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ENGR5002: Design and Practice II Student will work to redesign a ‘faulty’ Screw Pump by following distinct stages  from conception to completion that entail the engineering design process

Mechanical Engineering

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ENGR5002: Design and Practice II

Student will work to redesign a ‘faulty’ Screw Pump by following distinct stages  from conception to completion that entail the engineering design process.

Figures 1 and 2 on pages 3-4 depict an exploded and a sectional view of the general assembly of screw pump that you are going to model and redesign. At

.you are required to submit a detailed report with all the drawings of your  proposed design solution where it will be evaluated. If your proposed concept  offers the ‘best’ design solution amongst all other students

1.1 Learning outcomes assessed

Semester 1

a) Understand and apply Engineering Design process.

b) Select and use appropriate industrial components for theirdesigns.

c) Understand the use of modern computer technology in the designprocess

d) Use a range of 3D modelling techniques

e) Produce designs of mechanical engineering products

f) Apply engineering principles and analytical techniques in the designprocess

g) Create a virtual prototype design of a part using CAMtools

h) Work with others to produce a design prototype

i) Ability to communicate effectively as a group.

2.0 Assignment tasks

1. Produced a general design specification.

2. Produced a functional analysis of the design problem, i.e Screw Pump

3. Produced their own creative ideas, and adapted ideas from the study of

existing technology.

4. Divided their main design into further-subsystems and produced a range of

possible solutions

5. Used logical well-reasoned selection techniques to choose the optimum

solution for the subsystems and the whole.

6. Developed the chosen solution to the point where good outline CAE models

can be produced

7. Used engineering theory in the development of their chosen design, giving

appropriate references to standard theory .

8. Carried out FMEA and produced CAM machining instructions and an

approximate cost for the proposed design concept.

9. Write your final report .

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Figure 1. Exploded view of ‘faulty’ Screw Pump

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Figure 2. Sectional view of the General Assembly

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3.0 Group work - weekly tasks

Task Week

Effort

Individual

1.

Project brief & form working groups 1 x

2.

Complete Design Specification and

functional analysis of the ‘faulty’

Screw pump.

2-3 x

3.

Concept generation of proposed

design improvements and concept

selection.

3-4 x

4.

Progress meeting 5 x

5.

CAD model(s) of the selected

concept.

5-6 x

6.

2D Manufacturing drawings, limits &

fits, GDT, bearings and seals.

6-10 x

7.

Failure Mode and Effects Analysis

(FMEA)

8-9 x

8.

CAM of redesigned pump part(s)

and overall prototype cost.

9-12 x

9.

Arduino, control & instrumentation,

water pump sensors labs.

10-12 x

9.

Submit Report TBA x

Stage 1

complete the design specification (as far as possible) including quantifiable

aspects, for example a mass flow rate of 10kg/s etc. In addition draw a functional

analysis diagram of the whole assembly in an A3 paper format and list all

design faults as insufficient actions.

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Stage 2

Hand draw Concept Sketches of the pump that you would like to redesign.

You have the freedom to entirely redesign the pump (although it must have a

screw rotor). Equally you can improve the existing pump by eliminating

some of the design 'faults' that will be highlighted during the lecture/seminar

sessions. Each student member has to produce at least one design

sketch/idea.

 Stage 3

To report on the following:

a) Concept ideas considered (at least one hand drawn concept sketch per

group member; neat, clear, readable and well annotated).

b) Sketches must show the location of bearings, seals and an indication of

fit between various parts (i.e clearance, interference and class i.e

H7/c11 or H7/k6 etc same approach as the in-class examples). In

addition you must show what feature(s) you've considered (if any) that

aid concentricity /radial alignment of the whole assembly.

c) Concept idea you would like to take for further development (i.e "best"

concept idea) based on the Matrix Selection Method (please refer to

Concept Selection slides on Moodle).

In addition, you may want to read on how to attribute weighting of the selection

criteria based on the binary dominance matrix method by consulting the

following textbook:

Criteria ranking for concept selection based on

the binary dominance matrix method. Engineering Design Principles by Ken

Hurst, section 4.3.

Stage 4

Preparation for detailed design of your chosen concept, hence, it is important

that by end of week 6 you have carried out the following:

a) Chosen a concept sketch and if necessary improve as discussed during

the feedback session in week 5.

b) Show location of bearings, seals and an indication of fit between various

parts (i.e clearance, interference).

c) Considered important features that aid concentricity/radial alignment of

the assembly.

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d) Considered issues that may prevent assembly and/or disassembly.

e) Any major manufacturing issues that may lead to a costly part or design.

f) Stated some overall dimensions for the assembly (check your design

specification in terms of overall size of the pump) (length x depth x

height)

g) Made an effort to create a CAD model of the Rotor for the chosen

concept - assume a nominal shaft diameter of 25mm.

Stage 5

Detailed design work will entail

a) Flow rate calculations for you chosen rotor in order to deliver a specified

mass flow rate (kg/s)

b) Radial and Axial loads from the rotor on the bearings/system.

c) Selection of suitable bearings and seals.

d) Design housings for the bearings and seals that conform to relevant

standards.

e) Design the rest of the parts and complete the assembly.

f) Carry out a Failure Mode and Effect Analysis (FMEA) and if necessary

improve the design further.

g) Carry out CAM manufacture using HSMWorks of selected parts.

h) Estimate overall prototype cost.

i) Detail how the pump can be instrumented in order to control motor

speed and measure mass flow rate (separate info to follow).

j) Prepare design report for submission at the beginning of January 2023.

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5.0 Assessment information

50 % of the total module mark will be allocated for producing a redesigned model

of your of the screw pump (which includes control and instrumentation to be

carried towards the end of Semester 1). This will include marks for producing 2D

detailed CAD drawings of each part and assembly drawings and manufacturing

as necessary in the form of a design report.

For a detailed marking scheme see page 12.

Length of the Task 5000 words