Objectives:

To enable students experience the design process of tooling for manufacturing metal and plastic products.

Introduction:

This is a group project. Groups must self-manage each student’s contribution.

The project includes four main elements:

(i) Sketches of product, sketches of the mould and die sets

(ii) Design calculations

(iii) Computer models & engineering drawings of the product, mould parts (core and cavity) or die parts (strip layout, die layout) and assembly of mould or die set (with BOM) using a CAD software (Solidworks available)

(iv) Written report and Power Point presentation by each group member

This project requires that students apply design principles to design tooling for manufacturing the assigned product. These design principles can be obtained from the material covered in lectures, other

subjects, from relevant texts, Australian standards, the Internet, manufacturer’s catalogues and most importantly your own knowledge/judgement. All sources of information must be referenced appropriately at the end of each chapter.

NOTE: Records will be kept on weekly attendance and participation of each group member. The result of this record may affect the final allocation of marks.

I Project report submission:

A product will be given to each group. Dismantle the product and divide the parts among the group members. The group report must have a standard format, including Cover page, Contents and executive summary, introduction, discussion/ conclusion appropriate references (literature review, include at least 8 to 10 cited Journal articles no later than last 8 years) and appendices. All the figures, tables and appendices should be captioned with appropriate contextualisation within text. The content page should contain list of chapters, tables, figures and appendices with appropriate page numbers. The report should indicate what the individual student has done i.e. your chapter should have your name with it. Each chapter can have its own appendices with proper contextualisation. The complete report must also be submitted in PDF/docx format in the attached CD/USB. Each group/member must complete the following requirements for their part:

 

Assessment Title: PDE40001 Project report, drawings and presentation

Due Date: In week 12 Tutorials before your presentation

Assessment Weighting: 30% for project report & engineering drawings and 10% for presentation

Assessment Length: Maximum 4000 words for report, 4 to 5 drawings in total & 5 minutes

presentation

Assessment: Individual/ Group

 

PDE40001

Design for manufacture

Project brief and assessment rubrics

 

2

 

1. Material and Manufacturing process selection (5 marks)

• Select a suitable material and manufacturing process for the product and justify your selection by comparing it to another possible process and material that could be used. Use the “Solidworks Sustainability Tool” to assist you in selecting the material and process. This may be forward or backward extrusion, forging, deep drawing, punching, injection moulding or other process that best suits your product.

2. Mould/Die design calculations 

• Use basic principles to carry out all necessary calculations for each part of your die/mould design. It may include clamping or press force requirements, number of cavities, volume, type of runners and gates, die cooling and sequence of press work.

• Include a brief description of a suitable machine for manufacturing your product. Discuss the size, capacity and economic viability (costing) of the machine selected.

3. Hand sketches of part, mould/die set assembly

• Sketch the part assigned to you with all dimensions.

• Search and obtain suitable standard mould base or die set from suppliers to incorporate into your design.

• Hand sketch the cross section view of an assembly to show the integration of your punch and die block or core and cavity design with the standard parts of the die set or mould base. Show major/overall dimensions.

4. CAD model of part, mould or die parts 

• Create a computer model of the part assigned to you

• Create computer models of the metal die/plastic mould parts (strip layout, die layout and punch layout, core and cavity)

5. Assembly model of mould/ die set 

• Create a fully constrained assembly of the manufacturing tool:

• Download a suitable standard mould base or die set models from suppliers (or use from blackboard)

• Create a computer assembly of the die/mould parts you created with the standard parts you downloaded (e.g: pack plates, ejector pins, locating rings, springs etc.).

6. Detail drawings/Assembly drawings

• Produce fully detailed engineering drawings including third angle views, sectional views and any broken-out views necessary to show all the dimensions of your part and parts of the mould/die you created

• Prepare a drawing of an exploded view of the die/mould set. On this drawing, include balloons and the “Bill of Material” for the whole die/mould assembly.

• These drawings are to be completed on standard A3 drawing templates, with fully completed title blocks. Print on A4 sheets and include in your report. All drawings to be according to Australian Drawing Standards AS1100

7. Cost of product 

Find the cost of material and tooling to determine production rates necessary to achieve 30% profit margin. The purchase price will be given with each product. Refer to Die/Mould Design on Blackboard for method and examples.