Senior Design Projects in Mechanical Engineering: A Guide Book for Teaching and Learning

✍ Scribed by Yongsheng Ma, Yiming Rong

• Publisher: Springer
• Year: 2021
• Tongue: English
• Leaves: 552
• Category: Library

✦ Synopsis

This book offers invaluable insights about the full spectrum of core design course contents systematically and in detail. This book is for instructors and students who are involved in teaching and learning of ‘capstone senior design projects’ in mechanical engineering.

It consists of 17 chapters, over 300 illustrations with many real-world student project examples.

The main project processes are grouped into three phases, i.e., project scoping and specification, conceptual design, and detail design, and each has dedicated two chapters of process description and report content prescription, respectively. The basic principles and engineering process flow are well applicable for professional development of mechanical design engineers.

CAD/CAM/CAE technologies are commonly used within many project examples. Thematic chapters also cover student teamwork organization and evaluation, project management, design standards and regulations, and rubrics of course activity grading. Key criteria of successful course accreditation and graduation attributes are discussed in details. In summary, it is a handy textbook for the capstone design project course in mechanical engineering and an insightful teaching guidebook for engineering design instructors.

✦ Table of Contents

Preface
Acknowledgements
Contents
About the Authors
Acronyms, Abbreviations, and Short Form Definitions
1 Framework and Syllabus: Introduction to Capstone Projects—A Hidden Gem of Engineering Education
1.1 What is a Senior Design Project Course?
1.2 Goal and Objectives
1.3 Design of the Course Structure
1.4 Course Characteristics—“Keepin’ It Real”
1.5 Design Competition
1.6 Course Learning Outcome Measurement
1.7 Course Accreditation and Graduate Attributes
1.8 Syllabus
1.9 Lecture Schedule
1.10 Proposals, Project Assignment, and Example Projects
1.11 Project Team Meetings
1.12 Project Submission Marking
1.13 Electronic Document Submission
1.14 Technical Resources
1.15 Capstone Design Awards
1.16 Advice to Students
1.17 Student Mental Health
1.18 Summary
2 Project Proposals and Intellectual Properties
2.1 Introduction
2.2 The Role of Sponsors
2.3 Project Cost
2.4 Institutional Support
2.5 Industrial Project Sponsorship Motivation
2.6 Research Project Sponsorship Motivation
2.7 How to Obtain High Quality Project Proposals?
2.8 Key Elements in a Good Proposal
2.9 Soliciting and Working with Sponsors
2.10 IP Arrangements for Projects
3 Teamwork and Group Dynamics
3.1 Team Selection Rationale
3.2 Cooperative Learning
3.3 What are the Expected Group Behaviours?
3.4 How to Develop a Plan for Effective Teams in the Senior Design Course?
3.5 Dealing with Team Conflict
3.6 Time Management Hints
3.7 Using a Web-Based Teamwork Support Tool—CATME
3.8 How Group Dynamics is Managed in the Senior Design Course of Mechanical Engineering?
3.9 Group Formation
3.10 Group Meetings
3.11 Group Involvement
3.12 Maintaining Student Sanity
3.13 Group Dynamics Performance Evaluation
4 Design Process and Evolving Phases
4.1 Introduction
4.2 What is a Design?
4.3 Design (Product) Quality
4.4 Product Life Cycle
4.5 Design Process
4.6 Typical Mechanical Design Process
4.7 Why Study the Design Process?
