activity (that relates to the corresponding design class) to be viewed and signed by the tutor.

Your work in this unit will also form part of a Professional Portfolio (submitted in your final Project Unit) to assist you with work placements and employer interviews as evidence of your skills and competency.

At the beginning of the unit, you will be made aware of the ways in which you can ask questions or seek clarification from the Unit Coordinator and Tutors.

You are expected to:

• Engage with timetabled activities on campus and ask questions.
• Manage your time to engage with online resources outside of timetabled activities. These will be available on the unit Canvas site. You will receive regular email announcements regarding release of these resources.
• Engage with your peers in a learning community to practice problem solving and then work independently to complete your assessment tasks.
• Prepare for timetabled classes and activities and follow up on any work not completed.
• Complete assessment tasks by working consistently across the semester and meeting the due dates that are published via the unit Canvas site.

Feedback on Learning and Assessment

You will receive feedback in various forms throughout the semester which may include:

1. Rubrics provided to show the expected standard for each criteria in an assessment item
2. Individual oral feedback on weekly journal (calculations and solid modelling work)
3. Comments returned to you via Canvas.
4. Lecture / consultation sessions may be available for group and individual feedback prior to assessment due dates and on completion of project tasks.

Generic comments provided via QUT Canvas and in class.

Assessment

Overview

Assessment will be based on the following assessment tasks: problem solving tasks, design audit project and final examination. These assignments are designed to facilitate the development of different learning outcomes and include individual and team work, as well as self-study. Within the problem solving tasks, hand calculations, standard calculations, and FEA modelling will be learnt, applied, and compared. In the project these will be applied together to an independently chosen real machine component.

Formative Assessment:
You will get opportunity to practice and reflect on a range of marked assignments and project reports as well as on formative in-class exercises with feedback from peers and a tutor.

Unit Grading Scheme

7- point scale

Assessment Tasks

Assessment: Journal

You will keep a journal to record design calculations and ANSYS models that you will present to tutors at weekly design or computer labs for feedback and sign-off.

Assessment item is individual work and peer reviewed.

This is an assignment for the purposes of an extension.

Assessment: Project (applied)

Report, analysis, standards and ANSYS audit

There will be one major machine design audit project, carried out in a collaborative setting but with individually written report, involving the design analysis of specific practical machine components chosen by the students. The system to be analysed will involve both welded and bolted joints under fatigue loading with the load cases used for the analysis estimated and justified by the student. The machine system will be subjected to a design audit to ensure adequate operational life following the three phase design workflow taught within the unit.

This is an assignment for the purposes of an extension.

Assessment: Examination (written)

Students are responsible for material from lecture, tutorial, practical, and TEXT. One, 2-hour exam at the end of the semester will cover all aspects of the subject. The primary emphasis will be (i) problem identification, formulation and solution and (ii) demonstration of fundamentals of machine component design, (iii) application of machine component design and analysis to key problems. You are allowed to bring one A4 page of notes (written both sides) with your own summary and all necessary equations.

“If campus access is restricted at the time of the central examination period/due date, an alternative, which may be a timed online assessment, will be offered. Individual students whose circumstances prevent their attendance on campus will be provided with an alternative assessment approach.”

Academic Integrity

Students are expected to engage in learning and assessment at QUT with honesty, transparency and fairness. Maintaining academic integrity means upholding these principles and demonstrating valuable professional capabilities based on ethical foundations.

Failure to maintain academic integrity can take many forms. It includes cheating in examinations, plagiarism, self-plagiarism, collusion, and submitting an assessment item completed by another person (e.g. contract cheating). It can also include providing your assessment to another entity, such as to a person or website.

You are encouraged to make use of QUT’s learning support services, resources and tools to assure the academic integrity of your assessment. This includes the use of text matching software that may be available to assist with self-assessing your academic integrity as part of the assessment submission process.

Further details of QUT’s approach to academic integrity are outlined in the Academic integrity policy and the Student Code of Conduct. Breaching QUT’s Academic integrity policy is regarded as student misconduct and can lead to the imposition of penalties ranging from a grade reduction to exclusion from QUT.

Resources

Resource Materials

Prescribed text(s)

H.-H. Lee, Finite Element Simulations with ANSYS Workbench 21, SDC Publications (2021)

Recommended text(s)

R.C. Juvinall, K.M. Marshek, Machine Component Design, 6th Ed. International Student Edition Version, Wiley (2017)

Risk Assessment Statement

You will be informed of any requirements pertaining to a safe workplace. In lectures, tutorials and such, the information will include location of fire exits and meeting points in case of fire. If you do not follow legitimate instructions or endanger the safety of others or do not act in accordance with the requirements of the Workplace Health and Safety Act, you will be required to leave the session.

