# Mechanical Design A

## Details

Code 23808

Level of study Second Year

Credit value 20

Semester 1&2

## Module description

The aim of the module is to enhance your knowledge and understanding of the mathematics and scientific principles related to mechanics, materials, manufacturing and design processes, and to develop your ability to apply this knowledge in a number of topics.

SYLLABUS
COMPUTER AIDED DESIGN AND MATERIALS SELECTION:
Use of Solidworks, Use of CES Edupack

DESIGN:
Product Design Specification, Engineering drawings to BS8888

MATERIALS:
The concept of materials selection using specific values of density, modulus, strength and cost.
Review of Hooke's law, elastic, shear and bulk moduli, Poisson ratio.
Introduction to Ashby materials selection maps and Granta software (or equivalent)

SUSTAINABILITY:
Use of eco-audit tools to assess Carbon Footprints and impact of materials choices

IN-SERVICE FAILURE:
Concept of finite and infinite life of machine components. The stress-strain curve and its relationship to fatigue. Understanding different fatigue regimes. Fatigue analysis using Soderburg and Goodman diagrams. Stress raisers and fatigue initiation. Identifying the features of a fatigue fracture. Effect of surface and other processes on fatigue, peening/blasting, welding, geometry and size.

MACHINE ELEMENT THEORY:
Theory of gears - nomenclature, conjugate sliding motion, sliding velocities, contact ratios, numbers of teeth, geometric relationships. Types of gear, Gear trains.
Mechanical clutches - toothed, jawed. Friction clutches rim, axial, belt, conical, centrifugal.
Shafts - Sizing and failure analysis, DET and MSST theories, design methods, stress analysis, shear force, bending moment and deflection analysis.
Bearings - types of bearing - plain and rolling element, failure analysis, life predictions and sizing.

MATERIALS PROCESSING:
Machining - Conventional & non-conventional machining, turning, drilling, milling, grinding, EDM.
Metal forming - bulk forming, forging, extrusion, sheet metal forming - rolling, pressing.
Casting - sand, HP die, investment, gravity die, low pressure die.
Polymer forming - injection, sheet, blow, rim, rotary moulding, vacuum forming, extrusion.
Joining - fusion welding, resistance welding, adhesive bonding, rivets.
Special Processes - additive manufacturing, prototyping, laser deposition, CVD - surface coatings, plasma spraying.