4.8 Concurrent Engineering
4.9 Measures of the Effectiveness of the Design Process
4.10 Effect of Design Process on Cost
4.11 Effect of Design Process on Product Quality
4.12 Effect of Design Process on Time to Market
4.13 Ten Key Design Best Practices
4.14 Overall Design Project Process
4.15 Product Discovery
4.16 Background Research for Product Discovery
4.17 Accessing Patent Information
4.18 Conceptual Design
4.19 Detail Design, Prototyping and Testing
4.20 Summary
4.21 Example Project Discovery Assignment
5 Phase 1 Process: Problem Definition, Design Specification
5.1 About the Course—Capability and Experience
5.2 Follow the Design Process
5.3 Why Do We Invest in Design?
5.4 Why Do We Consider Product Design Process (Qureshi a 2015)?
5.5 Product Development Cycle
5.6 Cost Effective Design Process
5.7 Phase 1 Process within the Product Development Cycle
5.8 Problem Definition
5.9 Needs Versus Solutions
5.10 Market Research
5.11 Client Interviews
5.12 Engineering Challenge Appreciation—Gap Analysis
5.13 Symptoms Versus Root Cause
5.14 Technical Research
5.15 What are the Features that a Product Must/Should/Could Have?
5.16 Design Specifications
5.17 Work Out Design Specification with Quality Function Deployment (QFD)
5.18 A Checklist When Completing Design Specifications (Qureshi a 2015)
5.19 Project Planning and Schedule
5.20 Requirements for Phase 1 Project Planning
5.21 Estimate the Time Required to Complete Each Task
5.22 Peer Review and Training
5.23 Engineering Cost Estimation
5.24 Problem Definition Documentation—Report and Appendices
5.25 Phase 1 Deliverables and Report Requirements
5.26 Design Success
5.27 Helpful Tips, Comments, Suggestions
5.28 A Case Study
6 Phase 2 Process: Concept Generation, Design and Evaluation
6.1 Phase 2 Introduction
6.2 Phase 2 Design Success Depends on Work of Phase 1
6.3 Where to Start? Phase 2 Design Process in Overall Product Development Cycle
6.4 Learning Steps
6.5 Learn a “Creative” Teamwork Process in Cycles
6.6 Brainstorming
6.7 Brainstorming Hopper
6.8 Brainstorming and Concept Sketches
6.9 Major Considerations for Phase 2 Design
6.10 Functional Analysis
6.11 Example Function Analysis—Orange Squeezer
6.12 Create a Morphological Chart
6.13 Mapping Exercises for Engineering Design
6.14 Concept Engineering Analysis
6.15 Conceptual Engineering Calculations
6.16 Conceptual Analysis Strategies
6.17 Engineering Analysis: Tasks, Connections, and Iteration
6.18 Engineering Toolbox
6.19 Material Selection
6.20 Conceptual Design 3D Model Representation
6.21 Proof of Concept—Testing with Effectiveness in Mind
6.22 Proof of Concept—Advanced Analysis and Testing
6.23 Proof of Concept—Industrial Design and Acceptable Engineering Models
6.24 Conceptual Design Analysis—Global “Best Practice”
6.25 A Case Study—Successful Enterprises Depend on Excellent Creative Design Processes
6.26 More Interesting Case Studies for Product Development
7 Phase 3 Process: Detail Design
7.1 Learning Objectives
7.2 Phase 3 Process Within the Product Development Cycle
7.3 Preconditions for Successful Detail Design
7.4 Keeping Your Sanity
7.5 Detailed Design Contents
7.6 Detail Calculations
7.7 What Should Be Completed if Applicable with CAE Engineering Analysis?
7.8 Complete Design Models
7.9 Detailed Design Drawings
7.10 Design Compliance Matrix
7.11 Project Schedule Review
7.12 Critical Design Review
7.13 Did You Get It?
