EGME 421 Mechanical Design Spring 2017 Syllabus

Instructor
Dr. Joseph Piacenza
Office: E-412
Office Hours: M, W 10:00 11:30am
Phone: 657-278-3449
email: jpiacenza@fullerton.edu
Lecture
Sec. 1: TR 4:00-5:15 PM, E201
Sec. 3: MW 8:30-9:45 AM, E-201
Text
Required: Shigleys Mechanical Engineering Design, 10th
edition, Budynas & Nisbett, McGraw-Hill
Reference: Machinerys Handbook, 29th edition & Marks
Mechanical Engineering Handbook
Course Learning Outcomes:
Upon successful completion of this course, students
will be able to:
1. Reverse engineer a real product and analyze
external forces.
2. Select and apply an appropriate static failure
theory to a machine component.
3. Select and apply an appropriate dynamic (fatigue)
failure theory to a machine component.
4. Select mechanical components for a given load
situation and analyze for failure.
5. Perform a competitive analysis and provide
insights on risk and reliability.
6. Communicate analysis results and basic
engineering concepts.
Prerequisites: EGCE 301/ME 331, & ME335
In EGME 335 (Kinematics of Mechanisms), you learned
about the presence of known or planned motions, and
the design fundamentals of kinematic mechanisms. In
this course, we focus on machine component analysis,
specifically, analysis techniques used to predict a
components failure and/or factor of safety. Reverse
engineering of a product will be used as the vehicle for
real product analysis.
Class Format
The class format will include lectures and discussions,
with quizzes, readings, and homework.

Grading
Class Participation
Quizzes:
Midterm Exam 1:
Midterm Exam 2:
Team Project
Team Presentation:

5%
30% (5 x 6%)
20%
20%
20%
5%

Course Grade
90% - 100% A 80% - 89.9% B 70% - 79.9% C 60%
69.9% D
The above ranges for the course letter grades may be adjusted based on the
overall performance of the class. That will be determined at the end of the
semester. +/- grading will be used in this course.

Quizzes, Exams, and HW

5 quizzes will be administered throughout the term at
the beginning of the classes shown below in the course
outline unless otherwise noted. These quizzes are halfhour long, closed-book, and closed-note unless
otherwise noted. There will be 2 midterm exams in
this course and no final exam. There will be
absolutely NO MAKE-UP EXAMS OR QUIZZES. The quiz
and exam material will largely be based on material
covered during the lectures, up to the lecture preceding
the exam date, problem sets assigned as HW, and
sample problems in the textbook. You are strongly
encouraged to work them all as they are likely to
appear in exams and quizzes. There will be specific
sets of HW problems assigned at the beginning of each
week, with solutions posted at the end of that same
week. The HW will not be graded.
Team Project
In addition to the exams and quizzes, EGME 421 is built
around a team project to analyze an existing product
for safety and reliability to determine whether it was
designed in a satisfactory fashion, or whether redesign
is necessary to improve the product to meet the
engineering requirements. Students will work in teams
of 3 to analyze an existing mechanism and present
improvements that can be made. This will culminate in
a final report and presentation due during finals week.
Project details are described below.

Project Outline
Project completion involves the following tasks:
1. Work and turn
assignments.

in

team-based

project

2. Select a mechanical product for study-something one or more of you is familiar with.
The product must have at least 5 moving parts
and must not be made of plastic. Your team
must obtain a functioning version of the
product to work with. An assembly manual,
service manual, and/or other product
documentation is also helpful. Final approval of
your product selection will be given by Dr.
Piacenza on Wednesday/Thursday Feb. 1,2.
3. Disassembly: Take product apart, clean it, and
understand and describe how it works.
4. Generate a set of presumed engineering
requirements for the product. You will have to
estimate much of the information on
engineering
requirements.
Note
all
assumptions.

(Times Roman, single line spacing, 12-point font, 1-inch

margins). The primary audience for this report is an
imaginary company who is interested in understanding
and analyzing the failure potential and reliability of the
product you have selected. Your audience will use the
report to decide whether to invest in this product as is,
or invest in a redesign to make it more reliable. Be sure
to calibrate the quality and level of your writing to
effectively address this readership. A report-grading
rubric will be provided. Pay close attention to the
rubric contents when preparing your report. The
project report must contain the following sections
1. 1-page executive summary
2. Introduction and description of the system
studied: What is the purpose of the analysis
study and the report? What is your system?
What does it do? How does it work? How might
it fail/how has it failed in the past (show
historical sources)? How would you expect it to
fail (show failure modes analysis)?
3. Force characterization and free body diagrams

5. Create free body diagrams in all critical

operating modes. The free body diagrams must
be of the entire product and all the major
components.
To do this will require
characterization of the power source(s), losses
and loads. Note all assumptions made.

4. Static and dynamic failure analysis

6. Find the stresses at critical points in the

product. You must find at least five of the most
critical points. These points should involve
different loading types: tension, compression,
shear, bending and torsion.

6. Conclusions and recommendations to your

bosses: summary of your system, the analysis
results, and the systems failure potential;
insights on how you re-design the device
better; recommendations on whether your
company should invest in this product further.

7. Perform static and dynamic failure analyses on

the product.
The analyses may include
strength, stiffness, wear, material selection, and
manufacturing.
8. Recommend improvements for redesign of the
product to makes it safer/more reliable.
9. Physically re-manufacture one of the 5 parts
that was analyzed, incorporating the team
recommendations.
10. Prepare a written report detailing your findings
and recommendations (see below).
Project Report
Project Report: The written project report must be
computer-generated with a length of 9-10 pages

5. Discussion of reliability and risk aspects: why

was the system designed to the factor of safety
youve computed? (Compare to findings about
past failure cases in Section 2.) What
component needs to be redesigned and why?