You will be required to undertake practical sessions in the laboratory under the supervision of members in the teaching team and technical staff. Prior to entry to a laboratory space you must complete the Undergraduate Health, Safety and Environment Induction (annual completion requirement). You will be advised of requirements of safe and responsible behaviour and will be required to wear appropriate protective items (e.g. closed shoes or steel capped shoes, lab coat, and safety glasses). The unit’s Canvas site will provide you with a copy of the risk assessment and will provide you with details on how to perform the laboratory tasks safely.

Standards/Competencies

This unit is designed to support your development of the following standards\competencies.

Engineers Australia Stage 1 Competency Standard for Professional Engineer

1: Knowledge and Skill Base

1. 
   Relates to: Journal, Examination (written)
2. 
   Relates to: Journal, Project (applied)
3. 
   Relates to: Journal
4. 
   Relates to: Journal, Project (applied)

2: Engineering Application Ability

1. 
   Relates to: Journal, Project (applied), Examination (written)
2. 
   Relates to: Project (applied)

3: Professional and Personal Attributes

1. 
   Relates to: Journal, Project (applied)
2. 
   Relates to: Project (applied)

Course Learning Outcomes

EN01 Bachelor of Engineering (Honours)

1. Make decisions ethically within the social, cultural, and organisational contexts of professional engineering practice.
   Relates to: ULO2, ULO4, Journal, Project (applied)
2. Engage stakeholders professionally and communicate the outcomes of your work effectively to expert and non-expert audiences using appropriate modes.
   Relates to: ULO3, Journal, Project (applied)
3. Display leadership, creativity, and initiative in both self-directed and collaborative contexts of professional engineering practice.
   Relates to: ULO4, Journal, Project (applied)
4. Manage projects to solve complex engineering problems, using appropriate information, engineering methods, and technologies.
   Relates to: ULO1, Journal, Project (applied), Examination (written)
5. Deploy appropriate approaches to engineering design and quality.
   Relates to: ULO1, ULO2, ULO3, ULO4, Journal, Project (applied), Examination (written)
6. Engage with and apply regulatory requirements relating to safety, risk management, and sustainability in professional engineering practice.
   Relates to: ULO2, Journal, Project (applied)
7. Demonstrate a thorough understanding of one engineering discipline, its research directions, and its application in contemporary professional engineering practice.
   Relates to: ULO1, ULO2, Journal, Project (applied), Examination (written)

EN55 Master of Professional Engineering

1. Apply advanced and specialist knowledge, concepts and practices in engineering design, analysis management and sustainability.
   Relates to: Journal, Project (applied), Examination (written)
2. Critically analyse and evaluate complex engineering problems to achieve research informed solutions.
   Relates to: Project (applied), Examination (written)
3. Apply systematic approaches to plan, design, execute and manage an engineering project.
   Relates to: Project (applied)
4. Communicate complex information effectively and succinctly, presenting high level reports, arguments and justifications in oral, written and visual forms to professional and non specialist audiences.
   Relates to: Journal, Project (applied)
5. Organise and manage time, tasks and projects independently, and collaboratively demonstrating the values and principles that shape engineering decision making and professional accountability.
   Relates to: Journal, Project (applied)

EV01 Bachelor of Engineering (Honours)

1. Make decisions ethically within the social, cultural, and organisational contexts of professional engineering practice.
   Relates to: Journal, Project (applied)
2. Engage stakeholders professionally and communicate the outcomes of your work effectively to expert and non-expert audiences using appropriate modes.
   Relates to: Journal, Project (applied)
3. Display leadership, creativity, and initiative in both self-directed and collaborative contexts of professional engineering practice.
   Relates to: Journal, Project (applied)
4. Manage projects to solve complex engineering problems, using appropriate information, engineering methods, and technologies.
   Relates to: Journal, Project (applied), Examination (written)
5. Deploy appropriate approaches to engineering design and quality.
   Relates to: Journal, Project (applied), Examination (written)
6. Engage with and apply regulatory requirements relating to safety, risk management, and sustainability in professional engineering practice.
   Relates to: Journal, Project (applied)
7. Demonstrate a thorough understanding of one engineering discipline, its research directions, and its application in contemporary professional engineering practice.
   Relates to: Journal, Project (applied), Examination (written)