8 Phase 1 Report: Problem Definition, Design Specification, and Project Plan
8.1 The Cover Letter (Letter of Transmittal)
8.2 Phase 1 Report (Design Specification Report) Requirement
8.3 Background to Client’s Business and Design Requirements
8.4 Design Objectives
8.5 Marketing and Sales Information
8.6 Preliminary Manufacturing Cost Estimates
8.7 Manufacturing Considerations
8.8 Focus for the Design Space
8.9 Defining the End of the Project
8.10 Design Constraints and Customer Requirements
8.11 Design Specifications to Be Discussed in the Report
8.12 Governing Design Standards and Regulations
8.13 Design Specification Matrix
8.14 Design Specification Matrix Template
8.15 Project Planning, Scheduling and Critical Path Analysis
8.16 Report Writing—General Comments
8.17 Marking Scheme for Cover Letter
8.18 Marking Scheme for Specification Report
8.19 Marking Scheme for Specs Matrix
8.20 Marking Scheme for Project Management
9 Phase 2 Report: Conceptual Design
9.1 Learning Objectives
9.2 Conceptual Design Deliverables (25% of the Course)
9.3 The Cover Letter (Letter of Transmittal)
9.4 Executive Summary
9.5 Conceptual Design Report
9.6 Design Objective(s)
9.7 Description of Design Concept Candidates
9.8 Conceptual Design Diagrams, Sketches and Solid Models
9.9 Design Evaluation
9.10 Design Evaluation Matrix
9.11 Conceptual Analyses
9.12 Project Management
9.13 Project Schedule Update
9.14 Project Schedule Review in the Main Body of Phase 2 Report
9.15 Appendices
9.16 Marking Scheme for Phase 2 Report
10 Phase 3 Report: Detailed Design
10.1 Learning Objectives
10.2 Phase 3—Deliverables (30% of the Total Course)
10.3 Phase 3 Detail Design Report
10.4 Report Requirements
10.5 Detailed Engineering Calculations and Analysis
10.6 Calculations and Analyses Readability
10.7 Design Compliance Matrix
10.8 Detail Design Drawings
10.9 Example Top Level General Assembly
10.10 Project Management
10.11 Peer Review Survey
10.12 Design Conference
10.13 Design Posters
10.14 eCopy Deliverables
10.15 A Sample Phase 3 Report
10.16 Example Calculations
10.16.1 Stress Analysis
10.16.2 Heating Analysis
10.17 Phase 3 Submission Marking Scheme
10.18 Poster Marking Scheme (as Per Winter Term 2014/15)
10.19 Design Conference Presentation Marking Scheme
11 Research and Information Resources in Mechanical Engineering Design
11.1 Comprehensive Searching for Engineering Content
11.2 Selected Databases of Interest to Mechanical Engineers
11.2.1 IEEE Xplore Digital Library
11.2.2 SAE Digital Library (1906−)
11.2.3 Compendex (1884−)
11.2.4 Web of Science (1900−)
11.3 Information Research Skills in Industry
11.4 Engineering Information Sources
11.5 Textbooks
11.6 Handbooks
11.7 Research Journal Papers
11.8 Research Conference Papers
11.9 Standards and Codes
11.9.1 Standards
11.9.2 Codes
11.9.3 Standards Sources Available at U of A
11.10 Patents, Trademarks, and Copyrights
11.10.1 Patents
11.10.2 Patent Sources
11.10.3 Trademarks
11.10.4 Copyrights
11.10.5 Trade Secret
11.11 Contact Specialists to Obtain Info for Mechanical Engineering Literature
11.12 The Gateway of Libraries
11.13 Managing Your References—Using a Reference and Citation Management Tool
Acknowledgements
12 Industrial Design Part 1: Elements in Product Development—What Makes a Good Industrial Design?
12.1 Introduction
12.2 What is Industrial Design?
12.3 What Do Industrial Designers Do?
12.4 What Makes a Good Product Design from an Industrial Design (or ID) Point of View?
