In this module, you will develop skills in mechanical engineering design by undertaking the design of a reduction gearbox (initially using simple analytic methods, and then using computer-based methods).  You will develop an understanding of the design process, from evaluating high-level concepts and choosing appropriate solutions, through to detailed design of components.  You will learn how to apply skills you have already learnt in the areas of mechanics, materials, manufacturing, computer aided design and drawing, to real-world design problems. You will undertake the manufacture and testing of a component of your gearbox and compare the real-world performance of your design with computer models. You will learn how to work with reasonable assumptions and incomplete information, and the module will encourage you to adopt good team-working and project/time management practices.  

1. Demonstrate competence in the application of engineering knowledge and understanding to design. 
2. Show appreciation of the technical requirements of design and manufacture, including the influence of design constraints. 
3. Design simple mechanical systems using hand calculations and other simple methods. 
4. Develop the design of mechanical components using computer-aided engineering methods (including competence in Finite Element Analysis using commercial packages). 
5. Appreciate and reflect on differences between the predictions of calculations or simulations tools, and real-world performance of designs.  
6. Communicate design solutions via appropriate methods such as report writing, presentations and technical drawings.

The module will be delivered through a blend of online teaching and learning material, guided study, and on-campus face-to-face classes (tutorials, feedback sessions). For practical workshops, a rota will be provided.
 

Throughout the module, you will develop graduate attributes in a number of areas: 

1. Collaborative, Ethically, Social and Environmentally Awareness  

•     Work as part of a design team, managing time, resources and skills in order to conduct a  professional design project. 

2. Effective Communications 

•    Use and interpretate design descriptions including drawings and manufacturers'  catalogues and standards. 
•     Present a solution for a given design problem using both “classic” hand-calculation tools  and Finite Element analysis  
•    Communicate effectively through written reports, presentations and drawings to a  professional standard. 

3. Independent and critical thinkers  

•   Understand and interpret design specifications, and identify and evaluate potential  solutions. 
•    Learn to make suitable assumptions and simplifications based on available data, and  compare theoretical predictions with real performance. 

4.Innovative, Enterprising and Commercial Aware 

•    Generate original ideas and apply creative, imaginative and innovative thinking in response to a given design problem.  

5. Reflective and Resilient  

•     Manage time, completing work within a specified time and submitting assessments by a specified deadline 

The module is assessed through coursework, as follows: 

Outline Gearbox Design Project  

Assessment 1 (LO 1-3, 6) is worth 50% of the module mark and consists of a technical report presenting the initial design of a reduction gearbox using hand-calculation methods for sizing and selection of all components. The report will justify the design using calculations and other information, and will present technical drawings of the initial gearbox design.  This coursework allows you to demonstrate Learning Outcomes 1, 2, 3 and 6 

Detailed Component Design Project 

This is worth 50% of the module mark and includes two assessments: 

• Assessment 2 (LO 4, 6), a presentation, is worth 35% of the module mark, presenting the detailed development of the designs of the components of your gearbox, to a stage where they are suitable for final manufacture, using FEA software to develop and improve your designs. This allows you to demonstrate Learning Outcomes 4 and 6. 
   

• Assessment 3 (LO 5, 6) involves the manufacture and testing of one component in order to critically evaluate FEA methodology by comparison with test results. A 5 page technical report will be produced following testing and is worth 15% of the module mark. This coursework allows you to demonstrate Learning Outcomes 5 and 6 and is a qualifying element. 
   

In order to pass the module, not only must the minimum pass mark of 40% be achieved overall, assessment 3 must be passed in its own right as it is a qualifying element.  

All components above are group-based summative assessments to reflect the relatively complex nature of engineering design projects, as these typically require an effective team-based approach, while also being aligned with Engineering Council accreditation requirements. All marks are subject to peer review. The peer review outcomes are scrutinised by the module leader to ensure they are reflective of the team dynamics observed throughout the academic year.  

OPPORTUNITY FOR REASSESSMENT 

The opportunity for reassessment in this module will be set at component level. The remit of the reassessment will be set by the module leader while also mapped against the module learning outcomes. Opportunities for re-assessment is only permitted provided you have not failed more credit than in the resit rule adopted by your programme. If the amount of credit you have failed is more than permitted by the relevant resit rule, you may be permitted to repeat study if you are within the threshold set for the Repeat rule adopted by your programme.  You will be notified of your eligibility to resit/repeat any modules after the Examining Board in the Summer period. 

All resit assessments will be held in the Resit Examination period, prior to the start of the following academic session. 

• Static calculations applied to mechanical design 

• Design for strength, stiffness and fatigue 

• Component design 

• bending 

• torsion 

• stress concentration 

• fasteners 

• bearings 

• power transmission 

• FE modelling using commercial software 

• Manufacture and testing