7. Appendices with engineering requirements,

FMEA, and appropriate detailed analysis and
drawings (not part of the 10-page limit)
8. Note also that all calculations included in the
report should be annotated with a written
explanation and all associated assumptions
should be noted. Calculations lacking this
explanatory information will be disregarded.
In order to help keep the project on track, 5 sub
assignments
(e.g.,
project
proposal,
FBD,
static/dynamic analysis, executive summary) will be
collected throughout the term, and graded qualitatively
using a +/- system. These assignments will
constitute part of your class participation grade.

Project Presentation
You will deliver a 10 min. professional presentation of
your project where you will explain the basic concepts
of stress, force, and static and fatigue failure, as well as
describe your specific device and your analysis results.
You will also present your re-manufactured
component.
Project Peer Evaluation
To ensure fair grading of the team-produced
deliverables, the overall team project grades will be
corrected for each student with a weighting factor.
This factor will be developed through each team
member's confidential evaluation of all team members
(including themselves) for the percent of his/her
contribution to the analysis, production of the project
report, and manufacturing process. The evaluations
will be averaged by the instructor to find each student's
contribution and the weighting factor made
proportional to it. See course web site for team
evaluation form.
Important Notes
The University requires students with disabilities to
register with the office of Disabled Student Services,
located in UH-101 and at (657) 278-3117, in order to
receive accommodations appropriate to their disability.
Students requesting accommodations should also
inform the instructor during the first week of classes
about any disability or special needs that they have.
Additional
information
is
available
at:
http://www.fullerton.edu/DSS.
During an emergency it is necessary for students to
have a basic understanding of their personal
responsibilities and the Universitys emergency
response procedures. Please, review these procedures
at:
http://www.fullerton.edu/emergencypreparedness/ep
_students.html.

Disruptive activities that cause distractions for other

students in the classroom are not allowed. Such
disruptive behaviors include: late arrival to the
classroom, early exit from the classroom, using mobile
phones/pagers, texting and conversations outside the
course related discussions led by the instructor.
Additional information on this issue and possible
disciplinary actions can be found in the Student
Handbook at: http://www.fullerton.edu/handbook.

Academic dishonesty will not be tolerated. According

to the CSUFs University policy, Academic dishonesty
includes cheating, inventing false information or
citations, plagiarism and helping someone else commit
an act of academic dishonesty. It usually involves an
attempt by a student to show possession of a level of
knowledge or skill which he/she does not possess.
More details are available at:
http://www.fullerton.edu/senate/PDF/300/UPS300021.pdf.

Course Outline
Week

M/T

Date

1/23,24

W/R
M/T

1/25,26
1/30,1/31

W/R
M/T

2/1,2
2/6,7

W/R
M/T

2/8,9
2/13,14

W/R
M/T

2/15,16
2/20,21

W/R
M/T

2/22,23
2/27,28

W/R
M/T

3/1,2
3/6,7

W/R
M/T
W/R
M/T

3/8,9
3/13,14
3/15,16
3/20,21

10
11

3/22,23
3/27-3/31
4/3,4

12

4/5,6
4/10,11

W/R
M/T
W/R
M/T
W/R
M/T
W/R
M/T
W/R
M/T
W/R
M/T
W/R
M,T

13
14

15

16
Finals
Week

4/12,13
4/17,18
4/19,20
4/24,25
4/26,27
5/1,2
5/3,4
5/8,9
5/10,11
5/16,17

Topic

Introductions and Team Assignment, Team Contract

Done in Class
Team Formation Continued
Project: Proposal Due, Introduction & Review of Basics,
Stress Analysis, HW 1: Stress analysis
Stress Analysis & Force Analysis
Force Analysis Continued, Engineering Requirements
HW 2: Stress States/Mohr
Force Analysis Continued
Quiz 1, Failure Modes Analysis, Reliability
HW 3: Static/Force Analysis
Project: Free Body Diagrams Due, Static Failure
*No Class Monday 2/20*, Static Failure Continued
HW 4: Static Analysis
Static Failure Continued
Fatigue Analysis
HW 5: Fatigue Analysis
Quiz 2, Fatigue Analysis Continued
Project: Static Analysis Due, Fatigue Analysis Continued
HW 6: More Fatigue Analysis
Fatigue Analysis Continued
Midterm Review, Project Q & A
Midterm Exam 1
Gears/Springs
HW 7: Gears/Springs
Gears/Springs Continued
Spring Recess
Gears/Springs Continued
HW 8: More Gears/Springs
Quiz 3, Gears/Springs Continued
Applications: Bearings
HW 9: Bearings
Project: Fatigue Analysis Due, Bearings Continued
Quiz 4, Bearings Continued
Screws and Fasteners
Project: Executive Summary Due, Screws and Fasteners
Continued
HW 10: Screws and Fasteners
Screws and Fasteners Continued
Failure Detection & Monitoring
HW 11: TBD
Quiz 5, Failure Detection & Monitoring Continued
Project: Final Report Due, Midterm Review
Midterm Exam 2
Final Presentations E-201, (MW Class 9:30-11:20am),
(TR Class 5:00-6:50pm)

Reading Material

Mechanism
Specifications
Chapters 1,2

Chapter 3

Chapter 5

Chapter 6

Chapters 10, 13, 14,

15

Chapters 11, 12

Chapter 8

Handout