12.4.1 Good Design is Innovative
12.4.2 Good Design Makes a Product Useful
12.4.3 Good Design is Aesthetic
12.4.4 Good Design Makes a Product Understandable
12.4.5 Good Design is Honest
12.4.6 Good Design is Unobtrusive
12.4.7 Good Design is Long-Lasting
12.4.8 Good Design is Thorough Down to the Last Detail
12.4.9 Good Design is Environmentally Friendly
12.4.10 Good Design is as Little Design as Possible
12.5 Industrial Design is About Physical and Mental Experience
12.6 Design on What’s Going to Happen Rather Than on What’s Something is Going to Look Like
12.7 Design the Meaning of a Product
12.8 Product Design with Industrial Design Involved
13 Industrial Design Part 2: Cases in Product Development—What Makes a Good Product Design?
13.1 Examples of Mechanical Designs with Industrial Design Inputs
13.2 Case 1: Ventriculoperitoneal Shunt Valve Vibrator
13.3 Case 2: Craniotomy Surgical Tool
13.4 Case 3: Eco-Car, Aeroshell Body Design
13.5 Case 4: Fuel Cell/LED Green Construction Lighting
13.6 Case 5: Neutral Spine Walker
13.7 Case 6: Cross-Country Sit-Ski for Novice and Leisure Skiers with Lower Body Disabilities
14 Project Planning and Management
14.1 Real World Practice Introduction
14.2 Project Planning and Management
14.3 Design Project Planning and Management for the Course
14.4 Creating Letter of Intent
14.5 Workout Project Tasks and the Schedule
14.6 Critical Path Method for Project Scheduling
14.7 Gantt Chart
14.8 A Recommended Project Planning and Management Tool—LiquidPlanner®
14.9 Finalizing the First Project Baseline Plan
14.10 Updating Project Plans with Constant Data Login and Updates According to Progress
14.11 Managing Senior Design Projects Under the Course Framework
14.12 Summary
15 How to Write Engineering Report
15.1 Introduction
15.2 Why Write a Design Report Every Phase in the Senior Design Course?
15.3 Report Writing: The Plan
15.4 General Points About Writing a Full-Text Report
15.5 Report Writing Tips: Writing Contents
15.6 Report Writing Tips: Grammar, Writing Tone, and Formality
15.7 Report Writing Tips: Rules of Referencing and Citations
15.8 Report Writing Tips: Graphics
15.9 Text? Illustrations? Text + Illustrations?
15.10 What Would Make This Illustration More Effective?
15.11 Report Writing Tips: Formatting
15.12 Report Writing Tips: Editing
15.13 What is an Appendix?
15.14 Snapshot of the Project Plan
15.15 CAD Generated Conceptual 3D Models
15.16 Conceptual Design Analysis
16 Design Standards and Regulations
16.1 What Are Standards?
16.2 What Are Codes?
16.3 Why Do Engineers Need to Use Standards and Follow Codes?
16.4 Material Standards and Codes
16.5 SAE Aerospace Material Specifications
16.6 Design Standards
16.7 Industry System Standards
16.8 Industrial Equipment and System Standards
16.9 ASME B20.1-2018 Safety Standard for Conveyors and Related Equipment (ANSI ASME 2020)
16.10 ASME Y14.5-2018 Dimensioning and Tolerancing (ANSI ASME 2020)
16.11 ASME A17.1/CSA B44-2019 Safety Code for Elevators and Escalators (ANSI ASME 2020)
16.12 ASME B30.20-2018 Below-The-Hook Lifting Devices (ANSI ASME 2020)
16.13 ASME B30.5-2018 Mobile and Locomotive Cranes (ANSI ASME 2020)
16.14 ASME BTH-1-2017 Design of Below-The-Hook Lifting Devices (ANSI ASME 2020)
16.15 Standards for Boiler and Pressure Vessel Design and Manufacturing
16.16 BPVC Section I—Power Boilers (ANSI ASHRAE 2020)
16.17 BPVC Section II—Materials (ANSI ASHRAE 2020)
