ME 452 COURSE PROFILE
DEGREE PROGRAM: Mechanical Engineering

COURSE NUMBER: ME 452 COURSE TITLE: Design for Manufacturability
REQUIRED COURSE OR ELECTIVE COURSE: Elective TERMS OFFERED: Winter
TEXTBOOK / REQUIRED MATERIAL: PRE / CO-REQUISITES: MECHENG 350. I (3 credits)
COGNIZANT FACULTY: S. Kota
COURSE TOPICS:
  1. Product development process. Customer requirements
  2. Product design specifications, product status and quality function deployment
  3. Conceptual design. Concept selection matrix
  4. Principles of design: Principles of nesting, cascading, matching, least constraint, biasing, separation and combination of functions and regenerative principle
  5. Mechanical compliance and design for no-assembly
  6. Design for assembly: Assembly efficiency evaluation-Boothroyd-Dewhurst method
  7. Design of snap-fits: Cantilever, annular and torsional snap joints
  8. Material selection criteria
  9. Manufacturing tolerances. Statistical tolerancing method
  10. Design for injection molding
  11. Rapid prototyping methods
  12. Taguchi methods: Quality loss function, parameter design, orthogonal arrays and linear graphs, analysis of variance. Case studies
BULLETIN DESCRIPTION: Conceptual design. Design for economical production, Taguchi methods, design for assembly, case studies. Product design using advanced polymeric materials and composites; part consolidation, snap-fit assemblies; novel applications. Design projects.
COURSE STRUCTURE/SCHEDULE: Lecture: 2 days per week at 1.5 hours

COURSE OBJECTIVES:
for each course objective, links to the Program Outcomes are identified in brackets.

  1. To teach students various steps in the product development process and the significance of early phases of design [1, 2, 3, 8, 11]
  2. To teach fundamental principles of design and application of these principles in practical design problems [3, 5, 10, 11]
  3. To teach design of systems for ease of assembly and manufacture [3]
  4. To teach interrelations among part geometry, tolerances, materials and manufacturing processes [3]
  5. To teach principles of robust design procedures and how to set values for various design variables so that the product meets the performance requirements and remains insensitive to variations in manufacturing and use [3, 10, 11]
COURSE OUTCOMES:
for each course outcome, links to the Course Objectives are identified in brackets.
  1. Given a set of functional requirements and constraints, generate alternate concepts and objectively evaluate the concepts [1, 2, 3]
  2. Map customer requirements to engineering characteristics, part characteristics, process parameters and production requirements [1, 2]
  3. Application of fundamental principles of design to improve performance and/or ease of manufacture [3, 4, 5]
  4. Given a product design, evaluate and improve the assembly efficiency [3]
  5. Establish a list of candidate materials for each component of design through identification of functional requirements and selection criteria based on loading [1, 4]
  6. Identify manufacturing methods based on part geometry and tolerances (ISO tolerances) [4]
  7. Identify control factors, noise factors, and an appropriate orthogonal array to set up an experiment to establish relation between various design variables and performance requirements [2,5]
  8. Apply all of the design methods learned in this course to redesign a product for ease of manufacture, and robustness (insensitive to variations) [5]
ASSESSMENT TOOLS:
for each assessment tool, links to the course outcomes are identified
  1. Regular homework assignments
  2. Exam(s) and/or project(s)

PREPARED BY: S. Kota
LAST UPDATED: 05/23/2011