EMAE 360 Fall 2014 Schedule

WEEK Sunday Monday Tuesday Wednesday Thursday Friday Saturday

1 (Aug) 24 Aug 25 Administrative

26 27 28 29 Team Assignment, Project Assignment

30

2 (Sept) 31 Sept 1 LABOR DAY NO CLASSES

2 3

4 5 6

3 7 8 PROJECT PLAN REVIEW 9 10 PROJECT PLAN REVIEW

11 12 PROJECT PLAN REVIEW

13

4 14 15 16 17 18 19 20

5 21 22 Progress Reports 23 24 Progress Reports 25 26 27

6 (Oct) 28 29 30 Oct 1 2 3 4

7 5 6 CONCEPTUAL DESIGN REVIEW

7 8 CONCEPTUAL DESIGN REVIEW

9 10 CONCEPTUAL DESIGN REVIEW

11

8 12 13 14 15 16 17 18

9 19 20 Progress Reports MIDTERM GRADES DUE

21 22 Progress Reports 23 24 25

10 26 27 FALL BREAK NO CLASSES

28 29 30 31 Nov 1

11 (Nov) 2 3 Progress Reports 4 5 Progress Reports 6 7 8

12 9 10 11 12 13 14 15

13 16 17 Progress Reports 18 19 Progress Reports 20 21 22

14 23 24 25 26 27 THANKSGIVING

28 THANKSGIVING BREAK NO CLASSES

29

15 (Dec) 30 Dec 1 DESIGN REVIEW 2 3 DESIGN REVIEW 4 5 DESIGN REVIEW 6

16 7 8 FINAL REPORTS DUE 9 10 FINAL REPORTS DUE 11 12 FINAL REPORTS DUE 13

17 14 15 16 17 18 19 FINAL GRADES DUE 20

EMAE 360

Team Design Assignment

The Spartan Motorcycle Company is planning to introduce a new motorcycle model for 2016. First year

sales are anticipated to be 7500 units, with volumes increasing to 12,000 in the second year and 15,000

in the third year. Your design team is responsible for the new engine design that will differentiate this

motorcycle from other competitors.

Engine Requirements:

2 or more cylinders, 4-stroke cycle

Displacement 1500 to 1800cc

Fuel injection, spark ignition

Runs on standard gasoline

Compression ratio 9:1 to 10:1

Performance Requirements:

Capable of 5000 rpm continuous service, idle at 800 rpm

Powers a six-speed transmission

Must meet all relevant specifications and standards for safety, fuel efficiency, noise and emissions

Your design should be planned to maximize fuel efficiency, minimize overall dimensions and weight, and

minimize the cost to produce. Engine reliability and durability should also be considered.

Your design file should include technical specifications, a theory of operations, a risk analysis and FMEA,

and a detailed design with a bill of materials. Each component should be described (manufacturing

process, mechanical drawing, material of construction, heat treatment if needed, cost to manufacture or

buy, etc.) Assembly and required fluids and lubricants should also be covered.

EMAE 360

Design for Manufacturing II

Fall 2014

Instructor: Sunniva R. Collins, Ph. D.

Office: 415B Glennan

Office Hours: MW 12:20 to 1:30; or by appointment

Phone: 216-368-4155 (office)

216-536-6198 (cell)

Email: sunniva.collins@case.edu

Course Description and Requirements

Catalog Description: This is the final course of a 3-course sequence focusing on "Engineering

Design and Manufacturing," and is the senior design course focused on a semester-long design

project. The course draws on a student's past and present academic and industrial experiences

and exposes them to the design and manufacture of a product or device that solves an open-ended

"real world" problem with multidimensional constraints. The students form design teams to

work on the solution to a common problem. The outcomes of the course continue to focus on the

student's ability to function on multidisciplinary teams while applying their knowledge of

mathematics, science and engineering to design a system, component, or process that meets

desired needs within realistic, multidimensional constraints, such as: economic, environmental,

social, political, ethical, health and safety, manufacturability, and sustainability. Professional

communication skills are emphasized and expected during all stages of the design process and

will include formal and informal oral presentations, periodic peer-focused design reviews, and a

development through its various evolutionary stages to completion.

Prerequisites: EMAE 160 or EMAE 172, and EMAE 260. Counts as SAGES senior Capstone

Course Objectives: On completion of this course, students should have developed:

1. An ability to apply knowledge of mathematics, science, and engineering to an engineering

design problem

2. An ability to design mechanisms and machinery to meet desired needs

3. An ability to function in multi-disciplinary teams

4. An ability to identify, formulate, and solve an engineering design problem

5. An ability to communicate effectively, orally and in writing

6. An ability to use the techniques, skills, and modern engineering tools necessary for

engineering practice

7. Experience in interacting with professionals in the field

8. Independence in approach and methodology in solving engineering problems

9. An understanding of professional and ethical responsibility 10. A recognition of the need for, and the ability to engage in life-long learning

Requirements: The class meets three times a week: MWF 4:00 to 4:50 p.m. in Bingham 103.

The class will organize into design teams. Each team formulates the details of the project,

determines the team’s mode of operation, the design activities that must be performed, the

individual responsibilities, the schedule of work, and other aspects of the development of the

design. Starting from performance requirements, each team considers alternative ways of

meeting the requirements, selects methods to investigate in detail, develops a conceptual design,

and then refines it to the preliminary design level, with the help of the instructor, TA, and

mentor(s).

Teams will report weekly on the progress of their design. Most weeks follow a prescribed

schedule of activities. Class periods are devoted to presentations of design progress and

discussions of the developing designs; work by each team separately; or lectures for background

information needed to complete the project. The instructor is available to meet with each team.

Progress Reports: Oral presentations are given weekly. These may be by one or more persons in

a group at each session, but every member of the team must participate in a progress report

presentation during the semester. In addition, each team submits a one-page weekly progress

report that includes plans for the next reporting period and a timeline of tasks.

Final Report: At the end of the semester, each team makes an oral presentation (including a

summary poster) and submits a written report describing its design. The written report should be

a good engineering report of professional quality. It should be able to be understood by a

technically trained reader who is not necessarily familiar with the particular subject matter, and

also useful to a reader who is interested in continuing the design.

Grading: The grade in this course is based primarily (75% of final grade) on the written and oral

final reports. Team grades will be self-reporting: each team member will have input on the

team’s performance, individually and collectively. The progress reports will also contribute (25%

of final grade) for this course.

Bibliography: The following texts are recommended as a starting point; they are on reserve for

this class at the Kelvin Smith Library:

Introduction to internal combustion engines, 4th ed., Richard Stone, SAE International, Warrendale PA, 2012

Design of machinery : an introduction to the synthesis and analysis of mechanisms and machines / Robert L. Norton

Kinematics and dynamics of machinery / Charles E. Wilson, J. Peter Sadler

Internal combustion engine fundamentals / John B. Heywood

Vehicular engine design / Kevin L. Hoag

Special Notes on Conduct

There is a “no cell phone” policy during class lectures. Laptops may be used to take notes. Other uses of

the laptop during class are not permitted. If there is a special circumstance requiring the use of a laptop or

cell phone during a specific class, please see the instructor in advance.

Be engaged in class:

a. Share your concerns and ideas with the entire class, not just the person sitting next to you.

b. Ask questions.

c. Be inclusive; ask others to share their opinions and insights.

d. Professionalism and civility are expected behaviors.

We support and uphold the academic integrity standards of Case Western Reserve University

(http://www.case.edu/provost/ugstudies/acintegrity.htm). Please review the document for definitions of

violations and the standard procedures for adjudication.