16.18 BPVC Section III—Rules for Construction of Nuclear Facility Components (ANSI ASHRAE 2020)
16.19 BPVC Section IV—Heating Boilers (ANSI ASHRAE 2020)
16.20 BPVC Section V—Non-destructive Examination (ANSI ASHRAE 2020)
16.21 BPVC Section VI—Care and Operation of Heating Boilers (ANSI ASHRAE 2020)
16.22 BPVC Section VII—Care of Power Boilers (ANSI ASHRAE 2020)
16.23 BPVC Section VIII—Pressure Vessels (ANSI ASHRAE 2020)
16.24 BPVC Section IX—Welding and Brazing Qualifications (ANSI ASHRAE 2020)
16.25 BPVC Section X—Fiber-Reinforced Plastic Pressure Vessels (ANSI ASHRAE 2020)
16.26 BPVC Section XI—Rules for In-Service Inspection of Nuclear Power Plant Components (ANSI ASHRAE 2020)
16.27 BPVC Section XII—Transport Tanks (ANSI ASHRAE 2020)
16.28 Standards on Standard Machine Elements
16.28.1 Bearing
16.29 Manufacturing Standards
16.30 Other Emerging Categories of Standards and Codes
16.31 CSA Standards
16.32 CWC Standards
16.33 ISO Standards
16.34 API Standards
16.35 API Standards for Exploration and Production
16.36 API Standards for Transportation
16.37 API Standards for Refining and Marketing
16.38 API Standards for Fire Protection, Health and Environmental Issues
16.39 API Standards for Work Procedure Guidelines
16.40 IHS Markit® Standard Portal
16.41 Accessing Standards via IHS Engineering Workbench Portal
16.42 AWS Standards
16.43 AWS New Publications (AWS Catalog 2020)
16.44 GPA Standards
16.45 IEEE Standards
16.46 ISA—International Society of Automation
16.47 NACE (National Association of Corrosion Engineers) Standards
16.48 NFPA Standards
16.49 TAPPI—Technical Association of the Pulp and Paper Industry
16.50 The Basic Principles Governing Design Standards and Regulations in Design Engineering
17 Accreditation and Graduate Attributes
17.1 Who is the CEAB?
17.2 CEAB Accreditation Information
17.3 Graduate Attributes (GAs)
17.4 CEAB Accreditation Criteria
17.5 Minimum Curriculum Components
17.6 The Major Documents that Are Required for CEAB Accreditation: CEAB Questionnaire
17.7 Why the Accreditation Audit Visit?
17.8 Whom Are the CEAB Visitors Going to Meet?
17.9 Who Are “They” (CEAB and the Visiting Panel)?
17.9.1 Investigate the Education Culture
17.9.2 Graduate Attribute Assessments
17.9.3 GA Organization and Hierarchy
17.9.4 Continual Improvement Process (CIP)
17.10 Information on the Accreditation Full Process
17.11 Accreditation Units (AUs)
17.12 Learning Outcomes (LOs)
17.13 Curriculum Mapping
17.14 Food for Thought to Faculty Members on CEAB Interviews
17.15 Words from a Wise Colleague
17.16 Timeline to Accreditation
Appendix A An Example Syllabus
Appendix B A Sample Project Proposal Template
Appendix C IP Agreement Templates
Appendix D Sample Posters
Appendix E Mental Health Support
Appendix F A Sample Teaching Schedule
Appendix G A Sample Team Charter and a Template
Appendix H CATME Rating Scale
Appendix I Group Dynamics Evaluation Rubrics
Appendix J A Sample Project Proposal
Appendix K Poster of Craniostomy Ventriculostomy Drill
Appendix L EcoCar Aeroshell Proposal
Appendix M Poster of EcoCar Aeroshell
Appendix N Green Lighting Proposal
Appendix O Poster of Green Lighting
Appendix P Poster of Neutral Spine Walker
Appendix Q Poster of Para-Nordic “Sit Ski”
Appendix R Sample Hand Calculations in Traditional Fashion
Appendix S Sample Calculation Sheet Produced with MathCad
Appendix T Catalogue Descriptions of Related Courses
References