Accelerate your Career with a Master of Engineering in Design and Manufacturing

Menu

DM 814

DM 814 - Rapid Mechanical Design

Rapid Mechanical Design addresses all aspect of mechanical design, including consideration for end-of-life issues, with the focus and emphasis of the course being on rapid product development. In this course, the participants will be introduced to the various state-of-the-art methodologies and off-the-shelf tools and facilities for rapid design. The course will have an introductory section on a limited set of classical design topics in order to prepare the students for the in-depth discussion of the advanced topics on rapid prototyping.

Course Leader: Beno Benhabib, University of Toronto

Course Overview

Rapid Design addresses all aspect of mechanical design, including consideration for end of- life issues, with the focus and emphasis of the course being on rapid product development. In this course, the participants will be introduced to the various state-of-the art methodologies and off-the-shelf tools and facilities for rapid design. The course will have an introductory section on a limited set of classical design topics in order to prepare the students for the in-depth discussion of the advanced topics on rapid prototyping. The introductory topics will include: Manufacturing Management Strategies, Concurrent Engineering, Conceptual Design, and Design for X. The advanced rapid-design topics are categorized into virtual and physical prototyping. Virtual prototyping topics include: Geometric Modeling (including major CAD software packages), Computer-Aided- Engineering (CAE) Analysis, Engineering Optimization, Design of Experiments, and Virtual Reality. Physical prototyping topics include: Introduction to Polymerization, Sintering, Casting, and Chemical Machining, Material-Additive Layered Prototyping (including Photolithography, Sintering, Deposition, Lamination, and Laser-Induced- Fusion Based Rapid-Prototyping Systems), Material-Removal-Based Prototyping, and Reverse Engineering.

Activities & Schedule

The first module of this course will focus on accelerating the implementation of classical design methodologies, while the second module will deal with rapid-product prototyping issues. The instructors expect that each student will both be prepared for and attend all of the class sessions and participate fully in the group project. Active participation is critical since especially during Module 2 of the course class time will be allocated to the discussion of the group project and other outstanding issues and concerns. In addition to marking of the group and individual projects there will be an individual class-participation grade (about 20%) that will be based upon the student’s questioning of the material covered and contribution to in-class discussions.

Module 1: Increasing the Efficiency of Traditional Design Methodologies and Virtual Prototyping

Day 1 - Introduction
  • Manufacturing Matters
  • Automotive Manufacturing Industry
  • Recent History of Computing Technologies
  • Manufacturing Management Strategy
  • International Manufacturing Management Strategies
  • Rapid Design
Day 2 – Design Tools and Methodologies
  • Concurrent Engineering
  • Conceptual Design
  • Modular Product Design
  • Industrial Design
  • Axiomatic Design Methodology
  • Design for X
  • Group-Technology Based Design
Day 3 – Virtual Prototyping
  • Geometric Modeling
  • Computer-Aided-Engineering (CAE) Analysis via Finite-Element Modeling
  • Engineering Optimization
  • Design of Experiments
  • Virtual Reality (VR)
Day 4

Assignment of the group project – Redesign of a commercial product via dissection; grouping of the students into small teams; researching of the work at hand; and, presentation of preliminary findings at the end of the day in terms of a hard copy report (including ideas, sketches, etc.).

Module 2: Rapid Physical Prototyping

Day 1
  • Polymerization
  • Sintering
  • Casting
  • Chemical Machining
Day 2
  • CAD-based Part-Data Preparation;
  • Photolithography-Based RP Systems;
  • Sintering-Based RP Systems;
  • Deposition Based RP; Lamination Based RP;
  • Laser-Induced Fusion for Metal RP; and,
  • Summary and Comparison of Additive Rapid-Prototyping Technologies.
Day 3
  • Material-Removal Based Prototyping
    • Introduction to Machining
    • Principles of Workholding
    • Numerical Control of Machine Tools
    • Laser-Beam Machining
    • Comparison of Machining to Additive RP Methods
  • Reverse Engineering
    • Reverse Engineering Steps
    • External-Dimension Measurement Tools
    • Internal-Dimension Measurement Tools
    • Geometric Modeling
Day 4

Short Power-point student presentations of the project assigned on Day 4 of Module 1, followed by an overall class discussion – summing up of all ideas. Assignment of the individual projects (from a list to be given by Prof. Benhabib). Review of a specific design activity in the automotive industry, and discussion of expectations. A hardcopy of the project report (in power-point form) must be submitted within six weeks.

Course Evaluation

  • 40% - Group project from Module 1
  • 40% - Individual project from Module 2
  • 20% - Class participation

Recommended Reading

Benhabib, B. (2003). Manufacturing: Design, Production, Automation, and Integration. Marcel-Dekker/CRC Press.


Biography of Course Leader

Beno Benhabib, P.Eng.
benhabib@mie.utoronto.ca

Beno Benhabib is a Professor in the Department of Mechanical & Industrial Engineering and in the Institute of Biomaterials & Biomedical Engineering at the University of Toronto. His research interests are in the area of design and control of intelligent autonomous systems. He is also a member of the NSERC Canadian Network for Research and Innovation in Machining Technology. His research in the past 25 years was supported by over 100 Masters and Doctoral Students, as well as a large number Postdoctoral Fellows and Research Engineers, with an overall funding level of almost $4M. Their combined effort has resulted in over 325 international journal and conference publications, as well as several book chapters.

Contact Us

University of Western Ontario
Queen's University